EP4104254A1

EP4104254A1 - Electrical assembly of a housing and a plug-in connector

Info

Publication number: EP4104254A1
Application number: EP21706482.3A
Authority: EP
Inventors: John Bengtson; Dennys ENRY BARRETO GOMES; Brian Kousgaard BENDSEN
Original assignee: Vestas Wind Systems AS
Current assignee: Vestas Wind Systems AS
Priority date: 2020-02-10
Filing date: 2021-02-08
Publication date: 2022-12-21
Also published as: WO2021160229A1

Abstract

An electrical assembly (70) is disclosed which comprises a housing (1) with an insertion opening for connection to a plug-in connector and the plug-in connector (50). An insertion head of the plug-in connector can be inserted into the insertion opening, where a wall diameter is substantially the same over a depth of the insertion opening. A contact plug (7) is arranged to supporting a plurality of contacts which can be electrically contacted to associated contacts of a contact part of the plug-in connector. A coding element formed in the wall arranged together with coding elements (53) of the insertion head ensures guided insertion in a predetermined angular position. The connector body comprises an end face (55) with a projected diameter being larger than the wall diameter of the insertion opening for moist protection.

Description

ELECTRICAL ASSEMBLY OF A HOUSING AND A PLUG-IN CONNECTOR

FIELD OF THE INVENTION

The present invention relates to an electrical assembly comprising a housing for connection to a plug-in connector and the plug-in connector.

BACKGROUND OF THE INVENTION

In large electro-mechanical installations there are the need for connecting electrical equipment together, such as connecting sensors and actuators to a computing unit. Such connection can be implemented by an electrical assembly where a housing is arranged with connector inserts for connection to plug-in connectors. The assembly enables electrical signals to be transmitted between electrical equipment, but may also support supply of power to equipment.

The insertion inserts of the housing may be formed with insertion openings into which the plug-in connectors can be inserted in an insertion direction. A coding element may be provided in the insertion insert to ensure that the plug-in connector is inserted into the insertion opening in a predetermined angular position about the insertion direction, and stay in the angular position when in the inserted state.

If the assembly is placed at a site with varying environmental conditions during operation, for example varying temperatures and humidity, e.g. an assembly placed in a wind turbine, the assembly may undergo thermal expansion, be exposed to moist, etc. Even in such conditions there is a need for that the plug-in connector to be easy to insert, and easy to pull out, while the plug-in connector remains in electrical connection in a moisture resistant manner.

EP3189564 discloses an example of an assembly. Nevertheless, there is still a need for alternative advantageous assemblies. SUMMARY OF THE INVENTION

It would be advantageous to achieve an electrical assembly of a housing for connection to a plug-in connector and the plug-in connector which even under varying environmental conditions supports that the plug-in connector is easy to insert and easy to pull out, while the plug-in connector remains in electrical connection in a moisture resistant manner, and where this is achieved by an assembly which is relatively simple to manufacture.

Accordingly, in a first aspect, there is provided an electrical assembly comprising a housing for connection to a plug-in connector and the plug-in connector; wherein the housing comprises: an insertion opening into which an insertion head of the plug-in connector can be inserted along an insertion direction; a wall surrounding the insertion opening; wherein a wall diameter along a direction transverse to the insertion direction is substantially the same over a depth of the insertion opening; a contact plug arranged at a bottom of the insertion opening, the contact plug supporting a plurality of contacts which can be electrically contacted to associated plurality of contacts of the plug-in connector; a coding element formed in the wall, arranged to be brought into guided arrangement with a coding element of the plug-in connector so that the plug-in connector can be inserted into the insertion opening in a predetermined angular position; and wherein the plug-in connector comprises: an insertion head comprising a plurality of contacts and a coding element; a connector body supporting the insertion head, and wherein the connector body comprises an end face arranged to cover a rim part of the insertion opening upon insertion of the plug-in connector into the insertion opening, and wherein the diameter of the projected area of the end face is larger than the wall diameter of the insertion opening

The housing is made with an insertion opening into which an insertion head of the plug-in connector can be inserted along an insertion direction, wherein a wall diameter of the wall surrounding the insertion opening is substantially the same over the depth of the insertion opening. This supports relative simple manufacture as the mould does not need to provide for different wall diameters along the insertion opening. Easy insertion and extraction of the plug-in connector can be ensured by a proper dimensioning of the wall diameter in relation to the insertion head of the plug-in connector. However as there may be a risk of forming a moist passage along the gap between the insertion head and the wall, the end face of the connector body is formed to cover a rim part of the insertion opening upon insertion of the plug-in connector, where the diameter of the projected area of the end face is larger than the wall diameter of the insertion opening.

