Fastener-Activated Wedge Cable Connector for Simpler Tap Clamping
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Solution Overview
Problem
Existing wedge type electrical connector assemblies for transmission and distribution circuits are complex, with multiple components that increase assembly time and complexity.
Innovation Solution
Integration of a conductor interface with a fastener-activated wedge assembly within a C-shaped frame, reducing the number of components and simplifying the connection process between main and tap conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate components are used for conductor interface and wedge assembly, then each component can be optimized independently, but the overall assembly complexity and assembly time increase
Solution Approach 1:
The patent combines the conductor interface and wedge assembly into a single integrated unit. The wedge assembly includes a wedge body with contact surfaces for both the main conductor and tap conductor, eliminating the need for separate interface components. This integration reduces the number of parts, simplifies assembly procedures, and decreases overall assembly time while maintaining the ability to optimize the entire assembly as a unified structure.
2Adaptability or versatility
If multiple separate components are used for conductor interface and wedge assembly, then component flexibility is improved, but assembly time increases
Solution Approach 1:
The integrated wedge assembly consolidates multiple functions into a single component that can be installed in one operation. The wedge body simultaneously provides conductor support, electrical contact, and mechanical clamping through its integrated structure with contact surfaces for both main and tap conductors, eliminating sequential assembly steps and reducing total installation time.
3Reliability
If a traditional multi-component connector assembly is used, then component functionality can be independently optimized, but the number of components and assembly steps increase
Solution Approach 1:
The patent integrates the wedge body with embedded contact surfaces for both main conductor and tap conductor into a single assembly unit. This unified structure maintains reliable electrical and mechanical connections while reducing the number of assembly steps. The wedge body itself serves as both the structural element and the electrical contact element, eliminating the need for separate contact components and improving assembly efficiency.
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 reduces assembly time and complexity by integrating the conductor interface and wedge assembly, enhancing the electrical and mechanical connectivity between conductors in transmission and distribution circuits.
Implementation Method 1
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.
Data Source
AI summary
An electrical connector is disclosed which is particularly adapted to electrically and mechanically connect a main conductor to a bail or tap conductor. The connector 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. A head portion of the fastener may include a breakaway feature to help prevent over tightening of the fastener.