Angled Test Plug with Break-Before-Make Fingers
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Solution Overview
Problem
Existing test plugs require manual wiring for connection and reconnection to test switches, and the accessibility of the connection surface is limited, making the process inefficient and cumbersome.
Innovation Solution
A test plug design featuring a housing with angled inputs for easy access, fingers that break connections before making electrical contact with the test switch jaws, and blades that engage with the test switch for secure contact, allowing for automatic disconnection and reconnection without manual wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual wiring of leads is used to connect test plugs to test switches, then connection can be made, but the process is inefficient and cumbersome
Solution Approach 1:
The patent replaces manual wiring operations with a mechanical plug-and-blade connection system. The test plug insert automatically engages with test switch jaws through inserted blades, eliminating the need for manual lead wiring. This mechanical substitution transforms a labor-intensive manual process into an automated mechanical engagement, directly improving connection efficiency and reducing manual effort.
2Ease of operation
If test plug connection surface is made accessible, then ease of use improves, but connection surface accessibility is currently limited
Solution Approach 1:
The patent angles the first side of the housing relative to the base, creating an oblique connection surface that protrudes from the main housing body. This dimensional change in the housing structure brings the electrical connector inputs into a more accessible position, allowing operators to easily access and connect test leads without strain, thereby improving ease of operation while maintaining structural integrity.
3Reliability
If fingers extend beyond blade end surface, then connection breaking is ensured, but structural complexity increases
Solution Approach 1:
The patent designs the fingers to extend beyond the end surface of the blades, enabling the fingers to break the connection between current jacks and test switch jaws before the blades make contact. This preliminary action ensures safe disconnection by removing existing connections before establishing new ones, preventing electrical arcing or short circuits. The increased structural complexity is justified by the critical safety and reliability function this sequence provides.
Data Source
AI summary
A test plug has a housing with a first side that has inputs for receiving various connection types, a second side having blades and fingers extending thereform, and a base. The first side extends at an oblique angle from the base, providing accessibility to the input connections thereon. The second side is capable of a removable connection to a test switch in which the fingers separate the current jack contacts before the electrical connection between the test plug blades and test switch jaws is made.