AU2009100664B4

AU2009100664B4 - Electrical loom system

Info

Publication number: AU2009100664B4
Application number: AU2009100664A
Authority: AU
Inventors: Edward Burness
Original assignee: AUSTECH PROJECTS Pty Ltd
Current assignee: AUSTECH PROJECTS Pty Ltd
Priority date: 2009-07-16
Filing date: 2009-07-16
Publication date: 2010-01-14
Anticipated expiration: 2017-07-16
Also published as: AU2009100664A4

Description

1 ELECTRICAL LOOM SYSTEM IP Australia INNOVATIVE PATENT 2009100664 2 0 OCT 2009 NEW CLAIM APPLICATION No. 1 5 FIELD OF INVENTION This invention relates to electrical power systems and in particular systems which accommodate looms for the wiring of electrical circuits such as for lighting systems. 10 BACKGROUND OF THE INVENTION Conventional lighting loom socket outlets have a permanent connection between each pin receptacle and their respective terminal which is also directly connected to the power supply. 15 Accordingly, the electrical wiring to each socket outlet is specific in that the control of each outlet is governed by the power supply connection to the outlet which power supply control is externally managed. As each socket outlets in the loom system is wired to suit the control requirements of the allocated luminaire, the final assembled loom system can become quite cumbersome to 20 handle and difficult to install normally requiring the outlet positions to be marked-out prior to erection of the loom harness. Before a fixed wiring loom systems can be designed and assembled, it is essential that the electrical design and operational control requirements for the loom system are finalised and known. In most cases this will not become available until the building construction is 25 completed thus limiting access and causing the erosion of time and costs in the erection of the loom system. There are a number of electrical outlets currently available for lighting systems which are designed to receive two four pin plugs. For example design registration AU 97367 S in the 30 name of HPM Industries Pty Limited illustrates such an outlet. Clipsal Australia Pty Ltd market a series 414 outlets with twin four pin plugs. Fig. 1 Oa shows the connection arrangements of Clipsal414/4P5 twin 4 pin outlets with five terminals suitable for a five wire loom system and Fig. Ob shows the connection arrangements of the Clipsal 414/4P6 twin four pin outlets with 6 terminals suitable for a six wire loom system. 35 2 However the looms of the above systems only provide for fixed connections from the power supply to the pin receptacle. There is no internal mechanism or facility that would enable the power supply connections to the outlet pin receptacles to be diverted to alternative power supply sources. 5 The loom outlets of present fixed connected loom systems have a limited number of tunnel type terminals and once the connections have been made it is difficult and time consuming to change them to accommodate different circuit arrangements. OBJECT OF THE INVENTION 10 It is therefore an object of the present invention to provide a loom system of socket outlets with multiple terminals coupled by an interconnecting wiring harness to form a loom system with a capability to readily change power supply connections from within the socket outlets and in so doing minimise the need for fixed power supply connections which variations will 15 provide the opportunity to install loom systems in position prior to the final electrical designs becoming available. COMMENTS ON PRIOR ART. 20 US 5601455 (Bagga) teaches a plug socket with quadruplex 3 pin receptacles which can be selectively separated into 2 duplex 3 pin receptacles with power being supplied by fixed connection from either one or 2 sources of supply. There is a single fixed connection between each power supply terminal and the respective pin receptacle. Each socket outlet is limited to 3 pin receptacles and seemingly it is not readily adaptable to be increased to accept 4 pin 25 plug tops. There is no internal mechanism that provides for selective changes to the source of power supply to any pin receptacle. There is no internal switch over mechanism that provides for the selective interruption of the power supply to any pin receptacle. US 3673361 (Bulgin) teaches a plug socket with a plurality of terminals connected to 30 duplicate 5 and 3 pin socket outlets. There is a single fixed connection between each power supply terminal and the respective socket pin receptacle. There is no internal mechanism that provides for selective changes to the source of power supply to any pin receptacle. There is no internal switch over mechanism that provides for the selective interruption of the power supply to any pin receptacle. There is an internal mechanism that selectively interrupts the 3 connection between the incoming and outgoing power supply on two of bus ties numbered 40 & 41 in the descriptive document. Us 6666713 (Norvelle) teaches an apparatus for the joining of duplex plug socket outlets by 5 means of external bus connectors which are purpose manufactured to suit each terminal connection type. The interconnections between socket outlets are fixed and external. There is no internal mechanism that provides for selective changes to the source of power supply to any pin receptacle. There is no internal switch over mechanism that provides for the selective interruption of the power supply to any pin receptacle. 10 STATEMENT OF THE INVENTION 15 According to the present invention, an electrical loom system comprises two or more outlets with a controlling outlet having twin sets of four pin receptacles linked to a plurality of terminals inside the controlling outlet some of which terminals have fixed connections to a power supply and others of which terminals are selectively connected to alternative power supplies via a switch over mechanism that is contained within the controlling outlet. 20 Preferably the terminals of the controlling outlet are of a tunnel type construction, which holds an electrical wire by means of a clamping screw in the wall of the tunnel, integrated with a post type construction which receives a slide on clamping contact. 25 Preferably a first incoming and outgoing active conductor of the controlling outlet are connected to a terminal, a second incoming and outgoing active conductor is connected to a second terminal, an incoming and outgoing neutral conductor is connected to a third terminal and an incoming and outgoing earth conductor is connected to a fourth terminal. 30 Preferably the controlling outlet further comprises three or more terminals to provide control terminal connections. Preferably the system further comprises one or more slave outlets having internal post top terminals which receive a slide on clamping contact integrated with a shaped spring contact 35 receptacle which receive the pin of plug tops.

