Spring Loaded Insulation Piercing Connector for Power Lines
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Solution Overview
Problem
Conventional power line clamp connectors require complex maneuvering with a utility lineman's hot stick, increasing operating costs and difficulty in maintenance and installation operations.
Innovation Solution
A spring-loaded electrical connector with pads, insulation displacing contacts, and a fastener system that allows for easy alignment and secure connection of conductors, featuring pivotable pads and a spring member for clamping force, enabling efficient connection of conductors of varying diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional power line clamp connectors with threaded eye bolts are used, then secure connection of conductors is achieved, but complex maneuvering with hot stick is required increasing operation difficulty and time
Solution Approach 1:
The connector employs a spring-loaded mechanism with movable pads that can dynamically adjust during installation. The spring member stores mechanical energy and automatically applies clamping force when the connector is engaged, eliminating the need for complex manual manipulation of threaded components while maintaining secure connection.
Solution Approach 2:
The invention extracts and eliminates the threaded eye bolt component from the connector design. By removing this complex manual operation component and replacing it with a spring-loaded automatic clamping mechanism, the design simplifies the installation process while maintaining connection security.
2Adaptability or versatility
If conventional clamps with fixed structure are used, then simple design is maintained, but inability to accommodate varying conductor diameters limits versatility
Solution Approach 1:
The connector features movable pads that can shift position along the spring member's axis, allowing the clamping structure to dynamically adapt to different conductor diameters. This dynamic adjustment capability enables the same connector design to accommodate varying conductor sizes without requiring multiple specialized connectors.
Solution Approach 2:
The spring-loaded mechanism serves multiple functions: it provides automatic clamping force, accommodates varying conductor diameters through pad movement, and maintains electrical contact pressure. This multi-functional design achieves versatility without proportionally increasing structural complexity.
3Reliability
If parallel cable clamps with mechanical fasteners are used, then secure connection is achieved, but complex alignment and assembly process increases operation difficulty
Solution Approach 1:
The spring member automatically applies clamping force when the connector pads are positioned around the conductors. The elastic potential energy stored in the spring self-generates the necessary clamping pressure without requiring additional manual tightening operations, making the connector self-servicing and eliminating complex alignment procedures.
Solution Approach 2:
The spring member is pre-loaded with elastic potential energy during manufacturing or assembly preparation. This preliminary action stores the mechanical work needed for clamping, so that during installation, the connector simply needs to be positioned around the conductors and the pre-stored energy automatically executes the clamping action without requiring complex real-time alignment or manual force application.
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 simplifies the connection process, reduces operating costs, and facilitates easier maintenance and installation by providing a secure and efficient method for connecting conductors, accommodating different conductor sizes and orientations.
Implementation Method 1
The spring member is positioned around the fastener biasing the first pad and the second pad towards one another
Data Source
AI summary
An electrical connector includes first and second pads. The first pad includes first and second grooves and the second pad includes third fourth grooves. A first insulation displacing contact extends from the first groove to the second groove. A second insulation displacing contact extends from the third groove to the fourth groove. The first and second pads are connected by a mechanical fastener. When the first and second pads are connected the first groove aligns with the third groove and the second groove aligns with the fourth groove.