Stepped Terminal Block Layout for Universal Test Plug Switching
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Solution Overview
Problem
Existing electrical series terminals require the use of plugs of different lengths for various switching operations, making it difficult to design a test plug block suitable for multiple purposes and increasing production costs and complexity.
Innovation Solution
The series terminal features a stepped metal strip design with multiple steps, allowing the second metal strips to be fastened to any step, adjusting the length of the current bars and contact sections, and incorporating C-shaped contact springs for easier assembly and adaptable contact force, enabling multiple configurations with only two types of current bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If plugs of different lengths are used for various switching operations, then multiple switching functions can be achieved, but the design complexity and production costs increase
Solution Approach 1:
The patent implements a universal test plug design where a single plug type can perform multiple switching operations by contacting different contact sections (first and second contact sections) on the current bars. The plug block contains multiple identical or similar test plugs that can achieve various switching functions through different contact configurations rather than requiring plugs of different lengths, thus reducing design complexity while maintaining versatility
2Adaptability or versatility
If plugs of different lengths are used for various switching operations, then multiple switching functions can be achieved, but production costs increase
Solution Approach 1:
The patent reduces production costs by manufacturing multiple identical or similar test plugs instead of producing plugs of different lengths. The universal plug design allows a single mold and production process to be used for all test plugs in the block, significantly reducing tooling costs, manufacturing complexity, and inventory requirements while still achieving multiple switching functions through the contact bar design
3Ease of operation
If the second contact area is arranged before the first contact area in the insertion direction, then the plug contacts the second contact sections first, but this requires precise positioning of contact sections
Solution Approach 1:
The patent arranges the second contact area before the first contact area in the insertion direction of the plug, so that when the plug is inserted, it automatically contacts the second contact sections first. This preliminary arrangement of contact areas ensures the correct switching sequence without requiring complex control mechanisms, though it does require precise positioning during manufacturing to maintain the correct spatial relationship between contact sections
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 simplifies switching operations, reduces production costs, and allows for a single type of test plug to be used across multiple series terminals, minimizing the risk of mis-contact and enabling flexible configuration options.
Implementation Method 1
C-shaped contact springs for easier assembly and adaptable contact force
Data Source
AI summary
An electrical terminal block with simplified switching operations, which can be produced in a cost-effective and time-saving manner.