AU2020463499A1 - Four pole outgoing plugging assembly - Google Patents

Four pole outgoing plugging assembly Download PDF

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Publication number
AU2020463499A1
AU2020463499A1 AU2020463499A AU2020463499A AU2020463499A1 AU 2020463499 A1 AU2020463499 A1 AU 2020463499A1 AU 2020463499 A AU2020463499 A AU 2020463499A AU 2020463499 A AU2020463499 A AU 2020463499A AU 2020463499 A1 AU2020463499 A1 AU 2020463499A1
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AU
Australia
Prior art keywords
housing
female plug
terminal
plugging assembly
assembly
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
AU2020463499A
Inventor
Peter Alexeev
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ELSTEEL (PVT) Ltd
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ELSTEEL PVT Ltd
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Publication date
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Publication of AU2020463499A1 publication Critical patent/AU2020463499A1/en
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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R9/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, e.g. terminal strips or terminal blocks; Terminals or binding posts mounted upon a base or in a case; Bases therefor
    • H01R9/22—Bases, e.g. strip, block, panel
    • H01R9/24—Terminal blocks
    • H01R9/2491—Terminal blocks structurally associated with plugs or sockets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/03—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations
    • H01R11/05—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations the connecting locations having different types of direct connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/10—Sockets for co-operation with pins or blades
    • H01R13/11—Resilient sockets
    • H01R13/115—U-shaped sockets having inwardly bent legs, e.g. spade type
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2107/00—Four or more poles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/28—Clamped connections, spring connections
    • H01R4/30—Clamped connections, spring connections utilising a screw or nut clamping member
    • H01R4/36—Conductive members located under tip of screw
    • H01R4/363—Conductive members located under tip of screw with intermediate part between tip and conductive member

Abstract

The invention is an improved four pole outgoing plugging assembly adapted for connecting electrical equipment installed in functional units (withdrawable and removable units) in low-voltage switchgear and controlgear assemblies, to external conductors. It comprises a male plug and a matching female plug. Depending on the location of the female plug, the invention discloses two variations of such plugging assemblies namely 'side-access' and 'rear-access'. The invention is equipped with specially shaped terminals for external conductors in the female plug to increase the number of external conductors which will be connected to each terminal for external conductors.

Description

FOUR POLE OUTGOING PLUGGING ASSEMBLY
TECHNICAL FIELD
The present invention relates to the field of electrical power distribution centers and motor control centers, particularly with regard to plug-in connections used to connect electrical equipment installed in functional units (withdrawable and removable units) in low-voltage switchgear and controlgear assemblies, to external cables.
BACKGROUND ART
Low-voltage switchgear and controlgear assemblies are intended to be used for distribution of electric power to consumers. The assemblies are internally separated into sections, sub-sections and compartments depending on the requirements of the end user. There can be three types of compartments in a low-voltage switchgear and controlgear assembly, as per the international standards IEC 61439, i.e. functional unit compartments, busbar compartments and cable compartments. The terminals for external conductors are accommodated in cable compartments. The functional units of a low-voltage switchgear and controlgear assembly can be of four different types, i.e. fixed, plug-in, removable and withdrawable.
The internal separation between sections, sub-sections or compartments is carried out by barriers and/or partitions. The international standard IEC 61439-2 classifies internal separation into 4 forms. Forms 2, 3 and 4 are sub-classified into sub-forms “a” and “b”. All the forms of internal separation show how busbars, functional units and terminals for external conductors are separated from each other.
The above described internal separations and types of functional units are two important technical concerns of today’s low- voltage switchgear and controlgear assembly manufacturers. The functional units need to be interconnected with dropper busbars to supply current to incoming circuits in the functional unit and need to be interconnected with terminals for external conductors to distribute current to outgoing circuits through external conductors. In order to facilitate these interconnections of a functional unit, various types of devices and methods are used in low-voltage switchgear and controlgear assemblies. One such method is a male plug plugging-in and contacting with a bare conductor in a mating female plug using a plugging assembly. When a plugging assembly is used to supply current to incoming circuits it is called as ‘incoming plug’. When a plugging assembly is used to distribute current to outgoing circuits, it is called as ‘outgoing plug’. Such plugging assemblies facilitate connection and disconnection of current between the functional units and the conductors.
It is also one of important requirements in the industry is that a functional unit is removed from the low-voltage switchgear and controlgear assembly without dismantling any external conductors from their terminal; the assembly is not fully shut down at any time for repairs or maintenance.
The plugging assembly closest to this invention, is disclosed in PCT/IB2013/001597 and patented under EP2875551. In that invention a different type of plugging technology is disclosed to make interconnections with respect to power, control and data connections. The operational current of that invention was limited due to the size of the plug pins. Another such mechanism closest to this invention, is disclosed in PCT/IB2019/061395 invented by this inventor. The invention disclosed in PCT/IB2019/061395 is not capable of handling high operational currents. Furthermore, it supports a maximum of two outgoing cables per phase in a limited cable space. The present invention is an improvement of the invention disclosed in PCT/IB2019/061395.
TECHNICAL PROBLEM
When it comes to plugging assemblies used in a low-voltage switchgear and controlgear assembly, the interconnections between incoming circuits and outgoing circuits are achieved by plug-in and plug-out operations. These plugging assemblies are found with many mechanical and electrical issues. The contact clips of the male plug and the receiving terminals of the female plug need to be strong enough to withstand greater number of plug-in and out operations. Furthermore, the contact clips and receiving terminals wear-out when they are used for many times and need to be adjusted mechanically to establish proper contact. The end users look for compact functional units having high operating currents in order to save space. Since the space inside a functional unit and its compartment are limited, the plugging assemblies cannot be designed as bulky and sturdy plugs. On the contrary, the cross section of the conductor parts used inside the male and female plugs should be increased corresponding to the operational current. Apart from that, the space meant of terminal for external conductors in the female plug determines the number of external conductors which can be connected to the terminals. Therefore, designing a compact plugging assembly with high operational current has become a challenging task.
On the other hand, the low-voltage switchgear and controlgear assembly manufacturers cannot compromise the protection offered by internal separation, since the safety of the personnel working around the switchgear and controlgear assemblies are one of the most demanding requirements in the industry.
In case of maintenance or repair work on one of functional units, other units should stay live. The removal of the functional unit should be as easy as possible. The technicians are not expected to dismantle conductors inside the unit before it is taken out or remove external conductors.
DISCLOSURE OF THE INVENTION
The invention is a plugging assembly with improved operational current, comprising a male plug and a matching female plug used to interconnect incoming circuits in a functional unit, with terminals for external conductors in a cable compartment of a low-voltage switchgear and controlgear assembly. Depending on the location and orientation where the male plug plugs-in the female plug and the shape of the terminal to which the external conductors are connected to the female plug, the invention discloses two variations namely side-access outgoing plugging assembly and rear-access outgoing plugging assembly. The invention consists specially shaped terminals for external conductors in the female plug to increase the number of external conductors connected to a terminal for external conductors. ADVANTAGEOUS EFFECTS
The invention eliminates the requirement of dismantling external conductors during removal of a functional unit from the switchgear or controlgear assembly. The heavy-duty terminals for external conductors allow accommodating external conductors with a greater cross-section as there is enough space between each terminal. The invention enables functional units to be taken out entirely from a low-voltage switchgear or controlgear assembly and replace it while the assembly is live.
The cable connections can be arranged as per the requirements of the application as the invention supports alternative ways of cable connections from rear or side cable compartments with respect to functional unit compartment, where the external conductors are accessed from a separate compartment achieving Form 4 in accordance with the international standard IEC 61439-2. Accidental contact with terminals for external conductors is protected by polycarbonate covers in this invention.
BRIEF DESCRIPTION OF DRAWINGS
Drawings do not appear in their correct scale. Some components of the invention are illustrated comparatively larger or smaller than their actual appearance.
Fig. 1 is an illustration of the first variation of the invention, i.e. side access plugging assembly comprising male plug and female plug.
Fig. 2A is an illustration of the male plug of the side access plugging assembly.
Fig. 2B is an illustration of bottom view of the male plug of the side access plugging assembly.
Fig. 3 is an illustration of the female plug of the side access plugging assembly and its sides as referenced in the description.
