Hot pluggable electrical device assembly

A camera includes a base configured for mounting to a support structure. The base includes a first connecting structure. A camera unit is configured for releaseable attachment with the base. The camera unit comprising second connecting structure configured for releasable connection with the first connecting structure to releaseably secure the camera unit to the base.

FIELD

The present disclosure generally relates to an electrical device assembly such as a pan/tilt/zoom (PTZ) camera, and more particularly to PTZ camera for use in harsh or hazardous environments.

BACKGROUND

Conventional PTZ cameras may be used in hazardous environments such as the marine and oil and gas industry, and can be designed to perform safely and reliably under these often extreme corrosive and physically demanding environments. Typically, these PTZ cameras are large and heavy and require cranes and qualified engineers for installation on site. For example, PTZ cameras of this type are often housed in large steel housings/enclosures. A qualified team will also be needed if the cameras require servicing or replacing. These PTZ cameras are also configured as single unitary housing assemblies such that when it becomes necessary to service or replace the camera, the entire camera must be removed from the work site. This process can be expensive and time consuming.

SUMMARY

In one aspect, a camera generally comprises a base configured for mounting to a support structure. The base includes a first connecting structure. A camera unit is configured for releaseable attachment with the base. The camera unit comprising second connecting structure configured for releasable connection with the first connecting structure to releaseably secure the camera unit to the base.

In another aspect, an electrical device generally comprises an electrical device body housing electronics for operating the electrical device. A connector is coupled to the electrical device body. The connector includes a hot pluggable electrical connector configured for making an electrical connection with a base to electrically connect the electrical device to the base when the base is energized.

In yet another aspect, a method of installing a camera in a hazardous environment generally comprises mounting a base of the camera to a mounting structure. Attaching a camera unit of the camera to the base after the base has been mounted to the mounting structure. The camera unit includes camera electronics for operating the camera unit.

In still another aspect, a base for use with an electrical device generally comprises a mount assembly configured for attaching the base to a support surface. The mount assembly provides structure on the base for attaching the electrical device to the base. A hot pluggable electrical connector is coupled to the mount assembly and configured for making an electrical connection with the electrical device to electrically connect the base to the electrical device when the base is energized.

DETAILED DESCRIPTION

Referring toFIGS.1and2, a pan/tilt/zoom (PTZ) camera (broadly, an electrical device assembly) of the present disclosure is generally indicated at10. The camera may comprise a base12configured to mount to a mounting structure (e.g., wall or other fixed structure) to secure the PTZ camera to the mounting structure, and a camera unit14(broadly, an electrical device) removeably attachable to the base to connect the camera unit to the base and configure the PTZ camera for use. In one embodiment, the camera unit14is removeably attachable to the base12without the use of any tools or separate connectors such that the camera unit can be easily attached and detached from the base. In another embodiment, a tool15(FIG.8B) may be used to secure the camera unit14to the base12. This facilitates removal and replacement of the camera unit14from the base12without having to detach or disconnect the base from the mounting structure and/or a power/communication source. Therefore, changing/replacing the camera unit14can be accomplished without the need for a qualified engineer or technician. As a result, different camera units14can be used based on the desired functionality and easily interchanged by an individual at the work site. In the illustrated embodiment, the camera10is PTZ camera. However, the camera10could have other configurations without departing from the scope of the disclosure. For example, the camera10could be a fixed camera, a camera lacking one or more of the pan, tilt, and zoom features, and/or a camera having other features not described in the current disclosure. Additionally, the base12can be used with electrical devices other than a camera.

