Threaded Cable Joint Assembly for Fast Flexible Power Splicing
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Solution Overview
Problem
Existing methods for joining electric power cables are time-consuming and lack efficiency, particularly when creating flexible transition joints between two cables of different configurations.
Innovation Solution
A cable assembly and method utilizing a joining element with threaded end sections that screw into aligned openings in the cables, allowing simultaneous connection without rotating the cables, and optionally featuring an intermediate section and sleeve for enhanced stability and tool interface for easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the stranded wires of each cable end are unwound and pulled back to expose the ends of each layer and the central rod, then the cables can be thermally joined between the central rods, but the assembly process becomes very time-consuming
Solution Approach 1:
The joining element is divided into multiple functional segments: a first engagement portion for the first cable, a second engagement portion for the second cable, and an intermediate portion connecting them. This segmentation allows each portion to be optimized independently for its specific function while enabling simultaneous engagement with both cables without requiring complete unwinding of strands.
Solution Approach 2:
The joining element is designed with pre-formed engagement portions that can directly engage with the cable structures. The first engagement portion is pre-configured to interface with the first cable's conductor structure, and the second engagement portion is pre-configured for the second cable, eliminating the need for time-consuming unwinding and preparation of cable strands.
2Reliability
If the stranded wires are unwound and pulled back to access central rods for thermal joining, then a secure electrical connection can be achieved, but the process complexity increases
Solution Approach 1:
The joining element serves multiple functions through its different portions: the first engagement portion provides mechanical and electrical connection to the first cable, the second engagement portion provides the same function to the second cable, and the intermediate portion provides structural connection and stress distribution. This multi-functionality in a single component reduces assembly complexity compared to multiple separate components.
Solution Approach 2:
The intermediate portion of the joining element acts as a mediator between the two cable engagement portions. It distributes mechanical stresses, provides structural support, and enables the simultaneous engagement of both cables without requiring direct interaction between the cable strands, thereby simplifying the overall assembly process.
3Productivity
If the joining element allows simultaneous connection to both cables through rotation, then assembly time is reduced, but the cables themselves cannot be rotated during assembly
Solution Approach 1:
The joining element is designed with rotational capability around its longitudinal axis, allowing it to dynamically adjust its orientation during assembly. The engagement portions are configured to maintain secure connection to both cables while the joining element itself rotates, enabling efficient assembly without requiring cable manipulation.
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
This approach enables a more efficient and flexible method for joining cables, allowing them to be handled and installed similarly to non-spliced sections, reducing assembly time and ensuring a strong, smooth connection.
Implementation Method 1
the first threaded end section is connected to the first conductor; wherein the second threaded end section is connected to the second conductor. The first threaded end section is connected to an opening provided in the first conductor; and the second threaded end section is connected to an opening provided in the second conductor.
Data Source
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AI summary
The present invention relates to a cable assembly (100) comprising a first cable (20) having a first conductor (22), a second cable (40) having a second conductor (42) and an electrically conducting joining element (60). The joining element (60) comprises a first threaded end section (61) and a second threaded end section (62) opposite of the first end section (61. The first threaded end section (61) is connected to the first conductor (22). The second threaded end section (62) is connected to the second conductor (42). The present invention also relates to a method for joining a first cable (20) having a first conductor (22) and a second cable (40) having a second conductor (42).