Fig. 4A is an illustration of the main components of the female plug.
Fig. 4B is an illustration of the top view of the female plug with its top cover removed.
Fig. 5 is an illustration of the front isometric view of the terminal conductor of side access plugging assembly.
Fig. 6 is an illustration of the configuration of the housing and the extended base of the female Plug.
Fig. 7A, 7B and 7C are illustrations of the upper supporting busbar holder and the lower supporting busbar holder of the female plug.
Fig. 8 A is an illustration of the front surface of the top cover of the female plug.
Fig. 8B is an illustration of the back of the top cover of the female plug.
Fig. 8C is an illustration of the top side of the housing of the female plug with its terminal conductors in.
Fig. 9 is an illustration of the bottom of the housing of the female plug.
Fig. 10 is an illustration of the horizontal mounting brackets, vertical mounting bracket and how the female plug is mounted to those mounting brackets. Fig.11 A and 1 IB are illustrations of how the horizontal mounting brackets and vertical mounting bracket are mounted to frame member of switchgear or controlgear assembly.
Fig. 12 is an illustration of how the female plug is mounted to a frame member.
Fig. 13 is an illustration of how the female plug is mounted to a frame member with transparent cover.
Fig. 14 is an illustration of the second variation of the invention, i.e. rear access plugging assembly comprising male plug and female plug.
Fig. 15 is an illustration of the female plug of the rear access plugging assembly and its sides as referenced in the description.
Fig. 16A is an illustration of the main components of the female plug of the rear access plugging assembly.
Fig. 16B is an illustration of the bottom view of the female plug of the rear access plugging assembly.
Fig. 16C is an illustration of the female plug of the rear access plugging assembly with its terminal conductors and upper and lower supporting busbar holders.
Fig. 17 is an illustration of the female plug of the rear access plugging assembly without its top cover.
Fig. 18 is an illustration of the terminal conductor of the female plug of the rear access plugging assembly.
Fig. 19 is an illustration of the housing and the extended base of the female plug of the rear access plugging assembly.
Fig. 20A, 20B and 20C are illustrations of the upper supporting busbar holder and the lower supporting busbar holder of the female plug of the rear access plugging assembly.
Fig. 21 is an illustration of the housing of the female plug without its top cover.
Fig. 22A and 22B are illustrations of front view of the top cover of the female plug. Fig. 23 is an illustration of the back of the top cover of the female plug.
Fig. 24 is an illustration of bottom view of the female plug.
Fig. 25 is an illustration of the arrangement of the horizontal mounting brackets, vertical mounting bracket and female plug before mounting to a frame member.
Fig. 26 is an illustration of how the horizontal mounting brackets and vertical mounting bracket are mounted to a frame member.
Fig. 27A and 27B are illustrations of how the rear access plugging assembly is mounted to a frame member.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION
The invention is a plugging assembly which allows the power connections coming from internal switching devices installed in functional units in electrical switchgear and controlgear assemblies, to be connected or disconnected with external cables connected with the load, by means of a plugging-in mechanism. The plugging assembly comprises a male plug and a female plug. The ‘external conductors’ and ‘terminals for external conductors’ mentioned in the above sections, are respectively referred to as ‘external cables’ and ‘external cable terminals’ in this detailed description.
The invention discloses two variations of such plugging assemblies in which the variation between the two plugging assemblies lies in the manner which the external cables are connected with the plugging assembly and the location where the male plug is plugged into the female plug.
Fig. 1 shows the first variation of the invention which is a plugging assembly (1) to which external cables are connected from its right side and the male plug is plugged in on the top. This plugging assembly (1) is identified as ‘side access outgoing plug’ by the inventor. The plugging assembly (1) is comprised of two parts, i.e. male plug (2) and female plug (3).
As shown in Fig. 2A. The male plug (2) of the plugging assembly (l)consists twelve ‘U’ shaped spring-loaded clips (4) and their corresponding four terminals (5) meant for internal wiring, fixed on a rigid insulating housing (6), and is fixed in a functional unit (“unit”) in a low-voltage switchgear or control gear assembly. Since clips (4) are spring-loaded, they are expandable and shrinkable when they are engaged and disengaged with solid matter. Each ‘U’ shaped spring- loaded clip(4)is accommodated in and supported by a base (7) protruded downwards from the housing (6). It is fixed in manner which extends-out its ‘U’ shaped spring- loaded clips (4)towards the rear side of the unit allowing the spring-loaded clips (4) to be mechanically inserted into the female plug (3) when the unit is pushed into its compartment in the assembly. As shown in Fig. 2B, each terminal (5) is fixed with three ‘U’ shaped spring-loaded clips (4). These three clips (4) are designed in three different heights, creating three levels of clips (4) to avoid connecting all clips (4) at the same time to terminal connectors in the female plug (3). Thus, when the unit is pushed into and removed from its compartment, the effort to be deployed against mechanical force due to springs in the clips (4), is reduced. Furthermore, the ‘U’ shaped spring-loaded clips (4) are covered and protected by their bases (7) in three sides to increase clearances and creepage distance between two clips (4). The terminals (5) are internally wired with the devices inside the unit. As shown in Fig. 2A, each of the terminals (5) is covered from insulating barriers (8) protruded upwards from the housing (6), which limit access to live parts- terminals (5). The terminals (5) can be covered with a transparent cover having square shaped cutouts.
The female plug (3) of the plugging assembly (1) is the component which receives the ‘U’ shaped spring-loaded clips (4) of the male plug (1) and makes the power connection with the external cables to complete the outgoing circuits. For the ease of description, the sides of the female plug (3) is referenced as top side (9), bottom side (10), left side (11) and right side (12), as shown in Fig. 3.
As shown in Fig. 4A, the female plug (3) consists of four terminal conductors (13), a part of which is placed inside a cuboid shaped rigid housing (14), with an extended base (15) and a top cover (16) moulded out of an insulating material. As shown in Fig. 4B, the housing (14) has insulating internal barriers (17) with holders (18) and border walls (19) with holders (18), creating slots (20a) to accommodate the terminal conductors (13) in the housing (14). The internal barriers (17) separate each of the terminal conductors (13). The holders (18) hold the terminal conductors (13) vertically and firmly in the slots (20a). The housing (14) has five screw holes (21)of which two screw holes (21) are attached to border walls (19) and the rest is on internal barriers (17) for fixing the top cover (16). The top cover (16) is fixed to the housing (14) by driving five screws into the screw holes (21).
As further shown in Fig. 4B, the four terminal conductors (13) are meant for four poles, three phases and neutral. Each terminal conductor (13) is a solid plate of conductive material, having a rectangular shaped longitudinal profile with a substantial thickness, which runs from the left side (11) to the right side (12) of the female plug (3).
As shown in Fig. 5, the terminal conductor (13) has three sections, i.e. receiving terminal (22), insulated section (23) and external cable terminal (24). One end of the terminal conductor (13) is identified and functions as receiving terminal (22). The other end of the terminal conductor (13) has an ‘L’ shaped section, identified and functions as external cable terminal (24). The in- between section (23) of the terminal conductor (13) is covered with an insulator (25) and identified as insulated section (23). The insulator covers the bare area of the terminal conductor, the section of which is just inside from the housing (14)to the beginning of the external cable terminal (24) and thereby provides protection against risk of arc faults. As shown in Fig. 6, each terminal conductor (13)runs from the left side to the right side of the female plug (3) and is placed with its larger face vertically in slots (20a) in the housing (14) and in channels (20b) on the extended base (15)of the female plug (3). The receiving terminal (22) is caught, from its top, by the spring-loaded clip (4) in the male plug (2) when the male plug is plugged into female plug (3). The external cable terminal (24) end of the terminal conductor (13)is designed to have ‘L’ shape with holes (26), creating more space to accommodate more cables, i.e. it increases the number of external cables connectable to a terminal conductor (13). The holes (26) on the ‘L’ shaped external cable terminal (24) are used to fix external cables. Each hole (26) can be connected with two external cables. The terminal conductor (13), at its insulated section (23), is outwardly bent at two points (27) in a manner which the receiving terminal (22) and the external cable terminal (24) are offset to each other, creating required clearances between the terminal conductors (13) when it is outside of the housing (14). Thus, the distance between each external cable terminal (24) is increased; the number of external cables connected to the female plug (3) per phase is increased. Each terminal (5) in the male plug (2) has three ‘U’ shaped spring-loaded clips (4). The receiving terminal (22) of each terminal conductor (13) in the female plug (3) receives three spring-loaded clips (4) in the male plug (2)and connects them (4) from the top of the receiving terminal (22), and the external cable terminal (24) of each terminal conductor (13) accommodates at least two external cables connected to the load. The terminal conductor (13) could be of Copper or Aluminum having cross-sectional area corresponding to operating current. As a result, the operating current of the plugging assembly (1) and the outgoing circuit are increased.
