Range-Taking Shear Bolt Structure for Controlled Cable Clamping
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Solution Overview
Problem
Existing electrical cable connectors face challenges in securely connecting a range of cable sizes without damaging the conductors, as they require precise torque control to avoid over-tightening and ensure consistent break points for shear bolts.
Innovation Solution
The development of a range taking shear bolt with external screw threads and a non-round internal bore, featuring internal grooves perpendicular to the center axis and longitudinal grooves parallel to the axis, which creates a shear plane and narrows the break point tolerance, allowing for secure clamping and controlled breakage at a specific torque value.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shear bolt is used to secure cables in a connector, then the cable connection is secured, but the bolt head protrudes beyond the connector surface creating an uneven surface
Solution Approach 1:
The shear bolt is divided into two functional segments: a driven portion that protrudes to engage the cable and a clamping portion that remains flush with the connector surface. The segmented design allows the bolt to provide secure cable retention while maintaining a uniform connector surface when viewed from the exterior.
2Object-affected harmful factors
If precise torque control is used to avoid over-tightening, then conductor damage is prevented, but the complexity of the installation process increases
Solution Approach 1:
The shear bolt features a predetermined shear strength that causes the driven portion to automatically break off when a specific torque threshold is reached during installation. This self-limiting mechanism eliminates the need for complex torque control equipment or procedures, as the bolt itself controls the torque to prevent conductor damage.
3Manufacturing precision
If the bolt head is designed to break away at a specific torque, then consistent break points are achieved, but the break point location may vary beyond the connector surface
Solution Approach 1:
The shear bolt design incorporates a tubular support structure that extends along the longitudinal axis and provides dimensional constraints. This support structure guides the break point to occur at a specific location relative to the connector surface, ensuring that the driven portion breaks away cleanly without protruding beyond the connector exterior while maintaining consistent break point positioning.
4Force
If a non-round internal bore is used to engage the drive tool, then torque transmission is improved, but the manufacturing complexity increases
Solution Approach 1:
The internal bore of the shear bolt features a non-round, asymmetric cross-sectional shape that complements the drive tool's geometry. This asymmetric design creates mechanical interlocking that prevents slippage during torque application, ensuring efficient force transmission from the drive tool to the shear bolt without requiring additional locking mechanisms.
Data Source
AI summary
Range taking shear bolts and bolt installation (drive) tools are described herein, which are configured for use with a variety of range taking connectors and conductors.