A puncture wire clamp for improving stress distribution and creep compensation

Abstract

This invention discloses a piercing clamp for improving stress distribution and creep compensation, comprising an upper and lower housing clamped by torque bolts, a piercing blade arranged in a mounting groove in the lower housing, and cable management structures at both ends of the piercing area. The cable management structures consist of an upper clamp, a lower clamp, a lead screw, an ear plate, a fixing plate, and a compression spring. Through synchronous adjustment on both sides, they provide circumferential clamping and axial guidance of the conductor, aligning the inlet and outlet axes and providing elastic compensation at the end clamping level. A butterfly-shaped washer is provided in the torque bolt clamping path to continuously compensate for the overall clamping force of the housing; a wave spring is arranged in the mounting seat at the bottom of the piercing blade to ensure more uniform contact pressure between the blade teeth and the conductor. This structure improves the piercing force distribution during installation, slows down preload decay during operation, reduces contact resistance and heat generation risk, and improves the long-term safety and reliability of the line connection.

Description

Technical Field

[0001] This invention relates to puncture connection technology for power distribution, specifically to a puncture clamp that improves stress distribution and creep compensation. Background Technology

[0002] A piercing clamp (also known as an insulated piercing clamp) is an electrical connector used for unstripped connections between main and branch lines in power distribution lines. During installation, the main and branch conductors are placed into the cable tray, and the torque bolt is tightened to allow the blade to pierce the conductor's insulation layer and establish electrical contact with the metal conductor. The torque element automatically slips and limits the torque after reaching the set torque, thus obtaining a relatively stable initial clamping force. At the same time, the housing and sealing material complete the insulation and waterproofing.

[0003] However, these products are mostly for one-time installation and are not typically disassembled for maintenance. On-site installation usually relies on manual straightening of the pierced wires before closing the housing to improve alignment and stress distribution. However, due to wire springback, installation posture, and space limitations, bending and misalignment can still easily occur at both ends of the piercing zone. These deviations during installation can lead to uneven stress distribution between the piercing teeth, with some teeth contacting and overloading first, while others lag behind or remain suspended. Stress concentration occurs at the end insulation, making it difficult to maintain consistent initial contact resistance. This can also easily cause problems such as unequal clamping strokes at the left and right ends and unstable wire posture.

[0004] The more uneven the stress distribution, the greater the local compressive stress on individual teeth and their corresponding insulation and sealing parts, making them more prone to indentation and material damage in the early stages of operation, thus creating hidden dangers for subsequent compression creep. Therefore, the uneven stress distribution generated during the installation stage and the creep during the operation stage are not two independent problems, but rather they are superimposed and amplify the risks. For traditional piercing clamps, if the stress between the piercing teeth is already significantly dispersed during initial installation, with some teeth overloaded and others having insufficient contact, then in the long-term operation, the insulation layer and sealing material in the area corresponding to the overloaded teeth will preferentially undergo compression creep or even local crushing, reducing the contact area, further increasing the contact resistance, and exacerbating heat generation. Meanwhile, those teeth with lower initial stress or even weak contact are more prone to contact failure or partial discharge channels after the overall preload decays over time. In this way, the deviation and stress dispersion in the original installation stage will evolve into more severe load redistribution and local concentration under the action of creep and thermal cycling, making the high-temperature area hotter and the weak contact area looser, forming a vicious cycle and significantly increasing the risk of conductor insulation aging, ablation, or even burnout.

[0005] Therefore, there is an urgent need for a puncture clamp that can improve the uniformity of force on the puncture teeth during the installation stage and effectively compensate for the long-term creep of cables and related components during operation, while maintaining the puncture connection path. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to improve the stress distribution in the puncture zone and effectively compensate for the long-term compression creep of the wire and sealing material without changing the existing puncture connection mechanism, so that the puncture clamp maintains a relatively uniform stress and reliable electrical contact throughout its life cycle.

[0007] To achieve the above objectives, this invention provides a puncture clamp for improving stress distribution and creep compensation, comprising an upper housing, a lower housing, a puncture blade, and a torque bolt for clamping the upper and lower housings. A wire management structure is provided at both ends of the puncture area, comprising an upper wire clamp and a lower wire clamp for circumferentially clamping and positioning the wire; a lead screw and a lug with a threaded engagement with the lead screw are provided on each side, the lug moving axially along the lead screw under guidance; a fixing plate is provided on each lead screw, and a compression spring is provided between the fixing plate and the corresponding lug; the two ends of the lower wire clamp are fixed to the upper ends of the lug, so that the two ends form a continuous normal clamping of the wire.

