Battery-Powered Connector Installation Tool Without Charge Cartridges
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Solution Overview
Problem
Conventional electrical connector installation tools rely on charge cartridges with ignitable powders, which can be hazardous and inefficient for installing connectors between multiple conductors.
Innovation Solution
A pole-mounted connector installation tool powered by a battery, featuring a c-shaped tool head with a ram that is extendable via a pressurized fluid system, allowing for controlled and safe insertion of connectors between conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional charge cartridges with ignitable powders are used to drive the ram, then the tool can achieve sufficient force for connector installation, but safety hazards increase due to the use of ignitable materials
Solution Approach 1:
The patent replaces the chemical ignition system (charge cartridge with ignitable powder) with an electric motor-driven mechanical system. The motor connects to the ram through a drive mechanism, eliminating the need for explosive materials while maintaining the force required to install connectors. This substitution directly resolves the safety hazard caused by ignitable powders.
Solution Approach 2:
The patent employs a pneumatic or hydraulic system where a motor drives a piston that moves fluid through conduits to extend and retract the ram. This fluid-powered mechanism provides controlled force delivery without requiring ignitable materials, thereby eliminating safety hazards while maintaining adequate driving force for connector installation.
2Productivity
If conventional impact-driven mechanisms are used, then connector installation can be achieved, but precision and control over insertion force are reduced
Solution Approach 1:
The patent incorporates control circuitry that monitors the operation of the motor and drive mechanism, enabling precise control over the ram's extension and retraction. This feedback system allows for controlled application of force during connector installation, improving insertion precision while maintaining installation capability.
Solution Approach 2:
The patent uses a dynamically controllable motor-driven system instead of a static impact mechanism. The motor can adjust its output based on operational requirements, providing controlled and variable force application during connector installation. This dynamic control enhances precision while maintaining productivity.
3Adaptability or versatility
If a long elongated body is used to reach distant conductors, then accessibility to multiple conductors is improved, but the tool becomes more difficult to control and maneuver
Solution Approach 1:
The patent divides the tool into distinct modular segments: a handle portion for user control, an elongated body for reach, and a separate tool head for connector installation. This segmentation allows each component to be optimized independently - the handle remains maneuverable while the elongated body provides reach, and the tool head can be positioned precisely at the end of the body.
Solution Approach 2:
The patent introduces articulation joints that allow the tool head to pivot or articulate relative to the elongated body. This adds a rotational dimension to the tool's operation, enabling the user to orient the tool head in different directions while maintaining the reach provided by the elongated body, thereby improving both accessibility and maneuverability.
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 tool provides a safe and efficient means to install connectors between conductors, reducing the risk of accidents associated with ignitable powders and improving the precision of connector insertion.
Implementation Method 1
The battery is supported on the body and is configured to provide power to an actuator when the switch is in the first position
Implementation Method 2
A pressurized fluid is configured to flow through the conduit when the switch is in the first position
Data Source
AI summary
A connector installation tool includes an elongated body, a handle, a battery, and a c-shaped tool head. The elongated body includes a first end, a second end, and an axis extending therebetween. The handle includes a switch and is positioned proximate the first end. The switch is moveable between a first position and a second position. The battery is supported on the body and is configured to provide power to an actuator when the switch is in the first position. The C-shaped tool head is positioned proximate the second end. The c-shaped tool head includes a stop surface and a ram, and the ram is extendable toward the stop surface.