Cable Connector Actuator Ribs for Compact Spring Stability
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Solution Overview
Problem
Existing contact carrier apparatuses and actuators for electrical cable connections lack mechanical stability, which can lead to breakage under clamping spring force, especially when designed for compactness and preinstallation on holding plates.
Innovation Solution
The design incorporates stiffening ribs on the actuator arms to enhance stability, allowing the actuator to be produced from plastics material via injection molding, with an open actuation web for reduced friction and automatic return, and installation strips for preinstallation guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the actuator is designed for compactness and preinstallation on holding plates, then the device complexity is reduced and ease of manufacture is improved, but the mechanical stability of the actuator deteriorates, leading to breakage under clamping spring force
Solution Approach 1:
The actuator is divided into multiple functional segments including actuation arms, an actuation web connecting the arms, a holding portion, and integration with a cage-like busbar structure. This segmentation allows each part to be optimized for its specific function while maintaining overall stability through the distributed structural arrangement
Solution Approach 2:
The actuator is merged with the cage-like busbar structure, where the busbar serves dual purposes as both the electrical conductor and the structural framework for the actuator. The actuation arms are integrated into the busbar walls, eliminating separate mounting structures and enhancing mechanical stability through the unified construction
2Ease of manufacture
If the actuator design is simplified for injection molding production, then the ease of manufacture is improved and cost is reduced, but the mechanical stability deteriorates
Solution Approach 1:
The design parameters of the actuator are optimized for injection molding production, including uniform wall thicknesses, appropriate rib configurations for structural reinforcement, and geometric features that facilitate mold design. These parameter changes enable cost-effective mass production while maintaining adequate mechanical strength through properly engineered thickness and reinforcement elements
Solution Approach 2:
The actuator utilizes plastic material with potential reinforcement elements, combining the manufacturing advantages of injection molding with the mechanical strength requirements. The plastic material provides ease of formation for complex geometries while reinforcement features within the plastic structure enhance load-bearing capacity
3Ease of operation
If the actuation web is designed open for reduced friction, then the ease of operation is improved and automatic return is enabled, but the mechanical stability of the actuator deteriorates
Solution Approach 1:
The actuation web is designed with an open structure where material is extracted or removed to create passages and reduce mass. This extraction reduces friction during actuation by minimizing contact surfaces while the remaining structural elements are strategically positioned to maintain adequate stability for the actuator's function
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 provides a compact, reliable, and stable contact carrier apparatus with reduced friction, enabling the use of large cable cross sections and cost-effective production, while ensuring the actuator's stability and ease of installation.
Implementation Method 1
By virtue of the actuator being transferred or pushed down into its release position, the clamping spring is elastically deformed and releases the electrical cable again
Data Source
AI summary
In order to design a cable connection system so as to be operable particularly reliably and to be simultaneously compact, the actuator (1′) is provided at the ends of its actuation arms (122) with an actuation web (123), in the form of a protrusion (13), for reducing friction forces. In order to save on construction space for the collar of an electric cable and for regions of a clamping spring, the actuator (1′) has a receiving opening (120) above the actuation web (123). For the resultantly necessary stabilization, it has stiffening ribs (127) which are integrally formed on the outside of the actuation arms (122). As a result, the actuator (1′) can advantageously be manufactured from plastic and nevertheless have sufficient stability. In addition, the stiffening ribs (127) can be used as an installation aid.