Ramp-Shaped Cable Connector for High Current Tensile Loads
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Solution Overview
Problem
Existing cable connectors for high currents in harsh environments, such as wind power plants and naval shipbuilding, face issues with mechanical stress, heat, and vibration, leading to changes in the effective contact surface and potential failure under tensile loads.
Innovation Solution
A cable connector design featuring identical, ramp-shaped contact surfaces that absorb tensile forces and prevent changes in the contact surface area, along with captive fastening means and angled toothing for secure electrical contact, ensuring consistent performance under mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cable connectors are used with flat contact surfaces, then the structure is simple, but the effective contact surface changes under tensile load leading to connection failure
Solution Approach 1:
The contact surfaces are designed with an inclination angle rather than being flat, allowing them to dynamically respond to tensile loads by maintaining constant contact pressure through the ramp geometry. This dynamic design ensures the contact surfaces remain effective under mechanical stress while preserving manufacturing simplicity.
2Strength
If fastening means are used to secure connecting pieces, then tensile strength is improved, but the fastening means are subjected to tensile stress causing potential failure
Solution Approach 1:
The invention extracts the tensile load-bearing function from the fastening means by introducing inclined contact surfaces that absorb tensile forces through their geometry. The fastening means are relieved of tensile stress and only need to prevent separation, significantly improving their reliability while maintaining strong tensile strength.
3Ease of manufacture
If identical connecting pieces are used, then manufacturing and assembly costs are reduced, but the connectors must be designed to work in both orientations
Solution Approach 1:
The connecting pieces incorporate asymmetric inclined contact surfaces with specific orientation marks, allowing identical pieces to be used in both orientations while maintaining proper electrical contact. The asymmetry is deliberately designed to guide correct assembly while enabling universal use of identical components, reducing inventory complexity.
4Power
If the contact surface area is increased to handle high current, then current carrying capacity is improved, but the connector size and weight increase
Solution Approach 1:
The invention optimizes the contact surface parameters by using inclined surfaces that concentrate contact pressure effectively. This allows achieving high current carrying capacity with a compact contact area, avoiding the need for proportionally larger and heavier connectors while maintaining the required power transmission capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a stable and consistent electrical connection that maintains contact integrity under mechanical loads and vibrations, reducing the risk of failure and simplifying assembly with identical parts and reduced storage and production costs.
Implementation Method 1
The electrical contact surfaces each extend in a longitudinal direction and rise towards a free end of the connecting piece in the manner of a ramp in such a way that the connecting pieces transmit a force to the ramp-shaped contact surface of the other connecting piece in the event of a mechanical tensile load
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
Cable connectors for high-current cables, comprising a first and a second connector, each having a contact socket for connection to an end of the cable, and fastening means for detachably connecting the connectors to each other, wherein each connector has an electrical contact surface extending in a longitudinal direction and rising towards a free end of the connector in the manner of a ramp, such that, under a mechanical tensile load along the longitudinal direction, it transmits a force to the ramp of the other connector.