WO2020099883A1 - A modular power distribution system - Google Patents

A modular power distribution system Download PDF

Info

Publication number
WO2020099883A1
WO2020099883A1 PCT/GB2019/053237 GB2019053237W WO2020099883A1 WO 2020099883 A1 WO2020099883 A1 WO 2020099883A1 GB 2019053237 W GB2019053237 W GB 2019053237W WO 2020099883 A1 WO2020099883 A1 WO 2020099883A1
Authority
WO
WIPO (PCT)
Prior art keywords
socket
assembly
power distribution
distribution system
modular power
Prior art date
Application number
PCT/GB2019/053237
Other languages
French (fr)
Inventor
George TERRY
Original Assignee
Zodiac Interconnect Uk Limited
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from FR1860580A external-priority patent/FR3088775A1/en
Priority claimed from GBGB1901380.4A external-priority patent/GB201901380D0/en
Priority claimed from GBGB1906080.5A external-priority patent/GB201906080D0/en
Application filed by Zodiac Interconnect Uk Limited filed Critical Zodiac Interconnect Uk Limited
Publication of WO2020099883A1 publication Critical patent/WO2020099883A1/en

Links

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
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/15—Pins, blades or sockets having separate spring member for producing or increasing contact pressure
    • H01R13/187—Pins, blades or sockets having separate spring member for producing or increasing contact pressure with spring member in the socket
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B13/00—Dowels or other devices fastened in walls or the like by inserting them in holes made therein for that purpose
    • F16B13/04—Dowels or other devices fastened in walls or the like by inserting them in holes made therein for that purpose with parts gripping in the hole or behind the reverse side of the wall after inserting from the front
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B13/00—Dowels or other devices fastened in walls or the like by inserting them in holes made therein for that purpose
    • F16B13/04—Dowels or other devices fastened in walls or the like by inserting them in holes made therein for that purpose with parts gripping in the hole or behind the reverse side of the wall after inserting from the front
    • F16B13/10—Dowels or other devices fastened in walls or the like by inserting them in holes made therein for that purpose with parts gripping in the hole or behind the reverse side of the wall after inserting from the front with separate gripping parts moved into their final position in relation to the body of the device by a separate operation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B21/00—Means for preventing relative axial movement of a pin, spigot, shaft or the like and a member surrounding it; Stud-and-socket releasable fastenings
    • F16B21/06—Releasable fastening devices with snap-action
    • F16B21/065—Releasable fastening devices with snap-action with an additional locking element
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B7/00—Connections of rods or tubes, e.g. of non-circular section, mutually, including resilient connections
    • F16B7/18—Connections of rods or tubes, e.g. of non-circular section, mutually, including resilient connections using screw-thread elements
    • 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
    • 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
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/70—Coupling devices
    • H01R12/7005—Guiding, mounting, polarizing or locking means; Extractors
    • H01R12/7011—Locking or fixing a connector to a PCB
    • H01R12/7047—Locking or fixing a connector to a PCB with a fastener through a screw hole in the coupling device
    • 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
    • H01R13/62—Means for facilitating engagement or disengagement of coupling parts or for holding them in engagement
    • H01R13/627—Snap or like fastening
    • H01R13/6277—Snap or like fastening comprising annular latching means, e.g. ring snapping in an annular groove
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R25/00—Coupling parts adapted for simultaneous co-operation with two or more identical counterparts, e.g. for distributing energy to two or more circuits
    • H01R25/16—Rails or bus-bars provided with a plurality of discrete connecting locations for counterparts
    • H01R25/161—Details
    • 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
    • H01R13/44—Means for preventing access to live contacts
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2101/00—One pole
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
    • H01R24/005—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure requiring successive relative motions to complete the coupling, e.g. bayonet 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
    • 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
    • H01R4/10—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/20—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve

