U.S. patent number 3,813,772 [Application Number 05/280,161] was granted by the patent office on 1974-06-04 for method of forming steel supported aluminum overhead conductors.
This patent grant is currently assigned to Reynolds Metals Company. Invention is credited to Harold W. Adams.
United States Patent |
3,813,772 |
Adams |
June 4, 1974 |
METHOD OF FORMING STEEL SUPPORTED ALUMINUM OVERHEAD CONDUCTORS
Abstract
The conductors disclosed herein each comprise a hollow tube of
aluminum supported on a steel cable received within the tube. The
cable has a smaller outside diameter than the inside diameter of
the aluminum tube. The latter need not be integral; it may be
fabricated from flat strips, wires or rods, shaped or round.
Strips, wires or rods are stranded over the cable; integral tubes
are extruded over the cable or folded over the cable from a broad
strip and longitudinally welded. Soft aluminum wires may be
stranded radially between the steel cable and the hard-drawn
aluminum conductor, then crushed by the application of radial
pressure to provide internal space between the aluminum covered
steel core and the hard-drawn aluminum conductor. Under operating
conditions, substantially all mechanical tension on the steel
supported aluminum overhead conductor is borne by the steel cable
and the conductor is largely immune to hazards of galloping,
aeolian vibration, loss of strength as a result of high operating
temperatures, and creep at normal and high operating
temperatures.
Inventors: |
Adams; Harold W. (Richmond,
VA) |
Assignee: |
Reynolds Metals Company
(Richmond, VA)
|
Family
ID: |
26729099 |
Appl.
No.: |
05/280,161 |
Filed: |
August 14, 1972 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
51128 |
Jun 30, 1970 |
|
|
|
|
Current U.S.
Class: |
29/872; 57/9;
174/42; 174/130; 57/215; 174/108 |
Current CPC
Class: |
H01B
13/0235 (20130101); H01B 5/104 (20130101); Y10T
29/49201 (20150115) |
Current International
Class: |
H01B
13/02 (20060101); H01b 013/26 () |
Field of
Search: |
;156/47,49,50-56
;29/624,23C,202.5,505,429,435,473.9,474.1
;174/12R,12C,12D,103,15R,16R,16D,108,128,13D,126CP,40,42
;57/160,161,15,3,6,9,138,139,144,145,166 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Lanham; Charles W.
Assistant Examiner: Walkowski; Joseph A.
Attorney, Agent or Firm: Glenn, Palmer, Lyne & Gibbs
Parent Case Text
This is a division, of application Ser. No. 51,128 filed June 30,
1970 and now abandoned.
Claims
I claim:
1. A method for manufacturing steel supported aluminum overhead
conductor comprising providing a steel core, forming an
intermediate layer of soft aluminum upon the steel core,
fabricating a tubular aluminum conductor about said intermediate
layer of soft aluminum, applying circumferentially spaced radially
inwardly directed forces upon the tubular aluminum conductor of
sufficient magnitude to crush the intermediate layer into greater
intimacy with the steel core and to thereby provide radial spacing
between the exterior of the steel core and the interior of the
tubular aluminum conductor that when the steel supported aluminum
overhead conductor is strung overhead with consequent reduction in
diameter of the steel core and the tubular aluminum conductor as
both elongate, substantially all mechanical tension is borne by the
steel core.
Description
BACKGROUND OF THE INVENTION
Conventional aluminum conductors employed in the construction of
overhead lines are exposed in service to hazards which may cause
different kinds of damage, the degrees of which are extremely
difficult to predict. Among these hazards and the types of damage
are:
1. Aeolin vibration which can result in fatigue breakage of
aluminum wires. Tension limitations based upon aeolian vibration
considerations are principal parameters in overhead line design.
(Aeolian vibration is a relatively high frequency, low amplitude
resonant oscillation that is normally caused by winds from about 3
to 15 miles per hour. Amplitudes of aeolian vibration are less than
the conductor diameter. Galloping is a low frequency, large
amplitude phenomena. Most usually it occurs when an ice formation
on the conductor causes the overall cross section to assume the
shape of an air foil, so there is an actual lift of the conductor
by the wind. Amplitudes of galloping can be several feet.)
