Abstract:
A tool for reconfiguring the pins of an SAE J560 electrical connector includes a handle and head. A plurality of openings provided in the free end of the head lead to a plurality of parallel equal diameter channels within the head. An elongate separator pin with a conical nose and a cylindrical body is concentrically fixed within each channel. The separator pins are configured to properly separate split electrode pins of an SAE J560 electrical connector, which inevitable deform through repeated coupling and decoupling.

Description:
FIELD OF THE INVENTION 
     This invention relates generally to vehicular electrical connectors, and, more particularly, to a tool for reconfiguring the pins of an SAE J560 electrical connector used to electrically couple a tractor to a trailer. 
     BACKGROUND 
     A standard seven-pin (six circuits and one ground) SAE J560 electrical connector is commonly used to transmit electrical signals between a tractor and a trailer. One component comprises a receptacle containing seven pins. SAE J560 refers to a published standard by the Society of Automotive Engineers, “Primary and Auxiliary Seven Conductor Electrical Connector for Truck-Trailer Jumper Cable” SAE J560 (2009). The pins of such a connector are typically split pins. The mating component is a plug with seven sockets configured to receive the seven pins. The receptacle is typically provided on a trailer, while the plug is typically connected to a self-coiling cable attached to the rear of the tractor. 
     The electrical signals include lighting and ABS braking signals. Failure of the connector could result in a catastrophic vehicular accident. 
     The plug and receptacle are frequently mated and separated. This cycle repeats each time a trailer is separated from and hitched to a tractor. This repetitive cycle can be hostile to the integrity and alignment of the pins. The split pins are particularly vulnerable to deformation such as spreading, compression and other bending. As a consequence, the deformed pins may not make sound contact with the socket terminals unless the pins are straightened, and the split terminals are spread apart to the diameter of the socket and the pins are aligned with the sockets. 
     Unfortunately, straightening, spreading and re-aligning pins can be extremely tedious. Typically, a driver will urge each pin to a desired position using a screw driver. The process is imprecise and time consuming. Frequently, pins are accidently broken in the process. When a pin is broken, the receptacle must be removed and replaced, at great delay and expense. A need exists for a tool to quickly and reliably reconfigure the split pins of a SAE J560 electrical connector. 
     The invention is directed to overcoming one or more of the problems and solving one or more of the needs as set forth above. 
     SUMMARY OF THE INVENTION 
     To solve one or more of the problems set forth above, in a exemplary implementation of the invention, a tool. A tool for reconfiguring the pins of an electrical connector used to electrically couple a tractor to a trailer includes a handle having a proximal end and distal end. A head is attached to the distal end of the handle. The head has a free end and an attached end. The attached end is opposite the free end and attached to the distal end of the handle. A plurality of openings are provided in the free end of the head. The plurality of openings lead to a plurality of parallel channels within the head. Each opening leads to one channel. Six of the seven channels are equal in diameter and length to each other channel. The top (12 o&#39;clock) channel is deeper and larger diameter than the others to accommodate a larger split pin electrode that protrudes further. An elongate separator pin is fixed within each channel. The separator pin is concentric with the channel and has a conical nose attached to a cylindrical body. Each elongate separator pin includes a collar at a distal end of the body and a tail at a distal end of the collar. The collar is fastened to the head. The electrical connector is an SAE J560 electrical connector. Each opening in the free end of the head may have a larger diameter than a diameter of the channel to which the opening leads. The edges of each opening may be filleted, chamfered or beveled. A hand grip may be provided on the handle. The handle and head may be comprised of plastic and the elongate separator pins may be comprised of metal. 
     The head may have an outer periphery between the free end and the attached end, and a key tab on the outer periphery. The key tab is sized and positioned to mate with a key slot in a receptacle of the electrical connector. The plurality of openings includes seven openings in the free end of the head. 
     The tool may include a thumb guard attached to the handle. The thumb guard defines a curved cove against which a thumb may rest. The thumb guard has a height (e.g., ⅜ to 1 inch) greater than the width of a thumb. The thumb guard protects the thumb from a cover for a receptacle of the electrical connector. If the head is keyed, then the key tab and thumb guard may be aligned. 