Definitions

  • the present invention relates to a modular power system that is particularly, but not exclusively, applicable for use on an aircraft.
  • terminal blocks typically embody a fixed number of threaded posts, overmolded with plastic insulation that are fixed to the aircraft structure by bolts on either end. Power distribution is achieved by stacking multiple ring terminals on to a single post. The ring terminals are then fastened to the posts with a nut by a manual torqueing operation.
  • the terminal blocks are often protected with a plastic cover to protect from foreign object debris (FOD) and prevent operators touching live parts. These covers are fixed to the terminal block with quarter turn bolts secured with lock wire.
  • FOD foreign object debris
  • the torqueing operating can often cause delays in installation and may also result in reworking being necessary. This may arise from issues such as the ring terminals being misaligned, which requires the cable to be axially torqued to align the ring terminal with the post, or as a result of damage to the ring terminal from the torqueing tool, which may require a new ring terminal to be crimped to a cable, which in turn may require the reworking of a harness installation to adjust for the reduced available cable length.
  • the torqueing operation may tend to twist the position of the ring terminal on the post, so that the ring terminal and cable are skewed so that they may come into undesirable contact with an adjacent cable or with a rigid part of either the terminal block or the frame, which again may require reworking to avoid damage to those parts or to the cable.
  • Another problem that may arise when connecting cables to a conventional terminal block is that there may be potential FOD issues, arising from the use of loose washers and nuts.
  • terminal blocks themselves are also relatively inflexible in nature, being manufactured with a fixed number of terminal posts, normally between three and twelve per terminal block. This may results in the requirement for a large number of variants, each requiring a separate mould tool for its construction and resulting in a large number of different product numbers and products to be ordered, stored and appropriately distributed for installation aboard an aircraft.
  • the terminal block variant selected for installation will normally be based on the number of posts required to meet all the optional extras offered on a particular platform. However, an operator purchasing that platform will typically select only a limited number of those optional extras.
  • a modular power distribution system comprising a module assembly, the module assembly comprising a socket assembly and a base assembly.
  • the socket assembly comprises a conductive connector socket having a plurality of electrically connected connection points, each connection point being arranged to releasably receive a conductive pin connected to a feeder cable.
  • the socket assembly further comprising an electrically insulating socket housing in which the connector socket is housed.
  • the base assembly comprises a port for releasably mounting the socket assembly and is arranged to be mounted to an aircraft frame or the like, or to one or more other base assemblies.
  • the present invention provides a socket assembly where a conductive connector permits multiple feeder cables to be connected together in a manner functionally equivalent to attaching multiple ring terminals and associated cables to a common terminal post of a terminal block.
  • the connector socket of the present invention is contained within its own socket housing, which electrically insulates the conductive connector socket and which forms a self-contained socket assembly. This is releasably mounted in a port of a base assembly, to form a module assembly of the power distribution system, which can be mounted at a desired location or combined with other such modules.
  • port is defined as any point on the base assembly arranged to releasably receive, support and maintain in place a socket assembly. This need not necessarily take the form of an aperture, as in the embodiments disclosed in and described with reference to the drawings of this specification, but instead could be in the form of a fixing for receiving and releasably engaging with a socket assembly.
  • a major advantage of the invention is that it permits only a desired number of socket assemblies to be used and secured to one or more base assemblies to form a terminal block and for this to comprise multiple components of the same type.
  • the modular power distribution system comprises a plurality of interchangeable socket assemblies, wherein the base assembly has multiple ports arranged to receive multiple socket assemblies. This permits interchangeable or identical socket assemblies to be selected and installed in a single base assembly, as required.
  • the modular power distribution system may comprise a plurality of base assemblies, each base assembly having one or more ports arranged to receive one or more socket assemblies, to thus provide a plurality of module assemblies. This enables multiple module assemblies to be built which may be used together to form a modular terminal block for a specific application,
  • the above arrangement may not only permit a terminal block to be assembled that has the correct number of socket assemblies (terminals) for a specific application, but it may also permit the dimensions of the terminal block to be determined by the space available to accommodate that terminal block.
  • a terminal block arranged to receive a set number of cables could comprise a large number of base assemblies, each arranged to receive a single socket assembly, which would result in a terminal block having a relatively low profile but being relatively wide.
  • that same number of cables could be accommodated by a terminal block comprising half the number of base assemblies but with each base assembly accommodating two socket assemblies stacked one above the other, which would likely approximately double the height of the resultant terminal block whilst halving the width. Both arrangements would share a pool of common component types.
  • the modular power distribution system may further comprise a rail to which the multiple base assemblies are arranged to be mounted.
  • a terminal block may easily be constructed to receive and connect any desired number of cables using multiple identical components.
  • Such a rail could be provided in standard lengths and be cut to size depending on the application.
  • the rail could be provided in different lengths.
  • each base assembly is arranged to be releasably attached to the rail without the use of tools, enabling a terminal block to be assembled relatively easily, possibly requiring only that the rail be cut to an appropriate length to receive the desired number of base assemblies and mounted to an aircraft or similar.
  • Appropriate preassembled module assemblies could then be attached to the rail, effectively building the terminal block“on site” enabling the terminal block to be assembled for a specific application.
  • each base assembly is assembled from a plurality of interchangeable parts arranged to be selected and assembled to form one or more ports in the base assembly, dependent on the number of socket assemblies that are to be received by the base assembly.
  • a base assembly of a module assembly comprising only a single socket assembly may share common and interchangeable parts with a base assembly comprising two or more socket assemblies. In this manner a relatively few part types may be used to construct different configurations of a base assembly.
  • a terminal block may comprise a plurality of interchangeable socket assemblies each substantially planer in shape and wherein the or each base assembly has a base portion by which it is to be mounted and a plurality of ports arranged to receive the socket assemblies in a side by side and on edge configuration above the base portion.
  • each base assembly comprises two parts which may be separated to remove a socket assembly from the base assembly, without disconnecting feeder cables connected to the socket assembly, enabling a connected group of cables and an associated socket assembly to be released from the base assembly without disconnecting those cables.
  • each base assembly is arranged to hold multiple socket assemblies in a spaced apart configuration, which may provide sufficient access to each cable to enable a cable to be removed without requiring the socket assembly to be removed from the base assembly.
  • Each socket assembly may have a first end and a second end, each with a respective connection point to be connected to a feeder cable, wherein the socket assembly is arranged to be received in a port of the base assembly at a midpoint between the two ends, to leave each connection point accessible for the
  • each socket assembly may act to join two lengths of cable or to form a branch or spur.
  • Each socket assembly may be substantially H-shaped having a H-shaped connector socket with four connection points, one at or towards each tip of the H- shape socket assembly, thus providing four electrically connected connection points.
  • This is a particularly advantageous configuration for when a number of such socket assemblies are arranged in respective base assemblies to form a terminal block, the H-shaped configuration may be arranged to provide a particularly high density of connection points, with each capable of providing a two- way or three-way branch.
  • This arrangement may also permit a standard rigid shunt to be provided and used to connect the connector sockets of two adjacent pairs of socket assemblies together, to then provide six available electrically connected connection points. Multiple shunts could be used to provide any number of interconnected connection points.
  • the modular power distribution system further comprises multiple pin connectors for connecting feed cables to respective connection points of the, or each, socket assembly, with each pin connector comprising a conductive pin and a pin housing.
  • the socket housing of each socket assembly may then be arranged to completely cover the connector socket, leaving only the connection points accessible to receive respective conductive pins of the pin connectors.
  • the socket housing has a locking feature arranged to releasably engage with a respective pin housing and retain the pin housing in place and thus to then provide, together with the pin housing, a continuous electrically insulating shield over the connection between the connector socket and the conductive pin. This may then be used to provide a completely electrically insulated terminal block, avoiding the need to provide any additional covers and associated locking wires, or the like.
  • the locking feature is part of a quick connect/disconnect connection between the socket assembly and pin connector, enabling each pin connector and associated feeder cable to be quickly and easily attached to a socket assembly without the use of tools.
  • a quick connect/disconnect connection is defined as a connection which can be made by hand, substantially as a single movement and without the use of tools. Examples of such connections being push and turn or push and clip type
  • each pin housing and respective socket housing together provide a visual indication as to whether or not they are securely connected, enabling all connections on a terminal block to be verified by a visual inspection.
  • Each pin connector may comprise a crimp adapted to receive different gauges of cable, enabling different gauges of cable to be connected to a pin connector and thus to a socket assembly.
  • Each pin connector may comprise a keyed element, with different pin connectors having different keyed elements each arranged to cooperate with respective corresponding keyed elements of a socket assembly.
  • it may be arranged that is only possible to connect appropriately keyed pin connectors to a particular socket assembly. This may be particularly advantageous to ensure connections cannot be made between inappropriate pin connectors and their associated cables.
  • This may thus be used, for example, to ensure that a pin connector associated with one phase cannot be connected, via a socket assembly, to a pin connector associated with a different phase, even if the pin connectors are disconnected from a terminal block comprising multiple socket assemblies and subsequent attempts are made to incorrectly reconnect them.
  • a modular power distribution system in accordance with the present invention comprises a plurality of socket assemblies
  • each of these may bear a respective different colour, with each pin connector bearing the corresponding colour to indicate which socket assembly it should be connected to.
  • socket assembly for use in a system in accordance with a first aspect of the invention.
  • a base assembly for use in a system in accordance with a first aspect of the invention.
