Patent ID: 12224515

DETAILED DESCRIPTION OF THE FIGURES AND OF EMBODIMENTS

Reference will now be made in detail to the various embodiments, one or more examples of which are illustrated in each figure. Each example is provided by way of explanation and is not meant as a limitation. For example, features illustrated or described as part of one embodiment can be used on or in conjunction with any other embodiment to yield yet a further embodiment. It is intended that the present disclosure includes such modifications and variations.

Within the following description of the drawings, the same reference numbers refer to the same or to similar components. Generally, only the differences with respect to the individual embodiments are described. Unless specified otherwise, the description of a part or aspect in one embodiment can be applied to a corresponding part or aspect in another embodiment as well.

According to embodiments described herein, a cable lug device is a device by which two electrical conductors can be connected, especially electrically connected. In particular, a cable lug device is a device for connecting two cables with each other; especially a cable lug device is a device for electrically connecting two cables with each other. Typically, a cable lug device has a receiving part, in which a first cable can be inserted and fixed. Further, a cable lug device also has a contacting part, which is contacted by a second cable, the contacting part being e.g., in the form of a loop part or an eye part. Typically, the loop can either contact the second conductor with a plane or the second conductor may be passed through the “hole” of the loop.

A cable lug device according to embodiments described herein is an emergency break cable lug device. That means that the cable lug device has an emergency break function for the case of an emergency (as for instance mentioned above for offshore wind turbine installations: storm, high swell, earthquake and the like). In some embodiments, the emergency break function may be used for (intentionally) disconnecting the cables, e.g., for replacement or maintenance reasons. In particular, with the emergency break cable lug device according to embodiments described herein, a cable connected to the cable lug device according to embodiments described herein can be pulled out of the cable lug device without damage, in particular without damaging the cables, the bushings, and/or a connector device. Typically, the cable lug device according to embodiments described herein will give the cable free, if a force on the cable and/or the cable lug device is above a defined threshold value, especially a tension force.

According to embodiments described herein, the emergency break cable lug device allows pulling out the cable without severe damage by providing a pin element and a socket element, wherein the pin element can be inserted into the socket element to form the cable lug device according to embodiments described herein. A pin element as referred to in embodiments described herein may be understood as a pin-like element or a bolt-like element being adapted for being inserted in a socket element to form a cable lug device. A socket element as referred to in embodiments described herein may be understood as a socket-like element or a sleeve-like element being adapted for receiving the pin element for forming the cable lug device according to embodiments described herein. Typically, both the pin element and the socket element may be adapted to fit to each other and hold each other (especially up to a predefined force acting on the cable lug device). Typically, further elements may be provided between the pin element and the socket element, and respective receiving parts may be provided in one of the pin element and the socket element, or both.

FIG.1ashows an embodiment of a pin element100as described herein. The pin element100is a pin element for an emergency break cable lug according to embodiments described herein. The pin element100includes a fixing part101for fixing a cable to the pin element100. Typically, the fixing part101of the pin element100may have a substantially tube-like shape or cylinder-like outer shape having a round basis area, or a polygon-like basis area, such as a hexagonal basis area. According to some embodiments, which may be combined with other embodiments described herein, the fixing part101may be adapted for fixing a cable to the fixing part101by crimping (resulting e.g., in a press fit of the cable in the fixing part101) or/and screwing.

FIG.1bshows the pin element100according toFIG.1ahaving a cable400fixed to the fixing part101of the pin element.

The pin element100according to embodiments described herein further includes a pinning part102, which is configured to be inserted in a respective receiving part201of the socket element200, as shown inFIGS.2ato2cexplained in detail below. In particular, the pinning part102may have a bolt-like shape or a plug-like shape. The pinning part102being configured for being received by the receiving part201of a socket element200according to embodiments described herein may be adapted by size and shape to fit in the receiving part of the socket element, in particular adapted by length, diameter, surface (such as surface material, surface roughness, surface quality), material, fitting shape, receptacles, notches, threads and the like.

