Connection Device Rocker Mechanism Low Insertion Force
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Solution Overview
Problem
Existing connection devices for electrical lines require significant insertion force and are prone to accidental closure due to vibrations or shocks, making them difficult to deliver and use safely.
Innovation Solution
A connection device featuring a rocker element with a bearing head and rocker leg that tilts to release the contact element from an open position to a contacting position upon insertion of the electrical line, allowing for automatic closure with low insertion forces and enhanced stability during transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the contact element is held in the open position by a latching mechanism, then the connection device can be delivered in the open position for easy line insertion, but the device may accidentally close due to vibrations or shocks during transport
Solution Approach 1:
The rocker element is designed with a latching mechanism that actively prevents unintended activation during transport. The latching section engages with the rocker element to lock the contact element in the open position, creating a preliminary counter-action against vibrational or shock-induced closure attempts before they can occur.
Solution Approach 2:
The connection device is delivered with the contact element pre-positioned in the open state through the latching mechanism. This preliminary action ensures the device is ready for immediate line insertion without requiring manual opening, while the latch maintains this state throughout transport.
2Reliability
If a rigid electrical line with ferrule is used, then the connection device can be reliably triggered, but flexible electrical lines with low insertion force cannot automatically close the device
Solution Approach 1:
The rocker element is designed as a dynamic component that can tilt between different angular positions. This dynamic capability allows the same mechanism to respond to varying insertion forces from different line types - rigid lines with ferrules provide sufficient force to tilt the rocker and trigger closure, while the latching mechanism ensures flexible lines with low insertion force don't cause accidental activation.
Solution Approach 2:
The system changes its operational parameters based on the inserted line type. When a rigid line with ferrule is inserted, the insertion force is sufficient to overcome the latching mechanism and tilt the rocker element, triggering closure. When flexible lines are inserted with low force, the latch maintains the open position, preventing accidental closure while still allowing intentional closing when needed.
3Extent of automation
If the contact element is spring-loaded to enable automatic closing, then connection is simplified, but the device requires significant insertion force that may damage flexible lines
Solution Approach 1:
The spring-loaded contact element is pre-loaded to provide automatic closing force, but the latching mechanism on the rocker element is engaged beforehand to prevent this force from being activated during transport. This preliminary latching action allows the device to maintain automatic closing capability while protecting against unintended activation that would require excessive force.
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
Enables easy and reliable connection of electrical lines with low insertion forces and prevents accidental closure during transport, ensuring secure and stable operation.
Implementation Method 1
The rocker element (12) can be tilted from the first tilted position into a second tilted position by the action of the electrical line on the rocker leg (120, 121) when the electrical line is inserted into the plug-in opening
Implementation Method 2
An electrical contact element (11) is arranged in the housing and can be moved from an open position into a contacting position relative to the housing in order to make electrical contact in the contacting position with an electrical line inserted into the plug-in opening
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 3A~3B
AI summary
A connection device (1) for connecting an electrical conductor (2) comprises a housing (10) with a plug-in opening (100) and an electrical contact element (11) arranged on the housing (10), which is adjustable from an open position to a contact position in order to make electrical contact with an electrical conductor (2) inserted into the plug-in opening (100) in the contact position. The connection device (1) also comprises a rocker element (12) having a bearing head (124) which is tiltably mounted on a bearing section (113) fixed to the housing (10), and a rocker arm (120, 121) extending from the bearing head (124). The rocker element (12) is configured to hold the contact element (11) in the open position in a first tilting position.The rocker element (12) can be tilted from the first tilting position to a second tilting position by the action of the electrical conductor (2) on the rocker arm (120) when the electrical conductor (2) is inserted into the plug-in opening (100), in order to release the contact element (11) for transfer to the contacting position.