Stepped Swaged Connector for High Tension Power Lines
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Solution Overview
Problem
Existing connectors for high tension power transmission lines are long, heavy, and require numerous crimps or swages, leading to installation challenges such as bending and inefficiencies in cable compression, which affects reliability and efficiency.
Innovation Solution
A connector with a stepped series of cylindrical inner surfaces providing progressive compression, allowing for a smaller, lighter design that can be installed with fewer swages and is less prone to bending, using a single die set and suitable swaging tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If prior art connectors use numerous crimps or swages to achieve full tension fitting, then the connector can sustain required tensile load, but the connector becomes longer and heavier
Solution Approach 1:
The connector body is divided into multiple stepped internal cavities with progressively smaller diameters, allowing sequential compression of the cable in distinct zones. This segmentation enables full tension capacity with fewer, more efficient swaging operations rather than requiring numerous uniform crimps along the entire connector length.
Solution Approach 2:
Each internal cavity is designed with a specific diameter tailored to the local compression requirements at that position. The stepped configuration provides varying compression forces at different locations along the cable, optimizing the mechanical bond strength where needed most while reducing overall connector length and weight.
2Strength
If prior art connectors use numerous crimps or swages to achieve full tension fitting, then the connector can sustain required tensile load, but the connector becomes heavier
Solution Approach 1:
The stepped cavity structure concentrates the load-bearing function into specific segmented zones rather than requiring uniform reinforcement throughout the connector. This allows the connector to achieve full tension capacity with less material, reducing weight while maintaining strength.
Solution Approach 2:
The internal diameter parameter of the connector body is varied along its length through the stepped configuration, creating zones of different compression intensity. This parameter change optimizes the distribution of mechanical stress and reduces the total material required to achieve the required tensile load capacity.
3Strength
If prior art connectors have larger size and require more swages, then full tension fitting can be achieved, but installation time increases and installation becomes more difficult
Solution Approach 1:
The stepped internal cavities create natural segmentation of the swaging process into fewer, more efficient stages. Each cavity zone performs a specific compression function, allowing the installer to achieve full tension capacity with fewer tooling operations and less installation time compared to uniform multi-crimp connectors.
Solution Approach 2:
Each cavity is optimized for its specific local compression requirement, enabling more efficient material deformation and bonding in each zone. This local optimization reduces the total number of swaging operations needed and accelerates the installation process while maintaining full tension capacity.
4Strength
If prior art connectors are longer in length, then full tension fitting can be achieved through multiple crimps, but the connector becomes more prone to bending during installation
Solution Approach 1:
The stepped cavity design concentrates the load-bearing and compression functions into a more compact segmented structure. This reduces the overall connector length and improves rigidity, making the connector more resistant to bending during installation while still achieving full tension capacity through the optimized stepped zones.
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 connector achieves quicker and easier installation while sustaining 95% or more of the cable's rated strength, meeting class 1 full tension fitting requirements with reduced material damage and improved electrical contact.
Implementation Method 1
A series of swages, progressing successively from a light compression to a heavier compression, ensures that the connector will sustain the required tensile load.
Data Source
AI summary
An improved full tension connector for electrical conductors has a substantially cylindrical outer surface and a stepped series of substantially cylindrical inner surfaces with progressively smaller inside diameters. The design of the connector allows for improved control of the compression of the cable inside the fitting. A series of swages, progressing successively from a light compression to a heavier compression, ensures that the connector will sustain the required tensile load.