Patent Publication Number: US-2013244471-A1

Title: Coupling apparatus for high power electrical connectors

Description:
TECHNICAL FIELD 
     The present invention relates to an apparatus for assisting in the connecting together of electrical connectors for very heavy duty cables. 
     BACKGROUND 
     The discussion of any prior art documents, techniques, methods or apparatus is not to be taken to constitute any admission or evidence that such prior art forms, or ever formed, part of the common general knowledge. 
     Very heavy duty electrical cables are found in a number of contexts including mining. These cables are capable of meeting the very high power requirements of large electrical machines. For example, cables capable of carrying 800 Amp currents at 22,000V may be used in such environments. 
     The cables are typically terminated with specially made electrical connectors. In order to join one length of cable to another the corresponding end connectors must be appropriately manipulated so that they can be interconnected. 
     However, cables of this type are very heavy and have little flexibility. For example, heavy duty power cables used in underground or open cut mines are frequently made with lead insulation and steel wire armor over copper conductors. In order to manipulate the cables so that they can be interconnected a number of workers are typically required to lift and align the cables and connectors. 
     It will be realized that this presents a laborious and time intensive job which has the potential to injure to workers. 
     Furthermore, the workers have been known to inadvertently rupture the electrical connection inside a connector so that once the connectors are interconnected, correct functionality of the joined cables is lost. 
     It is an object of the present invention to provide an apparatus that addresses one or more of the above-described problems. 
     SUMMARY OF THE INVENTION 
     According to a first aspect of the present invention there is provided a coupler to interconnect first and second connector assemblies of respective first and second electrical cables and able to be released from the cables after interconnection, the coupler including: 
     a first retaining assembly to retain the first connector; 
     a second retaining assembly to retain the second connector with the first connector; 
     a translation assembly for relative motion of said first assembly and said second assembly toward each other to thereby mate the first connector with the second connector. 
     Preferably at least one of the first and second retaining assemblies includes an arrangement for rotation of at least one of the first or second connector. 
     Preferably the translation assembly is arranged to move at least one, or both, of the first and second retaining assemblies toward each other. 
     In the preferred embodiment the first retaining assembly includes the arrangement for rotation of the first connector. 
     In a further embodiment of the invention the second retaining assembly is also arranged to rotate the second connector assembly. 
     In the first embodiment the translation assembly is arranged to move the second retaining assembly toward the first retaining assembly. 
     Preferably the first retaining assembly comprises a first yoke for retaining the first retaining assembly. The first yoke may be formed in opposing parts which can be opened to receive the first connector assembly. In a preferred embodiment the opposing parts define a receptacle for a sleeve, or as it may be called an “adaptor”, which holds the first connector in use. 
     A power actuator is preferably provided to open and close the first yoke. 
     Preferably a drive train is provided for rotating the sleeve within the yoke. 
     The drive drain may include a drive pinion arranged to mesh with teeth formed about the sleeve. 
     Preferably the sleeve is formed of a resilient material such as polypropylene or polyurethane or nylon to thereby cushion the connector. 
     In a first embodiment the drive chain is driven by a wheel for rotation by an operator. Alternatively, the drive chain may be driven by a motor. 
     Preferably the second retaining assembly comprises a second yoke for retaining the second connector assembly. The second yoke may be formed in opposing parts which can be opened to receive the first connector. In a preferred embodiment the opposing parts define a receptacle for a sleeve or “adaptor” which holds the second connector in use. 
     In the preferred embodiment the opposing parts of the second yoke are hingedly connected by a pivot pin so that a first part of the first yoke may be pivoted away from a second part of the second yoke. 
     A power actuator is preferably provided to open and close the second yoke. 
     The translation assembly may comprise a rack and pinion arrangement associated with the second retaining assembly. Preferably the first retaining assembly and the second retaining assembly are mounted upon a common frame. 