[0008] Preferably, pads are provided on the inner sides of the upper and lower housings respectively. The piercing blade is installed in the mounting groove of the lower housing and is limited by the mounting groove in the end face and side, so that the clamping force is stably transmitted to the blade through the pads and housing.

[0009] Preferably, the upper clamp is a detachable part that can be installed and removed laterally between the lead screw and the ear plate. The ear end of the upper clamp is clamped and positioned between the fixed plate and the lower end face of the ear plate, which facilitates side installation without passing the wire end through.

[0010] Preferably, the upper end of the ear plate is provided with an internal threaded hole that mates with the lead screw, and the lower end of the ear plate is provided with a guide hole that mates with the diameter of the lead screw, so as to ensure the linear guidance and assembly accuracy of the ear plate.

[0011] Preferably, the portion of the lead screw below the fixed plate is a scale post, the outer circle of which is provided with circumferential scale, and the bottom surface of the ear plate is used as the scale reading reference.

[0012] Preferably, a hand-tightening nut and a drive gear connected thereto are provided on the outer edge of the upper housing, and driven gears are fixed to the lead screws on both sides respectively. The drive gear meshes with the two driven gears to synchronously drive the lead screws at both ends to rotate. A protective cover can be provided at the outer edge and connected by screws or buckles for protection and maintenance.

[0013] Preferably, a butterfly washer is provided between the nut of the torque bolt and the washer plate to provide elastic compensation for the clamping path of the housing and to counteract the thickness change caused by compression creep during operation.

[0014] Preferably, each puncture blade has a centrally hollowed-out mounting seat, and a wave spring is provided inside the mounting seat to give the blade limited axial compliance, so as to distribute the load and suppress local stress concentration when contact is established.

[0015] This invention employs a two-section cable management structure to circumferentially clamp and axially guide the conductor at both ends of the puncture zone, aligning the input and output wire axes to significantly reduce stress dispersion on the puncture teeth and end stress concentration. A fixing disc, compression spring, and ear plate maintain stable end clamping. A butterfly-shaped gasket provides recoverable axial thrust along the clamping path of the housing, delaying the decay of the clamp's preload. A wave spring within the blade mounting base ensures balanced contact between the tooth tips and the conductor. Through this structural combination, stress distribution in the puncture zone is improved during installation, and creep compensation inhibits stress re-concentration during long-term use, thereby reducing the risk of increased contact resistance and localized overheating, and improving the long-term safety and reliability of the puncture connection. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of a puncture clamp that improves stress distribution and creep compensation.

[0017] Figure 2 This is a schematic diagram of the side structure of a puncture clamp that improves stress distribution and creep compensation.

[0018] Figure 3 This is a schematic diagram of a puncture clamp for removing the protective cap, which improves stress distribution and creep compensation.

[0019] Figure 4 A schematic diagram of the wire management structure in a puncture wire clamp that improves stress distribution and creep compensation.

[0020] Figure 5 This is an exploded schematic diagram of the wire management structure in a puncture wire clamp designed to improve stress distribution and creep compensation.

[0021] Figure 6 This is an enlarged schematic diagram of the lower shell structure and puncture blade structure of a puncture clamp for improving stress distribution and creep compensation.

[0022] Attached icon numbers:

[0023] 1. Upper housing; 11. Outer edge; 12. Protective cover; 2. Lower housing; 21. Mounting groove; 3. Cable management structure; 31. Upper cable clamp; 32. Lower cable clamp; 33. Ear plate; 34. Lead screw; 35. Fixing plate; 36. Compression spring; 37. Scale post; 4. Washer plate; 5. Hand-tightening nut; 51. Drive gear; 52. Driven gear; 6. Torque bolt; 61. Nut; 62. Butterfly washer; 7. Piercing blade; 71. Mounting base; 72. Wave spring. Detailed Implementation

[0024] The technical solutions of this application will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of this application.

[0025] A piercing clamp (also known as an insulated piercing clamp) is an electrical connector used for unstripped connections between main and branch lines in power distribution lines. During installation, the main and branch conductors are placed into the cable tray, and the torque bolt is tightened to allow the blade to pierce the conductor's insulation layer and establish electrical contact with the metal conductor. The torque element automatically slips and limits the torque after reaching the set torque, thus obtaining a relatively stable initial clamping force. At the same time, the housing and sealing material complete the insulation and waterproofing.