In the embodiment of the pin element100shown inFIG.1a, a receptacle, in particular an elastic element receptacle103for an elastic element, such as a spring-like element, is provided. According to some embodiments, the elastic element receptacle may be a notch or notch area. Two elastic elements500,501are exemplarily shown in the embodiment shown inFIG.1f. For instance, the spring-like element may be a spring. According to some embodiments, the elastic element may be a specifically wound device made of an elastic material, such as metal. In some embodiments, which may be combined with other embodiments described herein, the elastic element may be wound in an angular or inclined manner. In some embodiments, which may be combined with other embodiments described herein, the elastic element may be made from a first elastic material, such as a metal (e.g., copper) and may be coated with a second material. According to some embodiments, the elastic element may be made from one (or two) electrically conducting material(s).

Typically, the elastic element as described herein may be provided between the pin element100and the socket element200according to embodiments described herein. More typically, the elastic element as described herein may be provided between a pin element and a socket element of the cable lug device for increasing or ensuring an electrical contact between the pin element and the socket element. According to some embodiments described herein, the elastic elements provide a sliding contact securing the current flow, especially the current flow between the pin element and the socket element of the cable lug device according to embodiments described herein. The elastic element being provided between the pin element and the socket element may be in contact with both, the pin element and the socket element.

Additionally or alternatively, the elastic element500,501placed between the pin element100and the socket element200may be provided as a holding element or clamping element for increasing or ensuring a proper halt of the pin element in the socket element. In some embodiments, the elastic element provides a suitable elasticity or tension force. For instance, the elastic element being provided between the pin element and the socket element may be designed and adapted (e.g., by size, shape, and/or material(s)) to perform a holding function, in particular to perform the holding function up to a predefined force (e.g., a tensile force) acting on the cable fixed to the fixing part101of the pin element100or the cable lug device. In some embodiments, the elastic element holds the pin element100in the socket element200up to a predefined threshold value of force acting on the pin element100and/or the socket element and/or the cable being fixed to the fixing part101of the pin element100. According to some embodiments described herein, when a force exceeding the predefined threshold value acts on the cable lug device, the pin element is no longer held in the socket element, e.g., due to a break of the elastic element. For instance, the predefined threshold value for a break of the connection between the pin element and the socket element by the elastic element may be adjusted by adapting the size, shape, or material of the elastic element.

For instance, the elastic element being adapted for breaking at a predefined threshold value of force acting on the cable fixed to the fixing part101of the pin element100(or on the socket element of the emergency break cable lug device), may break in case of an emergency exceeding the predefined threshold value of force (e.g., due to a storm, or swell acting on the cable of an offshore installation) and may release the connection between the pin element100and the socket element200of the cable lug device according to embodiments described herein. According to some embodiments, the pin element100may additionally or alternatively be halted in the socket element by a fastening device, such as a shear off fastening device, as will be described in detail below. In some embodiments, the cable lug device according to embodiments described herein has a sliding (electrical) contact (typically between pin element and socket element, more typically provided by an elastic element) and a fastening device with shear off function.

FIG.1cshows an embodiment of the pin element100having two elastic element receptacles103,104, which may for instance be two notches acting in particular as a receptacle for two elastic elements as described in detail above. According to some embodiments, the number of elastic elements (and thus the number of elastic element receptacles in the pin element100of the cable lug device) may be chosen according to the respective application and the operational conditions of the application. As an example, the pin element may typically provide more than 1 elastic element receptacle, more typically more than 2 elastic element receptacles, and even more typically more than 3 elastic element receptacles.

FIG.1dshows an embodiment of a pin element100for a cable lug device according to some embodiments described herein. The pin element100as shown in the example ofFIG.1dprovides a fastening device receptacle105for a fastening device, such as a screwing device, in particular a shear off screwing device. Typically the pin element100as exemplarily shown inFIG.1dalso provides two elastic element receptacles103,104for elastic elements as described above. According to some embodiments, the fastening device, which may be placed in the fastening device receptacle105of the pin element100, may provide a holding function between the pin element100and the socket element200. The holding function of the fastening device may be provided additionally or alternatively to a holding function of one or more elastic elements. Especially, the fastening device is described in detail below with respect to the socket element and the cable lug device according to embodiments described herein.

