Electrical Conductor Splice Jaws With Torque-Limited Slack-Span Clamping
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Solution Overview
Problem
Automatic splice devices for electrical conductors are ineffective in 'slack-span' applications where little or no tension is applied, and they require specialized tools and multiple components for reliable connections, especially when conductors have different diameters or are under vibration.
Innovation Solution
A splice device with a main housing, jaws, and a movement conversion assembly that converts tightening movement into clamping force, accommodating conductors of varying diameters and tensions, using a driver with torque limiting features and biasing members to ensure secure connections without specialized tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automatic splice devices are used for electrical conductors, then connection speed and automation are improved, but reliability deteriorates in slack-span applications where little or no tension is applied
Solution Approach 1:
The splice device automatically adjusts to different conductor diameters and tension conditions without requiring external tools or manual intervention. The movement conversion assembly self-adjusts through the gap between the driver and main housing, allowing the device to serve itself across varying application conditions including slack-span scenarios.
Solution Approach 2:
The splice device incorporates dynamic adjustment capabilities through the movement conversion assembly that can adapt to different conductor diameters and tension levels. The gap between driver and main housing enables the assembly to move and adjust dynamically, transforming a single-purpose automatic device into a multi-condition adaptable system.
2Reliability
If splice devices are designed for slack-span applications with specialized tools, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The splice device is designed to perform multiple functions across different application conditions using a single device configuration. The movement conversion assembly can handle both tensioned and slack-span conductors, eliminating the need for separate specialized devices or tools for different application types.
Solution Approach 2:
The patent combines the capabilities of multiple specialized splice devices into a single unified device. By integrating the movement conversion assembly with adjustable gaps and biasing members, it merges the functionality of tension-based automatic splicers with slack-span capable splicers into one versatile unit.
3Reliability
If splice devices use multiple components and specialized tools, then connection reliability is improved, but splicing time and cost increase
Solution Approach 1:
The biasing member is pre-configured to provide initial clamping force on the conductor before the driver is fully tightened. This preliminary action ensures proper conductor positioning and initial grip, eliminating the need for multiple adjustment steps or specialized tools during the splicing process.
Solution Approach 2:
The invention extracts and eliminates the requirement for specialized crimping tools and multiple component assemblies. By integrating all necessary functions into the movement conversion assembly and using standard fastening mechanisms, it removes the time-consuming steps associated with specialized tooling while maintaining connection reliability.
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 reliable mechanical and electrical connections of conductors under varying tension conditions, including slack-span scenarios, with self-adjustment for different diameters and compatibility with common tools, reducing costs and complexity.
Implementation Method 1
a movement conversion assembly operatively associated with the first and second sets of jaws to convert a tightening movement of a driver into linear outward movement of the first and second sets of jaws along the conductor axis
Implementation Method 2
a biasing member configured to provide an initial clamping force on the first set of jaws prior to the tightening movement of the driver
Data Source
AI summary
A splice device is provided that includes a main housing, a first set of jaws, and a movement conversion assembly. The first set of jaws is in the main housing and depend outward along a conductor axis. The first set of jaws receive a first electrical conductor therein. The movement conversion assembly is in the main housing and includes a driver operatively associated with the first set of jaws so that a tightening movement of the driver is converted into a clamping force of the first set of jaws on the first electrical conductor.