Contactor Connection Section with Split Fastening and Contacting Elements
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Solution Overview
Problem
Electrical switching devices in automotive engineering face challenges related to weight, installation space, electrical safety, and production costs, which are not adequately addressed by general electrical engineering applications.
Innovation Solution
The design of an electrical switching device with a fastening element that prioritizes mechanical strength over electrical conductivity, allowing for the use of non-precious materials in the fastening element and a conductive contacting element, which reduces weight, space requirements, and costs, while ensuring secure and efficient electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fastening element is made from high-purity copper or other precious metals to ensure sufficient electrical conductivity and mechanical strength, then electrical safety and connection reliability are improved, but weight, space requirements, and production costs increase
Solution Approach 1:
The connection section is divided into two separate elements: a fastening element for mechanical attachment and a contacting element for electrical conduction. This segmentation allows each element to be optimized for its specific function, with the fastening element using lightweight high-strength materials and the contacting element using conductive materials, thereby reducing overall device weight while maintaining connection reliability
Solution Approach 2:
Different material properties are assigned to different parts of the connection section. The fastening element is made from materials optimized for mechanical strength (such as aluminum alloys or high-strength steels), while the contacting element is made from materials optimized for electrical conductivity (such as copper or copper alloys). This local differentiation of material quality allows weight reduction without compromising either mechanical strength or electrical conductivity
2Strength
If the fastening element is designed with sufficient mechanical strength to secure the electrical conductor, then connection stability is improved, but the use of expensive materials that are both strong and conductive increases production costs
Solution Approach 1:
The connection section is divided into two separate elements: a fastening element for mechanical attachment and a contacting element for electrical conduction. This segmentation allows each element to be optimized for its specific function, with the fastening element using lightweight high-strength materials and the contacting element using conductive materials, thereby reducing overall device weight while maintaining connection reliability
Solution Approach 2:
Different material properties are assigned to different parts of the connection section. The fastening element is made from materials optimized for mechanical strength (such as aluminum alloys or high-strength steels), while the contacting element is made from materials optimized for electrical conductivity (such as copper or copper alloys). This local differentiation of material quality allows weight reduction without compromising either mechanical strength or electrical conductivity
3Adaptability or versatility
If the contacting element is spaced from the fastening element to allow separate optimization of mechanical and electrical functions, then material selection flexibility is improved, but the complexity of the connection section increases
Solution Approach 1:
The connection section is divided into two separate elements: a fastening element for mechanical attachment and a contacting element for electrical conduction. This segmentation allows each element to be optimized for its specific function, with the fastening element using lightweight high-strength materials and the contacting element using conductive materials, thereby reducing overall device weight while maintaining connection reliability
Solution Approach 2:
The fastening element and contacting element are combined into a single integrated connection section that serves both mechanical and electrical functions. This merging approach simplifies the overall structure compared to using completely separate components, while still allowing material optimization for each functional element
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The present invention relates to an electrical switching device (1), in particular to a contactor or relay, with a connection section (4) for fastening and contacting an electrical conductor (26), wherein a fastening element (8) for fastening the electrical conductor (26) and, for example, a separate, electrically conductive contacting element (18), which reaches from the fastening element (8) to a contact point (20) of a current-carrying element (22) spaced from the fastening element (8) and extending in an inner section (6) of the electrical switching device (1), are present on the connection section (4), wherein the fastening element (8) exhibits a greater mechanical strength than the contacting element (18), and wherein the contacting element (18) is electrically conductive. In this way, inter alia the selection of material for the fastening element (8) can be geared solely towards mechanical requirements. This makes it possible to save weight, installation space, and/or costs for the electrical switching device (1).