FIG.1eshows a pin element100according to some embodiments described herein. The pin element100ofFIG.1ehas two elastic element receptacles103,104for an elastic element (as for instance described above), and a fastening device receptacle105for a fastening device. According to some embodiments, which may be combined with other embodiments described herein, the pin element100ofFIG.1ehas a pin stopper part106with a contact area for standing in contact with a respective area of the socket element, when assembled together to a cable lug device according to embodiments described herein. Typically, the pin stopper part106may act as an assembling aid, or an additional contact area for the pin element and the socket element when assembled. For instance, the pin stopper part may stop movements of the pin element100into the socket element200and may ensure a proper function of the elastic elements and/or the fastening device (in particular by limiting a force acting as a compressive force onto the pin element100in direction of the socket element200).

FIG.1fshows an embodiment of the pin element100as exemplarily shown inFIG.1e. The pin element100ofFIG.1eadditionally shows examples of two elastic elements500,501, in particular in the elastic element receptacles103,104of the pin element100according to embodiments described herein. The elastic elements500,501shown inFIG.1fmay be elastic elements as described above.

FIG.2ashows a socket element200for an emergency break cable lug device according to embodiments described herein. The socket element200includes a receiving part201configured for receiving a pinning part102of the pin element100, typically a pinning part of a pin element100as described in embodiments above, and more typically a pinning part with one or more elastic elements mounted thereon. According to some embodiments, the receiving part201may be adapted by size, shape, surface properties and material to the pinning part101of the pin element100. For instance, the receiving part201may be adapted so that a pin element100with one or more elastic elements mounted to the pin element100can be inserted in the receiving part201of the socket element. According to some embodiments, which can be combined with other embodiments described herein, the one or more elastic element may be designed and adapted that the elastic element(s) may partially be compressed for the montage so that the pin element together with the (one or more) elastic element can be inserted in the receiving part of the socket element200. As can be seen inFIG.2a, the receiving part201of the socket element200can be provided with at least one first receiving receptacle203(such as a notch or notch area). The at least one first receiving receptacle203of the socket element200may be adapted to carry the elastic element500together with the elastic element receptacle103of the pin element100. That is, the first receiving receptacle203of the socket element200and the elastic element receptacle103of the pin element100hold the elastic element500between the pin element100and the socket element200. In particular, the first receiving receptacle203of the socket element200and the elastic element receptacle103of the pin element100form together a gap or a cavity for the elastic element.

The socket element200according to embodiments described herein further includes a palm part202for electrically connecting the socket element200to an external conductor600, in particular an external cable or wire. For instance, the palm part202of the socket element200according to embodiments described herein may provide a surface, by which an external conductor, such as a wire or cable, may electrically be contacted. In some embodiments, the palm part202of the socket element200may include a hole207for electrically contacting an external conductor, such as a wire or cable, especially by guiding the external conductor through the hole.

FIG.3shows a side view of the socket element200according to some embodiments of the present disclosure. In the side view of the exemplary embodiment ofFIG.3, it can be seen that the palm part202contacts an external conductor600through the hole207shown inFIGS.2ato2c. Further,FIG.3shows that the receiving part202of the socket element200may have a cylinder-like shape in some embodiments, especially a hollow cylinder-like shape.

FIG.2bshows an embodiment of the socket element200, which may in particular correspond and fit to the embodiment of the pin element100shown inFIG.1c. The socket element200, and in particular the receiving part202of the socket element200, provides in the embodiment shown inFIG.2btwo first receiving receptacles203and204. Typically, the two first receiving receptacles203and204offer space for two elastic elements500and501, as explained in detail above.

FIG.2cshows a further embodiment of the socket element200. The socket element200ofFIG.2cprovides two first receiving receptacles203and204and, additionally, a second receiving receptacle205for a fastening device700for fastening the pin element100in the socket element200of the cable lug device according to embodiments described herein. According to some embodiments, which may be combined with other embodiments described herein, the second receiving receptacle205may be adapted for a fastening device, such as a screw, a bolt, a pin, or the like. According to some embodiments, which may be combined with other embodiments described herein, the fastening device (such as a fastening device700exemplarily shown inFIG.4) provided in the second receiving receptacle205may be a fastening device with a shear off function, typically a screw, and more typically a shear bolt or shear screw. In particular, a fastening device including a shear off function allows breaking the screw (in some applications removing the screw head) after having fastened the fastening device. According to embodiments described herein, a fastening device with shear off function, such as a shear off screw, is capable of limiting a force, especially a tensile force, acting on the cable.

