Spring Clamp Conductor Terminal to Prevent Clamping Leg Torsion
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Solution Overview
Problem
Clamping springs with asymmetrical actuation in conductor terminals can lead to torsion and an inclined position of the clamping leg, causing issues with conductor insertion and removal, especially for large cross-section conductors, due to uneven force distribution and twisting.
Innovation Solution
The conductor terminal design includes a contact leg with a single-point contact at the actuating area, a bead embossed on the clamping spring for stiffness, and an oblique angle fixation of the contact leg to minimize twisting, allowing for a parallel orientation of the clamping section to the clamping surface during actuation, and a U-shaped busbar for stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If asymmetrical actuation is used to achieve compact design, then device size is reduced, but torsion and inclined position of clamping leg occur
Solution Approach 1:
The actuating area is deliberately arranged asymmetrically (eccentrically) relative to the clamping leg in the width direction, enabling compact terminal design while maintaining functionality through controlled asymmetric deformation
2Ease of operation
If single-point contact is used to allow rotation freedom, then ease of operation is improved, but contact stability deteriorates
Solution Approach 1:
The contact edge geometry is optimized with specific angular orientations (e.g., 45 degrees to the longitudinal direction) and positioned at predetermined distances from the clamping surface, creating optimal balance between rotation freedom and contact stability
3Ease of operation
If clamping leg is kept parallel to clamping surface, then conductor insertion is facilitated, but asymmetrical actuation effects cannot be compensated
Solution Approach 1:
The contact edge is pre-positioned and pre-oriented to compensate for expected asymmetric actuation effects, allowing the clamping leg to maintain parallel orientation to the clamping surface during insertion while accommodating actuation-induced deformation
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 design minimizes asymmetrical actuation effects, ensures secure conductor insertion and removal, maintains a compact terminal size, and prevents the clamping leg from becoming inclined, thus maintaining a clear conductor insertion channel and reducing stress on terminal components.
Implementation Method 1
a clamping spring (4), having an actuating area (46), which is designed to deflect the clamping leg (43) by manually actuating the actuating area (46)
Implementation Method 2
a spring bend (42), and a contact leg (41) for fastening and supporting the clamping spring (4) against a clamping force applied by the clamping leg (43) to the electrical conductor (20)
Data Source
AI summary
A conductor terminal, including a spring-force clamping connection for clamping an electrical conductor via spring force. The spring-force clamping connection having a clamping spring, which includes a clamping leg for clamping the electrical conductor on a clamping surface, a spring bend, and a contact leg for fastening and supporting the clamping spring against a clamping force applied by the clamping leg to the electrical conductor. The clamping leg being connected to the contact leg via the spring bend, and the contact leg being fixed to a holder. An actuating area deflects the clamping leg by manually actuating the actuating area. The clamping leg extending from the spring bend to a free end of the clamping spring in a longitudinal direction, and the actuating area being arranged eccentrically to the clamping leg in a width direction of the clamping leg which is orthogonal to the longitudinal direction.