Fastener-Activated Wedge Cable Connector for Secure Clamping
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Solution Overview
Problem
Existing wedge type electrical connectors require multiple components and complex assembly processes to achieve secure electrical and mechanical connections between conductors in transmission and distribution circuits, which can be cumbersome and prone to over-tightening.
Innovation Solution
A simplified wedge type electrical connector assembly integrating a conductor interface with a fastener-activated wedge, featuring a C-shaped frame, guide walls, and a breakaway fastener head to reduce component count and facilitate easy assembly and secure clamping without over-tightening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components are used in traditional wedge type electrical connectors, then the connection can be secure and reliable, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines the conductor interface and fastener-activated wedge into a single integrated connector assembly. The C-shaped frame with curved top and bottom walls forms a unified structure that simultaneously provides conductor guidance, wedge support, and clamping functionality, eliminating the need for separate components and simplifying the assembly process while maintaining secure electrical and mechanical connections
2Ease of operation
If traditional fasteners are used without breakaway features, then the fastener can be tightened freely, but over-tightening may damage the conductors or connector components
Solution Approach 1:
The fastener head incorporates a breakaway feature designed with a predetermined failure point that will break if excessive torque is applied. This preliminary design feature prevents over-tightening damage before it can occur, allowing operators to tighten the fastener freely without risk of damaging conductors or connector components
3Manufacturing precision
If the wedge assembly requires precise alignment during assembly, then the connection quality can be high, but the assembly process becomes more difficult and time-consuming
Solution Approach 1:
The C-shaped frame incorporates curved top and bottom walls that guide the wedge assembly into proper alignment during insertion. The curved surfaces provide natural alignment paths that accommodate minor positioning variations, ensuring the wedge body correctly engages with the conductors and frame without requiring precise manual alignment, thus maintaining high connection quality while simplifying assembly
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 solution provides a more efficient and secure electrical and mechanical connection between conductors, reducing the number of components needed and preventing over-tightening, thus enhancing ease of use and reliability in transmission and distribution circuits.
Implementation Method 1
The primary contact surface is adapted to contact the main conductor and the secondary contact surface is adapted to contact the bail or tap conductor when the wedge body is moved from the conductor receiving position to the conductor clamping position
Data Source
AI summary
An electrical connector adapted to electrically and mechanically connect a main conductor to a bail or tap conductor includes a C-shaped frame having a curved top wall adapted to fit over a main conductor and a curved bottom wall adapted to receive a bail or tap conductor. A fastener-operated wedge assembly is carried within the frame between a conductor receiving position and a conductor clamping position. The wedge assembly has a wedge body with a primary contact surface adapted to contact the main conductor and a secondary contact surface adapted to contact the bail or tap conductor when the wedge body is moved from the conductor receiving position to the conductor clamping position. The fastener positively moves the wedge body between the positions so that the clamping action of the connector can be tightened or loosened as desired.