According to some embodiments, the fastening device with shear off function may be adapted to break at a predetermined threshold value of force, for instance, if tensile force acting on the pin element100placed in the socket element200and/or the socket element200becomes too large. Such a defined breaking point of the shear screw or shear bolt may support the emergency break function of the cable lug device according to embodiments described herein. In particular, the fastening device breaking at a predefined threshold value of force may allow the pin element100leaving the socket element200without severe damage of the respective parts (apart from the shear off screw). According to some embodiments described herein, a fastening device with shear off function may break at forces of typically between about 300 N and about 1200 N, more typically between about 400 N and about 1100 N, and even more typically between about 500 N and about 1000 N.

In other words, the fastening device may act as a holding element holding the pin element100in the socket element200during normal operation, either additionally or alternatively to the elastic element described above.

Going back to the embodiment of the socket device200shown inFIG.2c, one can say that the socket element having a second receiving receptacle may be combined with different embodiments of pin elements100. For instance, the socket element200ofFIG.2cmay be combined with the pin element100shown inFIG.1dhaving a fastening device receptacle105according to some embodiments described herein. That means that the fastening device700may be held by both the fastening device receptacle105of the pin element100and the second receiving receptacle205of the socket element. In some embodiments, the socket element200shown inFIG.2cmay be combined with a pin element100as for instance shown inFIG.1cwithout a substantial fastening device receptacle. In this case, the fastening device may be used like a fastening and clamping device clamping the pin element within the socket element.

According to some embodiments, any combination of first and second receiving receptacles in the socket element may be used, as suitable for the respective application. For instance, any number of first receiving receptacles for elastic elements may be combined with any number of second receiving receptacles for fastening devices.

As can be seen inFIG.2c, the embodiment of the receiving part201of the socket element shown may provide a socket stopper part206with a contact area for standing in contact with a respective stopper part or area106of the pin element100, when assembled. According to some embodiments, the stopper part106of the pin element100and the stopper part206of the socket element200may allow a better assembly and a secure stop against compression forces acting on the pin element in direction of the socket element, as exemplarily explained with respect toFIG.1e.

FIG.4shows a cable lug device according to embodiments described herein. The cable lug device300is an emergency break cable lug device and includes a pin element100for fixing a cable400and a socket element200, in which the pin element100is insertable and which is configured to be connected to an external conductor600, in particular an external cable or wire. Typically, the pin element100of the cable lug device300may be a pin element as described in embodiments above. Typically, the socket element200of the cable lug device300may be a socket element as described in embodiments above. The cable lug device300is designed and adapted so that the pin element100exits the socket element upon a predefined threshold value of force, especially a tensile force, acting on the pin element100and/or the socket element200. Typically, the function of an exiting pin element of the cable lug device may be provided by an elastic element, as described in embodiments before and/or a respective fastening device as described in embodiments before (in particular a shear off screw, a shear off bolt or the like). For instance, the shape and size of the elastic element receptacles of the pin element100of the cable lug device and the parameters (such as size, shape and material) of the elastic element and/or the size and shape of the second receiving receptacle of the socket element and the parameters (such as size, shape, material, and shear off function) of the fastening device may contribute to the function of the cable lug device to fall into the single pieces pin element and socket element under defined circumstances. In some embodiments, the materials and the geometry of the pin element and the socket element may lead to the effect of the cable lug device falling into the single pieces at appearance of a predefined threshold value (especially without the need for an elastic element or a fastening device). For instance, the pin element and/or the socket element may be provided with geometric implementations, such as spikes or the like, for ensuring the emergency break function of the cable lug device.

According to some embodiments described herein, the function of separating the mounted parts of the cable lug device (i.e. at least the pin element and the socket element) may be triggered at a predefined threshold value of tensile force acting on the pin element and/or the socket element. In particular, a tensile force coming from the cable400fixed to the fixing part of the pin element100and/or a tensile force coming from an external conductor being in contact with the palm part of the socket element200may affect the separation of the pin element and the socket element.

