Locking Plate Splice Connector Assembly Without Specialized Tools
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing splice connectors require specialized hand tools and power tools for assembly, which is inconvenient in field applications.
Innovation Solution
A locking plate splice connector system using friction-fit plates and pins that can be assembled with common tools like a hammer, providing a secure mechanical and electrical connection between conductors without the need for specialized tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If specialized hand tools and power tools are used for splice connector assembly, then connection reliability is improved, but ease of operation deteriorates due to tool availability requirements
Solution Approach 1:
The splice connector is designed with self-aligning features where the connector body and contact elements automatically position themselves during insertion, eliminating the need for specialized alignment tools. The spring-loaded contact mechanism self-adjusts to ensure proper electrical connection without requiring precision tools for assembly.
Solution Approach 2:
A spring-loaded intermediate contact element serves as a mediator between the connector body and the electrical contact. This spring mechanism provides both mechanical connection and electrical conduction while accommodating tolerances, thereby maintaining connection reliability without requiring specialized tightening tools.
2Manufacturing precision
If specialized tools are required for splice connector installation, then manufacturing precision is improved, but productivity deteriorates due to tool preparation time
Solution Approach 1:
The splice connector is divided into modular segments that can be independently assembled and then connected. Each segment is pre-assembled with basic components using standard tools, and field installation only requires connecting the segments together, thereby maintaining assembly precision while improving productivity by eliminating the need for specialized tools at the installation site.
3Ease of operation
If friction-fit pins are used instead of specialized fastening mechanisms, then ease of operation is improved by allowing common tool usage, but manufacturing precision may deteriorate due to tolerance requirements
Solution Approach 1:
The friction-fit pin design incorporates a tapered geometry that transitions from a smaller diameter at the insertion end to a larger diameter at the locked end. This parameter change along the length of the pin allows easy insertion with common tools while progressively increasing friction and mechanical interlock to compensate for dimensional tolerances, thereby maintaining both ease of operation and adequate connection strength.
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
Enables easy and reliable connection of conductors in the field using common tools, ensuring a robust and efficient mechanical and electrical bond.
Implementation Method 1
A pin is dimensioned to be friction fit within the orifices extending through the first and second plates
Data Source
AI summary
An electrical conductor splice connector includes a first plate including a first pair of channels and an orifice extending through first plate. A second plate includes a second pair of channels and an orifice extending through the second plate. A pin is dimensioned to be friction fit within the orifices extending through the first and second plates.