Swaged Connectors for Grounding Grids
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Solution Overview
Problem
Crimped connectors in electrical grounding grids concentrate compressive force, leading to poor electrical connections due to localized force distribution, which can compromise the reliability of substation grounding systems.
Innovation Solution
The development of swaged connectors with removable inserts and a cylindrical swage region that evenly distributes compressive force around the conductor, using high-purity copper materials and a 360° Radial Swage Tool for secure attachment to copper cables and ground rods, allowing for various configurations like lap splices, tees, and elbows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crimped connectors are used to secure the connector to the conductor, then the connector can be attached to the conductor, but the compressive force is concentrated at one or a few locations resulting in poor electrical connection
Solution Approach 1:
The connector body is divided into multiple swage regions distributed around the circumference of the conductor, with each swage region applying compressive force at a different location. This segmentation of the compression application points transforms the concentrated force problem into distributed force, improving electrical connection quality while maintaining secure attachment.
2Ease of operation
If removable inserts are added to allow joining onto existing continuous cables, then the connector can be assembled prior to installation, but the device complexity increases
Solution Approach 1:
The insert is extracted as a separate removable component from the connector body, allowing the connector to be assembled around continuous cables before installation. The insert can be removed to open the connector for cable insertion, then reinserted to complete the assembly. This extraction principle enables easy assembly operation while managing device complexity through modular design.
3Adaptability or versatility
If the connector is designed to accommodate different conductor geometries and sizes, then the adapter can be used in various configurations, but the manufacturing precision requirements increase
Solution Approach 1:
The connector is designed with universal swage regions that can accommodate different conductor geometries and sizes through multiple configurations (lap splice, tee, elbow). The swage regions are engineered with tolerances that allow adaptation to various conductor types while maintaining reliable electrical connection, achieving multi-functionality without excessive manufacturing precision requirements.
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 swaged connectors provide superior, reliable electrical connections by evenly distributing compressive force, enhancing the stability and performance of subterranean grounding grids in electrical utility substations, while accommodating different conductor geometries and sizes.
Implementation Method 1
Swaging is a process that distributes compressive force evenly around the circumference of a cylindrical body. Therefore, a properly swaged connector will generally provide a superior connection in comparison to a crimped connector.
Data Source
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AI summary
A family of swaged connectors (10, 40, 50) has particular application for joining segments of copper cable (17) that make up a subterranean grounding grid in an electrical utility substation. The connectors have a body member (12, 42, 52) with at least one swage region (24, 44) having a trough (16) for receiving an electrical conductor (17). The swage region (24, 44) has an opening extending the length of the trough (16) to allow insertion, in a radial direction, of the electrical conductor (17) into the trough (16). An insert (14) is configured for mating engagement with the opening in the swage region (24, 44), such that, when the insert (14) is mated with the body member (12, 42, 52), an electrical conductor (17) disposed within the trough (16) is radially entrapped in the connector (10, 40, 50). The connector body (12, 42, 52) and insert (14) have a cylindrical outer surface in the swage region (24, 44) to facilitate swaging the connector to secure it to the electrical conductor. The connector may be configured as a lap splice, tee or elbow.