     Each elongate separator pin is about 20 to 40 mm in length and has a maximum diameter of about 1.5 to 3 mm. Each channel has a depth of about 15 to 30 mm and a diameter of approximately 6 to 10 mm. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing and other aspects, objects, features and advantages of the invention will become better understood with reference to the following description, appended claims, and accompanying drawings, where: 
         FIG. 1  is a top perspective view of an exemplary tool according to principles of the invention; and 
         FIG. 2  is a front view of an exemplary tool according to principles of the invention; and 
         FIG. 3  is aside view of an exemplary tool according to principles of the invention; and 
         FIG. 4  is a side section view of an exemplary tool according to principles of the invention; and 
         FIG. 5  is a side view of an exemplary spreading pin for a tool according to principles of the invention; and 
         FIG. 6  is a top perspective view of an exemplary spreading pin for a tool according to principles of the invention; and 
         FIG. 7  is a front perspective view of an exemplary seven-pin receptacle with a hinged cover according to principles of the invention; 
         FIG. 8  is a schematic conceptually illustrating use of an exemplary tool according to principles of the invention with a seven-pin receptacle; and 
         FIG. 9  is another schematic conceptually illustrating use of an exemplary tool according to principles of the invention with a seven-pin receptacle; and 
         FIG. 10  is a side view of an exemplary un-deformed split electrode pin for a receptacle according to principles of the invention; 
         FIG. 11  is a side view of an exemplary deformed split electrode pin for a receptacle according to principles of the invention. 
     
    
    
     Those skilled in the art will appreciate that the figures are not intended to be drawn to any particular scale; nor are the figures intended to illustrate every embodiment of the invention. The invention is not limited to the exemplary embodiments depicted in the figures or the shapes of pins, handle configuration, shapes, relative sizes, ornamental aspects or proportions shown in the figures. 
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , an exemplary tool  100  for reconfiguring the pins of an SAE J560 electrical connector used to electrically couple a tractor to a trailer according to principles of the invention is shown. The tool  100  includes a handle  105 , a head  110  attached to the end of the handle  105 , a key  125  for engaging the keyed slot opening of a corresponding receptacle, such as the receptacles shown in  FIGS. 7 through 9 , a thumb guard  120  and a grip  115 . 
     The thumb guard  120  is a raised curved shield configured to receive a thumb. The height of the thumb guard  120  is equal to or greater than the thickness of a typical thumb. A height of ⅜-inch to 1-inch may be used, with a height of ½ to ¾ inches being preferred. Receptacles into which the tool  100  is inserted typically have a hinged door or cover that is spring biased into a closed position, such as the cover  315  shown in  FIG. 7 . The spring exerts considerable torque. The thumb guard  120  protects the thumb from the cover  315  when the tool  100  is being used. 
     The tool includes features to prevent a grasping hand from slipping. The thumb guard  120  provides a stop against which a thumb may push. The exemplary grip  115  is a textured surface  115  on the handle. Other non-slip grips may be utilized, including sleeves and overmolded features. 
     The head  110 , as shown in  FIGS. 1 and 2 , includes a plurality of openings  130 ,  135 ,  140 ,  145 ,  150 ,  155 ,  160  (“ 130 - 160 ”). Seven openings  130 - 160  are shown. Each opening leads to a channel. By way of example, openings  130 ,  145  and  150  are shown for channels  165 ,  170  and  175  in the side section view of  FIG. 4 . Though three channels are shown, it is understood that each opening leads to a channel. Most of the channels are parallel and of equal depth. A depth of about 15 to 30 mm is preferred. Each channel is configured (i.e., sized and positioned) to receive a split electrode pin of a receptacle. The channel  165  at the twelve o&#39;clock position is larger in diameter and deeper than the others because it receives a larger electrode that protrudes more from the receptacle than the other electrodes. A channel diameter of approximately 6 to 10 mm is preferred. The opening for a channel  130 ,  145  and  150  is preferably filleted, chamfered or beveled and has a slightly larger diameter (e.g., 101% to 125%) than the channel  165 ,  170  and  175  to facilitate receipt of a split electrode pin. 
     A spreading pin  180 ,  185 ,  190  is provided within each channel. Although three pins are shown in  FIG. 4 , it is understood that every opening leads to a channel and every channel has a pin. As shown in  FIGS. 5 and 6 , each spreading pin  200  includes a conical nose  205 , a cylindrical body  210 , a collar  215  and a tail  220 . The collar  215  defines an area to be molded into, snap fit into or fastened into the head  110 . Each spreading pin is concentric with its channel. The pin may be snap fit, bonded and/or fastened to the head  110  within the channel. Each pin is preferably about 20 to 40 mm in length (from tip of nose  205  to tail  220 ) and has a maximum diameter of about 1.5 to 3 mm at the body  210  and a conical nose  205  with a length of approximately one half of the total length of the spreading pin  180 ,  185 ,  190 . The spreading pins are rigid, capable of withstanding repeated use and suitable for spreading split pin electrodes to their original un-deformed configuration. Metals, plastics and composites may be used for the spreading pins. 
