Abstract:
An apparatus to connect a connector half ( 13 ) at an end of a first cable ( 15 ) to a second cable ( 6 ) is described as having a male member ( 32 ) coupled to the first cable ( 15 ) and a female member ( 31 ) coupled to the second cable ( 6 ). An actuation mechanism includes a tapered surface ( 33 U;  33 L) where at least a part ( 16 ) of one of the first and second cables is connected to the tapered surface ( 33 U;  33 L) by a trapping means ( 33 L;  16 L). Preferably, the apparatus is arranged such that movement of the tapered surface ( 14; 33 U;  33 L) along a longitudinal axis in a first direction forces the said part ( 16 ) to move radially outwardly to form the connection and movement of the tapered surface ( 33 U;  33 L) in the opposite direction along the longitudinal axis forces the said part ( 16 ) to move radially inwardly to break the connection. Preferably, the trapping means ( 33 L;  16 L) is a key ( 16 L) provided on the said part ( 16 ) and a slot ( 33 L) formed in the mandrel ( 14 ) in which the key ( 16 L) is trapped. A guide means ( 36 ) is also provided to constrain the said part ( 16 ) to move only in the radial direction.

Description:
FIELD OF THE INVENTION 
     This invention relates to a coupler for joining connections and particularly to a multiway coupler for joining a number of connections, particularly but not exclusively, for use in hostile environments, for example, subsea environments. 
     BACKGROUND OF THE INVENTION 
     Umbilicals used underwater typically comprise a number of internal cables, hoses or wires carrying, for example electrical wires, hydraulic lines, pneumatic lines, fibre optic cables or other types of wires, lines, cables or the like (hereinafter referred to as “cables”) used for transmitting, for example, power, signals, data, etc. At the point where the umbilical connects to a host facility or structure with corresponding cables, it may be necessary to connect each cable within the umbilical separately. Such connections may be difficult and time consuming to effect. 
     This problem has been tackled by connecting and locking two parallel plates, each plate comprising mating connector halves mounted on their mating face. However, these plates are difficult to align and connect, and the connectors mounted on them are prone to damage and to dirt ingress. The problems associated with these plates are exacerbated in subsea or other difficult environments. 
     U.S. Pat. No. 6,530,794 to the present inventor, Thomas David Shon Littlewood, describes a coupler for joining connections and the present invention generally, but not exclusively, relates to improvements to the coupler described therein and the whole contents of U.S. Pat. No. 6,530,794 are incorporated herein by reference. 
     BRIEF SUMMARY OF THE INVENTION 
     According to a first aspect of the present invention there is provided an apparatus to connect a first cable to a second cable, the apparatus comprising:
         a male member coupled to the first cable;   a female member coupled to the second cable, and   an actuation mechanism comprising a tapered surface wherein at least a part of one of the first and second cables is connected to the tapered surface by a trapping means.       

     Preferably, the part of one of the first and second cables is connected to the tapered surface such that movement of the tapered surface along a longitudinal axis in a first direction forces the said at least part to move in a first direction substantially transverse to the longitudinal axis and movement of the tapered surface along the longitudinal axis in a second opposite direction forces the said at least part to move in a second opposite direction substantially transverse to the longitudinal axis. 
     According to the first aspect of the present invention there is provided a method of connecting a first cable to a second cable, the method comprising the steps of:
         providing a male member having a longitudinal central axis coupled to the first cable;   providing a female member coupled to the second cable;   providing an actuation mechanism comprising a tapered surface wherein at least part of one of the first and second cables is connected to the tapered surface;   wherein the tapered surface is capable of moving along the longitudinal central axis of the male member in a first direction such that the said part is forced to move in a first direction substantially transverse to the longitudinal central axis in order to connect the first and second cables together; and   wherein the tapered surface is capable of moving along the longitudinal central axis in an opposite direction to force the said part to move in an opposite direction substantially transverse to the longitudinal central axis in order to disconnect the first and second cables.       

     Preferably, the part of one of the first and second cables is connected to the tapered surface by a trapping means. 
