Wedge Connector Assembly With C-Shaped Spring
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Solution Overview
Problem
Conventional electrical connectors for power distribution systems, such as bolt-on and compression connectors, face issues with inconsistent and unreliable connections due to torque dependency and skill variability, while wedge connectors are costly and require a large inventory of parts to accommodate various conductor sizes.
Innovation Solution
A wedge connector assembly featuring a C-shaped spring member and a wedge member with multiple mating orientations, allowing for consistent clamping force and reduced part inventory through strategic selection of dimensions and orientations to accommodate various conductor sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wedge connectors are used to provide reliable connections, then connection reliability is improved, but device complexity and part inventory requirements increase
Solution Approach 1:
The spring member is designed with a single C-shaped body that can accommodate multiple conductor size combinations through adjustable wedge positions. The spring member serves multiple functions: providing elastic clamping force, accommodating different conductor diameters, and working with the wedge at different positions to create reliable connections for various conductor sizes, eliminating the need for multiple sized connectors
Solution Approach 2:
The spring member is designed as an elastic, deflectable component rather than a rigid structure. The spring can be deflected by the application tool during installation and will deflect differently based on the conductor sizes being connected. This dynamic behavior allows the same spring member to adapt to various conductor size combinations while maintaining reliable electrical connection
2Adaptability or versatility
If multiple wedge sizes are used to accommodate different conductor sizes, then adaptability is improved, but device complexity and cost increase
Solution Approach 1:
The spring member is designed with a single C-shaped body that can accommodate multiple conductor size combinations through adjustable wedge positions. The spring member serves multiple functions: providing elastic clamping force, accommodating different conductor diameters, and working with the wedge at different positions to create reliable connections for various conductor sizes, eliminating the need for multiple sized connectors
Solution Approach 2:
The connector is divided into two functional components: a universal spring member that provides the clamping structure and accommodates various conductor sizes, and a wedge that can be positioned at different locations. This segmentation allows the spring member to remain standardized while the wedge position varies to accommodate different conductor size combinations
3Ease of operation
If bolt-on connectors are used for ease of installation, then ease of operation is improved, but connection reliability deteriorates due to torque dependency
Solution Approach 1:
The spring member is designed to be self-adjusting through its elastic properties. During installation, the application tool deflects the spring member, and the spring automatically returns to its original position, creating consistent clamping force on the conductors. This self-service mechanism eliminates the need for torque-controlled fasteners and ensures reliable connections without depending on installer skill or tool calibration
4Ease of manufacture
If compression connectors are used to reduce cost, then manufacturing cost is improved, but ease of operation deteriorates due to installation difficulty
Solution Approach 1:
The spring member is designed to be self-adjusting through its elastic properties. During installation, the application tool deflects the spring member, and the spring automatically returns to its original position, creating consistent clamping force on the conductors. This self-service mechanism eliminates the need for torque-controlled fasteners and ensures reliable connections without depending on installer skill or tool calibration
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 reliable, repeatable, and cost-effective connection that maintains consistent clamping force across different conductor sizes, reducing the need for multiple parts and improving installation convenience compared to conventional systems.
Implementation Method 1
a spring member having a generally C-shaped body with an inner surface... configured to deflect and clamp the conductors
Data Source
AI summary
A wedge connector assembly includes a spring member having a generally C-shaped body with an inner surface, and a wedge member having opposed first and second sides. The wedge member is mated with the spring member such that the wedge member is configured to securely retain a first conductor between the first side and the spring member and a second conductor between the second side and the spring member. The wedge member has at least two final mating positions based on the orientation of the wedge member with respect to the spring member. Optionally, the wedge member may have two orientations, namely a first orientation and a second orientation, wherein the first and second sides are flipped with respect to one another in the first and second orientations. A top of the wedge member may engage the inner surface in the first orientation and a bottom of the wedge member may engage the inner surface in the second orientation.