[0026] However, these products are mostly for one-time installation and are not typically disassembled for maintenance. On-site installation usually relies on manual straightening of the pierced wires before closing the housing to improve alignment and stress distribution. However, due to wire springback, installation posture, and space limitations, bending and misalignment can still easily occur at both ends of the piercing zone. These deviations during installation can lead to uneven stress distribution between the piercing teeth, with some teeth contacting and overloading first, while others lag behind or remain suspended. Stress concentration occurs at the end insulation, making it difficult to maintain consistent initial contact resistance. This can also easily cause problems such as unequal clamping strokes at the left and right ends and unstable wire posture.

[0027] The more uneven the stress distribution, the greater the local compressive stress on individual teeth and their corresponding insulation and sealing parts, making them more prone to indentation and material damage in the early stages, thus creating hidden dangers for subsequent compression creep. Therefore, the uneven stress distribution generated during the installation stage and the creep during the operation stage are not two independent problems, but rather they superimpose each other and amplify the risks. For traditional piercing clamps, if the stress between the piercing teeth is already significantly dispersed during initial installation, with some teeth overloaded and others having insufficient contact, then in subsequent long-term operation, the insulation layer and sealing material in the area corresponding to the overloaded teeth will preferentially undergo compression creep or even local crushing, reducing the contact area, further increasing the contact resistance, and exacerbating heat generation. Meanwhile, those teeth with lower initial stress or even weak contact are more prone to contact failure or partial discharge channels after the overall preload decays over time. In this way, the deviation and stress dispersion in the original installation stage will evolve into more severe load redistribution and local concentration under the action of creep and thermal cycling, making the high-temperature area hotter and the weak contact area looser, forming a vicious cycle and significantly increasing the risk of conductor insulation aging, ablation, or even burnout.

[0028] Therefore, this invention discloses a puncture clamp that improves stress distribution and creep compensation, aiming to improve the uniformity of force on the puncture teeth and effectively compensate for long-term cable creep without changing the existing puncture connection mechanism.

[0029] The piercing clamp in this embodiment includes an upper housing 1, a lower housing 2, a piercing blade 7, a wire management structure 3, and a torque bolt 6. The upper housing 1 and the lower housing 2 are clamped together by the torque bolt 6. A pad 4 is provided at the upper end of the upper housing 1, and a pad 4 is also provided at the lower end of the lower housing 2. The torque bolt 6 passes through the clamping path between the two pads 4 and the two housings. A butterfly washer 62 is provided between the nut 61 and the lower pad 4. After the torque bolt 6 reaches the set torque, it automatically slips out to form a stable initial preload. The butterfly washer 62 stores energy after being compressed and forms a recoverable axial thrust. When the material in the clamping path thins over time, the butterfly washer 62 springs back and pushes the pads 4 and the housings to maintain the overall clamping of the piercing area. A mounting groove 21 is formed in the middle of the lower housing 2. The piercing blade 7 is inserted into the mounting groove 21 by its mounting seat 71 at the bottom. The mounting groove 21 provides end face and lateral positioning and limiting for the piercing blade 7, ensuring that the clamping force is reliably transmitted from the pad 4 and the housing to the piercing blade 7. The mounting seat 71 has a hollow cavity in the middle, and a wave spring 72 is arranged in the cavity. The wave spring 72 is clamped by the end face in the axial direction. During operation, it is compressed and rebounded only in the axial range. The wave spring 72 has a symmetrical structure with space on both sides. The mounting seat 71 and the corresponding groove make it easy and stable to install the piercing blade 7, while also providing continuous fit to changes in the thickness of the contact area over a long period of time. The mounting seat 71 preferably forms an annular guide cavity and has a shoulder at the end. The two ends of the wave spring 72 are supported by flat support rings to prevent lateral movement.

