Rotary Lever Connection Device with Cam Actuation
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Solution Overview
Problem
Existing connection devices face difficulties in handling and structural design, particularly when connecting conductors of larger diameters, requiring improvement for efficient and reliable contact and release.
Innovation Solution
A connection device with a housing, busbar section, clamping spring assembly, and rotary lever assembly, where the rotary lever assembly rotates the clamping spring assembly from an open position to a contact position using a cam section and guiding device, ensuring reliable contact and release by engaging a pin in a slotted link for secure fixation on a metal busbar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional connection device structure is used, then the device is simple in design, but it requires high actuating forces and is difficult to operate, especially with larger diameter conductors
Solution Approach 1:
The connection device employs a dynamic cam mechanism where the cam profile changes the mechanical advantage during the actuation cycle. As the lever rotates, the cam profile dynamically adjusts the force transmission, providing higher mechanical advantage at the beginning of the closing stroke when actuating force is needed, and reducing resistance as contact is established.
Solution Approach 2:
The invention introduces a rotational dimension to the actuation mechanism. Instead of linear motion, a rotary lever rotates around an axis, converting rotational input into the linear motion needed to close the connection. This dimensional change provides mechanical advantage through the lever arm length and allows for more ergonomic operation.
2Reliability
If the contact position is fixed only in the plastics housing, then the structure is simple, but the contact position is not durably secured
Solution Approach 1:
The connection device combines plastics housing with metal reinforcement elements (cam mechanism and fixing components). The metal elements provide the necessary strength and durability for secure contact fixation, while the plastics housing provides insulation and structural support. This composite approach achieves reliable durable contact positioning without excessive complexity.
Solution Approach 2:
The cam mechanism is pre-configured with a specific profile that guides the clamping elements into the correct contact position. The geometry of the cam and associated slots is designed in advance to automatically ensure proper alignment and secure fixation when the lever is rotated to the closed position, eliminating the need for complex adjustment mechanisms.
3Ease of operation
If a cam mechanism with rotary lever is used, then lower actuating forces are required and operation is easier, but the structural design becomes more complex
Solution Approach 1:
The rotary lever assembly serves multiple functions: it provides the mechanical advantage through lever arm rotation, drives the cam mechanism for force multiplication, and incorporates the fixing mechanism for securing the contact position. By combining these functions into a single integrated assembly, the design achieves ease of operation without proportionally increasing overall device complexity.
Solution Approach 2:
The invention merges the cam mechanism, lever assembly, and fixing components into an integrated unit. The cam profile is formed as part of the lever assembly or in close integration with it, and the fixing elements are positioned to work automatically with the cam rotation. This merging reduces the number of separate components and simplifies the overall structure despite the sophisticated mechanism.
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 reliable and durable contact of conductors with lower actuating forces, maintaining a high contact force and ensuring easy operation by securely fixing the end contact position on the metal busbar, allowing for simple and consistent usability.
Implementation Method 1
The clamping spring assembly (4) has one or two clamping springs and one or two clamping limbs (410, 420) which press on the conductor end (3) when the end contact position is reached
Implementation Method 2
the rotary lever assembly has an axis of rotation D2 which is positioned above the axis of rotation D1 of the clamping spring assembly
Data Source
AI summary
A connection device for the connection of a conductor end includes a housing having a slotted link, a busbar section having a slotted link aligned with the housing slotted link, an d clamping spring assembly rotatably connected with the housing and operable between an open position and a contact position with the conductor end. A rotary lever assembly including a rotary lever element is operably connected with the clamping spring assembly. The rotary lever element has a cam section and a control curve section on which the clamping spring assembly slides during movement into the contact position. A clamping device is arranged on the cam section and is retained by the housing and busbar slotted links.