Referring toFIGS.3and4, the base12comprises a mounting plate16and a camera mount (broadly, a mount)18projecting laterally from the mounting plate. The mounting plate16and camera mount18may be broadly considered a mounting assembly. The camera mount18is shown as being formed integrally with the mounting plate16. However, the camera mount18could be formed separately from the mounting plate16and suitably attached to the mounting plate. In the illustrated embodiment, the mounting plate16has a generally rectangular shape and defines fastener holes20for receiving fasteners (not shown) to attach the mounting plate to the mounting structure. It will be understood that the mounting plate16could have other shapes and configurations without departing from the scope of the disclosure. The camera mount18provides the structure on the base12for attaching the camera unit14to the base. The camera mount18comprises a generally cylindrical structure. However, the camera mount18could have other shapes and configurations without departing from the scope of the disclosure. An exterior surface of the camera mount18has connecting structure22configured to engage with corresponding connecting structure24(FIG.7) on the camera unit14to releaseably lock the camera unit to the base12. In the illustrated embodiment, the connecting structure22comprises a plurality of slots26extending along the outer surface of the camera mount18. Each slot26comprises a first, axially extending section28extending from a rim30of the camera mount18toward the mounting plate16. A second, circumferentially extending section32extends from an end of the first section28partially around a circumference of the camera mount18. The second section32extends slightly toward the mounting plate16as the second section extends around the camera mount18. In the illustrated embodiment, there are two slots26in the outer surface of the camera mount18. The first sections28of the slots26are disposed on diametrically opposite sides of the camera mount18. It will be understood that one or more than two slots could be used without departing from the scope of the disclosure. A ledge34extends circumferentially around the outer surface of the camera mount18. In the illustrated embodiment, the ledge34extends continuously around an entire circumference of the camera mount18. As indicated above, and explained in greater detail below, the connecting structure22, including the slots26, is engageable with the connecting structure24on the camera unit14to releaseably lock the camera unit to the base12. It will be understood that the connecting structure22on the base12could have over configurations without departing from the scope of the disclosure. For instance, threads could extend around the outer surface of the camera mount18for mating with threads on the camera unit14. Still other connecting structure configurations are envisioned.

The base12may be formed from any suitable material. In one embodiment, at least the camera mount18is formed from a polymer material. In another embodiment, an entirety of the base12is made from a polymer material. Forming some or all of the base12from a polymer material substantially reduces the weight of the base as compared to conventional PTZ cameras that are made from stainless steel. In one embodiment, the base12weights less than 2 kg. Additionally, the lighter base12facilitates easy installation of the base to a mounting structure as a single person can install the base. Further, the person need not have any specific camera installation expertise as the camera unit14is not part of the initial installation of the camera10. That is, the wiring of the camera unit14is not connected to the base when the base12is mounted to the mounting structure. It will be understood, however, that some or all of the base12could be made from another material. For instance, the base12could be formed from stainless steel.

Referring toFIGS.4-6, the camera mount18also houses internal electrical components36of the base12for electrically connecting the base to the camera unit14. Wiring extends from the electrical components36for caring the electrical signals to and from the electrical components. A first set of wiring38extends from the electrical components36through a port40in the camera mount18to an exterior of the camera mount. A cable42encloses the first set of wiring38at an exterior of the base12. The cable42is extendable to a power source (not shown) for providing power to the camera10. A second set of wiring44extends from the electrical components36to a plurality of connector assemblies46(broadly, electrical connectors). Each connector assembly46is configured to make an electrical connection with a connector assembly47(broadly, electrical connector) in the camera unit14. In the illustrated embodiment, the connector assemblies46,47comprise hot pluggable connectors such that the camera unit14can be connected to the base12and electrically connected to the electrical components36in the base without having to disconnect the base from the power source. This is particularly advantageous when the camera10is used in hazardous environments because the camera unit14can be connected and disconnected without having to have a gas clearance indicating that the environment is not explosive. Thus, the connection and disconnection of the camera unit14can be performed within a hazardous/explosive environment. Broadly, the base12, or least the camera mount18of the base, may be considered a junction box of the camera10such that it includes the electrical components36and wiring38,44for delivering power and functionality to the camera unit14. In one embodiment, a cap (not shown) may be disposed over the camera mount18when the camera unit14is not attached to the camera mount to configure the base as an exe structure or provide IP ingress protection.

Referring toFIGS.5and6, each connector assembly46comprises a first, lower housing48and a second, upper housing50attached to the first housing. A tubular connector element52is at least partially received in the first housing48. The tubular connector element52may be broadly considered an electrical contact. The first housing48comprises an annular member54extending around the tubular connector element52. The tubular connector element52includes a wire connector portion53extending below the annular member54. The annular member54includes a plurality of fingers56spaced circumferentially around the annular member. Each finger56includes an axially extending portion and a catch portion projecting radially inward from the axially extending portion. The catch portion is configured to latch on to the second housing50to secure the first housing48to the second housing as will be explained in greater detail below. The second housing50comprises a cylindrical bottom section62, a conical top section64, and an annular middle section66between the top and bottom sections. A recess or cutout68in the bottom and annular sections62,66forms a shoulder70in the bottom section. In the illustrated embodiment, each connector assembly46is an Exde connector. However, the connector assemblies46could have other configurations without departing from the scope of the disclosure.

