Multi-fit Transformer Stud Connector with V-Groove Threads
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical terminal connectors require multiple sizes for different stud diameters, leading to inefficiencies in clamping force, increased machining complexity, and cost due to line contact issues and separate parts that are difficult to handle.
Innovation Solution
A stud connector hole with a shallow V-groove and intersecting straight wall, featuring threads on the flanks for both size studs, allowing for multiple points of contact and reduced machining operations, and is economically produced through punch broaching or extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If only one thread in a larger bore is provided, then manufacturing is simple, but different connectors are required for different stud diameters
Solution Approach 1:
The connector body is designed with a single bore containing multiple threads of different diameters (e.g., 1-1/4" and 3/4" threads) that can accommodate different sized transformer studs. This universal design allows one connector to serve multiple functions for various stud sizes, eliminating the need for multiple different connectors while maintaining manufacturing simplicity.
2Device complexity
If threads are provided on the same surface, then the structure is compact, but only line contact is established resulting in insufficient holding force
Solution Approach 1:
Instead of providing threads on the same surface (2D arrangement), the invention places threads on opposite surfaces of the connector body (utilizing the third dimension). This allows set screws to clamp the connector onto the stud at one location while full thread contact is established at the opposite location, creating multiple points of contact that significantly increase holding force while maintaining structural compactness.
3Adaptability or versatility
If thread diameters do not exactly match stud diameters, then the connector can accommodate various studs, but over tightening of set screws occurs resulting in destruction of the stud connector
Solution Approach 1:
The connector provides exact thread-to-stud diameter matches at specific locations (e.g., 1-1/4" thread for 1-1/4" stud, 3/4" thread for 3/4" stud). This local precision ensures that when a specific sized stud is installed, the corresponding thread provides exact contact without requiring over-tightening, thereby preventing destruction of the stud connector while maintaining versatility for different stud sizes.
4Manufacturing precision
If three offset bores are provided for different stud threads, then full thread contact is provided for both studs, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The invention merges multiple separate bore operations into a single bore containing multiple threads. Instead of requiring three separate drilling and threading operations on three different centers, the design provides all necessary threads (e.g., 1-1/4" and 3/4") within one bore, dramatically reducing manufacturing complexity and cost while still achieving full thread contact for different sized studs.
Data Source
AI summary
An electrical connector is provided with a stud connector hole disposed into one end thereof which has a shallow V-groove therein, the flanks of the V-groove provided with threads for both sizes of studs commonly disposed therein wherein the threads of the smaller diameter stud are disposed into the flanks of the V-groove spaced from the threads of the larger diameter stud. The shallow V-groove provides at least two areas of contact on either size stud inserted therein, the areas of contact maintained along the length of the stud.