IDC Conductor Terminal With Spring Force for Large Cables
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Solution Overview
Problem
Existing conductor connection terminals require stripping of electrical conductors before connection, which is labor-intensive, especially for large conductor cross-sections.
Innovation Solution
A conductor connection terminal with an insulation displacement connection (IDC) that uses a force accumulator to apply a compressive force, allowing for direct connection of insulated electrical conductors without stripping, and featuring a manual actuating element and a stamp with a conductor guide contour.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional connection methods are used, then reliable electrical connection is achieved, but conductor stripping is required which increases workload and time consumption
Solution Approach 1:
The cutting edges are pre-positioned on the insulation displacement contact to automatically cut the insulation when the conductor is inserted, eliminating the need for preliminary stripping by the operator. The force accumulator is pre-loaded to provide the necessary insertion force automatically.
Solution Approach 2:
The insulation displacement contact performs multiple functions automatically: cutting the insulation, displacing it, and establishing electrical contact with the conductor core, all without requiring external tools or preliminary preparation by the operator.
2Reliability
If large conductor cross-sections are connected, then high current transmission is enabled, but stripping becomes significantly more labor-intensive
Solution Approach 1:
The force accumulator is pre-loaded with sufficient energy to handle large conductor cross-sections, and the cutting edges are positioned to automatically cut through the insulation of large conductors upon insertion, eliminating the manual stripping step that becomes increasingly difficult with larger conductors.
Solution Approach 2:
The force accumulator acts as an intermediary that provides the necessary mechanical force to insert large conductors into the insulation displacement contact, overcoming the increased friction and resistance associated with larger conductor diameters without requiring excessive manual force from the operator.
3Ease of operation
If insulation displacement connection is used, then stripping is eliminated, but sufficient contact force must be maintained for long-term stable connection
Solution Approach 1:
The force accumulator dynamically adjusts the contact force between the insulation displacement contact and the conductor core, maintaining optimal pressure over time to ensure long-term connection stability while allowing for thermal expansion and mechanical settling.
Solution Approach 2:
The force accumulator modifies the mechanical parameters of the connection by providing sustained compressive force, ensuring that the contact pressure remains within the optimal range for both immediate electrical conductivity and long-term mechanical stability.
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 and efficient connection of electrical conductors with large cross-sectional areas by eliminating the need for stripping, ensuring a long-term stable and secure electrical connection.
Implementation Method 1
The force accumulator can be embodied, for example, as a compression spring, tension spring or elastic block of material
Implementation Method 2
The force accumulator can be designed, for example, as a spiral spring or as a disk spring
Implementation Method 3
The contact edges cut the insulation of the electrical conductor so that the contact edges come into electrical contact with the electrically conductive inner material
Implementation Method 4
The manual actuating element may be designed, for example, as a pivoting actuating lever or as an actuating pusher. Especially in the case of large conductor cross-sections, the formation of the actuating element as a pivotable actuating lever is advantageous, since with such an actuating lever, larger conductor contact forces can be transmitted to the electrical conductor.
Data Source
AI summary
A conductor connection terminal for connecting an electrical conductor by means of an insulation displacement connection, wherein the conductor connection terminal has at least one insulation displacement connection, a pressure piece that can be pressurized by means of a manually generated actuating force, a stamp acting on the electrical conductor and a compression spring arranged between the pressure piece and the stamp, wherein the insulation displacement connection has an insulation displacement contact with two contact edges arranged next to each other, wherein between opposite sides of the contact edges a cutting slot is formed, wherein the force of the compression spring is effective in the longitudinal direction of the cutting slot.