According to some embodiments, which may be combined with other embodiments described herein, the pin element100and the socket element200may be made of an electrically conductive material, such as a metal. Typically, the pin element100and/or the socket element200may be made or may contain non-ferrous materials, in particular materials like copper, copper-alloys, aluminum, and/or aluminum alloys. According to some embodiments, the cable lug device300provides an electrically conducting path from the cable400fixed to the pin element100to an external conductor600being in contact with the socket element200, in particular a palm part202of the socket element200.

FIG.5shows a cross-sectional view of an emergency break cable lug device according to some embodiments described herein. The cable lug device shown inFIG.5includes a pin element100and a socket element200with a palm part202. A cable400is shown inFIG.5being fixed to the fixing part101of the pin element100. The cable400(and the cables described herein) may typically be a high voltage cable (e.g., by size, shape, material and isolation). Generally, HV cables particularly may include a conductor, an insulating layer, shield wires, and an outer sheath. The cables described herein may in particular be cables suitable for offshore applications. According to some embodiments, the cable400fixed to the pin element100of the cable lug device may have a core insulation401and a stress cone402.

In the context of the present disclosure, a high voltage (HV) is particularly to be understood as a voltage higher than 1 kV for alternating currents or higher than 1.5 kV for direct currents.

FIG.6shows an embodiment of a cable lug device300having a pin element100and a socket element200being placed in a connector device800. As can be seen inFIG.6, a cable400is fixed to the pin element100of the cable lug device. According to some embodiments, the connector device800includes a receiving part801for receiving and housing the cable lug device and a part of the cable400according to embodiments described herein. Further, the connector device800may include a contact part802housing the palm part202of the socket element200of the cable lug device as described in embodiments described herein. Typically, the contact part802houses the palm part of the cable lug device and the external conductor, which may electrically be connected to the cable400fixed in the pin element100of the cable lug device. In some embodiments, the external conductor may be an external cable (such as cable600shown inFIG.3) being guided through the hole207of the palm part202of the socket element200of the cable lug device300. According to some embodiments, the contact part802of the connector device800may provide a path803for the external conductor to be connected to the cable fixed by the cable lug device.

With the emergency break cable lug device300according to embodiments described herein, a cable fixed to the cable lug device can be pulled out of the connector device800if a specific force (in particular a tensile force) on the cable400becomes to high.

According to some embodiments, a method is provided for mounting an emergency break cable lug device300having a pin element100and a socket element200. Typically, the pin element100may be a pin element100as described in detail in embodiments above. Typically, the socket element200may be a socket element as described in detail in embodiments above. The method900is exemplarily shown as a flow chart inFIG.7a. The method900according to embodiments described herein includes in block901inserting the pin element100into the socket element200for forming the emergency break cable lug device300. In block902, the method900according to embodiments described herein includes providing at least one elastic element500between the pin element100and the socket element200and/or a fastening device700between the pin element100and the socket element200. The elastic element between the pin element and the socket element allows or enables, as described in detail above, that the pin element100exits the socket element200upon a predefined threshold value of force acting on the pin element100and/or the socket element200. In particular, the force causing a separation of the pin element and the socket element of the cable lug device may be a tensile force, especially a tensile force acting on a cable being fixed to the pin element of the cable lug device (as for instance shown inFIG.1b) and/or a tensile force acting on the socket element of the cable lug device (for instance via the palm part of the socket element). According to some embodiments, the elastic element provided between the pin element and the socket element may be a sliding electrical contact, especially for ensuring the current flow, especially the current flow between the pin element and the socket element of the cable lug device according to embodiments described herein.

Additionally or alternatively, the pin element and the socket element may be adapted (such as by shape, geometrical implementations such as spikes or the like, material, or surface properties, such as surface roughness) to be separated at appearance of a predefined threshold value of force acting on the cable lug device.

According to some embodiments, which may be combined with other embodiments described herein, an elastic element (e.g., a spring element as described above) may be mounted to the pin element100before the pin element100is inserted into the socket element200for forming the cable lug device300according to embodiments described herein.FIG.1fshows an example of a pin element100being equipped with two elastic elements500,501before being inserted into a socket element of a cable lug device.

