DESC:FIELD
The present disclosure generally relates to electrical cable joints. More particularly, the present disclosure relates to an extended ferrule with solid core for 1.1 kV cable.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
A power distribution network typically consists of multiple substations connected to each other via feeders. Each substation includes a distribution transformer for stepping down the voltage level. The transformer is connected to a Low-Tension Panel (LTP). The LTP typically includes one incoming circuit and multiple outgoing circuits to feeder pillar panels. The feeder pillar panels supply power to different areas and are connected to one another via underground cables.
The existing underground distribution systems face major challenges in identification of cable faults, determination of exact fault location and repairing the cable faults. Traditionally, a cable fault is repaired by removing a damaged cable part and connecting/jointing a new conductor in place of the faulty/damaged part. The jointing process broadly includes the following steps:
i. preparing the cable by removing the cable over sheath and wire armour, separating wire armour, placing a support ring under the armour at each side of joint, and cutting and removing the insulation from each of the conductors of the cable;
ii. connecting each end of the exposed conductors to a (metal) ferrule connector, tightly fixing the ferrule connectors by crimping them, and insulating the ferule connectors by taping them;
iii. binding the wires tightly and taping them together;
iv. restoring the armour and applying mesh tape over the armoured cable; and
v. re-establishing the over sheath using a self-fusing tape.
Various types of cable jointing kits are available for implementing the jointing process. The traditional LT cable repair or jointing kit consists of the following items -
a. Galvanized Iron (G.I.) wire mesh – used to provide mechanical strength to the joint and protect it from stones in the ground which can put pressure on the joint and lead to its failure.
b. Tinned copper braid – used to provide earthing continuity and fault current path across the cable joints.
c. Stainless steel hose clip – used to fix tinned copper braid with armour.
d. Heat shrinkable wrap around sleeve – used to provide ingress protection against moisture and dust along with mechanical protection.
e. Inline crimp type ferrule connector – used to carry the current of the respective phases.
f. Black mastic tape – This acts as a sealant to avoid entry of water and make the surface of the crimped ferrule smooth.
g. Internal insulating tubing for ferrules – used to seal the ferrule and prevent ingress of moisture and dust.
h. Cleaning tissue with solvent – used to remove unwanted conductive particle from inside as well as outside the ferrule.
i. PVC Tape – used to cover sharp edges of the joint.
j. Emery paper – used to make the crimped surface of the ferrule smooth.
k. Tinned copper wire – used to bind the armour properly.
Thus, repairing a cable fault is a manual job that involves excavation work, often in roads. Therefore, cable fault repairing is a cumbersome and risky process, particularly, in metro cities where underground gas line routes may be parallel to the cable routes. Moreover, road excavation and road reinstatement (RI) charges constitute a significant portion of the total cable fault repair cost. A quantum change in these charges can lead to major cost savings in cable fault repairing.
In addition to above, the conventional ferrule connectors are hollow and cylindrical. Therefore, in the conventional straight jointing process using these ferrule connectors, two joints are required to be made at two ends of the inserted cable piece. Thus, a high servicing time, cost and road excavation length is required for cable repairing, which is not desired.
Therefore, there is a need for an extended design and a cable jointing kit that alleviates the abovementioned problems.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present disclosure is to provide an extended ferrule with solid core for 1.1 kV cable.
Another object of the present disclosure is to provide an extended ferrule with solid core and a cable jointing kit that requires road excavation of lesser length for repairing a cable fault as compared to the conventional cable jointing kits.
Still another object of the present disclosure is to provide an extended ferrule with solid core and a cable jointing kit that reduces road excavation charges and road reinstatement (RI) charges.
Yet another object of the present disclosure is to provide an extended cable jointing kit ferrule that reduces the time required for road excavation and reinstatement.
Still another object of the present disclosure is to provide a cable jointing kit ferrule that reduces the number of joints required for cable repairing and jointing operation by half.
Yet another object of the present disclosure is to provide a cable jointing kit ferrule that eliminates the requirement of a cable piece between the joints.
Still another object of the present disclosure is to provide a cable jointing kit ferrule that reduces the cable repairing service cost and time.