  • Figure 1 is a perspective view of a first module assembly of a modular power distribution system according to the present invention
  • FIG 2 is a perspective view of a socket assembly forming part of the module assembly of Figure 1 ;
  • Figure 3 is a perspective exploded view of the socket assembly of Figure 2;
  • Figure 4 is a cross-sectional plan view of the socket assembly of Figures 2 and 3;
  • Figure 5 is a perspective view of a base portion of a base assembly of the module assembly of Figure 1 ;
  • Figure 6 is a front exploded view of the module assembly of Figure 1 ;
  • Figure 7 is a front exploded view of an alternative module assembly to that show in Figure 6;
  • Figure 8 is a perspective view of the module assembly of Figure 7;
  • Figure 9 shows the module assembly of Figure 1 mounted on a rail
  • Figure 10 is a section along the line A-A of Figure 9;
  • FIG 11 correspond to Figure 10, but shows the module assembly being released from the rail
  • Figure 12 shows four module assemblies of Figure 1 mounted on a common rail
  • Figure 13 shows four module assemblies of Figure 8 mounted on a rail with a number of pin connectors and associated power feeder cables connected to the socket assemblies of the module assemblies;
  • FIG. 14 illustrates an alternative socket assembly
  • Figure 15 illustrates how a blanking plug may be used with the module assembly of Figure 8.
  • Figure 16 shows how a shunt may be used with a module assembly of Figure 8.
  • FIG. 17 is a perspective view of an alternative module assembly in accordance with the present invention.
  • Figure 18 is a perspective view of a pin connector and associated feed cable.
  • a module assembly indicated generally as 1 , comprises a socket assembly 2 securely held in a port 3 of a base assembly 4.
  • the socket assembly 2 is shown separately in Figure 2 and is FI - shaped and provided with four connection points 8A to 8D, one at each tip of the“FI”. Each connection point 8A to 8D is arranged to connect to a respective pin connector, such as the pin connector 5 and associated feeder cable 6 shown in Figure 18 and discussed later with reference to Figure 18.
  • FIG 3 is an exploded view of the components of the socket assembly 2 of Figure 2.
  • This comprises a metal connector socket 7 which is FI-shaped and comprises the four connection points 8A to 8D, (see Figure 4, a plan cross-section through the assembled components of Figure 3).
  • Each connection points 8A to 8D is arranged to receive a conductive pin 44 of an associated pin connector 5, as shown in Figure 18.
  • connection point 8A to 8D comprises a snap ring 9 arranged to engage with a groove on a conductive pin 44 of a pin connector 5 to retain the conductive pin 44 in the associated connection point 8A to 8D.
  • connection point 8A to 8D also has a contact band 10 to improve connection with a conductive pin 44.
  • the connector socket 7 is shown located between two halves 11 A and 11 B of socket housing 11. This is made of an insulating plastic and the two halves 11 A and 11 B snap fit over the connector socket 7, and envelop the whole of the connector socket 7, with the exception of the connection points 8A to 8D. All the connection points 8A to 8D of the socket assembly 2 are electrically connected by virtue of being formed within the single metal connector socket 7.
  • FIG. 5 shows a base portion 13 of the module assembly 1 of Figure 1.
  • the base portion 13 defines a lower half of port 3.
  • this port 3 is arranged to receive the socket assembly 2 of Figure 2, which is then clamped in position by a saddle portion 14 retained in place by fasteners 15.
  • the fasteners 15 are shown, in the exploded view of Figure 6, separate from saddle portion 14, these are quarter turn fasteners held captive within the saddle portion 14 and are used to secure the socket assembly 2 in the base assembly 4 as shown in Figure 1.
  • Figures 7 and 8 these essentially corresponds to Figures 6 and 1 respectively and use the same numbering to indicate the same components, which function in the same manner as those described with reference to Figures 6 and 1.
  • an additional stacking component 16 is incorporated between the base portion 13 and saddle portion 14, to define two identical ports 3 for receiving two identical socket assemblies 2.
  • FIGS 9 to 11 show how the module assembly 1 of Figure 1 , or the module assembly 17 of Figure 8, which share the same base portion 13, may be mounted to a rail 18.
  • a section along the line A-A of Figure 9 the base portion 13 of the module assembly 1 is retained on the rail 18 partially by means of a pair of lugs 19, only one of which can be seen in Figure 10, which engage under a first lip 20 of the rail 18.
  • lugs 19 also protrude into the recesses 21 in the lip 20, seen in Figure 9 and prevent the base portion from sliding along the rail 18.
  • a slide bar 23 In a recess 22, in a lower face of the base portion 13, is located a slide bar 23.
  • the slide bar 23 is held in place by a fastener 24 extending through an elongate slot 25 in the slide bar 23, slide bar 23 is biased to the left, as shown in Figure 10, by a spring 26, held captive in a recess in the base portion 13 by the slide bar 26.
  • the slide bar 23 is pulled to the right so that it adopts the position shown in Figure 1 1 , releasing the lugs 27 from engagement with the second lip 28, permitting the base portion 13 to be removed from the rail 18.
  • the base portion 13 may be installed on the rail 18 by the reverse process, although pushing down on the module assembly 1 , once correctly positioned on the rail 18, should be sufficient to displace the lugs 27 against the action of the spring 26, to enable the base portion 13 to engage with the rail 18.
  • the above arrangement permits a number of module assemblies 1 , to be mounted to a common rail 18, as shown in Figure 12.
  • single tier modules assemblies 1 are shown and such an arrangement is particularly advantageous if the terminal block 29 so formed, is to have a low profile, to permit it to be mounted, or assembled, in a location where it needs to have a low profile due to space restrictions.
  • two two tier module assemblies 17, as illustrated in Figure 8 could be installed on the rail 18 to create a terminal block 30, as shown in Figure 13. This is functionally equivalent to the terminal block 29 of Figure 12 but provides a higher density arrangement of connection points.
  • the rail 18 has a number of slots 31 which may be used to secure the rail and thus the module assemblies 1 or 17 to an aircraft frame or similar.
  • the base portion 13 of a module assembly 1 or 17 may be arranged to connect directly to an aircraft frame or similar.
  • appropriate components can be selected to construct an appropriate number and type, or types, of module assemblies to provide a desired number of connection points 8A to 8D, for example the single tier module assembly 1 of Figure 1 or the two tier module assembly 17 of Figure 8, prior to a base portions 13 of those module assemblies being fixed directly to an aircraft frame, or to a rail 18 previously fixed to the aircraft frame, to provide a terminal block having appropriate dimensions for that application.
  • a rail 18 this may be supplied as a standard length and cut to length dependent on the number of module assemblies 1 , 17 that are to be attached to the rail 18.
  • the module assemblies 1 , 17 can be mounted to the rail 18 without the use of tools.
  • the pin connectors 5 can then be connected to socket assemblies 2 by a simple push and turn action, again without the need for tools.
  • a terminal block from a number of module assemblies, for example the terminal block 29 of Figure 12 or terminal block 30 of Figure 13, for the bulk of the assembly work can be done either off site or in a convenient location on site before the module assemblies 1 , 17 are either simply clipped to the rail 18 or secured by some other means in a location where space may be considerably more restricted.
  • one pin connector 32 is shown removed from its respective socket assembly 2, in order to illustrate how, even with this particularly dense arrangement of socket assemblies 2, sufficient access is still available for insertion of a finger and thumb between the feeder cables 6 to permit the pin connector 32 to either be attached or detached to or from a respective socket assembly, making it possible to remove the pin connector 32 and the associated feeder cable 6 without disturbing any other pin connector 5 or feeder cable 6.
  • a modular power distribution system in the form of block 30, for example, may be located in particularly confined locations.
  • this shows an alternative socket assembly 33 having only three connection points, suitable for establishing a single branch.
  • connection points 8A to 8D may be used as shown in Figure 15, the same functionality may be achieved by using a socket assembly 2 with four connection points 8A to 8D and inserting a blanking plug 34 in one of those connection points to prevent the ingress of any FOD and to ensure complete electrical insulation of all live components.
  • Figure 16 shows how a shunt 35 may be applied across two identical socket assemblies 2 to provide six available electrically connected connection points.
  • FIG 17 shows an alternative base assembly 36 in which the socket assemblies 2 are received in vertically aligned ports 37, such that the socket assemblies 2 are arranged in a side by side and on edge configuration.
  • the socket assemblies 2 are sandwiched between a lower portion 38 and upper portion 39 of the base assembly 36, with the lower portion 38 and upper portion 39 being held together by quarter turn screws 40 captive in the upper portion 39.
  • An advantage of this arrangement is that on removal of the upper portion 40 any one socket assembly 2 may be removed without disturbing any other socket assembly.
  • connection points 8A to 8D of each socket assembly 2 are likely to be electrically isolated from those of any adjacent socket assembly and likely to be either of different polarities or different phases.
  • each one of the socket assemblies 2 may be associated with a different phase of a three phase supply.
  • the socket assemblies 2 can be conveniently labelled“one”,“two” and“three”, as illustrated, to indicate different phases or to indicate any other desired characteristic.
  • each connection point 8A to 8D can be identified, for example by a“1”,“2”,“3” or“4”, as shown in Figure 17 and this can be used to assist in connecting the correct pin connectors 5, which may also be labelled to indicate the socket assembly 2 and connection points 8A to 8D of that socket assembly they are to be connected to.
  • the socket housings 11 of the socket assemblies 2 can be marked with a colour or can be moulded of different coloured plastics, for example in three colours to represent each phase of a three phase supply.
  • pin connectors 5 can be similarly marked with an appropriate colour or moulded from an appropriate coloured plastic to match that of an appropriate socket assembly 2, to clearly indicate which socket assembly 2 they are to be connected to.
  • each connection point 8 is provided with two studs 41 to engage with inner L-shaped slots 42 in the pin connector 5 of Figure 18, which together provide a quick connect/ disconnect function.
  • a pin connector 5 may simply be pushed in and turned in order to establish an electrical connection and secure the pin connector 5 in place on an appropriate socket assembly 2, as discussed previously with reference to Figure 13.
  • the L-shaped slots 42 are located on an inner wall of the housing 43 of the pin connector 15 and this is free to rotate relative to the conductive pin 44, which is connected to feeder cable 6. Therefore, the conductive pin 44 and feeder cable 6 can be inserted into an appropriate connecting point 8A to 8D of a socket assembly 2 and rotated to lock the pin connector 5 in place without any rotational torque being applied to the feeder cable 6.
  • a crimp 45 of the pin connector 5 is crimped and fixed to the feeder cable 6 and attached to pin 44, but this is also free to rotate relative to the pin housing 43.
  • the crimp 45 is arranged to receive and engage with feeder cables with a range of different gauges.
  • the pairs of studs 41 of a socket assembly 2 and pairs of L-shaped slots 42 of a pin connector 5 may have different angular separations depending on, for example, what phase a socket assembly 2 and a pin connector 5 are to be associated with, so that a pin connector 5 will only be able to connect to a socket assembly 2 if they are both to be associated with the same phase. Thus they are each keyed by means of their respective pairs of L-shaped slots 42 and studs 41. This provides one example of how pin connectors 5 and socket assemblies 2 may be keyed, to selectively engage with each other, but there are many alternative ways of achieving this.
  • the pin housing 43 of the pin connector 5 of Figure 18 has a visual indicator

