Automatic Cable Splice with Pilot Cup Guide
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Solution Overview
Problem
Utility linemen face difficulties in ensuring proper insertion of cables into automatic splices due to the lack of visual inspection and the need for significant force, which can lead to insecure connections and safety risks, especially in harsh environmental conditions.
Innovation Solution
The automatic splice design includes a casing, guide, pilot cup, jaw, and biasing member, with features like ribs, slots, and a frangible connection, allowing for guided cable insertion and secure clamping, ensuring proper cable seating without excessive force and providing visual indicators for secure connection confirmation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If significant force is applied to insert cables into the automatic splice, then cable insertion is achieved, but the difficulty of operation increases and the risk of improper insertion increases
Solution Approach 1:
The patent introduces a pilot cup as an intermediary component that guides the cable during insertion. The pilot cup has a tapered leading end that facilitates cable entry and a frangible connection to the guide that allows it to break away after serving its guidance purpose, thereby easing insertion while ensuring proper cable positioning
Solution Approach 2:
The patent replaces the need for significant manual insertion force with a mechanical guidance system consisting of the guide and pilot cup. The guide extends into the interior cavity and provides a predetermined path, substituting brute force with a controlled mechanical guidance mechanism that ensures proper cable seating
2Strength
If the automatic splice housing is made solid for structural integrity, then strength is improved, but the difficulty of detecting and measuring cable insertion status increases
Solution Approach 1:
The patent incorporates visual indicators (such as colored bands or markings on the guide or pilot cup) that change or become visible based on cable insertion status. This allows linemen to detect proper cable seating through color or visual cues without compromising the solid housing structure
Solution Approach 2:
The pilot cup serves as a visual mediator that indicates cable insertion status. When the cable is properly inserted, the pilot cup's position or condition provides visual feedback to the operator, enabling detection of proper seating while maintaining the integrity of the solid housing
3Difficulty of detecting and measuring
If visual inspection capability is added to the automatic splice, then the difficulty of detecting cable insertion status is reduced, but the device complexity increases
Solution Approach 1:
The patent uses simple color-coded visual indicators integrated into existing components (such as colored rings on the guide or pilot cup) rather than adding complex electronic or mechanical indication systems. This provides clear visual feedback on cable insertion status while minimizing increases in device complexity
Solution Approach 2:
The patent uses visual indicators that replicate or mirror the insertion status through simple visual cues (such as the position of the pilot cup relative to the guide, or colored bands at specific positions). This provides detection capability through simple visual copying of the insertion state rather than complex sensing mechanisms
Data Source
AI summary
A cable splice includes a casing, a guide, and a pilot cup. The casing has a first opening and an interior cavity. The guide includes a receiving end and a shaft extending at least partially into the interior cavity. The pilot cup is integrally formed with the guide and frangibly connected to the shaft. The cable splice may also include a clamp positioned in the interior cavity and moveable between a loading position and a terminated position. A biasing member urges the clamp into the terminated position. During movement of the clamp from the loading position to the terminated position, the clamp contacts the guide causing at least a portion of the shaft to exit the interior cavity. The guide may also include a rib and a slot allowing the guide to fit in casings having different sized interior cavities.