2. High operating temperatures resulting from heavy electrical
loads which can result in the partial annealing of aluminum wires.
High operating temperatures, especially during emergencies, become
an increasingly important factor as system capacities are
progressively enlarged.
3. Creep, or inelastic elongation, of aluminum wires that takes
place over a relatively long period of time. The rate of creep is a
function of time, temperature, stress, and of the amount of prior
creep at any given point in time. Creep causes an increase in
conductor sag and can result in problems with electrical
clearances.
The principle of providing aluminum upon steel as an overhead
conductor has been widely used in recognition of the current
carrying capacity of the former and the strength of the latter. The
designation by which this kind of conductor is usually known in
technical and trade literature is "ACSR" for Aluminum Conductor,
Steel Reinforced. However, with conventional steel reinforced
conductors, tension is borne by the aluminum wires in all
circumstances, except sometimes at high temperatures. The
proportionate tension borne by aluminum and steel wires is
primarily a function of temperature of operation (aluminum expands
and contracts approximately twice as much as steel with changes in
temperature) and of the amount of creep occurring in the aluminum.
Sometimes conductors are prestressed during stringing to accelerate
the creep of the aluminum wires, but this does not eliminate
tension in them.
Conventional accessories such as dead ends, jumper terminals,
splice connectors, armor rods, jumper filler rods, come alongs,
socks, grading rings, suspension clamps, stringing sheaves and the
like used in the stringing, cutting, sagging, terminating and
splicing of ACSR and expanded ACSR conductors do not disturb the
relative positions of the aluminum and steel strands of the
conductors and so do not significantly affect the division of
tension between the aluminum and steel portions of the conductors.
When tension is applied to a long length of conventional steel
reinforced aluminum conductor having such fittings on each end,
both the aluminum and steel components are stretched equally and by
an amount proportional to the average, or virtual modulus of
elasticity. This, in turn, results in substantial stresses in both
the alunimum and steel components of conventional conductors.
Some expanded ASCR conductors incorporate non-metallic filler or
hollow metallic tubes between the central steel strand(s) and the
radially distributed aluminum strands. Other expanded ACSR
conductors employ aluminum wires stranded over a steel tube.
In expanded ACSR constructions which incorporate paper filler for
expansion, there remains a need for conductor-metal contact
throughout the diameter of the line. This is needed to preclude the
development of voltage differentials that might result in arcing
that could destroy the paper filler.
A feature common to all the expanded types of conductor, is that
there is always a solid underlying base to support the radial
pressures of overlying layers of wires. It is, therefore,
impossible for the helices of the overlying wires to contract as
they must to prevent the development of consequential tension in
the wires.
SUMMARY OF THE INVENTION
The conductors disclosed herein each comprise a hollow tube of
aluminum supported on a steel cable received within the tube. The
steel cable has a smaller outside diameter than the inside diameter
of the aluminum tube. The latter need not be integral; it may be
fabricated from flat strips, wires or rods, shaped or round.
Strips, wires or rods may be stranded over the steel cable;
integral tubes may be extruded over the steel cable or folded over
the cable from a broad strip and longitudinally welded. Soft
aluminum wires may be stranded radially between the steel cable and
overlaying hard-drawn aluminum conductor, then crushed by the
application of radial pressure to provide internal space between
the aluminum covered steel core and the hard-drawn aluminum
conductor. Under operating conditions, substantially all mechanical
tension on the steel supported aluminum overhead conductor is borne
by the steel cable and the conductor is largely immune to hazards
of galloping, aeolian vibration, loss of strength as a result of
high operating temperatures, and creep at normal and high operating
temperatures.
There are three reasons why this is so. First, relative to aluminum
wires, steel wires are much more resistant to vibration damage, are
not adversely affected by operating temperatures that cause partial
annealing of aluminum wires, and have a very low creep rate
throughout the operating temperature spectrum. Second, with little
or no mechanical stress on the aluminum, fatigue of the aluminum is
not likely to occur. Third, since there is no reliance on the
strength of aluminum, creep would be of no consequence, and
annealing of the aluminum would not cause any loss of rated
strength.
