Spring Contact Terminal Structure for High-Current Meter Connections
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Solution Overview
Problem
Current meter plug-in terminals are limited by the design of their spring contacts, which restrict current strength to around 63 amps, making them unsuitable for higher current intensities and prone to errors during assembly, posing safety risks.
Innovation Solution
An electrical spring contact terminal with a contact tulip and contact tab design featuring two transfer sections that allow for increased current conduction and adjustable clamping force, enabling the terminal to handle nominal currents up to 80 amps and peak loads up to 128 amps, while ensuring safe and error-free assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional spring contact terminals with contact tulips are used, then the terminal can be easily manufactured and assembled, but the current capacity is limited to around 63 amps
Solution Approach 1:
The terminal is divided into multiple independent contact elements (first contact element, second contact element, third contact element) instead of using a single contact tulip. Each contact element has its own clamping legs and connecting sections, allowing the current capacity to be increased by distributing the current across multiple parallel paths while maintaining the overall terminal structure
Solution Approach 2:
Multiple contact elements are combined within a single terminal housing, with each contact element handling a portion of the total current. The connecting sections of multiple contact elements are merged to create a common electrical connection point, achieving higher current capacity while maintaining structural integration
2Reliability
If screw connections are used for meter connections, then the electrical connection can be secure, but the installer faces increased safety risks and potential for errors during tightening
Solution Approach 1:
The terminal uses spring-loaded clamping legs that automatically apply clamping force to the contact pins when inserted. The spring mechanism provides dynamic adjustment of the clamping force, ensuring reliable electrical connection without requiring manual tightening operations that expose installers to live voltage
Solution Approach 2:
The spring contact mechanism is self-actuating - when the contact pin is inserted, the spring automatically engages and applies the necessary clamping force. This eliminates the need for installer intervention to tighten connections, removing the safety hazard of working on live connections while ensuring proper contact pressure
3Reliability
If box terminals or extruded blocks are forgotten during installation, then the electrical connection becomes poor, but the risk of hot spots and fires increases
Solution Approach 1:
The terminal pre-configures the complete connection path including the connecting sections that link multiple contact elements to the common connection point. This preliminary arrangement ensures that proper electrical connections are established by design, eliminating the possibility of forgotten connection elements and the associated hot spot risks
Solution Approach 2:
The terminal design changes the connection architecture from a single-point connection to a multi-point parallel connection system. This parameter change in the connection topology provides redundant current paths, ensuring that even if one connection path is compromised, the electrical connection remains reliable and hot spots are prevented
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 allows for reliable and safe high-current connections without the need for screwing, reducing the risk of 'hot spots' and fires, and enables easy replacement of electricity meters without interrupting the power supply.
Implementation Method 1
a contact tulip with a first clamping leg and a second clamping leg, which are connected to each other via a connecting section and serve to contact and clamp a contact pin of the electricity meter
Implementation Method 2
a first transfer section which electrically and mechanically connects the first clamping leg to the contact tab at a distance from the connecting section, and a second transfer section which electrically and mechanically connects the second clamping leg to the contact tab
Data Source
Figure 1
Figure 2~3
Figure 4~7
AI summary
An electrical spring contact terminal (3) is specified for a meter plug-in terminal, which serves to connect an electricity meter to the electrical power supply network. The spring contact terminal (3) has a contact tulip (31) with a first clamping leg (32) and a second clamping leg (32), which are connected to each other via a connecting section (34) and serve to contact and clamp a contact pin of the electricity meter on both sides. The spring contact terminal (3) also has a contact tab (37) integrally connected to the contact tulip (31) for establishing contact with the electrical power supply network.Furthermore, the spring contact terminal (3) has a first transition section (36) which electrically and mechanically connects the first clamping leg (32) to the contact tab (37) at a distance from the connecting section (34), and a second transition section (36) which electrically and mechanically connects the second clamping leg (32) to the contact tab (37) at a distance from the connecting section (34). A meter plug-in terminal with such a spring contact terminal (3) is also specified.