Conductor Clamping Structure for Flexible Stranded Wire Reinsertion
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Solution Overview
Problem
Existing conductor clamping devices fail to safely and repeatedly contact flexible multi-wire stranded conductors, leading to malfunctions and difficulties during repeated insertions.
Innovation Solution
A conductor clamping device with a ladder system in the clamping area, featuring extended V-shaped bends that guide the conductor strands, preventing them from spreading, and an open-edge recess for secure spring contact, ensuring reliable and repeatable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional conductor clamping device is used, then rigid solid or rigid stranded conductors can be contacted reliably, but flexible stranded conductors cause malfunctions and cannot be contacted reliably
Solution Approach 1:
The housing is divided into three regions with different cross-sectional shapes: the insertion region has a first cross-sectional shape, the clamping region has a second cross-sectional shape, and the end region has a third cross-sectional shape adapted to the inserted conductor arrangement. This local differentiation allows each region to be optimized for its specific function, enabling reliable contact of flexible stranded conductors while maintaining performance for rigid conductors
2Reliability
If a conductor is clamped with sufficient force to ensure reliable contact, then contact reliability improves, but the conductor strands spread out and become difficult to reinsert
Solution Approach 1:
The clamping device is segmented into distinct functional regions: the insertion region for guiding conductor insertion, the clamping region for applying contact force, and the end region for preventing strand spreading. This segmentation allows the clamping force to be applied locally without causing overall conductor deformation, enabling easy reinsertion while maintaining contact reliability
Solution Approach 2:
The housing cross-sectional shape varies along the insertion direction, creating a three-dimensional graduated structure. The end region's cross-sectional shape is specifically adapted to match the inserted conductor arrangement, providing lateral guidance in the third dimension and preventing strand spreading while allowing smooth reinsertion
3Ease of manufacture
If the housing cross-section is uniform throughout, then manufacturing is simplified, but flexible conductors cannot be properly guided and cause malfunctions
Solution Approach 1:
Rather than using a uniform cross-section, the housing employs locally optimized cross-sectional shapes in different regions. The end region's cross-sectional shape is specifically adapted to the inserted conductor arrangement, providing necessary guidance and support for flexible conductors while maintaining manufacturing feasibility through systematic design
4Reliability
If the bends are extended deeply into the housing to guide conductors, then lateral guidance improves, but the device complexity increases
Solution Approach 1:
The housing is segmented into three regions with progressively different cross-sectional characteristics. The bends are extended into the end region where the cross-sectional shape is adapted to provide lateral guidance, but the guidance is concentrated in the specific region where it is most needed, avoiding unnecessary structural complexity in other regions
Solution Approach 2:
Rather than extending bends throughout the entire housing length, the guidance function is localized to the end region by varying the cross-sectional shape in that specific area. This dimensional approach provides effective lateral guidance only where required, simplifying the overall structure while maintaining guidance 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 design ensures safe and repeatable contact of flexible multi-wire conductors, preventing strand displacement and deformation, allowing easy reinsertion and maintaining secure connections.
Implementation Method 1
a clamping spring (19) which is attached to the base (6) in the clamping region (12) and which acts on the inserted electrical conductor (2) in the clamping region (12)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a conductor clamping device (1) for clamping contact of at least one electrical conductor (2), comprising a contact housing (4) with a housing base (6) and housing walls (8) formed on its longitudinal edges, the housing walls having angled sections (9) at their free ends. The angled sections (9) are designed such that each angled section (9) has a front insertion area (11) in the insertion direction (X) of the electrical conductor (2) and a clamping area (12) adjoining it. In the insertion area (11) and in the clamping area (12), the respective angled sections (9) are shaped such that a conductor contact is formed for the inserted electrical conductor (2), which is V-shaped in cross-section. Two contact areas extending in the longitudinal direction of the conductor are provided for the electrical conductor (2).In the area of the clamping section (12), a clamping spring (19) is attached to the base of the housing (6). This clamping spring has at least one leg extending from the base of the housing (6), so that the inserted electrical conductor (2) is pressed against its conductor assembly by the spring force of the clamping spring (19). A rear end section (13) adjoins the clamping section (12) in the insertion direction (X). This end section has a conductor assembly whose cross-sectional shape is adapted to the V-shaped conductor assembly of the insertion section (11). The bends (9) in the end section (13) are extended at their free end such that, in the end section (13), the bends (9) extend towards the base of the housing (6) over at least half the height of the inserted and clamped conductor (2) with its maximum permissible diameter. Furthermore, the invention comprises a base for an electrical installation device comprising at least one conductor clamping device (1) according to the invention.