For the aluminum to have substantially no stress, means must be
provided for it to elongate with the stress but without picking up
any consequential load. Ideally, the amount of elongation required
would be that which would occur in the steel at about 50 percent of
its rated strength plus the difference in length between steel and
aluminum caused by a temperature change of about 60.degree. F. The
amounts are approximately:
Steel Stretch = 100,000 psi/27,000,000 = 0.0037 inch/inch
Temp. Diff. = (60) (0.0000128-.0000064) = 0.0004 inch/inch
TOTAL = 0.0041 inch/inch The need to compensate for this difference
is illustrated by the fact that in a 10,000 foot length of
conductor on a reel the total amount of differential elongation is
about 10,000 .times. 0.0041 = 41 feet.
This necessary compensation can be provided for by designing the
conductor so that an axial elongation of the helix of stranded
aluminum wires or elements of whatever shape of 0.41 percent can
take place without introducing consequential tension in the
aluminum wires or elements. The relationship between the axial
length of a stranded conductor and the length of an individual
element in its helix is such that, unless the element itself is
stretched, any lengthening of the helix must be accompanied by a
reduction in the diameter of the helix. Means must be provided,
therefore, for appropriate reduction in the diameters of the
helices of aluminum wires or elements as the helices are
lengthened.
Where the conductor is of multi-layer construction, alternate
layers of the conductors are of opposite-sense pitch of
counterbalance the torque in each layer that tends to unwind the
helices when tension is applied, and to counterbalance internal
magnetic effects caused by electrical current in each layer. This
also simplifies manufacturing operations. The problem of torque is
minimized by the conductor of the invention. Pitch angles for the
helices may be critically established in relation to wire (round,
keystone, flat or otherwise) dimensions so that wires do not crowd
each other as the helices are stretched and their diameters
reduced.
In order for consequential stresses not be transferred from the
steel to the aluminum during changes in tension and temperature,
the aluminum must not press tightly over the steel reinforcement.
This can be accomplished by employing trapezoidally shaped aluminum
wires for the innermost layer. With wires so shaped, the radial
compressive force resulting from tension is carried by the
"keystone" effect in a circumferential direction. The effect is,
therefore, that of a tube which will not collapse and bear upon the
underlying steel reinforcement. This tube, if made large enough,
may serve as a means for producing an expanded, hollow (except for
the steel reinforcing) conductor.
the shaped wires in the inner layer can also function to provide
for the required reduction in diameter referred to above. This can
be done by employing soft annealed wires for this layer, or by
modifying the shape so that distortion takes place at a relatively
low tension level. This will allow the inner layer to collapse to a
smaller diameter as tension is applied, but not to such a degree
that it will bear upon the steel.
Since there is no utilization of the strength of aluminum wires,
there is no requirement for a hard temper for them. This may result
in decreased cost of manufacturing and in an increase in
conductivity when wires of a softer temper are used. It may also
permit the use of trapezoidally shaped wires or round wires of
larger diameter than conventionally employed.
To reduce any possibility of corrosion, the entire conductor may be
impregnated with a suitable grease to preclude the entry of
moisture. The grease may be employed simply as a coating on
individual wires or as a means to fill up the voids in the
interstices and thus to preclude the entry of moisture. However, it
is not necessary or possible to keep all of the internal voids
filled with grease.
Another advantage of the conductor construction of the present
invention is that aeolian vibration and galloping are inhibited.
This is believed to be because the absence of consequential radial
force permits the maximum amount of conductor self damping by
interstrand friction at all frequencies and amplitudes.
Another advantage is that the full strength of the steel
reinforcing wires can be utilized. Conventional conductors utilize
only the strength of the steel at 1 percent extension because of
the elongation limitations of hard drawn aluminum wires.
Another advantage is that computations of sags and tensions are
greatly simplified by the elimination of factors such as stress
distribution between different materials, differences in thermal
coefficients of expansion, creep of aluminum, loss of strength due
to elevated temperature, maximum operating temperature based upon
possible conductor damage, tension limitations based upon aeolian
vibration and galloping considerations. Such a conductor will
permit the maximum tension limitation to be based solely on safety
factors judged suitable under maximum ice and wind loading. Also
the maximum operating temperature can be established as the
temperature at which sags are the same as under maximum ice and
wind loading.
