Spring Clamping Busbar Edge for Multi-Core Conductor Retention
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Solution Overview
Problem
Existing spring-loaded terminal connections struggle to securely hold multi-core conductors, particularly under tensile forces, and may damage conductors due to insufficient holding force.
Innovation Solution
Designing a busbar clamping edge with a radius of less than or equal to 0.2 mm, which acts as a sharp edge to dig into the conductor, combined with a clamping spring, providing additional holding force and ensuring the conductor is securely fixed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional busbar clamping edge is used, then the device structure is simple, but the conductor holding force is insufficient for multi-core conductors
Solution Approach 1:
The busbar is designed with a localized clamping edge feature that has different geometric properties (small radius ≤0.2mm) compared to the rest of the busbar structure. This local quality enhancement at the clamping edge provides high holding force for multi-core conductors without requiring the entire busbar structure to be complex.
Solution Approach 2:
The busbar clamping edge is pre-formed during busbar manufacturing with a specific small radius (≤0.2mm) to create a sharp edge that will dig into the conductor. This preliminary preparation ensures that when the conductor is inserted, the holding force is immediately effective without requiring additional adjustment or preparation steps.
2Force
If the busbar clamping edge radius is increased, then the manufacturing is easier, but the conductor holding force decreases
Solution Approach 1:
The critical parameter of the busbar clamping edge radius is precisely controlled to be ≤0.2mm. This parameter change creates a sharp edge that significantly increases the holding force by allowing the edge to dig into the conductor, while still being manufacturable using standard precision forming processes.
3Force
If only spring clamping force is used, then the device structure is simple, but the holding force is insufficient under tensile loads
Solution Approach 1:
The solution merges two clamping mechanisms: the spring clamping force from the clamping spring and the mechanical digging force from the sharp busbar clamping edge. This combination provides sufficient holding force under tensile loads while maintaining relatively simple device structure, as both mechanisms work together in the same clamping point.
4Reliability
If the clamping force is increased to prevent conductor pull-out, then the conductor is securely held, but the conductor may be damaged
Solution Approach 1:
The sharp busbar clamping edge (radius ≤0.2mm) is designed to intentionally dig into the conductor, converting what could be considered a harmful concentrating stress into a beneficial mechanical interlocking effect. This digging action increases holding force and reliability while the distributed nature of the clamping point prevents excessive localized damage.
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 solution achieves a high conductor holding force, preventing conductors from being pulled out and minimizing damage, especially for multi-core conductors.
Implementation Method 1
a clamping spring (3a, 3b) arranged at each of the diametrically opposite ends of the busbar (2)... each having a clamping leg (6a, 6b), which extends to a section of the busbar (2), with the clamping leg (6a, 6b) having a spring clamping edge (7a, 7b) and, together with the busbar (2), forming a clamping point for an electrical conductor to be clamped
Implementation Method 2
By designing a busbar clamp edge with a very small radius, a spring-loaded terminal connection is created that has a high conductor holding force... the busbar clamping edge can cut into the electrical conductor to be clamped, and the busbar clamping edge thus digs into the electrical conductor to be clamped
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to a spring-loaded clamping connection (1) with a busbar (2) and a clamping spring (3a, 3b) which has a clamping leg (6a, 6b), wherein the clamping leg (6a, 6b) extends towards the busbar (2) and has a spring clamping edge (7a, 7b) for clamping an electrical conductor (17), and wherein the busbar (2) has a busbar clamping edge (11a, 11b) for fixing the electrical conductor (17) to be clamped, wherein the busbar clamping edge (11a, 11b) has a radius less than or equal to 0.2 mm.