Yet another object of the present disclosure is to provide a cable jointing kit ferrule that reduces the likelihood of hindering the traffic movement as the road excavation length is reduced.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages an extended ferrule for connecting two ends of a 1.1 kV cable. Each end of the cable has one or more insulated conductors. The ferrule is defined by a solid metallic core and hollow end members extending from the ends of the solid metallic core. Each of the end members is configured to receive an exposed portion of the conductors of the cable therein to establish a connection between two conductors at the two ends of the cable. The hollow end members are dimensioned such that an outer diameter of each hollow member is greater than an inner diameter of the conductors.
The material of the ferrule is selected from a metal or a metal alloy. In an embodiment, the ferrule is made of an alloy comprising 93.5 to 96 % by weight of Aluminium (Al), 4-5 % by weight of Magnesium (Mg), 0 to 0.35 % by weight of Iron (Fe), 0 to 0.25 % by weight of Zinc (Zn), 0 to 0.2 % by weight of Silicon (Si), 0 to 0.15 % by weight of Manganese (Mn), 0 to 0.15 % by weight of Chromium (Cr), 0 to 0.15 % by weight of Copper (Cu), 0 to 0.1 % by weight of Titanium (Ti), and 0 to 0.15 % by weight of Residuals.
In an embodiment, the ferrule is cylindrical in shape and has a length of 240 mm, wherein the solid core has a length of 120 mm, and each hollow end member has a length of 60 mm.
The present disclosure further envisages a method of connecting two ends of a 1.1 kV cable, the cable having an outer sheath and a wire armour. Each end of the cable has one or more insulated conductors. The method comprises preparing the cable by removing the outer sheath and the wire armour from the two ends of the cable; removing an insulation from the cores of the cable at each end of the cable; inserting an exposed portion of the conductors at each end of the cable into an extended ferrule from both the sides of the extended ferrule, wherein the extended ferrule has a solid core at the center and two hollow end members for receiving the exposed conductors; crimping the hollow end members of the ferrules onto the conductors inserted therein; insulating each of the crimped ferrules by taping them; binding the insulated ferrules tightly and taping them together; restoring the armour on the taped ferrules and applying a mesh tape over the armour; and re-establishing the outer sheath using a self-fusing tape.
In an embodiment, the cable is 4 Core, 300 sq mm cable. The ferrule has a length of 240 mm, wherein the solid core has a length of 120 mm and each hollow end member has a length of 60 mm.
The present disclosure also envisages a cable jointing kit for 1.1 kV cable comprising the extended ferrule with modified solid core.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
An extended ferrule with solid core for 1.1 kV cable of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1A illustrates a schematic view of fault occurrence on a feeder pillar panel outgoing circuit;
Figure 1B illustrates a schematic view of traditional cable joints made to remove fault from the outgoing faulty circuit of Figure 1A;
Figure 2A illustrates a perspective view of a cable jointing kit ferrule in accordance with the prior art;
Figure 2B illustrates a perspective view of an extended ferrule with modified solid core, in accordance with the present disclosure;
Figure 3A illustrates a perspective schematic view of cable joints for a 3 core cable in accordance with the prior art;
Figure 3B illustrates a perspective schematic view of cable joints for a 3 core cable, in accordance with the present disclosure; and
Figure 4 illustrates a flow diagram of a method for connecting two ends of a 1.1 kV cable using the extended ferrule of Figure 2B.
LIST OF REFERENCE NUMERALS
10 – Feeder pillar panel
12 – Fuse
14 – Joints
16 – New cable piece
18 – Underground cable
20 – Conventional cable joint kit ferrule
22 – Cable conductors
100 – Extended ferrule
100a – Solid core
100b – Hollow end members
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details, are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being “engaged to,” "connected to," or "coupled to" another element, it may be directly engaged, connected or coupled to the other element. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
Terms such as “inner,” “outer,” "beneath, "lower," "above," "upper," and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
Typically, a distribution network consists of a plurality of substations which are connected to one another via feeders. Each substation includes a distribution transformer for stepping down the voltage level for transmission. The transformer is connected to a Low-Tension Panel (LTP) which includes one incoming circuit and multiple outgoing circuits. Each outgoing circuit connects to a feeder pillar panel.
A traditional feeder pillar panel includes busbars, an isolator/disconnector for the incoming circuit and multiple outgoing ways, i.e., outgoing feeders for connecting to other feeder pillar panels and distributing power to various residential and commercial areas via underground cables. Each outgoing circuit comprises an electrical fuse for protection of upstream equipment such as incoming cables, bus bars, LT breaker, transformer, HT breaker etc. from long time sustained fault currents and damage.
