Switchboard Terminal Block Conductor Assembly with Pre-Assembled Resilient Retainer
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Solution Overview
Problem
Existing conductive assemblies for switchboard terminal blocks are unstable and require complex assembly processes, leading to increased production costs, errors, and limitations in handling, storage, and packaging due to the need for multiple bending operations and internal stabilization within the terminal block.
Innovation Solution
A conductive assembly comprising a conductor element with a U-shaped form and resilient means featuring a spring with a parallel arm, acute internal angle, and L-shaped foot, allowing for simple and stable engagement with the conductor element, enabling easy production and preassembly for secure wire retention with minimal assembly operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the resilient strip is formed with a U-shaped base for engagement with conductor elements, then the assembly provides stable electrical connection, but the production requires a large number of bending operations and multiple assembly movements increasing complexity and time
Solution Approach 1:
The resilient strip is divided into functionally distinct segments: a base portion for engagement with the conductor element, a resilient portion for gripping the wire, and connection portions for electrical connection. This segmentation allows each part to be optimized independently and simplifies the assembly process by enabling pre-assembly of the base with the conductor element before final installation.
Solution Approach 2:
The base of the resilient strip is pre-assembled with the conductor element to form a stable conductive assembly before being installed in the terminal block. This preliminary action stabilizes the assembly during production, storage, and packaging, eliminating the need for complex internal stabilization structures within the terminal block.
2Ease of manufacture
If the conductor element and resilient retaining means are joined without pre-stabilization, then the assembly can be easily manufactured, but the forces generated during insertion are insufficient to stabilize the assembly for safe handling
Solution Approach 1:
The base of the resilient strip is merged with the conductor element through a simplified engagement process that creates a stable conductive assembly. This combination provides sufficient stabilization for handling, production, storage, and packaging without requiring complex connecting structures or internal stabilization features in the terminal block.
3Reliability
If multiple bending operations are performed on the resilient strip during production, then the resilient means can engage conductor elements, but production time and cost increase significantly
Solution Approach 1:
The resilient strip is designed with predetermined bend lines that divide it into manageable segments. These segmentation features allow the strip to be formed with fewer bending operations during production, as the bends occur at predetermined locations rather than requiring multiple arbitrary bending steps.
Solution Approach 2:
The resilient strip incorporates predetermined bend lines with specific geometric parameters that facilitate easier forming during production. These parameter optimizations reduce the number and complexity of bending operations required while maintaining the necessary engagement capability with conductor elements.
4Reliability
If the assembly requires internal contact and reaction surfaces in the terminal block for stabilization, then the connection is stable during use, but the terminal block complexity and manufacturing cost increase
Solution Approach 1:
The stabilization function is moved from the terminal block to the conductive assembly itself through the pre-engagement of the resilient strip base with the conductor element. This preliminary stabilization action eliminates the need for complex internal contact and reaction surfaces in the terminal block, simplifying its structure while maintaining connection stability during use.
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 stable, easy-to-produce conductive assembly that can be handled and inserted into terminal blocks with fewer operations, ensuring reliable electrical connection and retention while reducing production costs and preventing incorrect operation.
Implementation Method 1
said resilient means comprise essentially a strip which is deformed by means of compression so as to allow opening of a slit and the entry of the wire into its seat; once insertion has been completed, the strip is released and returns elastically into its rest position, causing the wire to be gripped against the counteracting electrical connection element
Data Source
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AI summary
Conductive assembly for switchboard terminal blocks comprising a conductor element (200) for electrically connecting together the input and output (IN/OUT) of a switchboard terminal block, and resilient means for retaining electric wires (1) comprising at least one resilient element (100) with a body (110) having a first arm (111) substantially parallel to the vertical direction (Z-Z) and a second arm (112) forming an acute internal angle with the first vertical arm (111), which arms are resiliently connected together by a curved section (113), said conductor element (200) having a substantially U-shaped form and arms (211) which extend parallel to a substantially vertical direction (Z-Z) and are situated opposite each other in the longitudinal direction (X-X), wherein the conductor element comprises a pair of shoulders (212), each extending from the base (212) parallel to the vertical direction (Z-Z) and arranged facing, at a suitable distance, a respective vertical arm (211) of the conductor element. The first arm (111) of the at least one resilient element (100) has a substantially L-shaped foot (115) comprising a lug (115b) bent in the longitudinal direction (X) outwards.