As further shown in Fig. 6, the housing (14) of the female plug (3) has an extended base (15) with channels (20b) to support and hold the terminal conductors (13). The channels (20b) on the extended base (15) are spreaded outwards from the housing (14)and has the same longitudinal bended shape of the insulated section of the terminal conductor (13). As the part of the terminal conductor which is outside of the housing (14), i.e. the insulated section (23)and the external cable terminal (24), is longer than the part of the terminal conductor which is inside the housing
(14), i.e. receiving terminal (22), the extended base (15)is required to hold and support the terminal conductors in proper positions. The receiving terminal end (22) of the terminal conductor (13) resides in slots (20a) in the housing (14) of the female plug (3) whereas the insulated section (23) of the terminal conductor (13) resides outside of the housing (14)in the channels (20b) on the extended base (15). The slot (20a) in the housing (14)and a channel (20b) on the extended base (15) combine and create one single path which continues until the second outward bend (27) of the extended base (15). The depth of channels (20b) on the extended base
(15) is lower than that of the slots (20a) in the housing (14). The extended base (15) is strengthened by the ribs (28) on its surface.
As shown in Fig. 7A, the stability and the distance between each external terminal (26) is maintained by a pair of supporting busbar holders - upper supporting busbar holder (29a) and lower supporting busbar holder (29b), which are placed on and under, and closer to the end of the insulated section (23)of the terminal conductors (13), and are tightened by screws (30) inserted through upper holes (31a) in the upper supporting busbar holder (29a) and driven through selftapping screw holes (31b)on the lower supporting busbar holder (29b). The supporting busbar holders(29a and 29b) bind and avoid terminal conductors (13) leaning sideways, deforming or moving due to the weight of external cables connected to each terminal conductor (13). As shown in Fig. 7B, the lower supporting busbar holder (29b) has lower holes (32b) to insert screws (33) and fix the lower supporting busbar holder (29b) to vertical mounting bracket which is described under Fig. 12. As shown in Fig. 7C, the upper supporting busbar holder (29a) has upper holes (32a) to insert through a screwdriver to reach screws (33) when fixing the female plug (3) with supporting busbar holders (29a and 29b) to a vertical mounting bracket.
As shown in Fig. 8 A, the top cover (16) is configured to have a set of openings (35) for ‘U’ shaped spring-loaded clips (4) and set of screw holes (36) for top cover fixing screws. The openings (35)for spring-loaded clips (4) are shaped into thin rectangular with rounded corners, which resembles the shape of the base (7) of ‘U’ shaped spring-loaded clip (4). The size of the opening (35) is slightly greater than the size of the base (7) of the spring-loaded clip (4); thus, allowing the spring-loaded clips (4) and its base (7) to enter into the opening (35) and the spring- loaded clips (4) to reach and catch the terminal conductor (13) in the housing (14) of the female plug (3). The shape of the base (7) is designed to have an inwardly tapered top. Similarly, the opening (35) for spring-loaded clip (4) is designed to have the same shape with a tapered bottom. Hence, the tapered top of the base (7) of the clip (4) reaches the tapered bottom of the opening (35) and stops at a distance to maintain a gap between the housing (6) of the male plug (2) and the front surface of the top cover (16) of the female plug (3) to protect the female plug (3) being hit by the male plug (2), while the clips (4) fully engage with the terminal conductor (13) and stops without imposing extra force to the terminal conductor (13).
Further shown in Fig. 8B, the back of the top cover (16) has a configuration of channels (37) designed to be sunk into the internal barriers (17) and the three border walls (19) in the housing (14) of the female plug (3) when the top cover (16) is placed on the top of the housing (14). As shown in Fig.s 8B and 8C, at the top edges of the three border walls (19) of the housing (14), the border walls (19) have an inward step (38) on the outside of the border walls (19). When the cover (16) is placed on top of the housing (14), the top edges of the internal barriers (17) and that of border walls (19) sink into their respective channels (37)at the back of the top cover, until the bottom of edges (39) of the top cover (16) hit the inward step (38) on the border walls (19) of the housing (14). The cover (16) is fixed to the housing (14) with screws driven into cover fixing screw holes (36).
As shown in Fig. 9, at the bottom side (10) of the housing (14) has a spring clip (40) with a notch (41) and four mounting channels (43) on the two long edges and at the center, which are used to mount the female plug (3), and two square-shaped knobs (49). The spring clip (40) is positioned in the bottom side (10) of the housing (14) along the center line of the width of the housing (14), keeping one end of the spring clip (40) as a free end (42).
As shown in Fig. 10, two rectangular steel horizontal mounting brackets (44) and a rectangular steel vertical mounting bracket (50) are used to mount the female plug (3) to the low-voltage switchgear or controlgear assembly. Each of the two horizontal mounting brackets (44) has a slide stopper (45) and mounting screw holes (46) and its two long edges are formed as flanged edges (47) to allow sliding-in mounting channels (43) on the bottom side (10) of the housing (14) of female plug (3). The vertical mounting bracket (50) is a steel plate of which the two vertical edges (54a and 54b) have been folded in opposite directions at right-angle and the surface has been twice vertically folded to have a step-down level creating an upper level (51) and lower level (52)on the surface, which in turn increases creepage clearance on the vertical mounting bracket (50). The vertical mounting bracket (50) has cutout-holes (53) on one folded edge (54a); openings (55), mounting-cutouts (56), lock hole (59)and lower supporting busbar holder mounting holes (57) on the upper level (51); and cover fixing holes (58) on both upper level (51) and lower level (52)and on vertical edge (54b).
As shown in Fig. 11 A, the vertical mounting bracket (50) is mounted vertically to left or right side of a vertical frame member (60), depending on the requirement, by inserting the cutoutholes (53) into half-way pre-fixed screws on the vertical frame member (60); the screws are fully tightened by screwdriver inserted through mounting-cutouts (56) while the tightening operation is viewed through openings (55). The vertical mounting bracket (50) is mounted in a direction to which the bracket (50) and its vertical edge (54b) extends-out towards the adjoining compartment, i.e. cable compartment, at left or right side of the functional unit compartment. As shown in Fig. 11B, once the vertical mounting bracket (50) is mounted to frame member (60) of switchgear or controlgear assembly, the two horizontal mounting brackets (44) are mounted horizontally to the front side of the same frame member, in the same direction of which the vertical mounting bracket (50) is mounted, locating the flanged edges (47) in the functional unit compartment using mounting screw holes (46). The female plug (3) is mounted in the functional unit compartment facing its (3) top side (9) towards the front side of the low-voltage switchgear or control gear and keeping its openings (35) for ‘U’ shaped spring-loaded clips (4) in the functional unit compartment.
Referring to Fig.s 9, 10, 11A and 11B, in order to mount the female plug (3), it is inserted through the four mounting channels (43) on its back along the flanged edges (47) of the two horizontal mounting brackets (44), from the side of the vertical mounting bracket (50), and slided-in until the two knobs (49) on the bottom side of the female plug (3) hit the two slide stoppers (45) on the two horizontal mounting brackets (44) and the notch (41) on the free end (42) of the spring clip (40) reaches the middle opening (55) on the vertical mounting bracket (50) and locks making a “click” sound. The middle opening (55) provides space to accommodate the notch (41) on the spring clip (40) at the time of the female plug (3) is fully inserted into the two horizontal mounting brackets (44). The middle opening (55) is connected with lock hole (59) on the vertical mounting bracket (50), through which a tool is inserted to press the free end (42) to release the notch (41) from the middle opening (55) when the female plug (3) is dismantled by sliding-out from the horizontal mounting brackets (44).
