Modular DIN Rail Adapter with Cam Turn Tab Grounding
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Solution Overview
Problem
Existing DIN rail adapters are not easily configurable for different connector types and do not allow for quick selectable grounding, and they limit the density of connectors in enclosures without requiring additional DIN rail space, leading to inefficiencies and increased costs.
Innovation Solution
A modular DIN rail adapter with a snap-in jack/module carrier and cam turn tab for easy assembly and grounding, allowing for increased connector density without expanding the DIN rail footprint, and enabling tool-free grounding configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dedicated adapters with fixed connectors are used, then manufacturing simplicity is improved, but adaptability deteriorates
Solution Approach 1:
The adapter is divided into two main segments: a housing portion and a carrier portion. The carrier portion can be detached and replaced, allowing different connector types to be installed without replacing the entire adapter. This segmentation enables easy reconfiguration while maintaining manufacturing simplicity for each individual component.
Solution Approach 2:
The adapter transitions from a static, fixed-connector design to a dynamic, reconfigurable design. The carrier portion can be removed and reattached with different connector types, allowing the adapter to adapt to different network requirements (CAT 5e, CAT 6, CAT 6A, etc.) without requiring complete replacement.
2Adaptability or versatility
If the entire adapter is replaced to change connector types, then connector compatibility is improved, but loss of time and productivity deteriorates
Solution Approach 1:
By separating the carrier portion containing the connector from the housing portion, only the carrier needs to be replaced when changing connector types. This reduces the time and effort required compared to replacing the entire adapter assembly.
Solution Approach 2:
Multiple carrier portions with different connector types can be prepared in advance and stored for quick replacement. This preliminary preparation allows technicians to rapidly swap connectors without extensive reconfiguration or custom fabrication.
3Quantity of substance
If additional DIN rail space is used for more connectors, then connector density is improved, but enclosure space utilization deteriorates
Solution Approach 1:
The adapter utilizes vertical stacking capability, allowing multiple carriers to be mounted one above another on the same DIN rail position. This transitions from horizontal space utilization to vertical space utilization, increasing connector quantity without expanding the horizontal footprint on the DIN rail.
Solution Approach 2:
Multiple carrier portions can be nested or stacked within the same housing structure, allowing multiple connectors to be accessed through a single adapter footprint on the DIN rail. This nesting approach maximizes connector density within the available enclosure space.
4Reliability
If grounding tab access requires removing patch cords, then grounding safety is improved, but ease of operation deteriorates
Solution Approach 1:
A cam-actuated mechanism serves as an intermediary between the user and the grounding tab. By manipulating the cam, the grounding tab is exposed or concealed without requiring removal of patch cords. This intermediary mechanism maintains safety by controlling access while improving ease of operation through simple cam manipulation.
Solution Approach 2:
The manual screwdriver-based grounding mechanism is replaced with a cam-actuated mechanical system. The cam provides leveraged motion that can easily expose the grounding tab with finger pressure, substituting the complex multi-step process of cord removal and screwdriver operation with a simple cam rotation action.
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
Enables flexible and efficient installation of modular connectors and grounding, increasing connector density within existing enclosures without additional rail space, and simplifies grounding adjustments, reducing installation complexity and costs.
Implementation Method 1
Compression spring 38 is squeezed and set into a pocket in the left housing 28. When assembled, compression spring 38 forces latching arm 36 upward to engage into DIN rail 26.
Implementation Method 2
cam turn tab 40 can be turned clockwise 180 degrees (or to 6 o'clock) to engage ground bar 32 to a jack/module 22
Implementation Method 3
In the staking process, a peg protruding from left housing 28 fits into a hole in the right housing 30. The peg is then deformed through the cold flow of the plastic to form a head which mechanically locks the two components together.
Data Source
AI summary
A DIN rail adapter is provided. The DIN rail adapter is comprised of an adapter sub-assembly, a jack/module carrier, and a cam turn tab. The adapter sub-assembly has a grounding bar configured to make contact to the DIN rail when it is mounted. The jack/module earner attaches to the adapter sub-assembly and can be configured to contain a jack, module, or another similar device. The cam turn tab is configured to reversibly connect the grounding bar to the jack or module contained within the jack/module carrier. In one embodiment, the cam turn tab connects the grounding bar to the jack or module by pushing a portion of the grounding bar such that it makes contact with the jack or module within the jack/module carrier.