4 Preferably the conductors of interconnection wiring between outlets are terminated with female lugs that connect with the post top terminals of the socket outlets. 5 BRIEF DESCRIPTION OF THE DRAWINGS Fig 1 is a front perspective view of a twin four pin controlling outlet Fig 2 is a perspective view of the assembled gear tray inside the outlet of Fig.1 Fig 3 is a plan view corresponding to Fig 2. 10 Fig.3a is an exploded view corresponding to Fig.2 Figs 4a and b are perspective views of combined post-top and tunnel terminals Fig 5 is a perspective of the switch over mechanism providing optional connections and switching controls to 2 pin receptacles. Fig.5a is a schematic drawing of the connections relative to Fig.5 15 Fig 6 shows a 5 conductor wiring harness fitted with slide on post-top terminal connectors Fig 7 is a schematic of a twin 4 pin controlling outlet connections of the present invention Figs 8a is a perspective view of the front of a single 4 pin plug slave socket outlet of the present invention. Fig.8b is a perspective internal view of a single 4 pin plug slave socket outlet of the present 20 invention. Fig.8c is a perspective of the combined post-top terminal and pin receptacle used in slave plug socket outlets relative to Figs. 8, 9 and 11. Fig 9a is a perspective view of the front of a single 3 pin plug slave socket outlet of the present invention. 25 Fig.9b is a perspective internal view of a single 3 pin plug slave socket outlet of the present invention. Fig.9c is a perspective of the clip on back plate common to all single socket outlets of the present invention. Fig. 10 shows the possible connections for Clipsal 4 14

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4 p series outlets. 30 Fig 1 la is a perspective view of the front of a twin 4 pin plug slave socket outlet of the present invention. Fig 11 b is a perspective internal view of a twin 4 pin plug slave socket outlet of the present invention. Fig1 Ic is a perspective of the clip on back plate common to all twin socket outlets of the 35 present invention.

5 Fig. 12 shows an example pattern of a speculative loom grid system Figl3. Spare. Fig.14 shows plan and perspective views of the twin 4 pin controlling outlet. 5 DETAILED DESCRIPTION OF THE INVENTION The invention provides an array of single and duplex plug socket outlets with either 3 or 4 pin receptacles which are interconnected with a wiring harness (Fig.6) to develop loom systems such as the example shown in Fig.12. 10 Various power supply connection options are available to provide selective control of the operation of the loom system achieved primarily through a switch over mechanism (20) as shown in Fig.5 which is located within the special twin 4 pin socket outlets (Fig 14) that are also fitted with combined post-top and tunnel type terminals (Figs. 4 & 4a). The face of the special controlling outlet (Fig.1) accepts two 4 pin male plug tops into the pin 15 receptacles (1), (2), (3), (4) and (5), (6), (7), (8) respectively. Figs.2, 3 and 3a reveal the internal construction of the controlling outlet with pin receptacles (1) and (5) permanently connected by metal strap (30) to terminal (9); pin receptacles (2) and (6) permanently connected by metal strap (31) to terminal (11); pin receptacles (3) and (7) permanently connected by metal strap (34) to terminal (15); pin receptacles (4) permanently 20 connected by metal strap (33) to terminal (13); and pin receptacle (8) permanently connected by metal strap (32) to terminal (14.). Terminal (12) is not permanently connected but may be selectively connected to either or both terminals (13) and (14) by the switch over mechanism of Fig.5. Terminal (10) is isolated without any connection within the outlet. Preferably the tunnel terminals (16) of the combined post-top/tunnel terminal (Fig.4) are 25 used for the connection of the 240V AC power supply conductors and also for the connection of external ancillary wiring such as switching controls. The post-top terminals (17) are preferably used for the interconnection of the wiring harness (Fig.6) between the loom socket outlets. Terminal (11) and its attached pin receptacles (2) and (6) are permanently allocated as the Neutral terminal where the connection is fixed and any power supply is constant. 30 Similarly terminal (15) and its attached pin receptacles (3) and (7) are permanently allocated as the Earth terminal where the connection remains fixed. Fig 5 and 5a show the arrangement of the switch over mechanism used to vary the power supply connections to pin receptacles (4) and (8). Terminal (12) is aligned with terminals (13) and (14) and located in the position as shown in Fig.5.