Abstract

The present invention provides a modular power distribution system (30) which comprises one or more module assemblies (17),each comprising a socket assembly (2) and a base assembly (4),wherein the base assemblies (4) are of a modular design sharing common components.

Description

A Modular Power Distribution System
The present invention relates to a modular power system that is particularly, but not exclusively, applicable for use on an aircraft.
More and more electrical equipment is being used on aircraft, where reliable relatively light and compact electrical motors and actuators may be used instead of the more conventional and heavier mechanical and hydraulic actuators. This also making it possible to use more flexible and lightweight electrical cables instead of the conventional mechanical linkages and hydraulic lines.
The extensive use of electrical equipment in modern aircraft, particularly large commercial aircraft, requires relatively complex power distribution networks to be installed in a reliable and safe manner and such a distribution network will normally employ numerous terminal blocks at various locations in the aircraft, which are normally mounted to the aircraft frame.
Currently electrical power in an aircraft is distributed by connecting cables, terminated with crimped ring terminals, to terminal blocks. These typically embody a fixed number of threaded posts, overmolded with plastic insulation that are fixed to the aircraft structure by bolts on either end. Power distribution is achieved by stacking multiple ring terminals on to a single post. The ring terminals are then fastened to the posts with a nut by a manual torqueing operation. The terminal blocks are often protected with a plastic cover to protect from foreign object debris (FOD) and prevent operators touching live parts. These covers are fixed to the terminal block with quarter turn bolts secured with lock wire.
Using conventional terminal blocks is a relatively time consuming process because securing the ring terminals to the post by a nut requires that the nut be manually torqued, requiring the use of tools in what may be a relatively confined space. Additionally, the requirement to have sufficient access to a terminal block to permit the torqueing operation to be performed may prevent a terminal block from being installed in a particularly restrictive location.
The torqueing operating, together with the use of crimped ring terminals in general, can often cause delays in installation and may also result in reworking being necessary. This may arise from issues such as the ring terminals being misaligned, which requires the cable to be axially torqued to align the ring terminal with the post, or as a result of damage to the ring terminal from the torqueing tool, which may require a new ring terminal to be crimped to a cable, which in turn may require the reworking of a harness installation to adjust for the reduced available cable length.
Additionally the torqueing operation may tend to twist the position of the ring terminal on the post, so that the ring terminal and cable are skewed so that they may come into undesirable contact with an adjacent cable or with a rigid part of either the terminal block or the frame, which again may require reworking to avoid damage to those parts or to the cable.
Once the cabling is correctly connected and the nuts on the terminal posts correctly torqued, additional time may then be spent securing the protective plastic cover in place by quarter turn screws and performing the locking wire operation.
Another problem that may arise when connecting cables to a conventional terminal block is that there may be potential FOD issues, arising from the use of loose washers and nuts.
In addition to the above mentioned problems associated with the connection of the cables to a terminal block, terminal blocks themselves are also relatively inflexible in nature, being manufactured with a fixed number of terminal posts, normally between three and twelve per terminal block. This may results in the requirement for a large number of variants, each requiring a separate mould tool for its construction and resulting in a large number of different product numbers and products to be ordered, stored and appropriately distributed for installation aboard an aircraft. Also the terminal block variant selected for installation will normally be based on the number of posts required to meet all the optional extras offered on a particular platform. However, an operator purchasing that platform will typically select only a limited number of those optional extras. Thus, it is common for terminal blocks to be installed where a number of posts are unused, thus a particular terminal block may be larger and heavier than necessary.
In addition to the above, other issues which arise with conventional terminal blocks is the risk of incorrectly connecting different power phases, the risk of exposed electrically live metal parts posing a risk to the operator and also the risk of those exposed metal parts potentially corroding with time, as for example in the case of aluminium ring terminals.
Once in service, if it is necessary to subsequently perform a repair operation or otherwise modify the power distribution system in any way, it is not possible to remove a single cable from a post without releasing all cables to that post and possibly removing some or all of those cables, if the cable it is desired be removed is not the top cable. This can be particularly problematic where a number of possibly related cables (one associated with each of three phases for example) are to be simultaneously removed from a terminal block.
The use of electric motors and actuators, instead of the more conventional hydraulic and pneumatic actuators, may also require power to be distributed at higher voltages, which will only act to compound some of the above mentioned problems.
It is an object of the present invention to provide an improved power distribution system that addresses some or all of the above mentioned problems.
According to a first aspect of the present invention there is provided a modular power distribution system comprising a module assembly, the module assembly comprising a socket assembly and a base assembly. The socket assembly comprises a conductive connector socket having a plurality of electrically connected connection points, each connection point being arranged to releasably receive a conductive pin connected to a feeder cable. The socket assembly further comprising an electrically insulating socket housing in which the connector socket is housed. The base assembly comprises a port for releasably mounting the socket assembly and is arranged to be mounted to an aircraft frame or the like, or to one or more other base assemblies.
The present invention provides a socket assembly where a conductive connector permits multiple feeder cables to be connected together in a manner functionally equivalent to attaching multiple ring terminals and associated cables to a common terminal post of a terminal block. However, unlike with a terminal post of a terminal block, the connector socket of the present invention is contained within its own socket housing, which electrically insulates the conductive connector socket and which forms a self-contained socket assembly. This is releasably mounted in a port of a base assembly, to form a module assembly of the power distribution system, which can be mounted at a desired location or combined with other such modules.
The term“port”, as used in the context of the present specification, is defined as any point on the base assembly arranged to releasably receive, support and maintain in place a socket assembly. This need not necessarily take the form of an aperture, as in the embodiments disclosed in and described with reference to the drawings of this specification, but instead could be in the form of a fixing for receiving and releasably engaging with a socket assembly.
A major advantage of the invention is that it permits only a desired number of socket assemblies to be used and secured to one or more base assemblies to form a terminal block and for this to comprise multiple components of the same type. Preferably, the modular power distribution system comprises a plurality of interchangeable socket assemblies, wherein the base assembly has multiple ports arranged to receive multiple socket assemblies. This permits interchangeable or identical socket assemblies to be selected and installed in a single base assembly, as required.
More preferably, the modular power distribution system may comprise a plurality of base assemblies, each base assembly having one or more ports arranged to receive one or more socket assemblies, to thus provide a plurality of module assemblies. This enables multiple module assemblies to be built which may be used together to form a modular terminal block for a specific application,
constructed using many common components, which may be assembled in multiple different configurations.
The above arrangement may not only permit a terminal block to be assembled that has the correct number of socket assemblies (terminals) for a specific application, but it may also permit the dimensions of the terminal block to be determined by the space available to accommodate that terminal block. For example, a terminal block arranged to receive a set number of cables could comprise a large number of base assemblies, each arranged to receive a single socket assembly, which would result in a terminal block having a relatively low profile but being relatively wide. Alternatively, that same number of cables could be accommodated by a terminal block comprising half the number of base assemblies but with each base assembly accommodating two socket assemblies stacked one above the other, which would likely approximately double the height of the resultant terminal block whilst halving the width. Both arrangements would share a pool of common component types. The modular power distribution system may further comprise a rail to which the multiple base assemblies are arranged to be mounted. In this manner, a terminal block may easily be constructed to receive and connect any desired number of cables using multiple identical components. Such a rail could be provided in standard lengths and be cut to size depending on the application.
Alternatively the rail could be provided in different lengths.
Advantageously, each base assembly is arranged to be releasably attached to the rail without the use of tools, enabling a terminal block to be assembled relatively easily, possibly requiring only that the rail be cut to an appropriate length to receive the desired number of base assemblies and mounted to an aircraft or similar. Appropriate preassembled module assemblies (base assemblies and associated socket assemblies) could then be attached to the rail, effectively building the terminal block“on site” enabling the terminal block to be assembled for a specific application.
