Wedge Connector Assemblies for High Voltage Power Distribution
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Solution Overview
Problem
Existing electrical connectors for high voltage power distribution systems face challenges in securely connecting main power line conductors with tap conductors of varying sizes, requiring specialized designs that ensure reliable mechanical and electrical connectivity while accommodating different conductor diameters.
Innovation Solution
A wedge connector system comprising a C-shaped sleeve member, a wedge member, and a locking mechanism that captures elongate electrical conductors, applying clamping loads through a sleeve engagement portion and clamping mechanism to ensure secure connections between main and tap conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wedge connectors are designed to accommodate different conductor sizes, then adaptability is improved, but device complexity increases due to multiple wedge sizes required for each channel member
Solution Approach 1:
The wedge member is designed with a universal geometry that can accommodate different conductor sizes within a single channel member, eliminating the need for multiple specialized wedge sizes. The wedge's tapered surface and positioning features allow it to adapt to varying conductor diameters while maintaining secure electrical connection.
Solution Approach 2:
The channel member incorporates adjustable or selective positioning features that can be configured for different conductor sizes. This allows the same wedge member to work effectively with various conductor diameters by modifying the local engagement characteristics rather than requiring entirely different wedge components.
2Reliability
If compression connectors are used to clamp conductors, then connection reliability is improved, but ease of operation deteriorates due to difficult installation and removal
Solution Approach 1:
The connector transitions from a static compression design to a dynamic wedge-based system where the wedge can be inserted and removed along the axis of the channel member. This dynamic insertion/removal mechanism maintains reliable clamping force during operation while significantly improving ease of installation and removal compared to traditional compression connectors.
Solution Approach 2:
The wedge member acts as an intermediary that translates axial insertion force into radial clamping force on the conductors. This mediation allows for easy linear installation while achieving the complex multi-directional clamping action needed for reliable connections, avoiding the difficulty of directly applying compression forces.
3Adaptability or versatility
If bolt-on connectors with multiple connector halves are used, then adaptability is improved for different conductor configurations, but device complexity increases due to multiple separate pieces
Solution Approach 1:
The connector integrates multiple functional elements into a unified structure where the channel member and wedge member work together as a coordinated system. This merging eliminates the need for separate connector halves and multiple discrete pieces while maintaining the ability to accommodate different conductor configurations through the wedge's adaptive geometry.
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 wedge connector system provides a secure, reliable, and adaptable means of connecting conductors of different sizes, ensuring efficient power distribution by maintaining electrical connectivity and withstanding operational forces, while allowing for easy installation and disassembly.
Implementation Method 1
The clamping mechanism can be operated to force the wedge member into the sleeve cavity to apply clamping loads on the first and second conductors
Data Source
AI summary
A wedge connector system for connecting first and second elongate electrical conductors includes a C-shaped sleeve member, a wedge member and a locking mechanism. The sleeve member defines a sleeve cavity and opposed first and second sleeve channels on either side of the sleeve cavity. The wedge member includes a wedge body having first and second opposed wedge side walls. The locking mechanism includes a lock member including a sleeve engagement portion, and a clamping mechanism coupled to the wedge member. The sleeve member and the wedge member are configured to capture the first and second conductors such that the first conductor is received in the first sleeve channel between the sleeve member and the first wedge side wall and the second conductor is received in the second sleeve channel between the sleeve member and the second wedge side wall. The locking mechanism is mountable on the sleeve member and the wedge member such that the sleeve engagement portion interlocks with the sleeve member and the clamping mechanism can be operated to force the wedge member into the sleeve cavity to apply clamping loads on the first and second conductors.