Insulation Piercing Connector with Shear-Off Bolt
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Solution Overview
Problem
Conventional insulation piercing connectors are complex and cumbersome to install in the field, requiring special tools and lacking ease of use for quick installation.
Innovation Solution
The insulation piercing connector features a connector body with a cable receiving slot and threaded bore, a bolt with a shear-off head, and a piercing pin supported by an insulator, allowing for easy installation without tools and enabling sensor integration for monitoring electrical cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulation piercing connectors use metal piercing blades with sets of teeth, then electrical continuity between conductors is achieved, but the connector becomes complex and cumbersome to install
Solution Approach 1:
The connector is divided into separate functional components: a body member, a bolt member with piercing pin, and an insulator member. This segmentation allows each component to be optimized independently - the piercing pin can be simple and sharp for easy installation, while the body provides structural support and electrical isolation, resolving the contradiction between reliability and ease of operation.
Solution Approach 2:
The piercing function is extracted from the traditional blade structure and implemented as a separate piercing pin on the bolt member. This extraction simplifies the installation process by providing a focused, single-point piercing action rather than requiring complex multi-tooth blade engagement, while still achieving reliable electrical continuity through the conductor.
2Reliability
If conventional insulation piercing connectors use complex blade structures, then electrical connection is achieved, but special tools are required for installation
Solution Approach 1:
The bolt member serves dual functions: it provides the mechanical fastening connection through threading into the body member, and simultaneously drives the piercing pin through the cable insulation and onto the conductor. This self-service mechanism eliminates the need for separate piercing tools, achieving reliable electrical connection without special tools.
3Reliability
If conventional insulation piercing connectors are designed for field installation, then connection capability is achieved, but installation time increases
Solution Approach 1:
The piercing pin is pre-positioned on the bolt member and the insulator member is pre-assembled in the body, creating a pre-assembled unit ready for rapid field installation. This preliminary preparation eliminates the need for complex assembly steps during installation, reducing installation time while maintaining reliable connection capability through the pre-configured piercing and fastening mechanism.
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
Facilitates quick and tool-free installation on existing power lines, eliminating the need for cable stripping or cutting, and allows for sensor integration to monitor electrical distribution systems, enhancing ease of use and functionality.
Implementation Method 1
The head is configured to be sheared off by a torque exceeding a predetermined value as the bolt is rotated
Implementation Method 2
an insulator member that electrically insulates the piercing pin from the bolt
Implementation Method 3
The threaded shank is threadingly engaged with the threaded bore
Data Source
AI summary
An insulation piercing connector includes a connector body, a bolt, a piercing pin, and an insulator member that electrically insulates the piercing pin from the bolt. The connector body includes a cable receiving slot and a threaded bore in communication with the cable receiving slot. The bolt includes a threaded shank with a central bore, and a head joined to the threaded shank by a shear-off section. The piercing pin is supported within the central bore by the insulator member and includes opposite first and second ends. The first end is configured to pierce the insulation of an electrical cable extending through the cable receiving slot and contact a conductor. The central bore of the bolt threadingly receives a sensor. The sensor includes a probe that contacts the second end of the piercing pin to obtain information from the conductor, such as voltage, current, and/or thermal information.