Top Drive Cable With Embedded Heating Elements
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Solution Overview
Problem
Heavy industry power cables, such as top drive service loop cables, face issues with insulation cracking or breaking in cold environments due to stiffness, and existing flexible polymers lack chemical and abrasion resistance, while pre-loading with power is time-consuming and prone to operator errors.
Innovation Solution
Integration of embedded heating elements within the cable structure, such as powered electric heating elements, to maintain flexibility and prevent insulation cracking by evenly distributing heat, combined with a robust construction including aramid fiber reinforcement and stainless steel braided armor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional durable polymers are used for cable insulation, then chemical and abrasion resistance is improved, but flexibility in cold temperatures deteriorates causing insulation cracking
Solution Approach 1:
The patent applies parameter changes by implementing a two-layer insulation structure where the inner layer uses a cold-temperature flexible polymer and the outer layer uses a durable polymer. This layered approach allows each layer to optimize its properties: the inner layer maintains flexibility at low temperatures while the outer layer provides chemical and abrasion resistance, resolving the contradiction between durability and cold-temperature flexibility.
2Reliability
If pre-loading power is applied to warm the cable before use, then insulation flexibility is improved, but operation time and reliability deteriorate due to operator error
Solution Approach 1:
The patent applies preliminary action by embedding heating elements within the cable structure that can be activated before cable deployment in cold environments. These heating elements pre-warm the insulation and conductor, ensuring the cable reaches operational temperature and flexibility before use, eliminating the need for manual pre-loading procedures and reducing operator error risk.
3Reliability
If heating elements are embedded in the cable, then cold temperature flexibility is improved, but device complexity increases
Solution Approach 1:
The patent applies merging by integrating heating elements directly into the cable structure, combining the heating function with the existing cable components. The heating elements are embedded within the insulation layers and conductor arrangement, creating a unified cable assembly that provides both power transmission and thermal management functions without requiring separate external heating systems.
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 ensures the cable remains flexible and resistant to chemical and abrasion damage in cold conditions, preventing insulation failure and reducing the risk of operator errors associated with pre-loading processes.
Implementation Method 1
embedded heating elements 100... powered electric heating elements... provides inherent warming of the conductor and its insulation
Implementation Method 2
evenly distributing heat... provides inherent warming of the conductor and its insulation
Data Source
AI summary
A cable including at least one primary conductor and at least one secondary conductor. A metallic shield element surrounds the primary and secondary conductors. A jacket surrounds the elements of the cable. At least one heating element is disposed under the shield element.