Prior to attaching the first housings48to the second housings50, the tubular connector elements52are placed in registration within respective openings72in a connector plate74. The second housings50are also placed in registration with one of the openings72in the connector plate74. To attach the first housing48to the second housing50, the cylindrical bottom section62of the second housing is inserted through one of the openings72in the connector plate74. The tubular connector element52of the first housing48is then inserted into a bottom of the cylindrical bottom section62of the second housing50. The catch portions on the fingers56snap over the shoulders70on the second housing50forming a plurality of latches for securing the first housing48to the second housing. With the first and second housing48,50connected together, the annular middle section66of the second housing seats on a top surface of the connector plate74.

Referring toFIGS.1,2, and7-8B, the camera unit14comprises a camera body80housing the internal camera components of the camera unit, a stem82attached to the camera body at a first end of the stem and extending laterally from the camera body to a second end of the stem, and a connector84attached to the second end of the stem. The connector84comprises a sleeve85attached to the stem82and a collar87secured around the sleeve. In the illustrated embodiment, the sleeve85and collar87comprise generally annular members. However, the sleeve85and collar87could have other configurations without departing from the scope of the disclosure. The connector84is configured to connect to the camera mount18on the base12to releaseably connect the camera unit14to the base. In particular, an interior surface86of the collar87has the connecting structure24configured to engage with the connecting structure22(FIG.3) on the camera mount18of the base12to releaseably lock the camera unit to the base. In the illustrated embodiment, the connecting structure24comprises a plurality of flanges88extending radially inward from the interior surface86of the collar87. Each flange88is configured to be received in a slot26in the camera mount18to secure the connector84to the camera mount. Thus, the number of flanges88corresponds to the number of slots26in the camera mount18. In one embodiment, the flanges88and slots26provide a bayonet style connection between the camera unit14and base12.

Referring toFIG.7-8B, a plurality of ridges90extend from an exterior surface92of the collar87. The ridges90provide a grip surface for grasping the connector84to rotate the collar87around the camera mount18. The collar87may be rotated by hand or with a tool15(FIG.8B). It will be understood that the collar87rotates independently of the sleeve85such that the sleeve remains fixed relative to the stem82. In one embodiment, each flange88has a corresponding ridge90aligned therewith to provide an indication to the user of the location of the flange on the interior surface86of the collar87. This facilitates inserting the flanges88into the slots26in the camera mount18when the flanges are not visible by the user on the interior surface86of the collar87. In one embodiment, the ridges90that are aligned with a flange88are indicated with an indicia94. In the illustrated embodiment, the indicia94comprises a color coding on the ridge90. However, other forms of indicia are envisioned without departing from the scope of the disclosure. In one embodiment, at least the connector84is formed from a polymer material. In another embodiment, an entirety of the camera unit outer housing is made from a polymer material. Forming some or all the camera unit outer housing from a polymer material substantially reduces the weight of the camera unit14as compared to conventional PTZ cameras that are made from stainless steel. In one embodiment, the camera unit14weights less than 20 kg. It will be understood, however, that some or all of the camera unit14could be made from another material. For instance, the camera unit14could be formed from stainless steel.

Referring toFIGS.9-12, a plurality of connector assemblies47are mounted in the connector84by a mounting plate96. Each connector assembly47comprises a connector housing98and a contact pin100extending through the connector housing (FIG.10). The connector housings98include a hollow conical body102, a cylindrical top portion104extending from a top of the hollow conical body, and an annular rim portion106extending around a bottom of the hollow conical body. The contact pins100are secured to a printed circuit board (PCB)108seated on top of the cylindrical top portions104of the connector housings98. The contact pins100extend downward from the PCB through the hollow conical body102and past the annular rim portion106such that a portion of the contact pin is exposed below the connector housing98. The exposed portions of the contact pins100are configured to make electrical contact with respective tubular connector elements52of the connector assemblies46in the base12to electrically connect the camera unit14to the base. In the illustrated embodiment, each connector assembly47is an Exde connector. However, the connector assemblies47could have other configurations without departing from the scope of the disclosure.

