EMC Contact Clamp Assembly for Variable Shield Lengths
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Solution Overview
Problem
Existing contacting systems for diverting electrical currents from long-formed parts require a strict sequence of assembly steps and precise length of the stripped shield, leading to assembly complications and tolerances.
Innovation Solution
A contacting system comprising a screw sleeve with a connection section, actuating element, and clamping element, allowing for independent activation and deactivation of the EMC seal, and enabling flexible assembly by applying a radial force to the clamping element through the actuating element, which can deform radially to accommodate varying shield lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the stripped shield length is specified to a precise length, then reliable electrical contact is ensured, but assembly tolerances are reduced and assembly complexity increases
Solution Approach 1:
The clamping element is designed with a conical inner circumferential surface that can be radially deformed by the actuating element. This parameter change allows the clamping element to adapt to different shield lengths and diameters, eliminating the need for precise shield length specifications while maintaining reliable electrical contact
Solution Approach 2:
The clamping element transitions from a static rigid structure to a dynamic deformable structure. By applying radial force through the actuating element, the clamping element can dynamically adjust its inner radius to accommodate varying shield dimensions, ensuring reliable contact without precise manufacturing tolerances
2Reliability
If the assembly sequence is strictly specified, then proper contact and sealing are achieved, but assembly time increases and ease of operation decreases
Solution Approach 1:
The contacting system is segmented into independent functional components: the screw sleeve with connection thread for mounting, the clamping element for electrical contact, and the actuating element for activation. This segmentation allows each component to be prepared independently and assembled in flexible sequences without compromising contact or sealing quality
Solution Approach 2:
The clamping element can be pre-installed on the shield before final assembly, and the actuating element can be activated after mounting. This preliminary action approach allows preparatory steps to be performed independently, reducing assembly time and simplifying the overall process while maintaining reliability
3Strength
If the clamping element is made rigid, then structural strength is maintained, but adaptability to different shield lengths is reduced
Solution Approach 1:
The clamping element features a conical inner circumferential surface with specific geometric properties that concentrate radial force locally. This local quality design allows the clamping element to maintain overall structural strength while enabling controlled radial deformation at the contact interface to accommodate different shield lengths
Solution Approach 2:
The clamping element combines materials or structural characteristics that provide both strength and deformability. The conical geometry acts as a mechanical composite structure that maintains rigidity in the axial direction for strength while allowing radial flexibility for adaptability
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
Facilitates assembly by allowing for flexible positioning of the clamping element on the shield, independent of the assembly of the elongated part, and ensures reliable electrical contact without requiring precise shield length, simplifying the assembly process and enhancing tolerance.
Implementation Method 1
by screwing the actuating element to the screw sleeve, the radial force can be applied to at least the first end face of the clamping element by at least the counterpressure end face of the actuating element being contactable with a first end face of the clamping element
Implementation Method 2
an inner radius of the clamping element can be reduced at least in sections by means of a radial force
Implementation Method 3
a contacting system, in particular for electromagnetically compatible high-current applications
Data Source
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AI summary
The invention relates to a contact-making system, in particular for electromagnetically compatible high-current applications. The contact-making system comprises a screw bushing, an actuating element and a clamping element. The clamping element comprises at least one inner lateral surface and at least a first end face. The screw bushing comprises a connecting thread on a first side of the screw bushing, for connection to a connecting geometry. The actuating element comprises a counterpressure end face. An inner radius of the clamping element can be reduced at least in some sections by means of a radial force. The actuating element can be screwed to the first side of the screw bushing, wherein the radial force can be applied to at least the first end face of the clamping element by screwing the actuating element to the screw bushing, in that at least the counterpressure end face of the actuating element can be brought into contact with a first end face of the clamping element.