Set Screw Connector Bit With Shear Torque Limiting
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Solution Overview
Problem
Existing electrical set screw connectors face challenges in consistently and repeatably applying the required pressure for secure connections, often necessitating specialized tools or numerous part numbers, which can be costly and difficult to manage.
Innovation Solution
A system comprising a connector body with a set screw and a torque-limiting bit that shears at a specific torque limit, allowing for easy and repeatable torque application using standard tools, eliminating the need for specialized equipment and reducing part complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If dedicated tools with torque control are used to apply the set screw, then the torque application precision is improved, but the device complexity and cost increase
Solution Approach 1:
The patent employs disposable bits with integrated torque limiting features that shear at predetermined torque values. These inexpensive, single-use bits eliminate the need for expensive, complex torque-controlled tools while ensuring consistent torque application. The bit is discarded after one use, maintaining simplicity and low cost.
Solution Approach 2:
The torque control function is extracted from the expensive tool and transferred to the inexpensive bit. The bit contains the torque limiting mechanism (shear section) that separates the torque control function from the power application function, allowing standard tools to be used with precision-limited bits.
2Measurement precision
If multiple specialized connectors with different set screw designs are used to achieve different torques, then the torque application precision is improved, but the device complexity and part numbers increase
Solution Approach 1:
The patent creates a universal connector body design that can accommodate different bits with varying torque limits. The connector body remains standardized while the interchangeable bits provide the torque differentiation, allowing one connector design to serve multiple torque requirements through bit selection rather than creating specialized connectors for each torque level.
Solution Approach 2:
The torque control function is segmented into separate interchangeable bits rather than being integrated into the connector body itself. This allows the connector body to remain simple and standardized while torque precision is achieved through the selection of appropriate bits with different shear strengths.
3Ease of operation
If standard tools are used without torque limitation, then the ease of operation is improved, but the torque application precision deteriorates
Solution Approach 1:
By using inexpensive disposable bits with built-in torque limits, the patent allows standard easy-to-use tools to achieve precise torque application. The bit acts as a torque-limiting interface between the standard tool and the set screw, maintaining operational simplicity while ensuring precision through the bit's predetermined shear point.
Solution Approach 2:
The bit serves as an intermediary element between the standard tool and the set screw. It translates the tool's rotational input into controlled torque output, shearing at a predetermined torque level to prevent over-tightening while allowing the use of simple, non-specialized tools.
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
Enables consistent and repeatable torque application to ensure secure electrical connections without the need for specialized tools, allowing for easy installation and reinstallation of conductor cables while minimizing costs.
Implementation Method 1
The torque limiting region shears at the torque limit
Data Source
AI summary
An electrical set screw connector system is provided. The system includes a connector body and a bit. The connector body has a set screw and a pressure limitation for mechanically and electrically securing a conductor cable therein. The pressure limitation corresponds to a torque limit applied to the set screw. The bit has a torque limiting region that separates a body mating portion from a tool mating portion. The body mating portion operatively mates with the set screw, while the tool mating portion operatively mates with a tool. The torque limiting region shears at the torque limit.