6 A metal electrical conducting bar (29) is tapped to accommodate 3 switching screws (24) that are pitched to align with the contact plates (25), (26) and (27) which are permanently attached to terminals (12), (13) and (14) respectively. Operating the switching screws (24) of the switch over mechanism (20) provide alternative 5 power supply connection combinations as well as an isolating capability which allows pin receptacles (4) and (8) to be: 1. either jointly or separately connected: and, 2. connected to or disconnected from either one of the 3 sources of supply that may be available at terminals (12), (13) or (14). 10 The switch over Mechanism performs a double function in that it allows pin receptacles (4) and (8) to be selectively connected to the power supply available at any one of 3 terminals and also for the same pin receptacles to be selectively isolated from the system. Benefits derived from the present invention, not presently available with other existing types of loom systems, include the following: 15 1. because of the many optional power connections to the control pin receptacles (4) and (8) through the workings of the switch over mechanism, the socket outlets are not required to be allocated to particular luminaires prior to installation of the loom system. Hence it is possible for a speculative loom system to be installed during the construction of a building with the loom operation to be later configured when the 20 electrical design has been finalised. Most prominent amongst these possible applications is the installation of a loom system grid in building projects under construction particularly relevant where multi-tenancies are expected. 2. the switch over mechanism together with the quick fit post top terminal connections contribute to saving in time and costs in the manufacture, assembly and installation of 25 the loom system. and any subsequent redesign of the loom system. 3. Slave Outlets (Figs. 8, 9 and 11) also derive the benefits of the inbuilt switch over mechanism (20) in the controlling outlet. In a 5 wire system (Fig.6) of the present invention the power supply to the active pin receptacles within the slave outlets can be sourced selectively and separately from the controlling outlet, by connecting to 30 any of the active post top terminals (9), (10), (12), (13) or (14) in the controlling outlet using the three active conductors in the interconnecting wiring harness (Fig.6). The lugged ends (19) of any unassigned conductors in the wiring harness can be parked on the parking posts (23) moulded into the gear tray (21) within the controlling outlet. 35 7 As shown in Figs. 2 and 3a, the gear tray (21), which is moulded from PVC or similar insulating material, accommodates the switch over mechanism and terminals. The completed gear tray assembly (21) is attached to the moulded socket outlet housing (40-Fig 14) by the 4 screws (22). 5 Figs 8, 9 and 11 show the various slave plug socket outlets that are available for interconnection by the wiring harness shown in Fig.6. All connection terminals in slave outlets are post-top types which are combined with their respective pin receptacle as shown in Fig. 8c. The 4 pin twin socket slave outlet (Fig. 11) is dimensioned exactly to that of the controlling 4 10 pin twin socket outlet (Fig.14) and both outlets share common-to-both clip-on back plates (Fig.11 c) that are suitable for either surface mounting or for suspension from a catenary wire. The housings for these 2 outlets differ in that the controlling outlet has an identification "A" embedded in the front face (Fig 14) Both the 3 pin (Fig.9) and 4 pin (Fig.8) single slave outlets have the same housing 15 dimensions and both share common-to-both clip-on back plates (Fig 9c). The maximum variation in operational control of the loom system is achieved using a 5 wire loom system. Connection between outlets is achieved with a wiring harness (Fig.6) fitted with insulated flag type terminals (19) that quick connect to the post top terminals (17) and (37). The five conductors in the wiring harness (Fig.6) are colour coded with two of the 20 conductors being permanently allocated. The green/yellow conductor is permanently connected to the earth terminal (15) and the blue conductor is allocated and connected to the neutral terminal (11). The 3 remaining separately coloured conductors are either active or controlled active conductors which are selectively connected to either of terminals (9), (10), (12), (13) or (14). 25 Figs 4a and 4b show two alternative terminal constructions of the controlling outlet which combine a tunnel terminal that secures a connecting wire (not shown) in tunnels (16) by means of a screw (18) and slip-on connectors (19) on to posts (17). The interconnecting wiring harness shown in Fig 6 has insulated flag type slotted lugs (19) fitted to each conductor which slip on to either the post-top terminals (17) in the combined post-top/tunnel 30 terminals of the controlling outlet or the post-top terminals (37) in the combined post-top/pin receptacle terminals that are used on all slave outlets. . Each outlet of the adjustable twin controlling outlet (Fig.14) may be separately controlled. Additionally the switch over mechanism (20) in each outlet facilitates the multiple switching of light fittings, either singularly or in banks, or the connection of other ancillaries at slave 35 outlets to satisfy a required design.

