Pressure Bar for Electrical Connector Conductor Stability
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Solution Overview
Problem
Existing split bolt electrical connectors lack effective mechanisms to securely engage and stabilize conductors, leading to potential disconnection and instability in electrical connections.
Innovation Solution
A pressure bar with a bottom section, first leg, and second leg, featuring a groove for conductor contact and adjustable shoulders, is integrated into the connector assembly, allowing for enhanced engagement and stability through a fastener component that adjusts the pressure bar's position within the conductor channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional split bolt connector without a pressure bar is used, then the device complexity is reduced, but the reliability of the electrical connection deteriorates due to potential conductor disconnection and instability
Solution Approach 1:
The pressure bar is divided into distinct functional segments: a bottom section with a groove for conductor contact, first and second legs extending upward, and transition regions forming shoulders. This segmentation allows each part to perform its specific function optimally while maintaining overall structural integrity and reliability of the electrical connection.
Solution Approach 2:
The pressure bar is designed as a movable component that can be adjusted within the conductor receiving channel. The fastener component enables dynamic positioning of the pressure bar to apply appropriate engagement force to the conductors, ensuring reliable electrical connection while allowing for installation adjustments and conductor variations.
2Adaptability or versatility
If the pressure bar is made with fixed shoulders, then the manufacturing precision is improved, but the adaptability to different conductor sizes and positions deteriorates
Solution Approach 1:
The pressure bar incorporates movable legs with transitions forming shoulders that can be adjusted along the length of the pressure bar. This dynamic design allows the shoulders to be positioned at different locations to accommodate various conductor sizes and positions, providing adaptability while maintaining manufacturing feasibility through standardized transition geometries.
Solution Approach 2:
The pressure bar design allows for variation in the position of the shoulders formed by the transitions between the legs and bottom section. By changing the positional parameters of these transitions, the connector can adapt to different conductor configurations while maintaining consistent manufacturing processes for creating the transition regions.
3Ease of operation
If the pressure bar extends fully through the fastener component, then the mechanical strength is improved, but the ease of operation deteriorates due to difficulty in positioning and adjustment
Solution Approach 1:
The pressure bar is designed as a movable component within the conductor receiving channel, allowing it to be positioned and adjusted to the appropriate depth and engagement force. The fastener component provides guidance and constraint while enabling operational adjustment, balancing ease of positioning with sufficient mechanical strength for reliable conductor engagement.
Solution Approach 2:
The fastener component acts as an intermediary between the pressure bar and the upright members, providing a mechanism for adjusting and securing the pressure bar at the desired position. This intermediary structure enables easy operation for positioning while ensuring adequate engagement force is transmitted to the conductors through the pressure bar.
Data Source
AI summary
An electrical connector includes a split bolt, a fastener component, and a pressure bar. The split bolt includes a base, a first upright member, a second upright member, and a conductor receiving channel defined between the first and second upright members. The fastener component has a top surface, a bottom surface, and an opening receiving the first and second upright members. The pressure bar has a bottom section, a first leg, and a second leg. The pressure bar is movably received in the conductor receiving channel.