The conductor of this invention can include a plastic filler,
either metallic or nonmetallic, that would collapse, or could be
caused to collapse, to provide the required tube to core spacing in
the field, before the conductor is placed in service. Another
reason for introducing the space during stringing rather than at
the factor would be to avoid the possibility of traffic damage from
chafing.
While it would be desirable to have zero stress in the aluminum
conductor of the invention at all times, practical manufacturing
the line construction considerations may dictate a minimal stress
during initial installation and early periods of service. For
example, it is desirable to joint successive lengths of conductor
with fittings that rigidly connect both the steel and aluminum
components.
In further summary, objects of the invention include:
1. Elimination of the possibility of aeolian vibration of fatigue
damage.
2. Reduction of the possibilities of the occurrence of aeolian
vibration and galloping.
3. Elimination of problems associated with creep of aluminum
wires.
4. Elimination of the possibility of loss of strength due to
partial annealing of aluminum wires at elevated temperatures.
5. Elimination of any need to limit the utilization of the strength
of steel to its strength at 1 percent extension.
6. Simplification of sag and tension computations.
7. Allowance of maximum operating temperature to be limited by sag
rather than by possibility of conductor damage.
8. Provision of a means for producing an improved expanded
conductor.
To most effectively accomplish these objects, the tubular aluminum
conductor desirably possesses the following characteristics:
1. Under all operating conditions, the inside diameter of the tube
is larger than the outside diameter of the steel cable positioned
inside of the tube.
2. The tube has sufficient radial stability to provide a base for
overlying layers of wires, strips or rods during fabrication and
during stringing.
3. The tube is capable of being elongated by approximately 0.50
percent at a very low level of longitudinal stress.
4. The length of lay of the helix is as long as practicable.
5. The reduction in diameter of the tube upon elongation is
sufficient to allow overlying layers of helices to elongate an
equal amount without developing consequential levels of stress.
6. The tube has an essentially round cross section, with no
protruding irregularities either inside or outside. (Radius and
smoothness of a surface is a factor that influences the voltage
gradient in the air immediately surrounding a conductor. This, in
turn, is a factor that influences corona discharges and associated
radio interference. Any distortion will cause the radius at various
positions around the periphery to vary, and possibly [but not
necessarily] to introduce corona and radio interference phenomena.
A small degree of distortion can be tolerated depending upon
conductor size and voltage. If conductors are produced in a plant
with the internal space between the core and tubular conductor,
they may be distorted when placed on reels. If this distortion is
all elastic in nature, however, it disappears when the conductor is
strung. On the other hand, if internal space is introduced during
stringing [for example, as by the use of pressure rolls as
discussed below respecting FIGS. 9 and 10], this potential problem
is eliminated.)
7. The tube must have sufficient flexibility to accommodate field
stringing operations.
The principles of the invention will be further hereinafter
discussed with reference to the drawings wherein preferred
embodiments are shown. The specifics illustrated in the drawings
are intended to exemplify, rather than limit, aspects of the
invention as defined in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
IN THE DRAWINGS:
FIG. 1 is a transverse cross-sectional view of a steel supported
aluminum overhead conductor incorporating aluminum strips;
FIG. 2 is a fragmentary elevational view of the conductor of FIG. 1
with layers progressively cut away to expose constructional
details;
FIG. 3 is a schematic representation of equipment for manufacturing
the conductor of FIGS. 1 and 2;
FIG. 4 is a fragmentary, partly cut away top plan view of the
closure die region of the equipment of FIG. 3;
FIG. 5 is an end elevational view of a portion of the equipment of
FIG. 3 showing the spatial relation of the forming rolls for the
first aluminum strip layer to the conductor undergoing
manufacture;
FIG. 6 is a transverse cross-sectional view of a steel supported
aluminum overhead conductor incorporating an integral aluminum
tube;
FIG. 7 is a transverse cross-sectional view of a steel supported
aluminum overhead conductor incorporating an aluminum tube welded
longitudinally from broad strip stock;
FIG. 8 is a transverse cross-sectional view of a steel supported
aluminum overhead conductor incorporating stranded trapezoidally
shaped aluminum wire;
FIG. 9 is a transverse cross-sectional view of a steel supported
aluminum overhead conductor incorporating stranded aluminum wire
over soft aluminum filler wires in an as-stranded condition;
FIG. 10 is a transverse cross-sectional view of the conductor of
FIG. 9 after the soft aluminum filler has been crushed between the
steel core and overlying hard aluminum wires; and
FIG. 11 is a transverse cross-sectional view of a steel supported
aluminum overhead conductor similar to FIG. 10, but wherein the
post stranding deformation is of a plastic filler.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS
Following a practice which is common in the industry, the entire
article of the invention is referred to herein as a "conductor"
even though the tubular aluminum portion thereof would in a
strictly technical sense be more accurately designated the
conductor. It is believed that this practice will cause no problem
for those skilled in the art and familiar with its practices and
vocabulary.
