Tap Plug Assembly for High-Torque Hotstick Installation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing tap plugs are inadequate in terms of manufacturing cost, ease of retrofitting, suitability for high torque applications, ability to be installed using a hotstick, and ease of disassembly, particularly in 900 amp applications.
Innovation Solution
A tap plug design featuring a housing with a rotatable first member and second member, each with threads for engaging a conductor lug and a stud, and a guide member connected by a releasable connection that ensures proper alignment and torque application, allowing for easy installation and disassembly, and capable of withstanding high torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional tap plug design is used, then the manufacturing cost is reduced, but the ability to withstand high torque and suitability for 900 amp applications deteriorates
Solution Approach 1:
The tap plug is divided into multiple members (first member, second member, third member) that can rotate independently relative to each other. This segmentation allows each member to be optimized for specific functions while collectively withstanding high torque loads through distributed stress across multiple components.
2Device complexity
If a traditional tap plug design is used, then the device complexity is reduced, but the ease of installation using a hotstick and ease of disassembly deteriorates
Solution Approach 1:
The tap plug employs dynamic members that can rotate relative to each other, enabling the device to adapt its configuration during installation and disassembly operations. This dynamic capability allows for easier manipulation with hotsticks and simpler disassembly while maintaining structural integrity during use.
3Ease of manufacture
If a traditional tap plug design is used, then the manufacturing cost is reduced, but the ability to reduce load for testing deteriorates
Solution Approach 1:
The tap plug is designed with multiple members and rotation capabilities that enable it to perform multiple functions: it can withstand high torque for 900 amp applications, reduce load for testing operations, and facilitate easy installation and disassembly. This multi-functionality is achieved while maintaining cost-effectiveness through the modular member structure.
Data Source
AI summary
A tap plug for engaging a conductor lug and a stud is provided. The tap plug includes a housing, a first member, and a second member. The housing has an inner bore defining a longitudinal axis. The first member is in the inner bore and is rotatable with respect to the housing about the longitudinal axis. The first member has an external thread at a first end, where the external thread engages the conductor lug. The second member is rotatable with respect to the housing about the longitudinal axis and has an internal thread at the first end. The first end is open so that the internal thread can engage the stud.