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Resin casting of the aluminum master pattern forms a plastic mold for encapsulating a cable connector. An elastomer is injected into the mold and cured. The mold is disassembled leaving an elastomeric encapsulation around the connector.
Termination adapter replaces braid ring and ensures permanent attachment and grounding of sheath wires. The inner ferrule of the termination is slipped inside the exposed ends of the sheath wires and the outer ferrule is placed over the wires and crimped in place to secure the wires for grounding.
Connection can be made without removing insulation, and connector case insulates splice. Device can be made in various sizes and saves time, especially when working on prototype boards with several interconnecting test leads.
Faults in wiring systems are a serious concern for the aerospace and aeronautic (commercial, military, and civilian) industries. Circuit failures and vehicle accidents have occurred and have been attributed to faulty wiring created by open and/or short circuits. Often, such circuit failures occur due to vibration during vehicle launch or operation. Therefore, developing non-intrusive fault-tolerant techniques is necessary to detect circuit faults and automatically route signals through alternate recovery paths while the vehicle or lunar surface systems equipment is in operation. Electrical connector concepts combining dust mitigation strategies and cable diagnostic technologies have significant application for lunar and Martian surface systems, as well as for dusty terrestrial applications. The dust-tolerant intelligent electrical connection system has several novel concepts and unique features. It combines intelligent cable diagnostics (health monitoring) and automatic circuit routing capabilities into a dust-tolerant electrical umbilical. It retrofits a clamshell protective dust cover to an existing connector for reduced gravity operation, and features a universal connector housing with three styles of dust protection: inverted cap, rotating cap, and clamshell. It uses a self-healing membrane as a dust barrier for electrical connectors where required, while also combining lotus leaf technology for applications where a dust-resistant coating providing low surface tension is needed to mitigate Van der Waals forces, thereby disallowing dust particle adhesion to connector surfaces. It also permits using a ruggedized iris mechanism with an embedded electrodynamic dust shield as a dust barrier for electrical connectors where required.
The reliability, cost and performance of electrical connectors are a concern in all types of electrical systems, and demands on connectors used on photovoltaic (PV) systems include that connectors maintain electrical conductivity and physical strength, endure ultraviolet sunlight and high ambient temperature, and resist moisture and chemical intrusion over a very long (>25 year) performance period. Connector failures increase operation and maintenance (O&M) costs and reduce plant production, but connector failure can also cause safety and liability problems, which are of greater concern. This work results from a three-year collaboration between Sandia National Laboratories (SNL), the Electric Power Research Institute (EPRI), and the National Renewable Energy Laboratory (NREL) and funded by the U.S. Department of Energy (DOE) Solar Energy Technology Office (SETO) under Agreements #39035 and #38531 "Connector Reliability Across the US Solar Sector." a multi-pronged investigation of PV connector health across the US (see https://energy.sandia.gov/pvconnectors/). This report presents derivation of a Techno-Economic Analysis (TEA) that models failure modes and frequencies (how often failure occurs), estimates O&M costs and lost production associated with connector failures, and then calculates the effect that PV module connectors can have on Levelized Cost of Energy (LCOE). The model is informed with initial data from quantitative assessment of failure rates, root causes and mechanisms, in-situ diagnostics and data collection, lab-based forensics, and interviews with PV connector manufacturers and plant operators. SNL conducted site inspections at multiple utility-scale sites in different climates and subjected field samples of new, used, and degraded connectors to visual and electrical characterization. EPRI conducted metallurgical analysis of the pin and sleeve conductors to study failure-induced morphological and compositional changes. There is in general a shortage of statistically valid data, but data from PVROM database maintained by SNL was sufficient to ascertain failure rates and lost production as well as provide qualitative insight in its curated maintenance records. This report details the structure of the mathematical model but the sources of data to inform the model will continue to evolve. Analysis of a 100 MW PV plant is provided as an example of the use of the model, with results indicating that connectors are responsible for Annualized O&M Costs of $\$$71,933/year; Annualized Unit O&M Costs of $\$$0.72/kW/year; that a Reserve Account of $\$$187,220 should be available to fund repairs related to connectors; that connectors add $\$$1,494,004 to the Net Present Value of the O&M Costs (project life); and that O&M related to connectors adds about $\$$0.00088/kWh to the Levelized Cost of Energy. The impact of this model is to provide a tool to make the US solar sector more robust by quantifying and monetizing the reliability risks to utility-scale PV systems posed by poorly installed, mismatched and/or poorly designed and manufactured connectors. The TEA provides a model incorporating failure statistics, O&M cost data, and lost production into a single figure of merit, informing decisions and enabling practitioners to optimize cost and performance trade-offs. Stakeholders include connector manufacturers, system designers and equipment specifiers, standards bodies, installers and O&M providers, investors and insurance underwriters. This report supports continued growth of PV predicated on assurances that properly installed and maintained PV system connectors are safe and reliable. The project team is proposing future work including accelerated testing of connectors and expanding the approach taken here to other PV system components, such as TEA for rapid shut-down devices.