As shown in Fig. 12, once the female plug (3) is fully inserted into horizontal mounting brackets (44), the lower supporting busbar holder (29b) of the female plug (3) is fixed to vertical mounting bracket (50) using screws (33) inserted through lower holes (32b) in the lower supporting busbar holder (29b). The screws (33) are fastened by inserting a screwdriver through upper holes (32a) on the upper supporting busbar holder (29a). Thus, the female plug (3) is installed in a manner which the top side (9) of the female plug (3) stays in the functional unit compartment and keeping its (3) openings (35) for spring-loaded clips (4) in the functional unit compartment while the external cable terminals (24) for external cables extend-out to adjoining left or right cable compartment of the switchgear or controlgear assembly.
Once the female plug is (3) is mounted to the horizontal mounting bracket (44) and to the vertical mounting bracket (50), lugged external cables, which supply power to the load in the outgoing circuit, are connected to external cable terminals (24), using nuts and bolts fasten through holes (26). The increased distance between two external cable terminals (24) due to the outward bends (27) and the ‘L’ shaped design of the external cable terminals (24), creates considerable amount of space to accommodate more than one external cable per phase. Thus, the current carrying capacity of the plugging assembly (1) is increased. Finally, the external cable terminals (24) are covered by a transparent cover (61) which is identified as Form 4B cover. The cover (61) comprises square-shaped cutouts (62) on all sides of the cover and fixing brackets (63). The cover (61) guards against accidental contact with live parts in the female plug (3), i.e. cable lugs and external cable terminals. The square-shaped cutouts (62) allows ventilation to reduce the temperature generated inside the cover when current passes in the circuits. The cutouts (62) can be removed from anywhere on the cover (61) in any shape to create external cable entry holes for external cables extended towards external circuits. Lugged external cables are passed through such cable entry holes on the transparent cover (61). Fig. 13 shows the way it appears when it is fully installed in switchgear or controlgear assembly without connecting external cables.
The female plug (3) is dismantled from the horizontal mounting bracket (44) by first removing the (61), disconnecting external cables from external cable terminals (24), removing screws (33) from lower holes (32b) on the lower supporting busbar holder (29b) and pressing the free end (42) on the spring clip (40) to release the notch (41) from the middle opening (55) by a tool inserted through lock hole (59), while sliding-out the female plug (3) from the horizontal mounting bracket (44).
When the functional unit is fully inserted into its compartment, the male plug (2) fixed in the unit engages its ‘U’ shaped spring-loaded clips (4) with the terminal conductors (13) in the female plug (3) making power connections with female plug (3) mounted on the frame members of the switchgear or controlgear assembly. When the unit is removed from its compartment, the male plug (2) disengages its spring-loaded clips (4) from the terminal conductors (13) and withdraws from the female plug (3) disconnecting the power connections.
The above described variation of the invention - side access outgoing plug - makes the interconnection between the internal circuit in the functional unit and the outgoing circuit in the switchgear or controlgear assembly, i.e. it connects the devices in functional units with the external cables which supply power to load in the downstream, where the external cables are connected to the female plug (3) from the compartment which is adjacent to the functional unit compartment on the right or left. As shown in Fig. 13, the female plug (3) is mounted horizontally on two adjoining vertical frame members (60) in the low-voltage switchgear or controlgear assembly, facing its top side (9) towards the front of the assembly, keeping its openings (35)for ‘U’ shaped spring-loaded clips (4) extended out from male plug (2), in the functional unit compartment and the external cable terminals (24)for external cables extending- out to the cable compartment located on the left or right of the functional unit compartment. As a result, the external cable terminals (24) and holes (26) meant for external cables are accessed from the adjacent cable compartment located on the left or right of the functional unit compartment when connecting external cables to the female plug (3).
The Fig.14 shows another variation of the invention which is identified as ‘rear-access outgoing plug’. This plugging assembly (80) has the exactly same functionality as the first variation of the invention which was described above as the side-access outgoing plug (1). The same male plug (2) in the first variation of the invention is used as the male plug for female plug (81) in the second variation. What mainly differs from the first variation is the openings for U-shaped clips and holes in the top cover; openings, holes and internal barriers in the housing, the side from which receiving terminal is caught by ‘U’ shaped clips and configuration of the terminal conductor of the female plug (81).
For easy description, the female plug (81) of the second variation (rear-access outgoing plug) is referenced as top side (85), bottom side (86), left side (87) and right side (88) as shown in Fig. 15.
As shown in Fig. 16A, Fig. 16B and Fig. 16C, the female plug (81) consists of a cuboid shaped rigid housing (100) with an extended base (106) and four terminal conductors (90), a top cover (110), upper supporting busbar holder(120a), lower supporting busbar holder(120b), vertical mounting bracket (50), two horizontal mounting brackets (44) and transparent cover (61).
As further shown in Fig. 16C, the female plug (81) of the second variation consists of four terminal conductors (90), a part of which is placed inside the cuboid shaped rigid housing (100) with an extended base (106) and a top cover (110) which are moulded with insulating material.
As shown in Fig. 17, the housing (100) has insulating internal barriers (101) with holders (102)and border walls (103) with holders (102), creating slots (104a) to accommodate the receiving terminal (91) of the terminal conductors (90) in the housing (100). The internal barriers (101) in the housing (100) separate each of the terminal conductors (90). The holders (102) hold the terminal conductors (90) vertically and firmly in the slots (104a) with their larger face vertical. The housing (100) has five top cover fixing screw holes (105) on the internal barriers (101) and close to border walls (103) to fix top cover (110). The top cover (110) is fixed to the housing (100) by driving five screws into the screw holes (105). The extended base (106) has channels (104b) to hold terminal conductors (90) as described below under Fig. 19.
As shown in Fig. 18, the terminal conductor (90) has three sections, i.e. receiving terminal (91), insulated section (94) and external cable terminal (92). Same as in the first variation (1) of the invention, the four terminal conductors (90) meant for four poles, i.e. three phases and the neutral, provide the same functionality and has a rectangular shaped longitudinal profile of which one end is identified and functions as receiving terminal (91)and the other end is identified and functions as external cable terminal (92) with two holes (93) to connect external cables. The in between section (94) of the terminal conductor (90) is covered with an insulator (95) and identified as insulated section (94). The insulator (95) covers the bare area of the terminal conductor just inside from the housing (100) to the beginning of the external cable terminal (92) and thereby provides protection against risk of arc faults. As shown in Fig. 19, each terminal conductor (90) is a solid plate of conductive material, with a substantial thickness, runs from the left side (87) to the right side (88) of the female plug (81) and is placed with its larger face vertically in slots (104a) in the housing (100) and in channels (104b) on the extended base (106) of the female plug (81). The external cable terminal (92) of the terminal conductor (90) is different from that of the first variation. The external cable terminal (92) of the terminal conductor (90) is designed to be long enough to provide cable connecting space to connect at least two external cables. The holes (93) are used to fix external cables. Depending on the size of the external cables, two external cables can be connected to each hole (93) on the external cable terminal (92).
Further to Fig. 18, the terminal conductor (90), at its insulated section (94), is outwardly bent at two points (96) in a manner which the receiving terminal (91) and the external cable terminal (92) are offset to each other, creating required clearances between the terminal conductors (90). Thus, the distance between each external cable terminal (92) is increased; the number of external cables connected to the female plug (81) per phase is increased. As shown in Fig. 2A, each terminal (5) in the male plug (2) has three ‘U’ shaped spring-loaded clips (4). The receiving terminal (91) is caught, from the side of the receiving terminal (91), by the spring-loaded clip (4) in the male plug (2) when the male plug is plugged into female plug (81). The receiving terminal (91) of each terminal conductor (90) in the female plug (81) receives three spring-loaded clips (4) in the male plug (2), and the external cable terminal (92) of each terminal conductor (90) accommodates at least two external cables connected to the load. The terminal conductor (90) could be of Copper or Aluminum having cross-sectional area corresponding to operating current. As a result, the operating current of the plugging assembly (80) and of the outgoing circuit is increased.