     Typically, the trapping means comprises a key provided on one of the said part and the tapered surface and a slot in which the key is trapped provided on the other of the said part and the tapered surface. 
     Typically, the male member comprises a mandrel wherein the tapered surface(s) are formed on the mandrel. 
     The trapping means preferably forces the said part to move in a first radial direction in response to movement of the tapered surface along the first direction of longitudinal movement of the male member in order to connect the first and second cables together and more preferably the trapping means forces the said part to move in the second radial direction in response to movement of the tapered surface along the second direction of longitudinal movement of the male member in order to disconnect the first and second cables. Most preferably, the first radial direction is outwardly from the longitudinal central axis of the male member and the second radial direction is inwardly toward the longitudinal central axis of the male member. 
     Preferably, the trapping means are arranged to permit sliding movement between the said part of the first cable and the tapered surface in either direction along the longitudinal axis of the male member and to deny relative radial movement between the tapered surface and the said part of the first cable. 
     Typically it is the part of the first cable that is connected to the tapered surface. 
     Preferably, the apparatus is adapted to connect a plurality of first cables to a respective plurality of second cables. Typically, each part of the first cable is connected to a respective tapered surface. Accordingly, there are a plurality of tapered surfaces in preferred embodiments, one tapered surface being provided for each said part of the first cable. 
     Optionally, the degree and/or the height of each tapered surface may be designed or matched with the desired or required length of radial movement required to connect the respective first cable to the respective second cable. Optionally, the height of each of the parts of the first cables may be designed or matched with the desired or required length of radial movement required to connect the respective first cable to the respective second cable, such that a combination of different first cables having different sizes and make up travel lengths are accommodated. 
     Preferably, the apparatus further comprises a guide means to prevent rotational movement between the male and female members. Typically, the guide means further prevents non-radial movement of the part of the first cable. Typically, the said part of the first cable comprises a sliding surface adapted to permit longitudinal sliding movement with respect to the tapered surface and cause radial movement of the said part. Preferably, the sliding surface and/or the tapered surface is/are planar and/or linearly shaped. Preferably, the said part of the first cable comprises a guiding/aligning slider plate. 
     According to a second aspect of the present invention there is provided an apparatus to connect a first cable to a second cable, the apparatus comprising:
         a male member coupled to the first cable;   a female member coupled to the second cable, and   an actuation mechanism operable to move at least a part of the first cable relative to a part of the second cable into connection together, wherein the said portion that moves is constrained in its movement by a guide means.       

     According to the second aspect of the present invention there is provided a method of connecting a first cable to a second cable, the method comprising the steps of:
         providing a male member having a longitudinal central axis coupled to the first cable;   providing a female member coupled to the second cable;   wherein actuation of an actuation mechanism moves at least a part of one of the first and second cables in a first direction substantially transverse to the longitudinal central axis in order to connect the first and second cables together; and   constraining the said part to move only along the first direction or in a second direction opposite to the first direction.       

     Typically, the said part is constrained by a guide means. 
     Preferably, the guide means is arranged to prevent rotational movement between the male and female members. Typically, the guide means further prevents non-radial movement of the said part that moves and preferably, the guide means prevents longitudinal movement of the said part that moves and more preferably prevents rotational movement of the said part that moves. 
     Preferably, the guide means comprises a substantially cylindrical member preferably having one or more radially extending slots within which the said part is constrained. Preferably, the said part comprises a flange portion which can act against an outer portion of the guide means surrounding the slot to prevent longitudinal movement of the said part. More preferably, the guide means prevents non-longitudinal movement of the mandrel of the male member, wherein the guide means prevents radial movement of the mandrel. Optionally, one or more cables may pass through apertures formed in the guide means. 
     Preferably, more than one first cable may be provided with the same sliding surface such that the said more than one first cable move radially synchronously on the same sliding surface. 
     Preferably, at least part of the second cable which is connected to the first cable is compliant, wherein the said at least part of the second cable is arranged to compensate for different tolerances in the length of travel of the said parts of the first cable. 
