Movable Connection Knife Housing for Misaligned Terminal Blocks
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Solution Overview
Problem
Existing electrical panel assembly processes are time-consuming due to the manual connection of wires between electrical devices and distribution devices, and interconnection devices are prone to jamming if terminal blocks are not perfectly aligned.
Innovation Solution
An interconnection device with movable connection knives that can accommodate positioning variations of input terminals, allowing independent connection to corresponding terminal blocks, reducing the risk of jamming and simplifying the connection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid conductive elements terminating in connecting knives are used to connect terminal blocks, then electrical connection is achieved, but the device jams if terminal blocks are not perfectly aligned
Solution Approach 1:
The connection knife is designed to be movable relative to the connection box, allowing it to dynamically adjust its position to accommodate misalignment between terminal blocks. The limited range of motion ensures the knife remains guided while adapting to positioning variations, preventing jamming during insertion.
Solution Approach 2:
The invention changes the positional parameter of the connection knife by allowing it to move within a limited range relative to the connection box. This parameter change enables the knife to compensate for alignment deviations without requiring perfect precision in terminal block positioning.
2Reliability
If each wire end is positioned and secured individually, then secure electrical connection is achieved, but the assembly process becomes time-consuming
Solution Approach 1:
Multiple connection knives are integrated into a single interconnection device with a common connection box, allowing simultaneous connection to multiple terminal blocks. This merging of connection functions into one unitized device enables parallel assembly operations, significantly improving productivity while maintaining secure connections.
Solution Approach 2:
The interconnection device serves multiple functions: it provides electrical connection between terminal blocks, accommodates positioning variations through movable knives, and facilitates simultaneous multi-point connection. This multi-functionality eliminates the need for separate wire-by-wire connection operations.
3Device complexity
If connection knives are fixed in position within the connection box, then structural simplicity is maintained, but the device cannot accommodate positioning variations of input terminals
Solution Approach 1:
The connection knife transitions from a fixed to a movable element within the connection box, gaining the ability to adapt to positioning variations. The movement is constrained by guide elements that define a limited range of motion, maintaining structural control while enabling adaptability.
Solution Approach 2:
The connection knife is introduced into a new dimensional freedom by allowing movement in addition to its primary connection function. This additional degree of motion enables the knife to compensate for misalignment in the insertion direction without complicating the overall connection box structure.
Data Source
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AI summary
This interconnection device (200) is configured to be electrically connected to a terminal block comprising input terminals. The interconnection device includes a set of cables (202), each associated with a respective input terminal, and connecting knives (220) fixed to the end of each cable. According to the invention, the interconnection device also includes a connection housing (230) that houses the connecting knives, each of which comprises a connection portion (224) extending outside the connection housing for its connection to a respective input terminal. The connection housing provides recesses (244), each of which receives a respective connecting knife with a dimensional clearance around each connecting knife, so as to allow movement, with a limited amplitude along a transverse axis (X210) of the connection housing, of the corresponding connection portion (244) relative to this connection housing.