CONDUCTOR ASSEMBLY WITH TWO CONDUCTIVE CORE PARTS

Abstract

A conductor assembly having first and second conductive core parts, wherein the first conductive core part is axially moveably arranged in respect to the second conductive core part, and having at least one insulating sleeve that is axially moveably arranged in respect to the first and second conductive core parts. At least one loading arrangement is embodied such that the first conductive core part is loaded in an axial direction against the second conductive core part. At least one insulating sleeve having first and second contact surfaces is clamped between the first and second conductive core parts. The clamping force of the loading arrangement is applied by a first corresponding contact surface of the first conductive core part and a second corresponding contact surface of the second conductive core part to the first and second contact surfaces of the at least one insulating sleeve.

Claims

1. A conductor assembly comprising: a first conductive core part and at least a second conductive core part, wherein the first conductive core part is axially moveably arranged in respect to the at least second conductive core part, and comprising at least one insulating sleeve that is axially moveably arranged in respect to the first conductive core part and the at least second conductive core part, and at least one loading arrangement, wherein the at least one loading arrangement is embodied such that the first conductive core part is loaded in an axial direction against the at least second conductive core part, wherein the at least one insulating sleeve is arranged in respect to the first conductive core part and the at least second conductive core part such that it is clamped between the first conductive core part and the at least second conductive core part due to the loading between the first conductive core part and the at least second conductive core part applied by the least one loading arrangement and wherein the at least one insulating sleeve comprises a first contact surfaced and an at least second contact surface, wherein the first conductive core part comprises an first corresponding contact surface to the first contact surface of the at least one insulating sleeve, wherein the at least second conductive core part comprises a second corresponding contact surface to the at least second contact surface of the at least one insulating sleeve and wherein the clamping force of the at least one loading arrangement is applied by the first corresponding contact surface of the first conductive core part and the second corresponding contact surface of the at least second conductive core part to the first and the at least second contact surface of the at least one insulating sleeve.

2. The conductor assembly according to claim 1, wherein the first conductive core part is embodied as a pin, and wherein the at least second conductive core part is embodied as a bushing, and wherein the pin is arranged slideably in the bushing.

3. The conductor assembly according to claim 1, wherein the at least one loading arrangement is arranged axially between an axial end of the first conductive core part and an axial stop of an axial end of the at least second conductive core part.

4. The conductor assembly according claim 1, wherein the at least one loading arrangement comprises at least one preloadable spring and at least one guidance member for the at least one preloadable spring, wherein the preloadable spring is axially clamped by a radial flange of the at least one guidance member and a washer mounted axially slideable on the at least one guidance member.

5. The conductor assembly according to claim 1, wherein the at least second conductive core part comprises a stud-like extension, and wherein the first conductive core part comprises a jacket-like extension encompassing the stud-like extension, and wherein the stud-like extension and the jacket-like extension each comprises at least one abutment surface facing towards each other.

6. The conductor assembly according to claim 5, wherein the stud-like extension and the jacket-like extension are embodied out of a material selected out of the group consisting of: titanium, stainless steel, a high strength metallic alloy, MP35N.

7. The conductor assembly according to claim 1, wherein the at least one loading arrangement comprises at least one guidance member and at least one preloadable spring, wherein the preloadable spring is mounted on the at least one guidance member, and wherein the at least one guidance member is arranged axially moveable in respect to the first conductive core part, and wherein the at least one guidance member is arranged axially fixed in respect to the at least second conductive core part.

8. The conductor assembly according to claim 1, wherein the first conductive core part comprises an external thread and an jacket-like extension of the first conductive core part a corresponding internal thread for screwing the jacket-like extension to the first conductive core part and wherein the at least second conductive core part comprises an internal thread, and wherein an stud-like extension of the at least second conductive core part comprises at least a stud with an external thread and a thread adapter with a corresponding internal thread for screwing the stud in the thread adapter and an external tread for screwing the thread adapter in the at least second conductive core part, and at least one locking pin which is positioned between the jacket-like extension and the stud-like extension to provide a circumferential locking of the jacket-like extension to the at least second conductive core part.

