Split Bushing Connector for Corrugated Cable Grip
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Solution Overview
Problem
Existing connectors for high-powered electrical cables fail to securely attach to cables with corrugated armor shields due to inadequate grip, leading to potential disconnection and safety hazards.
Innovation Solution
A connector design featuring a split bushing with radially split sections and external chamfers that compresses around the corrugated cable surface when a nut is tightened, providing a secure wedge action to attach the connector to the cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional connector design is used, then the structure is simple, but the connector fails to securely attach to cables with corrugated armor shields
Solution Approach 1:
The bushing is split into multiple radial segments that can independently compress around the corrugated cable surface. This segmentation allows each segment to conform to the cable's geometry while maintaining collective gripping force, resolving the contradiction between secure attachment and structural simplicity.
Solution Approach 2:
The bushing transitions from a static rigid structure to a dynamic compressible structure. When the connector is assembled, the bushing segments are forced together, creating a dynamic gripping action that adapts to the corrugated cable surface, thereby improving attachment security without excessive complexity.
2Reliability
If a split bushing with wedge action is used, then the grip on corrugated surface is improved, but the manufacturing complexity increases
Solution Approach 1:
Dividing the bushing into radial segments simplifies the manufacturing of each individual piece while achieving the complex function of conforming to corrugated surfaces. Each segment can be manufactured separately and then assembled, reducing overall manufacturing complexity despite the improved grip function.
Solution Approach 2:
The bushing design incorporates chamfered surfaces at specific angles to create wedge action. By optimizing the chamfer angles and segment geometry, the design achieves reliable grip on corrugated surfaces while maintaining manufacturability through standard machining operations.
3Reliability
If the bushing is compressed around the corrugated surface, then the connector is securely attached, but the installation process becomes more complex
Solution Approach 1:
The bushing segments are pre-configured with chamfered surfaces that automatically engage the corrugated cable surface during assembly. The wedge action is built into the geometry, so the compression and securing action occurs automatically as the connector is assembled, reducing installation complexity while maintaining connection stability.
Solution Approach 2:
The bushing design allows the connector assembly process itself to create the securing compression. As the connector components are assembled, the wedge action between chamfered surfaces automatically compresses the bushing segments against the cable, eliminating the need for separate securing operations and simplifying installation.
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 ensures a reliable and secure attachment of the connector to the cable, preventing disconnection and enhancing safety by compressing the bushing around the corrugated surface, thus addressing the grip issues of existing connectors.
Implementation Method 1
As the nut is tightened onto the body, wedge action on the first and second bushing chamfers compresses the bushing around the corrugated exterior surface to secure the connector to the cable
Data Source
AI summary
A cable has a corrugated armor exterior surface, and a split bushing defines an interior surface which conforms to the corrugated exterior surface. The bushing is split radially in one place to form a gap which may be opened to allow the bushing to open, or the bushing is split radially at two or more places to form two or more parts, and is fitted about the corrugated exterior surface. The bushing defines first and second external chamfer surfaces. A connector includes a body having external threads and a chamfer which urges against the first bushing chamfer. A nut has internal threads which engage the external threads of the body, and a chamfer which urges against the second bushing chamfer. As the nut is tightened onto the body, wedge action on the first and second bushing chamfers compresses the bushing around the corrugated exterior surface to secure the connector to the cable.