Spring-Loaded Clamping Element Anti-Direct Plugging Design
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Solution Overview
Problem
Existing spring-loaded clamping elements fail to effectively prevent direct plugging of flexible conductors, particularly multi-wire conductors, due to inadequate design features that allow automatic opening during conductor insertion.
Innovation Solution
The clamping element features a clamping section with a first section at an obtuse angle to the busbar and a second section at an acute angle, preventing direct insertion while ensuring secure clamping through the spring force, and includes a frame element for self-support and optimized contact edge for enhanced clamping force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the clamping leg is slightly bent over in the direction of the busbar to improve clamping force, then the clamping force is improved, but direct plugging of flexible conductors becomes possible
Solution Approach 1:
The clamping leg is divided into multiple sections (first section bent over, second section bent back) with different orientations. The first section provides clamping force while the second section prevents direct plugging by presenting a transverse barrier to conductor insertion.
Solution Approach 2:
The clamping leg features asymmetric bending with different angle sections. The first section has a specific bend angle for optimal clamping, while the second section has a different orientation (transverse to insertion direction) to block direct plugging, creating an asymmetric profile that serves dual functions.
2Ease of operation
If the clamping section is made straight for easy conductor insertion, then ease of operation is improved, but clamping force is reduced
Solution Approach 1:
The clamping section is segmented into multiple bent portions rather than being straight. Each segment serves a specific function: one segment facilitates conductor approach while another segment provides the bending force for clamping, achieving both ease of operation and sufficient clamping force.
Solution Approach 2:
The clamping leg incorporates curved/bent sections instead of straight lines. The bends in the clamping leg create mechanical advantage for applying clamping force while the overall configuration still allows conductor insertion through proper spatial arrangement.
3Ease of manufacture
If the clamping leg has a simple U-shape for easy manufacture, then manufacturing complexity is reduced, but the ability to prevent direct plugging is insufficient
Solution Approach 1:
While maintaining the basic U-shaped structure for manufacturability, the clamping leg is segmented with additional bends in specific locations. This adds the anti-plugging functionality without completely redesigning the basic U-shape, keeping manufacturing relatively simple.
Solution Approach 2:
The simple U-shape is maintained in the main body for easy manufacture, but local modifications (additional bends in the clamping leg) are introduced specifically in the regions where anti-plugging functionality is needed, without complicating the entire structure.
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
This design effectively prevents direct insertion of multi-wire conductors and securely clamps single-wire conductors, ensuring reliable electrical connection and mechanical stability.
Implementation Method 1
a spring-loaded clamping element with a busbar and a clamping spring
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A spring-loaded clamping element (1) is described having a bus bar (2) and a clamping spring (3) that has a contact limb (4), a spring arc (5) adjoining said contact limb (4) and a clamping limb (6) adjoining said spring arc (5), said clamping limb having a main portion (8) that extends from the spring arc (5) and a clamping portion (7) oriented in the direction of the bus bar (2). The clamping portion (7) has a clamping edge (11) at a free end of the clamping portion (7) for forming a clamping point between the clamping edge (11) and the bus bar (2) for clamping an electrical conductor. The clamping portion (7) has a first portion (9) which is bent from the main portion (8) in the direction of the bus bar (2) and a second portion (10) which has the clamping edge (11), adjoins the first portion (9) and is bent again back in the direction of extension of the main portion (8). When the clamping spring (3) is in a resting position in which there is no electrical conductor inserted and the clamping edge (11) rests on the bus bar (2), the first portion (9), viewed in the direction of extension (FR) of the clamping spring (3) starting from the spring arc (5), is at an obtuse angle α to the bus bar (2) and the second portion (10) is at an acute angle ß to the bus bar (2).