When a cable fault occurs in an outgoing circuit of a feeder pillar panel, the electrical fuse of that circuit blows, thereby providing protection to the upstream equipment. For example, Figure 1A shows a fault at location ‘f’ on an underground cable 18 of an outgoing feeder of a feeder pillar panel 10, causing the fuse 12 of that feeder to blow.
Upon occurrence of fault, a technician tracks the fault location and clears the fault by repairing/replacing the faulty/damaged cable. As shown in Figure 1B, the fault location is identified, and damaged cable part is removed. A new cable piece 16 is inserted and connected between the two exposed ends of the cable 18 via joints 14. A jointing kit is used for connecting the cable piece 16 to underground cable 18 and a standard jointing procedure is followed.
The jointing procedure involves preparing the cable 18 by removing the over sheath, wire armour, and insulation from each of the conductors of the cable 18; connecting each end of the exposed conductors to a (metal) ferrule; crimping the ferrules; insulating the ferules by taping them; binding the insulated wires tightly and taping them together; restoring the armour and applying mesh tape over the armoured cable; and re-establishing the over sheath using a self-fusing tape.
Traditionally, the ferrules 20 used for crimping are hollow and cylindrical in nature as shown in Figure 2A. The conductors 22 of the underground cable 18 are inserted into the hollow ferrule 20 and the ferrule 20 is tightly fixed to the conductors by crimping. This process is followed for each core/conductor 22 of the cable 18. So, if the cable 18 is a 3-core cable, three cores of the new cable piece 16 will be connected to 3 cores of underground cable 18 at both the ends through ferrules 20. Thus, six such ferrules 20 will be required for repairing a fault on a 3-core cable.
Thus, traditionally, to repair a cable fault, two joints 14, a new cable piece 16, and ferrules 20 equal to double the number of cores/conductors 22 in the underground cable 18 are required as shown in Figure 3A. This increases the servicing area, and therefore the area or length of excavation required to repair the faulty cable is also increased. This ultimately increases the cost of jointing kit, the cost of road excavation and road reinstatement (RI), and subsequently the overall service charge.
In order to overcome aforementioned drawbacks, the present disclosure envisages a novel design of a jointing kit ferrule 100 for connecting two ends of a 1.1 kV cable. Each end of the cable has one or more insulated conductors/ cores.
Referring to Figures 2B and 3B, the jointing kit ferrule 100 of the present disclosure is defined by a solid metallic core 100a and hollow end members 100b. The hollow end members 100b extend from the ends of the solid metallic core 100a. Each of the end members 100b is configured to receive an exposed portion of the conductors 22 of the cable therein to establish a connection between two conductors 22 at the two ends of the cable. The ferrule 100 is dimensioned such that an inner diameter of the hollow end members 100b is greater than an outer diameter of the cable conductors 22 so that the ferrule 100 can receive the cable conductors 22 therein.
During the jointing process, the cable conductors 22 are inserted in the hollow end members 100b of the ferrule 100 up to the solid core 100a and the hollow end members 100b are crimped onto the conductors 22.
The ferrule 100 has a cylindrical shape. The ferrule 100 is made from a metal or a metal alloy. The ferrule material can be selected from the group consisting of, but not limited to, stainless steel, aluminum, and copper.
In an embodiment, the ferrule is an aluminium magnesium alloy comprising 93.5 to 96 % by weight of Aluminium (Al), 4-5 % by weight of Magnesium (Mg), 0 to 0.35 % by weight of Iron (Fe), 0 to 0.25 % by weight of Zinc (Zn), 0 to 0.2 % by weight of Silicon (Si), 0 to 0.15 % by weight of Manganese (Mn), 0 to 0.15 % by weight of Chromium (Cr), 0 to 0.15 % by weight of Copper (Cu), 0 to 0.1 % by weight of Titanium (Ti), and 0 to 0.15 % by weight of Residuals.
Typically, for a low voltage 1.1kV grade, heat shrink, 4 Core x 300 sq mm straight through joint for XLPE/SWA Aluminum Cable, the ferrule 20 has a length of 90 mm. The traditional ferrule 20, as shown in Figures 2A and 3A, is hollow and receives cable conductors 22 of a new cable piece 16 from one end and cable conductors 22 of the underground cable 18 from another end, up to the length of 45 mm. During cable jointing, the hollow ferrule 20 is crimped onto the conductors 22 on both the sides.
