Spring-Loaded Parallel Clamp Connector for Low-Resistance Taps
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Solution Overview
Problem
Conventional methods for tapping an overhead power distribution line, such as wire binding, result in undesirable contact resistance, I squared R losses, heat on joints, increased installation costs, time, and safety concerns, and reduced conductor life.
Innovation Solution
An electrical connector design featuring two pads of the same shape with a connector body having grooves and a hole, a fastener, and a spring, allowing for pivotable connection of conductors with reduced movement and enhanced grip, utilizing a spring-loaded parallel clamp for efficient and safe installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wire binding is used to connect conductors, then installation is simple, but contact resistance increases and conductor life decreases
Solution Approach 1:
The patent replaces the mechanical wire binding system with an electrical connector system that uses a fastener and spring mechanism to clamp conductors between pads. This substitution eliminates the high contact resistance associated with wire binding while maintaining ease of installation through the standardized connector design.
Solution Approach 2:
The patent changes the connection parameters by using a controlled clamping force through the spring mechanism, ensuring optimal contact pressure between conductors and pads. This parameter control reduces contact resistance compared to wire binding while maintaining installation simplicity.
2Ease of manufacture
If wire binding is used to connect conductors, then installation is simple, but heat generation increases
Solution Approach 1:
The patent replaces the wire binding mechanical system with a pad-clamp electrical connection system that provides superior thermal contact. The increased surface area contact between pads and conductors dissipates heat more effectively, reducing temperature at joints while maintaining installation simplicity.
3Ease of manufacture
If conventional tapping methods are used, then installation cost is reduced, but installation time increases
Solution Approach 1:
The electrical connector is pre-assembled with the fastener and spring mechanism before installation. This preliminary preparation allows for rapid installation by simply positioning the connector and securing it, reducing installation time while maintaining cost-effectiveness through standardized components.
Solution Approach 2:
The patent replaces time-consuming conventional tapping methods with a standardized electrical connector system that can be quickly installed using basic tools, significantly reducing installation time while keeping costs low through mass-producible components.
4Ease of manufacture
If conventional tapping methods are used, then installation cost is reduced, but safety decreases
Solution Approach 1:
The patent replaces unsafe conventional tapping methods with a standardized electrical connector system designed with inherent safety features including proper grounding paths, insulated components, and secure clamping mechanisms that eliminate common safety hazards while maintaining cost-effectiveness.
5Ease of manufacture
If wire binding is used to connect conductors, then installation is simple, but conductor life decreases
Solution Approach 1:
The patent replaces the conductor-damaging wire binding system with a pad-clamp connection system that distributes clamping force evenly across the conductor surface. This prevents mechanical damage, corrosion, and stress concentration, thereby extending conductor life while maintaining installation simplicity.
Solution Approach 2:
The patent changes the clamping pressure distribution parameter by using wide pads instead of narrow wire bindings, reducing stress concentration on the conductor. This parameter optimization prevents conductor degradation and extends service life while keeping installation simple.
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
The electrical connector significantly reduces contact resistance, I squared R losses, heat, and improves conductor life, while lowering installation costs, time, and enhancing safety and reliability compared to conventional methods.
Implementation Method 1
A spring is between a first end of the fastener and one of the two pads having the same shape so that the spring biases the two pads having the same shape towards each other
Data Source
AI summary
An electrical connector includes two pads having the same shape. Each pad has a connector body with a first groove, a second groove, and a hole. The hole extends through the connector body between the first groove and the second groove. A fastener extends through the hole of both of the two pads so that the two pads having the same shape are connected to one another and are pivotable around the fastener relative to one another with the two first grooves contacting a first conductor when the first conductor is in an installed position and the two second grooves contacting a second conductor when the second conductor is in an installed position. A spring is between a first end of the fastener and one of the two pads having the same shape so that the spring biases the two pads having the same shape towards each other.