It may be particularly advantageous if each base assembly is assembled from a plurality of interchangeable parts arranged to be selected and assembled to form one or more ports in the base assembly, dependent on the number of socket assemblies that are to be received by the base assembly. Thus a base assembly of a module assembly comprising only a single socket assembly may share common and interchangeable parts with a base assembly comprising two or more socket assemblies. In this manner a relatively few part types may be used to construct different configurations of a base assembly.
In an alternative arrangement, a terminal block may comprise a plurality of interchangeable socket assemblies each substantially planer in shape and wherein the or each base assembly has a base portion by which it is to be mounted and a plurality of ports arranged to receive the socket assemblies in a side by side and on edge configuration above the base portion. An advantage of this configuration is that, should it be necessary to remove or replace a particular socket assembly, the base assembly may be arranged such that any one of the multiple socket assemblies may be removed from the base assembly, without removing any other socket assembly.
Preferably, each base assembly comprises two parts which may be separated to remove a socket assembly from the base assembly, without disconnecting feeder cables connected to the socket assembly, enabling a connected group of cables and an associated socket assembly to be released from the base assembly without disconnecting those cables.
Advantageously, each base assembly is arranged to hold multiple socket assemblies in a spaced apart configuration, which may provide sufficient access to each cable to enable a cable to be removed without requiring the socket assembly to be removed from the base assembly.
Each socket assembly may have a first end and a second end, each with a respective connection point to be connected to a feeder cable, wherein the socket assembly is arranged to be received in a port of the base assembly at a midpoint between the two ends, to leave each connection point accessible for the
connection of a respective feeder cable whilst the socket assembly is mounted in a port of the base assembly. Such an arrangement is advantageous because each socket assembly may act to join two lengths of cable or to form a branch or spur.
Each socket assembly may be substantially H-shaped having a H-shaped connector socket with four connection points, one at or towards each tip of the H- shape socket assembly, thus providing four electrically connected connection points. This is a particularly advantageous configuration for when a number of such socket assemblies are arranged in respective base assemblies to form a terminal block, the H-shaped configuration may be arranged to provide a particularly high density of connection points, with each capable of providing a two- way or three-way branch. This arrangement may also permit a standard rigid shunt to be provided and used to connect the connector sockets of two adjacent pairs of socket assemblies together, to then provide six available electrically connected connection points. Multiple shunts could be used to provide any number of interconnected connection points.
Preferably, the modular power distribution system further comprises multiple pin connectors for connecting feed cables to respective connection points of the, or each, socket assembly, with each pin connector comprising a conductive pin and a pin housing. The socket housing of each socket assembly may then be arranged to completely cover the connector socket, leaving only the connection points accessible to receive respective conductive pins of the pin connectors. The socket housing has a locking feature arranged to releasably engage with a respective pin housing and retain the pin housing in place and thus to then provide, together with the pin housing, a continuous electrically insulating shield over the connection between the connector socket and the conductive pin. This may then be used to provide a completely electrically insulated terminal block, avoiding the need to provide any additional covers and associated locking wires, or the like.
Preferably, the locking feature is part of a quick connect/disconnect connection between the socket assembly and pin connector, enabling each pin connector and associated feeder cable to be quickly and easily attached to a socket assembly without the use of tools. For the purposes of this specification a quick connect/disconnect connection is defined as a connection which can be made by hand, substantially as a single movement and without the use of tools. Examples of such connections being push and turn or push and clip type
connectors.
Preferably, each pin housing and respective socket housing together provide a visual indication as to whether or not they are securely connected, enabling all connections on a terminal block to be verified by a visual inspection.
Each pin connector may comprise a crimp adapted to receive different gauges of cable, enabling different gauges of cable to be connected to a pin connector and thus to a socket assembly. Each pin connector may comprise a keyed element, with different pin connectors having different keyed elements each arranged to cooperate with respective corresponding keyed elements of a socket assembly. Thus it may be arranged that is only possible to connect appropriately keyed pin connectors to a particular socket assembly. This may be particularly advantageous to ensure connections cannot be made between inappropriate pin connectors and their associated cables. This may thus be used, for example, to ensure that a pin connector associated with one phase cannot be connected, via a socket assembly, to a pin connector associated with a different phase, even if the pin connectors are disconnected from a terminal block comprising multiple socket assemblies and subsequent attempts are made to incorrectly reconnect them.
Additionally, or alternatively, to the above arrangement, where a modular power distribution system in accordance with the present invention comprises a plurality of socket assemblies, each of these may bear a respective different colour, with each pin connector bearing the corresponding colour to indicate which socket assembly it should be connected to.
According to a second aspect of the invention there is provided socket assembly for use in a system in accordance with a first aspect of the invention.
According to a third aspect of the invention there is provided a base assembly for use in a system in accordance with a first aspect of the invention.
Several embodiments of the present invention will now be described, by way of example only, with reference to the accompanying figures, in which like numerals are used throughout to indicate like parts, and of which:
Figure 1 is a perspective view of a first module assembly of a modular power distribution system according to the present invention;
Figure 2 is a perspective view of a socket assembly forming part of the module assembly of Figure 1 ; Figure 3 is a perspective exploded view of the socket assembly of Figure 2; Figure 4 is a cross-sectional plan view of the socket assembly of Figures 2 and 3;
Figure 5 is a perspective view of a base portion of a base assembly of the module assembly of Figure 1 ;
Figure 6 is a front exploded view of the module assembly of Figure 1 ;
Figure 7 is a front exploded view of an alternative module assembly to that show in Figure 6;
Figure 8 is a perspective view of the module assembly of Figure 7;
Figure 9 shows the module assembly of Figure 1 mounted on a rail;
Figure 10 is a section along the line A-A of Figure 9;
Figure 11 correspond to Figure 10, but shows the module assembly being released from the rail;
Figure 12 shows four module assemblies of Figure 1 mounted on a common rail;
Figure 13 shows four module assemblies of Figure 8 mounted on a rail with a number of pin connectors and associated power feeder cables connected to the socket assemblies of the module assemblies;
Figure 14 illustrates an alternative socket assembly;
Figure 15 illustrates how a blanking plug may be used with the module assembly of Figure 8;
Figure 16 shows how a shunt may be used with a module assembly of Figure 8;
Figure 17 is a perspective view of an alternative module assembly in accordance with the present invention; and
Figure 18 is a perspective view of a pin connector and associated feed cable.
Referring to Figure 1 , a module assembly, indicated generally as 1 , comprises a socket assembly 2 securely held in a port 3 of a base assembly 4.
The socket assembly 2 is shown separately in Figure 2 and is FI - shaped and provided with four connection points 8A to 8D, one at each tip of the“FI”. Each connection point 8A to 8D is arranged to connect to a respective pin connector, such as the pin connector 5 and associated feeder cable 6 shown in Figure 18 and discussed later with reference to Figure 18.
Referring now to Figure 3, this is an exploded view of the components of the socket assembly 2 of Figure 2. This comprises a metal connector socket 7 which is FI-shaped and comprises the four connection points 8A to 8D, (see Figure 4, a plan cross-section through the assembled components of Figure 3). Each connection points 8A to 8D is arranged to receive a conductive pin 44 of an associated pin connector 5, as shown in Figure 18.
Each connection point 8A to 8D , as shown in Figure 4, comprises a snap ring 9 arranged to engage with a groove on a conductive pin 44 of a pin connector 5 to retain the conductive pin 44 in the associated connection point 8A to 8D. Each connection point 8A to 8D also has a contact band 10 to improve connection with a conductive pin 44.
Returning to Figure 3, the connector socket 7 is shown located between two halves 11 A and 11 B of socket housing 11. This is made of an insulating plastic and the two halves 11 A and 11 B snap fit over the connector socket 7, and envelop the whole of the connector socket 7, with the exception of the connection points 8A to 8D. All the connection points 8A to 8D of the socket assembly 2 are electrically connected by virtue of being formed within the single metal connector socket 7.
Referring now to Figure 5, this shows a base portion 13 of the module assembly 1 of Figure 1. The base portion 13 defines a lower half of port 3. As shown in Figure 6, this port 3 is arranged to receive the socket assembly 2 of Figure 2, which is then clamped in position by a saddle portion 14 retained in place by fasteners 15. Although the fasteners 15 are shown, in the exploded view of Figure 6, separate from saddle portion 14, these are quarter turn fasteners held captive within the saddle portion 14 and are used to secure the socket assembly 2 in the base assembly 4 as shown in Figure 1. Referring now to Figures 7 and 8, these essentially corresponds to Figures 6 and 1 respectively and use the same numbering to indicate the same components, which function in the same manner as those described with reference to Figures 6 and 1. Flowever, in the embodiment of Figures 7 and 8 an additional stacking component 16 is incorporated between the base portion 13 and saddle portion 14, to define two identical ports 3 for receiving two identical socket assemblies 2.
