Single Mounting Carrier for Overload Relay Electrical Connection
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Solution Overview
Problem
Overload relays with cage spring connections often cannot be directly connected to contactors due to space constraints in control cabinets, requiring an alternative method for electrical connection that is both easy and quick to implement.
Innovation Solution
A single installation support with bushings for electrical contacts and lines, incorporating a spring clamp element to facilitate easy and secure electrical connection between the overload relay and the contactor, allowing for individual setup and potential conversion to direct attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If overload relay with cage spring connections is directly connected to contactor, then electrical connection is established, but space constraints in control cabinet prevent implementation
Solution Approach 1:
The system is divided into separate components: the overload relay can be connected individually to the adapter without requiring direct connection to the contactor. The adapter serves as an intermediate segment that bridges the electrical connection while allowing spatial separation, thus resolving the space constraint issue in the control cabinet.
Solution Approach 2:
The adapter acts as an intermediary device between the overload relay and the contactor. It provides cage spring connections that facilitate electrical connection without requiring the overload relay to be directly mounted on the contactor, thereby overcoming the space limitations in the control cabinet while maintaining reliable electrical connectivity.
2Area of stationary object
If individual installation support is used for overload relay, then space constraints are overcome, but connection process becomes more complex
Solution Approach 1:
The adapter is designed with universal cage spring connections that can accommodate different types of electrical contacts and wiring configurations. This multi-functionality simplifies the connection process by providing a standardized interface that works with various overload relay and contactor types, reducing the complexity that would otherwise arise from using generic individual installation supports.
Solution Approach 2:
The adapter modifies the connection parameters by providing pre-configured cage spring connections with appropriate electrical and mechanical properties. This changes the connection interface from a complex custom installation to a standardized connection process, thereby reducing complexity while still allowing flexible spatial arrangement in the control cabinet.
3Reliability
If screw terminals are used for overload relay connection, then electrical connection is established, but installation time increases
Solution Approach 1:
The adapter replaces the traditional screw terminal mechanical connection system with a cage spring connection system. This mechanical substitution eliminates the need for threading and tightening screws, allowing for quick plug-and-play installation while maintaining reliable electrical connection, thus significantly reducing installation time.
Solution Approach 2:
The cage spring connections in the adapter are designed to automatically clamp and secure the electrical contacts when inserted, without requiring manual tightening or adjustment. This self-service mechanism ensures reliable electrical connection while eliminating the time-consuming screw tightening process, thereby reducing installation time while maintaining connection reliability.
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 easy and secure electrical connection of overload relays with cage spring connections to contactors, overcoming space constraints and simplifying the connection process, while reducing material costs through the use of a double spring clamp element or alternative spring clamp designs.
Implementation Method 1
an individual installation support having at least one spring clamp element for clamping and making electrical contact with the at least one electrical contact of the overload relay and for clamping and electrical contacting of the at least one electrical line from the electrical device
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The itemized holder (1) has three lead-throughs (2,3,4) for receiving an electrical contact of the overload relay and accommodates an electrical line of an electrical equipment. The holder has a spring clamping element for fixing and electrical contacting of an electrical contact of the overload relay. The spring clamp element attaches and electrically contacts the electrical line from an electrical equipment.