9. The conductor assembly according to claim 1, further comprising: a stud-like extension comprising at least a stud and a locking element threaded into the stud, and wherein the at least one loading arrangement comprises at least one preloadable spring and at least one guidance member for the at least one preloadable spring, and wherein the locking element axially connects the at least one guidance member to the stud-like extension.

10. The conductor assembly according to claim 1, further comprising: at least one sealing element arranged radially between the at least one insulating sleeve and the first conductive core part and/or the at least second conductive core part.

11. The conductor assembly according to claim 1, wherein the at least one insulating sleeve is a one piece part and/or wherein the insulating sleeve comprises an outer surface and an inner surface and wherein the outer surface and/or the inner surface comprises at least one conductive coating.

12. The conductor assembly according to claim 1, wherein the conductor assembly is a penetrator assembly or a connector pin assembly of a connector part of a connector unit.

13. A method for operating a conductor assembly according to claim 1, wherein the method comprises: connecting a first conductive core part and an at least second conductive core part in a loaded position in an axial direction by at least one loading arrangement, wherein the first conductive core part is pulled due to a directed loading force in the axial direction against the at least second conductive core part, clamping the at least one insulating sleeve between the first conductive core part and the at least second conductive core part due to the loading between the first conductive core part and the at least second conductive core part applied by the least one loading arrangement, and establishing an electrical link between the first conductive core part and the at least second conductive core part.

14. The method of claim 13, further comprising: preloading at least one spring of a loading arrangement due to the clamping of the at least one insulating sleeve between a first conductive core part and an at least second conductive core part, wherein the clamping force of the at least one loading arrangement is applied by a first corresponding contact surface of the first conductive core part and a second corresponding contact surface of the at least second conductive core part to a first and an at least second corresponding contact surface of the at least one insulating sleeve.

15. The method of claim 13, further comprising in an arbitrary sequence: machining at least one insulating sleeve out of a block of solid material, finishing the at least one insulating sleeve, wherein both possible sequences result in an integrally formed pre-assembly insulating sleeve, and wherein the method further comprises: assembling the obtained integrally formed pre-assembly insulating sleeve in the conductor assembly by clamping the least one insulating sleeve between a first conductive core part of the conductor assembly and an at least second conductive core part of the conductor assembly due to the loading between the first conductive core part and the at least second conductive core part applied by at least one loading arrangement and wherein the first conductive core part is pulled due to a directed loading force of the least one loading arrangement in an axial direction against the at least second conductive core part.

16. The conductor assembly according to claim 2, wherein the bushing comprises a cap.

17. The method of claim 14, further comprising: holding a loading force of the spring in the assembled state of the conductor assembly so that the spring has a spring force that has a preload between 10% and 90%.

18. The method of claim 17, wherein the preload is about 60%.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0049] The aspects defined above and further aspects of the present invention are apparent from the examples of embodiment to be described hereinafter and are explained with reference to the examples of embodiment. The invention will be described in more detail hereinafter with reference to examples of embodiment but to which the invention is not limited.

[0050] FIG. 1: shows schematically an inventive subsea conductor assembly with two conductive core parts and an insulating sleeve,

[0051] FIG. 2: shows schematically pieces of a preload arrangement of the conductor assembly from FIG. 1 after a first assembly sequence,

[0052] FIG. 3: shows schematically the assembled preload arrangement from FIG. 2 arranged in a conductive core part from FIG. 1 after a second assembly sequence and

[0053] FIG. 4: shows the preload arrangement from FIG. 3 and the two conductive core parts from FIG. 1 in the fully assembled state.

DETAILED DESCRIPTION

[0054] The illustrations in the drawings are schematically. It is noted that in different figures, similar or identical elements are provided with the same reference signs.