When the components of Figure 7 are assembled they produce the module assembly 17 of Figure 8, a two tier version of the module assembly 1 , illustrated in Figure 1.
It will be appreciated from a comparison of Figures 6 and 7 that a number of common component types, namely the base portion 13, saddle 14 and fasteners 15, can be used to produce the different module assemblies 1 and 17 and although Figures 6 and 7 only show one tier and two tier assemblies, it is possible to add one, or even more, additional stacking components 16, in order to add additional tiers.
Referring now to Figures 9 to 11 , these show how the module assembly 1 of Figure 1 , or the module assembly 17 of Figure 8, which share the same base portion 13, may be mounted to a rail 18. As can most clearly be seen from Figure 10, a section along the line A-A of Figure 9, the base portion 13 of the module assembly 1 is retained on the rail 18 partially by means of a pair of lugs 19, only one of which can be seen in Figure 10, which engage under a first lip 20 of the rail 18. These lugs 19 also protrude into the recesses 21 in the lip 20, seen in Figure 9 and prevent the base portion from sliding along the rail 18.
In a recess 22, in a lower face of the base portion 13, is located a slide bar 23. The slide bar 23 is held in place by a fastener 24 extending through an elongate slot 25 in the slide bar 23, slide bar 23 is biased to the left, as shown in Figure 10, by a spring 26, held captive in a recess in the base portion 13 by the slide bar 26. A pair of lugs 27, (only one of which can be seen in Figure 10) integrally moulded with the slide bar 23, engage under a second lip 28 of the rail 18 and hold the base portion 13 of the base assembly 4 in position upon the rail 18.
To release the base portion 13 and thus the base assembly 4, the slide bar 23 is pulled to the right so that it adopts the position shown in Figure 1 1 , releasing the lugs 27 from engagement with the second lip 28, permitting the base portion 13 to be removed from the rail 18. Likewise, the base portion 13 may be installed on the rail 18 by the reverse process, although pushing down on the module assembly 1 , once correctly positioned on the rail 18, should be sufficient to displace the lugs 27 against the action of the spring 26, to enable the base portion 13 to engage with the rail 18.
The above arrangement permits a number of module assemblies 1 , to be mounted to a common rail 18, as shown in Figure 12. Here, single tier modules assemblies 1 are shown and such an arrangement is particularly advantageous if the terminal block 29 so formed, is to have a low profile, to permit it to be mounted, or assembled, in a location where it needs to have a low profile due to space restrictions. Alternatively, two two tier module assemblies 17, as illustrated in Figure 8, could be installed on the rail 18 to create a terminal block 30, as shown in Figure 13. This is functionally equivalent to the terminal block 29 of Figure 12 but provides a higher density arrangement of connection points.
As can be seen from Figures 9 and 13, the rail 18 has a number of slots 31 which may be used to secure the rail and thus the module assemblies 1 or 17 to an aircraft frame or similar. Alternatively, the base portion 13 of a module assembly 1 or 17 may be arranged to connect directly to an aircraft frame or similar.
In either case, it will be appreciated that appropriate components can be selected to construct an appropriate number and type, or types, of module assemblies to provide a desired number of connection points 8A to 8D, for example the single tier module assembly 1 of Figure 1 or the two tier module assembly 17 of Figure 8, prior to a base portions 13 of those module assemblies being fixed directly to an aircraft frame, or to a rail 18 previously fixed to the aircraft frame, to provide a terminal block having appropriate dimensions for that application.
Where a rail 18 is used, this may be supplied as a standard length and cut to length dependent on the number of module assemblies 1 , 17 that are to be attached to the rail 18. Once the rail 18 has been secured in place, the module assemblies 1 , 17 can be mounted to the rail 18 without the use of tools. As will become apparent from the discussion below, the pin connectors 5 can then be connected to socket assemblies 2 by a simple push and turn action, again without the need for tools.
The above features may be particularly advantageous when constructing a terminal block from a number of module assemblies, for example the terminal block 29 of Figure 12 or terminal block 30 of Figure 13, for the bulk of the assembly work can be done either off site or in a convenient location on site before the module assemblies 1 , 17 are either simply clipped to the rail 18 or secured by some other means in a location where space may be considerably more restricted.
With reference to Figure 13, one pin connector 32 is shown removed from its respective socket assembly 2, in order to illustrate how, even with this particularly dense arrangement of socket assemblies 2, sufficient access is still available for insertion of a finger and thumb between the feeder cables 6 to permit the pin connector 32 to either be attached or detached to or from a respective socket assembly, making it possible to remove the pin connector 32 and the associated feeder cable 6 without disturbing any other pin connector 5 or feeder cable 6. The possibility to make such a connection without the use of tools means that a modular power distribution system, in the form of block 30, for example, may be located in particularly confined locations.
Referring to Figure 14, this shows an alternative socket assembly 33 having only three connection points, suitable for establishing a single branch.
Alternatively, as shown in Figure 15, the same functionality may be achieved by using a socket assembly 2 with four connection points 8A to 8D and inserting a blanking plug 34 in one of those connection points to prevent the ingress of any FOD and to ensure complete electrical insulation of all live components.
Figure 16, shows how a shunt 35 may be applied across two identical socket assemblies 2 to provide six available electrically connected connection points.
Figure 17 shows an alternative base assembly 36 in which the socket assemblies 2 are received in vertically aligned ports 37, such that the socket assemblies 2 are arranged in a side by side and on edge configuration. The socket assemblies 2 are sandwiched between a lower portion 38 and upper portion 39 of the base assembly 36, with the lower portion 38 and upper portion 39 being held together by quarter turn screws 40 captive in the upper portion 39. An advantage of this arrangement is that on removal of the upper portion 40 any one socket assembly 2 may be removed without disturbing any other socket assembly.
In all previously described embodiments, unless a shunt 35 is provided between adjacent socket assemblies 2, the connection points 8A to 8D of each socket assembly 2 are likely to be electrically isolated from those of any adjacent socket assembly and likely to be either of different polarities or different phases.
For example, with reference to Figure 17, each one of the socket assemblies 2 may be associated with a different phase of a three phase supply. The socket assemblies 2 can be conveniently labelled“one”,“two” and“three”, as illustrated, to indicate different phases or to indicate any other desired characteristic.
Additionally, as shown, each connection point 8A to 8D can be identified, for example by a“1”,“2”,“3” or“4”, as shown in Figure 17 and this can be used to assist in connecting the correct pin connectors 5, which may also be labelled to indicate the socket assembly 2 and connection points 8A to 8D of that socket assembly they are to be connected to. Alternatively, or in addition, the socket housings 11 of the socket assemblies 2 can be marked with a colour or can be moulded of different coloured plastics, for example in three colours to represent each phase of a three phase supply.
Similarly, the pin connectors 5 can be similarly marked with an appropriate colour or moulded from an appropriate coloured plastic to match that of an appropriate socket assembly 2, to clearly indicate which socket assembly 2 they are to be connected to.
With reference to now to Figures 17 and 18, it will be seen that the housing 11 surrounding each connection point 8 is provided with two studs 41 to engage with inner L-shaped slots 42 in the pin connector 5 of Figure 18, which together provide a quick connect/ disconnect function. Flere a pin connector 5 may simply be pushed in and turned in order to establish an electrical connection and secure the pin connector 5 in place on an appropriate socket assembly 2, as discussed previously with reference to Figure 13.
The L-shaped slots 42 are located on an inner wall of the housing 43 of the pin connector 15 and this is free to rotate relative to the conductive pin 44, which is connected to feeder cable 6. Therefore, the conductive pin 44 and feeder cable 6 can be inserted into an appropriate connecting point 8A to 8D of a socket assembly 2 and rotated to lock the pin connector 5 in place without any rotational torque being applied to the feeder cable 6. Similarly, a crimp 45 of the pin connector 5 is crimped and fixed to the feeder cable 6 and attached to pin 44, but this is also free to rotate relative to the pin housing 43. The crimp 45 is arranged to receive and engage with feeder cables with a range of different gauges.
The pairs of studs 41 of a socket assembly 2 and pairs of L-shaped slots 42 of a pin connector 5 may have different angular separations depending on, for example, what phase a socket assembly 2 and a pin connector 5 are to be associated with, so that a pin connector 5 will only be able to connect to a socket assembly 2 if they are both to be associated with the same phase. Thus they are each keyed by means of their respective pairs of L-shaped slots 42 and studs 41. This provides one example of how pin connectors 5 and socket assemblies 2 may be keyed, to selectively engage with each other, but there are many alternative ways of achieving this. The pin housing 43 of the pin connector 5 of Figure 18 has a visual indicator
46. When the pin 44 is correctly pushed into a connection point 8A to 8D of a connector socket 2 and the pin housing 43 rotated to lock the pin connector 5 in place, as most clearly seen from Figure 15, the visual indicator 46 will then be aligned with a corresponding visual indicator 47 on the socket assembly 2, providing a visual indication that the pin connector 5 is correctly connected to the socket assembly 2.
The present invention has been described above by way of example only and many modifications may be made to the embodiments described, without departing from the scope of the invention, as defined by the appended claims.

