Subsea Cable Connector with Conical End Stops
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Solution Overview
Problem
Subsea connectors face challenges in reliably connecting cables with minimal electrical resistance and preventing external forces from dislodging the cable, due to the complex construction of cables with metallic cores and multiple insulation layers, which requires skilled operations and poses health and safety concerns with soldering.
Innovation Solution
A subsea connector cable connection system featuring a conical interface and retainer with screw threads and conical surfaces to create end stops, allowing for secure mechanical and electrical contact without complex construction steps, and a method for connecting cables using a retainer and interface with a locking mechanism to ensure stability and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect the cable core to the connector, then electrical connection quality is improved, but manufacturing complexity and operator skill requirements increase
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical system) with a mechanical crimping system. The cable core is mechanically compressed between the connector contact and a crimping element, creating a reliable electrical connection without requiring soldering skills or equipment. This substitution maintains electrical connection quality while dramatically simplifying the manufacturing process.
Solution Approach 2:
The crimping mechanism is designed to self-align and self-compress the cable core into place. The conical surfaces and end stops automatically position the cable core correctly during the crimping operation, eliminating the need for skilled operators to manually position and secure the connection. The system performs the alignment and securing functions automatically through its geometric design.
2Reliability
If soldering is used to connect the cable core to the connector, then electrical connection quality is improved, but health and safety risks increase
Solution Approach 1:
The patent eliminates soldering operations entirely by using a mechanical crimping system. This removes all health and safety hazards associated with soldering, including exposure to hot temperatures, toxic flux chemicals, and potential burns. The mechanical crimping process operates at ambient temperatures with no harmful emissions, making it safe for operators while maintaining connection quality.
3Object-affected harmful factors
If a crimp type cable joint is used instead of soldering, then health and safety risks are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The conical surfaces and end stops in the crimping mechanism automatically self-align the cable core during the crimping operation. The geometry of the conical surfaces guides the cable core into the correct position, and the end stops prevent over-compression. This self-aligning design eliminates the need for high-precision manual positioning, allowing standard manufacturing tolerances to achieve consistent, high-quality connections.
Solution Approach 2:
The patent employs conical (curved) surfaces instead of flat surfaces for the crimping interface. The conical geometry provides progressive compression and automatic self-centering of the cable core, ensuring precise alignment without requiring high-precision manufacturing of the cable positioning features. The curved surfaces distribute the compressive force evenly and guide the cable core into the correct position automatically.
4Strength
If the cable connection system includes multiple components (interface, retainer, conical surfaces), then mechanical strength is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into integrated components. The interface and retainer are designed as unified structures that simultaneously provide mechanical strength, electrical connection, and cable positioning functions. The conical surfaces are formed as integral features of these components rather than separate elements, reducing the total number of parts while maintaining the mechanical strength required to withstand external forces.
Data Source
AI summary
A subsea connector cable connection system has an interface and a retainer. One of the interface and the retainer has an external screw thread on a cylindrical section and the other has a corresponding internal screw thread on a cylindrical section. The interface further includes a conical body extending from the cylindrical section and the retainer further includes a corresponding conical internal surface extending from the cylindrical section and adapted to be spaced from the surface of the conical body when the interface and retainer are screwed together. Interaction of the conical body and conical internal surface produces a first end stop adapted to stop axial movement of the retainer. A second end stop remote from the first end stop is provided, adapted to stop axial movement of the cable.In one embodiment the connector may include a locking mechanism whereby undoing the joint requires more torque than doing up the joint.