Threaded Cable Terminal Assembly With Rotatable Busbar Alignment
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Solution Overview
Problem
Conventional terminal assemblies for cables in electric power systems are complex, cumbersome, and costly, with exposed parts susceptible to damage in harsh environments, and require specialized tools and expertise for assembly.
Innovation Solution
A terminal assembly comprising an elongated tongue for connection with a busbar, a tubular body with a recess, and a ferrule with external threads, which are secured using a coupling member with internal threads, allowing for easy assembly and rotation of the cable relative to the busbar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional terminal assembly with exposed cylindrical projection is used, then the assembly can be made, but the exposed portion is susceptible to damage in harsh environments and requires accurate alignment during assembly
Solution Approach 1:
The invention removes the exposed cylindrical projection from the terminal assembly design. Instead, the ferrule is received within the tubular body, with the ferrule projection inserted into a recess in the tubular body. This extraction of the exposed portion eliminates the vulnerability to environmental damage while maintaining the electrical connection function.
Solution Approach 2:
The ferrule is nested within the tubular body, with the ferrule projection fitting into a recess in the tubular body. This nesting arrangement protects the ferrule and eliminates exposed portions that could be damaged in harsh environments, while still allowing for proper electrical connection and mechanical securing.
2Reliability
If a complex terminal assembly with variable clocking and multiple interfaces is used, then electrical connectivity can be established, but the assembly process becomes time-consuming and requires specialized expertise
Solution Approach 1:
The terminal assembly is segmented into distinct functional components: the tubular body for structural support and cable reception, the ferrule for electrical connection and mechanical securing, and the simplified tongue for busbar attachment. This segmentation allows for easier manufacturing, assembly, and maintenance while maintaining reliable electrical connectivity.
Solution Approach 2:
The tubular body serves multiple functions: it provides structural support, receives and protects the ferrule, guides cable insertion, and enables rotational adjustment. This multi-functionality reduces the number of separate components needed, simplifying the overall assembly process and reducing assembly time while maintaining connection reliability.
3Adaptability or versatility
If a terminal assembly with radial offset tongue is used, then variable clocking is achieved, but the design becomes complex and costly
Solution Approach 1:
The tubular body is designed to rotate about its longitudinal axis, allowing dynamic adjustment of the ferrule and cable orientation relative to the busbar connection. This dynamic capability provides variable clocking and adaptability for different cable routing scenarios without requiring a complex radially offset tongue design, thereby reducing overall design complexity while maintaining versatility.
Data Source
AI summary
A terminal assembly for a cable includes an elongated tongue adapted for connection with a busbar and a tubular body disposed about a central axis. The tubular body has an end-wall integral with one end of the elongated tongue and a recess. The elongated tongue extends from a mid-portion of the end-wall and is co-axial with the central axis. The terminal assembly includes a ferrule coaxial with the tubular body. The ferrule has a tubular portion and a projection adapted for receipt by the recess. The tubular portion defines a cylindrical recess to receive a free end of the cable therein. Further, at least one of the tubular body and the ferrule defines a plurality of external threads. The terminal assembly includes a coupling member defining a plurality of internal threads to engage with the plurality of external threads on at least one of the tubular body and the ferrule.