     In a first embodiment the rack is fast with the frame and the pinion is fast with the second retaining assembly. In the first embodiment the pinion is coupled to a drive wheel for rotation by an operator. 
     In a second embodiment the first retaining assembly and the second retaining assembly are brought towards each other by means of powered actuators. For example, the powered actuators may comprise hydraulic rams arranged to slide the first retaining assembly and the second retaining assembly along members of the frame. 
     Preferably cable supports are mounted adjacent the first retaining assembly and the second retaining assembly for supporting respective cables of the first connector and the second connector. 
     The cable supports may comprise rotatable sheaves. 
     Preferably cable guides are provided for assisting in directing cables of the connector assemblies to respective cable supports during use. 
     Preferably respective powered risers are provided at opposite sides of the apparatus for lifting of the first cable and the second cable to assist in installing and removing the connector assemblies to and from the retaining assemblies. The powered risers preferably include telescopic arms coupled to power actuators. 
     Preferably the telescopic arms include pulleys through which lines run for attachment to the connector assemblies for lifting thereof. 
     In a preferred embodiment the frame is coupled to the stand via a linkage including a pivot for tilting the frame relative to the stand so that the first and second retaining assemblies may be tilted down to reduce the height through which connectors must be lifted for installation in the first and second retaining assemblies. 
     In an embodiment of the invention designed for use on sloping ground, as may be found in underground mines for example, the frame is pivotally mounted to a stand so that the frame may be rolled through a first angle relative to the stand. The stand may comprise a platform or a “basket” for an operator to stand in while using the coupling apparatus. 
     Preferably a motor is provided to adjust a pivot angle between the frame and the stand so that the frame may be kept at a desired angle, for example horizontal, irrespective of the slope of the surface supporting the stand. 
     According to a further aspect of the present invention there is provided an adaptor for an electrical connector comprising: 
     at least first and second parts defining a space for snugly receiving an electrical connector therein; and 
     an external surface for forcing by a rotation member. 
     In a first embodiment the at least first and second parts comprise two portions that are detachably interlocked. 
     Preferably the external surface is formed for meshing with gears of a pinion to thereby impart rotation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows: 
         FIG. 1  is a side view of a coupling apparatus according to a first embodiment of the present invention. 
         FIG. 2  is an end view of the coupling apparatus of  FIG. 1 . 
         FIG. 3  is a top plan view of the coupling apparatus of  FIG. 1 . 
         FIG. 4  is a perspective view of a sleeve or adaptor according to a first embodiment of an aspect of the present invention. 
         FIG. 5A  is a side view of the adaptor of  FIG. 4 . 
         FIG. 5B  is a front plan view of the adaptor of  FIG. 4 . 
         FIG. 5C  is a cross-section through the adaptor of  FIG. 4 . 
         FIG. 6  is a perspective view of a cradle according to an embodiment of an aspect of the present invention in use. 
         FIG. 7  is an isometric view of a coupling apparatus according to a further embodiment of the present invention. 
         FIG. 8  is a side plan view of the coupling apparatus of  FIG. 7 . 
         FIG. 9  is a top plan view of the coupling apparatus of  FIG. 7 . 
         FIG. 10  is an end view of the coupling apparatus of  FIG. 7 . 
         FIG. 11  is an end view of the coupling apparatus of  FIG. 7  in a tilted configuration with retracted arms. 
         FIG. 12  is an end view of the coupling apparatus of  FIG. 7  in a tilted configuration with extended arms. 
         FIG. 13  is a non-planar view of the coupling apparatus of  FIG. 7  in use during the raising of a connector assembly. 
         FIG. 14  is an end view of the coupling apparatus of  FIG. 7  in a non-tilted configuration with open yokes. 
         FIG. 15  is an isometric view of a coupling apparatus according to a further embodiment of the invention intended primarily for use in underground mines. 
         FIG. 16  is a top plan view of a slight variation of the coupling apparatus of  FIG. 15  wherein a gate has been replaced with a vehicle mounting bracket. 