Claims

Claims
1. A modular power distribution system comprising a module assembly, the module assembly comprising a socket assembly and a base assembly, wherein the socket assembly comprises:
a conductive connector socket having a plurality of electrically connected connection points, each connection point being arranged to releasably receive a conductive pin connected to a feeder cable; and
an electrically insulating socket housing in which the connector socket is housed, and wherein:
the base assembly comprises a port for releasably, mounting the socket assembly; and
the base assembly is arranged to be mounted on a surface, to a mounting, or to one or more other base assemblies.
2. A modular power distribution system as claimed in Claim 1 comprising a plurality of interchangeable socket assemblies, wherein the base assembly has multiple ports arranged to receive multiple socket assemblies.
3. A modular power distribution system as claimed in Claim 1 or Claim 2 comprising a plurality of interchangeable socket assemblies and a plurality of base assemblies each base assembly having one or more ports arranged to receive one or more socket assemblies to provide a plurality of module assemblies.
4. A modular power distribution system as claimed in 3 further comprising a rail to which the multiple base assemblies are arranged to be mounted.
5. A modular power distribution system as claimed in Claim 4 wherein each base assembly is arranged to be releasably attached to the rail without the use of tools.
6. A modular power distribution system as claimed in any preceding claim wherein the, or each, base assembly is assembled from a plurality of
interchangeable parts arranged to be selected and assembled to form one or more ports in the base assembly, in dependence on the number of socket assemblies that are to be received by the base assembly.
7. A modular power distribution system as claimed in Claim 6 wherein the base assembly has a base portion by which it is to be mounted and wherein the plurality of interchangeable parts are selected and assembled on the base portion, and/or each other, to form a base assembly in which multiple socket assemblies may be received in a vertically stacked configuration, one above the other above the base portion of the base assembly.
8. A modular power distribution system as claimed in any preceding claim wherein the port or ports are arranged to receive the or each socket assembly horizontally.
9. A modular power distribution system as claimed in any one of claims 1 to 6 comprising a plurality of interchangeable socket assemblies each substantially planer in shape and wherein the or each base assembly has a base portion by which it is to be mounted and a plurality of ports arranged to receive the socket assemblies in a side by side and on edge configuration above the base portion.
10. A modular power distribution system as claimed in any proceeding claim wherein the or each base assembly comprises two parts which may be separated to remove a socket assembly from the base assembly without disconnecting feeder cables connected to the socket assembly.
1 1 . A modular power distribution system as claimed in any proceeding claim wherein the or each base assembly is arranged to hold multiple socket assemblies in a spaced apart configuration.
12. A modular power distribution system as claimed in any proceeding claim wherein the or each socket assembly has a first end and a second end, each with a respective connection point to be connected to a feeder cable and wherein the socket assembly is arranged to be received in a port of the base assembly at a midpoint between the two ends, to leave each connection point accessible for the connection of a respective feeder cable whilst the socket assembly is mounted in a port of the base assembly.
13. A modular power distribution system as claimed in any proceeding claim wherein the or each socket assembly is substantially H - shaped having a H - shaped connector socket with four connection points, one at or towards each tip of the H - shaped socket assembly.
14. A modular power distribution system as claimed in any proceeding claim further comprising multiple pin connectors for connecting feed cables to respective connection points of the or each socket assembly, each pin connector comprising a pin and a pin housing, wherein the socket housing of each socket assembly is arranged to completely cover the connector socket, leaving only the connection points accessible to receive respective pins of the pin connectors, the socket housing having a locking feature arranged to releasably engage with a respective pin housing and retain the pin housing in place and to provide, with the pin housing, a continuous electrically insulating shield over the connection between the connector socket and the pin.
15. A modular power distribution system as claimed in Claim 14 wherein the locking feature is part of a quick connect/disconnect connection between the socket assembly and pin connector.
16. A modular power distribution system as claimed in claim 14 or 15 wherein each pin housing and respective socket housing together provide a visual indication as to whether or not they are securely connected.
17. A modular power distribution system as claimed in any one of claims 14 to
16 wherein each pin connector comprises a crimp adapted to receive different gauges of cable.
18. A modular power distribution system as claimed in any one of claims 14 to
17 wherein each pin connector comprises a keyed element and different pin connectors have different key elements to cooperate with corresponding key elements of a socket assembly, so that only selected pin connectors with the appropriate key elements can be connected to that socket assembly.
19. A modular power distribution system as claimed in any one of claims 14 to
18 comprising a plurality of socket assemblies each bearing a respective different colour and wherein each pin connector bears a corresponding colour, to indicate which socket assembly it should be connected to.
20. A modular power distribution system as claimed in any preceding claim wherein each connection point comprises a contact band for electrically connecting to a respective pin.
21 . A socket assembly for a modular power distribution system as claimed in any preceding claim.
22. A base assembly for a modular power distribution system as claimed in any one of claims 1 to 21 .
PCT/GB2019/053237 2018-11-16 2019-11-15 A modular power distribution system WO2020099883A1 (en)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
FR1860580A FR3088775A1 (en) 2018-11-16 2018-11-16 ELECTRICAL CONNECTION SYSTEM FOR POWER SUPPLY
FR1860580 2018-11-16
GBGB1901380.4A GB201901380D0 (en) 2019-01-31 2019-01-31 A connector and clip
GB1901380.4 2019-01-31
GB1906080.5 2019-04-30
GBGB1906080.5A GB201906080D0 (en) 2019-04-30 2019-04-30 A connector and clip

