Versatile Lug Connector for Portable Power Distribution
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Solution Overview
Problem
Conventional systems for temporary and portable power distribution lack versatility and efficiency in rapid connection, disconnection, and reconfiguration of power to multiple loads, often requiring specialized connectors and increasing inventory complexity, especially in confined spaces where polarity errors can be catastrophic.
Innovation Solution
A versatile lug connector with multiple attachment features allowing horizontal, vertical, and side-by-side mounting configurations, enabling simultaneous hardwire and eyelet connections, designed for thousands of installations and re-installations with appropriate torque, reducing the need for specialized connectors and simplifying inventory management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional terminal blocks and connectors are used for temporary power distribution, then connections can be made to multiple loads, but the system lacks versatility for rapid disassembly and reconfiguration, and requires specialized lugs for different mounting styles
Solution Approach 1:
The electrical connector is designed with multiple attachment features including a first attachment feature for compression connectors, a second attachment feature for stud mounted connectors, and a third attachment feature for tunnel mounted connectors. This multi-functional design allows a single connector type to serve multiple mounting configurations, eliminating the need for specialized lugs for different mounting styles and simplifying inventory management.
2Ease of operation
If conventional electrical connectors are used, then power can be distributed to multiple loads, but the connectors are not suited for multiple installations, removals and re-installations due to lack of rapid disassembly provisions
Solution Approach 1:
The electrical connector is designed as a segmented, modular component that can be independently attached and detached from power buses. The connector includes multiple attachment features that allow for tool-free or rapid installation and removal while maintaining secure electrical connections. This segmentation enables the connector to be easily installed, removed, and re-installed multiple times without compromising connection reliability.
3Productivity
If terminal blocks with studs and nuts are used, then electrical connections can be made, but the task is time consuming and subject to defects if proper procedures such as cleaning contacts and torquing nuts are not followed
Solution Approach 1:
The electrical connector incorporates self-aligning and self-securing features that automatically ensure proper connection without requiring operator intervention for cleaning or torquing. The attachment features include integrated contact surfaces and securing mechanisms that self-adjust to achieve optimal electrical contact and mechanical strength, eliminating the need for manual cleaning procedures and torque specifications.
4Area of stationary object
If conventional connectors are used in confined spaces, then power distribution is possible, but the connectors require significant room for proper installation and manipulation
Solution Approach 1:
The electrical connector is designed with a compact, three-dimensional attachment feature arrangement that utilizes vertical and lateral spaces efficiently. The attachment features are positioned on different faces and planes of the connector body, allowing installation in confined spaces where horizontal clearance is limited. This spatial optimization enables proper installation in tight environments without compromising connection quality.
Data Source
AI summary
An electrical connector adapted for portable power distribution systems and other applications in various embodiments includes a versatile lug which may be selectively and repeatedly coupled to a stranded or other conductor and mounted and re-mounted on a bus bar or other mounting surface via a variety of attachment features on the lug. The lug offers numerous ways to attach it to a power bus and is designed for thousands of installations and re-installations each requiring the appropriate torque on the connector rather than a few such installations for which a known connector is designed and rated. The attachment features included in various embodiments of the lug connector allow for horizontal, vertical, side by side and edge clamping among other mounting configurations.