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 misuse.
Innovation Solution
A cam-type wire connector with a housing, conductor, and lever system, featuring a cam-shaped operating portion that automatically returns to a specific position, preventing accidental closure and providing tactile feedback to ensure correct operation, and incorporating positioning structures to prevent excessive rotation and misuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the manipulator is rotated against frictional force to change the clamping spring state, then the wire can be released or clamped, but the lever may accidentally return to closed state due to accumulated rotation amplitude
Solution Approach 1:
The patent inverts the traditional rotary support area into a cam-shaped support area with a specifically designed cam profile. Instead of allowing free rotation, the cam profile guides the manipulator through a controlled path that includes a push-back phase, ensuring the lever returns to a predetermined position rather than allowing accidental closure through accumulated rotation.
Solution Approach 2:
The patent changes the geometric parameters of the support area from a simple circular arc to a cam profile with specific curvature variations. This cam profile includes regions with different radii of curvature that create varying frictional forces and mechanical advantages, controlling the manipulator's movement to prevent accidental state changes while maintaining reliable wire connection.
2Ease of operation
If the lever is made movable and swingable for operation, then the wire connector can be opened and closed, but the lever may be pushed into position incorrectly causing breakage
Solution Approach 1:
The patent incorporates tactile feedback mechanisms through the cam profile design, where the manipulator encounters specific resistance points and positioning features during its movement. These feedback signals guide the user to apply force at the correct position and magnitude, preventing incorrect operation that could lead to lever breakage while maintaining ease of use.
3Ease of manufacture
If the rotary support area has a simple shape for easy manufacturing, then production is simplified, but the lever cannot provide tactile feedback for correct operation
Solution Approach 1:
The patent applies local quality by creating a cam profile with specifically engineered variations in curvature and friction characteristics at different locations. Rather than uniform simplicity, the support area has localized complex features where needed to provide tactile feedback, while other regions remain simpler for manufacturing. This selective complexity achieves both manufacturability and operational feedback.
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 maintains the wire in a specific position, preventing accidental release or closure, enhancing user experience through tactile feedback and ensuring proper operation, while preventing lever breakage from misuse.
Implementation Method 1
The contour of the operating portion is formed as a cam so that the operating portion is capable of swinging with a non-fixed axial, and the elastic member is capable of deformed by the cam
Implementation Method 2
A plurality of elastic members is formed with an end of the wire clamping portion that far away from the carrier plate for extending toward the carrier plate
Data Source
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.