Lever-Locked Cable Contact Assembly for Tool-Free Confined Installation
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Solution Overview
Problem
Conventional passive distributors for actuator-sensor interfaces require tools and specific torque settings for assembly, making them unsuitable for use in confined spaces and complicating the installation process.
Innovation Solution
A contacting element design that allows for tool-free assembly, featuring a lower and upper part that are plugged together in a straight line, with a rotatable lever element that moves the parts linearly to lock into position, using contact pins to penetrate the cable insulation and establish electrical contact without damaging it.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional passive distributors use screw connections for assembly, then reliable electrical contact is achieved, but tool-free assembly and installation in confined spaces becomes difficult
Solution Approach 1:
The patent replaces the screw connection mechanism with a lever-based mechanical system. The lever element (11) rotates about a pivot point (27A) to directly move the upper part (9) and lower part (3) together, eliminating the need for screws and torque settings. This substitution maintains reliable electrical contact through direct mechanical force application while enabling tool-free assembly.
Solution Approach 2:
The patent introduces a dynamic lever mechanism that transforms rotational motion into linear motion. The lever element (11) rotates dynamically about pivot point (27A) to drive the closing action of the connector, providing controlled force application without requiring threaded fasteners. This dynamic system enables easy assembly while ensuring reliable contact.
2Manufacturing precision
If conventional passive distributors require specific torque settings, then contact force is controlled, but assembly complexity increases
Solution Approach 1:
The lever-based mechanism is designed to self-regulate the contact force during assembly. As the lever element (11) rotates and the upper part (9) closes onto the lower part (3), the mechanical system naturally limits the closing force, preventing over-compression. This self-service design eliminates the need for external torque control while maintaining appropriate contact force.
Solution Approach 2:
The dynamic lever mechanism provides inherent force control through its mechanical geometry. The rotation about pivot point (27A) creates a natural fulcrum system that regulates the closing force applied to the cable and contact pins, eliminating the need for precise torque settings or complex adjustment mechanisms.
3Reliability
If conventional distribution terminals are designed for active I/O devices, then they provide robust connections, but they are not suitable for passive distributor applications
Solution Approach 1:
The patent designs a universal connector structure that functions effectively as a passive distributor while maintaining compatibility with active I/O device requirements. The upper part (9), lower part (3), and lever mechanism (11) create a robust connection system that can serve multiple application types, including passive distribution and active device interfacing, without requiring design modifications.
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 space-saving, tool-free assembly and secure electrical contact in confined spaces, reducing installation complexity and minimizing damage to cable insulation.
Implementation Method 1
a lever element (11) which is rotatably mounted on the upper part (9) between an open and a locked position
Implementation Method 2
at least one contact pin (13A, 13B) adapted to at least partially penetrate the cable (7) received in the recess (5) in the locked position
Data Source
Figure 1
Figure 2A~3B
Figure 4A~4B
AI summary
The invention relates to a contacting element, comprising: a lower part (3, 3') having at least one recess (5, 5') for receiving a cable (7, 7'); an upper part (9, 9') having a lever element (11, 11') mounted on the upper part (9, 9') for rotation between an open position and a locked position, in order to lock the upper part (9, 9') on the lower part (3, 3') when the lever element is in the locked position; and at least one contact pin (13A, 13A', 13B, 13B') designed to at least partly penetrate the cable (7, 7') received in the recess (5, 5'), when the lever is in the locked position, in order to electrically contact at least one conductor (8A, 8A', 8B, 8B') in the cable (7, 7'); wherein, when the lever element (11, 11') is in the open position, the lower part (3, 3') and the upper part (9, 9') can be plugged together in a straight line in a plugging direction, and the lever element (11, 11') is designed to move the lower part (3, 3') and the upper part (9, 9') toward each other in a straight line as the lever element is transferred into the locked position. The invention also relates to an actuator sensor (AS) interface system (100).