Grounding Connection Assembly Using a Clamping Spring Contact
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Solution Overview
Problem
Existing connection systems for electrical devices require significant effort and risk due to loose connections, material deformation, and electromagnetic compatibility issues when grounding, often necessitating additional components and complex assembly processes.
Innovation Solution
A connection device with a clamping spring that securely attaches the grounding conductor to the electrical device's housing, allowing for one-step main protective conductor connection without additional sheet metal or covers, using a clamping spring to exert force and establish grounding, thereby simplifying the assembly process and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screwing in the cable is used to establish grounding connection, then the connection can be made, but the connection can come loose during insertion and loses clamping force over time causing material melting
Solution Approach 1:
The patent employs a dynamic spring mechanism that automatically adjusts and maintains constant clamping force on the grounding conductor. The spring element is pre-loaded to exert continuous pressure, ensuring the grounding connection remains secure without requiring manual tightening or adjustment during assembly or operation.
Solution Approach 2:
The spring-loaded clamping mechanism is designed to self-regulate the clamping force on the grounding conductor. As the conductor is inserted, the spring automatically compresses to the appropriate degree, maintaining optimal contact pressure without requiring external intervention or additional components to sustain the connection.
2Reliability
If additional plug-in terminals or receptacles are used for grounding connection, then grounding can be established, but the device complexity and number of components increases
Solution Approach 1:
The patent integrates the grounding connection function directly into the housing structure itself. The housing incorporates a receptacle with a spring-loaded clamping mechanism that combines the functions of mechanical support, electrical contact, and strain relief into a single integrated component, eliminating the need for separate plug-in terminals or additional grounding receptacles.
Solution Approach 2:
The housing receptacle is designed to serve multiple functions: it provides mechanical support for the power cable, establishes the grounding connection through the spring-loaded clamping mechanism, and maintains the Faraday cage effect. This multi-functional design eliminates the need for dedicated separate components for each function.
3Ease of manufacture
If the protective conductor is routed through the housing wall without effective contact, then the housing can be assembled, but the Faraday cage effect is not utilized and electromagnetic compatibility is compromised
Solution Approach 1:
The grounding conductor is pre-configured within the housing structure with the spring-loaded clamping mechanism positioned to make immediate electrical contact upon cable insertion. The receptacle is designed beforehand to ensure the grounding conductor establishes effective electrical contact with the housing wall, maintaining the Faraday cage effect from the moment of assembly.
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
This solution reduces manufacturing worksteps, ensures secure and reliable grounding, and improves electromagnetic compatibility by forming a closed Faraday cage, minimizing assembly errors and risks while maintaining safety and ease of installation.
Implementation Method 1
a clamping spring (107) designed as a tongue loaded by means of elastic deformation
Data Source
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AI summary
Connecting an electrical appliance to a suitable power plug is a costly process for appliance manufacturers, as the plugs must be adapted to the specific electrical connections of different countries. Furthermore, a reliable and secure grounding connection must be established.The present proposal includes a connection device for electrically contacting an electrical appliance with a mains plug, a mains cable and an appliance connection device, wherein the mains cable has an earth conductor, a neutral conductor and a phase conductor, and wherein the mains plug is located at one end of the mains cable and the appliance connection device is located at another end of the mains cable or in the middle, and the appliance connection device has a clamping spring and a housing plate for insertion into a housing plate receptacle of the electrical appliance, wherein the earth conductor is electrically connected to the housing plate, in particular by means of the clamping spring or in particular a crimp contact.