Modular Jumper with Movable Bridging Rail for Terminal Blocks
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Solution Overview
Problem
Existing switching bridges are limited in their flexibility and usability across different terminal blocks, requiring specific busbar designs with threaded holes and external screws, which restrict their application to only compatible terminal blocks.
Innovation Solution
A switching bridge with insulated contact elements that engage in busbar openings, featuring a movably held bridging rail with contact areas that can be electrically connected by screws or latching mechanisms, allowing for easy adaptation to various terminal blocks without the need for specific busbar designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If switching bridges use screw connections requiring threaded holes in busbars, then reliable electrical connection is achieved, but applicability is limited to terminal blocks with specific busbar designs
Solution Approach 1:
The switching bridge is designed with a universal connection system that can engage with different busbar types (openings, slots, or surfaces) through a standardized interface. The contact element can adapt to various terminal block designs without requiring specific threaded holes or modifications to the busbar, thereby achieving both reliable connection and broad compatibility.
Solution Approach 2:
An intermediary contact element is introduced between the switching bridge and the busbar. This contact element serves as a mediator that can interface with different busbar configurations (openings, slots, or flat surfaces) while providing consistent electrical connection. The intermediary element absorbs the variability of different busbar designs, allowing the switching bridge to maintain reliable connections across multiple terminal block types.
2Reliability
If switching bridges are designed for specific terminal blocks, then secure connection is achieved, but flexibility and ease of operation across different terminal blocks is reduced
Solution Approach 1:
The switching bridge incorporates a universal interface design that can operate with multiple terminal block types without requiring redesign or special installation procedures. The contact element can engage with different busbar configurations through a standardized mechanism, providing both secure connection and operational flexibility across various terminal blocks.
Solution Approach 2:
The switching bridge employs a dynamic contact mechanism that can adapt its engagement method based on the terminal block type. The contact element can flexibly adjust between inserting into openings, engaging with slots, or making surface contact, allowing the switching bridge to maintain secure connections while easily adapting to different terminal block configurations during operation.
3Reliability
If threaded holes are required in busbars for screw connections, then stable electrical connection is achieved, but device complexity and manufacturing requirements increase
Solution Approach 1:
The threaded hole requirement is extracted and removed from the busbar design. Instead of requiring threaded holes in the busbar, the switching bridge uses a contact element that can engage with simpler busbar configurations (openings, slots, or surfaces). This extraction of the threading requirement simplifies the busbar design while maintaining stable electrical connections through the modified contact mechanism.
Solution Approach 2:
The switching bridge uses a simple, easily manufacturable contact element that replaces the need for complex threaded busbar designs. The contact element is designed as a simple component that can be produced cost-effectively and provides sufficient connection stability without requiring expensive or complex busbar modifications such as threaded holes.
4Reliability
If external screws are required for connection, then reliable electrical contact is achieved, but ease of manufacture and adaptability to different terminal blocks is reduced
Solution Approach 1:
The electrical contact function and the connection function are merged into a single integrated contact element. This eliminates the need for separate external screws and threaded holes, as the contact element itself provides both mechanical connection and electrical contact. The merged design simplifies manufacturing by reducing the number of components and assembly steps while maintaining reliable electrical contact.
Solution Approach 2:
The switching bridge employs a simple, easily manufactured contact element that replaces complex screw-and-threaded-hole assemblies. The contact element is designed as a simple component that can be produced cost-effectively through standard manufacturing processes, eliminating the need for expensive machining of threaded holes and external fasteners while maintaining reliable electrical contact.
Data Source
Figure 1a~1b
Figure 2
Figure 3~4
AI summary
A jumper is described that comprises a housing (2) and is used for bridging two modular electric terminals (3, 3') which are arranged next to one another and are each equipped with a busbar (4, 4'). At least one opening (5, 6, 7) is formed in the busbars (4, 4'). In order to be able to easily actuate the jumper according to the invention and flexibly and easily insert the same into multiple modular terminals, two mutually insulated contact elements (8) are arranged in the housing (2) so as to engage into an opening (5, 6, 7) in one respective busbar (4, 4'), and a jumper rail (9) is movably retained in the housing (2). The jumper rail (9), which has two contact zones (10) and a connection zone (11) that connects the contact zones (10), can be moved from a first final position in which the contact zones (10) do not contact the contact elements (8) into a second final position in which the contact elements (8) are interconnected in an electrically conducting manner via the jumper rail (9).