Grounding Conductor Element With Flat-Lamina Spring for DIN Rail
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Solution Overview
Problem
Existing terminal blocks for switchboards face challenges in providing an easy, reversible, and safe ground connection to DIN support rails while maintaining conductive capacity for protection and safety, while also needing to adhere to standard dimensions and be inexpensive to produce and assemble.
Innovation Solution
A grounding conductor element with a conductor body featuring a longitudinal lamina, inclined sections, and a flat-lamina spring that engages with DIN rail flanges, providing three engaging points for stable and conductive contact, and allowing easy assembly and disassembly by deforming the spring legs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a grounding conductor element uses a flat-lamina spring with engaging points for DIN rail flanges, then the ease of operation and reversibility of connection is improved, but the device complexity increases due to the spring mechanism and multiple engaging points
Solution Approach 1:
The flat-lamina spring is designed to be self-actuating: when the conductor element is inserted into the terminal block, the spring automatically deforms and engages with the DIN rail flanges without requiring additional tools or operations. The spring's elasticity provides automatic retention force, making the system self-servicing during installation and removal.
Solution Approach 2:
The spring mechanism transforms the static connection into a dynamic one. The flat-lamina spring can elastically deform during insertion and removal operations, allowing easy engagement and disengagement. The dynamic flexibility of the spring enables reversible connection while maintaining reliable electrical contact during normal operation.
2Reliability
If the conductor element provides three engaging points with the DIN rail flanges, then the reliability and stability of connection is improved, but the manufacturing precision requirements increase to ensure proper alignment and contact
Solution Approach 1:
The connection interface is segmented into three distinct engaging points distributed along the conductor element. This segmentation allows each point to independently contact the DIN rail flanges at different locations, distributing the mechanical and electrical load. The segmented approach provides redundancy and enhances overall connection reliability without requiring all points to be perfectly aligned simultaneously.
Solution Approach 2:
The spring's elastic properties allow the engaging points to adapt their positions dynamically. During installation, the spring deforms to accommodate variations in DIN rail positioning, effectively compensating for manufacturing tolerances. The parameter change in spring deformation enables reliable engagement even when perfect alignment is not achieved.
3Adaptability or versatility
If the terminal block design maintains standard dimensions for DIN rail mounting, then the adaptability and ease of assembly is improved, but the device complexity increases to integrate the spring mechanism within standard dimensions
Solution Approach 1:
The conductor element is designed with universal compatibility for standard DIN rail dimensions. The flat-lamina spring and engaging points are configured to work with conventional DIN rail flange geometries, allowing the same component to be used across different terminal block models and manufacturers. This multi-functionality achieves adaptability without requiring custom designs for each application.
Solution Approach 2:
The spring mechanism is nested within the conductor element structure, with the flat-lamina spring integrated into the body housing. This nested arrangement allows the spring mechanism to be compactly contained within standard terminal block dimensions, achieving the required functionality without increasing the overall footprint beyond standard sizes.
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 easy, safe, and reversible connection to DIN rails with high conductive capacity, ensuring static and dynamic planarity and efficient earth discharge, while being easy to produce and assemble within standard dimensions.
Implementation Method 1
a flat-lamina spring (130) which has: a head (131) provided with an opening (131a) for coupling with the pin (127) of the engaging end of the conductor element; two flat-pin legs (132) separated by an interspace (132a), preferably the two legs have a respective free end forming a tongue (132b) inclined outwards at a suitable angle, for facilitating engagement with the rail B and for allowing operation thereof for disengagement from said rail
Data Source
Figure 1~3
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Figure 6~7
AI summary
Earth conducting element comprising: - a conductor lamina (110) designed to electrically connect together two wires (2); - a substantially vertical shaped body (120) extending in the longitudinal direction (X-X), said body having a bottom body section with: • a bottom free edge (123a) extending in the longitudinal direction (X-X) for resting in the vertical direction (Z-Z) on a DIN-standard rail B; • a first end (124), with a tooth (124b) designed to engage with one (B1) of the two folded flanges (B1, B2) of the DIN standard rail B; • a second end (125) opposite to the first end (124) and designed to form a means for engaging and retaining a flat-lamina spring (130); - a flat-lamina spring (130) which has a head (131) and two flat-pins legs (132) for engagement with the other folded flange (B2) of the rail B.