Method of making molded electric connector for use with flat conductor cables
Design and development of electric connectors for rigid and semirigid coaxial cables
A multi-bay electrical connector is described, of the type that has a frame (12, FIG. 2 ) with cavities (14) that each holds a separate module 20, which enables quick withdrawal of a single module from the frame and its quick replacement. A lock arm (42) is slidable along a first side (50) of a first cavity, and has at least one lock lug (80). A first module has a barrier part (70) that lies inward of the lock lug, which prevents outward movement of the first module out of the frame cavity. The lock arm can be moved to an unlocked position wherein the barrier part on the module lies inward of a gap (84) in the lock arm to permit the module to be pulled out of the frame cavity and later inserted therein. A latch (54) is slidable on the frame in directions (A, B) perpendicular to the sliding movement of the lock arm, and has an abutment (112, FIG. 5 ) that abuts a shoulder (114) on the lock arm to keep the lock arm in its unlocked position until the latch is released.
An extractor for separating electrical connectors is disclosed which imparts a prying force to connector elements in a plane normal to the mounting surface. The extractor comprises a lever pivotally connected to a rotatable fork that is adapted to fit under the end of a connector shell. A pair of extractors are deployed at opposite ends of a connector to pry the connector out of its mating socket gently and securely without damage to wires or connecting pins, even under crowded conditions.
Sterilization effects on soldered and welded joints, electronic equipment processes and materials, electric connectors, and wiring and cabling accessories
Research and development of improved electrical connectors for space shuttle systems
Unprotected quick disconnect electrical connectors were exposed to fibers of 3mm, 7mm, and 12mm lengths. The average exposure to failure was determined. Results indicate that when the fiber length divided by the airgap is less than one, multiple fibers are required to bridge the gap, and the exposure time to failure rises rapidly.
Polytetrafluoroethylene tape wrapped around electrical connectors protects them from heat damage during soldering. Tape is easily removed after contacts are joined.
This poster presents an overview of a study of the impact on PV system cost and performance imposed by electrical connectors used to connect PV system components.
Adjustable resistor taps in gain-control feedback loop of the transducer permit wide sensing range, shorting the pins on electrical connector allows selection of appropriate range. Electrical specifications of the transducer and its applications are cited.
Various technologies for integrating a microinverter with a photovoltaic module are disclosed. An alternating current photovoltaic (ACPV) module includes a photovoltaic module having a frame and a junction box including a direct current (DC) output connector, and a microinverter having a housing coupled to the frame and a DC input connector electrically mated with the DC output connector of the photovoltaic module.
A self-aligning electrical connector device includes a receptacle component having a conically contoured interior and a plug component having a correspondingly contoured conical body receivable in the receptacle component. The plug component has a number of spaced conductive ring elements with a mating face and the receptacle component includes corresponding spaced conductive ring elements providing mating interface with the mating face of the ring elements of the plug component when connected to it. Each ring element of the receptacle component has several segmented portions which defect downwardly when the plug component is inserted. A biasing force is asserted against the face of the ring elements of the plug component providing positive electrical contact and connection between the ring elements of the components.
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