Three-Core Power Cable Filler Profiles for Even Pressure Distribution
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Solution Overview
Problem
Existing power cables with filler elements experience uneven pressure distribution due to imperfect matching between filler profiles and cores, particularly at higher voltages and in deep-sea installations, risking damage during cable laying.
Innovation Solution
A method of manufacturing power cables with tailored filler profiles that match the elliptical shape of the cores by determining the cross-sectional shape of filler profiles based on core stranding angle, ensuring a better fit and even pressure distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If filler elements with arced outer surfaces are used to match the cores, then the fit between filler elements and cores should be good, but the pressure distribution becomes uneven due to the helix angle causing elliptical core cross-sections
Solution Approach 1:
The filler element cross-sectional shape is customized to match the local geometry of the cores at different positions. Specifically, the filler elements are designed with elliptical cross-sections that correspond to the elliptical shape of the cores caused by stranding, rather than using uniform circular or arced shapes. This local adaptation ensures even pressure distribution across all contact points.
Solution Approach 2:
The invention changes the geometric parameters of the filler elements based on the stranding configuration. The cross-sectional dimensions and shape of the filler elements are calculated as functions of the nominal outer diameter of the cores and the stranding pitch, allowing the filler elements to conform to the helically stranded core arrangement and provide uniform radial pressure.
2Power
If larger and heavier power cables are used for higher nominal voltages, then the cable can handle higher power, but the outer diameter increases reducing storage capacity on vessels
Solution Approach 1:
The invention performs preliminary calculation and optimization of the filler element geometry before manufacturing. By determining the exact cross-sectional shape of filler elements based on the core stranding parameters in the design stage, the cable structure is optimized to achieve the required mechanical properties with minimal outer diameter, maximizing vessel storage capacity.
3Manufacturing precision
If arced filler surfaces are used, then the theoretical fit with circular cores should be good, but the fit deteriorates when cores have elliptical cross-sections due to helix angle
Solution Approach 1:
The invention introduces asymmetry in the filler element design by making the cross-sectional shape of filler elements dependent on the stranding pitch and helix angle. Instead of using symmetric arced surfaces that assume circular core cross-sections, the filler elements are designed with asymmetric elliptical cross-sections that match the actual deformed shape of stranded cores, achieving precise surface matching.
Data Source
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AI summary
Method of manufacturing a power cable comprising three cores and three filler profiles arranged in a stranded configuration, the method comprising: A) in a design stage of the power cable: A0) defining a nominal outer diameter of the cores, and defining a stranding pitch P of the cores, A1) determining, in a transverse plane of the power cable, a shape of at least one of the cores, A2) determining a cross-sectional shape of the filler profiles in a transverse section of a filler profile based on the shape determined in step A1), B) in the production stage of the power cable: B1) manufacturing each of the cores with the nominal outer diameter, B2) obtaining the filler profiles with the cross-sectional shape obtained in step A2), and B3) stranding the cores and the filler profiles with the stranding pitch P in an assembly machine.