Transmission lines often suffer from conductor damage during operation, most of which are caused by excessive local stress of aluminum strands. However, one of the causes of conductor damage may be the tension paying off passing the pulley. At the same time, there are relatively few researches on the damage of conductor causing by passing pulley. Therefore, this paper studies the inter strand stress characteristics of aluminum strand when tension paying off passes through the pulley. The influence of envelope angle, tension load and friction on the stress characteristics between aluminum strands is studied by numerical simulation. The results show that the equivalent stress of the neutral layer of the aluminum strand is small, and the maximum equivalent stress appears at the contact position of the adjacent strand. The larger the envelope angle and tension load of the aluminum strands, the greater the equivalent stress in the cross section. Furthermore, the friction between aluminum strands has a certain effect on reducing the equivalent stress in the cross section. The equivalent stress of the aluminum strand increases from the outer layer to the inner layer, so the inner aluminum strand is more likely to be damaged than the outer layer. Finally, the experiment and the simulation have both been carried on, and then it is shown that the stress value in the corresponding section has a good consistency.
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