Cam Lever Clamp with Belleville Washers for High-Voltage Wire
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing anchoring clamps for high-voltage electric line spacers are prone to loosening due to human error, environmental factors, and complex assembly requirements, leading to premature failure and increased maintenance costs, necessitating skilled operators and specialized tools.
Innovation Solution
A clamp design featuring a cam lever system with Belleville washers that provides a calibrated 'on/off' tightening mechanism, eliminating the need for nuts and bolts and allowing automatic adjustment for wire diameter changes, ensuring consistent and secure fastening without requiring experienced personnel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional bolt and nut tightening is used for anchoring clamps, then the tightening can be adjusted according to working conditions, but the tightening is prone to loosening due to human error, environmental factors, and requires skilled operators with specialized tools
Solution Approach 1:
The clamp system performs self-tightening through the cam lever mechanism. When the cam lever is actuated, it automatically compresses the Belleville washers and secures the clamp onto the wire without requiring external tightening tools or skilled operators. The system serves itself by converting the lever movement directly into clamping force.
Solution Approach 2:
The traditional mechanical fastening system using bolts, nuts, and dynamometric wrenches is replaced with a cam lever mechanism combined with Belleville washers. This substitution eliminates the need for threaded fasteners and specialized tightening tools, simplifying the operation while maintaining reliability.
2Manufacturing precision
If dynamometric wrenches are used for tightening, then the tightening torque can be precisely controlled, but the operation becomes time-consuming and requires qualified personnel working at heights
Solution Approach 1:
The tightening parameter is changed from controlled torque (requiring dynamometric wrenches) to controlled displacement (cam lever rotation). The cam lever's geometric profile determines the clamping force, converting a time-consuming torque control operation into a quick positional adjustment that can be performed by any operator.
Solution Approach 2:
The system automatically achieves the required clamping force through the cam lever mechanism without requiring external measurement or control tools. The mechanical design inherently provides the necessary tightening, eliminating the need for time-consuming verification procedures.
3Adaptability or versatility
If multiple separate parts are assembled on-site, then the clamp can be adapted to different conditions, but the assembly becomes complex and error-prone under difficult working conditions
Solution Approach 1:
Multiple functional elements are merged into an integrated clamp unit. The cam lever, Belleville washers, and clamping jaws form a unified mechanism that achieves both adaptability and simplicity. The standardized design maintains versatility for different wire conditions while eliminating complex multi-step assembly procedures.
Solution Approach 2:
The clamp performs self-alignment and self-adjustment through its mechanical design. The cam lever mechanism automatically positions the clamping elements correctly when actuated, eliminating the need for precise manual alignment or complex assembly sequences that are error-prone under difficult working conditions.
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 solution simplifies the mounting process, ensures even tightening across the entire line, reduces maintenance needs, and maintains secure fastening over time, eliminating the risks associated with human error and environmental factors.
Implementation Method 1
elastic means in the shape of at least one Belleville washer being mounted on said tie rod
Data Source
AI summary
The present invention relates to a clamp and a spacer for bundle-shaped wires of high-voltage electric lines, as well as a relative mounting kit. The clamp comprises at least one arm (3) for the fastening to the wires (C), at the free end of which a first fixed jaw (4a) is formed, with which a second jaw (4b) is coupled, said second jaw being movable through disengageable tightening means, both jaws being provided with opposite saddles for the housing of the wire (C), wherein said second moving jaw (4b) has a first end mounted rotating on a pin (4c), carried by said fastening arm (3) in a position coinciding with a first end of the first jaw (4a), while with a second end it is apt to cooperate with tightening means, and said tightening means comprise a tie rod (7) having a proximal end (7a) mounted rotating on the second end of the second jaw (4b) and a distal end (7b) constrained through a constraint pin (9) to a cam lever (10), with said tie rod elastic means being engaged with the shape of at least one Belleville washer (11), arranged so as to lie between said cam lever (10) and a fixed abutment element (14) projecting from said fastening arm (3).