Note: Descriptions are shown in the official language in which they were submitted.
CA 02278910 2005-07-18
HANDLE OPERATED POWER
CONNECTOR
Field of the Invention
The present invention relates generally to electrical connectors, and more
particularly, to electrical power connectors.
Back~~round of the Invention
Electrical power connectors for connecting a receptacle and plug are
known. These connectors are used in transit applications, power applications,
Iight rail applications, tractor trailer trucks and buses, among other
applications.
Power connectors, by virtue of their wire size, are inherently large and
bulky. The cables used with power connectors are heavy and cumbersome.
Traditional methods for coupling connectors of these types are via thread or
bayonet coupling or locking levers. All are very difficult to implement as the
contacts, due to their size, have very high insertion and extraction forces.
The
weight of the cable connector, its physical size, and its location on a panel
or a
vehicle make it very difficult to align and couple.
In many instances, to couple an electrical power connector becomes a two-
m~ operation - one to hold and guide the plug and a second to activate the
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coupling mechanism. Bayonet or lever-lock is preferred over threads as the
activation requires less movement of the coupling mechanism. A bayonet lock
requires only a portion of a turn, but is difficult to accomplish because the
entire
plug has to be aligned with the receptacle and then the plug including cables
has
to be held in place while a coupling ring has to be rotated to effect mating
between the plug and receptacle. A thread usually requires three or more
turns.
A lever connector is generally rectangular with two hasps on the side which
need
to be activated nearly simultaneously in order not to "cock" the plug into the
receptacle.
Accordingly, a need exists in the art for an electrical power connector
which requires less than one turn to couple. A further need exists for an
electrical
power connector in which coupling can be accomplished by a single person.
Summar~of the Invention
It is an object of the present invention to provide an electrical power
connector in which the electrical connector can be coupled by a single person.
It is another object of.'the piesent invention to provide an electrical power
connector in which coupling between a plug and receptacle requires less than
360° rotation of the coupling mechanism.
It is another object of the present invention to provide an electrical power
connector in which a plug can be coupled to a receptacle in 120°
rotation or less.
It is yet a further object of the present invention to provide an electrical
power connector having a receptacle with a bayonet ramp and a plug having a
coupling ring with a handle.
These and other objects of the present invention are accomplished by
providing an electrical power connector having a plug and receptacle. The plug
includes a coupling ring having a handle extending radially therefrom. The
coupling ring is freely rotatable within limits on the plug when the plug is
not
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coupled to the receptacle: The receptacle includes one or more bayonet ramps
to
which the coupling ring can be coupled. Advantageously, the plug can be
coupled to the receptacle with 120° rotation or less by rotating the
coupling ring
120° or less. The,plug and receptacle each include a colored locking
indicator to
indicate to the person coupling the plug to the receptacle that the receptacle
and
plug are properly aligned to each other when coupled. Also an audible
indication
of locking is provided when the electrical plug and receptacle are fully
coupled.
Advantageously, the coupling ring, with a handle, allows the user to hold
and guide the connector with one hand and couple it with the other. The
arrangement of the present invention limits the travel of the coupling ring
and
handle such that it can be easily located in the proper position for coupling.
Once
the connector is positioned foi alignment - moving the handle in an arc of
90° to
120° allows the bayonet ramps to 'engage and supply the mechanical
advantage to
couple and uncouple easily. A clamping mechanism built into the panel or under-
carriage, nests anti~~hokis the handle-~ in place so it cannot be
inadvertently
uncoupled. v ' - ~ ~ , ., ; . ; : . :, . , ., .
These and other objects of the present invention are achieved by an
electrical power connector including a plug having at least one contact and a
receptacle including a corresponding at least one contact. The receptacle has
at
least one ramp. The plug and the receptacle have an unmated condition and a
mated condition. A coupling ring has a handle extending therefrom and includes
at least one locking pin. A first stop and a second stop are each positioned
in
either the coupling ring and the receptacle such that said coupling ring is
rotated
less than 360° to move the connector from the unmated condition to the
mated
condition.
