Lever-Actuated Connection Clamp for One-Handed Conductor Insertion
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Solution Overview
Problem
Existing connection arrangements for electrical conductors, particularly those with flexible conductors, require manual operation of an actuator to pivot a clamping spring away from a current bar for insertion, complicating the connection process.
Innovation Solution
A connection arrangement featuring a clamping spring with a locking arm and an actuating element that is pre-tensioned in the open position, allowing automatic retention without manual holding, facilitated by a lever element that interacts with the actuating element through a rotary motion, enabling one-handed operation and tool-free connection of flexible conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional connection clamp with single-touch structure is used, then the ease of operation is improved, but the connection strength and reliability deteriorate due to loose fitting and gaps
Solution Approach 1:
The connection clamp is divided into an upper clamp portion and a lower clamp portion that can be separately positioned and then joined together through welding or other connection methods. This segmentation allows each portion to be independently shaped to fit the battery pack surface contours precisely, ensuring tight contact without gaps while maintaining ease of assembly through the modular structure.
Solution Approach 2:
The terminal is nested within the connection clamp structure, with the connection clamp enveloping the terminal completely. This nested configuration ensures that the terminal is securely held and protected, while the clamp portions can be separately formed and joined, combining secure fitting with manufacturing efficiency.
2Stability of the object's composition
If the connection clamp is designed to fit complex battery pack surfaces, then the contact tightness is improved, but the manufacturing complexity increases
Solution Approach 1:
The connection clamp is divided into upper and lower portions that can be separately manufactured using standard forming processes. Each portion is shaped to fit specific contours of the battery pack surface, and the segmented design allows for simpler individual component manufacturing while achieving complex overall geometry. The portions are then joined through welding or other connection methods to form the complete clamp structure.
3Strength
If the connection clamp has sufficient thickness for strength, then the connection strength is improved, but the adaptability to different battery pack thicknesses deteriorates
Solution Approach 1:
The connection clamp is divided into upper and lower portions with different thickness characteristics. The lower clamp portion that contacts the battery pack surface can be designed with appropriate thickness for strength while the upper portion can be optimized for other functions. This segmentation allows the clamp to accommodate varying battery pack thicknesses while maintaining sufficient structural strength at critical locations.
Solution Approach 2:
Different portions of the connection clamp have different thicknesses optimized for their specific functions. The lower clamp portion has sufficient thickness to ensure strong contact and connection with the battery pack surface, while other portions may have reduced thickness to accommodate different battery pack configurations. This local variation in quality provides both strength where needed and adaptability where required.
Data Source
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AI summary
The invention relates to a connection assembly (100) for connecting an electrical conductor (300), comprising a current bar (110), a clamping spring (111) which has a holding leg (112) and a clamping leg (113), the conductor (300) to be connected being clamped against the current bar (127) of the current bar (110) by means of the clamping leg (113) in a clamped position of the clamping spring (111), and an actuating element (118) which can be guided linearly along an actuation direction (B) and by means of which the clamping spring (111) can be transferred from the clamped position into the open position, the actuating element (118) being braced with the clamping spring (111) in the open position and holding the clamping spring (111) in the open position and a rotatably mounted lever element (129) which acts on the actuating element (118) in order to actuate the actuating element (118).