Modular Terminal Block Layout for Clear High-Current Distribution
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Solution Overview
Problem
Existing terminal block systems are cumbersome and time-consuming to assemble, with varying dimensions leading to a confusing and complex layout on mounting rails, and are limited in their ability to distribute power efficiently, particularly for larger currents.
Innovation Solution
A modular terminal block design featuring uniformly dimensioned housings with direct plug-in spring terminals and cross-connector channels, allowing for easy assembly and efficient power distribution with integrated fuse protection, enabling clear and compact configuration for both feed and distribution terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If terminal blocks of different dimensions are assembled to form functional blocks, then power distribution capability is improved, but assembly complexity and layout confusion increase
Solution Approach 1:
The terminal block is divided into multiple individual terminal blocks that can be assembled in series. Each terminal block contains conductor connection devices for connecting conductors, and cross-connector channels for distributing potential. This segmentation allows flexible power distribution while maintaining uniform dimensions for simplified assembly.
Solution Approach 2:
Each terminal block is designed with universal dimensions and standardized features including conductor connection devices and cross-connector channels. This universality enables any terminal block to serve multiple functions in the series arrangement, eliminating the need for different sized blocks and simplifying assembly while maintaining versatile power distribution capability.
2Adaptability or versatility
If terminal blocks of different dimensions are used to accommodate various conductor cross-sections, then conductor connection flexibility is improved, but layout clarity and assembly time deteriorate
Solution Approach 1:
The terminal block system is segmented into identical modular units, each containing conductor connection devices capable of handling various conductor cross-sections. This segmentation maintains conductor connection flexibility while standardizing the modular dimensions for rapid assembly.
Solution Approach 2:
The conductor connection devices within each terminal block are designed to accommodate a range of conductor cross-sections through adjustable parameters, eliminating the need for different sized terminal blocks. This allows flexible conductor connection while maintaining uniform block dimensions that reduce assembly time and improve layout clarity.
3Productivity
If multiple terminal blocks are assembled in series to distribute power to several consumers, then power distribution efficiency is improved, but the number of components and assembly complexity increase
Solution Approach 1:
The power distribution system is segmented into a series of identical terminal blocks, each contributing to the overall power distribution function. The cross-connector channels in each block enable efficient potential distribution while the uniform design reduces the effective complexity by allowing standardized assembly procedures.
Solution Approach 2:
Multiple terminal blocks are merged in series to form a unified power distribution system. The standardized interfaces and uniform dimensions allow these blocks to be combined efficiently, achieving high power distribution efficiency while minimizing the practical complexity through repetitive modular assembly rather than complex custom configurations.
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
The solution simplifies the assembly and layout of terminal blocks, enhances power distribution efficiency, and reduces complexity by allowing clear and logical configuration of potential distribution with integrated fuse protection, accommodating higher current capacities in a fewer number of terminals.
Implementation Method 1
The conductor connection devices (7, 8) are designed as so-called push-in spring terminals with a compression spring connection. This spring serves to press the inserted conductor conductively against a busbar (not visible here).
Data Source
Figure 1a~1b
Figure 1c
Figure 1d~1g
AI summary
Terminal block comprising at least two or more modular terminals (2a, 2b,...; 102a, 102b,...) arranged next to one another in a row, which terminal block can be positioned on a mounting base, in particular a mounting rail, and having the following features: the modular terminals (2a,...; 102a,...) each have substantially disk-like housings (3, 103) comprising two main sides (3a, 3b), two narrow sides (3d, 3e), an upper side (3c) and a lower side; at least one of the modular terminals (2a, 102a) is configured as a feed-in terminal (2a, 102a) and, for this purpose, has at least one or two first conductor connection apparatuses (7, 8) for connecting external conductors for feeding in each case one or both potentials Plus and Minus, and the one or more other of the modular terminals are in the form of distribution board terminals (2b,...., 102b,...) for distributing the potential(s), for which purpose said one or more other of the modular terminals have at least one or more second conductor connection apparatuses (7, 8) for connecting external conductors for distributing the potential Plus or Minus to consumers, wherein the potential distribution is performed beyond the plurality of modular terminals of the terminal block by means of one or more associated cross-links, in particular cross connection link combs (12), which are plugged into one or more associated cross connection link channels (11), wherein all of the modular terminals of the terminal block have the same dimensions in the two directions perpendicular to the direction of modular arrangement (x), the first conductor connection apparatuses of the feed terminal for feeding the potential(s) to be fed are configured for connecting conductors of a first cross section, and the second conductor connection apparatuses (7, 8) of the distribution board terminals for connecting the consumers are configured for connecting conductors having a smaller cross section than the conductors to be connected to the first conductor connection apparatuses.