Abstract:
An electrical probe assembly includes a first probe housing pivotally connected to a base structure and receiving a first probe therein. The first probe is configured to interface with a first contact of an electrical component. A second probe housing is pivotally connected to the base structure and receives a second probe therein. The second probe is configured to interface with a second contact of the electrical component wherein the first and second contacts have a spatial relationship therebetween. An adjustment mechanism is connected to the first and second housing and configured to independently adjust an amount of rotation of the each of the housings to accommodate the spatial relationship.

Description:
RELATED APPLICATION INFORMATION 
     This application claims priority to provisional application Ser. No. 61/029,626 filed on Feb. 19, 2008, incorporated herein by reference. 
    
    
     BACKGROUND 
     1. Technical Field 
     This disclosure relates to electrical test fixtures, and more particularly, to a device and method for adjustable configuring test probes to perform testing on different electrical component configurations. 
     2. Description of the Related Art 
     In circuit breakers, a location of a lug and neutral strap may vary between different designs. In production, the different designs may need to employ the same test equipment, but the differences in the designs preclude such use. In conventional systems, functional production fixtures use electrical probes that are fixed in a housing and are not adjustable. To accommodate different components to be tested, the probes are manually bent by technicians to attempt to properly interface this connection with the component to be tested. Typically, the probes are bent by the use of a hammer or pliers. Due to these bending methods of the probes, the accuracy can vary greatly between testers and components to be tested. For example, a breaker may be non-conforming in one tester while passing in a different tester. This may be due to the location of the bent probes and the quality of the connection. 
     Further, the probes and the test fixtures are subject to damage due to the bending methods. Tooling of the probe is an additional disadvantage to the existing design since the probes usually are fabricated to prevent rotation of the probes during operation. For example, the electrical probes are hexagonal in shape and require special tooling to produce them. This type of design is employed so that the electrical probes do not rotate. 
     Electrical probes are usually supported in a single block configuration that cannot be adjusted in any manner. This requires that the location of the probes be exactly in position so that they interface with the line lug and neutral strap of a circuit breaker, for example. In some cases, the lugs may touch the plastic housing of the circuit breaker missing their target rather than making an electrical contact with the lug. The probe alignment becomes an issue in manufacturing during functional testing since circuit breaker designs may be different. Without proper electrical contact, the breakers could fail testing due to a lack of electrical continuity. Any design changes in the lug area of the breaker could require adjustments in the functional tester itself. 
     Typically, manufacturing will manually adjust the probes to meet the new design. However, this manual bending is not controlled to any specification, and the amount of bending varies from tester to tester and operator to operator. 
     SUMMARY OF THE INVENTION 
     An electrical probe assembly includes a first probe housing pivotally connected to a base structure and receiving a first probe therein. The first probe is configured to interface with a first contact of an electrical component. A second probe housing is pivotally connected to the base structure and receives a second probe therein. The second probe is configured to interface with a second contact of the electrical component wherein the first and second contacts have a spatial relationship therebetween. An adjustment mechanism is connected to the first and second housing and configured to independently adjust an amount of rotation of the each of the housings to accommodate the spatial relationship. 
     An electrical probe assembly for interfacing with a plurality of different circuit breaker designs includes a plurality of probe housings each having a corresponding test probe protruding therefrom. A pivot pin is configured to pass through the plurality of housings to pivotally connect the housings to a base structure such that the plurality of housings independently rotate about a same axis. An adjustment mechanism is connected to the plurality of housings and configured to independently adjust an amount of rotation of the each of the housings to accommodate different spatial relationships for contacts of different circuit breaker designs. 
     A method for testing a circuit breaker includes providing an electrical probe assembly having a first probe housing pivotally connected to a base structure and receiving a first probe therein, the first probe being configured to interface with a first contact of a circuit breaker, a second probe housing pivotally connected to the base structure and receiving a second probe therein, the second probe being configured to interface with a second contact of the circuit breaker wherein the first and second contacts have a spatial relationship therebetween, and an adjustment mechanism connected to the first and second housing; adjusting the adjustment mechanism to independently adjust an amount of rotation of each of the housings to accommodate the spatial relationship of contacts for a circuit breaker design; and testing the circuit breaker. 
