Floating Actuating Lever for Low-Wear Conductor Terminal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conductor connection terminals face challenges in ergonomics, manufacturing costs, and ease of assembly, with existing solutions experiencing wear and requiring complex assembly processes.
Innovation Solution
A conductor terminal design featuring a floating bearing actuating lever with a metal contact piece and plastic actuating lever, allowing for reduced wear and simplified assembly, along with a clamping spring mechanism that separates the bearing and clamping sections to optimize space and force guidance, enabling efficient force transmission and low-friction operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed axle bearing is used for the actuating lever, then the lever is stable in position, but the lever experiences increased wear and requires complex assembly procedures
Solution Approach 1:
The actuating lever is designed with a floating mounting that allows it to dynamically adapt its position based on operational forces. The lever can pivot slightly on its floating bearing to accommodate force variations, eliminating the need for complex fixed axle assemblies while reducing wear through self-adjusting contact points.
2Strength
If the actuating lever is made of metal for durability, then the lever is robust, but friction and wear increase at the bearing point
Solution Approach 1:
The actuating lever combines metal and plastic materials strategically: the metal contact piece provides robustness at the bearing point, while the plastic actuating lever body reduces friction during operation. This composite construction allows the lever to be both durable and low-friction simultaneously.
3Device complexity
If the bearing section and clamping section are integrated without separation, then the contact piece is simpler, but space utilization and force guidance are suboptimal
Solution Approach 1:
The contact piece is segmented into distinct bearing and clamping sections separated by the conductor receiving chamber. This segmentation optimizes space utilization by clearly defining functional zones and improves force guidance by directing clamping forces away from the bearing area, preventing force interference.
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 design reduces wear and manufacturing costs, enhances ergonomics, and simplifies assembly, providing a low-wear, low-friction, and efficient conductor connection solution with improved force transmission and ease of handling.
Implementation Method 1
a clamping spring (5), which applies a spring force to an electrical conductor at a conductor clamping point (30)
Implementation Method 2
an actuating lever (7), which can be actuated by a user and with which the clamping spring (5) can be actuated
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a conductor terminal (1) with the following features: a) at least one insulating housing (2), b) at least one contact insert (3, 5) arranged at least partially in the insulating housing, comprising at least one contact piece (3) and at least one clamping spring (5), c) wherein the contact piece with the clamping spring forms at least one conductor clamping point (30) for an electrical conductor (8) to be contacted by means of the conductor terminal (1), which can be subjected to a spring force of the clamping spring (5) at the conductor clamping point (30), d) at least one actuating lever (7) pivotably mounted in the insulating housing (2) for actuating the clamping spring (5),wherein the actuating lever (7) is pivotable from a closed position to an open position and vice versa relative to the insulating housing (2) and/or the contact piece (3) and, at least in the open position, an electrical conductor (8) inserted into the conductor terminal (1) is not subjected to the spring force of the clamping spring (5) at the conductor clamping point (30), e) wherein the actuating lever (7) is floatingly mounted and, at least in the open position, is supported at least partially on the contact piece (3).