Transformer Terminal with Integrated Clamp Busbars
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Solution Overview
Problem
Transformer terminals are currently complex and time-consuming to produce, requiring multiple pieces and soldering processes, which complicates the manufacturing and assembly processes.
Innovation Solution
A transformer terminal with a one-piece insulating housing and a detachable cover, featuring spring-loaded clamp connections and integrally formed winding wire connections on busbars, allowing for tool-free electrical connections and simplified production by using identical design components for both potentials, with exposed winding wire connections for automated soldering and enhanced insulation through a protruding partition wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components are used for electrical connections, then electrical reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The busbar is designed as a single integrated component that combines multiple functions: it serves as the electrical conductor, incorporates spring-loaded clamp connections for securing conductors, and includes integrally formed winding wire connections. This merging of multiple separate components into one busbar reduces the number of parts, simplifies manufacturing, and maintains electrical reliability through the integrated design.
2Stability of the object's composition
If traditional assembly methods are used, then connection stability is improved, but production time increases
Solution Approach 1:
The spring-loaded clamp connections and winding wire connections are pre-integrated into the busbar during manufacturing. This preliminary action ensures that when the busbar is installed, the connections are already stable and require no additional assembly steps, thereby maintaining connection stability while significantly reducing production and assembly time.
Solution Approach 2:
The spring-loaded clamp connections are designed to automatically secure conductors to the busbar through elastic deformation of the spring elements. This self-service mechanism eliminates the need for additional fastening operations or complex assembly tools, maintaining secure connections while accelerating the installation process.
3Ease of manufacture
If integrally formed connections are used, then manufacturing simplicity is improved, but electrical insulation requirements increase
Solution Approach 1:
The insulating housing is designed with separate, modular insulating elements that segment the electrical connections. These insulating elements are positioned to electrically isolate different parts of the busbar and connections, managing insulation requirements while maintaining the manufacturing simplicity of the integrated busbar design.
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
Simplifies the production and assembly of transformer terminals by enabling tool-free connections and automated soldering, while ensuring electrical insulation and mechanical stability through the use of spring-loaded clamp connections and a partition wall, reducing manufacturing complexity and increasing efficiency.
Implementation Method 1
a spring element (180, 180') which is formed in one piece with the busbar (10, 20) and is elastically deformable, and a clamp connection (140, 140') which is formed in one piece with the busbar (10, 20) and acts on the conductor end (40, 40') clamped by the spring element (180, 180') in its clamped state
Data Source
Figure 1
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AI summary
The invention relates to a transformer terminal comprising: an insulating housing which has an integrally designed main body (1) and a cover (2) which can be detachably mounted on the main body (1); a mounting device which is formed on the insulating housing and is designed to mount the insulating housing on a transformer; a first electrical conductor connection (4) for a first potential, comprising a first electrical connection assembly (8) having a first bus bar (8a); a first spring-force clamping connection which is formed on the first bus bar (8a) and is designed to clamp a first conductor for electrical connection to the first bus bar (8a); and a first winding wire connection (8c) for electrically connecting a first winding wire of the transformer to the bus bar (8a), the first winding wire connection (8c) being integrally moulded on the first bus bar (8a); and a second electrical conductor connection (5) for a second potential, which is different from the first potential, the first and second electrical conductor connections (4, 5) being electrically insulated from one another, the second electrical conductor connection comprising a second electrical connection assembly (9) having a second bus bar (9a); a second spring-force clamping connection (9b) which is formed on the second bus bar (9a) and is designed to clamp a second conductor for electrical connection to the second bus bar (9a); and a second winding wire connection (9c) for electrically connecting a second winding wire (9c) of the transformer to the bus bar (9a), the second winding wire connection (9c) being integrally moulded on the second bus bar (9a). The first electrical connection assembly (8) is arranged in a first installation space which is formed on the main body (1) in the region of a lateral face and has a first mounting opening toward said lateral face, and the second electrical connection assembly (9) is arranged in a second installation space (10b) which is formed on the main body (1) in the region of an opposite lateral face and has a second mounting opening (19b) toward said lateral face, the second installation space being separated from the first installation space.