Composite Pylon Crossbar Adapter for Even Load Distribution
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Solution Overview
Problem
Existing methods for attaching a crossbar to hollow composite pylons in power transmission and distribution systems often result in deformations and uneven stress distribution, particularly under wind forces and dissimilar loads.
Innovation Solution
A slideable adapter system that pivotably attaches the crossbar to the hollow composite pylons, allowing even force distribution and rotation to mitigate bending stresses, with features like a fork mount, internal/external bodies, and a guide for precise alignment and installation, including a spreader for additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the crossbar is clamped against the pylon or carried by a bracket bolted to the composite pylon, then the crossbar can be attached to the pylon, but deformations and locally great strains occur on the composite pylon
Solution Approach 1:
An adapter is introduced as an intermediary component between the crossbar and the composite pylon. The adapter distributes the attachment forces over a larger surface area of the pylon, preventing local deformations and strains while maintaining secure attachment. The adapter acts as a force-distributing mediator that interfaces between the crossbar mounting system and the composite pylon structure.
Solution Approach 2:
The attachment system is segmented into distinct functional components: the adapter with fork mount, the crossbar, and the composite pylon. This segmentation allows each component to be optimized for its specific function - the adapter for force distribution, the fork mount for pivotable connection, and the pylon for structural support - while working together as an integrated system.
2Stability of the object's composition
If the crossbar is rigidly attached to the pylon, then stable support is provided, but bending stresses occur when pylons deflect under wind forces
Solution Approach 1:
The fork mount provides a pivotable connection between the crossbar and the adapter, transforming the rigid attachment into a dynamic joint. This pivotable connection allows the crossbar to rotate and accommodate pylon deflection under wind forces, converting bending stresses into rotational movement while maintaining stable support.
Solution Approach 2:
The attachment system changes from a fixed rigid connection to a pivotable connection with rotational degrees of freedom. This parameter change in the connection type allows the system to adapt to varying load conditions and pylon deflections, reducing bending stresses while maintaining stability.
3Ease of manufacture
If the crossbar is attached at a lower level on the pylon, then installation may be simpler, but both design and load distribution are compromised
Solution Approach 1:
The adapter enables the crossbar to be positioned at an elevated level above the pylon top, utilizing the vertical dimension for optimal load distribution. The adapter extends the attachment capability beyond the pylon surface, allowing the crossbar to be mounted at a height that improves both design flexibility and load distribution while maintaining installation feasibility.
4Strength
If bolts are used to attach the crossbar to the pylon, then secure attachment is achieved, but the adapter cannot rotate around the pylon longitudinal axis under dissimilar loads
Solution Approach 1:
The fork mount with pivotable connection replaces the fixed bolted attachment, allowing the adapter to rotate around the pylon's longitudinal axis in response to dissimilar loads on conductors. This dynamic rotational capability maintains attachment security while adapting to varying load conditions.
Solution Approach 2:
The connection parameters change from a fixed angular position with bolts to a pivotable joint that allows rotational movement. This parameter change enables the adapter to orient itself optimally under different load conditions while maintaining secure attachment to the pylon.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A device, a system and a method for attaching a crossbar (8) to a hollow composite pylon (2) where the crossbar (8) is arranged to carry at least one conductor (12), the hollow composite pylon (2), the crossbar (8) and the conductor (12) forming components of a pylon structure (1) for the transmission or distribution of power, and wherein the device comprises an adapter (4), which, in the position of application, is attached to the crossbar (8), is slideable at least into or over the, in the position of application, upper end portion (6) of the hollow composite pylon (2) and mainly along the longitudinal axis (30) of the hollow composite pylon (2) during part of the installation phase.