Switchgear Connector Shielding via Molded Conducting Layer
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Solution Overview
Problem
Existing connectors for medium and high voltage switchgear panels often result in incomplete electrical shielding due to improper clamping of the insulating body's flange between cups, leading to sharp edges and high field density spots.
Innovation Solution
A connector design featuring a molded insulating body with an integrated earth wire and a conducting layer coating, along with hinged lips and a recessed cylindrical surface, ensures a consistent electrical connection and shielding even when the insulating body shifts or is not centered, using a cylindrical spacer and elastic fingers to maintain contact pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flange is arranged on the insulating body and clamped between two circumferential flanges of the cups, then electrical connection is established, but the flange may not be clamped correctly leading to sharp edges and reduced shielding effect
Solution Approach 1:
The insulating body is divided into functional zones: a clamping zone with circumferential clamping surfaces for mechanical engagement, and a shielding zone with the electrically conducting layer for electromagnetic shielding. This segmentation ensures that the clamping function and shielding function are independently optimized, preventing the shielding layer from being compromised during assembly while maintaining reliable electrical connection.
Solution Approach 2:
The electrically conducting layer is pre-applied to the insulating body before assembly, and the clamping surfaces are pre-formed on the insulating body. This preliminary preparation ensures that the shielding layer is already in place and protected before the clamping operation occurs, eliminating the risk of sharp edges and improper clamping that would occur if the shielding layer were applied after assembly.
2Productivity
If the insulating body is pushed further in one cup than in the other, then assembly is simplified, but the flange will not get clamped correctly between the flanges
Solution Approach 1:
The insulating body features asymmetric positioning elements: circumferential clamping surfaces positioned at specific locations to engage with the cups, and a positioning element that interacts with the electrically conducting layer. This asymmetric design provides built-in positioning guidance that prevents the insulating body from being pushed unevenly into the cups, ensuring correct clamping while maintaining assembly efficiency.
Solution Approach 2:
The insulating body incorporates an electrically conducting layer with specific electrical and mechanical properties that change the interaction parameters between the insulating body and the cups. This conducting layer provides electrical contact and mechanical guidance, ensuring that even if assembly speed varies, the positioning accuracy is maintained through controlled electrical and mechanical parameter interactions.
3Reliability
If a coating of electrical conducting layer is arranged on the insulating body, then electrical shielding is provided, but sharp edges reduce the shielding effect and cause high field density spots
Solution Approach 1:
The electrically conducting layer is applied with varying local properties: in the clamping zone, it provides electrical contact and mechanical flexibility; in the shielding zone, it provides continuous electromagnetic shielding. The local quality of the conducting layer is optimized for each function, ensuring that sharp edges do not form at critical shielding locations while maintaining electrical connection where needed.
Solution Approach 2:
The insulating body is a composite structure combining insulating material with an integrated electrically conducting layer. This composite design allows the insulating body to simultaneously provide mechanical support, electrical insulation where needed, and continuous electromagnetic shielding where required. The conducting layer is integrated into the composite structure, eliminating sharp edges and ensuring uniform shielding coverage.
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 reliable mechanical and electrical connection, maintaining effective shielding and preventing high field density issues, ensuring a controlled electrical field distribution and preventing flashovers.
Implementation Method 1
a coating of an electrical conducting layer is arranged on the ground wire and at least part of the insulating body
Implementation Method 2
each cup including a conductor end extending through a tip of the cone and into the cup
Data Source
AI summary
A connector for electrically connecting two panels having switchgear has: two cups having a truncated cone shape for arrangement in a panel, the cups each having a conductor end extending through the tip of the cone and into the cup; an insulating body having two opposite truncated cone shaped outer surfaces each for reception in one of the cups and having a central passage; an electrically conducting element for connecting with the conductor ends extending in the central passage of the insulating body; wherein the insulating body is a molded body having an earth wire molded in; and wherein a coating of an electrical conducting layer is arranged on the earth wire and at least part of the insulating body.