Pressure Spring Terminal Block for Large-Conductor Stability
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Solution Overview
Problem
Existing terminal blocks with direct-plug pressure spring connections lack stability and ease of use for conductors with large cross-sections, and require improved connection devices for plug-and-socket connectors or apparatuses.
Innovation Solution
A terminal block design featuring series-mounted, clamping and latching connection devices with direct-plug pressure springs, utilizing a one-armed lever actuating device and a compact, one-piece busbar structure for efficient conductor connection, allowing 90° actuation and easy mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If direct-plug pressure spring connections are used for connecting conductors with large cross-sections, then connection simplicity is improved, but stability and reliability deteriorate
Solution Approach 1:
The terminal block is divided into multiple series terminals, each with individual connection devices. This segmentation allows each connection point to be optimized independently for both ease of operation and stability, while the modular design enables scalable configurations for different conductor sizes.
Solution Approach 2:
The connection device employs a dynamic clamping mechanism with a clamping spring that automatically adjusts to the conductor size and insertion force. The spring-loaded contact provides continuous pressure to maintain reliable electrical connection, while the actuating device allows dynamic opening and closing of the clamping action.
2Volume of moving object
If a compact terminal block design is used, then installation size is reduced, but manufacturing complexity increases
Solution Approach 1:
Multiple functional components are merged into integrated units: the busbar is formed as a single piece with multiple contact zones, the actuating device is integrated into the housing structure, and the clamping spring is combined with the retaining and detent spring. This merging reduces the number of separate parts while maintaining compact dimensions.
Solution Approach 2:
The terminal block design incorporates universal features that serve multiple functions: the housing provides both structural support and mounting attachment, the busbar serves as both electrical conductor and mechanical support for the clamping spring, and the actuating device enables both opening and closing operations. This multi-functionality reduces overall component count and simplifies manufacturing.
3Force
If a one-armed lever actuating device is used, then actuation force requirement is reduced, but structural complexity increases
Solution Approach 1:
The actuating device utilizes a lever arm that pivots about an axis, creating a rotational motion that provides mechanical advantage. The curved path of the lever arm allows force applied at one end to be amplified at the other end, reducing the actuation force requirement while maintaining a relatively simple structural form.
Solution Approach 2:
The actuating device is designed to be self-contained within the terminal block housing, with the lever arm pivoting on an integrated axis. The mechanism automatically transitions between open and closed states through the lever action, eliminating the need for external actuation mechanisms or complex control systems.
4Reliability
If series terminals are designed for stable connection, then connection reliability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The clamping spring is pre-loaded during assembly to provide immediate clamping force when the conductor is inserted. The retaining and detent spring is pre-positioned to automatically engage with the clamping spring, ensuring stable connection without requiring additional adjustment or tightening operations during installation or manufacturing.
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 design provides a stable, ergonomic, and cost-effective terminal block with minimal force requirement for actuation, ensuring efficient power conduction and easy conductor connection, suitable for conductors with large cross-sections and compatible with plug-and-socket connectors.
Implementation Method 1
the clamping spring is configured as a pressure spring with which a conductor end introduced into the connection device can be pressed against the contact zone
Implementation Method 2
One actuating device can pivot in the housing about an axis of rotation to move a clamping limb of the clamping spring out of a relaxed position into a tensioned detent position
Data Source
AI summary
A terminal block includes a plurality of series terminals which can be series-mounted, which are clampingly and/or latchingly connected, and which each have a housing and a plurality of two or more connection devices inserted into the respective housing. The connection devices are designed as direct-plug pressure spring terminals for connecting a respective conductor end. The connection devices each have a busbar, which has at least a respective contact zone for contacting the respective electrical conductor end, and the clamping spring is configured as a pressure spring. Per connection device there is one actuating device which can pivot in the housing about an axis of rotation, wherein the actuating devices are configured like a one- armed lever having an actuating section and a leading contour to act on the clamping limb when the clamping spring is tensioned.