         FIG. 17  is a side view of the coupling apparatus of  FIG. 16 . 
         FIG. 18  is a view of the coupling apparatus of  FIG. 16  wherein the coupling assembly has been rolled anti-clockwise relative to resting position. 
         FIG. 19  is a view of the coupling apparatus of  FIG. 16  wherein the coupling assembly has been rolled clockwise relative to resting position. 
         FIG. 20  is a top planar view of a coupling apparatus according to an embodiment of the invention including two rotation assemblies for rotating yokes of the apparatus. 
         FIG. 2  comprises various views of a second embodiment of a coupler according to the present invention. 
         FIG. 3  illustrates a connector sleeve and drive sprocket used in the various embodiments of the invention. 
     
    
    
     Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. 
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       FIGS. 1 ,  2  and  3  are side, end and top plan views of a coupling apparatus or “coupler” according to a first embodiment of the present invention. 
     The coupler includes a frame  39  upon which are mounted a first retaining assembly  11  and a second retaining assembly  12  for retaining respective connector assemblies. The retaining assemblies may be brought relatively toward and away from each other by a translation assembly which comprises a rack  6  mounted to the frame and which meshes with a pinion  7 . The pinion  7  is coupled to a drive train of the second retaining assembly which is driven by an axle  16 , to one end of which there is mounted a wheel  4 . Accordingly, upon a worker rotating wheel  4  the second retaining assembly  12  may be brought toward and away from the first retaining assembly  11 . 
     With reference to the end view of  FIG. 2 , each of the retaining assemblies  11 ,  12  includes a yoke  1 A,  1 B which has an upper part that can be pivoted about a shaft  3  in order to open the yoke. 
     A connector adaptor in the form of a split sleeve  31 , as shown in  FIGS. 4 and 5A  to  5 C can then be inserted into the open yoke. The sleeve is formed of two interlocking and detachable parts that cooperate to define a space shaped to snugly retain the connector. Since the sleeve is preferably made of a synthetic material, e.g. polypropylene or polyurethane or nylon, it prevents metal-to-metal contact between the connector and the inner ring of the yoke  1 . It will be realized that a number of sleeves  31  may be made, all having the same outer configuration, but with different inner configurations to accommodate the profiles of different types of connectors. Consequently, the sleeve  31  comprises an adaptor between different shaped electrical connectors and the coupling apparatus. 
     The first retaining assembly  11  is fitted with an arrangement for rotation of the sleeve including pinion  2 . The pinion meshes with teeth  32  formed on the outside of the sleeve  31 . The pinion  2  is coupled to a drive wheel  5  by a drive train associated with the first retaining assembly  11 . Consequently, upon a worker rotating wheel  5 , the pinion  2  is rotated which in turn rotates the sleeve  31  within yoke  1 . 
     In the presently described embodiment, there is no such drive train for rotating the sleeve retained in the second retaining assembly  12  although in other embodiments of the invention both retaining assemblies may incorporate an arrangement to rotate their respective sleeves. Similarly, in other embodiments of the invention both of the retaining assemblies may be moved back and forth along the frame. 
     Cable supports in the form of sheaves  9  and  10  are provided at opposing ends of the frame  39  to support respective cables of the first connector and the second connector. The cable supports help to reduce strain between the internal connection of the cables and the connectors. As previously mentioned, the cable supports  9  and  10  include sheaves or rollers to support the cables. 
     The cable supports  9  and  10  assist workers in installing the connectors into the yokes of the first and second retaining assemblies. 