[0030] To improve attitude control and end clamping during installation, this embodiment provides cable management structures 3 at both ends of the piercing area. The cable management structure 3 is a two-section structure, with an upper cable clamp 31 and a lower cable clamp 32 positioned on the upper and lower sides of the conductor, respectively. Together, they clamp and position the conductor circumferentially, guiding the inlet and outlet axes to a near-coaxial state during installation. The upper and lower cable clamps 31 and 32 are preferably made of a resilient strip material, such as a spring steel strip covered with a wear-resistant rubber layer. Alternatively, they can be made of stainless steel strips with good toughness or high-strength engineering plastic strips. The inner side of the strip can be processed with fine serrations or corrugations as needed to increase friction with the conductor insulation layer. When further dispersing contact stress is required, a layer of wear-resistant cloth or a wear-resistant sleeve can be wrapped around the corresponding cable position before clamping, followed by the upper and lower cable clamps 31 and 32, making the clamping more gentle and reliable. During clamping, the strip elastically contracts circumferentially and conforms to the outer circumference of the conductor, forming a continuous circumferential surface contact. The upper clamp 31 is designed as a detachable component, eliminating the need for the wire end to pass through during installation. The operator simply inserts it from the side into the space between the lead screw 34 and the ear plate 33 to complete the installation. The two ends of the lower clamp 32 are fixed to the slots at the upper ends of the left and right ear plates 33. It can be connected using screws with ear holes or a snap-fit ​​structure, forming a secure connection between the lower clamp 32 and the ear plate 33 to bear the normal clamping force transmitted to the outer periphery of the wire by the lead screw 34.

[0031] Each side is equipped with a lead screw 34 and an ear plate 33. The ear plate 33 and the lead screw 34 form a threaded pair, and the ear plate 33 moves axially along the lead screw 34 under guiding constraints. To ensure guiding accuracy, the upper end of the ear plate 33 has an internal threaded hole that mates with the lead screw 34, and the lower end of the ear plate 33 has a guide hole that mates with the diameter of the lead screw 34. The internal threaded hole is responsible for force transmission and displacement, while the guide hole is responsible for linear guidance and assembly correction. The two holes are machined coaxially and mate with the external datum, which can effectively limit the swing and deflection of the ear plate 33 relative to the lead screw 34. A fixing plate 35 is fixedly installed on each lead screw 34. A compression spring 36 is installed between the upper surface of the fixing plate 35 and the upper end face of the ear plate 33. The compression spring 36 is pre-compressed during assembly and remains compressed throughout the operation. When the lead screw 34 rotates, the ear plate 33 moves relative to the lead screw along the pitch direction. The compression spring 36 continuously transmits the axial thrust to the ear plate 33 and the fixed plate 35, and then through the ear plate 33, the upper clamp 31, and the lower clamp 32 to the outer periphery of the conductor, forming a continuous and flexible end clamping. The compression spring 36, the upper clamp 31, the lower clamp 32, and the outer layer of the conductor form an elastic series node in the axial direction. After installation, the spring 36 has a clear preload. During long-term use, if the conductor insulation or the clamp covering layer becomes thinner, the ear plate 33 will move downward in the direction of the conductor under the continuous action of the spring 36. The spring 36 will correspondingly reduce the compression to compensate for the displacement, thereby maintaining the end clamping force in a stable range. The thickness change of the material during operation can be offset without rotating the lead screw 34 again. Since the ear plate 33 is only allowed to slide along a short guide stroke, the threaded pair clearance and lubrication conditions ensure the above movement. The thrust provided by the spring 36 can overcome the static friction of the interface, so that the end clamping force is absorbed by the elastic element and keeps the change smooth, avoiding sudden drops.

[0032] In the cable management structure 3, the upper cable clamp 31 and lower cable clamp 32 are arranged concentrically around the conductor. The upper cable clamp 31 is a detachable part, with both ends bent outward to form ears. Since the diameters of the main cable trough and the branch cable trough are different, the cable management structures 3 at both ends are matched with their respective cable troughs. In use, the main cable or branch cable is inserted into the main cable trough or branch cable trough of the lower housing 2 from the side, so that the conductor falls naturally at the bottom of the cable trough, with the geometric center of the cable trough as the reference position of the conductor. After the cable has been placed in the cable trough, the position of the ear plate 33 is adjusted by rotating the hand-tightening nut 5 or by directly adjusting the position of the ear plate 33. Before removing the upper cable clamp 31, first rotate the hand-tightening nut 5 to move the ear plates 33 downward along the screw 34 until the lower end of the screw 34 is disengaged from the guide hole space at the lower end of the ear plate 33. At this time, the ears of the upper cable clamp 31 can be removed from between the screw 34 and the ear plate 33, and the upper cable clamp 31 is detached from the side. After removing the upper clamp 31, pass the cable through the main cable tray, allowing the cable to fall naturally above the lower clamp 32. At this point, by appropriately rotating the hand-tightening nut 5 or directly adjusting the position of the ear plate 33, adjust the lower clamp 32 to a position relatively close to the lower side of the cable but still maintaining a significant gap. This ensures that the lower clamp 32 only serves to support and limit the cable in its initial state, without prematurely tightening the cable upwards. This prevents the adjustment of the cable management structure 3 relative to the upper housing 1 from pulling the wire away from the central area where the piercing blade 7 is located.

