Pre-assembled Control Panel with Spring Contact Terminals
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Solution Overview
Problem
Traditional control panel wiring methods are labor-intensive, costly, and prone to mis-wiring and poor connections, posing safety risks due to exposure to hazardous electrical components and environmental contaminants.
Innovation Solution
The use of a printed wiring board assembly with electrical spring contact terminals or pins, visual notification beacons, and audible notification devices affixed through the control panel enclosure walls, allowing for quick coupling with mechanical and electrical interfaces to complete connections without manual wiring or tools, ensuring safe and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wiring methods are used to connect pilot devices to the control system, then electrical connections can be established, but the assembly process becomes labor-intensive and costly
Solution Approach 1:
The control panel system is divided into separate modules: a control panel assembly with printed circuit board and a pilot device assembly with terminal blocks. These modular components can be assembled independently and then connected through a standardized interface, eliminating the need for labor-intensive custom wiring while ensuring reliable electrical connections.
Solution Approach 2:
A standardized interface assembly acts as an intermediary between the control panel and pilot devices. This interface includes pre-configured terminal blocks and connection elements that simplify the joining process, allowing rapid assembly while maintaining connection reliability without requiring manual wiring of each connection point.
2Ease of manufacture
If traditional wiring methods are employed for external pilot devices, then electrical connections are made, but the chance for mis-wiring and poor quality connections increases
Solution Approach 1:
By segmenting the system into pre-assembled modules with standardized interfaces, the complexity of manual wiring is eliminated. Each module comes pre-configured with proper connections, ensuring manufacturing precision while simplifying the overall assembly process.
Solution Approach 2:
Electrical connections are pre-configured and tested during module assembly before final installation. The terminal blocks and connection elements are pre-positioned and secured, ensuring accurate wiring connections are made before the module is installed in the final application, thereby eliminating mis-wiring issues.
3Object-affected harmful factors
If pilot devices are made accessible outside the control panel enclosure, then user safety is improved, but exposure to environmental contaminants increases
Solution Approach 1:
The system is segmented into an environmentally sealed control panel enclosure and externally accessible pilot devices. The enclosure acts as a protective barrier against environmental contaminants while the pilot devices remain accessible outside for user interaction, thus resolving the contradiction between protection and accessibility.
Solution Approach 2:
A sealed interface mechanism serves as an intermediary between the protected internal environment and the external user interface. This interface allows electrical and mechanical connections to pass through while maintaining environmental sealing, enabling pilot devices to be accessible outside the enclosure without exposing internal components to contaminants.
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 solution simplifies the assembly process, reduces labor and costs, enhances safety by isolating hazardous components, and minimizes the risk of mis-wiring, while maintaining environmental protection and user safety.
Implementation Method 1
The control panel includes electrical spring contact terminals or pins
Data Source
AI summary
An easy assembly control panel and method is disclosed. In one example, an enclosure is provided having a pilot device coupled to the enclosure. A pre-assembled control panel is inserted into the enclosure, quick coupling the control panel to the pilot device and providing control communication between the pilot device and the control panel. No additional manual wiring or manual mechanical coupling is needed to couple the user interface device to the control panel. The control panel can be used as part of a system, such as a submersible pump system.