Shear Bolt Grounding Connector for Secure Conductor Retention
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Solution Overview
Problem
Conventional grounding connectors often fail to securely attach conductors due to reversible engagement and require specialized tools, leading to insecure and durable connections.
Innovation Solution
A grounding connector assembly featuring a shear bolt with a shear torque mechanism that automatically shears upon reaching a target compression force, securely retaining conductors without the need for specialized tools, and a lay-in design allowing for easy installation and secure retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional grounding connectors use reversible engagement mechanisms, then installation and removal are easier, but the connection security and durability are compromised
Solution Approach 1:
The shear bolt is designed as a disposable component that is sheared off during installation to create an irreversible connection. The bolt includes a designated shear plane that fails at a predetermined load, permanently securing the conductor to the grounding connector and preventing reversible engagement or loosening over time.
Solution Approach 2:
The connection transitions from a reversible state to an irreversible state through controlled material failure. The shear bolt's physical state changes from intact to sheared, fundamentally altering the connection parameters to ensure permanent security while maintaining ease of installation through the controlled failure mechanism.
2Manufacturing precision
If conventional grounding connectors require specialized tools, then connection precision can be maintained, but installation complexity and time increase
Solution Approach 1:
The shear bolt mechanism is designed to self-regulate the connection precision through its inherent shear strength properties. Standard hand tools provide sufficient torque to reach the shear point, and the bolt automatically shears at the predetermined load without requiring specialized equipment, thereby maintaining precision while eliminating complex tool requirements.
Solution Approach 2:
The system replaces complex specialized tools with simple hand tools by utilizing the material properties of the shear bolt. The controlled failure mechanism substitutes for precision instrument control, allowing standard tools to achieve the same connection precision through the bolt's predetermined shear characteristics.
3Ease of operation
If grounding connectors use simple retention mechanisms, then installation is easier, but the ability to withstand pull-out forces is reduced
Solution Approach 1:
The shear bolt is pre-engineered with a specific shear strength that corresponds to the required pull-out resistance. During installation, the bolt is tightened until it shears, at which point it has already established the necessary clamping force and mechanical interlock to withstand the specified pull-out loads without requiring complex retention mechanisms.
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 provides reliable, irreversible, and secure grounding connections that are easy to install using standard tools, ensuring conductors are retained against a threshold pull-out force, addressing the limitations of conventional connectors.
Implementation Method 1
The shear bolt may have a shear torque at which a head of the shear bolt may be configured to shear from a body of the shear bolt. The shear torque may correspond to a target compression force between the shear bolt and the one or more conductors.
Data Source
AI summary
A grounding connector can include a connector body and a shear bolt. The connector body can have a recess sized to receive one or more conductors and a threaded portion. The shear bolt can be sized to engage the threaded portion of the connector body to secure the one or more conductors within the recess. When the shear bolt is tightened into the threaded portion of the connector body, the shear bolt can retain the one or more conductors within the recess. When the shear bolt is subject to a shear torque, a head of the shear bolt can shear from a body of the shear bolt. The shear torque can correspond to a target compression force applied between the shear bolt and the one or more conductors.