Compact Marshalling Terminal with Nested Clamping Spring
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Solution Overview
Problem
Existing marshalling terminals have a large width perpendicular to the mounting rail, making them inefficient and difficult to integrate into compact wiring systems.
Innovation Solution
The design incorporates a clamping and contact cage with extensions and clamping springs that form connections with busbar elements and conductor tracks, allowing for compact and cost-effective connections, including direct plug-in technology for conductors and soldering or welding options, while also providing protection against incorrect wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional marshalling terminals are designed with sufficient clamping force and contact reliability, then connection reliability is improved, but the width perpendicular to the mounting rail increases
Solution Approach 1:
The clamping spring is integrated within the clamping and contact cage structure, with the spring nested inside the cage's hollow body. This nesting arrangement allows the clamping mechanism to be contained within the existing footprint, eliminating the need for additional external space while maintaining full clamping functionality.
Solution Approach 2:
The connection means extend in the longitudinal direction (along the mounting rail) rather than requiring additional width perpendicular to the rail. By orienting the connection features along the length of the terminal, the design achieves reliable busbar connection without increasing the critical width dimension.
2Adaptability or versatility
If multiple connection functions are integrated into a single device, then device versatility is improved, but device complexity increases
Solution Approach 1:
The clamping and contact cage serves multiple functions simultaneously: it provides the clamping structure, houses the clamping spring, forms electrical contact with conductors, and provides connection means for busbar elements. This multi-functionality is achieved by designing the cage as a hollow body with integrated connection features (protrusions or recesses) that enable both conductor clamping and busbar connection without requiring separate components.
3Area of stationary object
If compact design is implemented to reduce width, then space efficiency is improved, but manufacturing complexity may increase
Solution Approach 1:
The clamping spring and clamping and contact cage are manufactured as a single integrated component or pre-assembled unit. The spring is positioned within the hollow body of the cage, and their connection means are aligned to work together as a unified system. This merging reduces the number of separate parts to manufacture and assemble, offsetting the complexity of the compact integrated design.
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 solution enables easier and more secure connections in a compact form, reducing the risk of incorrect wiring and enhancing the efficiency of terminal block design by allowing for direct plug-in connections and secure busbar element integration.
Implementation Method 1
at least one clamping spring (3), which serves as a spring element for applying a contact force to a conductor
Data Source
Figure 1a~1d
Figure 2
Figure 3a~3d
AI summary
A connecting device (1) in direct-plug design, comprising a clamping and contact cage (2), a V-shaped clamping spring (3) having a base limb (4) and at least one clamping limb (5, 6), wherein means, particularly shoulders and/or ribs, are designed on the clamping and contact cage (2), which in interaction with each other form a further connection (21) for connecting a conductor rail element, or means, particularly one or more shoulders and/or ribs, are designed on the clamping and contact cage (2) and on the clamping spring (3), which in the interaction with each other form a further connection (21') for connecting a conductor rail element (12), or the connecting device is provided for a shunt terminal and a means, particularly a shoulder and/or rib, is designed on the clamping and contact cage (2), said means forming a further connection (21") for the connection, in particularly the bonded connection, of a conductor track (121) or a conductor rail element (12).