     Often, the split electrodes are not aligned. Sometimes the slot in the electrode may be horizontal, vertical or some other orientation. A blade-like spreading pin will not work unless the slot in an electrode and the blade-like pin are properly aligned. After extensive experimentation, it was found that the spreading pin  200 , which includes a conical nose  205  and a cylindrical body  210  that has a diameter equal to the desired spread between the split electrode sections, works well, consistently, regardless of pin orientation. 
     Referring now to  FIG. 7  an exemplary receptacle  300  is shown. The receptacle includes a mounting plate  305 , a sleeve  310 , a spring biased cover  315  and a plurality of (e.g., seven) split pin electrodes within the sleeve  310 . The sleeve is keyed with a slot  325  at the top, as more clearly shown in the embodiment of  FIG. 8 . The slot  325  receives the key  125  at the head of the tool  100 . The cover  315  is omitted from  FIGS. 8 and 9  for clarity. 
       FIG. 7  shows a receptacle without the tool.  FIG. 8  illustrates the tool being positioned for inserting into the receptacle.  FIG. 9  illustrates the tool inserted into the receptacle. 
     Referring now to  FIGS. 10 and 11 , split electrode pins are conceptually shown. The split pins include a first electrode section  350  and a second electrode section  355  substantially separated by an elongate slit  360 . In  FIG. 10 , a pin is shown with the sections  350 ,  355  substantially parallel and an even space  360  between the sections. The width of the slit  360  (e.g., measured from the first section  350  to the second section  355 ) is about the diameter of the body  210  of a spreading pin  200 . 
     When the pin has been squeezed, the first section  350  and the second section  355  come together, as shown in  FIG. 11 . Such bending deformation of the first section  350  and second section  355  frequently occurs during disconnection of a trailer from a tractor. When the pin is deformed as shown in  FIG. 11 , the bent sections  350 ,  355  may not consistently maintain good contact with the receiving sleeve-like electrode of a mating connector. In such case, trailer lighting and/or trailer ABS braking may fail. To avoid such failure, each pin should be restored to its un-deformed configuration, as shown in  FIG. 10 , before a coupling is completed. 
     Referring again to  FIGS. 7 through 9 , use of the tool to restore each split electrode pin to its un-deformed configuration entails the following steps. First, the cover  315  of the receptacle  300  is lifted, as shown in  FIG. 7 . Then the head  110  of the tool  100  is aligned with the sleeve  310 , with the key tab  125  aligned with the key slot  325 , as shown in  FIG. 8 . In this configuration, each opening  130 - 160  and each corresponding channel will matingly receive a split electrode pin  320  when the head  110  of the tool  100  is inserted into the sleeve  310  of the receptacle  300 , as shown in  FIG. 9 . A spreading pin  200  within each channel will urge the sections  350 ,  355  of the split electrode pin  320  to their un-deformed configuration, thus ensuring a good electrical connection. Because the openings  130 - 160  are wider than the channel, even a slightly askew, oblique or otherwise bent electrode may easily be guided into the channel. The spreading pin  200  does not spread the pins more than is needed. The channels also prevent spreading of the pin sections  350 ,  355  further apart than appropriate for good electrical contact when coupled. Advantageously, all seven electrode pins are properly configured by the tool simultaneously. While the tool is used, the thumb guard  120  shields the user&#39;s thumb from the cover  315 . After full insertion of the head  110  of the tool  100  into the sleeve  310  of the receptacle, the head  110  may be withdrawn from the sleeve  310  and the cover  315  may close. 
     While an exemplary embodiment of the invention has been described, it should be apparent that modifications and variations thereto are possible, all of which fall within the true spirit and scope of the invention. With respect to the above description then, it is to be realized that the optimum relationships for the components and steps of the invention, including variations in order, form, content, function and manner of operation, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. The above description and drawings are illustrative of modifications that can be made without departing from the present invention, the scope of which is to be limited only by the following claims. Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents are intended to fall within the scope of the invention as claimed.