On the contrary, the extended ferrule 100 with solid core 100a of the present disclosure has a total length of 240 mm for the low voltage 1.1kV, 4 Core x 300 sq mm cable. The solid core 100a is 120 mm in length and each of the hollow end members 100b are 60 mm in length. During jointing, the cable conductors 22 of the underground cable 18 are inserted into the extended ferrule 100 from both the ends up to the length of 60 mm and the end members 100b are crimped on to the inserted conductors 22. In an embodiment, the inner diameter of the hollow end members is 25mm and the outer diameter of the ferrule 100 is 32 mm.
Thus, the solid core extension 100a of the ferrule 100 helps in repairing minor cable faults up to the length of 120mm. A new cable piece 16 is not required in the process of jointing using the proposed extended ferrule 100. Moreover, the number of joints 14 is reduced by half as two ends of the underground cable 18 are directly connected through the extended ferrule 100. This leads to a saving in cable length and hence in the road excavation and reinstatement charges. Further, the time required for road excavation, cable repairing, and road reinstatement is also drastically reduced.
The present disclosure further envisages a cable jointing kit having the extended ferrule 100 described above. Typically, a cable jointing kit includes various accessories such as wire mesh, copper braid, and hose clip. The dimensions of these cable accessories is varied in proportion to the dimension of the extended ferrule 100.
For low voltage, 1.1kV grade, heat shrink, 4 Core x 300 sq mm straight through joint for XLPE/SWA Aluminum Cable, the total length of ferrule 100 is increased from 90 mm to 240 mm and a solid core part 100a of 120mm is introduced in the center. This results in an increase in the joint length. Therefore, an appropriate increase in the joint kit accessories, such as, Galvanized Iron (G.I.) wire mesh, tinned copper braid, wrap around sleeve, and insulating tube is also required.
The following tables, i.e. Table 1 and Table 2, provide dimensions of accessories for traditional as well as the proposed cable jointing kits for 1.1kV grade, 4 Core x 300 sq mm respectively.
Sr. No. Material Required Size Required Quantity
1 G.I Wire Mesh 10000 mm 1
2 S.S Hose Clip 50-90 mm 2
3 T.C Braid 800 mm 1
4 Wrap Around Sleeve 850 mm 1
5 Ferrule connector 90 mm 4
6 Black Mastic Tape 6
7 Insulating Tube 170 mm 4
8 Installation instruction sheet 1
9 Cleaning tissue 5
10 PVC Tape 2
11 AI Oxide cloth 2
12 T.C Wire 1
Table 1 – Dimensions of Traditional Joint Kit accessories
Sr. No. Material Required Size Required Quantity Changes in Size
1 G.I Wire Mesh 10150 mm 1 150 mm
2 S.S Hose Clip 50-90 mm 2 0 mm
3 T.C Braid 950 mm 1 150 mm
4 Wrap Around Sleeve 1000 mm 1 150 mm
5 Ferrule connector 240 mm 4 150 mm
6 Black Mastic Tape 6 0 mm
7 Insulating Tube 370 mm 4 200 mm
8 Installation instruction sheet 1 0 mm
9 Cleaning tissue 5 0 mm
10 PVC Tape 2 0 mm
11 AI Oxide cloth 2 0 mm
12 T.C Wire 1 0 mm
Table 2 – Dimensions of Joint Kit accessories of the present disclosure
Referring to Figure 4, a method 200 of connecting two ends of a 1.1 kV cable is envisaged. The cable has an outer sheath and a wire armour. Each end of the cable has one or more insulated conductors. The method 200 comprises the following steps:
At step-202, preparing the cable by removing the outer sheath and the wire armour from the two ends of the cable;
At step-204, removing an insulation from the insulated conductors (i.e., cores) at each end of the cable;
At step-206, inserting an exposed portion of the conductors 22 at each end of the cable into an extended ferrule 100 from both the sides of the extended ferrule 100, the extended ferrule 100 having a solid core 110a at the center and two hollow end members 110b for receiving the exposed conductors 22;
At step-208, crimping the hollow end members 110b of the ferrules 100 onto the conductors 22 inserted therein;
At step-210, insulating each of the crimped ferrules by taping them;
At step-212, binding the insulated ferrules tightly and taping them together;
At step-214, restoring the armour on the taped ferrules and applying a mesh tape over the armour; and
At step-216, re-establishing the outer sheath using a self-fusing tape.
