Automated Reaction Force Cone Processing for HVDC Cables
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Solution Overview
Problem
Manual processing of reaction force cones for high-voltage direct current cables is time-consuming, laborious, and difficult to standardize, leading to poor quality and inefficiency in ultra-long-distance power transmission.
Innovation Solution
An automated method and apparatus for processing reaction force cones, involving a clamping device to stabilize the cable and a cutting device with adjustable cutting depth and position, driven by a planetary gear set and transverse feed device to cut the cone smoothly and accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual cutting method using glass sheet is used, then operation simplicity is maintained, but processing efficiency is low and quality is poor
Solution Approach 1:
The patent replaces the manual mechanical cutting method with an automated cutting device that uses a rotating cutting blade driven by a motor. The cutting blade is guided by a guide rail to move along the cable surface, automatically forming the reaction force cone without manual intervention. This substitution of manual mechanical operation with an automated mechanical system resolves the contradiction by significantly improving processing efficiency while maintaining acceptable device complexity through the use of standard mechanical components.
Solution Approach 2:
The cutting device is designed to automatically position and cut the cable insulation layer without requiring continuous manual adjustment. The guide rail system enables the cutting blade to self-guide along the cable surface, and the rotating blade automatically removes material to form the tapered reaction force cone shape. This self-service capability improves productivity by eliminating the need for constant manual intervention while keeping the device structure relatively simple.
2Manufacturing precision
If manual cutting method is used, then device complexity is low, but manufacturing precision is poor and difficult to standardize
Solution Approach 1:
The patent replaces manual cutting with an automated cutting device featuring a rotating blade driven by a motor and guided by a guide rail. This mechanical automation ensures consistent cutting depth and angle, producing standardized reaction force cones with uniform quality. The guide rail system maintains precise geometric relationships between cutting elements, ensuring manufacturing precision while keeping the device structure manageable through the use of standard mechanical components.
Solution Approach 2:
The cutting device allows for adjustable cutting parameters including cutting depth, blade rotation speed, and feed rate. These parameters can be modified to accommodate different cable sizes and reaction force cone requirements, ensuring high manufacturing precision across various applications. The ability to change parameters without redesigning the entire device resolves the contradiction by providing precision and adaptability while maintaining relatively simple device structure.
3Productivity
If existing auxiliary cutting devices are used, then some automation is achieved, but operation complexity increases and efficiency remains insufficient
Solution Approach 1:
The patent combines the clamping function and cutting function into a single integrated device. The clamping jaw secures the cable while the rotating cutting blade, guided by the guide rail, forms the reaction force cone in one continuous operation. This merging of functions eliminates the need for multiple separate auxiliary devices and manual repositioning, improving processing efficiency while maintaining ease of operation through a unified, straightforward process.
Solution Approach 2:
The integrated cutting device automatically performs the cutting operation once the cable is clamped. The rotating blade self-guides along the cable surface using the guide rail system, and the cutting process continues automatically until the reaction force cone is formed. This self-service capability improves productivity by eliminating manual intervention during cutting while keeping operation simple - the operator only needs to clamp the cable and start the device.
Data Source
AI summary
The present disclosure relates to the technical field of cable processing, and discloses a method for processing a reaction force cone of a cable main insulating layer. The method includes: two ends of a cable are clamped through a clamping device, and the cable is enabled to pass through a cutting device; a cutting depth of the cutting device in a radial direction and a cutting position of the cutting device in an axial direction are adjusted; the cutting device is started, and the cable is cut by the cutting device to form the reaction force cone.