Terminal Block Clip Layout for Power and Signal Terminations
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Solution Overview
Problem
There is a need for a terminal connector that securely connects large power cables to industrial equipment while also accommodating low-voltage signals for communication, control, and monitoring, as existing connectors often fail to efficiently integrate these signals.
Innovation Solution
A terminal connector design featuring a conductive clip within a terminal block housing, with a set screw that compresses spade connectors to secure them, allowing for the organization and secure connection of low-voltage electrodes, and a method for forming the clip using a punch die to create a resilient structure capable of accommodating various conductor types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a terminal block is designed to accommodate large power cable conductors, then it can securely connect high-current power cables, but it cannot accommodate low-voltage signal wires for communication and control
Solution Approach 1:
The terminal block is divided into separate functional sections: a first terminal block portion for receiving power cable conductors and a second terminal block portion for receiving low-voltage signal wires. This segmentation allows each portion to be optimized for its specific function while being part of an integrated assembly, resolving the contradiction between versatility and structural complexity
Solution Approach 2:
The terminal block assembly is designed as a multi-functional unit that can simultaneously accommodate both power cable conductors and low-voltage signal wires through its integrated structure with multiple receiving portions, achieving versatility without requiring separate disconnected components
2Adaptability or versatility
If multiple low-voltage connectors are connected to the same cable, then communication and control signals can be transmitted, but the connectors become disorganized and difficult to connect to equipment
Solution Approach 1:
The terminal block extends in multiple dimensions to provide separate receiving portions for different connectors. The first terminal block portion extends in one direction to receive power conductors, while the second terminal block portion extends in another direction to receive low-voltage signal wires, organizing them spatially in different dimensions for ease of connection
3Ease of manufacture
If a resilient clip is used to secure connectors, then mechanical connection is achieved, but the clip may deform or lose tension over time
Solution Approach 1:
The resilient clip is merged with the terminal block structure, where the clip is received within recesses formed in the terminal block portions. This integration combines the resilient securing function with the structural support of the terminal block, maintaining connection reliability over time while keeping the manufacturing process simple
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 provides a reliable and organized connection for both high-current power and low-voltage signals, ensuring secure mechanical and electrical contact, and facilitating the interfacing of signals with industrial equipment.
Implementation Method 1
The set screw exerts force on the clip to compress the spade connectors to the terminal block
Implementation Method 2
The clip is electrically connected to the conductor in the power cable and the spade connectors are electrically connected to the clip
Data Source
AI summary
There is provided a terminal for an electrical power cable that includes a conductive clip, a terminal block, and a set screw. The clip resides in the terminal block and includes a plurality of openings sized to receive low voltage connectors, such as spade connectors. The openings in the clip are arranged to organize the spade connectors and their respective pigtail connections. The location and orientation of the clip and the spade connectors is such that, when the set screw is installed in the terminal block, force is applied by the set screw onto the clip. The clip compresses and secures the spade connectors to the terminal block.