Clamping Unit Parallel Spring Arm Busbar Design
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Solution Overview
Problem
Existing electrical connection terminals with clamping springs and pin contacting elements have a large size requirement due to the stacked arrangement of these components, which limits their compactness and efficiency in conductor connection.
Innovation Solution
A clamping unit design where the conductor and pin contact share a common busbar, with a spring arm clamping both components to the busbar, allowing for a parallel arrangement and reduced size, enabling direct conductor-pin contact alignment and adaptable sizing for various pin diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the clamping spring and pin contacting element are arranged one below the other, then the contacting function is achieved, but the overall height and space requirement increase
Solution Approach 1:
The clamping spring and pin contacting element are merged into a single integrated clamping unit where the spring arm serves both functions: clamping the conductor to the busbar and contacting the pin contact. This eliminates the need for separate stacked components, reducing overall height while maintaining reliable electrical contact.
Solution Approach 2:
The spring arm is designed as a multi-functional element that simultaneously performs conductor clamping and pin contact engagement. By making the contacting element serve dual purposes, the design achieves both clamping and contacting functions without requiring additional vertical space for separate components.
2Reliability
If a screw terminal is used to fix the conductor, then the conductor connection is secure, but rigid conductors cannot be directly connected and the actuation effort increases
Solution Approach 1:
The screw-based mechanical fastening system is replaced with a spring-based elastic clamping system. The spring arm automatically clamps the conductor through elastic force, eliminating the need for screw tightening while maintaining secure electrical connection. This substitution reduces actuation effort and enables direct connection of rigid conductors.
Solution Approach 2:
The static screw connection is replaced with a dynamic spring mechanism that automatically adjusts to the conductor. The spring arm's elastic properties allow it to adapt to different conductor types and sizes, providing secure clamping without requiring manual tightening operations.
3Device complexity
If the current path from conductor to pin contact is long, then the terminal structure is simpler, but the voltage drop increases
Solution Approach 1:
The conductor and pin contact are positioned to rest on the same busbar, creating a direct current path through the busbar material. This merging of contact points on a common conductive surface minimizes the current path length and associated voltage drop while maintaining structural simplicity.
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 achieves a compact terminal with reduced voltage drop, lower wear on pin contacts, and improved current transmission efficiency due to a shorter current path and lower surface pressure, while maintaining secure contact with pin contacts of different diameters.
Implementation Method 1
the spring arm (7), which is connected directly to the busbar (2) via the connecting piece (8), in that the spring arm (7) presses the pin contact (5) against the busbar (2)
Implementation Method 2
The inserted conductor is clamped to a first side surface of the busbar by means of the clamping spring (3)
Implementation Method 3
The connecting piece is a flexible joint. The bending joint enables an improved spring effect of the spring arm
Data Source
Figure 1
Figure 2
AI summary
The aim of the invention is to provide a solution by means of which the overall size of an electrical connection terminal (16) can be significantly reduced in a clamping unit (1) of an electrical connection terminal (16). This is achieved in that the clamping unit (1) has a busbar (2), a clamping spring (3) for clamping a conductor to the busbar (2), and a pin contact-making element (4) for making contact with a pin contact (5), wherein the pin contact-making element (4) has a spring arm (7) which is arranged substantially parallel to the busbar (2) and which is connected to the busbar (2) by means of a connecting piece (8).