As shown in Fig. 19, the housing (100) of the female plug (81) has an extended base (106) with channels (104b) to support and hold the terminal conductors (90). The channels (104b) on the extended base (106) are spread outwards from the housing (100) and has the same longitudinal bended shape of the insulated section of the terminal conductor (90). As the part of the terminal conductor which is outside of the housing (100), i.e. the insulated section (94) and the external cable terminal (92), is longer than the part of the terminal conductor which is inside the housing (100), i.e. receiving terminal (91), the extended base (106) is required to hold and support the terminal conductors in proper positions. The receiving terminal (91) of the terminal conductor (90) resides in slots (104a) in the housing (100) of the female plug (81) whereas the insulated section (94) of the terminal conductor (90) resides outside of the housing (100) in the channels (104b) on the extended base (106). A slot (104a) in the housing (100) and a channel (104b) on the extended base (106) combine and create one single path which continues until after the second outward bend (96) of the extended base (106). The depth of channels (104b) on the extended base (106) is lower than that of the slots (104a) in the housing (100). The extended base (106) is strengthened by the ribs (107) on its surface.
As shown in Fig. 20A, the stability and the distance between each external cable terminal (92) is maintained by a pair of supporting busbar holders, i.e. upper supporting busbar holder (120a) and lower supporting busbar holder (120b), which are placed on and under, and closer to the end of the insulated section (94) of the terminal conductors (90), and are tightened by screws (121) inserted through upper holes (122a) in the upper supporting busbar holder (120a) and driven through self-tapping screw holes (122b) on the lower supporting busbar holder (120b). The supporting busbar holders (120a and 120b) bind and avoid terminal conductors (90) leaning sideways, deforming or moving due to the weight of external cables connected to each terminal conductor (90). As shown in Fig.s 20A, 20B and Fig. 20C, the lower supporting busbar holder (120b) has lower holes (123b) to insert screws (124) and fix the lower supporting busbar holder (120b) to vertical mounting bracket. The upper supporting busbar holder (120a) has upper holes (123 a) to insert through a screwdriver to reach screws (124) when fixing the female plug (81) with supporting busbar holders (120a and 120b) to vertical mounting bracket, as shown in Fig. 27A.
As shown in Fig. 21, the left side (87) of the housing (100) is configured to have a set of openings (108) for ‘U’ shaped spring-loaded clips (4). The openings (108) for spring-loaded clips (4) are shaped into thin rectangular with rounded corners, which resemble the shape of the base (7) of ‘U’ shaped spring-loaded clip (4). The size of the opening (108) is slightly greater than the size of the base (7) of the spring-loaded clip (4); thus, allowing the spring-loaded clips (4) and its base (7) to enter into the opening (108) and the spring-loaded clips (4) to reach and catch the terminal conductor (90) in the housing (100) of the female plug (3). The shape of the base (7) is designed to have an inwardly tapered top. Similarly, the opening (108) for spring- loaded clip (4) is designed to have the same shape with a tapered bottom. Hence, the tapered top of the base (7) of the clip (4) reaches the tapered bottom of the opening (108) and stops at a distance to maintain a gap between the housing (6) of the male plug (2) and the left side (87) wall of the housing (100) of the female plug (81) to protect the female plug (81) being hit by the male plug (2), while the clips (4) fully engages with the terminal conductor (90), from its side, and stops without imposing extra force to the terminal conductor (90).
As shown in Fig. 22A, the top cover (110) is configured to have a set of screw holes (111) for top cover fixing screws on its top surface. One long border wall (112a) of the top cover (110) has another set of openings (108) for ‘U’ shaped spring-loaded clips (4). As shown in Fig. 22B, the other long border wall (112b) of the top cover (110) has openings (114) into which top part of terminal conductors (90) are sunk when the top cover (110) is fixed to the housing (100). As shown in Fig. 22A and Fig. 22B, the edge of border walls(l 12a, 112b, 113a and 113b) of the top cover (110) is designed to have an inward step (118) on the outside of the boarder walls (112a, 112b, 113a and 113b).
As further shown in Fig. 21 and Fig. 23, the back of the top cover (110) has a configuration of holders (115) connected to border walls (113a and 113b) and internal barriers (117). The holders (115) are designed to be sunk into top part of terminal conductors (90) and held them tightly inside the housing (100). The inward step (118) at the edge of the border walls (112a, 112b, 113a and 113b) of the top cover (110) rests on the top of border walls (103) of the housing (100) when the top cover (110) is fixed. The top cover (110) is strengthened by ribs (119) with a set of slots (120) which are sunk into respective top edges of the internal barriers (101) in the housing (100) when the top cover (110) is fixed to the housing (100). As shown in Fig. 21, the top cover (110) is fixed to the housing (100) with screws driven into screw holes (105) on the housing (100) through screw holes (111) on the top cover (110). The border walls (103) of the housing (100) has a step (109) closer to top edge and inside to the boarder walls (103) on which the edges of boarder walls (112a, 113a and 113b)of the top cover (110) stop when the top cover (110) is placed on the housing (100).
As shown in Fig. 24 and as described for the first variation, at the bottom side (86) of the housing (100) has a spring clip (130) with a notch (131) and four mounting channels (132) on the two long edges and at the center, which are used to mount the female plug (81), and two square shaped knobs (133). The spring clip (130) is positioned in the bottom side (86) of the housing (100) along the center line of the width of the housing (100), keeping one end of the spring clip (130) as a free end (134).
Similar to first variation, the same two rectangular steel horizontal mounting brackets (44) and the same rectangular steel vertical mounting bracket (50), as shown in Fig. 25, are used to mount the female plug (81) to the low- voltage switchgear or controlgear assembly.
As shown in Fig. 26, the vertical mounting bracket (50) is mounted vertically to rear side of a vertical frame member (116) of the assembly, in the same manner described under the first variation of the invention. The vertical mounting bracket (50) is mounted in a direction which the bracket (50) and its vertical edge (54b) extend-out towards the adjoining compartment, i.e. cable compartment, at the back of the functional unit compartment. The two horizontal mounting brackets (44) are horizontally mounted to left or right side of the same frame member (116), depending on the requirement, in the same direction of which the vertical mounting bracket (50) is mounted, locating the flanged edges (47) in the functional unit compartment, in the same manner described under the first variation of the invention.
As shown in Fig. 27A, the female plug (81) is mounted to the horizontal mounting brackets (44) by inserting the female plug (81) through the four mounting channels (132), from the side of the vertical mounting bracket (50), along the flanged edges (47) of the two horizontal mounting brackets, facing the left side (87) of the female plug (81) towards the front side of the low- voltage switchgear or controlgear assembly in the functional unit compartment, in the same manner as described under the first variation. Thus, the female plug (81) is mounted in a manner which the left side (87) of the female plug (81) stays in the functional unit compartment, keeping its (81) openings (108) for spring-loaded clips (4) in the functional unit compartment, while the external cable terminals (92) for external cables extend-out to adjoining rear cable compartment of the switchgear or controlgear assembly, as shown in Fig. 27 A.
Once the female plug is (81) is mounted to the horizontal mounting brackets (44), it is fixed to vertical mounting bracket (50) by screws (124) inserted through lower holes (123b) on the lower supporting busbar holder (120b) and tightened by a screwdriver inserted through upper holes (123a) on the upper supporting busbar holder (120a). Thereafter, lugged external cables, which supply power to the load in the outgoing circuit, are connected to external cable terminals (92), using nuts and bolts fasten through holes (93). The increased distance between two external cable terminals (92) due to the outward bends (95) creates considerable amount of space to accommodate more than one external cable per phase. Thus, the current carrying capacity of the plugging assembly (81) is increased. Finally, the external cable terminals (92) are covered by the same cover (61) which is identified as Form 4B cover, in the same manner described under the first variation of the invention. Fig. 27B shows the way it appears when the female plug (81) is fully installed to a vertical frame member (116) of a switchgear or controlgear assembly without connecting external cables. The cut-outs (62) on the transparent cover (61) can be removed from anywhere on the cover (61) in any shape to create cable entry holes for external cables. Lugged external cables are passed through such cable entry holes on the transparent cover (61).
The female plug (81) is dismantled from the horizontal mounting bracket (44) by first removing the transparent cover (61), disconnecting external cables from external cable terminals (92), removing screws(124) from lower holes (123 b) on the lower supporting busbar holder (120b) and pressing the free end (134) on the spring clip (130) to release the notch (131) from the middle opening (55) by a tool inserted through lock hole (59), while sliding-out the female plug (81) from the horizontal mounting bracket (44).