[0055] FIG. 1 shows an inventive high voltage subsea conductor assembly 10 for connecting for example a subsea cable and a module (not shown). Thus, the conductor assembly 10 is a subsea penetrator. The conductor assembly 10 comprises a first conductive core part 12 or conductor pin 12 and a second conductive core part 14 or a bushing 14 or cap 14, respectively. Both conductive core parts 12, 14 are out of copper. Further, both conductive core parts 12, 14 may be encased in a housing (not shown). The first conductive core part 12 is for example connected to the cable and the second conductive core part 14 is arranged in a housing of the module (not shown).

[0056] The second conductive core part 14 comprises an axially extending bore 74. The first conductive core part 12 extends into the bore 74 and is arranged axially moveable and specifically slideably in the bushing 14. In a front region 76 the bore 74 of the second conductive core part 14 an electrical interface 78 with in this exemplary embodiment two multilams is provided to establish an electrical link between the two conductive core parts 12, 14.

[0057] Moreover, the conductor assembly comprises an insulating sleeve 16 out of, for example, insulative polyether ether ketone (PEEK). Generally, a different PAEK or glass filled PEEK, or a glass or ceramic may be used. The insulating sleeve 16 is arranged in circumferential direction 80 partly around the conductive core parts 12, 14. The insulating sleeve 16 is a one piece part or, in other words, an integrally formed pre-assembly insulating sleeve 16 pre-manufactured in such a case to fit the contours and dimensions of the conductive core parts 12, 14.

[0058] Moreover, the insulating sleeve 16 comprises an outer surface 142 and an inner surface 144. Both these surfaces 142, 144 comprise a conductive coating 146, 148. The conductive coating 148 is radially arranged between the conductive core parts 12, 14 and the insulating sleeve 16 (The coatings 146, 148 are not shown in detail.).

[0059] Furthermore, the insulating sleeve 16 comprises a radially broadened segment 82 to provide a locking structure for the locking of the penetrator in the module. Further, the insulating sleeve 16 is axially moveably arranged in respect to the first conductive core part 12 and the second conductive core part 14. Thus, there may be conditions where the insulating sleeve moves relative to the conductive core parts 12, 14.

[0060] To preventing entering of dirt into internals of the electrical contact area the conductor assembly comprises several sealing elements 72 embodied as elastic ring seals. In each case, two axially adjacently arranged sealing elements 72 are positioned radially between the insulating sleeve 16 and a radially enlarged section 84 of the first core part 12 or the second conductive core part 14. Since the radially enlarged section 84 and the cap 14 have the same axial length and the same diameter the insulating sleeve 16 can be manufactured symmetrically.

[0061] Due to the enlarged diameters of the enlarged section 84 and the second conductive core part/cap 14 in respect to a diameter of a pin-shaped section 86 of the first conductive core part 12 the insulating sleeve 16 comprises a first contact surface 36 and a second contact surface 38 and the first conductive core part 12 comprises an first corresponding contact surface 40 to the first contact surface 36 and the second conductive core part 14 a second corresponding contact surface 42 to the second contact surface 38. All contact surfaces 36, 38, 40, 42 are oriented perpendicular to an axis 88 of the conductor assembly 10.

[0062] To ensure that a tight connection between the respective contact surfaces 36, 38, 40, 42 is established and maintained during an operation of the conductor assembly 10 the conductor assembly 10 comprises a loading arrangement 18, that is embodied in such a way so that the first conductive core part 12 is loaded in an axial direction 20 against the second conductive core part 14 and that the insulating sleeve 16 is arranged in respect to the two conductive core parts 12, 14 in such a way so that it is clamped between the two conductive core parts 12, 14 due to the loading between the two conductive core parts 12, 14 applied by the loading arrangement 18. And specifically, the clamping force of the at loading arrangement 18 is applied by the first corresponding contact surface 40 of the first conductive core part 12 and the second corresponding contact surface 42 of the at least second conductive core part 14 to the first and the second contact surfaces 36, 38 of the insulating sleeve 16.

