Bolted Single-Pole Connector Resists Panel Stripping
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Solution Overview
Problem
Existing single-pole electrical connectors used in oilfield applications often strip out of distribution panels due to high torque requirements, leading to connection failures, safety risks, and increased installation time and costs, especially in modular inland drilling rigs where pre-wired systems are not common.
Innovation Solution
A bolted-together connector design is implemented, utilizing a lug-type connector on the panel mount and a bolted connection on the working side, with a nonconductive mounting base allowing for conductive panels, reducing the risk of connection separation and enhancing security and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pin and collet style connector is used with a large collet nut, then a secure electrical connection is achieved, but the connector tends to rotate and strip out of the distribution panel due to high torque
Solution Approach 1:
The connector is divided into separate functional components: a collet assembly for electrical connection and a mounting base for panel attachment. The mounting base includes separate mounting holes positioned away from the collet assembly, allowing the electrical connection and mechanical mounting functions to be independently optimized without interfering with each other.
Solution Approach 2:
The mounting holes are positioned in a different spatial dimension (peripheral area) away from the central collet assembly. This dimensional separation allows the mounting base to provide sufficient mechanical strength and torque resistance without interfering with the electrical connection mechanism.
2Strength
If the connector is pressed into the distribution panel with a knurled or grooved surface, then a more secure fit is achieved, but the connection still strips out under torque from tightening the collet nut
Solution Approach 1:
The connector is divided into separate functional components: a collet assembly for electrical connection and a mounting base for panel attachment. The mounting base includes separate mounting holes positioned away from the collet assembly, allowing the electrical connection and mechanical mounting functions to be independently optimized without interfering with each other.
Solution Approach 2:
The mounting function is extracted from the main connector body and placed in a separate mounting base with dedicated mounting holes. This extraction allows the mechanical mounting to provide sufficient torque resistance without requiring the knurled or grooved surface modifications that still failed to prevent stripping.
3Strength
If splines are machined into the connector body to engage the distribution panel, then resistance to torque is increased, but many connectors still strip out of the panel
Solution Approach 1:
The connector is divided into separate functional components: a collet assembly for electrical connection and a mounting base for panel attachment. The mounting base includes separate mounting holes positioned away from the collet assembly, allowing the electrical connection and mechanical mounting functions to be independently optimized without interfering with each other.
Solution Approach 2:
The mounting function is extracted from the main connector body and placed in a separate mounting base with dedicated mounting holes. This extraction allows the mechanical mounting to provide sufficient torque resistance without requiring spline machining that still failed to prevent stripping.
4Strength
If a set screw or key is added to engage a slot in the panel, then torque resistance is improved, but installation time and complexity increase
Solution Approach 1:
The mounting function is extracted from the main connector body and placed in a separate mounting base with dedicated mounting holes. This extraction allows the mechanical mounting to provide sufficient torque resistance without requiring additional set screws or keys, simplifying both the device design and installation process.
Solution Approach 2:
The patent does not apply color changes. This principle is not relevant to the solution.
Data Source
AI summary
A high-power, single-pole electrical connector is disclosed. A nonconductive mounting base is used to attach the connector to an electrical distribution panel. The connector extending from the panel has a bolted together connection, rather than a pin-and-collet configuration, as is found in some existing connectors. In the present invention, a panel-mounted connection is secured to a working side connection by bolting the two parts together.