    
    
     
       BRIEF DESCRIPTION OF THE INVENTION 
       Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:— 
         FIG. 1  is an exploded perspective view of an apparatus according to the present invention; 
         FIG. 2  is a more detailed view of  FIG. 1  of some of the components which together form a male member of the apparatus shown in  FIG. 1 ; 
         FIG. 3  is a more detailed view of some of the components shown in  FIG. 2 ; 
         FIG. 4A  is a perspective view of a mandrel which forms part of the male member of the apparatus of  FIG. 1 ; 
         FIG. 4B  is another perspective view of the mandrel of  FIG. 4A ; 
         FIG. 4C  is an end view of the mandrel of  FIG. 4A ; 
         FIG. 4D  is a cross-sectional view along section A of the mandrel of  FIG. 4C ; 
         FIG. 4E  is a view along section B of the mandrel of  FIG. 4D ; 
         FIG. 5A  is a cross-sectional view of the apparatus of  FIG. 1  when assembled in an uncoupled configuration; 
         FIG. 5B  is a view on section A of the apparatus of  FIG. 5A ; 
         FIG. 6A  is an end view of an end or back plate of the apparatus of  FIG. 1 ; 
         FIG. 6B  is a view on section A of the end of back plate of  FIG. 6A ; 
         FIG. 7A  is an end view of a guide plate of the apparatus of  FIG. 1 ; 
         FIG. 7B  is a view on section A of the guide plate of  FIG. 7A ; 
         FIG. 8A  is a side view of a cylinder spacer of the apparatus shown in  FIG. 5A ; 
         FIG. 8B  is an end view of the cylinder spacer of  FIG. 8A ; 
         FIG. 9A  is a perspective of a block or slider plate of the apparatus of  FIGS. 1 and 5A ; 
         FIG. 9B  is a cross-sectional view of the slider plate of  FIG. 9A ; 
         FIG. 9C  is a plan view of the slider plate of  FIG. 9A ; 
         FIG. 9D  is an end view of the slider plate of  FIG. 9B ; 
         FIG. 9E  is a view along section C of the slider plate of  FIG. 9B ; 
         FIG. 10A  is a side view of a body member of the apparatus of  FIG. 1 ; 
         FIG. 10B  is a view on section A of the body member of  FIG. 10A ; 
         FIG. 10C  is a view on section B of the body member of  FIG. 10A ; 
         FIG. 10D  is a detailed view on section C of the body member of  FIG. 10A ; 
         FIG. 10E  is a detailed view of a countersunk hole best seen on the body member shown on  FIG. 10B ; 
         FIG. 11A  is a side view of a housing of the apparatus of  FIG. 5A ; 
         FIG. 11B  is a plan view of the housing of  FIG. 11A ; 
         FIG. 11C  is an end view of the housing of  FIG. 11A ; 
         FIG. 11D  is a view on section C of the housing of  FIG. 11   a;    
         FIG. 12A  is a side view of a sliding plate retainer bar shown in  FIG. 5A ; 
         FIG. 12B  is a view on section A of the sliding plate retaining bar of  FIG. 12A ; and 
         FIG. 13  is a perspective view of an alternative embodiment of a slider plate having three connections to that shown in  FIG. 2 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to the drawings there is shown a coupler  30  in accordance with the present invention, comprising a female member or receptacle  31  and a male member  32  which together form a multiway coupler system  31 ,  32 . As will be described, the coupler is suitable for joining a number of connections, cables or fluid conduits such as hoses (hereinafter simply referred to as “cables”), and particularly finds application in hostile environments, such as subsea environments. 
     The male member  32  comprises a body member or casing  9 , a guide plate  36 , an end or back plate  12 , cables  15 , a nose cone  7  and a mandrel  14 . 
     The cables  15  are provided radially around the back plate  12 , and extend axially therefrom, and are coupled to blocks or slider plates  16 . The cables  15  may be in the form of hollow rods  15  and are typically flexible and may be displaced radially. Each rod  15  is preferably provided with a coil  23  at a location along its length which provides flexibility to the rods  15  in the radial direction and thus permits movement or bending of the rods  15  in their radial direction. 