[0063] The loading arrangement 18 is arranged in the bore 74 of the cap 14 axially between an axial end 22 of the first conductive core part 12 and an axial stop 24 of an axial end 26 of the second conductive core part 14 (see also FIG. 3). The loading arrangement 18 comprises a preloadable spring 28, a guiding member 30, a washer 32, a jacket-like extension 46 with a shoulder 90, a stud-like extension 44 with a stud 58 and a thread adapter 62, a locking pin 68 and a locking element 70.

[0064] The guidance member 30 is a cylindrical bushing comprising a radial flange 32 and a central bore 92 narrowing in a through hole 94 in a bottom 96 of the guidance member 30. Moreover, the jacket-like extension 46 is a cylindrical bushing comprising a central bore 98 narrowing in a through hole 100 in a bottom 102 of the jacket-like extension 46.

[0065] For a better understanding of the mechanics of the loading arrangement 18 an assembly sequence of the conductor assembly 10 and specifically the preload arrangement 18 is explained on the basis of FIGS. 2 to 4, which show assembly stages as well as the fully assembled conductor assembly 10.

[0066] The locking pin 68, embodied as a dowel pin, is inserted in an aperture 104 of the stud 58. The preloadable spring 28 and the washer 34 are mounted on the guidance member 30 so that the preloadable spring 28 is axially clamped by the radial flange 32 of the guidance member 30 and the washer 34 mounted axially slideable on the guidance member 30 building a spring assembly 106. Subsequently, the spring assembly 106 is secured to the stud 58 by inserting the locking element 70, embodied as a bolt, through the through hole 94 in the bottom 96 of the guidance member 30 and screwing it into a bore 108 of the stud 58. The connection is axially fixed by an abutment of a head 110 of the locking element 70 with the bottom 96 of the guidance member 30 and results in a spring-stud assembly 112 (see FIG. 2). Hence, the locking element 70 axially connects the guidance member 30 and thus the spring 28 to the stud-like extension 44.

[0067] In the next step the jacket-like extension 46, which also acts as an outer spring stop, is placed over the spring-stud assembly 112 so that the stud 58 extends through the through hole 100 in the bottom 102 and the shoulder 90 abuts the washer 34 (see FIG. 3). The stud 58 is slideably arranged in the jacket-like extension 46 or it's through hole 100, respectively. Subsequently, the stud 58 is screwed with its external thread 60 in the corresponding internal thread 64 of the thread adapter 62 and the resulting adapter assembly 114 is screwed with an external tread 66 of the thread adapter 62 in an internal thread 56 of the second conductive core part 14 to form a cap assembly 116.

[0068] In the next step the electrical interface 78, the multilams, are positioned into the bore 74 of the cap assembly 116 and sealing elements 72 are positioned at the cap 14 as well as at the enlarged section 84 of the pin 12 (see FIG. 1). Subsequently, the pin 12 is positioned in the insulating sleeve 16 by inserting it through an aperture 118 of the insulating sleeve 16. Further, a radial gap 120 between the pin 12 and the insulating sleeve 16 is filled with a suitable filler (i.e. a soft rubber, grease or an adhesive e.g. Sylgard 170) to provide good thermal contact between the copper core and the insulating sleeve 16. After the fill the used insertion hole 122 in the enlarged section 84 of the pin 12 is sealed with a seal bung 124.

[0069] By rotating the cap assembly 116 it is screwed with an internal thread 54 of the bore 98 of the jacket-like extension 46 to an external thread 52 of the pin 12 (see also FIG. 4). During the screwing the locking pin 68 positioned between the jacket-like extension 46 and the stud-like extension 44 provides a circumferential locking of the jacket-like extension 46 in respect to the second conductive core part 14. In other words, the locking element 70 prevents a rotation between the jacket-like extension 46 and the rest of the cap assembly 116. This allows the threads 52, 54 to be tightened by rotating the two conductive core parts 12, 14 within the insulating sleeve 16. The conductor assembly 10 is now completely assembled as it is shown in FIG. 1.

