Telescopic Electric Conductor Geometry Control

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Solution Overview

Problem

High voltage electric arrangements using aluminum wires face challenges in geometry control and corona discharge due to uncontrolled shapes and narrow radii, particularly in compact and high electric field environments.

Innovation Solution

A telescopic electric conductor comprising an electrically conductive first tube and a movable second tube, with an internal flexible element that elastically deforms along the longitudinal axis, providing dimensional stability, reducing corona discharge risk, and allowing for compact and high-stress-cycle-capable designs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If aluminum wires are used to connect electric apparatuses, then electrical connectivity is achieved, but geometry control is difficult and uncontrolled shapes are formed

Engineering Contradiction:
Improveelectrical connectivityVSAvoidgeometry control
Core Design Contradiction:
ReliabilityVSShape

Solution Approach 1:

The patent employs a flexible element with a specific geometry (wave-shaped or corrugated structure) that provides both flexibility for movement and control over the conductor's shape. This flexible element is enclosed within a protective sheath that maintains the overall geometry while allowing controlled deformation, thus resolving the contradiction between maintaining electrical connectivity and controlling the shape of the conductor.

Inventive Principle:
Principle #30Flexible shells and thin films

2Volume of moving object

If aluminum wires are used in compact arrangements, then space is utilized, but corona discharges occur due to narrow radiuses

Engineering Contradiction:
Improvecompact arrangementVSAvoidcorona discharge
Core Design Contradiction:
Volume of moving objectVSObject-generated harmful factors

Solution Approach 1:

The patent designs the flexible element with optimized curvature and radius of bending, ensuring that even in compact arrangements, the conductor maintains sufficient radius to avoid corona discharge. The wave-shaped or corrugated structure is designed with controlled curvature radii that prevent electric field concentration, thus eliminating corona discharge while achieving compact packaging.

Inventive Principle:
Principle #14Spheroidality (Curvature)

3Adaptability or versatility

If telescopic structure is implemented with movable tubes, then adaptability to movement is improved, but device complexity increases

Engineering Contradiction:
Improvemovement accommodationVSAvoidstructure complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements a telescopic structure where one tube is nested within another tube, allowing relative movement between the tubes to accommodate expansion and contraction of the flexible element. This nested configuration provides adaptability to movement while maintaining a relatively simple overall structure, as the moving parts are contained within each other rather than requiring separate mounting mechanisms.

Inventive Principle:
Principle #7Nested doll (Nesting)

4Shape

If flexible element is placed inside the tube, then geometry control is improved, but manufacturing complexity increases

Engineering Contradiction:
Improvegeometry controlVSAvoidassembly complexity
Core Design Contradiction:
ShapeVSEase of manufacture

Solution Approach 1:

The patent divides the conductor into separate segments: the flexible element and the protective tube, which are manufactured separately and then assembled. The flexible element is first formed with its specific wave-shaped or corrugated geometry to ensure control over shape and prevent corona discharge, then inserted into the protective tube. This segmentation allows each component to be optimized and manufactured independently, reducing overall manufacturing complexity despite the sophisticated geometry control requirements.

Inventive Principle:
Principle #1Segmentation

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 telescopic electric conductor maintains well-defined geometries, avoids sliding contacts, and withstands high stress cycles, ensuring reliable operation in high voltage and compact environments with reduced risk of corona discharge and partial discharge.

Implementation Method 1

An electrically conductive flexible element is arranged inside the first tube. The flexible element is mechanically and electrically connected to the first tube and to the second tube and is arranged to elastically deform along the longitudinal axis.

Methodology Applied
Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS11664610B2Telescopic electric conductor and high voltage arrangement
Publication Date: 2023.05.30 HITACHI ENERGY LTD
  • US11664610B2 patent drawing
  • US11664610B2 patent drawing
  • US11664610B2 patent drawing

AI summary

A telescopic electric conductor includes an electrically conductive first tube having a longitudinal axis and an electrically conductive second tube movable relative to the first tube along the longitudinal axis while being at least partly received within the first tube. An electrically conductive flexible self-supporting element is arranged inside the first tube and is mechanically and electrically connected to the first tube and to the second tube. The flexible element is arranged to elastically deform along the longitudinal axis. The flexible element has a waveform shape with several cycles of the waveform includes a number of sections that are welded together, each section having a shape of a half cycle of the waveform.