[0033] After the lower clamp 32 is adjusted to the desired position, the ears at both ends of the upper clamp 31 are re-inserted from the side into the gap between the screw 34 and the ear plate 33, so that the ears are positioned between the fixing plate 35 and the lower end face of the ear plate 33. Then, the hand-tightening nut 5 is rotated in the opposite direction, causing the ear plates 33 on both sides to move upward along the screw 34. During the upward movement, the ears of the upper clamp 31 are gradually clamped and locked in position by the fixing plate 35 and the lower end face of the ear plate 33. At the same time, the upward movement of the ear plate 33 causes the two ends of the lower clamp 32 to rise upward through the connection at its upper end. The middle of the lower clamp 32 elastically arches upward and gradually approaches the lower side of the cable. The middle part lifts towards the conductor and finally fits against the lower side of the conductor. In this way, the upper clamp 31 and the lower clamp 32 clamp the conductor from above and below, respectively. The two clamps tighten evenly along the circumference due to their own elasticity. With the synchronous rotation of the screws 34 on both sides, the conductor is gradually straightened and its posture is corrected under the constraint of the clamps, so that the inlet and outlet axes at both ends of the puncture area tend to be coaxial. Under the premise that the conductor management structure 3 and the upper shell 1 are relatively fixed, the conductor is straightened smoothly and will not be pulled away from the puncture center in an instant.

[0034] To facilitate consistent adjustment of the travel at both ends, a scale post 37 is formed on the lower section of each lead screw 34. The outer circumference of the scale post 37 is engraved with circumferential graduations, and the reading reference is taken from the bottom surface of the ear plate 33. During installation, aligning the scales on both sides ensures equal travel. Since the fixing plate 35 reliably presses the ear of the upper wire clamp 31, when the upper wire clamp 31 and lower wire clamp 32 effectively hold the wire, the ear end of the upper wire clamp 31 is inevitably clamped by the fixing plate 35 and the lower end face of the ear plate 33. The lower end of the lead screw 34 must also have passed through the guide hole area at the lower end of the ear plate 33. Therefore, using the bottom surface of the ear plate 33 as the reading reference for the scale post 37 provides a clear indication of the current pre-tightening travel, preventing over-tightening and damage to the wire. It also facilitates adjusting the other end after clamping the cable at one end, based on the corresponding scale value on the bottom surface of the ear plate 33 at that end, ensuring consistent travel on both sides and symmetrical wire axis. By converting the rotation angle into axial displacement using the lead screw pitch, the operator can intuitively adjust both ends to be consistent. The unavoidable differences caused by manufacturing and assembly tolerances are within an acceptable range within the drawing tolerances, ultimately resulting in a symmetrical clamping state at both ends. Compared to the traditional method of simply straightening by visual inspection and tightening in one go, this embodiment transforms the operator's subjective torque perception into a visible stroke. The operation is repeatable and comparable, significantly reducing the force dispersion caused by human differences. At the same time, the scale range of the scale column 37 can be limited within the clamping stroke allowed by the project during the design phase, combined with experiments. During installation, the operator only needs to adjust within the specified scale range to keep the clamping force of the wire clamp on the conductor within a reasonable range that can reliably clamp without damaging the insulation layer. This effectively reduces the possibility of damage to the insulation layer at both ends of the cable or local damage to the metal core due to over-tightening, ensuring the reliability of electrical contact while protecting the cable body.

[0035] To ensure the assembly process is visible and controllable, the operator uses the scale column 37 as the reading reference for symmetrical adjustment. Specifically, the lead screws 34 on both sides are first rotated synchronously to an initial scale, causing the upper and lower clamps to slightly pre-clamp the conductor. Then, the stroke is gradually increased by the same scale until the upper clamp 31 and lower clamp 32 are completely in contact with the conductor surface without slippage. Finally, the target scale given in the process table is used for final setting. For main lines and branch lines of different diameters, clamps of different widths and curvatures can be configured at both ends to match their respective grooves. The target scale of the lead screw 34 can also be specified separately in the process table. If site differences cause slightly greater force on one end, the driven gear 52 on one side can be temporarily disengaged, and a half-turn or one-turn adjustment can be made on one side. Then, the driven gear 52 is reinstalled, and the final scale value is used as the acceptance criterion to ensure that the stroke at both ends is quantifiable and verifiable.