When the functional unit is fully inserted into its compartment, the male plug (2) fixed in the unit engages its ‘U’ shaped spring-loaded clips (4) with the terminal conductors (90) in the female plug (81) making power connections with female plug (81) mounted on the frame member of the low-voltage switchgear or controlgear assembly. When the unit is removed from its compartment, the male plug (2) disengages its spring-loaded clips (4) from the terminal conductors (90) and withdraws from the female plug (81) disconnecting the power connections.
Thus, the above described second variation of the invention - rear access outgoing plug - makes the interconnection between the internal circuit and the external circuit in the low-voltage switchgear or controlgear assembly, i.e. it connects the devices in functional units with the external cables which supply power to the load in the downstream such that the external cables are connected to the female plug (81) from the compartment which is behind the unit. As a result, the external cable terminals (92) and holes (93) provided for connecting external cables are accessed from the compartment behind the functional unit compartment when connecting external cables to the female plug (81).

Claims (1)

  1. 23
    1. A plugging assembly adapted for making electrical interconnections between the devices installed in a functional unit compartment, and external cables of a low-voltage switchgear or controlgear assembly, wherein the improvements are made to increase usability of such plugging assembly, comprising: a. a male plug (2) to which internal wires coming from devices installed in the functional unit are connected, comprising: i. a rigid insulating housing (6) having insulating barriers (8) protruded upwards from the housing (6) and bases (7) protruded downwards from the housing (6), ii. a plurality of ‘U’ shaped spring-loaded clips (4) which expand and shrink when the clips are engaged with and disengaged from a terminal conductor and iii. a plurality of terminals (5) for internal wiring, each connected with ‘U’ shaped spring-loaded clips (4) having different heights creating different height levels; b. a female plug (3) of which ‘U’ shaped spring-loaded clips (4) of the male plug (2) are received from the top (9) and external cables are connected from the right side (12), comprising: i. a cuboid shaped rigid insulating housing (14) with an extended base (15), whereby the cuboid shaped housing having a plurality of insulating border walls (19) with holders (18), a plurality of insulating internal barriers (17) with holders (18), a plurality of slots (20a), a plurality of cover fixing screw holes (21) attached to border walls (19) and on internal barriers (17), and the extended base (15) having outward spreading channels (20b) and ribs (28), ii. a plurality of terminal conductors (13) having a rectangular shaped longitudinal profile of which one end functioning as receiving terminal (22) caught from its top by ‘U’ shaped spring-loaded clips (4) in male plug (2), the other end functioning as external cable terminal (24) having an ‘L’ shape with a plurality of holes (26) to which external cables are connected, and insulated middle section (23) with two bends (27) which outwardly bend the terminal conductor off-setting the receiving terminal (22) and the external cable terminal (24), iii. upper supporting busbar holder (29a) having upper holes (31a and 32a) and lower supporting busbar holder (29b) having self-tapping screw holes (31b) and lower holes (32b), placed on and under and closer to the end of the insulated section (23) of the terminal conductors (13)and tightened by screws (30) keeping certain fixed distance among terminal conductors (13), iv. a top cover (16) having a plurality of openings (35) for spring-loaded clips (4) and a plurality screw holes (36) for cover fixing screws on the top surface, and a configuration of channels (37) at the back of the cover (16) whereby the channels (37) are designed to be sunk into the top edges of the internal barriers (17) and that of the three border walls (19) in the housing (14) of the female plug (3), and v. a spring clip (40) with a free end (42), positioned in the bottom (10) of the housing (14) along the center line of the width of the housing (14), with a notch (41) and four mounting channels (43) on two long edges and at the center, and two square-shaped knobs (49); c. two rectangular steel horizontal mounting brackets (44) each having a slide stopper (45) and mounting screw holes (46) with its two long edges formed as flanged edges (47); d. a rectangular steel vertical mounting bracket (50) of which two vertical edges (54a and 54b) folded in opposite directions at right-angles and the surface twice vertically folded to have a step-down level creating an upper level (51) and lower level (52) on the surface, whereby cutout-holes (53) on the folded edge (54a); openings (55), mounting cutouts (56), lock hole (59) and lower supporting busbar holder mounting holes (57) on the upper level (51); and cover fixing holes (58) on both upper level (51) and lower level (52) of the surface and on vertical edge (54b); and e. a transparent cover (61) having square-shaped cutouts (62) on all sides of the cover and fixing brackets (63), which covers external cable terminals. A plugging assembly adapted for making electrical interconnections between the devices installed in a functional unit compartment, and external cables of a low-voltage switchgear or controlgear assembly, wherein the improvements are made to increase usability of such plugging assembly, comprising: a. a male plug (2) to which internal wires coming from devices installed in a functional unit are connected, comprising: i. a rigid insulating housing (6) having insulating barriers (8) protruded upwards from the housing (6) and bases (7) protruded downwards from the housing (6), ii. a plurality of ‘U’ shaped spring-loaded clips (4) which expand and shrink when the clips are engaged with and disengaged from a terminal conductor and iii. a plurality of terminals (5) for internal wiring, each connected with different corresponding ‘U’ shaped spring-loaded clips (4) having different heights creating different height levels; 26 b. a female plug (81) of which ‘U’ shaped spring-loaded clips (4) of the male plug (2) are received from the left side (87) and external cables are connected from the right side (88), comprising: i. a cuboid shaped rigid insulating housing (100) with an extended base (106) whereby the cuboid shaped housing having a plurality of insulating border walls (103) with holders (102) and a step (109), a plurality of insulating internal barriers (101) with holders (102), a plurality of slots (104a), a plurality of top cover fixing screw holes (105) on the internal barriers (101) and close to the border walls (103), and the extended base (106) having outward spreading channels (104b) and ribs (107), ii. a plurality of terminal conductors (90) having a rectangular shaped longitudinal profile of which one end functioning as receiving terminal (91) caught from its side by ‘U’ shaped spring-loaded clips (4) in male plug (2), the other end functioning as external cable terminal (92) long enough to connect external cables with plurality of holes (93) to which external cables are connected and insulated middle section (94) with two bends (96) which outwardly bend the terminal conductor off-setting the receiving terminal (91) and the external cable terminal (92), iii. upper supporting busbar holder (120a) having upper holes (122a and 123 a) and lower supporting busbar holder (120b) having self-tapping screw holes (122b) and lower holes (123b), placed on and under and closer to the end of the insulated section (94) of the terminal conductors (90) and tightened by screws (121) keeping certain fixed distance among terminal conductors (90), iv. a top cover (110) having a plurality of openings (108) for spring-loaded clips (4) on one long border wall (112a), a plurality of openings (114) on the other long border wall (112b), a plurality screw holes (111) for cover 27 fixing screws on the top surface, a configuration of holders (115) connected to border walls (113a and 113b) and internal walls (117) at the back of the cover, an inward step (118) at the edge of and on the outside of the border walls (112a, 112b, 113a and 113b), and v. a spring clip (130) with a free end (134), positioned in the bottom side (86) of the housing (100) along the center line of the width of the housing (100), with a notch (131) and four mounting channels (132) on two long edges at the center, two square-shaped knobs (133); c. two rectangular steel horizontal mounting brackets (44) each having a slide stopper (45) and mounting screw holes (46) with its two long edges formed as flanged edges (47); d. a rectangular steel vertical mounting bracket (50) of which two vertical edges (54a and 54b) folded in opposite directions at right-angles and the surface twice vertically folded to have a step-down level creating an upper level (51) and lower level (52) on the surface, whereby cutout-holes (53) on the folded edge (54a); openings (55), mounting cutouts (56), lock hole (59) and lower supporting busbar holder mounting holes (57) on the upper level (51); and cover fixing holes (58) on both upper level (51) and lower level (52) of the surface and on vertical edge (54b); and e. a transparent cover (61) having square-shaped cutouts (62) on all sides of the cover and fixing brackets, which covers external cable terminals. The plugging assembly of Claim 1, wherein the spring-loaded clips (4) and their bases (7) enter into the openings (35) and the spring-loaded clips (4) reach and catch the terminal conductors (13) in the housing (14) of the female plug (3), from their top. 28
    4. The plugging assembly of Claim 2, wherein the spring-loaded clips (4) and their bases (7) enter into the openings (108) and the spring-loaded clips (4) reach and catch the terminal conductors (90) in the housing (100) of the female plug (81), from their left side.