In an embodiment, the insertion opening and the insertion head may be of a general cylindrical shape. The wall diameter of the insertion opening along the depth of the opening, as well as other surfaces, e.g. coding tab surfaces, may be provided with a draft angle. The draft angle is provided in order to be able to withdraw the mould from the opening as is known in the art. The substantial same diameter over the depth of the insertion opening is understood to include such a draft angle. The draft angle may either be present to slightly widen the opening or slightly narrowing the opening depending on the moulding process. In an embodiment, the draft angle may increase towards the centre from both sides due to use of a split cast. The draft angle may be between 0.5 degrees and 1.5 degrees, such as 1 degree.

A second aspect is directed to a wind turbine comprising the electrical assembly. A wind turbine is a relative compact entity with a large amount of electrical equipment often placed at a remote location with varying ambient conditions, which requires stable cable connections over long time spans without a service technician present. And then during service or other maintenance, it is important that equipment can be easily handled.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will be described, by way of example only, with reference to the drawings, in which

Fig. 1 illustrates an embodiment of the housing of the electrical assembly;

Fig. 2 illustrates a single insertion opening of the housing of Figure 1 as seen in top view;

Figs. 3 and 4 illustrate different views of an embodiment of the insertion opening in the housing; Figs. 5A and 5B illustrate further embodiments of the insertion opening in the housing, shown in perspective view;

Fig. 6 illustrates in a schematic side view the plug-in connector;

Figs. 7 and 8 illustrate in schematic side view the insertion opening of the housing with and without the plug-in connector inserted;

Fig. 9 illustrates the overlaid cross-sections of the end face and the insertion opening; and

Figs. 10 and illustrate in schematic cross-section the area between the connector head, connector body and housing.

DESCRIPTION OF EMBODIMENTS

Figure 1 illustrates an embodiment of the housing 1 of the electrical assembly.

The housing comprises an insertion opening 2 into which an insertion head of the plug-in connector can be inserted along an insertion direction 3. The insertion opening comprising a substantially cylindrical wall 4 along the insertion direction 3.

Coding elements 5 are formed in the wall, and associated coding elements of the plug-in connector, and thereby the plug-in connector itself, can be brought into guided insertion into the insertion opening. In the illustrated embodiment, the coding elements protrude over the entire depth of the insertion opening from the wall in a direction traverse from the insertion direction to form insertion tracks 6 of varying widths.

Two or more coding protrusions are advantageously provided to form guide tracks between every two coding protrusions, such that in an inserted state corresponding coding elements of the plug-in connector part are positioned in the guide tracks, resulting in that the angular position of the plug-in connector is fixed relative to the housing.

Figure 1 further shows a cylindrical protruding contact plug 7 arranged at, and protruding from, a bottom of the insertion opening. The contact plug supports a plurality of contacts which can be electrically contacted to associated contacts of a contact part of the plug-in connector.

Figure 2 illustrates a single insertion opening of the housing of Figure 1 as seen in top view.

The insertion opening 2 is cylindrical with a circular cross section. The insertion opening 2 extends from a front surface 8 and is delimited by a back, or bottom, section, in the form of a shielding plate 20 which extends transversely in relation to the insertion direction and adjoins the wall in the opposite end of the insertion opening. The shielding plate includes at least one engagement opening 21 (which in this embodiment amounts to four) for receiving a latching element in a latching engagement.

While the housing 1 can be made of plastics material, the shielding plate 20 is preferably made of a metal, for example copper or steel. In this way the shielding plate can be used to electromagnetically shield components of the electrical device from the external environment outside the electrical assembly.

The shielding plate is also a mounting position for the contact plug 7. The contact plug thereby being arranged at the bottom of the insertion opening. The contact plug supports a plurality of contact pins 22 (which in this embodiment amounts to five) which provides electrical contact to associated contacts of the plug-in connector. While the shielding plate 20 supports the contact plug, the contact plug may be mounted (or attached) to the shielding place so that the contacts 22 are passed through the plate for contact to electrical equipment. In an embodiment, the bottom wall may merely function as a mounting location for the contact plug without providing the shielding. If a shielding is not needed, the bottom wall may advantageously be made in a plastic material.