[0070] By this assembling sequence the spring 28 of a loading arrangement 18 is preloaded due to the clamping of the insulating sleeve 16 between the two conductive core parts 12, 14. Especially, the dimensions of the pieces and the properties of the spring 28 are selected in such a way that in the assembled state of the conductor assembly 10 a loading force of the spring 28 is held so that the spring 28 has a spring force that has a preload of about 60%.

[0071] Beforehand of assembly the insulating sleeve 16 is prepared or manufactured, respectively. Therefore, the insulating sleeve 16 is machined out of a block of solid material and finished to obtain an integrally formed pre-assembly insulating sleeve 16. In the finishing step the coatings 146, 148 are for example applied. This obtained integrally formed pre-assembly insulating sleeve 16 is than assembled in the conductor assembly 10.

[0072] The loading arrangement 18 ensures that in case of external influences that may affect e.g. a spatial arrangement of pieces of the conductor assembly 10 or the material properties of pieces of the conductor assembly 10 the contact between the insulating sleeve 16 and the two conductive core parts 12, 14 remains. The loading arrangement 18 is toleranced such that the contact surfaces 36, 38, 40, 42 cannot be disconnected once assembled. The external influence can for example be a temperature change causing a different thermal reaction of the insulating sleeve 16 or the two conductive core parts 12, 14 or an applied so called snag-load acting on at least one of the conductive core parts 12, 14.

[0073] In the following passages these different scenarios will be described on the basis of FIGS. 1 and 4.

[0074] The plastics used for the insulating sleeve 16 have a much greater coefficient of thermal expansion than the copper of the conductive core parts 12, 14. So if a temperature in the operating environment drops, the insulating sleeve 16 contracts or shrinks to a higher extent than the conductive core parts 12, 14. Thus, without the loading arrangement 18 a gap would occur between the contact surfaces 36, 38, 40, 42 of the insulating sleeve 16 and the two conductive core parts 12, 14 (not shown). This is prevented by the loading arrangement 18.

[0075] When the insulating sleeve 16 contracts the cap 14 and the radially enlarged section 84 of the pin 12 are no longer axially held in a fixed position by the contact surfaces 36, 38 of the insulating sleeve 16. Thus, the cap 14 and the pin 12 move or are pulled axially towards each other due to the action of the spring 28. Specifically, the preloaded spring 28 expands and pushes the guidance member 30 via its flange 32 in direction 126 towards the pin 12. Because the guidance member 30 is arranged axially moveable in respect to the first conductive core part 12 and is axially fixed in respect to the conductive core part 14 the conductive core part 14 or cap 14 is pulled in direction 126 towards the pin 12 via a connection axis comprising the locking element 70, the stud 58 and the thread adapter 62.

[0076] At the same time, the spring 28 pushes the washer 34 in a direction 128 contrariwise to the direction 126 and consequently the pin 12 is pulled via a connection axis comprising the washer 34, the shoulder 90 and the jacket-like extension 46 in direction 128 towards the cap 14. During this action an axial space 130 between the axial end 22 of the pin 12 and the flange 32, an axial space 132 between the washer 34 and a head 134 of the stud 58 and an axial space 136 between an axial end 138 of the jacket-like extension 46 and the thread adapter 62 is reduced. These spaces 130, 132, 136 are selected during the assembly process in their dimension so that a maximal expected shrinking of the insulating sleeve 16 is taken into account (not shown).

[0077] In case the temperature in the operating environment increases the insulating sleeve 16 expands to a higher extent than the conductive core parts 12, 14. Hence, without the loading arrangement 18 the expansion of the insulating sleeve 16 may cause stresses on the conductive core parts 12, 14 or it might be damaged itself. This is prevented by the loading arrangement 18.

