Welding Lead Connector Collar With Flip Cover for Arc Protection
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Solution Overview
Problem
Female welding lead connectors pose a significant risk of electrocution and electrical arcing due to exposed conductive material when connections become loose, and existing solutions fail to adequately address these safety concerns.
Innovation Solution
A safety collar with a hingedly connected cover that can rotate between open and closed positions, featuring a torsion spring biasing apparatus and customizable grooves/bulges for secure fitment on various female welding lead connectors, shielding the receptacle and preventing accidental contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the female welding lead connector receptacle is left open and exposed for easy connection, then the ease of operation is improved, but the risk of electrocution and electrical arcing increases
Solution Approach 1:
The safety collar is pre-installed on the female connector with the cover in the closed position, performing the protective action before the connector is needed. The cover is held open by a biasing apparatus only when a male connector is being inserted, automatically providing protection beforehand and eliminating the need for manual intervention.
Solution Approach 2:
The safety collar with its hinged cover acts as an intermediary protective element between the exposed conductive receptacle and the external environment. This intermediate structure shields the receptacle during storage and transport, while still allowing easy access during operation through the automatic opening mechanism.
2Object-affected harmful factors
If a safety cover is added to shield the female receptacle, then the safety is improved, but the device complexity increases
Solution Approach 1:
The safety collar is divided into distinct functional segments: the collar body that fits over the connector, the hinged cover that provides shielding, and the biasing apparatus that enables automatic operation. This segmentation allows each component to perform its specific function efficiently while maintaining overall simplicity.
Solution Approach 2:
The biasing apparatus automatically opens the cover when a male connector is inserted and closes it when removed, eliminating the need for manual operation. This self-service mechanism reduces complexity by removing controls, switches, or manual intervention while maintaining the protective function.
3Reliability
If the safety collar is designed to fit tightly on the connector, then the reliability of protection is improved, but the ease of installation decreases
Solution Approach 1:
The safety collar is constructed from flexible, elastic material that can be easily stretched and molded onto the connector. This flexibility allows the collar to be installed by simply pulling it over the connector body, while the elastic properties ensure it maintains a tight, secure fit once installed, providing reliable protection.
4Object-affected harmful factors
If the cover is always in the closed position for maximum safety, then the protection is improved, but the productivity decreases due to repeated opening and closing
Solution Approach 1:
The cover transitions from a static closed position to a dynamic state that automatically opens when needed. The biasing apparatus creates a spring-loaded mechanism that stores energy in the closed position and releases it to open the cover when a male connector is inserted, eliminating the need for manual opening and closing operations.
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 safety collar significantly reduces the risk of electrocution and electrical arcing by ensuring the female receptacle is shielded, even when the welding lead connector is not in use, and provides a universal fit for different models, enhancing safety and usability.
Implementation Method 1
The biasing apparatus preferably comprises a torsion spring
Data Source
AI summary
A universal female welding lead connector collar including a safety cover hingedly connected to a main body of the collar. When engaged on the outer surface of a female welding lead connector, the safety cover can be kept closed to shield a female welding lead receptacle inside the female welding lead connector to prevent electrical arcing or electrocution.