The method 200 of jointing using the extended ferrule 100 can be used with a 4 Core, 300 sq mm cable. The ferrule has a length of 240 mm, wherein the solid core 100a has a length of 120 mm and each hollow end member 100b has a length of 60 mm.
Experimental results
The extended ferrule 100 and the proposed cable jointing kit results in time and cost savings in road excavation, cable repairing, and road reinstatement. The cost and time savings from the jointing kit were calculated by a sample execution at a site in Tata Power Distribution Network.
Tables 3 and 4 below provide a calculation of cost and time for cable jointing using traditional jointing kit and jointing kit of the present disclosure, respectively.
Sr. No. Materials/ Time Required Qty/length Required resource
1 Joint Cost 2 units Rs. 8600
2 Services for joint 2 units Rs. 3600
3 Excavation (RI) 7mtrs Rs. 63000
4 Excavation 5mtrs Rs. 764
5 Cable 2-3mtrs Rs. 2500
Total cost Rs. 78464
1 Time for jointing 2 joints 4Hrs
2 Backfilling 5mtrs 1.5Hrs
3 Time for excavation 5mtrs 3Hrs
Total time 8.5Hrs
Table 3 – cost and time calculation for cable jointing using traditional jointing kit

Sr. No. Materials/ Time Required Qty/ length Required resource
1 Joint Cost 1 unit Rs. 5000
2 Services for Joint 1 unit Rs. 1800
3 Excavation (RI) 5mtrs Rs. 45000
4 Excavation services 3mtrs Rs. 458
5 Cable 0 0
Total cost Rs. 52258
1 Time for jointing 1 Joint 2Hrs
2 Time for excavation 3Mtrs 2Hrs
3 Backfilling 3Mtrs 1Hrs
Total cost 5Hrs
Table 4 - cost and time calculation for cable jointing using jointing kit of the present disclosure
Thus, the cable jointing using the proposed jointing kit results in a cost saving of about 33% and time saving of about 41%.
The foregoing calculations are subject to change depending upon the site conditions, RI Charges as per existing norms of particular Municipal Corporation and can increase or decrease as per the handling of the site conditions.
Testing of the Jointing Kit and Results
The jointing kit was tested for Insulation Resistance (IR) values, AC voltage withstand strength, and the like. The results of the test obtained are as follows-
Sr. No. Test Description Requirement Result
1 Physical Inspection of BOM & accessories of above mentioned kit As per TATA Requirement Confirmed
2 Cable Cut and installation As per Revised Design of TATA BOM Confirmed
3 Insulation Resistance Test on Air Red Core vs Other Core 1 x 105 M ohm
4 Yellow Core vs Other Core 1.03 x 105 M ohm
5 Blue Core vs Other Core 1 x 105 M ohm
6 Black Core vs Other Core 1 x 105 M ohm
7 Red Core vs Ground 1.03 x 105 M ohm
8 Yellow Core vs Ground 1 x 105 M ohm
9 Blue Core vs Ground 1 x 105 M ohm
10 Black Core vs Ground 1 x 105 M ohm
11 AC withstand Test in Air (Phase to Ground Each Core) 4 kV for 1 Min Withstand
12 AC withstand Test in Water (Phase to Ground Each Core) 4 kV for 1 Min Withstand
13 Insulation Resistance test during water Red Core vs Other Core 1 x 105 M ohm
14 Yellow Core vs Other Core 1 x 105 M ohm
15 Blue Core vs Other Core 1 x 105 M ohm
16 Black Core vs Other Core 1.05 x 105 M ohm
17 Red Core vs Ground 1 x 105 M ohm
18 Yellow Core vs Ground 1 x 105 M ohm
19 Blue Core vs Ground 1 x 105 M ohm
20 Black Core vs Ground 1 x 105 M ohm
21 Impact Test 4 Kg weight fall from Height of 1 meter over either side and centre of joints Passed
Further, a routine/acceptance test was performed on the jointing kit. The results of the test obtained are as follows-
Sr. No. Test Description Requirement Results
1 Physical examination Heat shrinkable component in kit should be free from pin holes and other surface defects Checked and found OK