[0036] To improve adjustment efficiency and ensure synchronization on both sides, the outer edge 11 of the upper housing 1 is thickened to form a horizontal mounting platform. A hand-tightening nut 5 is arranged on the outer edge 11. The hand-tightening nut 5 outputs torque through the driving gear 51. The upper ends of the two lead screws 34 are respectively fixed to the driven gears 52, and the driving gear 51 meshes with both driven gears 52 simultaneously. When the operator rotates the hand-tightening nut 5, the two lead screws 34 are driven to rotate synchronously, thereby causing the ear plates 33 on both sides to move in the direction of the conductor or away from the direction of the conductor with the same displacement. The center distance and module of the gear transmission are determined according to the space of the outer edge 11 of the upper housing 1, and a one-to-one transmission is preferred to facilitate calibration. When it is necessary to make a small differential adjustment on both sides, the gear can be disengaged from the lead screw 34 on one side, and a small adjustment can be made on one side with the scale. After completion, the gear can be re-fixed. A protective cover 12 is provided on the outer edge 11. The protective cover 12 is connected to the outer edge 11 by screws or buckles for dustproof, waterproof and protective purposes. A sealing rib is provided between the periphery of the protective cover 12 and the upper housing 1, and a water guide groove can be provided on the upper surface to prevent rainwater or mud from entering the transmission area.

[0037] The upper housing 1 and lower housing 2 are made of weather-resistant, insulating, high-strength materials, which can be reinforced with engineering plastics or have an insulating coating on aluminum alloy. A pad 4 is installed on the inner side of the upper housing 1, corresponding to the pad 4 in the lower housing 2. Both pads jointly bear the axial clamping force of the torque bolt 6 and transmit the force to the piercing blade 7. The pad 4 is preferably made of steel or extruded aluminum alloy, with anodized or plated surfaces to improve corrosion resistance. The pad 4 is in close contact with the housing over a large area, with positioning ribs to prevent misalignment. A nut 61 is installed at the bottom of the lower housing 2, which mates with the torque bolt 6. A butterfly-shaped washer 62 is arranged above the nut 61, with its outer edge abutting against the pad 4. The elasticity of the butterfly shape forms an axial compensation channel. The butterfly-shaped washer 62 is made of spring steel or stainless steel stamping, tempered to obtain stable elasticity, operating within a safe strain range, and maintaining its recovery ability after multiple temperature cycles.

[0038] The piercing blade 7 is made of electrical copper alloy or tin-plated copper alloy. The blade teeth are arranged along the conductor axis, and the tooth shape is checked to ensure that it pierces the insulation and engages the conductor without cutting it. The mounting base 71 is riveted to the blade body or integrally machined. The bottom of the mounting base 71 mates with the mounting groove 21, and the side wall has a limiting shoulder. After installation, it is clamped and fixed by the upper housing 1 and the lower housing 2. The wave spring 72 is placed in the middle of the cavity of the mounting base 71. The wave spring 72 is preloaded when clamped and compressed as the housing clamps. After the blade teeth make contact with the conductor, the wave spring 72 maintains thrust within the usable stroke, so that the multiple rows of tooth tips share the load and suppress individual tooth overload or suspension. The shape and number of wave springs 72 can be determined according to the conductor range. A multi-wave symmetrical structure is preferred. If necessary, two pieces are stacked in parallel to increase the thrust.

[0039] After setting the end clamps, the operator places the main line and branch line into the wire groove of the lower housing 2, closes the upper housing 1 so that the piercing blade 7 is directly above the conductor, and then tightens the torque bolt 6 until the torque element slips. At this time, the butterfly gasket 62 is compressed and builds thrust within the clamping path. Under the action of the wave spring 72, the piercing blade 7 evenly adheres to the conductor. The upper wire clamp 31 and lower wire clamp 32 at the end maintain stable normal clamping under the continuous action of the compression spring 36. After closing, the readings of the scale column 37 can be checked again to see if they are consistent. If there is a deviation within the allowable range, it will be absorbed by the compression spring 36. If it exceeds the range, it should be corrected to be consistent according to the scale. Install the protective cover 12 at the outer edge 11, check the sealing rib of the cover, and then confirm the overall sealing of the wire clamp.

