Cam-Type Wire Connector Lever Mechanism
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Solution Overview
Problem
Existing wire connectors with levers can accidentally release or fix wires due to the elasticity of the clamping spring, leading to operational inconvenience and potential breakage from user misunderstanding.
Innovation Solution
A cam-type wire connector with a housing, conductive member, and lever system, featuring a cam-shaped operating portion that deforms the elastic member to prevent accidental closure and provides distinct tactile feedback for user guidance, incorporating positioning structures to ensure the lever remains in the actuated position and securely clamps wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the manipulator is rotated by toggling the lever against frictional force between the manipulator and support groove, then the wire clamp can be opened or closed, but the device may accidentally release or fix the wire after multiple unintentional collisions and rotations
Solution Approach 1:
The patent transforms the static rotary support area into a dynamic cam mechanism with a specifically designed cam contour. The cam profile includes a first cam surface for opening the clamp and a second cam surface for closing it, creating asymmetric mechanical advantage that prevents accidental state changes while maintaining easy manual operation. The lever oscillates between limited angular positions rather than rotating freely.
Solution Approach 2:
The cam mechanism is designed with predetermined cam surfaces that apply counteracting forces to prevent the spring from accidentally returning the lever to the closed state. The first and second cam surfaces are shaped to resist the spring's elastic force in the released state, requiring deliberate user action to overcome this preliminary anti-action and change the clamp state.
2Ease of operation
If the lever is made movable and swingable to operate the wire clamp, then the user can open or close the clamp, but the user may misunderstand that the lever has not been pushed into position and continue to force the lever, resulting in breakage
Solution Approach 1:
The patent incorporates tactile feedback mechanisms including a push-button that must be depressed to actuate the lever, and a snap-action mechanism that provides audible and tactile confirmation when the lever reaches its actuated position. The cam mechanism creates distinct mechanical resistance and release points that give the user clear feedback that the operation is complete, preventing excessive forcing.
Solution Approach 2:
The lever mechanism requires a preliminary action of depressing the push-button before the lever can be actuated. This preliminary action prepares the mechanism by releasing a latch or engaging the cam follower, ensuring that the user follows the correct sequence and does not apply excessive force directly to the lever without proper engagement.
3Reliability
If the cam mechanism is designed to prevent accidental release, then the lever remains stable in actuated position, but the device complexity increases with additional positioning structures
Solution Approach 1:
The patent merges multiple functions into the cam mechanism itself. The cam contour simultaneously provides the opening path, closing path, positioning stops, and tactile feedback. The first and second cam surfaces are integrated into a single cam component that works with the lever's oscillating motion, eliminating the need for separate positioning structures and reducing overall device complexity while maintaining reliability.
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 cam-type wire connector effectively prevents accidental release or fixation of wires, enhances user experience through tactile feedback, and ensures proper operation by maintaining the lever in the actuated position, securely clamping wires and preventing breakage.
Implementation Method 1
the elastic member is capable of deformed by the cam
Implementation Method 2
a leaf spring pressing the wire against the conductive member
Implementation Method 3
the spring will revert to the closed state from the released state due to the elasticity of the clamping spring
Data Source
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AI summary
A cam-type wire connector includes a housing, a conductor, and a lever. The housing has a plurality of insertion holes; the conductor comprises a conductive member and a leaf spring, the leaf spring has a carrier plate and a wire clamping portion that is formed with a plurality of windows. Wherein an elastic member is formed with the wire clamping portion for blocking the window; the lever has an operating portion and a toggle portion for cooperating with the leaf spring, the operating portion is constructed with a cam to allow the lever to swing without a fixed axis. When the lever is changed from an initial position to an actuate position, the elastic member is moved away from the carrier plate and an insertion channel is formed for allowing the wire to enter the window. The insertion channel is located in the interval between the second positioning surface and the fixed surface.