Unless otherwise indicated or obvious from the context, absolute
values of dimensions given herein are for illustrative purposes
only, to enable a more concise discussion of the preferred
embodiments.
With reference to FIGS. 1-5 and especially FIGS. 1 and 2, there is
depicted a steel supported aluminum overhead conductor 10
comprising a steel core 12 and a tubular aluminum conductor 14
received over the core 12. In the instance depicted, the tubular
aluminum conductor is fabricated from two superimposed layers 16,
18 of helically wound layers of aluminum strip stock 20.
The steel core 12 is preferably made of stranded steel wires. They
may be identical in composition and fabrication to the cores used
in standard ACSR conductors, see ASTM specification B232 "Aluminum
Conductors, Steel Reinforced, Concentric-Lay Stranded (ACSR)," ASTM
specification B341 "Aluminum-Coated (Aluminized) Steel Core Wire
for Aluminum Conductors, Steel Reinforced (ACSR)," ASTM
specification B502 "Aluminum-Clad Steel Core Wire for Aluminum
Conductors, Aluminum-Clad Steel Reinforced (ACSR/AW)," and ASTM
specification B498 "Zinc-Coated (Galvanized) Steel Core Wire for
Aluminum Conductors, Steel Reinforced (ACSR)." They may also be of
material having properties especially suitable to the disclosure,
for example, higher strength than required by the ASTM
specifications.
As illustrated, the steel core 12 consists of seven 0.1329 diameter
steel strands 22 helically stranded to produce a core having an
O.D. of 0.399 inches. (This is the same core as is found in 954 MCM
54/7 ACSR "Cardinal" conductor manufactured by Reynolds Metals
Company of Richmond, Virginia.)
In this same example, the first, inner layer of the tubular
aluminum conductor is provided by three helically stranded, rounded
edged aluminum strips each 0.1 inch thick and 0.6 inch wide, this
layer having an internal diameter of 0.50 inch, an external
diameter of 0.70 inch and a pitch of 7.2 inches. The second, outer
layer of the tubular aluminum conductor is helically stranded
immediately upon the first, in an opposite helical sense, and
consists of four, round edged aluminum strips each 0.1 inch thick
and 0.6 inch wide, this layer having an internal diameter of 0.70
inch, an external diameter of 0.90 inch and a pitch of 9.6 inches.
In each instance, the strips of aluminum are curved about the
longitudinal axis of the tubular aluminum conductor so that each is
arcuate as seen in transverse cross section.
The strips 20 are preferably of EC-H19 aluminum, although other
tempers and aluminum alloys, e.g. 5005 or 6201 could be
employed.
The layer 16 could be formed from a greater or a lesser number of
strips 20. To illustrate an alternative, the following table
relates to a layer 16 consisting of two helically intertwined round
edge strips of aluminum.
---------------------------------------------------------------------------
TABLE I
As When Fabricated Elongated 0.45%
__________________________________________________________________________
Thickness of each strip 0.070 inch 0.070 inch Inside diameter
0.5505 inch 0.500 inch Inside circumference 1.729 inchs 1.571
inches Outside diameter 0.7105 inch 0.660 inch Outside
circumference 2.232 inches 2.073 inches Lay factor 11.09 .times.
I.D. 12 .times. O.D. Pitch (length of lay) 7.88 inches 7.92 inches
Maximum strip width 0.832 inch 0.7598 inch Recommended nominal
strip width 0.750 inch 0.750 inch
__________________________________________________________________________
The layer 16 of Table I may be stranded over the same 0.399 inch
O.D. steel core as described above and an outer aluminum layer 18
of opposite helical sense may be laid directly on the layer 16 of
this alternative example.
