Sheet Metal Ground Conductor Clamp Conformability
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Solution Overview
Problem
Cast copper alloy ground conductor clamps are rigid and brittle, leading to poor current flow and low pull-out load values due to localized contact with ground rods or electrodes, limiting their effectiveness in electrical connections.
Innovation Solution
A ground conductor clamp made from non-rigid sheet metal with an overlapped section and a threaded insert nut, where the nut is spin riveted to prevent rotation, allowing the clamp body to conform to the ground conductor and increase contact area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cast copper alloy materials are used for ground conductor clamps, then structural strength is improved, but electrical contact quality deteriorates due to rigid point-to-point connection and localized contact area
Solution Approach 1:
The clamp body is formed from sheet metal (16 gauge or thinner) instead of rigid cast materials, allowing the clamp to flex and conform to the ground rod surface. This flexibility creates extended contact area rather than point-to-point contact, improving electrical contact quality while maintaining adequate structural strength through the metallic sheet construction.
2Ease of manufacture
If cast materials are used for ground conductor clamps, then manufacturing simplicity is improved, but adaptability deteriorates due to inability to conform to various ground rod sizes and shapes
Solution Approach 1:
The sheet metal construction inherently provides flexibility that allows the clamp to adapt to various ground rod diameters and surface conditions. The thin metallic sheet can be formed into the required shape and will flex during installation to match the contours of different conductors, providing universal adaptability without complex manufacturing processes.
Solution Approach 2:
The clamp design utilizes changes in material thickness (16 gauge or thinner) and geometric configuration to achieve the desired balance between flexibility for adaptability and structural integrity. By controlling the sheet metal parameters, the clamp can conform to different conductor sizes while maintaining sufficient strength for secure attachment.
3Adaptability or versatility
If sheet metal with thickness of 1.9 mm (0.075 inches) or less is used, then adaptability and conformability are improved, but structural strength deteriorates
Solution Approach 1:
The patent specifies sheet metal thickness of 16 gauge (approximately 1.9 mm or less) as the optimal parameter that balances flexibility and strength. This thickness parameter allows sufficient conformability to ground conductors while maintaining adequate structural strength for secure mechanical attachment and electrical connection.
Data Source
AI summary
A ground conductor clamp has a sheet metal clamp body with overlapped portions. The clamp body may be stamped from sheet metal. The overlapped portions have aligned circular holes in them for receiving a threaded insert nut inserted into them. The insert nut is spin riveted to attach it to the overlapped portions of the clamp body. A flange of the insert nut has a flat face that engages the clamp body to prevent rotation of the insert nut. The overlapped portion includes an inner bent tab that strengthens the sheet metal clamp body. The clamp also includes a threaded fastener, such as a bolt, that is threaded into the insert nut to engage a conductive lead and a ground conductor, such as a ground rod or ground electrode.