[0040] During long-term use, the insulation of the wire, the sealant, and the blade holder may thin. These changes are initially compensated for by the compression spring 36 at the end, maintaining a stable clamping force between the clamp and the wire. If the total thickness of the clamping path between the upper and lower housings changes further, the axial restoring thrust provided by the butterfly gasket 62 counteracts the decrease in overall clamping force, ensuring reliable pressure in the puncture zone. The blade layer is maintained by the wave spring 72, ensuring balanced contact between the tooth tip and the conductor, preventing individual teeth from bearing the load alone. These three compensations work together to ensure that the clamp maintains uniform force and stable contact during long-term operation.

[0041] In this embodiment, the wire management structure 3 clamps and guides the wires circumferentially and axially during the installation stage, ensuring that the main wire and branch wires are straightened and essentially coaxial before the upper housing 1 and lower housing 2 are closed. The piercing teeth on the piercing blade 7 initially receive relatively similar loads, providing a more balanced force foundation for subsequent operation. The upper clamp 31, lower clamp 32, and compression spring 36, driven by the lead screw 34 and ear plate 33, form a continuous and flexible clamping effect on the wires. When slight compression deformation occurs in the wire insulation layer or clamp covering layer, the compression spring 36 can automatically compensate for the corresponding stroke with the slight displacement of the ear plate 33, preventing a sudden drop in end pressure or concentration at individual positions.

[0042] In the housing clamping path, the butterfly washer 62, located between the nut 61 of the torque bolt 6 and the washer plate 4, continuously compensates for the overall preload between the upper housing 1 and the lower housing 2. When the wire insulation, sealing material, and blade holder undergo compression creep along the thickness direction, the butterfly washer 62 provides additional axial thrust through its own elastic recovery, maintaining the required clamping force in the puncture area. A wave spring 72 is arranged inside the mounting seat 71 at the bottom of the puncture blade 7. The wave spring 72 provides a controllable thrust to the blade teeth in the axial direction, enabling each tooth tip to automatically level and share the load during the establishment of electrical contact, reducing overload situations caused by initial deviation or subsequent creep of individual teeth. Therefore, this embodiment does not simply mechanically combine the two measures of stress distribution optimization and creep compensation. Instead, it uses the combination of the cable management structure 3, compression spring 36, butterfly gasket 62 and wave spring 72 to form a continuous chain of action between the uniformity of stress during the installation stage and the creep compensation during the operation stage. This reduces the space for creep development from the source and suppresses new stress concentration when creep inevitably occurs, thereby reducing the risk of increased contact resistance and localized overheating throughout the entire service life.

[0043] In terms of materials and manufacturing, the upper housing 1 and lower housing 2 can be injection molded from glass fiber reinforced nylon, with a dark gray or black color to enhance UV resistance. The pad 4 is made of aluminum alloy or stainless steel plate, with anodized or nickel-plated surface treatment. The lead screw 34 is a cold-forged stainless steel part that is rolled to obtain a wear-resistant tooth profile. The ear plate 33 is an aluminum alloy or stainless steel block, with the internal thread hole and guide hole machined in one clamping to ensure coaxiality. The shape of the ear plate 33 matches the guide surface of the upper housing 1, allowing for smooth sliding without wobbling. The fixed plate 35 is a steel or aluminum disc, fastened to the lead screw 34 by pins or stepped shoulders. The compression spring 36 is made of spring steel wire wound and tempered, with working stress controlled within a safe range. The upper clamp 31 and lower clamp 32 have a belt body made of elastic stainless steel or spring steel strip covered with a wear-resistant elastic layer, with the inner side sandblasted or knurled to form a micro-texture, and the ears are locally reinforced to withstand clamping loads. The graduations on the scale column 37 are laser-etched or roll-formed, and a wear-resistant coating is applied to the outer surface to ensure long-term readability. The hand-tightening nut 5 is made of metal or high-strength engineering plastic, with a grip-friendly shape and anti-slip texture. The driving gear 51 and driven gear 52 are molded from metal or engineering plastic, with lubricated tooth surfaces. The protective cover 12 is injection-molded from engineering plastic and features water guide grooves and snap-fit. The butterfly gasket 62 is stamped from spring steel and phosphated for rust prevention. The piercing blade 7 has teeth that are cold-pressed or precision-milled and edge-shaped, with a tin-plated surface to reduce contact resistance. The clearance between the step of the mounting base 71 and the mounting groove 21 is controlled according to the drawing requirements. The wave spring 72 is stamped from stainless steel strip.

