Custom Backshell for SWA Cable Connector Stress Reduction
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Solution Overview
Problem
Steel wire armored (SWA) cables are not flexible, leading to connector pins being pulled out of the pin holder or wire crimps losing contact with the mating connector or receptacle during handling, causing production outages due to well site shutdowns.
Innovation Solution
A custom backshell is designed to encase excess core cables between the entry component and connector body, accommodating fluctuations in cable length during coiling and uncoiling by providing an interior space that reduces stress on connections, ensuring consistent physical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If SWA cable is coiled or bent during handling, then cable flexibility is improved, but connector pins are pulled out of pin holder or wire crimps lose contact causing production outages
Solution Approach 1:
The backshell provides a nested interior space that accommodates excess core cables between the entry component and connector body. This nested structure allows the cables to be contained within the backshell volume, absorbing the dimensional changes that occur during coiling and uncoiling operations without transmitting stress to the electrical connections.
Solution Approach 2:
The backshell design incorporates an interior space configured to encase a portion of core cables representing excess amount when uncoiled. This beforehand cushioning provides a buffer zone that absorbs the mechanical stress and movement of excess cables during handling, preventing the cables from pulling on the connector pins and crimps before damage occurs.
2Reliability
If excess core cables are accommodated in backshell interior space, then stress on connections is reduced, but backshell volume increases
Solution Approach 1:
The backshell interior space is specifically configured to encase only the necessary portion of excess core cables between the entry component and connector body. This local quality approach ensures that the volume increase is minimized by providing protection only where needed, rather than enclosing the entire cable assembly.
Data Source
AI summary
An apparatus includes a backshell, the backshell having a shell defining an interior space, the interior space configured to encase a portion of a plurality of core cables between an entry component and a connector body in a steel wire armored (SWA) cable, wherein the portion represents an excess amount of the core cables when the SWA cable is uncoiled.