Insulation-Piercing Wedge Connector for Faster Cable Installation
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Solution Overview
Problem
The installation of electrical connectors on insulated cables is challenging due to the need to strip the insulation layer, increasing the time and risk for line mechanics, especially in situations like natural disasters where efficiency and safety are critical.
Innovation Solution
An electrical connector design featuring a clamp body with a C-shaped configuration and an insulation piercing wedge with fins that can be driven into the clamp to pierce the insulation layer of the conductor, allowing for connection without stripping, using a tool like the BURNDY WEJTAP or similar tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulation layer is stripped before connector installation, then reliable electrical contact is achieved, but installation time increases and safety risks increase
Solution Approach 1:
The piercing fins extract and remove the insulation layer material through piercing action, separating the insulation removal function from the connector installation process. This allows the connector to be installed directly onto insulated conductors without pre-stripping, resolving the contradiction between reliable electrical contact and installation time by automatically removing the insulation barrier during installation.
Solution Approach 2:
The piercing fins act as an intermediary mechanism between the connector body and the insulated conductor. They facilitate electrical contact by creating conductive pathways through the insulation layer, enabling reliable connection without requiring separate insulation removal steps, thus reducing installation time while maintaining contact reliability.
2Reliability
If the insulation layer is stripped before connector installation, then reliable electrical contact is achieved, but the number of tools and steps increases
Solution Approach 1:
The insulation piercing function and connector installation function are merged into a single integrated operation. The piercing fins are integrated into the connector body, allowing both insulation removal and electrical connection to be achieved in one installation step, reducing process complexity while ensuring reliable contact.
Solution Approach 2:
The insulation removal function is extracted and integrated into the connector design itself through the piercing fins. This eliminates the need for separate stripping tools and steps, reducing installation process complexity while maintaining reliable electrical contact through the pierced conductive pathways.
3Ease of operation
If conventional wedge connectors are used on insulated cables, then connector installation is possible, but insulation removal is required which increases risk to line mechanics
Solution Approach 1:
The connector performs self-service by automatically piercing and removing the insulation layer through its integrated fins during the installation process itself. This eliminates the need for separate insulation stripping operations that expose line mechanics to hazards, making the installation easier and safer while maintaining reliable electrical contact.
Solution Approach 2:
The harmful insulation layer is extracted and removed by the piercing fins during installation, eliminating the safety hazard associated with manual stripping operations. This allows line mechanics to work with insulated conductors throughout the process, reducing exposure to electrical hazards while maintaining ease of operation through the integrated piercing 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 quicker and safer installation of connectors on insulated cables by allowing direct piercing of the insulation layer, reducing the time and tools required for line mechanics and ensuring reliable electrical contact.
Implementation Method 1
A wedge is inserted into the clamp body between conductors A, B. The wedge/tapered shape of the body 12 and the wedge member 14 provides for the body 12 and the wedge 14 to be removably connected to each other as they are fastened together in a press fit or interference fit configuration.
Data Source
AI summary
An electrical connector includes a clamp body having a substantially C-shaped configuration defining an interior cavity. A wedge is configured to be inserted into the clamp body. The wedge has a wedge body defining a conductor channel and a plurality of fins extending from the wedge body into the conductor channel. The plurality of fins is oriented to pierce an insulation layer of a conductor when the wedge is inserted into a clamp body.