Ground Rod Clamp Saddle Projection for Terminal Alignment

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Solution Overview

Problem

Standard ground rod clamps lack consistency and mechanical rigidity in connecting electrical terminals to conductive posts, making it difficult to achieve a repeatable and secure electrical bonding.

Innovation Solution

A clamp design featuring a saddle with a projection that centers and securely fastens the electrical terminal to the post using a U-bolt and nuts, providing a consistent and high mechanical rigidity connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If standard ground rod clamps are used to clamp the electrical terminal to the post, then the electrical bonding is provided, but the mechanical rigidity varies greatly and consistency cannot be achieved

Engineering Contradiction:

Improvemechanical rigidityVSAvoidassembly consistency

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

A projection is added to the clamp that serves as an intermediary element to engage with a corresponding hole in the electrical terminal. This projection acts as a positioning and centering mechanism that ensures consistent alignment and repeatable assembly, directly addressing the lack of assembly consistency while maintaining reliable electrical bonding

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If standard clamps are used to provide electrical bonding, then the electrical connection is established, but the mechanical rigidity and pullout force are insufficient

Engineering Contradiction:

Improvepullout forceVSAvoidmechanical rigidity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The projection extends from the clamp surface into the hole of the electrical terminal, adding a dimensional element that provides mechanical interlocking. This third-dimensional engagement feature significantly increases pullout force and mechanical rigidity beyond what a simple surface clamp could provide

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Productivity

If standard clamps are used to clamp the terminal to the post, then the installation can be completed, but the assembly process is not easily repeatable

Engineering Contradiction:

Improveinstallation efficiencyVSAvoidassembly repeatability

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The projection is pre-formed on the clamp during manufacturing, creating a built-in alignment and centering feature. This preliminary action eliminates the need for complex alignment procedures during installation, making the assembly process easily repeatable and improving installation efficiency

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS9515395B1Clamp having a saddle with a projection received in a hole in a terminal sandwiched between the saddle and a conductive post

Publication Date: 2016.12.06 HUBBELL INC

AI summary

A clamp for clamping an electrical terminal terminating an electrical wire to an electrically conductive post includes a saddle and a fastener. The saddle has an inner surface and at least partially circumferentially surrounds the post. A projection on the inner surface of the saddle is received in a hole of the electrical terminal. The fastener fastens the saddle to the post with the projection received in the electrical terminal so as to sandwich the electrical terminal between the post and the saddle.