Modular Signal Tower Contact Element Design
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Solution Overview
Problem
Existing optical signaling devices face challenges in ensuring reliable and efficient electrical contacting between interchangeable modules, leading to potential damage and increased design and economic efforts due to torque loads and manufacturing tolerances.
Innovation Solution
The use of contact elements with a contact ramp aligned with the longitudinal axis and adjustable contact surfaces that can compensate for manufacturing tolerances, providing reliable and secure electrical connections without generating torque, thus reducing the need for complex wire configurations and additional connecting wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wire loop-through configuration is used for electrical connection between modules, then electrical connectivity is achieved, but torque loads and manufacturing tolerances cause unreliable contacting and potential damage
Solution Approach 1:
The patent extracts the contacting function from the complex wire loop-through configuration and concentrates it into dedicated contact elements with contact ramps. This separates the electrical connection function from the structural module connection, eliminating the need for multiple wires to be precisely routed and connected between modules.
Solution Approach 2:
The contact elements with contact ramps serve as intermediary components between adjacent circuit boards. These intermediaries provide a mechanical interface that automatically ensures reliable electrical contact through the ramp geometry, compensating for manufacturing tolerances without requiring precise wire alignment.
2Reliability
If contact points are arranged to accommodate manufacturing tolerances, then contacting reliability improves, but torque loads increase causing potential damage
Solution Approach 1:
Instead of arranging contact points to accommodate tolerances (which creates torque), the patent inverts the approach by using contact ramps that actively compensate for tolerances. The ramp geometry is designed to self-align the contact surfaces, reversing the causal relationship between tolerance accommodation and torque generation.
Solution Approach 2:
The patent changes the geometric parameters of the contact interface by introducing ramps with specific angles and profiles. These parameter changes allow the contact surfaces to self-align during module assembly, converting potential misalignment into a beneficial self-correcting mechanism that eliminates torque while maintaining reliability.
3Reliability
If multiple contact points are used to ensure reliable electrical connection, then contacting security improves, but design effort and economic cost increase
Solution Approach 1:
The patent merges the functions of multiple contact points into a single integrated contact element with multiple contact ramps. This consolidation achieves the same electrical connection security as multiple separate contacts while simplifying the manufacturing process and reducing component count.
Solution Approach 2:
The contact elements serve multiple functions: they provide electrical connection, compensate for manufacturing tolerances, and guide module assembly. This multi-functionality replaces what would otherwise require multiple separate components, reducing design complexity and production effort while maintaining connection security.
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
An optical signaling device, in particular a modular signal tower (1) or the like, is provided with at least one first interchangeable light module (3) comprising at least one light element (10) for the optical indication of one or more different operating states of a technical device (2) such as a machine, a system, a vehicle or the like, wherein the first light module (3) has at least one first circuit board (11) oriented substantially in the direction of a longitudinal axis (8) of the signaling device, with the at least one first light element (10) and electrical components, wherein at least one contact (32) is provided between at least one first electrically contactable contact surface (19) and a second electrically contact surface (18) of an adjacently arranged,The second module (3, 4, 5, 6, 7) is designed as a second light module (3) and/or as a holding module (5) and/or as a base module (6) for holding and connecting the signaling device in an operating position, wherein the adjacently arranged module (3, 4, 5, 6, 7) comprises at least one second circuit board (11) oriented substantially in the direction of the longitudinal axis (8). The proposed design meets high requirements for the contact between two adjacent modules and simultaneously reduces the design effort and/or provides improved energy or power supply to the modules. According to the invention, this is achieved by arranging at least two electrically contactable surfaces (18, 19) of the contact (32), which can be detachably connected to each other, between the first circuit board (11) and the second circuit board (11) in the direction of the longitudinal axis (8).