Electrical Connection Bail Multi-Strand Solid Rod Design

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Solution Overview

Problem

Existing electrical connection methods, such as insulation piercing connectors, face challenges in efficiently and reliably forming connections between high voltage electrical distribution or transmission lines, particularly in environments where frequent tapping and disconnecting are required, as they can lead to arcing and damage to the wire strands, increasing maintenance costs and safety hazards.

Innovation Solution

A bail system comprising an inboard multi-strand conductor and an outboard solid rod conductor, combined with an insulation piercing connector and clamping mechanism, allows for secure and efficient electrical connections by penetrating the insulation layers and establishing comprehensive contact between the conductors without stripping the insulation, thereby enhancing both electrical and mechanical continuity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If insulation piercing connectors are used to form connections between high voltage electrical conductors, then mechanical and electrical connections can be established without stripping insulation, but frequent tapping and disconnecting operations cause arcing and damage to wire strands

Engineering Contradiction:

Improveease of connection formationVSAvoidconnection reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The bail is divided into two distinct conductor sections: an inboard multi-strand conductor for flexible connection to the main line, and an outboard solid rod conductor for stable tap line attachment. This segmentation allows the solid rod portion to withstand arcing and mechanical stress from frequent operations while the multi-strand portion maintains electrical flexibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bail combines two different conductor types (multi-strand and solid rod) into a single composite structure. The multi-strand conductor provides flexibility and ease of installation, while the solid rod conductor provides arc resistance and mechanical strength for frequent disconnecting operations, thereby resolving the contradiction between ease of connection and connection reliability.

Inventive Principle:

Principle #40Composite materials

2Reliability

If piercing blades with teeth are used to penetrate insulation layers, then electrical continuity can be achieved, but wire strands suffer damage and maintenance costs increase

Engineering Contradiction:

Improveelectrical continuityVSAvoidwire strand damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The bail acts as an intermediary component between the main line conductor and the tap line conductor. The insulation piercing connector pierces the insulation of both cables to establish electrical continuity, while the bail's robust solid rod conductor withstands the mechanical stress and arcing that would otherwise damage the wire strands directly, thereby maintaining electrical continuity while protecting the conductors.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The solid rod conductor portion of the bail serves as a protective cushion for the wire strands. By providing a robust, arc-resistant connection point, it absorbs the harmful effects of arcing and mechanical stress before they can reach and damage the delicate wire strands of the multi-strand conductor, thereby preventing wire damage while maintaining reliable electrical continuity.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Adaptability or versatility

If frequent tapping and disconnecting operations are performed, then adaptability is improved, but arcing and damage occur leading to increased maintenance costs

Engineering Contradiction:

Improvetapping flexibilityVSAvoidmaintenance cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The bail design incorporates a dynamic structure where the multi-strand conductor provides flexibility for easy installation and connection, while the solid rod conductor provides the mechanical strength needed for frequent disconnecting operations. This dynamic combination allows the system to adapt to frequent tapping operations without suffering from arcing and damage that would increase maintenance costs.

Inventive Principle:

Principle #15Dynamics

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 bail system provides improved safety and reduced maintenance costs by ensuring reliable connections, preventing arcing and wire damage, and maintaining insulation integrity, thus extending the lifespan of electrical infrastructure.

Implementation Method 1

The piercing member penetrating through the cable insulation layer and into electrical engagement with the multi-strand conductor and the cable conductor such that the multi-strand conductor and the cable conductor are electrically connected to one another through the at least one piercing member

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Data Source

PatentUS11329401B2Electrical connection bails and stirrup systems and methods including same

Publication Date: 2022.05.10 TYCO ELECTRONICS CANADA ULC

AI summary

A bail for forming a mechanical and electrical connection includes an inboard section and an outboard section. The inboard section includes an elongate, electrically conductive multi-strand conductor. The outboard section includes an elongate, electrically conductive solid rod conductor electrically connected to the multi-strand conductor.