Floating Frame Clamp Assembly for Conductor Height Tolerance
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Solution Overview
Problem
Existing electrical contact elements are difficult to handle and assemble due to their complex structure, which complicates the connection of electrical conductors and increases the risk of accidental contact during handling and assembly.
Innovation Solution
A plastic holder with a cavity and latching mechanism is introduced to securely hold a frame clamp, allowing it to be mounted in a floating manner orthogonal to the conductor insertion direction, featuring latching lugs that guide and stabilize the frame clamp, facilitating easy assembly and alignment despite conductor height tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the frame clamp is rigidly fixed in the plastic holder, then the assembly structure is simplified, but the electrical contact element becomes difficult to handle and assemble due to complex structure
Solution Approach 1:
The frame clamp is designed to be movable within the plastic holder rather than rigidly fixed, allowing it to adapt to conductor height variations while maintaining a simple overall assembly structure. The latching mechanism provides dynamic adjustment capability.
Solution Approach 2:
The position of the frame clamp relative to the plastic holder is made variable through the latching mechanism, allowing the frame clamp to adjust its position to accommodate different conductor heights while keeping the basic structure simple.
2Stability of the object's composition
If the frame clamp is rigidly fixed, then structural stability is improved, but handling and assembly become more difficult
Solution Approach 1:
The frame clamp is designed with movable capability within the plastic holder through the latching mechanism, allowing it to adjust to conductor variations while maintaining structural stability during operation. The latching provides both stability and adjustability.
3Ease of operation
If the frame clamp is mounted in a floating manner, then ease of assembly is improved, but mechanical stress on the frame clamp increases
Solution Approach 1:
The latching mechanism acts as an intermediary between the frame clamp and the plastic holder, allowing the frame clamp to be easily assembled while distributing and reducing mechanical stress through the latching connection rather than direct rigid contact.
Data Source
AI summary
An electrical contact element having a frame clamp comprises a frame with a stationary thread, a clamping shoe and a clamping screw engaging in the stationary thread and being supported on the clamping shoe. A plastic holder with a cavity having two insertion openings arranged on opposite walls of the cavity is provided for inserting two electrical conductors to be contacted with one another, in which the frame clamp is arranged. The frame clamp is captively fixed in the cavity of the plastic holder by means of a latching. The frame clamp is mounted in a floating manner in the cavity of the plastic holder in the direction of at least one axis, which is oriented orthogonally to an insertion direction of the electrical contacts into the insertion openings.