Tapered Grounding Lug for Flexible Cable Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing grounding lugs in rail vehicles lack flexibility in cable lug connections, restricting installation space and increasing material usage and weight, which in turn raises operational and manufacturing costs.
Innovation Solution
A grounding lug with a tapered design and mirror-symmetrical configuration, allowing for flexible placement and rotation of cable lugs, is created, optimizing its dimensions based on the cable lugs' geometric dimensions to reduce material usage and enhance installation flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the grounding lug has a constant thickness and rectangular shape, then the manufacturing is simple, but the connection flexibility of cable lugs is limited
Solution Approach 1:
The grounding lug transitions from a uniform rectangular shape to a design with varying thickness - thicker at the base for structural integrity and grounding contact, and thinner at the tip for flexibility. This local differentiation of geometric properties enables the grounding lug to accommodate cable lugs at various angles and positions while maintaining manufacturing feasibility through standardized forming processes
2Adaptability or versatility
If the cable lugs are arranged with larger inclination angles, then the connection flexibility increases, but the installation space requirement increases
Solution Approach 1:
The grounding lug extends beyond a single plane by incorporating a three-dimensional tapered geometry that allows cable lugs to be attached at multiple angles and orientations. This spatial extension in multiple dimensions enables flexible cable routing configurations while containing the overall footprint within compact boundaries suitable for vehicle installations
3Adaptability or versatility
If the grounding lug width is increased to accommodate more cable lugs, then the connection capacity increases, but the material usage and weight increase
Solution Approach 1:
The grounding lug employs a tapered cross-section where the thickness varies along its length - thicker at the base where structural strength and grounding contact are critical, and progressively thinner toward the tip where less mechanical strength is required. This localized variation in material distribution increases cable lug accommodation capacity while minimizing overall material consumption and weight
Solution Approach 2:
The grounding lug geometry is defined by variable parameters including tapered thickness, angled sides, and curved contours rather than fixed uniform dimensions. These parameter variations allow the grounding lug to optimize its material usage - providing sufficient thickness where needed for mechanical strength and electrical contact, while reducing thickness in less critical areas to decrease weight and material cost
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 increases connection flexibility, reduces material waste and weight, saving installation space and lowering operational costs while maintaining effective grounding functionality.
Implementation Method 1
For the grounding function, the grounding lug is of course electrically conductive and made from a corresponding material or material mix, in particular comprising a metal or a metal alloy, in particular steel.
Implementation Method 2
The base is grounded, for example, to a car body by being galvanically connected to it, in particular it is welded to it.
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a grounding lug (1) comprising a base (5) for integrally fastening the grounding lug (1) to a conductor, and comprising an eye (6) for detachably fastening a cable shoe (21, 22) to the grounding lug (1), the grounding lug (1) having a longitudinal central line which cuts the base (5) and a central axis of the eye (6). The grounding lug (1) is thus designed such that the width of the grounding lug (1) tapers horizontally towards the longitudinal central line from the base (5) to the eye (6).