As shown inFIG.2, the camera unit14is moved axially or longitudinally with respect to the axes of the connector84and camera mount18to locate the flanges88on the connector in registration with the slots26in the camera mount. The connector84may be centered on the camera mount18by locating a post110on the mounting plate74in the camera mount within a receptacle112in the mounting plate96in the connector (FIG.9). The camera unit14is then moved relative to the base12such that the flanges88are received in the first section28of the slots26. The collar87of the connector84is then rotated (e.g., clockwise) relative to the camera mount18to move the flanges88into the second sections32of the slots26. The collar87can be rotated until the flanges88reach an end of the second sections32of the slots26preventing further rotation. Completing this full rotation of the collar87releaseably locks the camera unit14to the base12via the engagement between the connector on the camera unit and the camera mount18of the base. Additionally or alternatively, a locking mechanism (e.g., a grub screw) can be used to prevent the collar87from being rotated in the opposite direction to detach the connector84from the camera mount18. Completing the full rotation of the collar87also electrically connects the camera unit14to the base12by engaging the connector assemblies47in the camera unit with the connector assemblies46in the base. In particular, the conical top sections64of the second housings50in the camera mount18are received in the hollow conical bodies102of the connector housings98in the connector84, and contact pins100of the connector assemblies47in the connector are received in the tubular connector elements52of the connector assemblies46in the camera mount. As such, the connector assemblies47in the camera unit14are configured to mate with the connector assemblies46in the base12to provide the necessary electrical connection for operating the camera unit14. Additionally, because the connector assemblies46,47are hot pluggable connectors, the camera unit14can be connected to the base12in this manner when the base is mounted and actively connected to a power source and energized. The hot-pluggable configuration of the connector assemblies46,47is such that the only time the contacts pins100are in electrical connection with the tubular connector elements52are when the pins and elements are contained within the exde chamber formed by the connector assemblies46,47. Thus, any spark resulting from the connection is contained within the exde chamber. When it becomes desirable to detach the camera unit14from the base12, the collar87of the connector84is rotated in an opposite direction (e.g., counter-clockwise) to move the flanges88from the second sections32of the slots26into the first sections28. Once in this position, the camera unit14can be moved axially away from the camera mount18to fully detach the camera unit from the base12. Rotating the collar87to detach the camera unit14from the base12also electrically disconnects the connector assemblies46,47so that the camera unit can be safely separated from the base.

Additionally, the camera10is configured to operate when the camera is located within a harsh or hazardous environment. In particular, the housing components (e.g., camera body80, stem82, connector84, base12) are specifically configured to withstand harsh or hazardous environments and insulate the internal spaces from those environments. As such, the camera10is explosion-proof such that the outer housing of the camera will contain any ignition preventing the explosive combustion from reaching an exterior of the camera to interact with the outside environment. For example, the camera10meets ATEX/IECEx Standards—EN 60079 regarding explosive atmospheres.

Examples of hazardous locations in which example embodiments can be used include, but are not limited to, an airplane hangar, an airplane, a drilling rig (as for oil, gas, or water), a production rig (as for oil or gas), a refinery, a chemical plant, a power plant, a mining operation, a steel mill, and the like.

In one embodiment, the camera10may be connected to a network to configure the camera to provide real-time analysis of the viewing space of the camera. The camera10may also be connected to a CCTV system or a cloud based data acquisition and analysis system to link the camera10to other connected systems for communicating information externally of the camera. The camera10when connected to a networked CCTV system, or the like, may also provide additional Advanced Data Analytics providing more comprehensive data about the camera viewing space.

Having described the disclosure in detail, it will be apparent that modifications and variations are possible without departing from the scope of the disclosure defined in the appended claims.

In view of the above, it will be seen that the several objects of the disclosure are achieved and other advantageous results attained.

As various changes could be made in the compositions without departing from the scope of the disclosure, it is intended that all matter contained in the above description shall be interpreted as illustrative and not in a limiting sense.