Publications (1)

Publication Number Publication Date
WO2020099883A1 true WO2020099883A1 (en) 2020-05-22

Family

ID=68696456

Family Applications (4)

Application Number Title Priority Date Filing Date
PCT/GB2019/053237 WO2020099883A1 (en) 2018-11-16 2019-11-15 A modular power distribution system
PCT/GB2019/053247 WO2020099889A1 (en) 2018-11-16 2019-11-15 A telescopic connector
PCT/GB2019/053259 WO2020099896A1 (en) 2018-11-16 2019-11-15 A fastener
PCT/GB2019/053235 WO2020099881A1 (en) 2018-11-16 2019-11-15 An electrical connector

Family Applications After (3)

Application Number Title Priority Date Filing Date
PCT/GB2019/053247 WO2020099889A1 (en) 2018-11-16 2019-11-15 A telescopic connector
PCT/GB2019/053259 WO2020099896A1 (en) 2018-11-16 2019-11-15 A fastener
PCT/GB2019/053235 WO2020099881A1 (en) 2018-11-16 2019-11-15 An electrical connector

Country Status (1)

Country Link
WO (4) WO2020099883A1 (en)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102018205929A1 (en) * 2018-04-18 2019-10-24 Fidlock Gmbh Fastening device with a base part and a locking part
TWI733555B (en) * 2020-08-12 2021-07-11 日馳企業股份有限公司 Thread locking mechanism for bicycle
EP4099519A1 (en) * 2021-06-01 2022-12-07 Aptiv Technologies Limited Male and female power terminal assembly, female and male power terminals
CN116544721A (en) * 2022-01-25 2023-08-04 泰科电子(上海)有限公司 Connector assembly and connector

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2488359A (en) * 2011-02-25 2012-08-29 Flex Connectors Ltd A modular electrical connection unit
WO2013178433A1 (en) * 2012-05-30 2013-12-05 Delphi International Operations Luxembourg S.À R.L. Interconnection assembly for vehicle devices and method of interconnection
DE102014109423A1 (en) * 2014-07-05 2016-01-07 Eaton Electrical Ip Gmbh & Co. Kg Housing and arrangement

Family Cites Families (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1595969A (en) * 1922-04-18 1926-08-10 Gen Electric Furnace crucible
US2661970A (en) * 1949-03-26 1953-12-08 Republic Aviat Corp Pivot pin or bolt
US3167105A (en) * 1959-12-15 1965-01-26 Rosan Eng Corp Self-locking nut and bolt unit
US4934885A (en) * 1985-02-25 1990-06-19 The Boeing Company Tack fastener
GB8905774D0 (en) * 1989-03-14 1989-04-26 Wilson Gordon B Telescopic pole
WO1995015596A1 (en) * 1993-12-01 1995-06-08 Blue Moon Ww S.A. Electrical connector
US6709212B1 (en) * 2002-09-05 2004-03-23 Hewlett-Packard Development Company, L.P. Toggling fastening device
EP2130270A1 (en) * 2007-03-27 2009-12-09 Van-System s.r.l Electrical connector
US9757164B2 (en) * 2013-01-07 2017-09-12 Spinal Simplicity Llc Interspinous process implant having deployable anchor blades
US9677587B2 (en) * 2011-09-21 2017-06-13 Bal Seal Engineering, Inc. Multi-latching mechanisms and related methods
TWI436530B (en) * 2011-09-29 2014-05-01 Delta Electronics Inc Cable interfacing protection apparatus, cables with protection apparatus, and method for fabricating the same
CN206657916U (en) * 2016-10-25 2017-11-21 泰科电子(上海)有限公司 Connector and connector assembly
CN108521047B (en) * 2018-04-08 2023-08-04 四川永贵科技有限公司 High-reliability single-core high-current electric connector

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2488359A (en) * 2011-02-25 2012-08-29 Flex Connectors Ltd A modular electrical connection unit
WO2013178433A1 (en) * 2012-05-30 2013-12-05 Delphi International Operations Luxembourg S.À R.L. Interconnection assembly for vehicle devices and method of interconnection
DE102014109423A1 (en) * 2014-07-05 2016-01-07 Eaton Electrical Ip Gmbh & Co. Kg Housing and arrangement

Also Published As

Publication number Publication date
WO2020099896A1 (en) 2020-05-22
WO2020099881A1 (en) 2020-05-22
WO2020099889A1 (en) 2020-05-22

Similar Documents

Publication Publication Date Title
WO2020099883A1 (en) A modular power distribution system
EP0582777B1 (en) Motor connection box, in particular for electric motors
US4386820A (en) Modular connector for power systems
JP2008509524A (en) Modular electrical connector and method of use
US7090544B2 (en) Modular electrical connector and method of using
CN112151979B (en) Electrical connection module and junction box
US20210159650A1 (en) Adapter Device For Power Busbar Systems
US7804026B2 (en) Enclosure for wiring devices
US20230344156A1 (en) Electrical cable connecting system
US3671918A (en) Intraconnector wiring change module
US20240097384A1 (en) Conductor assembly for a power distribution system
DE3045358C2 (en)
US3750086A (en) Rapid connector
EP2107649B1 (en) Encodable motor connector
US5316502A (en) Electrical connector with circuit protection
CN112151977B (en) Junction box connecting assembly and electrical connection module
US7121856B2 (en) Device for connection of busbars to equipment of an electrical switchboard
CN112151980B (en) Electrical connection assembly and cable terminal
DE19639401B4 (en) System for routing installation devices, in particular DIN rail mounted devices
US10297985B2 (en) Modular electrical devices and methods for assembling and mounting the same
EP3817163B1 (en) Conductor assembly for a power distribution system
AU2016102478A4 (en) Electrical plug and assembly
DE19737321A1 (en) Single-pole in-line cable connector for high power applications e.g for supplying traction current to traction units
US4699442A (en) Electrical connection devices
KR20070035616A (en) Modular electrical connector and method of using

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 19809568

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 19809568

Country of ref document: EP

Kind code of ref document: A1