Battery-Powered Connector Installation Tool for Precise Wedge Insertion
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Solution Overview
Problem
Conventional electrical connector installation tools rely on ignition of a charge cartridge, which can be hazardous and lacks precision in installing connectors between multiple conductors.
Innovation Solution
A pole-mounted, electrical connector installation tool equipped with a battery-powered actuator, a c-shaped tool head, and a pivoting mechanism, allowing for controlled and precise insertion of a wedge connector between conductors using a pressurized fluid system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a charge cartridge ignition system is used, then the tool can deliver high force for connector installation, but it introduces safety hazards and lacks precision
Solution Approach 1:
The patent replaces the chemical ignition-based charge cartridge system with an electric motor-driven mechanical system. The electric motor rotates an eccentric cam that converts rotational motion into linear reciprocating motion of the ram, eliminating explosive chemicals while delivering controlled installation force.
Solution Approach 2:
The patent employs a hydraulic system where the electric motor drives a pump that generates pressurized fluid. This pressurized fluid acts on a piston to extend the ram, providing controlled force delivery without the hazards of explosive charge cartridges.
2Power
If a charge cartridge system is used, then the tool can achieve high power output, but it reduces measurement precision and control accuracy
Solution Approach 1:
The patent incorporates a feedback mechanism where a sensor detects the position of the ram and sends signals to the control system. The control system adjusts the electric motor operation based on this feedback, enabling precise control of the ram's extension and retraction, thereby achieving both high power output and measurement precision.
Solution Approach 2:
The patent uses a dynamically controlled electric motor system that can adjust its speed and torque in real-time based on operational requirements. The motor controller regulates power delivery to the ram, enabling precise positioning while maintaining high power output when needed for connector installation.
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, precise, and efficient method for installing electrical connectors, enabling reliable connections in difficult-to-access locations while eliminating the hazards associated with conventional ignition-based systems.
Implementation Method 1
A pole-mounted, electrical connector installation tool equipped with a battery-powered actuator, a c-shaped tool head, and a pivoting mechanism, allowing for controlled and precise insertion of a wedge connector between conductors using a pressurized fluid system.
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.