The foregoing 'and other objects of the present invention are achieved by
an electrical connector including a plug having at least one male contact and
at
least one pin and a receptacle including a corresponding at least one female
contact and at least one corresponding ramp for receiving the at least one
locking
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pin. A handle is operatively associated with one of the plug and the
receptacle
and has a first surface and a second surface. A first surface and a second
surface
are each connected to one of the plug and the receptacle. The first surface
and the
second surface are circumferentially spaced from each other less than
360°. The
plug and the receptacle are in an unmated condition when the first surface of
the
handle abuts the first surface. When the handle is rotated, the plug and the
receptacle are brought into a mated condition when the second surface of the
handle abuts the second stop.
The foregoing and other objects of the present invention are achieved by a
method of coupling an electrical connector. The electrical connector includes
a
plug and a receptacle. The plug is aligned with the receptacle. The plug has
at
least one alignment key. The receptacle has a corresponding at least one
keyway.
A coupling ring is moved to a first circumferential position. The plug is
mated to
the receptacle when the coupling ring is rotated less than 360° to a
second
circumferential position.
Still other objects and advantages of the present invention will become
readily apparent to those skilled in the art from the following detailed
description,
wherein the preferred embodiments of the invention are shown and described,
simply by way of illustration of the best mode contemplated of carrying out
the
invention. As will be realized, the invention is capable of other and
different
embodiments, and its several details are capable of modifications in various
obvious respects, all without departing from the invention. Accordingly, the
drawings and description thereof are to be regarded as illustrative in nature,
and
not as restrictive.
Brief Description of the Drawings
The present invention is illustrated by way of example, and not by
limitation, in the figures of the accompanying drawings, wherein elements
having
CA 02278910 1999-07-27
the same reference numeral designations represent like elements throughout and
wherein:
Figure 1 is a perspective view of the lever operated power connector
according to the present invention with a plug and a receptacle being shown in
a
$ coupled position;
Figure 2 is a side perspective view of the lever operated power connector
of Figure 1 with the plug and receptacle being shown in an uncoupled position;
Figure 3 is a front view of the plug and coupling ring according to the
present invention;
Figure 4 is a side cross-sectional elevational view of the receptacle taken
along lines 4-4 in Figure 3;
Figure $ is a perspective view of the intermediate portion of Figure 4;
Figure 6 is a cross-sectional view of the intermediate portion taken along
lines 6-6 in Figure $;
1$ Figure 7 is a front elevational view of the receptacle of the handle
operated power connector of Figure 1; and
Figure 8 is a top plan view of the receptacle of Figure 1.
Best Mode for Carrying Out the Invention
Referring first to Figure 1, a lever-operated electrical power connector,
generally indicated at 20, is depicted in accordance with the principles of
the
present invention. -Although the lever-operated electrical power connector is
depicted in a horizontal orientation, it should be understood that the present
invention is operable in any orientation and accordingly terms such as "left"
and
"right" as used herein are to be construed in the relative sense. The
electrical
2$ power connector 20 includes a plug 22 and a receptacle 30. The plug 22
includes
a cylindrical body 24. The receptacle 30 includes a cylindrical receptacle
housing
32 which includes an outwardly extending rectangular flange 34 located at a
r
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central portion thereof. The receptacle 30 is fixedly secured via the flange
34 to a
mounting surface such as on a truck, bus or train.
The plug 22 includes a collar assembly 40 including an annular coupling
ring 42 having a radially outwardly extending handle 44 extending therefrom.
The annular coupling ring 42 is freely rotatable on the body 24 within
predefined
limits as explained in detail below. The length of handle 44 can be selected
depending upon the force required to effect connection between the plug 22 and
the receptacle 30. Similarly, the amount of rotation of the handle 44 can be
varied
depending on the application between the plug 22 and receptacle 30. Also, any
number of handles can be used. As depicted in Figure 1, the electrical power
connector 20 is shown in a coupled position with the plug 22 coupled to the
receptacle 30. An alignment pin 54 extends outwardly from the annular coupling
ring 42. A boss 56 acting as a protruding marker or indicator extends
outwardly
from the receptacle housing 32. As depicted in Figure 1, pin 54 and boss 56
are
aligned. The handle 44 is depicted in a coupled orientation. Pin 54 and boss
56
are preferably colored. A rear cylindrical portion 70 of receptacle 30 extends
behind the mounting surface:
A locking mechanism 300 built into the panel or under-carriage of a
vehicle such as a light rail car, can be moved into a position to nest and
hold the
handle 44 in place so it cannot be inadvertently uncoupled when the handle 44
is
moved into the coupled position. This locking mechanism 300 can be of any
known structure and can include a lock, for example, a key operated padlock
for
preventing malicious disengagement of the receptacle of the plug 22 and
receptacle 30.
