Rotating Contact Element for One-Handed Light Rail Module Assembly
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Solution Overview
Problem
Existing contacting elements for electrical or electronic modules on elongated luminaire support rails require complex assembly processes and often need two hands to establish electrical connections, which can be cumbersome and unsafe.
Innovation Solution
A contacting element with a fastening part and a connecting part that converts a simple translational actuation force into a rotary movement, allowing for automatic electrical connection during insertion, featuring a manipulation section and a connecting structure that facilitates rotation between assembly and coupling positions, enabling one-handed assembly and secure electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a lever is used to rotate the contact element for making electrical contact, then the electrical connection can be established, but the assembly process becomes complex and requires two hands (one for insertion, one for rotation)
Solution Approach 1:
The patent combines the insertion movement and rotation operation into a single unified action. The connecting element is inserted into the receiving space in one continuous motion, and the guiding structure automatically converts this linear insertion movement into the necessary rotation to bring the contact surface into contact with the busbar. This eliminates the need for a separate rotation operation with a lever, allowing one-handed assembly and simplifying the overall process.
Solution Approach 2:
The guiding structure is designed to automatically convert the insertion movement into rotation without requiring external manipulation. As the connecting element is inserted into the receiving space, the guiding structure's geometry automatically causes the connecting element to rotate, bringing the contact surface into engagement with the busbar. This self-converting mechanism eliminates the need for manual rotation operations.
2Reliability
If a lever protruding through a slot in the mounting bracket is used to rotate the contact element, then electrical contact can be made, but the mounting bracket requires additional openings and the assembly becomes more cumbersome
Solution Approach 1:
The patent removes the lever and slot mechanism from the mounting bracket design. Instead of having the lever protrude through a slot in the mounting bracket to rotate the contact element, the invention integrates the rotation function directly into the connecting element itself through the guiding structure. This extraction simplifies the mounting bracket to its essential function of providing the receiving space and busbar, without additional openings or lever mechanisms.
3Reliability
If manual rotation of the contact element is required, then electrical contact can be established, but assembly time increases and productivity decreases
Solution Approach 1:
The patent ensures continuous useful action throughout the assembly process. The insertion movement of the connecting element into the receiving space continuously performs multiple functions: it positions the connecting element, the guiding structure converts this movement into rotation, and the contact surface engages with the busbar. This continuous one-motion process eliminates idle time between insertion and contact establishment, maximizing assembly speed and productivity.
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 simplifies the assembly process, ensures secure and automatic electrical connection, and enhances safety by allowing single-handed operation and easy alignment of the contacting element with the luminaire support rail.
Implementation Method 1
The connecting structure is designed such that it converts a translational actuating force applied to a manipulation section into the relative rotation between the connecting part and the mounting part
Implementation Method 2
The connecting part has at least one electrical contact element which projects laterally or radially outwards with respect to the axis of rotation so that it moves around the axis of rotation together with the main body when the connecting part is rotated relative to the fastening part
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention relates to a contacting element (1) for connecting an electrical or electronic module (10) to an elongated mounting rail (100) of a lighting system (L). The contacting element (1) has a mounting part (2) and a connection part (3), which are rotatably connected to each other about an axis of rotation (X) via a connecting structure (4) in order to move the connection part (3) between a mounting position and a coupling position. The connection part (3) has a manipulation section (31), wherein the connecting structure (4) is designed such that it converts a translational actuating force (F) applied (axially) to an actuating section (32) of the manipulation section (31) into the relative rotation (R) between the connection part (3) and the mounting part (2), in order to move the connection part (3) from the mounting position to the coupling position.The invention further relates to an electrical or electronic module (10) with a carrier element (11), a contacting element (1) according to the invention, and an electrical or electronic unit electrically connected to the contacting element (1). The present invention also relates to the lighting system (L) with the lighting mounting rail (100) and the module (10) according to the invention.