Design Electrical Power Connectors | Hello!

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Discussion Overview

The discussion revolves around the design and manufacturing of electrical power connectors, specifically focusing on the parameters needed for designing connectors based on required current ratings. The scope includes theoretical calculations and practical considerations in the context of connectors used in transmission lines and substations.

Discussion Character

  • Exploratory, Technical explanation, Debate/contested

Main Points Raised

  • One participant inquires about the existence of a precise formula for designing connectors based on current ratings, mentioning that all connectors are made of aluminum alloy, which keeps certain material properties constant.
  • Another participant asks for clarification on the type of connectors being discussed.
  • A participant specifies that the connectors in question are power connectors, such as tee-connectors and parallel groove connectors used in transmission lines and substations.
  • There is a question regarding whether test results are available for the existing units or if the inquiry is based on theoretical calculations for new sizes.
  • A participant suggests calculating simple resistance to determine ohmic heating as a potential first-level approximation for design considerations.

Areas of Agreement / Disagreement

Participants have not reached a consensus on a specific formula or guiding factor for the design of the connectors. Multiple perspectives on the approach to design and testing remain present.

Contextual Notes

There are limitations regarding the assumptions made about the material properties and the need for empirical data versus theoretical calculations. The discussion does not resolve the mathematical steps or specific design parameters required.

closepet
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Hello!

I am in design and manufacturing of electrical power connectors. I need to know if there is any precise formula to design a connector, i.e. given the required current rating, is there a particular formula that gives the parameters of the connector, like length and thickness??

All our connectors are made of Aluminium alloy. So resistivity, material density and Specific heat remain constant.

Looking forward for a help...
 
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hi!

these are power connectors, like tee-connectors, parallel grove connectors used in transmission lines and substations...
 
closepet said:
hi!

these are power connectors, like tee-connectors, parallel grove connectors used in transmission lines and substations...

Do you have test results for your units? Or are you trying to do theoretical calculations to back up what you have?
 
yeh we do have test results. But for newer sizes, we require some kind of a guiding factor for the design...
 
Can you not just calculate the simple resistance and then determine ohmic heating?

EDIT: At least, as a first level approximation?
 

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