Referring now to Figure 2, the electrical power connector 20 is depicted
with the plug 22 and receptacle 30 in an uncoupled position. In Figure 2, the
handle 44 is depicted in an uncoupled orientation. As depicted in Figure 3,
the
plug body 24 includes a insulator 46 including three spaced male contacts 48,
50,
52 which are secured to the body 24 in a conventional manner such as by
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compression conformal fit. A fourth position 172 for a male contact is
depicted
and this position is not used in the depicted invention and is instead filled
with a
hole plug.
Returning to Figure 2, the receptacle 30 includes a forward cylindrical
portion or wall 60 and the rear cylindrical portion 70. The forward
cylindrical
portion 60 extends forwardly from the flange 34 for mating with the plug 22.
The
rear cylindrical portion 70 extends rearwardly from the flange 34 for
connection
to a backshell (not shown). The receptacle 30 includes three female contacts
62,
64 (see Figure 7), 66 having corresponding positions to the contacts 52, 48,
SO in
the plug 22. A fourth position 172 for a female contact is depicted which is
not
used in the depicted invention. Other contact configurations and number of
contacts can be used with the subject matter of this invention. Also, the
gender of
the contacts can be reversed. The contacts 62, 64, 66 are secured to the
receptacle
30 in a conventional manner such as by compression conformal fit. The mounting
flange 34 includes four holes for bolting the flange to a vehicle such as a
light rail
car or to any other stationary mounting surface.
The forward cylindrical portion 60 includes three bayonet ramps 112, 114,
116 (see Figure 2). Each bayonet ramp 112, 114, 116 has an opening 118
extending rearwardly from a forward surface 120 of the housing 30. Each of the
bayonet ramps 112, 114, 116 spirals rearwardly from the forward surface 120
approximately 120° in the circumferential direction in a clockwise
direction as
depicted in Figure 2. The ramps 112, 114, 116 must each spiral in the same
direction although the ramps could also spiral in a counter clockwise
direction.
Each of the ramps 112, 114, 116 extends inwardly from an outer surface 122 of
cylindrical portion 60 and each ramp has a rear surface 124, a front surface
126
and an outwardly facing surface 128. As depicted in Figure 3, preferably three
inwardly extending pins 222 in the collar assembly 40 ride in one or more of
the
bayonet ramps 112, 114, 116, respectively, and terminates its travel at a
terminal
end of bayonet ramp 112, 114, 116. Any number of ramps and pins could be
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used. The pins 222 are spaced at 120° apart and are press fit or staked
into the
annular coupling ring 42.
As depicted in Figure 2, extending outwardly from an inner surface 130 of
the cylindrical portion 60 are a plurality of keyways 160, 162, 164 (see
Figure 7).
Keyways 160, 162, 164 provide alignment of the plug 22 to the receptacle 30.
It
should be understood that any number of keyways can be used in this
application.
Refer now to Figures 3 and 4 depicting the details of the plug 22. Plug 22
includes an electrically insulative central body portion 200, an intermediate
portion 210 and an outer body portion or backshell 220. The backshell 220 can
screw on to the rear cylindrical portion 70 The male contacts 48, 50, 52 are
compression conformal fit into through bores of the central body portion 200.
The central body portion 200 is located radially inwardly from intermediate
portion 210 and is connected thereto using a snap ring 230. The outer body
portion is threadedly engaged witk the intermediate portion 210. The coupling
ring 42 includes a shoulder 232 positioned between the intermediate portion
210
and the outer body portion for axially retaining the coupling ring 42.
As depicted in Figure 3, pins 222 extend radially inwardly from annular
coupling ring 42. As depicted in Figure 4, an annular recess 180 is formed
between forward most portions of the annular coupling ring 42 and the
intermediate portion 210. Intermediate portion 210 extends forwardly relative
to
annular coupling ring 42.
As depicted in Figure 3, three keys 240, 242 and 244 extend radially
outwardly from intelinediate portion 210 into the annular recess 180. Key 240
can be aligned with keyway 160, key 242 can be circumferentially aligned to
keyway 162 and key 244 can be aligned with keyway 164 by rotating the body 24.
