Abstract:
The present invention provides an electrical connector for a motorized conveyor pulley which has a plate having a first side and a second side and an outer surface. The plate is preferably constructed of an insulating glass material. At least one electrical connector is supplied which provides electrical communication from the first side to the second side. The plate is formed around the electrical connector to fluidly seal the first side from the second side. In another aspect of the present invention, the electrical connector has an outer shell structure having an internal area and an outer area. A portion of the internal area encapsulates and is bonded to the outer surface of the plate.

Description:
BACKGROUND OF THE INVENTION 
     I. Technical Field 
     The present invention relates generally to an electrical connector for a motorized conveyor pulley and, more particularly, to an electrical connector for a motorized conveyor pulley which effectively fluidly seals a passage in which the electrical connector is positioned. 
     II. Discussion 
     Conventional mechanical technology many times requires electrical power to be supplied into an environment containing lubricants or other fluids. Specific devices which require such a power supply include motorized conveyor pulleys. For instance, electric motors for motorized conveyor pulley systems generally comprise operational parts and lubricant which together with the motor are completely enclosed within the pulley housing. However, for operation, the motor must be provided with electrical energy. In addition, the specific application of motorized conveyor pulleys require the pulley housing to selectively be supplied with power for operating various electrical devices such as braking systems disposed therein. To accomplish these functions, a shaft and an electrical cable must be provided which penetrates the pulley housing. The shaft is typically fitted with a passage through which an electrical cable having a plurality of conductors is passed to supply the motor and associated devices with electrical power. 
     While the motorized conveyor pulley housing effectively allows ingress and egress of the proper mechanical and electrical components, lubricant tends to leak through the passage in the shaft around the cable through which electrical power is supplied. The present invention was developed to overcome this problem. 
     SUMMARY OF THE INVENTION 
     It is therefore an object of the present invention to provide an electrical connector located in a passage of a motorized conveyor pulley shaft that provides a conduit for electrical wiring and seals the passage to thereby prevent leakage of lubricant therethrough. 
     To accomplish these and other objects, the present invention provides an electrical connector for a motorized conveyor pulley having a plate with a first side, second side, and an outer surface. The plate is constructed of an insulating glass material. At least one conductor pin is supplied which provides electrical communication from the first side to the second side. The plate is formed around the conductor pin to fluidly seal the first side from the second side. The electrical connector has an outer shell structure having an internal area and an outer area. A portion of the internal area surrounds and is bonded to the outer surface of the plate. 
     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are intended for purposes of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawings which illustrate the best mode presently contemplated for carrying out the present invention: 
     FIG. 1 is a sectional view of an electrical connector shown in assembled relationship with a shaft according to the present invention; 
     FIG. 2 is a diagrammatical perspective view of an electrical connector according to the present invention with electrical cables to be connected thereto; 
     FIG. 3 is a schematic view of an electrical connector according to the present invention; 
     FIG. 4 is a cross-sectional view of an electrical connector shown in assembled relationship with a motorized conveyor pulley according to the present invention; 
     FIG. 5 is an environmental view of an electrical connector and motorized conveyor pulley according to the present invention shown in an operative installation; and 
     FIG. 6 is a cross sectional view of an electrical connector according to the present invention shown in an operative installation. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
     Referring now to FIG. 1, a sectional view of an electrical connector  10  is shown positioned in a shaft  12 . An electrical connector  10  generally comprises plate  14  mounted to raised lip  16  of an outer shell  18 . Plate  14  has a first side  22 , which is exposed to an internal (See FIG. 4) environment (as will be discussed), and a second side  24  which is exposed to an external environment via an extended passage  25  in shaft  12 . Plate  14  also has an outer surface  26  which is mated to raise lip  16 . Glue, epoxy, or other suitable bonding arrangements, or any other suitable method can be used to attach these surfaces which ensures a fluid tight seal between outer surface  26  and raised lip  16 . 
     Outer shell  18  is preferably constructed of metal and is cylindrical in shape. Outer shell  18  extends a first predetermined distance  32  from first side  22  of plate  14  and extends a second predetermined distance  34  from second side  24 . At opposite ends of this extension, outer shell  18  terminates at first rim area  36  and second rim area  38 . Outer shell  18  acts as a mounting member to mount plate  14  to the inner diameter of shaft  12  (as will be discussed). This mounting is preferably a press fit of outer shell  18  into shaft  12 . However, since outer shell  18  serves merely as a mount, other mounting shells or, in fact, no mounting shell at all can be used to secure plate  14  within a passage in shaft  12 , provided that the outer surface of plate  14  sealably engages the walls of the passage in shaft  12  in fluid tight sealing relationship. 