The contact pins 22 may be connected to a printed circuit board (PCB) via electrical connections. The contact plug 7 may be attaches to cables which can connect the contact pins to the PCB or other equipment. The housing may further house such PCB, for example in a compartment behind the shielding plate, or in a separate abutting compartment. In an embodiment, the PCB is mounted onto the shielding plate with the contact plugs attached (e.g. soldered) directly onto the shielding plate. The contact plug being passed through the shielding plate though a hole in the plate. Figures 3 and 4 illustrate an embodiment of the insertion opening in the housing. In Fig. 3 the insertion opening is shown in a top view, whereas Fig. 4 illustrates the insertion opening in a cut-through perspective view. The insertion opening is delimited in a circumferential manner by a wall 4, where a wall diameter 30 along a direction transverse to the insertion direction is substantially the same over the depth of the insertion opening. The figures 3 and 4 illustrate coding elements 5 formed in the wall. In the illustrated embodiment five coding elements of different widths in the circumferential direction are show, thereby forming five coding tracks of different track widths between adjacent coding elements. With these coding tracks the coding element of the plug-in connector will be guided upon insertion so that the plug-in connector is inserted into the insertion opening in a predetermined angular position.

In an embodiment the track width 40 of a coding track may be the same along the entire depth of the coding track. However in the illustrated embodiment the track width of the coding track along the insertion direction is widened 41 at the end section of the coding track. A widening of the coding track may be advantageous as the narrow width towards the opening is used to ensure a proper guidance, whereas in the bottom where the guidance is no longer as important, the widened track helps to keep a loose fit which assist in easy insertion and easy release. The widening of the tracks may be done for all tracks or for a sub-group of the tracks.

Figure 5A illustrates a further embodiment of the insertion opening in the housing, shown in perspective view. Like illustrated on Fig. 4 the coding element 5 formed in the wall extends along the insertion direction over the entire depth of the insertion opening, however in the illustrated embodiment the track width 42 of a coding track is the same along the entire depth of the coding track.

The coding element comprises a coding element rim 43 where the coding element protrude further into the insertion opening at the bottom of the insertion opening than at the top of the insertion opening. In the illustrated embodiment the rim 43 is placed approximately halfway in the opening, however it can be placed at various heights along the opening. Advantageously the rim helps guiding the plug-in connection during the insertion, as coding tabs on the plug-in connector may hit the rim, upon which by turning the plug-in connector the coding tabs can be moved to the correct guide tracks. In an alternative embodiment shown on Fig. 5B, the coding tab 5 does only extend from the bottom and partly towards the opening. In this manner a coding tab rim 43 may also be formed by the upper end section of the coding tab.

Figure 6 illustrates in a schematic side view the plug-in connector 50 with an insertion head 51 supported by a connector body 52. The connector body schematically illustrating a cable electrically connected to a plurality of contacts (not shown) arranged behind the coding elements 53.

The insertion head 51 comprises a number of coding elements 53 for coded and guided engagement with the coding tracks in the insertion opening. Moreover, the insertion head comprises latching elements 54 for insertion into a latching engagement with associated engagement openings 21 in the shielding plate. The latching element may be a cantilever spring which upon insertion can be moved into latching engagement. The cantilever may be of a conducting material such as a metal. This may provide a conducting connection between the plug-in connector and the shielding plate. Alternatively the cantilever may be made of a flexible plastic material. The latching engagement may be achieved by a small protrusion at the free end of the cantilever lever spring which is moved by the wall of the engagement opening during forced movement of the plug-in connector.

As can be seen, the connector body comprises an end face 55 arranged to cover a rim part of the insertion opening upon insertion of the plug-in connector into the insertion opening. The diameter of the projected area of the end face being larger than the wall diameter of the insertion opening.

Figures 7 and 8 illustrate in schematic side view the insertion opening of the housing without the plug-in connector inserted (Fig. 7) and with the plug-in connector inserted (Fig. 8).

Figure 7 illustrates the housing 1 and the insertion opening 2 with the contact plug 7 arranged at a shielding plate 20 at a bottom of the insertion opening, the contact plug supporting a plurality of contacts 22 which can be electrically contacted to associated contacts of a contact part of the plug-in connector. Further, a PCB 60 is schematically illustrated mounted behind the shielding plate with the contact plug attached. Figure 8 illustrates the assembly with the plug-in connector inserted into the insertion opening, or more precisely the insertion head inserted into the insertion opening. In the illustrated embodiment, the plug-in head comprises a plug with a plurality of contacts for electric connection with the associated contacts on the contact plug 7. The specific implementation of the contact connection between the contacts on the connector head and the contact plug can be made in different ways. In the embodiments of the present invention, due to the coding elements, it can be ensured via the angular position that correct contact elements of the connector and the on the contact plug are connected together.

Figure 9 illustrates the overlaid cross-sections of the end face 55 and the insertion opening 2. To ensure a high degree of water resistance from water and moisture to enter into the connection, the end face 55 of the contact head cover a rim part of the insertion opening upon insertion, the diameter of the projected area of the end face 55 is larger than the wall diameter of the insertion opening 2. In an embodiment the size of overlap is so that the difference of the diameter of the projected area of the end face 55 is 0.5 mm to 2 mm larger than the wall diameter of the insertion opening 2.

