Subsea Cable Termination Crimping Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Subsea cable terminations face challenges in achieving reliable electrical and mechanical connections with minimal electrical resistance, particularly due to the complexity of cable construction and the need for skilled operations like soldering, which are time-consuming and pose health and safety risks.
Innovation Solution
A subsea connector cable termination system using a crimp component with integral conductive resilient members that latch to a housing, providing both mechanical and electrical connections without the need for soldering, and a method involving crimping and latching mechanisms to secure the cable core, reducing complexity and operational risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect the cable core to the connector, then reliable electrical connection is achieved, but the manufacturing process becomes time-consuming and requires skilled operators
Solution Approach 1:
The patent replaces the thermal-mechanical soldering process with a purely mechanical crimping system. The crimp component mechanically deforms the cable core and connector contacts to create a reliable electrical connection without requiring heat, flux, or skilled soldering operations, thereby dramatically improving manufacturing speed while maintaining connection reliability
Solution Approach 2:
The invention changes the fundamental parameter of connection establishment from thermal bonding (soldering) to mechanical deformation (crimping). This parameter change eliminates the need for skilled operators and reduces manufacturing time while ensuring reliable electrical contact through controlled mechanical force
2Reliability
If soldering is used to connect the cable core to the connector, then reliable electrical connection is achieved, but the process requires considerable operator skill and is time-consuming
Solution Approach 1:
The patent replaces the complex thermal and chemical processes of soldering with a simple mechanical crimping operation. This substitution makes the manufacturing process much simpler and easier to perform while maintaining reliable electrical connections, reducing the need for skilled operators
Solution Approach 2:
The crimp component is designed as a disposable or single-use element that is crimped onto the cable core and then discarded or integrated into the connector. This eliminates the need for complex soldering tools and skilled operators, making manufacturing simpler and more accessible
3Device complexity
If the cable termination interface is densely packed and deeply recessed, then compact connector design is achieved, but soldered joints become difficult to make with quality and repeatability
Solution Approach 1:
The patent replaces soldering with mechanical crimping, which is far more suitable for densely packed and deeply recessed interfaces. The crimping tool can access tight spaces and apply controlled mechanical force to create repeatable, high-quality connections without the difficulty of maneuvering soldering equipment in confined areas
Solution Approach 2:
The invention segments the connection process into distinct mechanical steps (insertion, crimping, locking) that can be performed sequentially in the densely packed interface. This segmentation allows each step to be optimized for the confined space, ensuring quality and repeatability despite the compact design
4Reliability
If soldering is used for cable termination, then electrical connections are made, but health and safety concerns and contamination issues arise
Solution Approach 1:
The patent replaces the thermal and chemical processes of soldering (which involve hot equipment, flux, and fumes) with a cold mechanical crimping process. This eliminates health and safety risks associated with heat exposure, chemical contamination, and fire hazards while maintaining reliable electrical connections
Solution Approach 2:
The invention converts the potential harm of complex thermal-chemical soldering processes into the benefit of a simple mechanical crimping process. By eliminating the harmful elements (heat, flux, fumes) and retaining only the essential function of creating electrical contact, the patent achieves reliable connections without health and safety risks
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 simplifies the termination process, reduces time and costs, and ensures reliable connections that withstand water pressure and handling forces, while minimizing health risks and avoiding contamination issues associated with soldering.
Implementation Method 1
two or more integral conductive resilient members adapted to be mounted radially outwardly of the cable core wherein the termination system further comprises a retainer
Implementation Method 2
A method of terminating a cable to a connector in a subsea cable connection system comprises exposing a section of cable core at one end of the cable by removing a section of insulation; fitting a crimp component or sleeve around the circumference of the cable core; crimping the crimp component to the cable core
Implementation Method 3
wherein one of the crimp body, or the conductive resilient members, are adapted to latch the crimp body to a housing
Data Source
AI summary
A subsea connector cable termination system for terminating a cable comprises a cable core (12) and a cable sheath (11). The termination system comprises a crimp component, the crimp component comprising a crimp body and further comprising two or more integral conductive resilient members (14) adapted to be mounted radially outwardly of the cable core. The termination system further comprises a retainer (18) or one of the crimp body, or the conductive resilient members, are adapted to latch the crimp body. A method of terminating a cable to a connector in a subsea cable connection system is also provided.