Set Screw Connector with Visual Torque Indicator
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Solution Overview
Problem
Existing set screws lack consistency in applying force to electrical conductors over time due to deformation of conductors and dimensional changes, and require torque wrenches for accurate force measurement, which can be cumbersome and time-consuming, especially in confined spaces.
Innovation Solution
A set screw design featuring an elastically deformable member, such as a coil spring or disc springs, between the screw body and screw face, with an indicator bar showing the force applied, allowing for visual inspection of the force without needing a torque wrench, and a break-away structure for ensuring proper torque application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a torque wrench is used to tighten the set screw, then the torque applied is accurate and consistent, but the installation process becomes time-consuming and cumbersome
Solution Approach 1:
The set screw system performs its own torque verification function through the indicator bar that visually displays whether the correct torque has been applied. This eliminates the need for external torque wrenches and inspection tools, allowing installers to quickly determine proper torque application at a glance without time-consuming measurements
Solution Approach 2:
The patent replaces the mechanical torque measurement system (torque wrench) with a visual indication system. The indicator bar translates the mechanical torque state into a visible position that can be assessed without mechanical measurement tools, substituting complex mechanical verification with simple visual inspection
2Reliability
If periodic torque measurement is performed using a torque wrench to ensure sufficient force, then the force on conductors can be verified, but equipment must be powered down and inspection becomes time-consuming
Solution Approach 1:
The indicator bar continuously displays the force application status without requiring external measurement tools or equipment shutdown. The system monitors and displays its own operational state, allowing inspectors to verify force maintenance on powered equipment through simple visual inspection
Solution Approach 2:
The patent replaces periodic mechanical torque measurement with continuous visual indication. The indicator bar provides ongoing feedback on force application status, eliminating the need for interruptive torque wrench measurements and allowing verification while equipment remains operational
3Strength
If torque is increased to ensure sufficient force application, then the mechanical connection is stronger, but friction between threads increases reducing the correlation between torque and force
Solution Approach 1:
The indicator bar serves as an intermediary that directly reflects the force application status rather than the torque input. It translates the complex relationship between torque, thread friction, and actual force into a direct visual indication of the resulting force state, bypassing the imprecise torque-force correlation
Solution Approach 2:
The patent substitutes torque-based measurement with direct force indication. Rather than inferring force from torque (which is affected by variable friction), the system directly displays the actual force application state through the indicator bar position, eliminating the measurement uncertainty
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 solution ensures a consistent and secure mechanical and electrical connection by maintaining the applied force over time, allowing for visual inspection of force levels without powering down equipment or using torque wrenches, and simplifies the installation and inspection process.
Implementation Method 1
an elastically deformable member disposed between the screw body and the screw face. The elastically deformable member is adapted to compress in response to force applied to the screw face along the axial direction relative to the screw body
Data Source
AI summary
A set screw for connecting conductors with electrical terminals, such as a terminal block of a load panel includes a screw body and a screw face. The screw face fits inside the screw body and is movable along the axis of the screw body. An elastically deformable member, such as a coil spring or set of spring washers is disposed between the screw body and the screw face. The elastically deformable member compresses in response to force exerted between the screw body and screw face. An indicator bar is connected with the screw face and moves along the axis of the screw body along with the screw face in response to the compressive force. The proximal end of the indicator bar extends proximal of the screw body and includes one or more indicia that show the deformation of the elastically deformable member.