Split Repair Sleeve for Frayed Power Cables
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Solution Overview
Problem
Existing repair sleeves for power transmission cables are difficult to fit over frayed cables and cannot be applied directly over a failing splice, requiring the removal and replacement of the splice for repairs.
Innovation Solution
A swaged repair sleeve with a center portion having an enlarged cavity and split into two interlocking portions, allowing easy insertion and securement of frayed cables or failing splices, utilizing a stepped or tapered inner surface for secure compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional repair sleeve is used, then the cable can be protected, but it cannot be fitted over frayed cables or existing splices
Solution Approach 1:
The repair sleeve is divided into two separate halves that can be opened like a clamshell, allowing the damaged cable or existing splice to be inserted without removal. The two halves are then joined together to enclose and protect the cable section.
Solution Approach 2:
The repair sleeve transitions from a closed cylindrical form to an open C-shaped configuration during installation, allowing insertion from the radial direction. After placement, it returns to its cylindrical closed form to provide protection.
2Adaptability or versatility
If the repair sleeve has a standard cylindrical shape, then manufacturing is simple, but it cannot accommodate frayed cables
Solution Approach 1:
The sleeve is manufactured as two separate C-shaped halves rather than a complete cylinder, allowing the damaged cable to be inserted between the halves. This segmented approach maintains relative manufacturing simplicity while enabling accommodation of irregular cable shapes.
Solution Approach 2:
The inner surface of the sleeve halves features a stepped configuration with varying diameters along the length, providing different clearance zones. The enlarged central cavity provides additional space for frayed cable sections, while the stepped portions provide secure fit zones.
3Ease of operation
If the repair sleeve is made as a single piece, then structural integrity is high, but it cannot be opened to fit damaged cables
Solution Approach 1:
The sleeve is divided into two halves connected by joining mechanisms (such as interlocking features, fasteners, or welding points) that maintain structural integrity when closed while allowing the sleeve to be opened for installation and closed afterward to protect the cable.
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
Enables efficient and direct repair of frayed cables and failing splices without the need to remove existing splices, ensuring reliable and quick restoration of power transmission lines.
Implementation Method 1
The repair sleeve is swaged onto the cable
Data Source
AI summary
A repair sleeve has first and second end portions, each of which has a substantially cylindrical outer surface. The end portions are bored to receive a cable of a particular diameter. The inner surface of each end portion may be stepped or tapered. The center portion of the repair sleeve, between the two end portions, has an interior diameter substantially larger than the nominal diameter of the cable so that the repair sleeve can be use on a frayed cable or a cable with a failing splice. The repair sleeve is split longitudinally into two interlocking portions, which, when separated, allows the damaged cable or failing splice under repair to be inserted into a first one of the portions in a radial direction. The other portion is then inserted into the first portion and the repair sleeve is swaged onto the cable.