Slider-Operated Clamp Spring Arm Electrical Connector
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Solution Overview
Problem
Existing electrical connectors with levers face challenges in securely connecting and disconnecting flexible or twisted conductors, as they require manual force to displace the spring arm, which can lead to conductor damage or unintended disconnection, and levers pose safety risks due to unintentional movement.
Innovation Solution
An electrical connector design featuring a slider mechanism that moves linearly to control the spring arm's position, allowing for controlled insertion and removal of conductors without forming a hook, thus ensuring secure connection and disconnection without manual force displacement and minimizing safety risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a lever is used to move the spring arm, then the spring arm can be displaced to insert conductors, but the lever forms a hook that can be moved unintentionally by moving conductors, leading to unsafe electrical conditions
Solution Approach 1:
A non-conductive slider is introduced as an intermediary component between the user's manual input and the spring arm. The slider moves linearly within the housing and translates this motion to the spring arm through sliding guides, eliminating the need for a lever that forms a hook. This intermediary prevents direct mechanical coupling that could allow conductors to inadvertently move the actuating mechanism.
Solution Approach 2:
The traditional lever-based mechanical system is replaced with a slider-based linear motion system. Instead of rotational lever movement that creates hook-shaped protrusions, the system uses linear sliding motion constrained within the housing, eliminating the harmful hook formation while maintaining the ability to displace the spring arm for conductor insertion.
2Ease of operation
If manual force is applied to displace the spring arm, then the conductor can be inserted, but this requires special manual positioning and can damage or break conductors
Solution Approach 1:
The slider mechanism automatically provides the necessary motion to displace the spring arm when the user inserts a conductor. The linear movement of the slider, driven by the insertion action itself, translates through sliding guides to move the spring arm and form the gap needed for conductor entry. This self-service mechanism eliminates the need for separate manual positioning actions that could damage conductors.
Solution Approach 2:
The slider acts as a mediator that converts the user's insertion motion into spring arm displacement. Instead of requiring direct manual force application to the spring arm, the slider intermediate mechanism translates the insertion action into the appropriate spring arm movement, reducing mechanical stress on the conductor.
3Ease of operation
If a lever is used to move the spring arm, then the spring arm can be actuated, but the lever needs special support in the housing or can be removed unintentionally, destroying the housing
Solution Approach 1:
The lever-based mechanical system is replaced with a slider-based linear motion system. The slider moves within linear constraints provided by the housing walls and is retained by shoulder portions that engage with corresponding features in the housing. This substitution eliminates the need for special lever supports and prevents unintentional removal while maintaining spring arm actuation capability.
Solution Approach 2:
The actuation mechanism transitions from rotational lever movement to linear slider movement along a different dimension (the longitudinal axis of the connector). This dimensional change allows the actuating component to move within the housing volume without requiring external lever arms or complex support structures, improving housing integrity.
4Volume of moving object
If connectors are made compact, then space is saved, but levers make compact design difficult
Solution Approach 1:
The complex rotational lever mechanism is replaced with a simple linear slider that moves along the longitudinal axis of the connector. This substitution dramatically reduces the spatial requirements for the actuating mechanism, enabling compact connector design. The slider's linear motion path is constrained within the existing housing dimensions, eliminating the need for additional space that would be required for lever rotation arcs and support structures.
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 slider mechanism enables precise control over the spring arm's position, ensuring secure connection and disconnection of conductors, reducing the risk of damage and providing enhanced safety by eliminating unintentional disconnections and mechanical stress on the housing.
Implementation Method 1
The spring arm can be pre-loaded towards the bus bar so that an electrical conductor inserted into a gap between the bus bar and the spring arm can be mechanically secured
Implementation Method 2
The slider includes two opposite sliding guides cooperating with a convex support surface of the spring arm such that a movement of the slider translates into a movement of the spring arm along the first axis
Data Source
AI summary
An electrical connector for receiving at least one electrical conductor comprises a housing, a bus bar arranged inside the housing, and at least one clamp arranged inside the housing. The clamp has a spring arm moveable relative to the bus bar between a connecting position and a disconnecting position. The spring arm cooperates with the bus bar to secure an electrical conductor to the bus bar when the spring arm is in the connecting position. The spring arm allows an end section of an electrical conductor to be inserted through an opening of the housing in the disconnecting position. At least one slider extends into the housing and is moveable relative to the housing between a closed position and an open position. The slider includes at least one sliding guide cooperating with the spring arm such that a movement of the slider translates into a movement of the spring arm.