Wedge Connector Lubricant Coating for Cable Strand Alignment
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Solution Overview
Problem
Existing methods for connecting electrical cables using wedge connectors often result in 'bird caging,' where conductor strands are misaligned, leading to poor connections, damage, and increased corrosion due to the high-speed impact of explosive tools.
Innovation Solution
A wedge connector system with a lubricant coating and a hydraulic power drive tool assembly that drives the wedge member into the sleeve cavity at a controlled rate of no more than 12 inches per second, preventing strand misalignment and ensuring proper engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If an explosively driven connecting tool is used to drive the wedge member at high velocity, then the connection is made quickly and the cables are prevented from bird caging, but the high speed causes conductor strands to misalign and creates bulging that leads to corrosion and increased electrical resistance
Solution Approach 1:
The patent changes the speed parameter from high velocity (explosive) to controlled low velocity (hydraulic), and introduces a lubricant coating to change the friction parameter, allowing slow driving without bird caging while maintaining strand alignment
Solution Approach 2:
The lubricant coating acts as an intermediary between the wedge member and conductor strands, reducing friction to prevent bird caging while allowing controlled slow movement that maintains strand alignment
2Productivity
If an explosively driven connecting tool is used, then the wedge member is driven quickly into position, but the high velocity causes bulging that allows corrosive elements to penetrate and deteriorate the conductor
Solution Approach 1:
The patent changes the driving speed parameter from high to low, and introduces lubrication to change the friction parameter, eliminating bulging while still achieving connection through controlled deformation
Solution Approach 2:
The patent converts the potentially harmful effect of friction (which causes bird caging at high speed) into a beneficial lubricated sliding action that allows slow controlled movement without strand misalignment or bulging
3Speed
If an explosively driven connecting tool is used, then the wedge member is driven at high speed, but this increases stress on the tool assembly and reduces its service life
Solution Approach 1:
The patent changes the speed parameter from high to low, which reduces the dynamic loads and stress on the tool assembly, thereby increasing durability and service life while still achieving the connection function
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 lubricant coating reduces friction, preventing 'bird caging' and ensuring a reliable, corrosion-resistant connection while reducing the stress on the tool assembly and extending its service life.
Implementation Method 1
a lubricant coating disposed on at least one of the sleeve member and the wedge member
Data Source
AI summary
A connector system for connecting first and second elongate conductors includes a wedge connector and a hydraulic power drive tool assembly. The wedge connector includes: a sleeve member defining a sleeve cavity and mountable on the first and second conductors; a wedge member; and a lubricant coating disposed on at least one of the sleeve member and the wedge member. The hydraulic power drive tool assembly is adapted to drive the wedge member into the sleeve cavity when the sleeve member is mounted on the first and second conductors to secure the wedge connector to each of the first and second conductors. According to some embodiments, the lubricant is a wax.