Dual-Lock Split Washer for Cable Gland Seal Replacement
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Solution Overview
Problem
The existing washer replacement process at electrical terminations is cumbersome and costly due to the need to mechanically disconnect cables and junction boxes, leading to downtime and compliance issues with IP ratings for ingress protection.
Innovation Solution
A unitary piece dual lock split washer with a resilient and flexible body and integrated locking mechanisms allows for installation without disconnecting cables, featuring a split design and dual locking mechanisms for secure sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a washer is replaced at an electrical termination, then the ingress protection rating is maintained, but the cable gland must be mechanically disconnected and reconnected, causing downtime and increased costs
Solution Approach 1:
The washer is segmented into two independent halves that can be separated and reconfigured. This allows one half to remain in place while the other is replaced, eliminating the need to disconnect the cable gland entirely. The segmented design enables maintenance without shutting down electrical equipment.
Solution Approach 2:
The washer incorporates a flexible joint structure that transitions from a closed sealed configuration to an open maintenance configuration. This dynamic transformation allows the washer to be opened for replacement of one half while maintaining the connection to the cable gland, then reclosed to restore the ingress protection rating.
2Reliability
If a washer is replaced at an electrical termination, then the ingress protection rating is maintained, but safety regulations require electrical isolation and de-energisation, increasing costs
Solution Approach 1:
The washer is segmented into two independent halves that can be separated and reconfigured. This allows one half to remain in place while the other is replaced, eliminating the need to disconnect the cable gland entirely. The segmented design enables maintenance without shutting down electrical equipment.
Solution Approach 2:
The dual-half washer design allows the system to maintain its own protective function during maintenance. One half remains installed to preserve the ingress protection rating, enabling the replacement of the other half without requiring external electrical isolation or de-energisation procedures.
3Ease of operation
If a traditional washer is used, then the joint structure must be fully disconnected for replacement, but this increases the complexity of the maintenance procedure
Solution Approach 1:
The washer is segmented into two independent halves that can be separated and reconfigured. This allows one half to remain in place while the other is replaced, eliminating the need to disconnect the cable gland entirely. The segmented design enables maintenance without shutting down electrical equipment.
Solution Approach 2:
The washer incorporates a flexible joint structure that transitions from a closed sealed configuration to an open maintenance configuration. This dynamic transformation allows the washer to be opened for replacement of one half while maintaining the connection to the cable gland, then reclosed to restore the ingress protection rating.
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 quick and efficient washer replacement without disrupting electrical systems, maintaining IP ratings, and reducing downtime and costs associated with traditional washer replacement methods.
Implementation Method 1
a single piece body made of a resilient and flexible material
Data Source
AI summary
A washer includes a single piece body made of a resilient and flexible material and having a split extending between an inner circumferential edge and a radially outer peripheral edge to provide the body with first and second ends. One end has circumferentially extending and radially spaced fingers, and the other end has circumferentially extending and radially spaced fingers. A joint structure is integrally formed with the first and second ends. The joint structure includes a first locking mechanism and a second locking mechanism. The second locking mechanism is only engageable after the first locking mechanism is fully engaged.