Analysis on the crimping quality of overhead transmission line conductors considering equivalent cross-sectional stiffness

Approximately 58% of wire failures are caused by slippage and fracture of electrical connectors, and the crimping quality analysis of connectors is based on equivalent cross-sectional stiffness. First, a JL/GLA 400/35 steel cord aluminum strand and NY-400/35 strain clamp are selected to fabricate 26 groups of specimens with different pipe penetration depths, opposite edge distances, inner diameters of the aluminum tube, and die widths. Then, through crimping tests on the aluminum tube and conductor and the steel core and steel anchor, five main crimping failures, namely, the slip at the outlet of the clamp, the slip at the outlet of the clamp with some broken aluminum strands, fracture of the aluminum tube in the non-pressure area, wire fracture at the outlet of the clamp, and separation of steel anchors, are observed. Finally, a failure analysis method for conductor crimping is proposed based on equivalent cross-sectional stiffness. Through the analysis of grip force and crimping quality, four failure modes and simplified curves of the load–displacement curve are obtained, and the failure principle of the conductor crimping is further elaborated. The results show that the stress release caused by the steel core and steel anchor of the crimping wire and the crimping aluminum tube and wire is the main reason for the slippage and fracture of the transmission line conductors and that it is also the key to improve the installation quality of the transmission line.