2 Volume Resistivity 1012 Ohm cm. (min.) 1.81 x 1014 Ohm Cm.
3 Heat Shock Test on Heat Shrinkable tubing/component 250°C for 30 minutes and there should not be any flowing/ Cracking Passed
4 Low Temperature Flexibility At (-20°C), there should not be any cracking in bending operation AFTER 4 hours Passed
5 Longitudinal change ± 10% (max.) + 5%
6 Dielectric strength 10 KV/mm (min.) 13.10 KV/mm
7 Tensile strength 8 N/mm2 (min.) 10.95 N/mm2
8 Ultimate Elongation 300% (min.) 410%
9 Water absorption Less than 0.5% 0.1%
The extended ferrule 100 and the 1.1 kV H.S. 4C x 300 sq. mm straight through joint for XLPE/SWA Aluminum Cable has the potential to save man hours and material. Further, the ferrule 100 and the straight through joint for XLPE/SWA Aluminum Cable provides savings in dual manner, firstly by reducing the outage time and hence increasing of units billed per consumer and secondly by reducing the cost of one joint and cost per joint and hence bringing about a change in the way the kits are manufactured and put to use.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of an extended ferrule with solid core for 1.1 kV cable that:
• requires road excavation of lesser length for repairing a cable fault as compared to the conventional cable jointing kits;
• reduces road excavation charges and road reinstatement (RI) charges;
• reduces the time required for road excavation and reinstatement;
• reduces the number of joints required for cable repairing and jointing operation by half;
• eliminates the requirement of a cable piece between the joints;
• reduces the cable repairing service cost and time; and
• reduces the likelihood of hindering the traffic movement as the road excavation length is reduced.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of devices, articles, or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation
,CLAIMS:WE CLAIM:
1. An extended ferrule (100) for connecting two ends of a 1.1 kV cable, each end of the cable having one or more insulated conductors, said ferrule (100) defined by:
a. a solid metallic core (100a); and
b. hollow end members (100b) extending from the ends of said solid metallic core (100a), each of said end members (100b) configured to receive an exposed portion of the conductors (22) of said cable therein to establish a connection between two conductors (22) at the two ends of said cable.
2. The ferrule (100) as claimed in claim 1, wherein an outer diameter of each hollow member (100b) is greater than an inner diameter of the conductors (22).
3. The ferrule (100) as claimed in claim 1, wherein the material of said ferrule (100) is selected from a metal or a metal alloy.
4. The ferrule (100) as claimed in claim 1, which is a metal alloy comprising 93.5 to 96 % by weight of Aluminium (Al), 4-5 % by weight of Magnesium (Mg), 0 to 0.35 % by weight of Iron (Fe), 0 to 0.25 % by weight of Zinc (Zn), 0 to 0.2 % by weight of Silicon (Si), 0 to 0.15 % by weight of Manganese (Mn), 0 to 0.15 % by weight of Chromium (Cr), 0 to 0.15 % by weight of Copper (Cu), 0 to 0.1 % by weight of Titanium (Ti), and 0 to 0.15 % by weight of Residuals.
5. The ferrule (100) as claimed in claim 1, which is cylindrical in shape.
6. The ferrule (100) as claimed in claim 1, which has a length of 240 mm, wherein said solid core has a length of 120 mm and each hollow end member has a length of 60 mm.
7. A method (200) of connecting two ends of a 1.1 kV cable, the cable having an outer sheath and a wire armour, each end of the cable having one or more insulated conductors, said method (200) comprising:
a. preparing (step-202) the cable by removing the outer sheath and the wire armour from the two ends of the cable;
b. removing (step-204) an insulation from the cores of the cable at each end of the cable;
c. inserting (step-206) the exposed conductors (22) at each end of the cable into an extended ferrule (100) from both the sides of said extended ferrule (100), said extended ferrule (100) having a solid metal core (100a) at the center and two hollow end members (100b) for receiving said exposed conductors (22);
d. crimping (step-208) said hollow end members of the ferrules (100) onto the conductors (22) inserted therein;
e. insulating (step-210) each of said crimped ferrules by taping them;
f. binding (step-212) the insulated ferrules tightly and taping them together;
g. restoring (step-214) the armour on the taped ferrules and applying a mesh tape over the armour; and
h. re-establishing (step-216) the outer sheath using a self-fusing tape.
8. The method (200) as claimed in claim 7, wherein said cable is a 4 Core, 300 sq mm cable.
9. The method (200) as claimed in claim 8, wherein said ferrule (100) has a length of 240 mm, wherein said solid core (100a) has a length of 120 mm and each hollow end member (100b) has a length of 60 mm.
10. A cable jointing kit for 1.1 kV cable comprising the extended ferrule as claimed in claim 1.

Dated this 02nd day of November, 2021

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI