Torsion Resistant Shielded Cable Alternating Winding
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Solution Overview
Problem
Wind turbine cables face torsional stress due to continuous rotation, leading to shield line fractures as the cables twist and reverse, affecting power generation efficiency and increasing maintenance costs.
Innovation Solution
A torsion-resistant shielded cable design featuring shield wires wound in a clockwise and counter-clockwise alternating pattern with a buffer section, providing additional extendability and distributed tension relief, combined with multiple layers of dielectric and weather-resistant materials to prevent fatigue and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If general cables are used in wind turbines, then the cable structure is simple and easy to manufacture, but the shield lines will fracture after continuous twisting and reversing due to torsional stress
Solution Approach 1:
The shield wire is divided into multiple independent sections, each wound in alternating clockwise and counter-clockwise directions. This segmentation allows different sections to compensate for torsional stresses independently, preventing fracture while maintaining overall shield integrity without requiring a completely different cable architecture.
Solution Approach 2:
The shield wire employs asymmetric winding patterns with alternating directions (clockwise and counter-clockwise) rather than uniform winding. This asymmetry creates balanced torsional resistance in both rotation directions, enabling the cable to withstand continuous twisting and reversing operations typical in wind turbine applications.
2Adaptability or versatility
If the cable allows continuous twisting to track wind direction, then the wind tracking capability is improved, but the shield wires undergo repeated torsion leading to fatigue and fracture
Solution Approach 1:
The shield wire is pre-configured with alternating winding directions and buffer sections that create built-in resistance against torsional fatigue. This preliminary anti-action structure counterbalances the torsional stresses generated during wind tracking operations, preventing fatigue accumulation and fracture before they occur.
Solution Approach 2:
Buffer sections are intentionally inserted between wound sections of the shield wire to provide cushioning against torsional stresses. These buffer zones absorb and distribute the mechanical stress from continuous twisting, protecting the shield wire from fatigue failure while allowing the cable to maintain its wind tracking adaptability.
3Object-affected harmful factors
If the shield wire is wound tightly to provide good shielding, then the electromagnetic shielding performance is improved, but the cable becomes rigid and cannot withstand torsional stress from rotation
Solution Approach 1:
The shield wire structure transitions from a static tight winding to a dynamic configuration with alternating winding directions and buffer sections. This dynamic design allows the shield to maintain its electromagnetic shielding function while adapting to torsional deformations during cable rotation, preserving both shielding performance and torsion resistance.
Solution Approach 2:
The winding parameters of the shield wire are changed from uniform tight winding to alternating winding patterns with varying tension zones. By modifying the winding direction and inserting buffer sections, the cable achieves optimal balance between electromagnetic shielding effectiveness and mechanical flexibility to withstand rotational torsion.
Data Source
AI summary
The present invention provides a torsion resistant shielded cable which includes at least one conductor; an insulating layer covering outside the conductor; a first isolating layer surrounding the insulating layer; and a shielded layer including a number of wires, single wires or strand wires, wound around the first isolating layer in a clockwise and counter-clockwise alternative order along an axial direction of the conductor to prevent the strand wires from breaking while the torsion resistant shielded cable is twisted.