Electrical Series Terminal with Spring-Loaded Contact Sections
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Solution Overview
Problem
Existing test disconnect blocks are cumbersome to assemble and have a risk of electrical contact issues due to the complex structure and assembly of insertion bridges, which can lead to twisted resilient current bars affecting the contact between the insertion bridge and the contact sections.
Innovation Solution
The electrical terminal block design features current bars with a second contact section and recesses for a jumper leg, allowing for simple and reliable cross-bridging between adjacent blocks via the jumper, eliminating the need for insertion bridges and ensuring a secure electrical connection that is easily switchable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insertion bridges are used to connect current bars in test disconnect blocks, then electrical connection between contact sections is achieved, but the structure becomes complex and assembly becomes cumbersome
Solution Approach 1:
The patent removes the insertion bridge component entirely from the system. Instead of using a separate insertion bridge to connect current bars, the design integrates the connection function directly into the current bars themselves through spring-loaded contact sections that automatically engage when the housing is assembled, thereby eliminating the complex insertion bridge structure while maintaining reliable electrical connection
Solution Approach 2:
The patent combines the functions of the current bar and the insertion bridge into a single integrated current bar design. The spring-loaded contact sections of the current bars perform both the current conduction function and the mechanical connection function that were previously separated into two different components, simplifying the overall structure
2Reliability
If insertion bridges are used to connect current bars, then electrical connection is established, but assembly becomes time-consuming and error-prone
Solution Approach 1:
The current bars are pre-formed with spring-loaded contact sections that are already configured to engage with complementary contact sections on adjacent current bars. This preliminary preparation of the connection interfaces eliminates the need for complex assembly operations involving insertion bridges, allowing for quick and error-free assembly when the housing is put together
Solution Approach 2:
The spring-loaded contact sections automatically engage with each other through elastic deformation when the housing is assembled, without requiring manual insertion or adjustment of separate connection components. The elastic force of the spring-loaded sections ensures reliable self-alignment and self-connection, making the assembly process faster and more reliable
3Reliability
If complex insertion bridge structures are used, then electrical connection is achieved, but the risk of twisted current bars and contact issues increases
Solution Approach 1:
The patent introduces dynamic spring-loaded contact sections that can elastically deform to accommodate minor misalignments and tolerances during assembly. This dynamic capability allows the current bars to self-adjust and maintain reliable electrical contact without requiring precise manual alignment or complex fixation mechanisms, thereby simplifying assembly and reducing the risk of contact issues
Solution Approach 2:
The spring-loaded contact sections are designed with built-in elastic compliance that compensates for assembly variations and tolerances before any contact issues can arise. The elastic force acts as a cushioning mechanism that maintains stable electrical contact even when minor deviations occur during assembly, preventing twisted or loose connections
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 design simplifies assembly, reduces the risk of electrical contact issues, and allows for modular configuration of terminal blocks with freely selectable numbers of poles, enhancing reliability and ease of use.
Implementation Method 1
the first contact sections together form a resilient contact area for receiving the plug of a test or service plug
Implementation Method 2
the current bars each having a connection section and a first contact section, the connection sections each being assigned to a conductor connection element
Data Source
Figure 1
Figure 2
Figure 3~6
AI summary
The invention relates to an electrical series terminal, in particular for connecting a current transformer, comprising a terminal housing (2), at least two conductor connector elements (4, 5), and at least two current bars (6, 7), wherein the current bars (6, 7) each have a connector section (8, 8') and a first contact section (9, 9'), wherein the connector sections (8, 8') are each assigned to a conductor connector element (4, 5) and the first contact sections (9, 9') together form a resilient contact region (10) to receive the plug (11) of the test or power plug (12), wherein the first contact sections (9, 9') are spaced apart from one another and are connected to one another in an electrically conductive manner via the plug (11) only when the plug (11) is inserted. By means of the electrical series terminal, a switchable transverse bridge to a neighbouring electrical series terminal can be produced in a reliable manner in that the current bars (6, 7) each have a second contact section (13, 13'), two further current bar pieces (14, 15) are arranged in the terminal housing (2), and at least one recess (16) is formed in at least one current bar piece (14, 15) for insertion of one branch (17) of a jumper (18), wherein in each case a current bar piece (14, 15) is assigned to a current bar (6, 7) in such a way that the second contact section (13, 13') of a current bar (6, 7) is connected to the assigned current bar piece (14, 15) in an electrically conductive manner when the plug (11) is not inserted, while the second contact section (13, 13') of a current bar (6, 7) is spaced from the assigned current bar piece (14, 15) when the plug (11) is inserted.