Electrical Contactor Terminal Assembly Angle Optimization
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Solution Overview
Problem
Existing electrical contactors with insulating casings and connection terminals are constrained in design, leading to limitations in cost, size, weight, simplicity, and ergonomics, particularly due to the requirement for parallel assembly of components which restricts freedom of design and user-friendliness.
Innovation Solution
The electrical contactor design allows the peripheral wall and cover to be assembled at an angle less than 30° with respect to the conductor insertion direction, featuring a contact spring with blades and blocking means to stabilize the spring during insertion and withdrawal, enabling a 'push-in' mechanism for easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connection terminal elements are mounted in the case along a mounting direction parallel to the conductor insertion direction, then the assembly is simplified and manufacturing is easier, but the design freedom is limited and the device size and weight cannot be optimized
Solution Approach 1:
The patent changes the mounting direction of the connection terminal elements from parallel to perpendicular relative to the conductor insertion direction. This dimensional change allows the elements to be mounted laterally in the case, providing greater design freedom while maintaining assembly simplicity through standardized perpendicular mounting configurations.
2Adaptability or versatility
If the connection terminal elements are mounted laterally into the case, then design freedom is improved, but the mounting becomes more complex and manufacturing is more difficult
Solution Approach 1:
The connection terminal is divided into separate elements (contact element, connection element) that can be independently mounted laterally in the case. This segmentation allows each element to be positioned and secured independently through simplified lateral mounting operations, reducing overall mounting complexity while maximizing design freedom.
3Adaptability or versatility
If traditional lateral mounting is used for connection terminal elements, then design flexibility is improved, but the device size and weight increase
Solution Approach 1:
The contact element and connection element are merged into a single integrated connection terminal structure that can be mounted laterally in the case. This merging eliminates the need for separate mounting operations and reduces the overall number of components, thereby reducing device weight while maintaining design flexibility.
4Productivity
If the mounting direction is changed to an angle less than 30° with the conductor insertion direction, then assembly simplicity is improved and manufacturing is easier, but the traditional parallel mounting constraint is relaxed
Solution Approach 1:
The patent introduces a degree of flexibility in the mounting direction by allowing angles less than 30° with the conductor insertion direction. This dynamic approach enables manufacturers to optimize assembly processes for higher productivity while accommodating variations in device design, effectively balancing assembly efficiency with design complexity.
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 design reduces costs, size, and weight while enhancing ergonomics and user-friendliness by allowing simpler and more efficient assembly of the connection terminal and electrical connection strip, overcoming the limitations of traditional lateral mounting requirements.
Implementation Method 1
a contact spring (15) configured so that the contact between the electrical conductor and the electrical connecting bar results from a force insertion of the electrical conductor in opposition to the action of the contact spring (15) and is automatically held by the contact spring (15) after the insertion of the electrical conductor
Data Source
Figure 1~2
Figure 3
AI summary
An electrical device comprises a housing formed from an electrically insulating material and at least one connection terminal (10) mounted in the housing for establishing and maintaining contact between an electrical conductor inserted into the connection terminal (10) and an electrical connecting bar (11) mounted in the housing to ensure an electrical connection between the electrical connecting bar (11) and the electrical conductor. The connection terminal (10) is of the pressure type and includes a contact spring (15) configured such that contact between the electrical conductor and the electrical connecting bar (11) results from the forced insertion of the electrical conductor against the action of the contact spring (15) and is automatically maintained by the contact spring (15) after the electrical conductor is inserted.The housing comprises a peripheral wall and a cover (12) configured so as to be assembled to each other along a mounting direction (13) substantially parallel to the direction (14) in which the electrical conductor is inserted into the connection terminal (10).