Although the conductors in the examples just described have overall
outer diameters smaller than one inch, it is believed that the
conductor of the invention has substantial and perhaps
predominating usefulness in overall outer diameters in excess of
one inch.
The properties and sag characteristics of several alternative
constructions embodying the principles of the invention are
contrasted with those of several ACSR constructions in the
following table (Table II). For the constructions embodying
principles of the invention approximately 5 to 10 percent more
steel is shown used in the core than in conventional constructions.
Note that the elevated operating temperatures at which sag equals
sag under maximum ice and wind loading are very high.
In the examples of Table II, the constructions in accordance with
the invention utilize a solid aluminum jacket over the steel core
for the conductor. The rated strengths were calculated on the basis
of the strength of steel at 205,000 psi and of aluminum at 9,000
psi. This assumes that the stretch of the steel will be sufficient
to cause load to be borne by the aluminum before break ##SPC1##
actually occurs, and that the aluminum is annealed.
The representative equipment shown in FIGS. 3-5 for fabricating the
steel supported aluminum overhead conductor of FIGS. 1 and 2 is
provided with appropriate legends to enable those skilled in the
art to rapidly grasp the salient features of its construction and
manner of operation.
Rather than utilize rounded edge strips of aluminum to fabricate
the layer(s) of the conductor 14, aluminum strands, of other
cross-sectional shape may be employed. By way of illustration (FIG.
8), there may be used, upon a 7 .times. 0.1489 inch helically
stranded steel core 12 having an outer diameter of 0.4467 inch, a
tube of aluminum 27 having an inside diameter, when elongated 0.45
percent, of 0.4767 inch and consisting of 10 trapezoidally shaped
wires 29 having a thickness of 0.20 inch. Other dimensions of the
tube, assuming a stretch of 0.45 percent are as follows:
---------------------------------------------------------------------------
TABLE III
As When Stranded Stretched
__________________________________________________________________________
Outside diameter 0.9498 inch 0.8767 inch Length of Lay 14.7d =
13.97 inches 16d=14.03 inch Outside base (are line) 0.2916 inch
0.2702 inch of trapezoidal wires nor- mal to length of wire
Required reduction in dimen- -- 7.5% sion of wire to permit
stretching
__________________________________________________________________________
One problem in the design, the tube using trapezoidally shaped
wires is ensuring that, when stranded, the tube will be stable
enough to provide a base for overlying layers of wires, and still
be able to stretch without a particularly high tension. (Stretch
for the overlying layers can be provided for by adjusting the
pitch, number of wires, and wire diameters to the amount of
diameter reduction expected in the tube.) It is obvious, however,
that the reduction in wire dimension of 7.5 percent shown above
cannot be achieved with ordinary wires by simply putting tension on
the tube. However, the wires may be drawn about 10 percent
undersize and every other wire given a zigzag shape with bends
about every inch or two. This permits a reduction in the diameter
of the tube by the forces that would tend to straighten out the
zigzag.
Referring now to FIG. 6, there is shown a steel supported aluminum
overhead conductor 30 which includes a steel core 12 as described
above in relation to FIGS. 1 and 2, and a tubular aluminum
conductor 32 extruded in an integral condition over the core.
Exemplary values for the conductor 30 are provided in Table IV.
---------------------------------------------------------------------------
TABLE IV
As When Crushed or Fabricated Elongated 0.45% (inches) (inches
__________________________________________________________________________
Core outside diameter 0.450 0.450 Tube Thickness 0.1053 Approx.
0.1053 Tube inside diameter 0.500 Approx. 0.450 Tube outside
diameter 0.7105 Approx. 0.6605 Tube outside circumference 2.232
Approx. 2.073
__________________________________________________________________________
Referring now to FIG. 7, there is shown an alternative to the
construction depicted in FIG. 6 in that tubular aluminum conductor
42 is provided for the steel supported aluminum overhead conductor
40 by wrapping a single broad strip 44 about the core 12 and
welding its formerly laterally opposite edges to one another at 46
utilizing conventional welding equipment and techniques. Exemplary
values for the conductor 40 are the same as in Table IV.