    5. The plugging assembly of Claiml, wherein the tapered top of the base (7) of the male plug (2) reaches the tapered bottom of the opening (35) for spring-loaded clip (4) and stops at a distance maintaining a gap between the housing (6) of the male plug (2) and the front surface of the top cover (16) of the female plug (3) while the clips (4) fully engage with the terminal conductor (13).
    6. The plugging assembly of Claim 2, wherein the tapered top of the (7) of the male plug (2) reaches the tapered bottom of the opening (108) for spring-loaded clip (4) and stops at a distance maintaining a gap between the housing (6) of the male plug (2) and the left side (87) wall of the housing (100) of the female plug (81).
    7. The plugging assembly of Claims 1 or 2, wherein the terminals (5) can be covered with a transparent cover having square shaped cutouts.
    8. The plugging assembly of Claims 1 or 2, wherein the insulating border walls (19 or 103) with holders (18 or 102) and insulating internal barriers (17 or 101) with holders (18 or 102) create slots (20a or 104a) and separate terminal conductors (13 or 90) in the housing of the female plug (3 or 81).
    9. The plugging assembly of Claims 1 or 2 and 8, wherein the slots (20a or 104a) in the housing (14 or 100) of the female plug (3 or 81) accommodate the terminal conductors (13 or 90) and hold the terminal conductors (13 or 90) vertically and firmly with the holders (18 or 102) in the slots (20a or 104a).
    10. The plugging assembly of Claims 1 or 2, wherein the slot (20a or 104a) in the housing (14 or 100) and the channel (20b or 104b) on the extended base (15 or 106) combine and create one single path which continues until the second outward bend (27 or 96) of the 29 terminal conductor (13 or 90), in which the depth of channels (20b or 104b) on the extended base (15 or 106) is lower than that of the slots (20a or 104a) in the housing (14 or 100).
    11. The plugging assembly of Claims 1 or 2, wherein the terminal conductor (13 or 90) accommodated in the housing (14 or 100) and extended base (15 or 106) of the female plug (3 or 81) is a single solid block of conductive material which is placed with its larger face vertically and runs from the left side (11 or 87) to the right side (12 or 88) of the female plug (3 or 81).
    12. The plugging assembly of Claims 1 or 2 and 11, wherein the receiving terminal end of the terminal conductor (13 or 90) resides in slots (20a or 104a) in the housing (14 or 100) of the female plug (3 or 81) and the insulated section (23 or 94) of the terminal conductor resides in the channels (20b or 104b) on the extended base (15 or 106).
    13. The plugging assembly of Claims 1 and 11, wherein the ‘L’ shaped design of the external cable terminals (24), creates considerable amount of space to accommodate more than one external cable per phase.
    14. The plugging assembly of Claims 1 and 11, wherein the ‘L’ shaped design of the external cable terminal (24), number of holes (26) on the external cable terminal (24) and outward bends (27) of the terminal conductor (13) increase the number of external cables connected to external cable terminal (24).
    15. The plugging assembly of Claims 2 and 11, wherein the length and the number of holes on the external cable terminal (92), and outward bends (96) of the terminal conductor (90) increase the number of external cables connected to external cable terminal (92).
    16. The plugging assembly of Claims 1 or 2 and 11, wherein the part of the terminal conductor (13 or 90) which is outside of the housing (14 or 100) is longer than the part of the terminal conductor (14 or 100) which is inside the housing (14 or 100). 30 The plugging assembly of Claims 1 or 2, wherein the distance between two external cable terminals (24 or 92) is increased by the outward bends (27 or 96) in the middle section of the terminal conductor and is maintained by supporting busbar holders (29a, 29b or 120a, 120b) which are tightened by screws (30 or 121) inserted through upper holes (31a or 122a) in the upper supporting busbar holder (29a or 120a) and driven through selftapping screw holes (31b or 122b) on the lower supporting busbar holder (29b or 120b). The plugging assembly of Claims 1 or 2, wherein the extended base (15 or 106) in the female plug (3 or 81) supports and holds terminal conductors (13 or 90) in outward spreading channels (20b or 104b) which has the same longitudinal bended shape of the insulated section (23 or 94) of the terminal conductors (13 or 90). The plugging assembly of Claims 1 or 2, wherein the insulated section (23 or 94) of the terminal conductor (13 or 90) starts from inside the housing (14 or 100) to the beginning of the external cable terminal (24 or 92). The plugging assembly of Claims 1 or 2, wherein the extended base (15 or 106) has a configuration of ribs. The plugging assembly of Claims 1 or 2, wherein each external cable terminal (24 or 92) of the terminal conductor (13 or 90) has at least two holes to connect at least two external cables. The plugging assembly of Claims 1 or 2, wherein the lower supporting busbar holder (29b or 120b) has lower holes (32b or 123b) to insert screws (33 or 124) and fix the lower supporting busbar holder (29b or 120b) to vertical mounting bracket (50) by means of a screwdriver inserted through upper holes (32a or 123a) on the upper supporting busbar holder (29a or 120a). 31 The plugging assembly of Claim 1, wherein the openings (35) for ‘U’ shaped spring- loaded clips (4) on the top cover (16) of the female plug (3) are shaped into thin rectangular with rounded corners with a tapered bottom resembling the shape of the base (7) of ‘U’ shaped spring-loaded clip (4) and are sized slightly greater than the size of the base (7) of the ‘U’ shaped spring loaded clip (4). The plugging assembly of Claim 2, wherein the top part of terminal conductors (90) are sunk into the plurality of openings (114) on the long border wall (112b) when the top cover (110) is fixed to the housing (100) of the female plug (81). The plugging assembly of Claim 2, wherein the (87) for ‘U’ shaped spring-loaded clips (4) on the left side of the housing (100) are shaped into thin rectangular with rounded corners with a tapered bottom resembling the shape of the base (7) of ‘U’ shaped spring loaded clip (4) and are sized slightly greater than the size of the base (7) of the ‘U’ shaped spring loaded clip (4). The plugging assembly of Claim 1, wherein the border walls (19) of the housing (14) have an inward step (38), at the top edges, on the outside of the border walls (19) of the housing (14), whereby the bottom of edges (39) of the top cover (16) hit the inward step (38) on the border walls (19). The plugging assembly of Claim 2, wherein the configuration of holders (115) at the back of the top cover (110) are sunk into top part of terminal conductors (90) and held them tightly inside the housing (100) and the inward step (118) at the edge of the border walls (112a, 112b, 113a and 113b) of the top cover (110) rests on the top of border walls (103) of the housing (100) when the top cover (110) is fixed with screws driven into screw holes (105) on the housing (100) through screw holes (111) on the top cover (110). The plugging assembly of Claim 2, wherein the top cover (110) is strengthened by ribs (119) with a set of slots (120) which are sunk into respective top edges of the internal barriers (101) in the housing (100) when the top cover (110) is fixed to the housing (100). 32 The plugging assembly of Claims 1 or 2, wherein the lock hole (59) on the upper level of the vertical mounting bracket (50), is designed to accommodate the notch (41) on the spring clip (40) at the time of the female plug (3 or 81) is fully inserted into the two horizontal mounting brackets (44). The plugging assembly of Claims 1 or 2, wherein the vertical mounting bracket (50) and the two horizontal mounting brackets (44) are mounted, both towards one direction, on different sides of the same vertical frame member of the switchgear and controlgear assembly in order to mount the female plug (3 or 81) in a functional unit compartment of a low-voltage switchgear or controlgear assembly. The plugging assembly of Claims 1 or 2 and 30, wherein the vertical mounting bracket (50) is mounted vertically to left or right side, or rear side of a vertical frame member, depending on the female plug being used (3 or 81), extending the vertical edge (54b) towards adjoining compartment on the left or right, or rear side of the functional unit compartment The plugging assembly of Claims 1 or 2 and 30, wherein the two horizontal mounting brackets (44) are mounted horizontally to front side, or left or right of a vertical frame member, depending on the female plug being used (3 or 81), in the same direction of which the vertical mounting bracket (50) is mounted, locating the flanged edges (47) in the functional unit compartment. The plugging assembly of Claims 1 or 2 and 30, wherein the vertical mounting bracket (50) is mounted to a vertical frame member of a low-voltage switchgear or controlgear assembly by inserting itself into half-way pre-fixed screws on the vertical frame member and fully tightening the screws by a screwdriver inserted through the mounting-cutouts (56) while viewing the tightening operation through the openings (55). The plugging assembly of Claims 1 or 2, wherein the middle opening (55) of the vertical mounting bracket (50) provides space to accommodate the notch (41) on the spring clip 33
    (40) at the time of the female plug (3 or 81) is fully inserted into the two horizontal mounting brackets (44).
