Universal Power Cable Connector Assembly for Multi-Size Installation
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Solution Overview
Problem
Existing power cable connectors for telecommunications equipment require different terminal blocks for various cable sizes, making installation difficult and labor-intensive, thereby increasing costs.
Innovation Solution
A power cable connector assembly that includes a main body, back cover, female conductor pins, insulator, seals, and a locking nut, allowing for the connection of multiple different sizes of conductor power cables, reducing installation time, and lowering costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different terminal blocks are used for different sized cables, then proper electrical connections are achieved, but installation difficulty and labor intensity increase
Solution Approach 1:
The connector body is designed with a universal structure that can accommodate multiple cable sizes (e.g., 1/2 inch, 3/4 inch, 7/8 inch) through adjustable components. The clamp mechanism can be repositioned along the connector body to secure different cable diameters, eliminating the need for multiple specialized terminal blocks while maintaining reliable electrical connections for each cable size.
2Reliability
If different terminal blocks are used for different sized cables, then proper electrical connections are achieved, but installation time increases
Solution Approach 1:
The universal connector design allows a single terminal block to handle multiple cable sizes, eliminating the time required to select and switch between different terminal blocks. The clamp mechanism can be quickly repositioned to accommodate different cable diameters, significantly reducing installation time while ensuring proper electrical connections for each cable size.
3Reliability
If different terminal blocks are used for different sized cables, then proper electrical connections are achieved, but costs increase
Solution Approach 1:
The connector design consolidates multiple terminal block functions into a single universal unit. By using one adjustable connector body with repositionable clamps instead of maintaining inventory of multiple specialized terminal blocks, manufacturing costs are reduced through standardized production processes and reduced part variety, while electrical connection reliability is maintained across all cable sizes.
Data Source
AI summary
The present disclosure describes a power cable connector. The connector includes a main body having a bore therethrough, a first threaded section, and a second threaded section; a back cover having a third threaded section configured engage the first threaded section of the main body; a pair of female conductor pins configured to be coupled to inner conductors of a power cable; an insulator having one or more recesses extending along an outer surface and a fourth threaded section configured to engage with the second threaded section of the main body, the insulator having a pair of inner channels extending therethrough sized to receive the pair of female conductor pins; an end cap including one or more recesses; and a locking nut including one or more protrusions extending radially inward. When the locking nut is inserted onto the insulator and end cap, the one or more recesses of the insulator and one or more recesses of the end cap are configured to receive and guide the one or more protrusions of the locking nut to secure the end cap to the insulator. Connector assemblies are also described herein.