Reversible Cable Contact via Mechanical Pressing
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Solution Overview
Problem
Existing methods for electrical contacting of cables, particularly in high-frequency measurements, are time-consuming and lack consistency due to soldering processes, which can vary in quality and are not suitable for cables with finer cores.
Innovation Solution
A device comprising a cable holder, contact plate, and fixing element allows for reversible, mechanical fixation and electrical contacting of cable conductors, ensuring consistent and repeatable connections through adjustable mechanisms and elastic spring elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect electrical conductors to measuring devices, then electrical contact is achieved, but the process is very time-consuming and quality varies greatly
Solution Approach 1:
The patent replaces the thermal soldering process with a mechanical pressing system. A cable holder mechanically presses the stripped conductor ends onto contact areas of a contact plate, eliminating the need for soldering while achieving reliable electrical contact. This mechanical substitution resolves the contradiction by providing both speed (no heating/cooling time) and consistency (uniform pressing force).
Solution Approach 2:
The device enables self-service electrical contacting where the cable holder and contact plate system automatically achieves consistent electrical contact through mechanical pressing without requiring skilled manual soldering operations. The standardized contact areas and pressing mechanism ensure uniform quality across all connections.
2Reliability
If manual soldering is performed on cables with small conductor cross-sections, then electrical contact is achieved, but the process becomes extremely time-consuming
Solution Approach 1:
The patent replaces manual soldering with an automated mechanical pressing system. The cable holder applies consistent mechanical force to press conductors onto contact plate areas, eliminating the time-consuming manual dexterity required for small conductor soldering while maintaining reliable electrical contact.
Solution Approach 2:
The cable preparation (stripping) is performed in advance, and the mechanical pressing system is pre-configured with contact plate areas positioned at precise locations. This preliminary preparation eliminates the need for time-consuming on-site soldering operations.
3Ease of manufacture
If soldering conditions and operators vary, then electrical contact can be made, but quality consistency deteriorates significantly
Solution Approach 1:
The patent replaces the variable human-dependent soldering process with a standardized mechanical pressing system. The cable holder and contact plate assembly provides consistent pressing force and alignment, eliminating quality variations caused by different operators or soldering conditions while maintaining ease of implementation.
Solution Approach 2:
The patent changes the fundamental parameter from thermal soldering to mechanical pressing. This parameter change standardizes the contact process, ensuring consistent quality regardless of operator skill or environmental conditions, while the mechanical system remains easy to implement and operate.
4Reliability
If positioning blocks with dielectric substrates are used for cable contact, then electrical contact is achieved, but the insertion process becomes very complex and time-consuming
Solution Approach 1:
The patent segments the contacting system into a cable holder for mechanical fixation and a separate contact plate for electrical contact. This segmentation simplifies the insertion process compared to complex positioning blocks, as the cable holder can be easily positioned and pressed onto the contact plate without complex alignment procedures.
Solution Approach 2:
The patent replaces the complex positioning block and dielectric substrate system with a simpler mechanical pressing system. The cable holder directly presses conductors onto contact plate areas, eliminating the need for complex positioning mechanisms while maintaining stable electrical contact.
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
This solution enables quick, reliable, and qualitatively consistent electrical contacting of cables, improving measurement repeatability and reducing variability in high-frequency measurements.
Implementation Method 1
an elastic, electrically conductive spring element is provided on the further contact area between the contact plate and the cable receptacle. The exposed conductor is pressed against the spring element by means of the cable holder, which always results in the same force acting on the exposed conductor.
Data Source
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AI summary
The invention relates to a device for reversible mechanical fixation and electrical contacting of one or more electrical conductors (11) of a cable (10). According to the invention, the cable (10) is fixed mechanically by means of the cable receptacle (2) and exposed conductor ends (12) of electrical conductors (11) are positioned on a contact plate (3). A fixation element (4) is provided for pressing the exposed conductor ends (12) onto the contact plate (3). Such a device and such a method are required for electrically contacting, in a temporary manner, one or more electrical conductors that are run in a cable. This is especially necessary for electrical measurements of such cables.