     These and other objects, features and advantages of the present invention will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       This disclosure will present in detail the following description of preferred embodiments with reference to the following figures wherein: 
         FIG. 1  is a perspective view of a probe assembly employed in testing electrical components in accordance with one illustrative embodiment; 
         FIG. 2  is a partial cross-sectional view of the assembly of  FIG. 1  showing an illustrative adjustment mechanism in accordance with one illustrative embodiment; 
         FIG. 3  is a partial cross-sectional view of the assembly of  FIG. 1  showing a pivot pin arrangement in accordance with one illustrative embodiment; 
         FIG. 4  is a front view showing an anti-rotation key for preventing rotation of test probes in accordance with one illustrative embodiment; 
         FIG. 5  is a perspective view of a probe assembly employed in testing electrical components showing a three probe arrangement for testing a circuit breaker in accordance with one illustrative embodiment. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The present invention provides adjustable electrical probes for functional testers that interface with a circuit breaker. The present principles may be used to retrofit existing functional testers in manufacturing facilities or may be part of the design of new functional testers. In one illustrative example, the probes may be employed in conjunction with any of a plurality of commercially available functional testers, e.g., for manufacture testing circuit breakers. The tester provides an electrical connection interface between a circuit breaker to be tested and the tester itself This interface may benefit from the present principles, which would then be employed to test the circuit breaker in manufacturing to ensure the end product meets test standards. 
     An improved electrical probe is provided to interface with the breaker. This probe provides the ability to make adjustments to a probe location to ensure electrical connection can be made even if a breaker design has changed. For example, a lug position or neutral strap position may have been related in a breaker design. In one embodiment, the probe employs industry standard bar stock as a core material to ensure easy replacement of the probe connections. To address the anti-rotation needed for the electrical probes, a key located in the probe housing may be employed, among other things. 
     The present embodiments will be described in terms of a probe assembly for a circuit breaker tester; however, the present principles are not limited to the illustrative example is and may be employed with other electrical component testers or even other devices where adjustments are needed to properly interface two components. All statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure). Thus, for example, it will be appreciated by those skilled in the art that the block diagrams presented herein represent conceptual views of illustrative system components and/or circuitry embodying the principles of the invention. 
     Referring now in specific detail to the drawings in which like reference numerals identify similar or identical elements throughout the several views, and initially to  FIG. 1 , an adjustable probe assembly  10  is shown in accordance with one illustrative embodiment. Assembly  10  provides a probe interface  12  configured to generally interface with a single pole circuit breaker (not shown) in accordance with one embodiment. The interface  12  includes probe housings  14  and  16 . Each probe housing  14  and  16  respectively includes an electrical probe  18  and  20 . As illustratively depicted, the probe  18  corresponds to a lug probe and the probe  20  corresponds to a neutral probe. 
     Each electrical probe  18  and  20  is mounted within its respective probe housing  14  and  16 , which are independently positionable relative to each other. A pivot pin  22  or other pivoting mechanism permits pivotal motion of each of housings  14  and  16  relative to a base structure such as support blocks  24  or other structures. Support block(s)  24  is mountable on or connectable to a tester  26 . In the example, the tester  26  includes a plate  28  mounted thereon. The interface between the tester  26  and the plate  28  may include bolts or other hardware (not shown) to secure the support block to the plate  28 , which in turn, is supported by the tester  26 . The plate  28  provides electrical lines to be routed from the tester  26  to the probe housings  14  and  16  to permit electrical testing using the probes  18  and  20 . 
     Support block  24  includes a portion  30  that partially encloses the probe housings  14  and  16 . Portion  30  provides a support area configured with manual or automatic adjustment controls for rotating the probes housing  14  and  16  thereby changing the angle of probes  18  and  20  to provide a desired adjustment. An adjustment mechanism  32  is illustratively depicted as an adjustment screw for each housing  14  and  16 ; however, the adjustment mechanism  32  may include any number of mechanisms such as, e.g., a servo, a thumb or power screw, a cammed adjustment member, a pneumatic cylinder, a hydraulic cylinder or any other suitable device. 