     A plurality of conductor pins  42  extend through plate  14  to provide electrical communication therethrough. Preferably, these conductor pins  42  are positioned in spaced relationship and extend through plate  14 , and outwardly from first side  22  and second side  24 , terminating at first end  44  and second end  46  respectively. Preferably, first end  44  and second end  46  are distanced less than first predetermined distance  32  and second predetermined distance  34  from their respective sides. This distancing ensures that first end  44  and second end  46  fall below first rim area  36  and second rim area  38  so as to facilitate encapsulation thereof in a non-conductive potting agent as will be discussed. 
     Plate  14  is constructed from E-glass, ceramic or other material which may be solidified around pins  42 . However, this material must have a high dielectric and mechanical strength so as to prevent shorting of the pins as well as to ensure they are mechanically supported. The formability of the material used to construct plate  14  ensures that an accurate and fixed fluid tight fit exists between the electrically conductive pins  42  and plate  14 . As will be further discussed, this fit ensures that lubricants contained within the internal environment of the pulley housing  12  do not leak to the external environment. 
     Shaft  12  is generally cylindrical in nature with a counter bore at one end adapted to accept electrical connector  10 . The counter bore ends at end  25 . Preferably, the diameter of the counter bore is slightly smaller than the outer diameter of electrical connector  10  to allow a press fit therebetween. End  25  is set in shaft  12  deep enough to allow first predetermined distance  32  to extend outward from shaft  12 . On an external area of shaft  12  is contained key slot  27 , ridge  29 , and steps  31 ,  33 , and  35  (for reasons which will be discussed). 
     Referring now to FIGS. 2 and 3, the operation of the present invention will be described. In FIG. 2, a first plurality of wires  52  extending from apparatus within the conveyor pulley is shown encased in casing  54 . From an edge of casing  54 , wires  52  lead up and connect to first end  44  of pins  42  extending from first side  22  of electrical connector  10 . A second plurality of wires  56  exits second side  24  and enters casing  54 . These wires are then carried to an electrical supply (as will be discussed) for providing power to the motorized conveyor pulley. 
     With respect to FIGS. 2 and 6, proper connection of wires  52  and  56  to their respective pins  42  is illustrated. Here, a non-conductive potting agent  58  is provided which ensures that each portion of pin  42  extending from plate  14  does not short. The non-conductive potting agent is potted around pins  42  in the cavity formed by second side  24  and outer shell  18 . Non-conductive potting agent  58  is produced as non-conductive clay-like material which can be shaped around objects and acts to insulate the space existing between each respective pin extending from first side  22  and second side  24 . Each wire  56  and  52  is connected to pin  42  by solder  49 . Solder  49 , in conjunction with potting agent  58  acts to secure wires  56  and  52  to pins  42 . 
     FIG. 3 illustrates electrical connector  10  being used in conjunction with a power source  50  and electrical device  64 . Power source  50  attaches, by positive lead  68 , to a second end  46  of a pin  42 . First end  44  of the pin  42  attaches to lead  70 , thereby supplying electrical power to electrical device  64  through the pin  42 . For grounding, electrical device  64  is connected to first end  44  of another pin  42  by lead  72 . This ground is completed by lead  74  connecting the ground of power source  50  to second end  46 . This series of electrical connections completes a circuit hereinafter referred to as a conductive loop  76 . 
     It is noted that for clarity purposes, the depiction in FIG. 3 illustrates only one conductive loop utilizing two pins  42 . Although not illustrated, the remaining pins  42  are used in a similar fashion by power source  50  to power other electrical devices not shown. Power source  50  can use a multiplexor, banks of switches, or other known means which are well known in the art for energizing a subset of a plurality of electrical circuits to accomplish this task. 
