Wedge Connector Installation Tool Limit Indicator
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Solution Overview
Problem
Conventional wedge connector installation tools often experience over-torquing during preparation, leading to difficulty in removing the tool after installation due to residual gas in the tool housing.
Innovation Solution
A limit indicator is integrated onto the ram of the installation tool, allowing users to visually determine the appropriate torque level by hiding when the tool is in the firing position, preventing over-torquing and ensuring the tool can be easily removed post-installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If torque is applied to compress the spring and move the load cell adjacent to the firing pin to put the installation tool in a firing position, then the tool is ready for operation, but over-torquing causes the ram to start pushing the wedge into the sleeve prematurely
Solution Approach 1:
The limit indicator uses visual indication (color change or visibility change) to signal to the operator when the correct torque has been applied. The indicator is positioned such that it becomes visible or changes appearance at the precise moment the ram contacts the wedge, preventing over-torquing without requiring complex mechanical stops or sensors.
2Productivity
If the ram pushes the wedge into the sleeve during over-torquing, then the connection is made, but gas remains in the tool housing after firing preventing easy tool removal
Solution Approach 1:
The limit indicator provides preliminary visual feedback before the firing operation completes, alerting the operator to stop applying torque before gas generation begins. This preliminary indication prevents the harmful condition of residual gas in the housing that would otherwise make tool removal difficult.
3Device complexity
If no limit indicator is provided, then the tool structure is simpler, but users cannot visually determine the appropriate torque level
Solution Approach 1:
A simple visual indicator is added to the tool that changes appearance or becomes visible at the correct torque level. This provides precise torque level detection through color change or visibility change without significantly increasing device complexity, as the indicator is integrated into the existing ram or housing structure.
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 limit indicator effectively prevents over-torquing, allowing for proper gas expulsion and easy removal of the installation tool from the wedge connector, facilitating efficient tool reuse.
Implementation Method 1
Torque is applied to the installation tool to compress the spring and move the load cell adjacent to the firing pin
Implementation Method 2
When the installation tool is fired, gas is generated in the tool housing to drive the wedge into the sleeve
Data Source
Figure 1
Figure 2~5
Figure 6~7
AI summary
A wedge connector assembly including an installation tool (21) having a tool body (23) and a frame (41) connected to the tool body. A sleeve (61) is received by the frame and a wedge (81) is received by the sleeve. A firing mechanism is movably connected to the tool body. A movable ram (91) extends from the tool body into the frame such that movement of the ram drives the wedge (81) into the sleeve when the installation tool is fired. A piston (28) is movably disposed in the tool body between the ram and the firing mechanism. The piston (28) is moved when the firing mechanism is activated, thereby driving the wedge into the sleeve. An indicator (95) disposed on the ram indicates when the installation tool (21) is in a proper firing position to substantially prevent over-torquing the installation tool.