In some embodiment, the method900as schematically shown inFIG.7bincludes in block903connecting (especially electrically connecting) at least a first cable400and a second cable or an external conductor600to each other with the cable lug device300. In particular, the first cable400may be fixed to the pin element100(especially the fixing part101of the pin element100as exemplarily described above). Typically, the second cable or external conductor600may be connected (or be in electrically conductive contact) with the socket element, in particular the palm part of the socket element of the cable lug device (as exemplarily shown inFIG.3). According to some embodiments, which may be combined with other embodiments described herein, the pin element and the socket element being made from an electrically conductive material and being additionally connected via the elastic element500offer an electrically conductive path from the first cable400through the pin element100further through the socket element200to the second cable or external conductor600.

According to some embodiments, which may be combined with other embodiments described herein, the method may further include fixing the first cable400to the fixing part101of the pin element100and aligning the palm part202of the socket element200to the second cable or external conductor600. Typically, the aligning may be performed after the pin element100has been inserted in the socket element200, and in particular before a fastening device (if any) is inserted in the respective receptacle (s) of the socket element and the pin element. Typically, the pin element100is rotatable within the socket element (especially before a fastening device is applied). A heavy offshore cable being connected to a known cable lug cannot be rotated for aligning the palm to a connector device. The cable lug device according to embodiments described herein (and especially the respective mounting method) allows a rotation and, typically, an alignment of the cable lug device to the second cable or external conductor600after having fixed the first cable400to the cable lug device300according to embodiments described herein. In particular, the cable lug device according to embodiments described herein enables a rotation of the pin element within the socket element (typically at least in a mounting stage and, more typically, before a fastening device is applied). This improves the montage of the cable lug device according to embodiments described herein, particularly of a cable lug device for high voltage applications, and even more particularly of a cable lug device for offshore applications.

According to some embodiments, the method may further include providing a fastening device in a second receiving receptacle of the socket element of the cable lug device. Typically, the fastening device may also be provided in a fastening device receptacle of the pin element of the cable lug device. As described in detail above, the fastening device may be a fastening device with a shear off function, which typically breaks up at appearance of a predefined force. The fastening device with a shear off function limits the force, especially the tensile force, acting on the cable lug device according to embodiments described herein or on one of the cable connected by the cable lug device.

In some embodiments, the method may further include connecting the cable lug device300to or into a connector device, such as a connector device800exemplarily shown inFIG.6. Typically, the connector device is pushed over the cable lug device onto the stress cone of the cable400. Typically, once the cable lug device according to embodiments described herein is placed in the connector device (more typically with a first cable fixed to the cable lug device), an external conductor, such as a second cable may be put in contact with the palm part202of the socket element200of the cable lug device. For instance, a second cable may be guided through the path803of the connector device for being electrically connected to the cable lug device according to embodiments described herein.

Before the pin element is inserted into the socket element to form a cable lug device according to embodiments described herein, the cable400may be prepared, e.g., by pushing on a stress cone, especially onto the core insulation of the cable400. Further, the pin element100may be pushed onto the cable400and fixed to it, e.g., by crimping, especially hexagonal crimping, or by screwing or the like. When pushing the socket element over the pin element (typically carrying one or more elastic elements), the elastic elements may catch with the socket and are placed in the first receiving receptacle(s) of the socket element (as e.g., explained in detail above). The connector device may further be pushed onto a bushing and fixed to it.

According to embodiments described herein, the cable lug device and the single elements of it as well as the method for mounting a cable lug device allows an easy separation of the electrically conductive connection provided by the cable lug device. In particular, the separation of the pin element and the socket element upon acting of a predefined force prevents the breakage of parts of the cable lug device, the connector, the bushing or the cable. Instead, sacrifice elements are provided, such as elastic elements between the pin element and the socket element, or a fastening device with shear off function, as described in detail above. This prevents severe damage at main parts of the cable-to-cable connection offered by a cable lug device. Also, the repair is simple by replacing the sacrifice elements, such as the elastic elements and/or the fastening device, and push the different parts of the cable lug together again.

Though the present invention has been described on the basis of some preferred embodiments, those skilled in the art should appreciate that those embodiments should by no way limit the scope of the present invention. Without departing from the spirit and concept of the present invention, any variations and modifications to the embodiments should be within the apprehension of those with ordinary knowledge and skills in the art, and therefore fall in the scope of the present invention which is defined by the accompanied claims.