     Individual cables/hoses (not shown) of a host facility/umbilical (not shown) are attached to bulkhead connectors  20  on the rear side of the back plate  12 . Each cable or hydraulic hose for example (not shown) on the male member  32  extends from bulkhead connectors  20  through the back plate  12 , through the cable or rod  15 , then through the slider plates  16  and into a connector half  13  which travels through an aperture  18  in the body member  9 . The connector half  13  is provided at the end of the cable to engage a complementary connector half  6  provided on a cable portion of the female member  31 . The female connector halves  6  are preferably compliant in that they may tolerate small variations in the travel experienced by the male connector halves  13 ; in other words, they  6 ,  13  will still all be able to connect with one another if one pair  6 ,  13  connect before the other respective pairs  6 ,  13  connect, as will be described subsequently. In other words, by providing compliant mountings for the connector halves  6  on the female coupler member  31 , any variations in the travel of the connector halves  13  of the male coupler member  32  (which could be due to manufacturing variations/tolerances) can be accommodated without the actuation mechanism being stopped out by the first pair of connector halves  6 ,  13  to make up fully, before the pairs of remaining connector halves  6 ,  13  have made up fully. 
     The mandrel  14  is coupled at its rear end to a cylinder spacer  45  which in turn is coupled at its rear end to a linear actuation mechanism in the form of a piston (not shown) located within a cylinder  47 , where the piston extends co-axially through an aperture  49  formed in the centre of the back plate  12 . It should however be noted that the cylinder  47  can be replaced by any suitable linear actuation mechanism which can provide movement in both directions along the longitudinal axis of the mandrel  14 . 
     The outer circumference of the mandrel  14  is generally cylindrical and a plurality (eight are shown in  FIG. 4   a ) of tapered channels  33  are formed therein, where the channels  33  comprise a square box shaped upper portion  33 U and a cylindrical groove lower portion  33 L. Preferably, the lower portion  33 L comprises a groove formed with a radius which circumscribes just over half the circumference of a circle such that the lower portion  33 L comprises a part, but over half, circular cross section. 
     The tapered channels  33  of the mandrel  14  are arranged such that the taper runs substantially linearly from a smaller diameter at the outer most or front end  14 F to a greater diameter at an inner most or rear end  14 R. 
     The slider plates  16  comprise a block portion or upper portion  16 U and a slider plate retaining bar or lower portion  16 L. The slider plate retaining bar  16 L comprises a lower most face in the form of a key having a radius which circumscribes just over half the circumference of a circle such that the slider plate retaining bar  16 L comprises a part, but over half, circular cross section. The radius of the slider plate retaining bar  16 L is arranged to be slightly smaller than the radius of the lower portion  33 L of the tapered channel  33  such that the slider plate retaining bar  16 L is a sliding fit in both longitudinal directions within the lower portion  33 L of the tapered channel  33 ; however, as will be appreciated, the slider plate retaining bar  16 L is also trapped within the lower portion  33 L in the radial direction. 
     The slider plate retaining bar  16 L is secured to the upper portion  16 U with any suitable fixing means such as screws. 
     It should however be noted that different connectors  6 ,  13  with different make up travel lengths may be accommodated on the same mandrel  14  by having tapered channels  33  having different radii and/or different slope of taper and/or by having a different height slider plate  16  in order to suit the particular make up travel of the particular connectors  13 ; in other words, the tapered channels  33  and/or the slider plates  16  can be varied to suit a combination of different connectors and their particular size and connector “make up” travel lengths. 
