Spring-Loaded Power Line Tap Clamp for Creep-Resistant Connections
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Solution Overview
Problem
Conventional power line clamps experience loosening of tap conductors due to material creep deformation, especially under elevated temperatures, leading to potential connector failure over time.
Innovation Solution
The electrical connector incorporates a clamp body with a spring force mechanism, including a boss with a cantilevered rear wall that provides a resilient spring force to secure the secondary conductor, mitigating creep-induced loosening by maintaining a clamping force over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional power line clamp uses only a fastener to secure the secondary conductor, then the device complexity is low, but the clamping force decreases over time due to material creep deformation
Solution Approach 1:
The clamp body incorporates a spring mechanism that provides dynamic, self-adjusting clamping force. The spring continuously applies pressure to the secondary conductor, automatically compensating for any loosening caused by material creep deformation over time, thereby maintaining reliable electrical connection without requiring complex additional components
Solution Approach 2:
The invention changes the physical state of the clamping force from static (fixed fastener) to dynamic (spring-loaded). The spring mechanism allows the clamping force parameter to self-adjust and maintain optimal pressure levels despite temperature variations and material creep, improving reliability without significantly increasing device complexity
2Reliability
If the clamp body provides additional spring force to the secondary conductor, then the clamping force and connection reliability are improved, but the manufacturing complexity of the clamp body increases
Solution Approach 1:
The spring mechanism is integrated directly into the clamp body structure itself, merging the fastening function and spring loading function into a single unified component. This integration eliminates the need for separate spring assemblies and complex mounting structures, making the clamp body manufacturable using standard fabrication processes while maintaining connection stability
Solution Approach 2:
The clamp body is designed to perform multiple functions simultaneously: it provides structural support, secures the secondary conductor, and generates spring force through its integrated geometry. This multi-functionality reduces the need for additional specialized components, simplifying manufacturing while ensuring reliable connection under varying temperature and creep conditions
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 spring force mechanism ensures a superior clamping force on the secondary conductor, preventing loosening and connector failure, even under temperature variations and material creep, thereby enhancing the durability and reliability of the connection.
Implementation Method 1
The clamp body is configured to provide a spring force to the secondary conductor when engaged with the secondary fastener
Data Source
AI summary
An electrical connector includes a clamp body having a base, a side portion, an upper portion, and a boss. The clamp body defines a cable groove configured to receive a primary conductor and an aperture for receiving a secondary conductor. A primary fastener is movably connected to the clamp body. A keeper is connected to the clamp body and moveable with the primary fastener to secure the primary conductor in the cable groove. A secondary fastener is configured to secure the secondary conductor in the aperture. The clamp body is configured to provide a spring force to the secondary conductor when engaged with the secondary fastener.