Conductor Connector Accessories Single-Step Compression
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for connecting conductors to conductor connector accessories are inefficient due to multiple compression steps, and these connections often fail under high temperature conditions, leading to costly and time-consuming processes.
Innovation Solution
A conductor connector accessory assembly featuring a tube with a grit coating, a barrel with radial passages, and lobes, which allows for a single-step compression method that securely connects conductors to accessories, providing improved high-temperature performance by utilizing materials with different expansion rates and a heat sink effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate compression steps are used to connect conductors and conductor connector accessories, then the connection robustness is improved, but the time and effort required increases significantly
Solution Approach 1:
The patent combines multiple separate compression steps into a single compression operation by designing a compression device that can apply compressive forces through multiple pathways simultaneously. The compression device includes a first compression element and a second compression element that can compress different portions of the conductor connector accessory in the same operational cycle, thereby reducing installation time while maintaining connection robustness.
Solution Approach 2:
The conductor connector accessory is divided into multiple portions that can be independently compressed. The accessory includes a body portion and a tail portion, each with specific compression requirements. By segmenting the compression targets and providing dedicated compression elements for each segment, the patent enables simultaneous multi-point compression in a single step.
2Temperature
If standard materials are used for conductor connector accessories, then the manufacturing cost is reduced, but the high temperature performance deteriorates
Solution Approach 1:
The patent specifies that the conductor connector accessory shall be made of a single piece of monolithic Inconel alloy or other suitable high-temperature alloy material. This composite material approach provides both high-temperature resistance and mechanical strength while maintaining manufacturability through single-piece construction that eliminates the need for assembly of multiple components.
Solution Approach 2:
The patent changes the material parameters by specifying Inconel alloy or other high-temperature resistant materials with specific mechanical properties. The material must have sufficient yield strength, elongation, and resistance to thermal creep at elevated temperatures. This parameter change from standard materials to specialized high-temperature alloys resolves the temperature performance issue while the single-piece design keeps manufacturing relatively simple.
3Productivity
If a single-step compression method is implemented, then the installation efficiency is improved, but the connection robustness may be compromised
Solution Approach 1:
The patent employs a dynamic compression system where the compression device can apply forces through multiple elements that act in coordination. The system includes adjustable compression elements that can be positioned and activated to provide optimized compression forces on different portions of the accessory simultaneously, ensuring robust connections while maintaining single-step operation.
Solution Approach 2:
The patent introduces compression elements as intermediaries between the compression device and the conductor connector accessory. These elements (such as compression plates or anvils) transfer and distribute the compressive forces evenly across the accessory portions, ensuring uniform and robust compression connections while enabling the single-step compression process.
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 enables efficient and robust connections with reduced time and effort, maintaining performance in high-temperature environments up to 250 degrees Celsius, eliminating the need for multiple compression steps and enhancing operational reliability.
Implementation Method 1
A grit coating is disposed on an inner surface of the tube
Implementation Method 2
compressing the outer shell, barrel, lobes, tube and end portion together
Implementation Method 3
providing improved high-temperature performance by utilizing materials with different expansion rates and a heat sink effect
Data Source
AI summary
A method for connecting a conductor and a conductor connector accessory includes inserting an end portion of the conductor into an interior of a tube, and inserting the tube into an interior of a barrel. The barrel defines a plurality of radial passages extending between an outer surface of the barrel and the interior of the barrel. The method further includes providing a plurality of lobes, each of the plurality of lobes disposed within one of the plurality of passages. The method further includes inserting the barrel into an interior of an outer shell, and compressing the outer shell, barrel, lobes, tube and end portion together.