     The guide plate  36  comprises a cylindrical ring with an aperture  87  formed at its centre, the aperture  87  having a diameter which is slightly greater than the outer diameter of the mandrel  14 . A number of radially extending slots  88  are formed from the inner bore partly outwards toward the outer circumference of the guide ring  36 , the number of slots  88  being provided being equal to the number of slider plates  16 . The mandrel  14  is inserted into the aperture  87  of the guide plate  36  and the two are aligned such that the slots  88  are co-axially arranged with the slider plates  16  and cables  15 . The outer diameter of the mandrel  14  is arranged to be a close fit within the aperture  87  of the guide plate  36 . The mandrel  14  is therefore constrained from any movement off the couplers  30  longitudinal axis by the closeness of the fit between the outer diameter of the mandrel  14  and the internal diameter of the aperture  87  of the guide plate  36  and the mandrel  14  is therefore able to react to any unbalanced forces from the connectors  13  during their make up or operation. 
     The slots  88  in the guide plate  36  thereby permit the slider plates  16  to move radially outwardly, as shown in  FIG. 5A , and prevent unwanted rotational movement of the slider plates  16 . The radial slots  88  in the guide plate  36  are aligned rotationally with, but offset axially from, the apertures  18  in the casing  9 . 
     The taper of each tapered channel  33  is designed to match the radial make up travel of the particular connectors  13  mounted in the particular slider plates  16 , with the axial travel or stroke of the mandrel  14 /cylinder  47 . 
     The slider plates  16 , cables  15 , back plate  12 , mandrel  14 , guide plate  36  and cables are inserted as a unit into a first end  34  of the casing  9 , until screw holes  89 F provided around the outer circumference of the guide plate  36  are aligned with screw holes  90 F formed through the side wall of the casing  9  and screw holes  89 R provided around the outer circumference of the back plate  12  are aligned with screw holes  90 R formed through the side wall of the casing  9 . At that point, screws are inserted into the screw holes  90 F,  90 R and are tightened into screw holes  89 F,  89 R in order to fix the guide plate  36  and back plates  12  in position within the casing  9 . The connector halves  13  of each cable are now radially aligned with the apertures  18  in the casing  9 . An outwardly extending peg  8  is provided on the outer face of the casing  9  proximate to its rear end  34 . 
     The nose cone  7  comprises a frusto-conical portion  39  and a cylindrical portion  40 , wherein the rearmost end of the cylindrical portion  40  is attached to the front end  35  of the casing  9 , and the frusto-conical portion  39  aids location of the male member  32  into the female receptacle  31 , as will be described. 
     The female receptacle  31  comprises a tubular portion  1  and a frusto-conically shaped receptacle  2 . Eight cable connectors  6  are equi-spaced around the outer face of the tubular portion  1 . 
     The inner bore of the tube  1  has a diameter large enough to allow entry of the casing  9 . The frusto-conical receptacle  2  is adapted to engage with the nose cone  7  to guide the male member  32  into the inner bore of the female receptacle  31 . A slot  3  extends through the sidewall of a portion of the tubular portion  1  and a portion of the frusto conical receptacle  2  of the female receptacle  31 , and is adapted to permit entry of the peg  8  of the casing  9 , as described below, in order to rotationally and axially align the male member  32  and female receptacle  31 . 
     The male  32  and female  31  members are now ready to be transported to their in use location, such as a subsea environment. 
     The individual cables/hoses (not shown) of the host facility/umbilical (not shown) not attached to the bulkhead connectors  20  are attached to the outermost ends of the connectors  6 . 
     When the male  32  and female  31  members are to be connected, the following steps are taken. 
     In use, the male member  32  is inserted into the female receptacle  31 . The nose cone  7  guides the male member  32  into the female receptacle  31 . The peg  8  on the male member  32  engages with the slot  3  in the female receptacle  31  and so thereby resist rotational movement between the male member  32  and female receptacle  31 . 
     The casing  9  continues into the tube  1  until the peg  8  on the casing  9  abuts against the front end of the slot  3  of the tube  1 . Continued movement of the casing  9  into the tube  1  is thereby resisted. 
     At this point the connectors  13  in the apertures  18  of the casing  9  are axially and rotationally aligned with the connectors  6  in the apertures  5  of the housing  1 . 
     The coupler  30  is now constructed and is in the configuration shown in  FIGS. 5A and 5B  with the connectors  13  rotationally aligned with the connectors  6  but spaced apart therefrom. 
