Electrical Connector for ACCC Cable Tensile Attachment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical connectors damage the composite core of Aluminum Conductor Composite Core (ACCC) cables due to high tensile strength but low compression strength, preventing a secure mechanical attachment and risking cable damage during connection.
Innovation Solution
An electrical connector assembly featuring ductile conforming wedges and an extension spring member that distribute the clamping force along the composite core, preventing crushing and ensuring a secure tensile connection by conforming to the core's surface and housing, allowing for suspension from transmission towers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional electrical connectors are used to connect to ACCC cable, then the connector can be easily attached, but the composite core is crushed or damaged due to high compression force
Solution Approach 1:
The patent changes the mechanical parameters of the connector by using a split-bolt design that converts direct compressive force into distributed tensile forces. The split bolt engages the composite core through radial expansion rather than axial compression, adapting the connection mechanism to the material's strength characteristics - leveraging the composite core's high tensile strength while avoiding its compression weakness.
Solution Approach 2:
The connector is segmented into multiple components: a split bolt that divides into two halves, and a housing that separates the connection functions. This segmentation allows the bolt to expand radially within the housing, distributing the clamping force around the composite core rather than concentrating it at a single point, thereby preventing crushing damage.
2Strength
If high compression force is applied to secure the connector, then the mechanical attachment is strong, but the composite core is damaged due to low compression strength
Solution Approach 1:
The patent inverts the traditional connection approach by using a split-bolt design that expands radially rather than applying axial compression. Instead of pushing the composite core axially (which it cannot withstand), the bolt expands perpendicular to the core axis, utilizing the composite material's superior tensile and shear resistance to create a secure mechanical attachment.
Solution Approach 2:
The connection mechanism changes from compression-based to tension-based engagement. The split bolt, when inserted and expanded, creates friction and mechanical interlocking through radial forces that the composite core can resist, transforming the force application mode from harmful compression to beneficial tension and shear.
3Device complexity
If the connector uses traditional compression design, then the structure is simple, but it cannot provide secure tensile connection without damaging the composite core
Solution Approach 1:
The connector is divided into a split-bolt component and a housing, where the split bolt can independently expand within the housing. This segmentation enables the connection mechanism to adapt to the composite core's mechanical properties while maintaining overall structural simplicity. The split design allows easy insertion followed by controlled expansion to achieve reliable tensile connection.
Solution Approach 2:
The split-bolt connector transitions from a static simple structure to a dynamic expansion mechanism. The bolt expands radially after insertion, transforming the connection from a simple pass-fit to an active mechanical engagement that provides secure tensile connection reliability while adapting to the composite core's dimensions and properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a secure, non-damaging attachment to ACCC cables, enabling them to withstand high tensile forces without compressive damage, thus ensuring reliable mechanical and electrical connections.
Implementation Method 1
an extension spring member to bias the three wedges towards a center channel formed by the three wedges
Implementation Method 2
ductile conforming wedges and an extension spring member that distribute the clamping force along the composite core, preventing crushing and ensuring a secure tensile connection by conforming to the core's surface and housing
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
An electrical connector assembly including a connector member; a housing having a general tube shape; wedges and an extension spring member. The housing includes a front end and a rear end. The front end of the housing is adapted to be fixedly connected with the connector member. The wedges are adapted to be located in the housing directly between the housing and a core member of a cable conductor. The connector member is adapted to push the wedges into the housing as the connector member and the housing are being connected with each other. The extension spring member surrounds the wedges to bias the wedges towards a center channel formed by the wedges.