    35. The plugging assembly of Claim 1, wherein the female plug (3) is installed in the functional unit compartment, facing its (3) top side (9) towards the front side of the switchgear or controlgear assembly and keeping its openings (35) for ‘U’ shaped spring- loaded clips (4) in the functional unit compartment while the external cable terminals (24) extending out to adjoining left or right cable compartment in the switchgear or controlgear assembly.
    36. The plugging assembly of Claim 2, wherein the female plug (81) is installed in the functional unit compartment, facing its (81) left side (87) towards the front side of the switchgear or controlgear assembly and keeping its openings (108) for ‘U’ shaped spring- loaded clips in the functional unit compartment while the external cable terminals (92) extending out to adjoining rear cable compartment in the switchgear or controlgear assembly.
    37. The plugging assembly of Claim 1 or 2, wherein the long edges of the horizontal mounting bracket (44) are formed as flanged edges (47) to allow sliding-in mounting channels (43 or 132) on the bottom of the housing of the female plug (3 or 81).
    38. The plugging assembly of Claims 1 or 2, wherein the plugging assembly (1 or 80) is used to supply power to the load connected to the external cables whereby each terminal conductor (13 or 90) in the female plug (3 or 81) passes current to at least two external cables connected and fastened with nuts and bolts to holes (26 or 93) on the external cable terminal (24 or 92).
    39. The plugging assembly of Claims 1 or 2, wherein the male plug (2) fixed in the functional unit is fully inserted into its compartment, the unit engages its ‘U’ shaped spring-loaded clips (4) with the terminal conductors (13 or 90) in the female plug (3 or 81) making power connections with female plug (3 or 81) mounted on frame members of 34 the switchgear or controlgear assembly and the male plug (2) disengages its spring- loaded clips (4) from the terminal conductors (13 or 90) and withdraws from the female plug (3 or 81) disconnecting the power connections.
    40. The plugging assembly of Claims 1 or 2, wherein the square-shaped cutouts (62) in the transparent cover (61) are removed from anywhere on the transparent cover (61), in any shape, to create cable entry holes for external cables extended towards external circuits.
    41. The plugging assembly of Claims 1 or 2, wherein the female plug (3 or 81) is dismantled from the horizontal mounting bracket (44) by first removing the transparent cover (61), disconnecting external cables from external cable terminals (24 or 92), removing screws (33 or 124) from lower holes (32b or 123b) on the lower supporting busbar holder (29b or 120b) and pressing the free end (42 or 134) on the spring clip (40 or 130) to release the notch (41 or 131) from the middle opening (55) by a tool inserted through lock hole (59), while sliding-out the female plug (3 or 81) from the horizontal mounting bracket (44).
    42. The plugging assembly of Claims 1 or 2 and 41, wherein the middle opening (55) of the vertical mounting bracket (50), is connected with lock hole (59) on the vertical mounting bracket (50), through which a tool is inserted to press the free end (42 or 134) to release the notch (41 or 131) from the middle opening (55) when the female plug (3 or 81) is dismantled by sliding-out from the horizontal mounting brackets (44).
    43. A method adapted for making electrical interconnections between the devices installed in a functional unit compartment, and external cables of a low-voltage switchgear or controlgear assembly, wherein the improvements are made to increase usability of such plugging assembly, as claimed in Claims 1 or 2, such method comprising steps of: a. Fixing male plug (2) in a functional unit of a switchgear or controlgear assembly in a manner which extends out the ‘U’ shaped spring loaded clips (4) towards rear side of the functional unit allowing the spring loaded clips (4) to be mechanically inserted into the female plug (3 or 81) when the functional unit is pushed into its compartment in a low-voltage switchgear or controlgear assembly; 35 b. Wiring the terminals (5) of the male plug (2) internally with the switching devices installed inside the functional unit; c. Fixing the vertical mounting bracket (50) vertically to left or right, or rear side of a vertical frame member, depending on the requirement and the female plug (3 or 81) being used, in a direction to which the vertical mounting bracket (50) extending out its vertical edge (54b) towards the adjoining compartment, by inserting the cutout-holes (53) into half-way pre-fixed screws on the vertical frame member; the screws are fully tightened by screwdriver inserted through mounting-cutouts (56) while the tightening operation is viewed through openings (55); d. Fixing the two horizontal mounting brackets (44) horizontally to the front, or left of right side of the same frame member and the same direction to which vertical mounting bracket (50) is mounted, depending on the requirement and the female plug (3 or 81) being used, locating the flanged edges (47) in the functional unit compartment using mounting screw holes (46); e. Mounting the female plug (3 or 81) in the functional unit compartment facing its (3 or 81) openings (35 or 108) towards the front side of the switchgear or controlgear assembly and keeping the openings (35 or 108) for ‘U’ shaped spring- loaded clips (4) in the functional unit compartment, by inserting through the four mounting channels (43 or 132) on its back along the flanged edges (47) of the two horizontal mounting brackets (44), from the side of the vertical mounting bracket (50), and sliding-in until the two knobs (49 or 133) on the bottom side of the female plug (3 or 81) hitting the two slide stoppers (45) on the two horizontal mounting brackets (44) and the notch (41) on the free end (42) of the spring clip (40) reaching the middle opening (55) on the vertical mounting bracket (50) and locks making a “click” sound; f. Fixing the lower supporting bracket (29b or 120b) of the female plug (3 or 81) to vertical mounting bracket (50) using screws (33 or 124) inserted through lower holes (32b or 123b) in the lower supporting busbar holder (29b or 120b) and fastening the screws (33 or 124) by inserting a screwdriver through upper holes (32a or 123a) on the upper supporting busbar holder ( 29a or 120a); g. Creating external cable entry holes on transparent cover (61) for lugged external cables by removing square-shaped cutouts (62) from transparent cover (61) and inserting lugged external cables through the external cable entry holes created on the transparent cover (61); h. Fixing lugged external cables to female plug (3 or 81) by connecting them to the external cable terminals (24 or 92), using nuts and bolts fastening through holes (26 or 93); i. Fixing the transparent cover (61) to the vertical mounting bracket (50) using fixing brackets (63); j. Fully inserting the functional unit into its compartment enabling the ‘U’ shaped spring-loaded clips (4) to be engaged with the receiving terminals (22 or 91) in the female plug (3 or 81) to make the electrical interconnections; and k. Removing the functional unit from its compartment enabling the ‘U’ shaped spring-loaded clips (4) to be disengaged with the receiving terminals (22 or 91) in the female plug (3 or 81) to remove the electrical interconnections.
AU2020463499A 2020-08-12 2020-08-12 Four pole outgoing plugging assembly Pending AU2020463499A1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IB2020/057590 WO2022034360A1 (en) 2020-08-12 2020-08-12 Four pole outgoing plugging assembly

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AU2020463499A1 true AU2020463499A1 (en) 2023-03-23

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Application Number Title Priority Date Filing Date
AU2020463499A Pending AU2020463499A1 (en) 2020-08-12 2020-08-12 Four pole outgoing plugging assembly

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EP (1) EP4197065A1 (en)
AU (1) AU2020463499A1 (en)
WO (1) WO2022034360A1 (en)

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN2358616Y (en) * 1998-12-21 2000-01-12 冯嘉国 Main circuit connecting functional assembly for low voltage complete set of device
WO2014016662A1 (en) 2012-07-23 2014-01-30 Elsteel (Pvt) Ltd. Assembly comprising a plugging-in unit, a receiving base unit and a steel rectangular mounting bracket

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