     Referring to  FIG. 2 , a cut away view of the portion  30  of support block  24  and plate  28  shows the housing  16  of the neutral probe  20  for illustration purposes. The housing  14  for the lug probe  18  includes a similar structure. The portion  30  of the support block  24  supports the adjustment mechanism  32 , in this case, an adjustment screw  34 . The adjustment screw  34  may be advanced or withdrawn from the position  30  in accordance with its threads. A jam nut  36  may be employed to secure the position of the screw  34  once the appropriate position is achieved. In this case, a biasing member  35  is employed at a position opposite the adjustment screw  34  to provide a restoring force to the housing  16 . The biasing member  35  may include a compression spring, Belleville washers, a pneumatic chamber, etc. It should be noted that depending on the adjustment mechanism selected the biasing member  35  is optional. For example, if the adjustment screw  34  is attached with a bearing-like connection to the housing  16 , the screw  32  may be employed as both an advancing and withdrawing adjustment member. 
     The housing  16  (and housing  14 ) has a pivot hole  38  formed therethrough to receive a pivot pin  22 . In this way, a pivot action in the direction of arrow “A” is provided to adjust the housings  14  and  16  and thereby adjust the positions of probes  18  and  20 . 
     Advantageously, both probe housings  14  and  16  can rotate freely about a single axis (pivot pin  22 ). The pivot pin  22  is supported in a lower portion of the support block  24  and held in a top portion of the support block  24  by a retaining clip  44  (see  FIG. 3 ). Both probe housings  14  and  16  may have a recessed area  39  on the back side to capture one end of a compression spring  35 . An opposite end of the spring  35  would rest on the existing mounting plate  28  (or support block  24  depending on the design) and provide a force that would bias the probe housings  14  and  16 . If the spring  35  needs to be captured, then a locating pin  37  may be provided for the spring  35 . 
     Referring to  FIG. 3 , an illustrative arrangement of the pivot pin  22  is shown. Support block  24  includes a pivot hole  40  therein which receives the pivot pin  22  therein. The pivot pin  22  passes through both housings  14  and  16  and is seated in a recess  42  on a lower portion of the support block  24 . A retaining clip or cotter pin  44  may be employed to prevent removal of the pin  22  and/or to improve operation of the pivot formed by the pin  22 . In an alternate embodiment, the pin  22  may be captured between the upper and lower support blocks  24 , and the cotter pin  44  may be eliminated. Other configurations are also contemplated. 
     Referring to  FIG. 4 , a front view of one of the housings  14  (or  16 ) is illustratively shown. The housing  14  may include a key  46 . The probe  18  (or  20 ) includes a corresponding keyway  48  formed therein. In this way, rotational motion of the probe  18  is eliminated. By employing standard bar stock or wire, the probe  18  or  20  can easily be replaced. While a flat or keyway  48  may be formed in the probe  18  or  20 , a set screw or similar mechanism may also be employed to prevent rotation. As the electrical probes  18  or  20  are inserted into the probe housing  14  or  16 , the probe  18  or  20  interfaces with the key  48  and prevents rotation of the probes. 
     Referring to  FIG. 5 , a three housing block probe assembly  100  is illustratively depicted with a two pole circuit breaker  102  for testing. In this embodiment, three probes  104  are provided on three separate housings  106 . Each housing  106  is independently adjustable about a pivot  122  relative to each other and a support block(s)  124 . Adjustments are made using three independent adjustment screws  132 . The probes  104  are configured to test a two pole circuit breaker  102  by interfacing with contacts  145 . Other embodiments may include a greater number of probes  104  and housings  106  as needed. 
     It is contemplated that the adjustment mechanism ( 32  or  132 ) may be made much more complex and may be automatically adjusted using pneumatics or servos. A technician may be able to program the tester to remember (in memory a particular setting for testing a particular circuit breaker. A code may be entered or a button may be pressed to automatically adjust the probes for that particular circuit breaker. Manual or local adjustments may also be made as well. Further, one embodiment may permit independent adjustment for x, y and z translational displacements of one or more of housing  106  (or  14  and  16 ). 
     Having described preferred embodiments for adjustable electrical probes for circuit breaker tester (which are intended to be illustrative and not limiting), it is noted that modifications and variations can be made by persons skilled in the art in light of the above teachings. It is therefore to be understood that changes may be made in the particular embodiments of the invention disclosed which are within the scope and spirit of the invention as outlined by the appended claims. Having thus described the invention with the details and particularity required by the patent laws, what is claimed and desired protected by Letters Patent is set forth in the appended claims.