2001 PPL CHALLENGE #1
Determine possible improved methods or equipment for terminating wires and cables on sliding link type terminal strips.About PPL Corp
Determine possible improved methods or equipment for terminating wires and cables on sliding link type terminal strips.About PPL Corp
Based in Allentown, Pennsylvania, PPL Corp. (http://www.pplweb.com) is a FORTUNE 500 company that delivers electricity and natural gas to more than 1.3 million customers in Pennsylvania; markets wholesale energy in 43 U.S. states and Canada; generates electricity at power plants in Pennsylvania, Maine, and Montana; delivers electricity to 1.4 million customers in southwest Britain; and delivers electricity to more than 800,000 customers in Chile, Bolivia, and El Salvador.
During the construction of a typical substation or power plant, we make thousands of wire connections. See photos below for samples of typical equipment and connections. These connections consist of twisted wire, sizes typically from #18 to #10. Each connection is made to a piece of equipment (typically a screw terminal - See photos below), a sliding link, or a ground bus. The connections at the equipment can not be changed, so this problem will concentrate on the connections at the sliding links.
We currently use two different styles of sliding links: States and Weidmuller (See photos below). The Weidmuller links do not require the use of crimp terminals on the wires, but they are generally not suitable for attaching two wires larger than #14 on the same side of the link. The States links use a post and nut arrangement, which require the use of a ring crimp terminal, and will support two wires up to #10 on the same side of the link. Our existing specifications state that no more then two (2) wires are to be connected on either side of the sliding link.
The voltage levels involved are 120 VAC, and 125 VDC, and the current level is generally below 20 amps nominal. Costs per connection for the existing design is $2.25 to $3.00 for factory wiring depending on the need for a crimp lug, and the size of the wire. Field wiring will generally cost more, use $1.00 per connection additional charge for your analysis.
· Research alternative suppliers of sliding link isolation devices.
· Research alternative methods of making connections to the
above devices; for example: crimp lugs, insulation displacement, compression, etc.
NOTE:Soldered
connections are not acceptable.
· Training required for proposed equipment and connection method.
· Special equipment required for connection method.
· Thomas Register at: http://www.thomasregister.com/
· Various magazines:
Electronic Buyers Guide at: http://www.ebnonline.com/
Manufacturing Net at: http://www.manufacturing.net/
Industry.net at: http://www.industry.net/
Instrumentation and Control News at: http://www.icsmagazine.com/.
We are looking for alternative ways to connect or terminate these wires with minimal costs and no loss of reliability, while maintaining the functionality of a sliding link for isolation purposes. Students are encouraged to research creative and imaginative solutions other than those suggested. Students are expected to show results of a cost/benefit analysis as part of their presentation, including training.
If you are selected to give an oral presentation for this problem, the
presentation will be held Thursday, March 29, 2001 at PPL
Headquarters in Allentown, Pennsylvania. You will be given directions
and an agenda later.