Contactor Connector with Mixed Screw and Spring Terminals
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Solution Overview
Problem
Existing connecting parts for contactors and circuit breakers are not simple to connect, as they often require complex terminal configurations and assembly methods, such as screw connections, which can be cumbersome and prone to manufacturing tolerances.
Innovation Solution
Designing screw connection terminals on the circuit breaker and spring-loaded terminals on the contactor, with electrical conductors terminating as perpendicularly and parallel contact pins on a plate-shaped insulating carrier, allowing for easy insertion of contact pins into spring-loaded terminals, and incorporating a hook-shaped configuration and plastic-coated wires to facilitate connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw connection terminals are used on both circuit breaker and contactor, then reliable electrical connection is achieved, but connection process becomes complex and time-consuming
Solution Approach 1:
The patent applies different terminal types at different locations: screw connection terminals are used on the circuit breaker side for reliable connection, while spring-loaded terminals are used on the contactor side for easy plugging. This local differentiation resolves the contradiction by optimizing each location for its specific function.
Solution Approach 2:
The connecting part is segmented into two distinct terminal configurations - screw terminals for the circuit breaker and spring-loaded terminals for the contactor. This segmentation allows each side to use the most appropriate connection type, achieving both reliability and ease of operation.
2Reliability
If perpendicular contact pins are used for screw terminals, then stable electrical connection is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies different contact pin orientations at different locations: perpendicular contact pins are used for screw terminals where precise alignment is critical for stable connection, while parallel contact pins are used for spring-loaded terminals where tolerance compensation is needed.
Solution Approach 2:
The patent changes the orientation parameter of contact pins based on the terminal type - perpendicular orientation for screw terminals to ensure stable electrical connection, and parallel orientation for spring-loaded terminals to accommodate manufacturing tolerances.
3Productivity
If spring-loaded terminals are used on contactor, then connection speed is improved, but connection stability may be reduced
Solution Approach 1:
The patent applies spring-loaded terminals specifically on the contactor side where quick connection is prioritized, while maintaining screw terminals on the circuit breaker side for enhanced stability. This local quality differentiation resolves the contradiction between connection speed and stability.
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 configuration simplifies the electrical connection process by allowing easy insertion of contact pins into spring-loaded terminals, compensates for manufacturing tolerances, and provides a secure, efficient mechanical and electrical link between the contactor and circuit breaker.
Implementation Method 1
spring-loaded terminals
Data Source
Figure 1~3
Figure 4
Figure 5
AI summary
The part (1) has a plate shaped carrier (6) made of insulation material with an electrical conductor, where ends of the conductor are designed as electrical contact pins (7, 8) for producing a direct electrical connection with connecting terminals (4, 5) that are formed as screw connection terminal and spring type terminal, respectively. The pins (7, 8) runs perpendicular and parallel to the plane for connection at the connecting terminals, respectively, where the plane determines the plate shape of the carrier. The conductor is formed as a wire covered with plastic.