Powder-Actuated Wedge Connector for Electrical Installation
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Solution Overview
Problem
Existing electrical connector tools and connectors face challenges in efficiently and cost-effectively facilitating installation in electrical power distribution systems, leading to increased operating costs and time requirements.
Innovation Solution
The development of an electrical wedge connector tool and connector system that utilizes a tapered wedge with a conductor groove and an explosive charge, driven by a firing ram, to quickly and securely connect electrical conductors to a connector shell, allowing for facilitated installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connector installation methods are used, then installation procedures are robust and reliable, but installation time increases and operating costs increase
Solution Approach 1:
The patent replaces traditional mechanical installation methods with a powder-actuated system that uses controlled explosive charges to drive the wedge connector into the shell, significantly reducing installation time while maintaining reliability through precise engineering of the firing mechanism and connector geometry
Solution Approach 2:
The invention changes the installation process from gradual mechanical forcing to instantaneous high-speed impact by using explosive powder charges, altering the force application parameters to achieve faster set times and reduced installation duration
2Stability of the object's composition
If traditional electrical connector installation methods are used, then connection stability is maintained, but operating costs increase
Solution Approach 1:
By substituting manual mechanical installation with a powder-actuated system, the patent reduces labor time and operational costs while achieving stable connections through the controlled high-velocity impact that ensures proper wedge engagement and conductor seating
3Productivity
If explosive charge is used to drive wedge into connector shell, then installation speed increases, but device complexity increases
Solution Approach 1:
The patent divides the installation tool into modular components including the wedge connector with integrated firing pin, the shell with cartridge receiving area, and separate explosive charges, allowing for simplified assembly and maintenance while achieving high installation speed
Solution Approach 2:
The wedge connector is pre-configured with a firing pin and the shell includes a pre-formed cartridge receiving area, so that when the explosive charge is ignited, the wedge is immediately driven into position without requiring additional alignment or setup steps, thus increasing productivity
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
This solution enables faster and more reliable connection of electrical conductors, reducing installation time and costs by using an explosive charge to drive the wedge into the connector shell, ensuring a tight mechanical and electrical connection.
Implementation Method 1
The opening is adapted to receive at least a portion of an explosive charge for driving the wedge into an electrical wedge connector shell
Implementation Method 2
The firing ram is adapted to receive gasses of an explosive charge in a direction opposite the first direction
Implementation Method 3
The wedge includes a generally tapered shape from the second end to the first end
Data Source
AI summary
Disclosed herein is an electrical wedge connector wedge. The electrical wedge connector wedge includes a first end, a second end, a first conductor groove, and an opening. The second end is opposite the first end. The wedge includes a generally tapered shape from the second end to the first end. The first conductor groove extends between the first end and the second end. The opening extends into the second end. The opening is adapted to receive at least a portion of an explosive charge for driving the wedge into an electrical wedge connector shell.