Double Leg Spring Mounting for Top-Hat Rail
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Solution Overview
Problem
Existing methods for mounting and unmounting modules on top-hat rails often require tools and can cause damage, especially in confined spaces where there is limited room for both the module and mounting tools.
Innovation Solution
A device featuring a one-piece double leg spring with coaxially arranged coil springs, which forms hooks that create a positive-fitting connection with the top-hat rail, allowing for tool-free and damage-free mounting and unmounting by leveraging the spring's force to secure the module without external tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting methods are used, then modules can be securely fastened to the top-hat rail, but tools are required and damage may occur during mounting and unmounting
Solution Approach 1:
The double leg spring device is self-contained with integrated hooks that engage directly with the top-hat rail and module openings. The spring mechanism provides self-latching functionality where the hooks automatically secure to the rail when the module is inserted, eliminating the need for external tools during both mounting and unmounting operations.
Solution Approach 2:
The spring element introduces dynamic flexibility to the mounting system. The spring can elastically deform to accommodate insertion and removal movements, then returns to its original position to maintain secure engagement. This dynamic behavior enables tool-free operation while preserving connection reliability.
2Ease of operation
If traditional mounting tools are used, then modules can be mounted and unmounted, but the process causes damage and requires additional space for tool manipulation
Solution Approach 1:
The device performs its own mounting and unmounting function through the spring mechanism and hooks. The hooks engage with the top-hat rail and module openings in a controlled manner that distributes forces evenly, avoiding concentrated stress points that would cause damage. The spring's elastic deformation absorbs mechanical shocks during installation and removal.
Solution Approach 2:
The spring constant and hook geometry are designed to optimize the force distribution during mounting. By carefully selecting the spring parameters, the system achieves sufficient holding force while limiting peak forces that could damage the module or rail during the mounting and unmounting process.
3Ease of operation
If mounting tools are provided inside the device, then modules can be mounted, but there is barely room for both the module and mounting tools in confined spaces
Solution Approach 1:
The mounting device is premounted to the module in a compact configuration that requires minimal space. The spring and hooks are integrated into the module housing or attached in a space-efficient manner, eliminating the need for separate tool storage space inside the device. The entire mounting function is built into the module itself.
Solution Approach 2:
The mounting device is designed as a compact, integrated unit with the spring and hooks arranged in a space-efficient configuration. The components are segmented and arranged to fit within the limited space available on the module, allowing the mounting function to be performed without requiring additional internal space for tool storage or manipulation.
4Ease of manufacture
If a simple mounting mechanism is used, then the device can be manufactured at low cost, but the connection may not be secure enough
Solution Approach 1:
The spring element and hooks are combined into a single integrated component that is preferably formed as one piece. This merging of functions into a single component simplifies the manufacturing process and reduces assembly steps while maintaining secure connection through the coordinated action of the spring and hooks.
Solution Approach 2:
The spring constant, wire diameter, and hook geometry are optimized to achieve the required connection security with minimal material usage. By carefully selecting these parameters, the device provides reliable mounting while keeping the amount of material and manufacturing complexity low, thus maintaining cost-effectiveness.
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 quick, reliable, and tool-free mounting and unmounting of modules in narrow spaces with reduced mounting effort and low production costs, as the device uses the spring's force to secure the module, ensuring a secure connection that can only be detached with targeted action.
Implementation Method 1
a one-piece double leg spring, having a first leg coil spring and a second leg coil spring arranged coaxially about a common spring axis
Data Source
AI summary
A device for the tool-free mounting of modules on a top-hat rail and for the damage-free, tool-free unmounting of the same. The device has a double leg spring, with a first leg coil spring and a second leg coil spring, which are arranged coaxially about a common spring axis. First and second spring legs of the double leg spring are dimensioned identically and in each case form a hook bent in the direction of an opposite end of the double leg spring. The double leg spring also has a common intermediate leg at another end, which leg forms a hook bent in the direction of a first end.