Looking for a more reliable method for securing connections in high vibration installations. Locking wedge washers like Nord-Locks seem like a good choice. The seem to test better than belleville/conical washers from what I have read. I am mainly thinking for inverter and battery connections.
Any thoughts?
Hi.
Regarding any vibration issues, the most effective solution is to eliminate the source entirely. Constant vibration can adversely affect system elements, including PCBs, internal components, and displays, ultimately shortening the lifespan of most components.
If removing the vibration is not feasible, I recommend using a longer bolt torqued to the correct setting for the materials involved. On the side where the bolt emerges, use either a double nut or a ny-loc nut to secure it, provided there is sufficient surface area to ensure a stable connection.
I have also used this paste in the past on certain customers applications, though I only recommend this for specific applications, it may or may not be for you.
I am sure others will have good suggestions/comments to add.
Good luck
Dave.
Only for mechanical connections, meaning steel bolt/nut on steel part. The teeth of the nordlocks dig too much into aluminium or copper for my taste. So for electrical connections im using NSK-E
Those look nice. A kind of modified conical washer. I have read that it is necessary to use a flat washer under the Nord-lock to prevent the digging in you describe or if you are going over a battery lug.
To me that then defeats the purpose of a nordlock, since you would be again be relying on the friction between the flat washer and the copper busbar. If that friction is enough, then you can use plain washers without any other locking element in the first place
Do you find that split lock washers are insufficient? We use them on all stud connections and find that in mobile environments they work quite well. We eliminate any serrated flange nuts and use split lock washers there, too. These cursed flange nuts come standard on Blue Sea switches, for example. Then, a tiny drop of blue threadlocker on top of the stud/nut interface after the final torque check during commissioning. That should prevent any loosening and also serve as a torque check mark. I’m curious what your experience is. Thanks.
That is nearly identical to my chosen method. And when I have to remove them it is difficult.
I personally have never had my own fasteners loosen but in the troubleshooting and repair side of my business I find it seems to be one of the primary reasons that systems loose efficiency or outright fail. I also hear a fair amount of talk about vibration and thermal creep on this forum that has me nervous.
I am just trying to fail proof my installations to the next level.
That’s admirable! I find that blue threadlocker is easy to remove. Red, not so much. When properly torqued, we don’t have problems with connections loosening over time. I raise absolute hell in our shop when I find an installer has left something loose or didn’t torque check AND mark a connection. Even when it’s all done properly, we aren’t diligent about reminding customers to check and retorque periodically and that’s something we need to do to be better.