Split Tubular Conductor Clamp for Low-Stress Rod Connections
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Solution Overview
Problem
Existing electrical connections to cylindrical rod conductors in medium voltage applications require large amounts of material, leading to high costs and unstable connections due to screw-based designs that cause electrical stress and dielectric breakdown.
Innovation Solution
An electrical connection arrangement using a tubular conductor with a longitudinal cut and a clamp that applies a variable force to secure the connection, reducing material usage while maintaining electrical resistance and minimizing stress points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large diameter conductor is used to reduce electrical stress and avoid dielectric breakdown, then the electrical connection reliability is improved, but the amount of material needed increases leading to higher cost
Solution Approach 1:
The conductor is divided into two functional parts: a massive rod conductor for mechanical strength and stress distribution, and a tubular conductor for electrical connection. This segmentation allows each part to optimize its function without requiring the entire conductor to be massive, thus reducing material usage while maintaining reliability.
Solution Approach 2:
The tubular conductor is nested over the rod conductor, creating a concentric arrangement where the tubular portion provides the electrical connection interface. This nesting allows the connection structure to achieve the effective diameter needed for stress reduction without requiring a single massive conductor throughout the entire assembly.
2Strength
If a threaded massive bar connection is used to connect the conductor, then the mechanical connection is achieved, but the electrical connection becomes unstable due to electrical stress on the threads
Solution Approach 1:
The connection structure separates mechanical fastening (handled by the clamp and screws) from electrical contact (handled by the tubular-conductor interface). The tubular portion provides a large surface area electrical contact that avoids the thread structure, preventing electrical stress concentration while maintaining mechanical strength through the clamp assembly.
3Quantity of substance
If a tubular conductor with longitudinal cut is used, then the amount of material is reduced, but the structural integrity and ability to maintain electrical contact may be compromised
Solution Approach 1:
The tubular conductor is cut longitudinally to create a C-shaped cross-section that can be opened and closed by the clamp. This segmentation allows the tubular portion to be installed over the rod conductor and then securely clamped, maintaining structural integrity at the clamp interface while using less material than a complete circular tube would require.
Solution Approach 2:
The tubular conductor maintains full circular cross-section at most locations to provide structural strength and electrical conductivity, but is locally cut open only where the clamp applies force. This localized modification reduces material usage and facilitates installation while preserving structural integrity in the critical uncut regions.
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 robust and cost-effective connection that reduces material usage and electrical stress, enhancing dielectric withstand voltage and preventing breakdowns.
Implementation Method 1
a clamp adapted to surround the outer diameter of the tubular end portion of the tubular electrical conductor, the clamp is configured to apply a variable force on the tubular end portion to connect the tubular end portion and the end portion of the electrical conductor rod mechanically and electrically
Implementation Method 2
The cut in the tubular end portion of the tubular electrical conductor facilitates for inserting the electrical rod conductor in the tubular electrical conductor since it allows for the tubular end portion to flex a little radially outwards, and to deform when exposed to the clamp force
Implementation Method 3
By applying the force on the tubular end portion, the clamp deforms the split tubular end portion and presses or forces it onto the electrical rod conductor to provide sufficient electric contact
Data Source
Figure 1~2
Figure 3~4C
Figure 5
AI summary
The present invention relates to an electrical connection arrangement (100) for connecting to an electrical conductor rod (1), the electrical connection arrangement (100) comprises: tubular electrical conductor (102) comprising a tubular end portion (104) with an inner diameter (d1) larger than the outer diameter (d2) of the electrical conductor rod (1), the tubular end portion (104) is adapted to receive an end portion (2) of the electrical conductor rod (1) inside the inner diameter (d1) of the tubular end portion (104), the tubular end portion (104) of the tubular electrical conductor (102) comprises at least one longitudinal cut (106); a clamp (108) adapted to surround an outer diameter (d3) of the tubular end portion (104) of the tubular electrical conductor (102), the clamp (108) is configured to apply a variable force on the tubular end portion (104) to connect the tubular end portion (104) and the end portion (2) of the electrical conductor rod (1) mechanically and electrically.