8 ADVANTAGES The features of the present invention including the switch over mechanism within the 5 controlling outlet; the combination post top connection terminals fitted to all socket outlets; and the ready interchange ability of outlets, together provide advantages that presently are otherwise either not available or practical, including the advantages outlined below: 1. With other loom systems using fixed connections between the power supply and the pin receptacles, each socket outlet is wired to specifically accommodate the control 10 requirements of the plugged-in luminaire or appliance which precise wiring obviously cannot be accomplished until the electrical design detailing the type & location of the luminaire and its operational control requirements is finalised. The alternative connections selectively available because of the switch over mechanism of controlling outlet of the present invention, enables adjustments to be made in situ at 15 each outlet to satisfy electrical designs that would otherwise require external wiring. Using controlling socket outlets of the present invention eliminates the need to pre assign outlets including slave outlets and this feature provides many practical opportunities including the installation of speculative loom grid systems prior to the finalisation of the electrical design. 20 2. As it is not necessary to assign socket outlets, a speculative loom system can be installed in the form of a grid having outlets interconnected with uniform lengths of wiring harness with seemingly the only prior consideration being that the loom system has an adequate number of outlets installed to meet future design requirements. This prompts the prefabricating of uniform harness lengths which, 25 because of their quick fit post-top terminal connections, can be readily installed/removed/reused as required to meet new and changing design requirements. 3. Luminaires or appliances that are connected to a single plug socket in the same twin socket controlling outlet can be separately switched and controlled. 4. Fig. 12 shows an example pattern of a speculative grid system of the present 30 invention. To saturate the area that is proposed to be illuminated, the example grid is formed in an offset pattern of outlets that totally comprise twin 4 pin receptacle slave outlets interconnected equidistant in both directions. The spacing between the loom outlets will obviously vary dependent upon the anticipated lighting level. As tenancy areas are identified and electrical designs become available, the slave outlets are 9 readily replaced with similarly dimensioned twin 4 pin receptacle controlling outlets as and where necessary to meet the required conditions. 5. Fig 1 Oa illustrates the fixed connections in a Clipsal 414/4P5 five wire system with three actives, a neutral and an earth. Fig 10b illustrates the fixed connections in a 5 Clipsal 414/4P6 six wire system with four actives, a neutral and an earth. Figs. 5a and 7 schematically show the many possible connection options with the present invention when using a 5 wire system with 3 actives, one neutral and an earth conductor. To optionally separate the control pin receptacles of the twin outlets, two outlet types are required when using the prior art outlets as shown in Figs. 1Oa and 10 1 Ob. With the present invention the same separation is readily achieved within the same outlet via the inbuilt switch over mechanism.

10 VARIATIONS It will be realised that the foregoing has been given by way of illustrative example only and that all other modifications and variations as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein set forth. Throughout the description and claims to this specification the word "comprise" and variation of that word such as "comprises " and "comprising" are not intended to exclude other additives components integers or steps

Claims

1. An electrical loom system comprising two or more interconnected outlets with a controlling outlet having twin sets of four pin receptacles linked to a plurality of terminals inside the outlet some of which pin receptacles are paired and joined by metal bridges that have fixed connections to single dedicated terminals and other pin receptacles that singularly have fixed connections to single dedicated terminals which terminals are optionally interconnected and optionally connected to one or more other terminals that collectively provide alternative connection and isolation combinations selectively structured through a switch over and bridging mechanism which assembly is built-in and forms part of the controlling socket.

2. The terminals of the controlling outlet of claim 1 of a tunnel type construction which hold an electrical wire by means of a clamping screw in the wall of the tunnel integrated with a post type construction which receives a slide on clamping contact.

3. The controlling outlet of claim 1 in which a first incoming and outgoing active conductor is connected to a terminal, a second incoming and outgoing active conductor is connected to a second terminal an incoming and outgoing neutral conductor is connected to a third terminal and an incoming and outgoing earth conductor is connected to a fourth terminal.

4. The controlling outlet of claim 1 which further comprises two or more terminals to provide control terminal connections.

5. The system of claim 1 further comprising one or more slave outlets having internal post top terminals which receive a slide on clamping contact integrated with a shaped spring contact receptacle which receive the pin of plug tops.