Conductor Splice Jaw Assembly for Slack-Span Clamping
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Solution Overview
Problem
Existing automatic splice devices for electrical conductors cannot reliably connect conductors in slack-span applications where tension is not maintained due to vibration or other conditions, and they fail to accommodate varying conductor diameters without specialized tools.
Innovation Solution
A splice device with two housing bodies, jaw subassemblies, and a biasing element that allows for mechanical and electrical connection of conductors with or without tension, accommodating different diameters through adjustable jaw movement and a torque-limiting tightening mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automatic splice devices are used to connect electrical conductors, then the connection process is automated and does not require specialized tools, but the devices cannot reliably connect conductors in slack-span applications where tension is not maintained
Solution Approach 1:
The splice device incorporates a dynamic tensioning mechanism that automatically generates and maintains clamping force on the conductors. The device includes a ratchet mechanism and reel assembly that can wind down the conductor tails, creating tension automatically without requiring external tensioning equipment. This dynamic system allows the device to adapt to both tensioned and slack-span conditions, resolving the contradiction between automation and reliability.
Solution Approach 2:
The device performs self-tensioning through its internal reel mechanism that winds the conductor tails during the splicing process. The ratchet mechanism prevents reverse motion, maintaining tension automatically. This self-service capability eliminates the need for external tensioning equipment while ensuring reliable connections in both tensioned and slack-span applications.
2Reliability
If automatic splice devices are designed for predetermined minimum tension, then they provide reliable connections under tension, but they cannot accommodate varying conductor diameters or slack-span conditions
Solution Approach 1:
The splice device is designed with universal applicability through adjustable jaw mechanisms that can accommodate conductors of different diameters. The reel and ratchet system provides multi-functionality by handling both tensioned and slack-span conditions. The device can operate in multiple modes: with external tension, without external tension, and even generating its own tension, making it versatile across various application scenarios.
Solution Approach 2:
The device incorporates dynamic adjustment capabilities through movable jaws and an adjustable reel mechanism. These dynamic elements allow the device to adapt to varying conductor diameters and tension conditions automatically, providing reliable connections across different application scenarios without requiring multiple specialized devices.
3Reliability
If splice devices apply high clamping force to maintain connection reliability, then electrical connections are secure, but the devices cannot accept conductors with variable diameters
Solution Approach 1:
The jaw mechanism is designed to be dynamic rather than fixed, allowing adjustment of clamping force and jaw position. This enables the device to first accept conductors of variable diameters with appropriate jaw positioning, then apply sufficient clamping force for reliable electrical connection. The dynamic system resolves the contradiction by providing both adaptability and connection security.
Solution Approach 2:
The device performs preliminary positioning of the conductor between the jaws before applying full clamping force. This preliminary action allows the operator to adjust jaw position for the specific conductor diameter, ensuring proper fit. Only after this preliminary positioning is the full clamping force applied, ensuring both adaptability to variable diameters and reliability of the electrical connection.
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
Enables reliable connections of conductors with or without tension, accommodating varying diameters, and provides a tactile indication of proper conductor positioning, while allowing tool-free initial assembly and preventing corrosion through drainage slots.
Implementation Method 1
a biasing element that provides an initial clamping force when the first and second electrical conductors are received by the first and second jaws
Data Source
AI summary
A splice device is provided that can include a first and second housing body, a first and second set of jaws, a biasing element and a tightening element. The first and second set of jaws is in the first and second housing body and depends outward along a conductor axis. The first and second set of jaws receive a first and second electrical conductor therein respectively. The tightening element of the splice device is operatively associated with the first and second set of jaws so that a tightening movement of the tightening element is converted into a clamping force of the first and second set of jaws on the first and second electrical conductors.