Misaligned Deadend Clamp for ACCC Cable Mechanical Hold
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Solution Overview
Problem
Conventional electrical connectors for Aluminum Conductor Composite Core (ACCC) cables face challenges in providing a strong mechanical hold without damaging the composite core due to the mismatch between the cable's high tensile strength and low compression strength, leading to potential disengagement when subjected to compression forces.
Innovation Solution
The electrical connector assembly features a collet with various configurations, including misaligned, angled, spiral/helix, and dimple inner channels, which provide enhanced friction and compression forces to maintain a strong tensile connection without exceeding the composite core's compression strength, using a combination of housing segments and a sleeve to distribute forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional compression electrical connectors are used to transmit tension on ACCC cable to supporting structure, then mechanical connection is achieved, but the composite core is crushed or damaged due to excessive compression force
Solution Approach 1:
The electrical connector is divided into multiple segments (first segment, second segment, third segment) that can be independently positioned and loaded. This segmentation allows the compression force to be distributed across multiple points and stages, preventing concentration of stress that would crush the composite core, while still achieving strong mechanical connection through progressive loading.
Solution Approach 2:
The connector segments are pre-configured with specific geometries (tapered surfaces, recesses, protrusions) that enable controlled engagement and load distribution before the actual tension is applied. The first segment engages the composite core with preliminary action, establishing a load path that distributes compression forces before the full tensile load is transmitted.
2Object-affected harmful factors
If compression force is reduced to prevent core damage, then composite core is protected from crushing, but mechanical attachment between core and connecting elements becomes weak, causing potential disengagement
Solution Approach 1:
The connector employs a dynamic, multi-stage loading mechanism where segments engage sequentially rather than simultaneously. The first segment engages with lower compression force to protect the core, then subsequent segments engage to progressively build mechanical attachment strength. This dynamic engagement ensures both core protection and reliable attachment.
Solution Approach 2:
The connector segments have varying geometrical parameters (taper angles, contact surface areas, recess depths) that change along the engagement sequence. These parameter changes allow the compression force and contact pressure to be optimized at each stage - lower initially to protect the core, then increased through subsequent segments to ensure reliable mechanical attachment.
3Ease of manufacture
If traditional single-piece connector design is used, then manufacturing is simple, but force distribution is insufficient to maintain strong hold without damaging core
Solution Approach 1:
The connector is segmented into multiple manufacturable components that can be produced using standard manufacturing processes and then assembled. Each segment can be manufactured independently with controlled geometries, and the assembly process establishes the force distribution characteristics. This segmentation maintains manufacturing feasibility while achieving the complex force distribution needed to hold the core without damage.
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
These configurations ensure a robust mechanical hold on the composite core, reducing the risk of damage and disengagement, while allowing for efficient power transmission by distributing compression forces within the acceptable limits of the core's compression strength.
Implementation Method 1
The misaligned inner surfaces of the plurality of housing segments form segments of discontinuous offset in the inner channel, providing enhanced friction and compression forces to maintain a strong tensile connection
Implementation Method 2
The inner surfaces of the plurality of housing segments are aligned and angled from each other such that their combination in the collet form a continuous wave in the inner channel
Implementation Method 3
The recessed channel of each housing segment is different and complementary to each other such that the combination of the recessed channels in the three housing segments form a spiral helix in the inner channel
Implementation Method 4
The inner surface of at least one of the plurality of housing segments includes a plurality of dimples
Data Source
AI summary
An electrical connector assembly configured to increase a mechanical hold on a core. The electrical connector assembly includes a connector member, a plurality of housing segments forming a collet having a tubular shape, and a sleeve having a tubular shape configured to slidably encase the outer surfaces of the plurality of housing segments in the collet.