     When it is desired that the connectors  13  be connected to the connectors  6 , the cylinder  47  is actuated. This causes the piston within the cylinder  47  to move outwardly therefrom (right to left in  FIG. 5A ). This therefore causes the mandrel  14  to move away from the cylinder  47  and the mandrel  14  is pushed further into the female receptacle  31  since the mandrel  14  moves independently of the casing  9 . The slider plates  16  lying within the tapered channels  33  on the mandrel  14  contact a wider (greater radius) portion of the tapered mandrel  14  and are pushed radially outwards. The cables  15  are also displaced radially outwards, with the coil  23  allowing movement of the cables  15 . The slider plates  16  in turn push the connectors  13  further outwardly, through respective apertures  18  in the casing  9 , such that the connectors  13  mate with the respective connectors  6  of the female receptacle  31 . 
     The connection between the cables/hoses attached to the connectors  6  and the cables/hoses attached to the connectors  13  is thus formed. The mandrel  14  may be locked in position by continued application of e.g. hydraulic fluid pressure within the cylinder  47 . Internal pressure or other environmental forces which may affect the connection are resisted by the slider plates  16  abutting with the tapered channels  14  thereby enhancing the integrity of the connection between the connectors  6  and  13 . 
     To disengage the connection, the procedure is generally reversed, that is, the mandrel  14  is retracted by reverse operation of the cylinder  47 . The slider plates  16  can then rest on a thinner (smaller diameter) portion of the tapered channels  14 , and the keying action between the lower portion  33 L and the slider plate retaining bar  16 L forces the return of the slider plates  16 . The connection is broken by the connectors  13  retracting back into the casing  9 . If required, the male member  32  is then free to be retracted back out of the female receptacle  31 . 
     An alternative embodiment of coupler  30 A is shown in  FIG. 13  where three connectors  13 A,  13 B,  13 C are provided on the one slider plate  16 A, for connection with three axially aligned but similarly spaced apart connectors (not shown) provided on the female member  31 . The three connectors  13 A,  13 B,  13 C will typically be provided with separate cables  15  containing the fluid or, for example, electrical signals. The cables  15  can connect into the rear most end of the slider plates  16  as in the first embodiment described above and can be routed through to the individual connectors  13 A,  13 B,  13 C. Alternatively, the front most connector  13 A can be provided with a separate pipe or cable  15 A which projects out of the side of the slider plate  16  and which passes through an aperture  95  formed in the guide plate  36 A. 
     The coupler  30  may be used to connect cables conveying any type of signals or power whatsoever including but not limited to pneumatic, electrical, hydraulic or optical signals or power. 
     It will be understood that although the embodiment described herein relates to a coupler connecting eight cables, the scope of the invention is not limited to such a coupler, as any number of cables may be connected with a coupler according to the present invention with simple modifications being made to the embodiment hereinbefore described. Furthermore, although the drawings show a generally cylindrically shaped coupler with a connector actuation mechanism aligned to it&#39;s central axis, the coupler could be another shape such as having a square or rectangular box cross sectional profile with the actuation mechanism (for example the mandrel  14 , slider plates  16  and guide plate assembly  36 ) being either aligned to or offset from the central longitudinal axis. 
     Improvements and modifications may be made to the hereinbefore embodiments without departing from the scope of the invention. For example, the slider plate retaining bar  16 L and lower portion  33 L of the tapered channels need not necessarily be part circular, but could be any matching shape which provides a force to move the slider plates  16  both radially inwardly and radially outwardly. Also, the multiway coupler system  31 ,  32  is not size dependant and can be utilised for any size of connectors, varying from very small to very large. Furthermore, one or more pairs of connectors  6 ,  13  mounted on the slider plates  16  and the female coupler body  1  can be modified to form a mechanical locking connection (as well as or instead of a connective connection) in order to lock the male  32  and female  31  coupler bodies together. Indeed, such a pair of modified connectors, as well as providing a mechanical locking mechanism, would aid the final fine alignment of the male  32  and female  31  coupler bodies.