One-Sided Rail Electrical Contact via Radial Bush Expansion
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Solution Overview
Problem
Existing methods for applying permanent electrical contacts to metal wall portions, such as rail webs or tubular profiles, require access from both sides, making them unsuitable for cases where access is limited to one side only.
Innovation Solution
A method and kit that utilize a bush and punch assembly with a pulling device to radially expand a tubular stem, allowing permanent anchoring in a hole from one side, accompanied by a terminal lug connection using an expansion bolt, enabling installation and electrical connection from a single access point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydraulic jack is used to expand the bush from the opposite side, then stable anchoring is achieved, but access from both sides of the rail web is required
Solution Approach 1:
The tool is divided into two functional parts: a punch with expansion elements that is inserted through the bush from the accessible side, and a pulling device that remains on the accessible side to apply expansion force. This segmentation allows the expansion function to be performed from one side only, eliminating the need for access to both sides of the rail web while maintaining stable anchoring.
Solution Approach 2:
The punch acts as an intermediary tool that transmits the pulling force from the pulling device (on the accessible side) to the bush, causing radial expansion. The punch with its expansion portions mediates between the pulling device and the bush, enabling one-sided access while achieving the same anchoring effect as the hydraulic jack.
2Ease of operation
If the bush is inserted from one side only, then ease of operation is improved, but stable anchoring becomes difficult to achieve
Solution Approach 1:
The punch is designed with movable expansion portions that can dynamically change shape from a compact insertion configuration to an expanded anchoring configuration. This dynamic transformation allows the punch to first pass through the bush easily, then expand to create stable anchoring forces on the bush, achieving both one-sided access and reliable fixation.
Solution Approach 2:
The expansion portions of the punch change their geometric parameters (size and shape) during the installation process. They start with a smaller cross-section to facilitate insertion through the bush, then expand to a larger cross-section to engage the bush walls and create stable anchoring, thereby achieving both ease of operation and reliable fixation.
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 the secure and stable installation of a permanent electrical contact on metal wall portions from a single side, ensuring tight contact and mechanical stability without the need for dual access.
Implementation Method 1
activating the pulling device to pull the punch with its expansion portion proximally completely through the tubular stem of the bush, while the abutment portion pushes distally against the proximal end of the tubular stem, thereby radially expanding the tubular stem and permanently anchoring it in the hole
Data Source
Figure 1~4
Figure 5~9
AI summary
Method for applying an electrical contact to a hole (2) of a metal wall portion (1), comprising the steps of providing a bush (12), a punch (11) with a shaft (16), an expansion portion (19) and a connecting portion (20) thereof, a pulling device (21) with an abutment portion (22) and a pulling mechanism (23) for engaging the punch (11) and to pulling it proximally with respect to the abutment portion (22), inserting the punch (11) in a passage hole (25) of the bush (12) so that the connecting portion (20) protrudes proximally from the bush and the expansion portion (19) is located on end (14), bush connecting the punch (11) to the pulling device (21), inserting the preassembled bush (12) -punch (11) -unit from a proximal side of the wall portion (1) distally in the hole (2) and activating the pulling device (21) to pull the punch (11) proximally through the bush, thereby radially expanding bush and permanently anchoring it in the hole (2).