It is also possible to fabricate a steel supported aluminum
overhead conductor 50 in accordance with the present invention
utilizing round (e.g. cylindrical, oval, rounded edge flat strip)
wires helically stranded upon the steel core. In order to do this,
a special technique and means are employed to achieve the necessary
spacing between the outside diameter of the core and the inside
diameter of the tubular aluminum conductor. Very succinctly, with
reference to FIG. 9, soft, annealed aluminum wires 52 are stranded
directly upon the core 12. Then layer(s) of harder aluminum wires
54 are helically stranded upon the soft aluminum wire layer. The
conductor 50 is shipped to where it is to be strung in this
condition. Then, with reference to FIG. 10, the conductor 50 is run
between pressure rolls applied to the exterior of the completely
fabricated article. The harder wires 54 are elastically formed by
the pressure rolls, but the softer underlying wires 52 are crushed
into greater conformance, with interstitial spaces in the core 12
and in the hard aluminum wires 54. When the wires 54 spring back
after passing the pressure rolls, the crushed wires 52 remain
engaging the core 12 and the desired space 56 is provided between
the composite core 12, 52 and the overlying tubular aluminum
conductor 54.
The conductor 50 looks and behaves much like a conventional
conductor in the plant and on shipping reels. After pressure
crushing, during stringing, the gap 56 allows sufficient space for
attendant reduction in diameter of the helical layer(s) of wires
54. Exemplary characteristics of a steel supported aluminum
overhead conductor constructed in accordance with the embodiment of
FIGS. 9 and 10 are presented in Table VIII.
TABLE VIII
1. Size: 1,046,105 circular mils 2. Stranding (Immediately after
stranding): a. tubular aluminum conductor 30.times. 0.1750" EC-H19
aluminum b. soft aluminum layer 11.times. 0.1076" EC-0 aluminum c.
core: 7.times. 0.1329" steel 3. Cross Section: a. Aluminum: 0.8216
sq. in. b. Steel: 0.0970 sq. in. c. Total: 0.9186 sq. in. 4.
Outside Diameter: a. As stranded: 1.3138" b. Under maximum load:
1.2250" 5. Weight per 1,000 feet: a. Aluminum: 985.6 lb. b. Steel:
329.0 lb. c. Total: 1,314.6 lb. 6. By weight: a. Aluminum: 75.0% b.
Steel: 25.0% 7. Rated strength (with Class A steel wire): a. As
stranded: 36,096 lb. b. Aluminum fully annealed: 26,484 lb. 8.
Summary of Lay (as stranded):
Inner Outer Soft Layer Layer Layer Maximum Length of Lay 11.318"
13.407" 7.95" O. D. of Layer .9638" 1.3138" .6138" Lay Factor 11.74
10.2 13.0
As should be apparent, integral or welded tubes, wire and strip may
all alternatively be used in the fabrication of conductor in
accordance with the invention disclosed in this document. The
particular mode which would be preferable at any given point in
time would be the one that could most economically be produced at
that time or meet other considerations of design prejudice. One of
the features of the conductor of the invention is that the basic
requirement for conventional conductors that aluminum wires have
the maximum possible strength has been eliminated. This makes
possible the consideration of materials other than hard drawn round
wires that may be produced by various processes. Combinations
certainly are possible. For example, the soft aluminum wires
referred to above in respect to FIGS. 9 and 10 could be replaced by
an extruded, equally crushable jacket of soft aluminum.
In all of the disclosed embodiments, once the conductor has been
strung, the top inside of the tubular aluminum conductor will
definitely touch the top of the outside of the core and the core
will not be precisely centered. This will result in some asymmetry
of the magnetic fields caused by electric current. The degree of
asymmetry should be quite small, however, and there should be no
consequential problem. There is no significant sag to noncircular
shape of the tubular aluminum conductor because of its resting on
the core when the conductor is fabricated in accordance with the
invention, as described hereinabove, and strung in accordance with
sensible procedures.
It should now be apparent that the steel supported aluminum
overhead conductors as described hereinabove possesses each of the
attributes set forth in the specification under the heading
"Summary of the Invention," hereinbefore. Because the steel
supported aluminum overhead conductors of the invention can be
modified to some extent without departing from the principles of
the invention as they have been outlined and explained in this
specification, the present invention should be understood as
encompassing all such modifications as are within the spirit and
scope of the following claims.
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