     Referring now to FIG. 4, electrical connector  10  is shown positioned in passage  25  of shaft  12  of motorized conveyor pulley  80 . Preferably, electrical connector  10  is press fit on the internal bore of passage  25 . To support shaft  12 , the external area of shaft  12  contains key slot  27 , ridge  29  and steps  31 ,  33  and  35 . Slot  25  provides a placement for key stock to ensure that shaft  12  does not rotate with respect to sleeve  93 . Ridge  29  sits within a corresponding groove to ensure that shaft  12  does not move laterally with respect to motorized conveyor pulley  80 . Step  31  supports bearing  95 , which allows outer plate  104  to rotate with respect to shaft  12 . Steps  33  and  35  support sleeves and retainers respectively which maintain shaft  12  in a sealed engagement with motorized conveyor pulley  80 . 
     Motorized conveyor pulley  80  contains a rotor stator assembly  82  which provides rotational energy to ring gear  92  by gear train  84 . Gear train  84  generally includes a rotor shaft  94  supported by a bearing  130 . On the opposing side of bearing  130  with respect to rotor stator assembly  82  is gear  131  which is meshed with a driver gear  98 . Driver gear  98  is attached to shaft  120  which sits behind shaft  100  in FIG.  4 . Shaft  120  is, in turn, engaged to pinion gear  122  which meshes with gear  124 . Gear  124  is engaged to shaft  100  which is supported by bearings  126  and  132 . Rotation of gear  124  causes rotation of shaft  100  and subsequently pinion gear  96  which is splined to shaft  100 . Pinion gear  96  then meshes with internal teeth provided on ring gear  92 . Ring gear  92  is in turn secured to outer plate  104  via mounting plate  102  by a plurality of fasteners  105 . 
     Shaft  12  is press fit into support sleeve  93 . Support sleeve  93  is attached to a network of internal frame work, such as frame components  140 , which support items such as bearings  130 ,  132  and  126  as well as the stator for rotor stator assembly  82 . Likewise, second shaft  112  is positioned within end plate  142  to keep similar components affixed to second shaft  112 . As a result, the internal components of motorized conveyor pulley  80  are unable to rotate about shaft  12  or second shaft  112 . As such, actuation of the rotor stator assembly  82  results in rotation of outer shell  88  about shaft  12  and second shaft  112 . 
     A housing is provided for encasing the internal components of motorized conveyor pulley  80  as well as providing a rotatable member for driving a belt (as will be discussed). Such internal components include, but are not limited to, gear train  84  and rotor stator assembly  82 . The internal components are protected from the external environment surrounding the motorized conveyor pulley  80  which can be harsh due to the severe conditions existing in manufacturing facilities which may use the present invention. The housing generally comprises outer tube  88 , outer plate  104 , and second outer plate  108 . Outer plate  104  is attached to an outer ring  89  secured to outer tube  88  by a plurality of bolts. Likewise, second outer plate  108  is attached to outer tube  88  at an outer diameter of outer plate  108  by a second plurality of bolts and outer ring  91 . Finally, second outer plate  108  and outer plate  104  are rotatably supported on second shaft  112  and shaft  12  respectively. Second outer plate  108  is supported by bearing  110  while outer plate  104  is supported by bearing  95 . Bearings  110  and  95  allow outer tube  88  to rotate with respect to second shaft  112  and shaft  12 . 
     In operation, rotor stator assembly actuates rotor shaft  94  which causes rotational energy to be transferred through gear train  84 . Ring gear  92  of gear train  84 , in turn, transfers this energy through mounting plate  102  to outer plate  104 . Because of the attachment of outer tube  88  to outer plate  104  and second outer plate  108 , outer tube  88  is able to be rotationally driven by outer plate  104  about shaft  12  and second shaft  112 . As shown in FIG. 5, shaft  12  and second shaft  112  are rotationally restricted by supports  116  and  114  respectively. As such, the rotational energy provided by outer tube  88  is transmitted to an outer component such as belt  110 . 
     Rotor stator assembly  82  is actuated by closing switch  86 , thereby completing conductive loop  76  (see FIG.  3 ). Because electrical connector  10  is sealingly secured within passage  25 , lubricant and other fluids contained within outer tube  88  are unable to pass through electrical connector  10  and leak out passage  25  of shaft  12 . Moreover, alternate conductive loops can be actuated to actuate other elements within motorized conveyor pulley  80  such as brake elements. 
     The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention. Such variations or modifications, as would be obvious to one skilled in the art, are intended to be included within the scope of the following claims.