LI Yan, TIAN Yongcai, ZENG Xiangrui, ZHAO Wenqian, DIAO Xun, LIU Yunpeng, HU Leilei, LI Mao
The medium-voltage cable joint is a critical component that determines the overall safety and reliability of cable systems, with bolt compression serving as the key process influencing joint quality. In conventional cable bolt connection design, the final configuration is often determined empirically based on the designer’s experience, lacking a systematic and scientific optimization approach. In this study, a three-dimensional finite element model of the cable bolt was developed to analyze the stress distribution and fatigue life characteristics during the compression process. By integrating Matlab with finite element co-simulation, a quantitative relationship among bolt size, position, and compression performance was established. Taking stress life, maximum stress, and average stress as the three optimization objectives, the NSGA-II algorithm was employed to obtain a Pareto-optimal solution set, and the TOPSIS method was subsequently applied to identify the optimal structural configuration. The results demonstrate that rational optimization of bolt dimensions and positioning can approximately double the average contact stress and extend the fatigue life by about 1.5 times. The optimized design effectively reduces contact resistance while enhancing mechanical integrity and electrical stability. Both simulation and experimental results confirm that the proposed method significantly improves the safety and reliability of cable joints, providing theoretical and technical guidance for the engineering optimization of bolted compression structures.