[0044] This embodiment does not limit specific dimensions. The conductor cross-section range, lead screw pitch, spring stiffness, number of gear teeth, and center distance can all be designed according to the target model, as long as the three-point action and three-point elastic compensation functions of the cable management structure are met. The upper clamp 31 can be configured in multiple specifications according to different wire diameters, and the width and curvature of the tape body can be matched with the size range of the wire groove. The connection method of the protective cover 12 can be selected between screws and clips, and the sealing structure can be selected as single or double sealing ribs according to the protection level. The blade tooth shape can be optimized for different conductor materials and insulation thicknesses, and the number of plates and wave height of the wave spring 72 can be determined as needed.

[0045] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Any modifications, equivalent substitutions, or improvements made by those skilled in the art without departing from the spirit and principles of this invention should be included within the scope of protection of this application.

Claims

1. A creep-compensated puncture clamp, comprising an upper housing (1), a lower housing (2), a puncture blade (7), and a torque bolt (6) for clamping the upper housing (1) and the lower housing (2), characterized in that: A wire management structure (3) is provided at both ends of the puncture area. The wire management structure (3) includes an upper wire clamp (31) and a lower wire clamp (32) for circumferentially clamping and positioning the wire. A lead screw (34) and an ear plate (33) threadedly engaged with the lead screw (34) are provided on each side. The ear plate (33) moves axially along the lead screw (34) under the guidance. A fixing plate (35) is provided on each lead screw (34), and a compression spring (36) is provided between the fixing plate (35) and the corresponding ear plate (33). The two ends of the lower wire clamp (32) are fixed to the upper end of the ear plate (33). The ear plate (33) drives the lower wire clamp (32) to adjust between a limiting state and a clamping state. In the limiting state, the lower wire clamp (32) maintains a gap with the lower side of the wire so that the wire falls into the bottom of the wire groove of the lower housing (2) and is positioned. In the clamping state, the lower wire clamp (32) fits against the lower side of the wire and cooperates with the upper wire clamp (31) to form a circumferential clamping and positioning of the wire.

2. The puncture clamp according to claim 1, characterized in that: The upper end of the upper housing (1) and the lower end of the lower housing (2) are respectively provided with pads (4), and the piercing blade (7) is installed in the mounting groove (21) of the lower housing (2) and is limited in the end face and side by the mounting groove (21).

3. The puncture clamp according to claim 1, characterized in that: The upper wire clamp (31) is a detachable part that can be laterally installed and removed between the lead screw (34) and the ear plate (33). The ear end of the upper wire clamp (31) is clamped and positioned between the fixed plate (35) and the lower end face of the ear plate (33).

4. The puncture clamp according to claim 3, characterized in that: The upper end of the ear plate (33) is provided with an internal threaded hole that mates with the lead screw (34), and the lower end of the ear plate (33) is provided with a guide hole that mates with the diameter of the lead screw (34), in order to ensure the linear guidance and assembly accuracy of the ear plate (33).

5. The puncture clamp according to claim 1, characterized in that: The portion of the lead screw (34) below the fixed plate (35) is a scale post (37). The outer circle of the scale post (37) is provided with circumferential scale, and the bottom surface of the ear plate (33) is used as the scale reading reference.

6. The puncture clamp according to claim 1, characterized in that: A hand-tightening nut (5) and a drive gear (51) connected thereto are provided on the outer edge (11) of the upper housing (1). Driven gears (52) are fixedly connected to the lead screws (34) on both sides respectively. The drive gear (51) meshes with the two driven gears (52) to synchronously drive the lead screws (34) at both ends to rotate.

7. The puncture clamp according to claim 2, characterized in that: A butterfly washer (62) is provided between the nut (61) of the torque bolt (6) and the pad (4) to provide elastic compensation for the clamping path of the housing.

8. The puncture clamp according to claim 2, characterized in that: Each of the piercing blades (7) has a centrally hollowed-out mounting base (71), and a wave spring (72) is provided inside the mounting base (71).

9. The puncture clamp according to claim 6, characterized in that: A protective cover (12) is also provided on the outer edge (11).

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