Figure 10 illustrates in a schematic cross-section the area between the connector head 51, connector body 52 and housing 1, in a situation where the plug-in connector is inserted into the housing in an engaging manner. As is shown an air gap 90 is present between the end face and the rim part. By proper dimensioning the elements of the assembly an air gap of a given size can be ensured. The size of the air gap may be dimensioned so that the air gap forms a hydrophobic electrostatic gap. In an embodiment the air gap is between 0.1 mm and 0.5 mm.

Figure 11 illustrates in a schematic cross-section another embodiment ensuring a high degree of water resistance from water and moisture entering into the connection.

In the illustrated embodiment a retaining force 100 of the latching element 54 is used, so that when in a latching engagement, the retaining force 100 of the latching element results in that the end face is forced towards the rim part of the insertion opening by an inwards force 101. In one embodiment, this can be achieved by utilizing a latching element with a cantilever spring which upon insertion can be moved into latching engagement by forcing the spring element into the engagement opening 21 of the shielding plate 20. By proper constructing the plug-in connector, the spring force of the latching element will force the connector heads inwards until the end face meets the rim part of the insertion opening, keeping the connector plug in forced engagement with the housing in a water resistant manner.

Example embodiments of the invention have been described for the purposes of illustration only, and not to limit the scope of the invention as defined in the accompanying claims.

Claims

1. An electrical assembly comprising a housing for connection to a plug-in connector and the plug-in connector; wherein the housing comprises: an insertion opening into which an insertion head of the plug-in connector can be inserted along an insertion direction; a wall surrounding the insertion opening; wherein a wall diameter along a direction transverse to the insertion direction is substantially the same over a depth of the insertion opening; a contact plug arranged at a bottom of the insertion opening, the contact plug supporting a plurality of contacts which can be electrically contacted to associated plurality of contacts of the plug-in connector; a coding element formed in the wall, arranged to be brought into guided arrangement with a coding element of the plug-in connector so that the plug-in connector can be inserted into the insertion opening in a predetermined angular position; and wherein the plug-in connector comprises: an insertion head comprising a plurality of contacts and a coding element; a connector body supporting the insertion head, and wherein the connector body comprises an end face arranged to cover a rim part of the insertion opening upon insertion of the plug-in connector into the insertion opening, and wherein the diameter of the projected area of the end face is larger than the wall diameter of the insertion opening.

2. The electrical assembly according to claim 1, where the coding element formed in the wall extends along the insertion direction over the entire depth of the insertion opening.

3. The electrical assembly according to claim 1, where the coding element formed in the wall extends along the insertion direction over a part of the depth of the insertion opening.

4. The electrical assembly according to any of the preceding claims, where the coding element comprises a rim so that the coding element protrude further into the insertion opening at the bottom of the insertion opening than at the top of the insertion opening.

5. The electrical assembly according to any of the preceding claims, wherein the coding element comprises at least two protrusions forming a coding track along the insertion direction, and where the coding element of the plug-in connector comprises coding protrusions arranged to be guided by the coding track.

6. The electrical assembly according to claim 5, wherein the coding element comprises at least two protrusions forming at least two coding tracks along the insertion direction, and where the at least two coding tracks have different track widths as measured in a circumferential direction.

7. The electrical assembly according to any of the preceding claims, wherein the coding track along the insertion direction is widened at the end section of the coding track.

8. The electrical assembly according to any of the claims 1 to 6, where the coding track along the insertion direction has substantially the same width.

9. The electrical assembly further comprising a shielding plate which extends transversely in relation to the insertion direction and adjoins the wall in the opposite end of the insertion opening.

10. The electrical assembly according to claim 9, wherein the plug-in connector further comprises a latching element, and wherein the shielding plate comprises at least one engagement opening for receiving the latching element in a latching engagement.

11. The electrical assembly according to claim 10, wherein the latching element is a cantilever spring.

12. The electrical assembly according to any of the preceding claims wherein upon insertion of the plug-in connector into the housing in an engaging manner, an air gap is present between the end face and the rim part of the insertion opening, so that the air gap forms a hydrophobic electrostatic gap.

13. The electrical assembly according to claim 12 wherein the size of the air gap is between 0.1 mm and 0.5 mm.

14. The electrical assembly according to any of the claims 1 to 11 wherein a retaining force of the latching element when in a latching engagement results in that an inwards force is imposed on the end face towards the rim part of the insertion opening.

15. The electrical assembly according to any of the preceding claims wherein the size of overlap is so that the difference of the diameter of the projected area of the end face is 0.5 mm to 2 mm larger than the wall diameter of the insertion opening.

16. A wind turbine comprising an electrical assembly according to any of the preceding claims.