     In use first and second adaptors  31  are initially fitted around each of the opposing connector assemblies that are to be coupled together. The adaptors  31  are then lifted into the yokes  1 A and  1 B which have previously opened to receive them. The yokes are then closed so that teeth  32  of adaptor  31  meshes with pinion  2  in the case of retaining assembly  11 . The cables from each of the connectors are located over sheaves  9  and  10 . An operator then turns wheels  4  and  5  in order to bring the connectors together and orientate them so that they are aligned to be mated together. Once mated together the connectors, with sleeves  31  still about them can be bolted together and lifted from the yokes onto a frame  34  as shown in  FIG. 6  where the cables  36  and bolts  38  can also be seen. 
     Referring now to  FIGS. 7 to 10 , there are shown isometric, rear, top and end views of a coupling apparatus  64  according to a second embodiment of the invention which is preferred for use in outside environments such as open-cut mines. 
     Coupler  64  is intended to be mounted to a vehicle by means of brackets  60  and  62  so that it may be moved to a location on site where it is required. Coupler  64  is fitted with substantially more power actuators, such as hydraulic rams and motors, than that of the embodiment of  FIG. 1 . The various hydraulic rams and motors are hydraulically powered by the vehicle to which it is mounted. 
     A motor  55  is provided to power the rotation pinion  2  so that the rotation wheel  4  of  FIG. 1  is not present. Similarly, a translation assembly in the form of hydraulic actuators  25  and  26  are provided to bring the first retaining assembly  12  and the second retaining assembly  11  toward and away from each other by sliding them along a member of frame  39 . 
     Furthermore, with reference to  FIG. 8 , yoke actuators  21  are provided to open and close the yokes so that no hands-on operator intervention is required. 
     Hydraulic rams  23  and  24  are also provided as part of riser assemblies at opposite ends of the coupler which also includes telescopic arms  66  and  68 . The hydraulic rams  23  and  24  are arranged to extend telescopic arms  66  and  68  which terminate at their upper ends in lateral beams  70  and  72  on which pulleys  74  and  76  are mounted respectively. Lines  78  and  80  are threaded through pulleys  74  and  76  and frame-mounted pulleys  82  and  84 . At one end the lines  78  and  80  are fixed to a frame of the coupler whereas at their opposite free ends they terminate in lifting hooks  86  and  88 . Consequently, extending the telescopic arms causes the hooks to rise and retracting the arms causes the hooks to lower. In an alternative embodiment the lines may be wound on a powered winch fast with frame  39 . 
     With reference to  FIG. 10 , frame  39  of the coupler is connected to tilt assembly  53  by a shaft  41  in order that it can be tilted about the shaft to assist in raising connector assemblies to be coupled as will be described shortly. A power actuator in the form of a hydraulic ram  29  is provided to power the tilting operation. 
     With reference to  FIGS. 11 to 14 , in use the tilt actuator  29  is operated to tilt the coupler toward the ground as shown in  FIG. 11 . In this position the cable guides  69  and  67  are lowered. The cable guides are useful in guiding the cables onto the cable support sheaves  9  and  10 . Telescopic arms  66  and  68  are extended by operation of rams  23  and  24  as shown in  FIG. 12  so that they reach past the yokes  1 A,  1 B. The yokes  1 A,  1 B are also opened by operation of rams  21  (which are visible in  FIG. 8 ). 
     As shown in  FIG. 13 , the lifting hooks  86 ,  88  at the end of lines  78 ,  80  are then attached to the end of the first connector assembly  90  which has already had an adaptor sleeve  31  fitted about it. The lines  78  and  80  are then withdrawn, by extending arms  66  and  68  to raise the connector assembly  90  as shown in  FIG. 13 . By varying the length of lines  78  and  80  the connector  90  and adapter sleeve  31  can be positioned over the open yoke  1 A. The lines  78  and  80  are then loosened to lower the connector and adapter sleeve  31  into the open yoke  1 A in the position as depicted in  FIG. 14 . 
     A similar operation is then carried out to lift and maneuver the other connector assembly including its fitted adapter sleeve  31  into yoke  1 B. The top portions of the yokes are then swung down and locked. This entails using the hydraulic actuators  21  to open and close the yokes. It is preferred that the hydraulic circuit that controls the yokes requires an operator to use both hands, e.g. one to power the circuit and one to initiate an open or close command, in order to reduce the risk of an operator&#39;s hand being caught during yoke closure. 
