Cable Connector Shear Bolt Torque Control
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Solution Overview
Problem
In the electrical utilities industry, maintaining cable integrity is critical, as losses can lead to power outages or safety hazards, particularly when forming electrical connections without proper torque control and environmental protection, especially in harsh environments.
Innovation Solution
A cable connector system featuring a connector body with a curved outer surface and a shear bolt that secures electrical cables, which breaks apart upon torque application, allowing a plug with a curved head and base to form an interference fit within the bolt bore, providing environmental protection and secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a shear bolt is used to secure the cable, then torque control is achieved, but the bolt head and threaded shaft expose bare metal surfaces that require environmental protection
Solution Approach 1:
The invention extracts the fastening function from the electrical connection function by using a separate shear bolt that secures the cable mechanically while the electrical connection is made through the connector body. The bolt head and threaded shaft are removed after securing, eliminating the need to protect bare metal surfaces while maintaining torque control during installation.
Solution Approach 2:
The connector system is segmented into multiple functional components: the connector body for electrical connection, the shear bolt for mechanical fastening with torque control, and the protective cover for environmental protection. Each component performs its specific function independently, allowing the bare metal surfaces of the bolt to be temporary and removable.
2Strength
If fastening bolts are used to secure cable ends, then mechanical strength is achieved, but torque control requires additional equipment that may be unavailable or inconvenient
Solution Approach 1:
The shear bolt is designed with integrated torque control features including a head with drive recesses for engagement with standard drivers, a threaded shaft for engaging the connector body, and shear sections that automatically limit the torque applied. The bolt serves itself by providing both the fastening strength and the torque control without requiring external torque-wrench equipment.
Solution Approach 2:
The shear bolt changes its physical state from intact to sheared at a predetermined torque level. The shear sections are designed with specific strength parameters that cause them to fail at a controlled torque, automatically providing torque control. This parameter change from solid to sheared state ensures the cable is secured with appropriate torque without requiring external control equipment.
3Object-affected harmful factors
If the connector outer surface is curved to match the cable, then environmental protection is improved, but manufacturing complexity increases
Solution Approach 1:
The protective cover is designed with a curved outer surface that conforms to the cylindrical shape of the cable and connector assembly. This curvature allows the cover to wrap around and protect the electrical connection from environmental factors while maintaining a simple monolithic structure that can be manufactured as a single molded piece, reducing assembly complexity.
4Object-affected harmful factors
If a plug is inserted into the bolt bore to protect the connection, then environmental protection is achieved, but the plug must fit precisely within the bore opening
Solution Approach 1:
The plug is designed with localized fitting features including a head portion that fits within the counterbore and a flange that engages with the connector outer surface. The threaded shaft portion of the plug engages with the remaining portion of the shear bolt, providing precise localization and alignment. This distributed fitting approach across multiple locations reduces the precision requirement for any single interface.
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
Ensures secure and environmentally protected electrical connections by providing torque-controlled fastening and preventing exposure of bare metal surfaces, thus enhancing cable integrity and reliability in harsh conditions.
Implementation Method 1
The shear bolt is adapted to be screwed down into the bolt bore to secure a cable in the connector. The shear bolt is configured to break apart upon application of sufficient torque to the shear bolt, whereupon a first portion of the shear bolt can be removed from the connector while a remaining portion of the shear bolt remains in the bolt bore
Implementation Method 2
The base is configured to be received in the bolt cavity such that the base forms an interference fit with the remaining portion to thereby secure the plug in the bolt bore
Data Source
AI summary
A cable connector system for connecting electrical cables includes a connector and a plug. The connector includes a connector body and a shear bolt. The connector body includes a connector outer surface and a bolt bore intersecting the connector outer surface at a bore opening. The connector outer surface is curved. The shear bolt is configured to be mounted in the bolt bore to secure an electrical cable in the connector body. The plug includes a head and is configured to be mounted in the bolt bore at the bore opening. The head has a head outer surface and the head outer surface is curved.