Tap Clamp With Adjustable Shaft For Conductor Sizing
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Solution Overview
Problem
Existing conductor tap clamps face challenges in securely and efficiently establishing electrical communication between conductors, particularly when attaching to energized transformers, as they often require complex mechanisms and may not accommodate varying conductor sizes effectively.
Innovation Solution
A clamp design comprising a main housing portion, a gripper portion, a clamp member, and a linear actuator with a resilient member, allowing for adjustable spacing to securely engage conductors through a U-shaped channel and a curved surface, enabling easy installation and secure connection of both conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing conductor tap clamps use complex mechanisms to securely engage conductors, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The clamp is divided into two separate housing portions (first housing portion and second housing portion) that can be independently positioned and adjusted. Each housing portion has its own clamp surface, allowing separate engagement with different conductors. This segmentation enables simplified individual components while achieving reliable multi-conductor connection through their coordinated arrangement.
2Manufacturing precision
If existing clamps use fixed spacing between clamp surfaces, then manufacturing precision is improved, but adaptability to varying conductor sizes deteriorates
Solution Approach 1:
The clamp incorporates adjustable spacing between the first and second housing portions along the longitudinal axis. The shaft coupling mechanism allows the distance between clamp surfaces to be dynamically adjusted to accommodate different conductor sizes and configurations. This dynamic adjustability maintains manufacturing precision for each individual component while providing versatility for various conductor dimensions.
3Reliability
If existing clamps require multiple adjustment steps to secure conductors, then connection reliability is improved, but ease of operation deteriorates
Solution Approach 1:
The clamp is pre-configured with two housing portions positioned at predetermined spacings along the longitudinal axis, with clamp surfaces oriented to face each other. This preliminary arrangement of conductors within the channels and positioning of housing portions eliminates the need for complex multi-step adjustments during installation. The shaft coupling mechanism allows for straightforward adjustment of the overall clamp size to match the specific conductor configuration.
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 clamp provides reliable electrical communication by accommodating various conductor sizes and securely attaching to energized conductors, ensuring efficient energy transfer while being easy to operate and adjust.
Implementation Method 1
a resilient member positioned within the first housing portion and operable to move the second housing portion relative to the first housing portion
Data Source
AI summary
A clamp provides electrical communication between a first conductor and a second conductor. The clamp includes a first housing portion having a first surface, a second surface, a first housing bore, and a cavity, the first housing bore extending along a longitudinal axis. The clamp further includes a clamp member at least partially disposed within the cavity of the first housing portion, the clamp member including a first clamp surface adjacent the second surface of the housing in a facing relationship. The clamp further includes a shaft oriented parallel to the longitudinal axis, the shaft coupling the first housing portion and the clamp member. The clamp further includes a second housing portion movably coupled to the first housing portion by the shaft, the second housing portion including a second housing bore and a second clamp surface, the second housing bore aligned with the longitudinal axis, the second clamp surface adjacent the first surface of the first housing portion in a facing relationship.