Pin Adapter Cable Connectors for Stranded Conductor Reliability
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Solution Overview
Problem
Existing electrical connectors struggle to securely connect stranded conductors to mechanical terminations in electrical equipment, leading to unreliable connections.
Innovation Solution
The development of pin adapter type cable connectors featuring a connector body with a conductor bore, a fastener, and a pin adapter with adjustable pins, which securely fasten the conductor to the connector body, ensuring robust electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stranded conductors are connected directly to mechanical terminations, then the connection process is simple, but the connection reliability is insufficient
Solution Approach 1:
The patent introduces a pin adapter as an intermediary component between the stranded conductor and the mechanical termination. The pin adapter includes a pin that penetrates through the conductor and a body that interfaces with the mechanical termination, providing a more reliable mechanical and electrical connection than direct attachment. This intermediary structure resolves the contradiction by sacrificing some structural complexity to gain significant improvement in connection reliability.
2Reliability
If a pin adapter is used to secure stranded conductors, then connection reliability improves, but the device complexity increases
Solution Approach 1:
The patent combines multiple functions into the pin adapter component: the pin serves both as a mechanical anchor through the conductor and as an electrical conductor, while the body provides both structural support and electrical interface. This merging of functions reduces the need for separate components, thereby improving reliability without proportionally increasing device complexity.
3Ease of operation
If the fastener is made movable to enter the conductor bore, then ease of operation improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent makes the fastener movable within its bore, allowing it to dynamically adjust its position as the conductor is inserted. This dynamic capability enables the fastener to self-align with the conductor, improving ease of operation. The design accepts increased manufacturing precision requirements by providing a tolerance range that accommodates normal assembly variations while maintaining functional reliability.
Data Source
AI summary
The present disclosure provides pin adapter type cable connectors used to terminate electrical conductors into mechanical connectors or other terminations typically found in electrical equipment. The connectors include a connector body having a conductor bore to receive a bare portion of an electrical conductor, a fastener that is coupled to the connector body and used to secure the bare portion of an electrical conductor to the connector body, and a pin adapter having an adapter body that can be removably connected to the connector body and a pin extending from the adapter body.