Pivotable Lever Terminal for Secure Power Supply Connections
Solution Overview
Problem
Conventional power pack connection terminals, such as screw and spring terminals, are cumbersome to install and prone to unintentional detachment, especially when space constraints are a concern, like in standard flush-mounted boxes.
Innovation Solution
A power pack design featuring a pivoted lever connection terminal that can be easily actuated from outside the housing, with the lever's pivotability restricted by the mounting surface, ensuring secure attachment without the need for additional tools and minimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a spring terminal is used instead of a screw terminal, then ease of operation is improved, but device complexity and space requirements increase
Solution Approach 1:
The terminal block is segmented into modular units, each handling individual conductors independently. This allows the use of simple screw terminals rather than complex spring mechanisms, reducing overall device complexity while maintaining ease of operation through standardized, repeatable connection points
Solution Approach 2:
The patent uses identical screw terminal designs for all conductor connections, copying the same simple, proven mechanism across multiple connection points. This avoids the need for complex spring terminals while maintaining consistent ease of operation across all connectors
2Ease of operation
If a spring terminal with actuation button is used, then ease of operation is improved, but reliability deteriorates due to unintentional loosening
Solution Approach 1:
The terminal block design incorporates preliminary protective measures against unintentional loosening through secure conductor clamping mechanisms and stable mounting arrangements that prevent accidental disconnection before operation even begins
Solution Approach 2:
Instead of using spring terminals that rely on button pressure to maintain connection, the patent inverts the approach by using screw terminals where the connection is maintained by continuous mechanical engagement, making unintentional loosening physically difficult without deliberate action
3Reliability
If a screw terminal is used, then reliability is improved, but ease of operation deteriorates due to tool requirement and manual dexterity needed
Solution Approach 1:
The terminal block is designed to be self-servicing by incorporating features that guide conductor insertion and screw engagement, reducing the skill level required. The design allows installers to complete connections independently without requiring high manual dexterity or complex procedures
Solution Approach 2:
The screw terminals are designed with optimized parameters including appropriate screw size, thread pitch, and clamping force requirements that balance reliability with ease of operation. The mechanical parameters are tuned to allow secure connections using standard tools without requiring excessive force or precision
4Ease of operation
If a spring terminal is used to simplify connection, then ease of operation is improved, but the housing space requirement increases
Solution Approach 1:
The terminal block is divided into compact modular segments that can be efficiently arranged within the housing. This segmentation allows screw terminals to be packed more densely and efficiently than spring terminals, reducing the overall space required while maintaining simple, reliable connection mechanisms
Solution Approach 2:
By copying identical, compact screw terminal designs across multiple connection points, the patent achieves space efficiency through standardization. The repeated use of the same compact terminal pattern allows for optimized space utilization compared to larger, more complex spring terminal arrangements
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
Facilitates simple and secure connection of conductors without tools, preventing unintentional detachment by leveraging the mounting surface to limit lever movement, thus enhancing installation ease and reliability within space-limited environments.
Implementation Method 1
a lever (34, 36, 42, 44) associated with each terminal (30, 32) and pivotably mounted on the terminal block inside the housing in each case about a pivot axis (38)
Implementation Method 2
with an associated spring element that is arranged to act on the lever in each case in a lever-arm-dependent manner
Data Source
Figure 1
Figure 2
AI summary
A power supply unit comprises a housing and at least one electrical terminal for connecting primary and/or secondary conductors to the power supply unit. The housing has two substantially parallel main surfaces and a circumferential surface. At least one associated lever is provided for connecting a conductor to the terminal; this lever is pivotably mounted and operable from outside the housing. When the housing is not mounted, the lever can pivot between a closed and an open position. The lever cannot pivot from the closed to the open position when the housing is mounted with one of its main surfaces against a wall.