Mechanical Shear Bolt IPC Connectors for Strip-Free Solar Taps
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Solution Overview
Problem
Existing compression connectors for electrical connections require conductor stripping and complex tooling, which increases installation complexity and cost in large-scale solar power installations.
Innovation Solution
The use of multi-tap mechanical shear bolt connectors with insulation piercing teeth that eliminate the need for conductor stripping and allow for flexible, repeatable connections using lighter tools, such as an impact driver, by incorporating shearable heads that prevent overtightening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compression connectors with insulation piercing teeth are used, then conductor stripping is eliminated and connection reliability is improved, but device complexity and tool requirements increase
Solution Approach 1:
The connector is divided into modular components: a conductor block with insulation piercing members, separate run and tap caps, and shear bolts with predefined torque limits. This segmentation allows each component to perform its specific function independently, achieving reliable connections while simplifying the overall assembly process and reducing tool requirements.
Solution Approach 2:
The shear bolts are designed with a predefined torque limit that causes the head to shear off automatically when the optimal tightening torque is reached. This self-service mechanism eliminates the need for complex torque control tools or additional tightening steps, providing both reliable connection and simplified operation.
2Strength
If traditional compression connectors are used, then connection strength is achieved, but installation complexity and time increase due to stripping and crimping requirements
Solution Approach 1:
The insulation piercing members are pre-installed on the conductor block, and the shear bolts are pre-configured with their heads positioned to contact the conductor. This preliminary preparation eliminates the need for on-site conductor stripping and complex crimping operations, significantly reducing installation time while maintaining connection strength.
Solution Approach 2:
The traditional mechanical crimping system is replaced with a rotational tightening system using shear bolts. The bolt rotation drives the tap conductor into the insulation piercing member, creating a secure mechanical and electrical connection without requiring compression tools, thereby reducing installation time and tool complexity.
3Reliability
If shearable heads are incorporated in bolts, then overtightening is prevented and connection reliability is enhanced, but device complexity increases
Solution Approach 1:
The shearable head is designed with a predefined weak point that fails at a specific torque limit, preventing any potential harmful effects of overtightening before they can occur. This preliminary protective measure ensures connection reliability by maintaining optimal clamping force without damaging the conductor or connector components.
Solution Approach 2:
The shearable head is designed as a disposable component that is replaced with each connection. This simple, low-cost component provides complex protective functionality by automatically limiting torque, enhancing connection reliability without requiring complex adjustable mechanisms or electronic controls.
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
Simplifies installation procedures, reduces tool complexity, and enhances connection reliability and flexibility in electrical distribution systems, particularly in solar power installations, by enabling direct connections without combiner boxes.
Implementation Method 1
The first shearable head is configured to disconnect from the first threaded shank on reaching a first torque limit
Data Source
AI summary
A connector includes a conductor block with a run line opening, a run insulation piercing member extending into the run line opening, a tap line opening, and a tap insulation piercing member extending into the tap line opening. A run cap extends over the run line opening. A run bolt extends through the run cap into the run line opening. The run bolt includes a first threaded shank and a first shearable head. The first shearable head is configured to disconnect from the first threaded shank on reaching a first torque limit. A tap cap extends over the tap line opening. A tap bolt extends through the tap cap into the tap line opening. The tap bolt includes a second threaded shank and a second shearable head. The second shearable head is configured to disconnect from the second threaded shank on reaching a second torque limit.