Overvoltage Protection Device Lever Mechanism
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Solution Overview
Problem
Existing overvoltage protection devices face challenges in tool-free, quick assembly and maintaining reliable, surge current-resistant connections, especially in DIN rail applications, as pointed contacts tend to burn off under surge current loads, leading to insecure connections that are often detected too late.
Innovation Solution
The overvoltage protection device features a base part with parallel grooves and hook-shaped extensions, combined with a lever part and insulation displacement connectors, allowing tool-free insertion and cutting through insulation for reliable contact, ensuring secure connections without requiring significant force or tools, even for larger conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pointed contacts are used for tool-free connection, then ease of operation is improved, but reliability deteriorates due to contact burn-off under surge current loads
Solution Approach 1:
The connection device is divided into two functional parts: a first connection device with insulation displacement terminals for making the electrical connection, and a second connection device with mating contacts for establishing the electrical contact. This segmentation allows each part to be optimized for its specific function, resolving the contradiction between ease of operation and reliability.
Solution Approach 2:
The insulation displacement terminals act as an intermediary mechanism that enables tool-free operation while maintaining reliability. These terminals penetrate the conductor insulation and establish a secure mechanical and electrical connection that can withstand surge currents, eliminating the need for pointed contacts that burn off.
2Productivity
If insulation displacement connectors are used without supporting tools, then productivity is improved, but manufacturing precision deteriorates due to inadequate contact for high currents
Solution Approach 1:
The connection system is segmented into insulation displacement terminals specifically designed for quick insertion and a separate contact mechanism ensuring high-current capability. This allows the insulation displacement function to operate quickly without tools while the contact quality is ensured by the specialized contact structure.
Solution Approach 2:
The insulation displacement terminals are designed with specific geometric parameters and material properties that enable them to penetrate insulation and create secure contacts for high currents without requiring supporting tools. The terminal design includes features that ensure adequate contact pressure and surface area for surge current resistance.
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
This design enables quick, tool-free assembly with reliable and permanent electrical connections that withstand surge currents, providing enhanced operational reliability and safety by ensuring extensive peripheral contact without the need for tools or complex prefabricated structural units.
Implementation Method 1
insulation displacement terminals, penetrating the conductor insulation
Data Source
Figure 1a~1d
Figure 2~5
AI summary
The invention relates to an overvoltage protection device with at least one overvoltage protection unit, consisting of a socket part and a plug part which can be connected to the socket part and which receives means for protecting against an overvoltage, wherein insulated electric conductors can be introduced into the socket part, said electric conductors being contacted using vampire or cutting clamps, thereby penetrating the conductor insulation, and with contact surfaces which can be found on the socket part and which correspond to mating contact surfaces on the base of the plug part. According to the invention, the socket part is made of multiple parts consisting of a base part and a lever part. The base part is designed as a marble panel and has multiple parallel grooves for inserting and receiving the insulated electric conductors. On one face of the base part, hook-shaped protrusions are provided parallel to the grooves. The lever part has axle stubs, which engage into the hook-shaped protrusions, on one lever end. The lever part has at least one cutting clamp on the lever part lower face facing the marble panel and in the vicinity of the axle stubs, wherein the cutting clamp leads to a plug contact which can be found in the lever part and which can be accessed from the upper face of the lever part in order to receive the plug part.