Single-Pole Electrical Connector Torque Resistance
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Solution Overview
Problem
Single-pole electrical connectors used in inland oil and gas drilling rigs often strip their connections to distribution panels due to inadequate torque resistance, leading to installation challenges, increased costs, and safety risks from arcing and fire hazards.
Innovation Solution
A single-pole electrical connector with a nonconductive mounting base and a bus bar connection, featuring a composite collet with copper for conductivity and wear-resistant materials for the outer threads, and an inverse tapered pin for improved mechanical and electrical contact, along with color coding and a locking ring for easy field replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a threaded shaft and collet nut connection is used, then the connector can be assembled in the field, but the connection to the distribution panel is not secure and the connector strips under torque
Solution Approach 1:
The connector is divided into two separate connection systems: a press-fit insertion connection for the distribution panel and a threaded collet nut connection for the electrical conductor. This segmentation allows each connection type to be optimized independently - the press-fit provides secure panel mounting while the threaded connection provides field-assemblable electrical connection.
Solution Approach 2:
A press-fit inserted connection acts as an intermediary between the connector and the distribution panel, providing a secure mounting point that can withstand the torque applied during collet nut tightening without stripping the panel connection.
2Reliability
If the collet nut is tightened to prevent pin pull-out, then electrical connection reliability improves, but the connector is more likely to strip the panel connection
Solution Approach 1:
The connection system is segmented into a torque-resistant press-fit panel connection and a threaded collet connection. This allows the collet nut to be tightened sufficiently for electrical reliability without the entire connector rotating and stripping the panel, as the press-fit connection anchors the connector body.
Solution Approach 2:
The press-fit inserted connection serves as an intermediary that absorbs the torque load during collet nut tightening, preventing this torque from being transmitted to the panel mounting holes and causing stripping.
3Strength
If splines are machined into the connector body, then resistance to panel connection stripping improves, but manufacturing complexity increases
Solution Approach 1:
The anti-stripping function is extracted from the connector body and placed into a separate press-fit inserted connection component. This eliminates the need for complex spline machining in the connector body while achieving the same torque resistance benefit.
Solution Approach 2:
A separate press-fit inserted connection acts as an intermediary component that provides torque resistance without requiring modification to the basic connector body structure, simplifying manufacturing while maintaining strength.
4Strength
If a slot is cut into the panel edge for a set screw, then torque resistance improves, but installation time increases
Solution Approach 1:
The anti-stripping feature is built into the connector assembly itself through the press-fit inserted connection, eliminating the need for additional panel modifications like slot cutting during installation. The connector is prepared in advance with the torque-resistant connection already in place.
Solution Approach 2:
The torque resistance function is extracted from the panel and placed into the connector assembly. This eliminates the need for additional panel preparation steps like cutting slots, reducing installation time while maintaining torque resistance.
Data Source
AI summary
An improved single-pole electrical connector is disclosed. The connector has a base electrical connection at one end and a pin-and-collet type electrical connection at the other end. A nonconductive mounting base is used to attach the connector to an electrical distribution panel. An electrical cable (e.g., an electrical supply line) is connected to the base electrical connection. Another electrical cable (e.g., from an electrical load) is connected to a pin, which is inserted into the collet. A collet nut is tightened to provide a secure electrical and mechanical connection between the pin and collet. The nonconductive mounting base provides a secure attachment to the distribution panel and insulates the electrically conductive parts of the connector from the panel. An insulating boot may be used to cover the pin and collet side of the connector in use.