Although keys 240; 242, 244 are depicted for use with the plug 22 and keyways
for use with the receptacle, it should be understood that the keys and keyways
could be reversed and other alignment means could also be used.
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A circumferentially extending slot 250 is depicted in Figure 4. An
inwardly extending member 252 extends from the annular coupling ring 42 into
the slot 250 as depicted in Figure 4. The inwardly extending member 252 can
be,
for example, a set screw which is screwed into annular ring 42. Following the
S insertion of member 252 into the slot 250, the handle 44 can be welded onto
the
annular coupling ring 42 to prevent the inadvertent removal of member 252. A
spring loaded clip 260 positioned between intermediate portion 210 and collar
assembly 40 biases the coupling nut away from the receptacle 30 and the plug
22
forward to the receptacle 30 to guarantee a seal between plug 22 and
receptacle 30
and to lock the pins 222 into the detents at the end of ramps 112, 114 and
116. It
should be understood that positions of the slot 250 and the member 252 could
be
reversed. For example, the slot 250 could be in the coupling ring 42 and the
member 252 could extend from the intermediate portion 210.
A seal 280, such as an 0-ring can be positioned at the bottom of the
annular recess 180 as depicted in Figure 4. The surface 120 of the receptacle
180
is brought into sealing contact with the seal 280 thereby sealing the plug 22
and
receptacle 30 from the environment. This is important because of the high
voltage and/or current being used with the electrical connector 20.
Refer now to Figure 5 where the intermediate portion 210 is depicted
alone for clarity. As depicted in Figure 5, intermediate portion 210 includes
a
centrally located slot 250. At opposite ends of slot 250 is a first stopper
261 and a
second stopper 262. As depicted in Figure 6, slot 250 preferably extends for
an
angle of 120° between the first stopper 261 and the second surface 262
although
any angle less than 360° can be used.
A side elevational view of the receptacle 30 is depicted in Figure 7. A
plurality of electrical connectors or contacts 48, 50, 52 are located within
the plug
22. These contacts 48, S0, 52 are respectively coupled to one of the female
contacts 62, 64, 66, respectively shown in Figure 7.
CA 02278910 2000-04-25
In Figure 4, the plug 22 is depicted. The pins 222 extend radially inwardly
from an outer diameter of the coupling assembly 40 for engagement with bayonet
ramps 112, 114, 116 (see Figure 2).
In operation, the collar assembly 40 is rotated using the handle 44 to the
S counter-clockwise position depicted in Figure 2. The plug 22 is brought into
engagement with the receptacle 30 and the keys 240, 242, 244 are
circumferentially aligned with one of the keyways 160, 162, 164, respectively.
The coupling assembly 40 and the pins 222 are aligned with openings 118 of
bayonet ramps 112, 114, 116 because the plug 22 is aligned with the receptacle
10 30. The handle 44 is then rotated clockwise 120° from the position
depicted in
Figure 2 to the position depicted in Figure 1. The pins 222 engage the front
surfaces 126 and provide a caroming action forcing the plug 22 into the mated
position with the receptacle 30. The connector 20 provides an audible sound
when the plug 22 is coupled to the receptacle 30. The male contacts 52, 48, 50
engage and fractionally mate with the corresponding female contacts 66, 64,
62.
Although a clockwise rotation is depicted in Figures 1 and 2, the invention
can
also utilize ramps which would provide rotation in a clockwise direction.
Advantageously, the ramps 112, 114, 116 and pins 222 provide a caroming
action. The slot 250, pin 252 and surfaces 261, 262 limit the travel of the
handle
44 to less than 360°, and preferably between 90° and
120°.
Alternatively, the coupling ring and bayonet ramps could be reversed and
positioned on the receptacle 30 and plug 22, respectively.
It will be readily seen by one of ordinary skill in the art that the present
invention fulfills all of the objects set forth above. After reading the
foregoing
specification, one of ordinary skill will be able to affect various changes,
substitutions of equivalents and various other aspects of the invention as
broadly
disclosed herein. It is therefore intended that the protection granted hereon
be
limited only by the definition contained in the appended claims and
equivalents
thereof.