[0078] When the insulating sleeve 16 expands the contact surfaces 36, 38 push due to the contact with the corresponding contact surfaces 40, 42 the pin 12 in direction 126 and the cap 14 in direction 128. In other words, the two conductive core parts 12, 14 are pushed away from each other. Due to these movements the spring 28 is compressed. Specifically, the pin 12 pulls the jacket-like extension 46 in direction 126 and this movement is transferred to the spring 28 via the connection axis comprising the shoulder 90 and the washer 34. At the same time the cap 14 pulls the guidance member 30 in direction 128 via the connection axis comprising the locking element 70, the stud 58 and the thread adapter 62.

[0079] During this action an axial gap 140 between the head 134 of the stud 58 and the bottom 102 of the jacket-like extension 46 is reduced (not shown). To restrict this axial movement and to provide a security feature that prevents that the spring 28 is compressed to such an extent that it might be damaged the stud-like extension 44 or the head 134 of the stud 58, respectively, and the jacket-like extension 46 comprise an abutment surface 48, 50 that face towards each other.

[0080] To further provide a secure construction that might resist even high forces, like high pulling forces (details see below) the stud-like extension 44 or its stud 58 and the thread adapter 62, respectively, and the jacket-like extension 46 are manufactured out of a high strength material and specifically, out of titanium. Thus, these parts are titanium retention components. A dimension of the gap 140 is selected during the assembly process in respect of the properties of the spring 28 or the adjusted preload of the spring 28.

[0081] This security features have an even higher relevance in case a pulling force or a snag-load acts on one or both of the conductive core parts 12, 14. When pulled at one of the core parts 12, 14 either in direction 126 (pin 12) or direction 128 (cap 14) the spring 28 is compressed according to the same mechanics as described above in case of the expansion of the insulating sleeve 16. An axial gap might be built between the contact surfaces 36, 38, 40, 42 of the insulating sleeve 16 and the two conductive core parts 12, 14 (not shown).

[0082] During the pulling action the preload arrangement 18 holds the conductor assembly 10 in its intended operational state or it can prevent gaps between the contact surfaces 36, 38, 40, 42 due to its self-acting mechanism. Specifically, the now even further compresses spring 28 expands and pushes the guidance member 30 via its flange 32 in direction 126 towards the pin 12. Consequently, the cap 14 is pulled in direction 126 towards the pin 12 via a connection axis comprising the locking element 70, the stud 58 and the thread adapter 62. Moreover, the spring 28 pushes the washer 34 in direction 128 and consequently the pin 12 is pulled via the connection axis comprising the washer 34, the shoulder 90 and the jacket-like extension 46 in direction 128 towards the cap 14. Hence, the forming of gaps between the contact surfaces 36, 38, 40, 42 is prevented and the gap 140 is re-established.

[0083] Thus, a method for operating the conductor assembly 10 comprises the steps of: Connecting the first conductive core part 12 and the second conductive core part 14 in a loaded position by the loading arrangement 18 and thereby establishing a reliable electrical link between the first conductive part 12 and the second conductive core part 14.

[0084] Hence, with such constructed loading arrangement 18 and consequently conductor assembly 10 a reliable and secure operation can be provided. This is still the case even if all and in this exemplary embodiment both of the sealing elements 72 at the pressurized end were to fail at the maximum differential pressure. Therefore, even a double seal failure, cannot cause either electrical or mechanical catastrophic failure of the conductor assembly 10. Moreover, the high strength fixed mechanical stop will prevent the spring 28 from being fully compressed which may damage or break the retaining spring 28.

[0085] It should be noted that the term comprising does not exclude other elements or steps and a or an does not exclude a plurality. Also elements described in association with different embodiments may be combined. It should also be noted that reference signs in the claims should not be construed as limiting the scope of the claims.

[0086] Although the invention is illustrated and described in detail by the preferred embodiments, the invention is not limited by the examples disclosed, and other variations can be derived therefrom by a person skilled in the art without departing from the scope of the invention.