     Once the first and second connectors are captured in their respective yokes, motor  55  is operated so that pinion  2  rotates and thereby rotates the sleeve, with which it meshes and so the connector that are installed within retaining assembly  11 . Rotation continues until the connectors are correctly aligned, i.e. the socket portions of the connectors are lined up collinear with dowel portions of the opposing connector. The connectors are then brought together by operating rams  25  and  26  ( FIG. 9 ) to slide retaining assemblies  12  and  11  along the rails of frame  39 . 
     Once the connectors have been rotationally aligned and drawn together by operating the rams  25  and  26  until they are interconnected, they are then bolted together in place. The yokes  1 A,  1 B are then opened and the interconnected cable can be lifted from the yokes and placed in a support such as that of  FIG. 6 . 
     This last operation includes the use of operating rams  23  and  24  to thereby lift the telescopic arms  66  and  68  and lines  80  and  86  to lower the coupled connectors. After the coupled connectors have been removed from the coupling apparatus the adaptor sleeves are then split to remove them so that they can be used for the next coupling. 
     Referring now to  FIGS. 15 to 18 , there is depicted a coupling apparatus  90  according to a third embodiment of the invention which is intended for use in underground mines where the mine roof may be sloping. The electrical cables are typically strung along the mine roof and so this embodiment of the coupler is designed to accommodate for that slope. The coupling apparatus  90  comprises a platform portion  17  which is pivotally connected to coupling assembly  92  that is very similar to the coupling apparatus  64  of  FIG. 7 . However, whereas the coupling apparatus  64  included a pair of brackets for attachment to a vehicle, the coupling assembly  92  is coupled to the platform  17  by a pivot  22 . As will be explained 
     Vehicle attachment brackets  94  are fastened about the platform so that the platform can be readily secured to a mining vehicle. 
     With reference to  FIG. 15 , the platform  17  is pivotally coupled to tilt assembly  53  by pivot  22 . An actuator is provided so that the tilt assembly  53  can be rolled about the pivot  22  as desired from the position shown in  FIG. 18  to that shown in  FIG. 19 . In the embodiment shown in  FIG. 15  an actuator in the form of a hydraulic ram  96  is used. Alternatively a stepper or indexing motor might also be used for the actuator in some embodiments. 
     Referring to  FIG. 17 , frame  39  of the coupler is connected to tilt assembly  53  by a shaft  41  in order that it can be tilted about the shaft in the manner previously described with reference to  FIGS. 11 to 14 . 
     A power actuator in the form of a hydraulic ram  29  is provided to power the tilting operation. 
     In use, platform  17  will typically be mounted to a vehicle. Once the vehicle is at the required location the tilt assembly  53  and so the coupler frame and coupler assembly are rolled about pivot  22  so that the frame is brought to the horizontal or a desired slope. This operation compensates for any steep sloping of the ground on which the vehicle rests. 
     The tilt actuator  29  is then operated to tilt the coupler toward the ground and the connectors are loaded into the yokes as previously described with reference to  FIGS. 11 to 14 . 
       FIG. 20  shows a further embodiment of the invention wherein both retaining assemblies  11  and  12  are fitted with rotation assemblies comprising motors  55 ,  55 A driving pinions  2  and  2 A respectively. This embodiment may be used where it is important that the coupling assemblies not be rotated through more than 90 degrees each as doing so might rupture or damage the cables to which they are connected. Accordingly, each rotation assembly provides up to 90 degrees of rotation thereby providing a maximum of 180 degrees relative rotation between them in use. 
     In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term “comprises” and its variations, such as “comprising” and “comprised of” is used throughout in an inclusive sense and not to the exclusion of any additional features. 
     It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. 
     The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.