Rail Socket Resilient Contact for Tolerance Adaptation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rail sockets face challenges in maintaining a stable electrical and mechanical connection with conductor rails due to construction tolerances such as ridges and dents, which can reduce the number of contact points and degrade the dissipation of electrical excess energy, potentially leading to non-compliance with electrical standards.
Innovation Solution
A rail socket design featuring a conductor receptacle with a resilient contact member, such as a flat spring or lamella-based spring, that can adapt to tolerances through torsional or rotational movement, and includes attachment sections with hook-like features to engage with the conductor rail, ensuring a secure and efficient connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rigid contact members are used in the rail socket, then the structure is simple and manufacturing is easy, but the connection stability deteriorates due to construction tolerances such as ridges and dents on the conductor rail
Solution Approach 1:
The contact member is designed as a resilient element that can dynamically adapt its position and shape to accommodate construction tolerances on the conductor rail. The resilient nature allows the contact member to deform and maintain stable electrical contact despite ridges, dents, or dimensional variations on the rail surface.
Solution Approach 2:
The contact member's physical parameters (shape, position, deformation state) are allowed to change in response to the conductor rail's surface conditions. By permitting controlled deformation rather than maintaining a fixed rigid geometry, the system achieves reliable contact across varying manufacturing tolerances.
2Reliability
If the number of contact points is increased to improve current transmission, then electrical performance improves, but the device complexity increases
Solution Approach 1:
The contact member is divided into multiple contact zones or segments along its length, allowing it to establish multiple contact points with the conductor rail simultaneously. This segmentation enables improved current transmission through parallel contact paths without requiring a complex assembly of separate contact elements.
Solution Approach 2:
Multiple contact functions are merged into a single resilient contact member structure. Rather than using multiple separate rigid contacts, the invention combines them into one flexible element that inherently provides multiple contact points through its deformation, simplifying the overall device structure.
3Reliability
If resilient contact members are used to adapt to tolerances, then connection reliability improves, but the device complexity increases compared to rigid contacts
Solution Approach 1:
The contact member is implemented as a thin, flexible resilient element that can bend and conform to the conductor rail's surface irregularities. This flexible structure provides adaptation to tolerances without requiring complex mechanisms, actuators, or multiple components.
Solution Approach 2:
The resilient contact member is designed to automatically adapt to the conductor rail's surface conditions through its own elastic deformation, without requiring external adjustment mechanisms, sensors, or control systems. The structure self-regulates its contact pressure and position to maintain reliable electrical connection.
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 and adaptable connection that maintains electrical and mechanical integrity, effectively dissipating electrical excess energy and ensuring compliance with standards by increasing the number of contact points and reducing current density.
Implementation Method 1
at least one electrically conductive resilient contact member (15), which extends into the conductor receptacle (23)
Implementation Method 2
at least one electrically conductive resilient contact member (15), which extends into the conductor receptacle (23)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a rail socket (13) for connecting a module device (2) to a conductor member (4), the rail socket (13) comprising a conductor receptacle (29) adapted to receive the conductor member (4). Rail sockets (13) of the art have the disadvantages that mechanical and/or electrical connection between the rail socket (13) and a conductor member (4) may be degraded by means of tolerances of the conductor member (4). The present invention solves this problem by providing the rail socket (13) with at least one electrically conductive resilient contact member (15) which extends into the conductor receptacle (23).