Dual-Bearing Spring-Clamp Terminal Block With Low-Force Lever Actuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing spring connection terminals for electrical conductors lack an efficient and compact design that balances ease of assembly, stability, and effective clamping force.
Innovation Solution
A spring terminal design featuring a lever with a driver that moves the clamping leg between open and closed positions, utilizing a U-shaped structure with bearing discs and a clamping spring, allowing for a compact and stable connection with reduced actuation force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a traditional pivot lever design is used with a single bearing point, then the structure is simpler, but the stability and precision of clamping force application deteriorates
Solution Approach 1:
The pivot lever is divided into multiple functional segments: a first bearing disc for rotational support, a second bearing disc for additional stability, and a driver section for actuation. This segmentation allows each part to perform its specific function optimally while contributing to overall system stability without excessive complexity.
Solution Approach 2:
The design transitions from a single-point bearing system to a distributed bearing system using two bearing discs spaced apart along the lever. This adds a spatial dimension to the support structure, distributing loads across multiple points and improving stability while maintaining reasonable structural complexity.
2Strength
If the clamping spring is directly connected to the busbar, then the connection is simpler, but the clamping force effectiveness and conductor accommodation deteriorates
Solution Approach 1:
The driver acts as an intermediary between the clamping spring and the busbar. It translates the spring's elastic force into effective clamping action on the conductor while maintaining proper alignment and force distribution. This intermediary component enhances clamping effectiveness without creating excessive structural complexity.
Solution Approach 2:
The clamping connection incorporates dynamic elements including the flexible clamping spring that can deflect to accommodate conductor variations, and the pivot lever that rotates to apply clamping force. This dynamic design allows the system to adapt to different conductor types and sizes while maintaining strong clamping force.
3Force
If a compact U-shaped lever design is used, then the actuation force is reduced, but the space requirements for bearing discs increase
Solution Approach 1:
The U-shaped lever design nests the driver and bearing discs within a compact configuration. The two bearing discs are positioned at different locations along the lever's U-shape, allowing them to be accommodated in a space-efficient manner within the housing while still providing the mechanical advantage needed to reduce actuation force.
Solution Approach 2:
The U-shaped curved geometry of the lever provides mechanical advantage by creating a longer actuation lever arm relative to the clamping point. This curved design reduces the required actuation force while the overall U-shape allows compact packaging of all components within the housing space.
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 design achieves a compact and stable connection with reduced actuation force, enabling efficient clamping of electrical conductors while maintaining a high clamping force and accommodating various conductor types, including stranded wires.
Implementation Method 1
a clamping spring (200), wherein the clamping spring (200) has a clamping leg (210), which, together with the busbar (100), forms a clamping point (K) for clamping the electrical conductor (2) to the busbar (100)
Implementation Method 2
The lever (400) has a first bearing disc (410) with a first part-circular outer contour (411) for supporting the lever (400) in a first counter bearing (510)
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The invention relates to a spring-clamp terminal block (1) for connecting an electrical conductor (2), with a bus bar (100), a clamping spring (200), a housing (300) and a lever (400), wherein the bus bar (100) and the clamping spring (200) and the lever (400) are accommodated at least partially in the housing (300), wherein the lever (400) has a first bearing plate (410) with a first semi-circular outer contour (411) for mounting the lever (400) in a first counter bearing (510), wherein the lever (400) has a second bearing plate (420) with a second semi-circular outer contour (421) for mounting the lever (400) in a second counter bearing (520), wherein the second bearing plate (420) is spaced apart from the first bearing plate (410), wherein the lever (400) has an actuation handle (490) which is connected to the first bearing plate (410) and to the second bearing plate (420), wherein the clamping spring (200) has a clamping arm (210), wherein the clamping arm (210) forms a clamping point (K) together with the bus bar (100) for clamping the electrical conductor (2) on the bus bar (100), and wherein the lever (400) has a follower (430) which is designed to move the clamping arm (210) out of a closed position (GS) into a open position (OS) when the lever (400) is actuated.