Building Controller Jumper Bar for Faster Multi-Terminal Wiring
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Solution Overview
Problem
Existing electronic modules, such as controllers and IO modules, face challenges in making efficient wiring connections due to the construction, design, and placement of terminal blocks and other components.
Innovation Solution
The introduction of a jumper bar with three or more spaced jumper terminals that are electrically shorted together, designed to be secured to and extend away from a jumper body, facilitating easier connections by engaging corresponding terminals on the electronic module's circuit boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional terminal blocks and wiring methods are used, then reliable electrical connections are achieved, but the wiring process becomes time-consuming and difficult
Solution Approach 1:
The jumper bar is divided into distinct segments: the handle portion for user manipulation, the insulating body for electrical isolation, and multiple jumper terminals for electrical connections. This segmentation allows each part to perform its specific function efficiently, making the wiring process simpler and faster while maintaining connection reliability.
Solution Approach 2:
The jumper bar serves as an intermediary tool that facilitates electrical connections between terminal blocks without requiring direct wire manipulation. By using the jumper bar as a mediator, installers can quickly establish connections by simply inserting the bar into the terminals, significantly reducing installation time while ensuring reliable electrical contact.
2Productivity
If multiple separate wiring connections are made individually, then reliable point-to-point connections are achieved, but the complexity and time of installation increases
Solution Approach 1:
Multiple jumper terminals are combined into a single integrated jumper bar structure, allowing an installer to make multiple electrical connections simultaneously by inserting one tool rather than making separate connections for each wire. This merging of multiple connection functions into one device dramatically increases wiring productivity while reducing the perceived complexity of the installation process.
Solution Approach 2:
The jumper bar is designed as a universal tool that can establish multiple electrical connections across different terminal blocks in a single operation. The multi-functional design, with several jumper terminals on one bar, allows it to replace multiple individual wiring operations, thereby increasing productivity without adding complexity to the installation procedure.
3Area of stationary object
If jumper terminals are positioned close to the circuit board, then space efficiency is improved, but accessibility for connection becomes difficult
Solution Approach 1:
The jumper bar features localized electrical contact points (jumper terminals) that are positioned to align with the terminal blocks on the circuit board, while the main body and handle extend outward to provide accessibility. This local quality approach allows the connection points to be compact and space-efficient while the manipulation portion remains easily accessible to the user.
Solution Approach 2:
The jumper bar extends in multiple dimensions: the jumper terminals contact the circuit board in one plane, while the handle and insulating body extend perpendicular to the board surface, providing accessibility from above. This dimensional arrangement allows compact integration with the circuit board while maintaining ease of operation from the accessible external dimension.
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 jumper bar simplifies the process of making wiring connections by allowing for quick electrical shorts, reducing the time and effort required for installation, and providing a more reliable and organized connection method.
Implementation Method 1
The three or more jumper terminals electrically shorted together. In use, the jumper bar is positioned such that a first part of the jumper bar remains outside of the housing of the electronic module and a second part of the jumper bar, which includes at least part of each of the three or more spaced jumper terminals of the jumper bar, extends into and through one or more of the apertures in the housing of the electronic module. Each of the three or more spaced jumper terminals of the jumper bar electrically engage a corresponding one of the three or more terminals defined by the one or more jumper sockets of the one or more circuit boards of the electronic module.
Data Source
AI summary
An electronic module having one or more jumper sockets defining three or more terminals, and a housing that includes one or more apertures for accessing the terminals from external to the housing. The jumper bar includes a jumper body and three or more spaced jumper terminals that are secured to and extend away the jumper body. In use, a first part of the jumper bar remains outside of the housing and a second part of the jumper bar, including at least part of each of the three or more spaced jumper terminals, extends through one or more of the apertures in the housing. Each of the jumper terminals of the jumper bar electrically engage a corresponding one of the three or more terminals. The first part of the jumper bar includes a graspable handle with a flange for pulling the jumper bar from the electronic module by hand.