Flexible Connecting Element for Switching Devices
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Solution Overview
Problem
Existing methods for connecting electromechanical switching devices require separate mechanical and electrical connections, which can be cumbersome and prone to alignment issues due to manufacturing tolerances, leading to increased insertion forces and complexity in wiring systems.
Innovation Solution
A connecting element with flexible, conductive pins and a plastic sheathing that allows for simultaneous mechanical and electrical connection without wires, compensating for manufacturing deviations and reducing insertion forces through a finger-shaped configuration that can bend in all spatial directions, and includes guides for secure insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate mechanical and electrical connections are used to connect switching devices, then the connection can be achieved with dedicated components, but the device complexity and number of connecting parts increases
Solution Approach 1:
The patent combines separate mechanical connection components and electrical connection components into a single integrated connecting element. This connecting element simultaneously establishes both mechanical coupling between switching devices and electrical contact between switching poles, thereby reducing the total number of connecting parts while maintaining reliable connection functionality.
Solution Approach 2:
The connecting element is designed to perform multiple functions simultaneously: it provides mechanical support and positioning, establishes electrical contact, and enables both mechanical and electrical connections through a single component. This multi-functional design eliminates the need for separate dedicated mechanical and electrical connectors.
2Reliability
If rigid coupling elements are used for electrical connection, then the electrical connection is stable, but manufacturing tolerances cause alignment issues and increased insertion forces
Solution Approach 1:
The patent replaces rigid, fixed-position coupling elements with flexible coupling elements that can dynamically adapt their position. These flexible elements bend and deform to accommodate manufacturing tolerances and misalignments between switching devices, thereby reducing insertion forces while maintaining stable electrical connection after insertion.
Solution Approach 2:
The coupling elements are designed with variable physical properties - specifically, they have regions of different flexibility along their length. The elements transition from a more rigid state during insertion to a stable connected state, allowing them to accommodate positional variations caused by manufacturing tolerances without requiring excessive insertion force.
3Force
If flexible coupling elements are used to compensate for tolerances, then the insertion force is reduced, but the electrical connection may be less stable
Solution Approach 1:
The coupling elements are segmented into different functional zones: a flexible portion that bends to accommodate tolerances and reduce insertion force, and a rigid contact portion that ensures stable electrical connection. This segmentation allows each part of the coupling element to perform its specific function optimally without compromising the other.
Solution Approach 2:
The patent employs flexible coupling elements with controlled elasticity that can bend to accommodate manufacturing variations. These flexible elements maintain sufficient rigidity at the contact points to ensure stable electrical connection while allowing the necessary deformation during insertion to reduce insertion forces.
4Manufacturing precision
If multiple separate connecting parts are used, then the connection can be more precise, but the installation time and productivity decreases
Solution Approach 1:
The patent integrates multiple separate connecting parts into a single unified connecting element that performs both mechanical and electrical connection functions simultaneously. This integration maintains connection precision while dramatically reducing installation time and improving productivity, as only one component needs to be positioned and installed rather than multiple separate parts.
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 rapid, wireless, and secure connections with reduced insertion forces and parts, facilitating simpler installation and tolerance compensation, while allowing for flexible wiring configurations and protection against short-circuit plasma and gas egress.
Implementation Method 1
the flexible embodiment of the coupling elements, with the result that these can engage in contact openings of the coupling element of the switching devices and bend outward. The flexible embodiment thus allows each coupling element to be bent per se—independently of one another—thereby compensating for tolerances.
Implementation Method 2
the conductive pins have a plastic sheathing. This improves safety in particular in situations where the plug-in connector is only connected to one switching device and the coupling elements not yet connected to a switching device are connected to power-carrying lines.
Data Source
AI summary
A connecting element is disclosed for the connection of at least two switching devices and a switching device and an electric distribution system. In order to allow for the rapid and wireless connection of a plurality of electromechanical devices, at least one embodiment of the invention proposes a connecting device for the connection of at least two switching devices, wherein the connecting element includes first element(s) for mechanically connecting the switching devices to one and another and second element(s) for electrically connecting switching poles of the switching devices. The second element(s) include flexible connecting elements for connecting the switching devices to the switching poles that are electrically connected to the connecting device.