Relay Base Screw-Terminal Layout for Tool-Free Wiring
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Solution Overview
Problem
Existing relay bases require special tools like crimping tools and extractors for making and breaking electrical connections, which is cumbersome and time-consuming.
Innovation Solution
A relay base with flexible connectors and screw-type terminals allows for easy connection and disconnection using standard tools, accommodating cables up to 6 mm² without the need for crimping, featuring a compact design and modular connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If special sockets and crimping tools are used to establish electrical connections, then reliable electrical connection is achieved, but the operation becomes cumbersome and time-consuming
Solution Approach 1:
The connection unit is designed to be self-configuring through the spring element's automatic engagement mechanism. When the connector is inserted, the spring element automatically compresses and locks into the recess, creating a reliable electrical connection without requiring manual crimping or special tools. The system serves itself by using the insertion force to activate the locking mechanism.
Solution Approach 2:
The invention replaces the manual crimping mechanical system with a spring-based automatic locking mechanism. Instead of using a crimping tool to deform the socket and secure the conductor, the spring element uses elastic deformation to create a secure mechanical and electrical connection through automatic engagement with the recess.
2Ease of repair
If special extractors are used to remove conductors from relay base, then conductor removal is achieved, but the process becomes cumbersome and time-consuming
Solution Approach 1:
The connection unit features a self-releasing mechanism where the connector can be easily removed by applying force to the outer housing, which automatically releases the spring element from the recess. This eliminates the need for special extractors and allows rapid conductor removal without complex tools or procedures.
Solution Approach 2:
The connection unit transitions from a static locked state to a dynamic release state through simple external force application. The spring element is designed to be held in the recess under normal operation but can be easily released when force is applied to the outer housing, enabling quick conductor removal and reconfiguration.
3Stability of the object's composition
If rigid connection structures are used in relay base, then structural stability is achieved, but adaptability to different cable sizes is reduced
Solution Approach 1:
The outer housing acts as a flexible shell that can accommodate different cable sizes and configurations. The housing provides structural stability while its design allows adaptation to various conductor cross-sections up to 6 mm², combining rigidity for stability with geometric flexibility for adaptability.
Solution Approach 2:
The connection unit is designed as a universal connector that can handle multiple cable sizes (up to 6 mm²) and different conductor types through its geometrically adaptable recess and spring element design. A single connection unit design serves multiple functions across different application scenarios.
Data Source
AI summary
A relay base for connection to a plug-in relay is disclosed. The relay base comprises a plurality of connection units. Each connection unit comprises an electrically conductive socket member having a first end configured to receive a pin of the relay, an electrically conductive flexible connector having a first end that is electrically connected to a second end of the socket member, and an electrically conductive insert having a first end that is electrically connected to a second end of the flexible connector. A second end of the insert is configured as an electrical connectivity receptacle (e.g., a screw type terminal comprising a thread for receiving a screw). The configuration of the second end of the insert allows for facilitated making and breaking an electrical connection between the relay and an external wiring.