Modular Feeder Terminal Block With Flexible Clamping
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Solution Overview
Problem
Existing terminal blocks face challenges in manufacturing and warehousing due to varied specifications, leading to high costs and complex assembly processes, especially as the number of wire holes increases, hindering efficient production and assembly.
Innovation Solution
A modular feeder terminal block design featuring an insulative case, a supply conductive plate, and a wire connecting module with flexible clamping sheets and supports, allowing for easy adjustment of wire insertion and assembly by using riveting bars, slots, and release sliders to manage wire clamping and connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If terminal blocks are designed with various specifications to meet different wiring needs, then adaptability is improved, but manufacturing complexity and inventory costs increase
Solution Approach 1:
The terminal block is designed with a standardized modular structure where the insulative case, conductive plates, and wire connecting modules can be combined in different quantities to create terminal blocks of various wire hole numbers (3, 4, 5, 6, 8, 10, 12 holes). This universal design allows a single basic module to serve multiple specifications, improving adaptability without increasing manufacturing complexity.
Solution Approach 2:
The terminal block is divided into independent modular components: insulative case, supply conductive plate, feed conductive plate, insulative supports, and flexible clamping sheets. These segmented modules can be assembled in different configurations to meet different wiring requirements, allowing customization without requiring entirely different designs for each specification.
2Adaptability or versatility
If the number of wire holes is increased to accommodate more wires, then adaptability is improved, but assembly difficulty increases
Solution Approach 1:
The terminal block uses modular wire connecting modules that can be independently assembled. Each module contains insulative supports with flexible clamping sheets pre-positioned on them. These standardized modules can be quickly assembled by simply connecting them together, maintaining ease of assembly even as the number of wire holes increases.
Solution Approach 2:
The flexible clamping sheets are pre-positioned on the insulative supports during manufacturing. This preliminary action ensures that when the terminal block is assembled, the clamping sheets are already in their correct positions and orientations, eliminating the need for complex alignment operations during final assembly and maintaining assembly ease regardless of the number of wire holes.
3Productivity
If terminal blocks are designed with fixed specifications, then manufacturing efficiency is improved, but flexibility to meet different wire numbers is reduced
Solution Approach 1:
The terminal block is designed as a modular system with standardized components that can be manufactured efficiently in large quantities and then assembled in different configurations. The insulative case, conductive plates, and wire connecting modules are standardized parts that can be mass-produced, maintaining manufacturing efficiency while allowing flexible assembly for different wire hole numbers.
Solution Approach 2:
A single standardized module design serves multiple purposes by being replicable in different quantities. The same basic wire connecting module can be used for 3-hole, 4-hole, 5-hole, 6-hole, 8-hole, 10-hole, or 12-hole terminal blocks simply by changing the number of modules assembled, providing flexibility without requiring different manufacturing processes for each specification.
4Ease of operation
If modular design is implemented to improve assembly ease, then assembly efficiency is improved, but device structure becomes more complex
Solution Approach 1:
Multiple functional elements are merged into integrated components. The insulative support and flexible clamping sheet form an integrated wire connecting module that combines mechanical support and electrical clamping functions. The riveting bars simultaneously provide mechanical fastening and electrical connection between the feed conductive plate and supply conductive plate. These merged structures reduce the number of separate parts to assemble while maintaining assembly ease.
Solution Approach 2:
The modular components are designed to nest together efficiently. The wire connecting modules with insulative supports are positioned within the insulative case, and the conductive plates are nested between the insulative components. This nested arrangement allows multiple modules to be compactly assembled without requiring complex external fastening structures, maintaining assembly simplicity.
Data Source
AI summary
A terminal block includes an insulative case, a supply-side conductive plate and a wire connecting module. The insulative case has two wire holes. The supply-side conductive plate is disposed in the insulative case. The wire connecting module is mounted on the supply-side conductive plate and includes a feed-side conductive plate, two insulative supports and two flexible clamping sheets. The feed-side conductive plate is electrically connected to the supply-side conductive plate and includes a first side wall and a second side wall opposite to each other. Each insulative support is arranged on the feed-side conductive plate. Each insulative support and the second side wall jointly form a clamping space. Each flexible clamping sheet is separately disposed on each insulative support. One end of each flexible clamping sheet is flexibly connected with the first side wall, and another end of each flexible clamping sheet is located in the clamping space.