Lever-Operated Clamping Spring Terminal with Busbar Support
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Solution Overview
Problem
Conductor connection terminals face challenges in providing robust and reliable support for operating levers, leading to issues with fixing and guiding them in open and closed positions, which affects the overall mechanical stability and ease of operation.
Innovation Solution
The operating lever is supported on the busbar with a recess and a support projection, allowing for robust support and guidance, and the busbar is designed with a bent area to facilitate compactness and secure latching, enabling the operating lever to be fixed in desired positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the operating lever is supported on the busbar with a recess and support projection, then the mechanical stability and guidance of the operating lever is improved, but the device complexity increases due to additional structural features
Solution Approach 1:
The support projection and recess are integrated into the existing busbar and operating lever structures, combining the support function with the structural components rather than adding separate support mechanisms. This merging approach improves mechanical stability while minimizing the increase in device complexity.
Solution Approach 2:
The busbar is divided into functional zones including the recess area and the bent area, allowing each segment to serve specific purposes (support, guidance, latching). This segmentation enables improved stability through dedicated support features while keeping each individual feature relatively simple.
2Volume of moving object
If the busbar is designed with a bent area for compactness and latching, then the compactness and ease of operation is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The bent area of the busbar is designed to be elastically deformable, allowing it to dynamically adapt during the latching process. This dynamic flexibility enables compact design while tolerating reasonable variations in manufacturing precision, as the elastic deformation can compensate for minor dimensional deviations.
Solution Approach 2:
The material properties of the busbar (particularly its elastic modulus and yield strength) are selected and controlled to ensure the bent area achieves the desired compactness while maintaining manufacturability. By optimizing material parameters, the design achieves compact form factor without requiring extreme manufacturing precision.
3Reliability
If the operating lever is fixed in desired positions through support on the busbar, then the reliability of position fixing is improved, but the ease of operation may be reduced due to increased friction and wear
Solution Approach 1:
The recess in the busbar acts as an intermediary element between the support projection and the operating lever, providing a controlled interface that reduces direct metal-to-metal contact. This intermediary structure minimizes wear while maintaining reliable position fixing, thereby preserving ease of operation over time.
Solution Approach 2:
The design incorporates wear compensation features in advance, where the recess and support projection are dimensioned to accommodate gradual wear. This beforehand cushioning ensures that the position fixing reliability is maintained throughout the service life, and the increased friction is minimized through proper clearance design.
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 design enhances the mechanical stability and compactness of the conductor connection terminal, allowing for secure fixing and operation of the operating lever, reducing wear and improving user experience.
Implementation Method 1
The clamping spring (4) has a contact leg (40) by means of which the clamping spring (4) is supported with a support force against a spring force introduced by the clamping leg (43)
Implementation Method 2
an operating lever (5) which is predominantly arranged in the area surrounding the insulating material housing (2) and which essentially extends outward with a manual operating section (50)
Data Source
AI summary
A conductor connection terminal, having an insulating material housing, a busbar, a clamping spring and an operating lever which is pivotably received in the insulating material housing over a pivoting range and can be pivoted between an open position and a closed position, wherein the clamping spring has an operating arm which is deflected via a spring driver of the operating lever at least in the open position, characterized in that the operating lever is supported in the open position at a first and a second support point spaced from the first, and that the operating lever is pulled against the first and the second support point by a tensile force of the clamping spring acting on the spring driver from the operating arm.