Self-Locking Contact Spring Assembly for Secure Linear Insertion
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Solution Overview
Problem
Existing contact spring arrangements for electrical conductors are difficult to assemble and require complex motion schemes, making them inefficient for high-cycle production and secure fixation under tensile forces.
Innovation Solution
A contact spring arrangement with a simple linear movement for insertion and securing the contact spring in the support wall structure can be accomplished with a simple linear movement. The retaining leg is inserted into the receiving shaft, and the retaining leg is inserted into the receiving shaft, and the retaining leg is inserted into the receiving shaft, and the retaining leg is inserted into the receiving slot until the locking lugs automatically engage with mating contours. This assembly process can be performed with a simple assembly machine that does not require a complex motion scheme, making it suitable for high-cycle production and secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact spring is secured to the support wall structure using traditional methods (e.g., riveting), then the fixation is secure under tensile forces, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The retaining leg is designed to automatically secure itself to the support wall structure through a self-locking mechanism. The locking lugs on the retaining leg engage with corresponding recesses in the support wall structure during a simple linear insertion movement, eliminating the need for external fastening operations like riveting while maintaining secure fixation under tensile forces
Solution Approach 2:
The retaining leg is pre-formed with locking lugs that are positioned to automatically engage with the support wall structure upon insertion. This preliminary configuration of the locking features allows the assembly to self-secure during the insertion process itself, avoiding subsequent complex fastening steps
2Reliability
If a complex motion scheme is used to assemble the contact spring, then secure fixation can be achieved, but the assembly machine becomes complex and production cycle time increases
Solution Approach 1:
The self-locking mechanism performs the fixation function automatically during a simple linear insertion movement. The locking lugs engage with the support wall structure through the insertion motion itself, eliminating the need for complex multi-step assembly machines while maintaining secure fixation and enabling high-speed automated assembly
Solution Approach 2:
The complex motion scheme and external fastening mechanisms are extracted from the assembly process. The invention reduces the assembly to a simple linear insertion movement by integrating the locking function directly into the retaining leg structure, allowing use of simple assembly machines with high cycle rates
3Productivity
If a simple linear insertion movement is used to assemble the contact spring, then assembly is simplified and productivity increases, but securing the contact spring under high tensile forces becomes difficult
Solution Approach 1:
The retaining leg features asymmetric locking lugs with specific geometric profiles that engage with corresponding asymmetric recesses in the support wall structure. This asymmetric design creates a mechanical interlock that resists tensile forces effectively while allowing easy linear insertion during assembly
Solution Approach 2:
The locking lugs and mating contours are designed with curved surfaces that facilitate smooth engagement during linear insertion while providing mechanical advantage for resisting tensile loads. The curved geometry allows the simple insertion motion to transition into a secure locked state that can withstand high tensile forces
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 assembly process is simplified, allowing for high-cycle production and secure fixation of the contact spring, even under high tensile forces, without the need for complex motion schemes.
Implementation Method 1
Due to the elastic restoring force of the spring, a gripping edge formed at the free end of the clamping arm engages the circumferential surface of the copper core
Data Source
Figure 1~3
Figure 4~8
Figure 9~12
AI summary
The invention relates to a contact spring assembly for the self-locking contacting of a wire (28) of an electrical conductor, comprising: - a support wall (24) made of a conductive material; - a contact spring (10), which has a base leg (20) held stationary with respect to the support wall and has a clamping leg (18) which, together with the support wall (24), forms an insertion receptacle (26) for the wire (28) of the conductor, the insertion receptacle being tapered in the insertion direction, characterized in that the base leg (20) of the contact spring transitions into a holding leg (22' 22'), which is inserted into a receiving shaft (30) stationary with respect to the support wall (24) and has two detent projections (38), which protrude perpendicularly to the base leg in opposite directions and are locked to mating contours (34) on the walls of the receiving shaft.