Helical Wellhead Connector Assembly for Self-Locking Conductor Grip
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors for wellheads and packers face challenges in providing reliable electrical connections in harsh environments while accommodating loosely-toleranced conductors, often requiring specialized connectors and additional fasteners.
Innovation Solution
An electrical connector assembly featuring a first connector with a helical engaging member and a second connector with a tapered cavity, where rotating the second connector relative to the first causes the helical engaging member to compress radially and form a secure, self-locking connection with the conductor, eliminating the need for additional fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional electrical connectors are used with loosely-toleranced conductors, then the connectors can accommodate a wide range of conductor diameters, but the electrical connection reliability deteriorates in harsh environments
Solution Approach 1:
The connector features a helical engaging member with varying geometry along its length, creating different engagement zones. The helical slot allows the engaging member to deform locally and conform to the conductor surface, providing both adaptability to different diameters and reliable electrical contact through localized high-contact-area regions.
Solution Approach 2:
The helical engaging member utilizes elastic deformation to change its geometric parameters dynamically. When the connector is assembled, the engaging member deforms elastically to match the conductor diameter, then maintains this deformed state to provide consistent electrical contact pressure, thereby adapting to various conductor sizes while ensuring connection reliability.
2Reliability
If specialized connectors with additional fasteners are used, then the electrical connection reliability improves, but the device complexity increases
Solution Approach 1:
The invention merges the electrical contact function and the mechanical fastening function into a single integrated helical engaging member. This member simultaneously provides electrical conductivity and mechanical retention through its helical geometry and elastic deformation, eliminating the need for separate fasteners and reducing overall connector complexity while maintaining connection reliability.
Solution Approach 2:
The helical engaging member serves multiple functions: it provides electrical conduction, mechanical retention, and adaptability to different conductor diameters. This multi-functional design replaces what would traditionally require multiple separate components, thereby improving reliability without proportionally increasing complexity.
3Strength
If set screws and additional fasteners are used, then the connection strength improves, but the ease of operation deteriorates requiring tools for installation
Solution Approach 1:
The helical engaging member is designed to automatically deform and conform to the conductor when the connector is assembled, creating a self-adjusting connection. The elastic deformation and helical geometry enable the member to self-lock onto the conductor without requiring external fasteners or tools, thereby maintaining connection strength while dramatically improving ease of installation.
4Reliability
If the helical engaging member compresses radially inwards, then the electrical contact reliability improves, but the force required for assembly increases
Solution Approach 1:
The helical engaging member utilizes dynamic elastic deformation to achieve radial compression. During assembly, the member gradually deforms elastically as it engages with the conductor, allowing the compression force to be applied progressively rather than instantaneously. This dynamic approach maintains electrical contact reliability while reducing the peak assembly force required compared to rigid compression mechanisms.
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 assembly provides a reliable, self-locking electrical connection that withstands harsh conditions and maintains conductivity without the use of set screws, ensuring a strong and tool-free installation process.
Implementation Method 1
The cavity is tapered such that advancing the insertion body into the cavity causes the helical engaging member to compress radially inwards into engagement with the electrical conductor
Implementation Method 2
The insertion body conducts electricity from the electrical conductor to the electrical contact via the connector body
Data Source
AI summary
An electrical connector assembly for a wellhead penetrator includes a first connector including an insertion body and defining a bore, the bore being configured to receive an electrical conductor. The insertion body includes a helical engaging member and defines a helical slot. The assembly includes a second connector defining a cavity therein, the cavity being configured to receive at least a portion of the insertion body therein, and the cavity being tapered such that advancing the insertion body into the cavity causes the helical engaging member to compress radially inwards into engagement with the electrical conductor.