Elbow Internal Assembly System for Epoxy Protection
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Solution Overview
Problem
Existing high voltage elbow assemblies face issues with damaging the epoxy coating on reducing taps due to the use of spanner wrenches and difficulty in applying precise torque for secure connections, especially when connecting a 600 amp reducing tap to a bushing.
Innovation Solution
An internal assembly system for the elbow featuring a rotating nut within the elbow body, allowing for direct connection of a 600 amp bushing without rotating the reducing tap, using a hex wrench and torque wrench through an axial bore to secure the threaded stud and cable connector, eliminating the need for a separate reducing bushing and reducing overall dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spanner wrench is used to rotate the reducing tap onto the threaded stud, then the connection is secured, but the epoxy coating on the reducing tap may be damaged due to applied stress
Solution Approach 1:
The connection mechanism is segmented into two independent parts: the reducing tap remains stationary while a separate rotating nut is used to secure the connection. This divides the function of connection security from the reducing tap itself, eliminating stress on the epoxy coating while maintaining reliable connection through the rotating nut mechanism
Solution Approach 2:
A rotating nut is introduced as an intermediary component between the reducing tap and the threaded stud. This mediator allows the connection to be secured by rotating the nut rather than the reducing tap itself, thereby protecting the epoxy coating from damage while ensuring reliable connection through the nut's engagement with the threaded stud
2Power
If a torque wrench is coupled to a short spanner wrench through additional distance, then torque can be applied, but additional stress is applied to the epoxy covering the reducing tap
Solution Approach 1:
The torque application system is segmented so that the torque wrench acts on the rotating nut rather than on the reducing tap. This separation ensures that all torque and stress are applied to the rotating nut and threaded stud connection, completely eliminating stress on the epoxy coating while maintaining full torque application capability for secure connection
3Volume of moving object
If the overall dimensions of the assembly are reduced, then installation in space-limited areas is enabled, but the complexity of the internal assembly system increases
Solution Approach 1:
The rotating nut is nested within the elbow body, and the threaded stud is nested within the rotating nut. This nested arrangement allows the connection mechanism to be compact and integrated within the existing elbow structure, reducing overall assembly dimensions while managing complexity through a standardized nested configuration rather than a custom complex mechanism
Data Source
AI summary
An elbow with an internal assembly system that includes an elbow body, a cable connection, a first tap, a second tap, a mid-section, a rotating nut and an axial bore. The cable connection adapted to receive a cable having a cable connector, the first tap adapted to receive a first interface device with a threaded stud and the second tap adapted to receive a second interface device. The rotating nut is located in the mid-section and has a threaded bore in communication with the first tap and an opposing closed end with a keyed opening for receiving a tool. The tool is inserted through the axial bore and into the keyed opening to rotate the rotating nut to secure the threaded stud in the rotating nut and secure the cable connector in place.