Spherical Contact Bodies for Reliable Electrical Conductor Connection
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Solution Overview
Problem
Existing methods for contacting electrical conductors, particularly in large cross-section cables, are complex and time-consuming, requiring removal of insulating materials and manual alignment, which complicates the connection process and increases the risk of errors during installation.
Innovation Solution
A device with spherical contact bodies and a force introduction element allows for isotropic force distribution, enabling reliable electrical contact without transverse forces on the conductor, using a connecting body that can be in one or multiple pieces, facilitating lateral swiveling of cables for connection, and incorporating a pasty mass for homogeneous contact body distribution and oxidation prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional contacting methods are used for large cross-section conductors, then insulating materials must be completely removed and individual wires manually aligned, but this makes the connection process complex and time-consuming
Solution Approach 1:
The invention extracts and removes the insulating material from the conductor assembly, separating it from the contacting process. This allows the contacting mechanism to focus solely on establishing electrical contact with the conductive elements without the complexity of dealing with insulating materials during the connection process.
Solution Approach 2:
The invention introduces a contacting element as an intermediary component that facilitates electrical contact between conductors. This element mediates the connection process by providing a standardized interface that simplifies the contacting operation while ensuring reliable electrical connection.
2Reliability
If insulating materials are completely removed and individual wires are manually combined, then electrical contact can be established, but this increases the risk of errors during installation
Solution Approach 1:
The invention enables the contacting element to perform the contacting function automatically once positioned. The design allows the element to self-align and establish contact with the conductor wires without requiring manual manipulation or precise alignment by the installer, thereby reducing installation errors.
Solution Approach 2:
The invention changes the physical parameters of the contacting element, such as its shape, size, and material properties, to optimize its interaction with the conductor wires. These parameter adjustments ensure that the element can reliably establish electrical contact while being easy to install and position correctly.
3Reliability
If spherical contact bodies are used with force introduction element, then isotropic force distribution is achieved, but this requires a specialized connecting body structure
Solution Approach 1:
The invention employs spherical contact bodies instead of traditional flat or irregularly shaped contacts. The spherical geometry enables isotropic force distribution in all directions, ensuring uniform pressure application on the conductor wires and improving electrical contact reliability while accommodating the specialized connecting body structure.
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 high current carrying capacity, and allows for reliable, long-term contact with reduced material costs and installation complexity, while maintaining low contact resistance and mechanical strength.
Implementation Method 1
the use of balls as contact bodies is advantageous since an isotropic force distribution can be achieved in a simple manner
Implementation Method 2
the device has at least one force introduction element acting on the contact medium, with which the contact force can be introduced into the contact medium
Implementation Method 3
the individual wires are again manually combined with the help of hose clamps and pressing tools into an almost circular shape with the diameter of the original conductor, so that they are inserted into the connecting element and sufficiently compressed by it
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an apparatus (1) for making contact with an electrical conductor (10, 20), in particular a cable conductor of a power supply cable, wherein the apparatus (1) has a connecting body (4) which delimits a receiving space (6) into which the conductor (10, 20) with which contact is to be made can be inserted by way of its end, and wherein the apparatus (1) has a contact medium (30) with which electrical contact can be made with the end of the conductor (10, 20) under the action of a contact force, characterized in that the contact medium (30) has a large number of electrically conductive contact bodies (32) which are introduced into the receiving space (6) and bear against one another and of which at least some can be brought into electrical contact-making contact with the end of the conductor (10, 20).