Orientation Agnostic Electrical Connector
The invention teaches how to establish 1 to 1 connection between a first group of n electrical signals to a second group of n electrical signals. A first connector half with a first group of n1 contacts equally spaced around a circle and a second connector half with a second group n2 connectors, also equally spaced around a circle, with n1−1=n2≥n. The angular extent of the individual contacts from the first group is e1, and that from the second group is e2. The angular extent of the gap between individual contacts from the second group is g2. Following relationship must be satisfied: e1<g2 and e2>(360/n1−e1). A switch interconnect means for connecting arbitrarily selected n contacts out of a first group of n1 contacts where (n1−1) n to n signals from a first group of n signals. The minimum number of signals required for doing this is n+(n1−n)*n. A single pole switch is connected from each of the n signals from the first group to each of the n arbitrarily selected contacts from the first group of n1 contacts. Each of the remaining n1−n contacts from first group, is connected to one end of a group of n switches. The other end of each switch from this group of switches is connected to each of the n signals from second group.
This application is a Continuation of U.S. application Ser. No. 15/844,552, filed on Dec. 17, 2017. These and all other referenced extrinsic materials are incorporated herein by reference in their entirety. Where a definition or use of a term in a reference that is incorporated by reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein is deemed to be controlling.
FIELD OF THE INVENTION AND PRIOR ART RELATED TO THE INVENTIONThe field of invention is electrical connectors. Specifically, the connectors that tolerate rotational misalignments. The basic techniques prevalent in the prior for transferring electrical energy across a swivel joint can be summarized into three categories: (i) a flexible, twistable or bendable cable that connects across the swivel and compensate for the swivel's motion. At one or both ends of the cable is a traditional detachable connector, (ii) an axial or radial slip ring or variant, (iii) integrating a rotary switch into the connector where a wiper can rotate to meet discrete contacts disposed along a circle. A search of prior art in class CPC/H01R35/00 reveals several examples of all of the three categories. Each of these techniques have certain limitations as described below.
- (i) Flexible Wire Type: U.S. Pat. Nos. 9,673,585; 9,325,134; 9,698,551, 9,160,100 disclose a connector which takes with it a cable that twists around to compensate for the swivel motion. Here, (a) the actual pieces across which the connector is split, still require precise alignment during mating, and this type of designs cannot be used if the rotational misalignment is across the two halves of the connector, (b) he twisting cable limits the life of the connector, (c) the swivel has to be large enough to be able to accommodate the cable, (d) being a twisting cable, it is required to be thin. Consequently, it's a challenge to apply such technique to large current connector.
- (ii) Slip Ring Type: U.S. Pat. Nos. 8,905,764 and 9,028,261 disclose traditional slip rings. The former is an axial and the latter is a radial slip ring design, both of which assign dedicated conductors for each signal. As a result, these designs need significantly more axial or radial space as the case may be. Furthermore, the slip rings and contacts are assembled permanently or quasi permanently as opposed to being on separable halves of mating connector. Thus, the final mating pin-and socket, i.e. the detachable parts of the connector still need precise alignment with respect to each other. Additional examples include U.S. Pat. No. 9,130,330 which discloses a radial liquid contact slip ring.
- (iii) Rotary Switch Type: U.S. Pat. Nos. 9,502,847, 8,597,059 disclose a connector that is a combination of a rotary switch and a plug. This can connect electricity only in few discrete angular positions. Due to the fundamental limitation of break-before make requirement, the connector cannot transfer energy when connector orientation does not match the few discrete functional positions.
As described above, each of the techniques described in prior are have shortcomings that limit their use for a high current, compact connector that can tolerate rotational misalignment. With the re-birth of electric vehicles (EVs), their charging system and in particular automatic or robotic charging system is fast becoming key enabling technology. At the core of such as charging system is a high current capacity connector, that is compact and can tolerate several degrees of misalignment. The connector's tolerance to rotational misalignment allows for robot to have one less degree of freedom, thus reducing complexity of end effector as well as the overall robot. The chassis of an EV or for that matter any vehicle is floating on its suspension springs and consequently the charge port attached to the chassis of a parked EV can still move several inches when for example, the drive closes the door, or puts groceries in the car. A robot plugging into the charge port or the charge port itself could easily get damaged when the EV chassis moves. Connector disclosed in this invention allows for the at least one of the necessary degrees of freedom, while safely delivering large charging currents.
Electrical power connectors have two halves, each carrying a group of connectors. These connector halves are brought together to mate with each other in a particular relative orientation. Frequently, the connectors have mechanical guides on one or both halves to guide the mating process into correct orientation such that each of the contacts from the first half mates with its matching counterpart from the second half. This invention teaches a contactor design that eliminates need for precise angular orientation of two halves of a power connector.
The Arrangement:
One of the embodiments of this invention is shown in
Each of the first group of contacts 6A, 6B and 6C is connected to first terminal of a pair of switches. Specifically, 6A is connected to one end of each of the two switches from the first pair 4A and 4B, 6B is connected to one end of each of the two switches from the second pair 2A and 2B and 6C is connected to one end of each of the two switches from the third pair 3A and 3B. The remaining end of first switch from each of the first, second and third pairs is connected to S1. The remaining end of second switch from each of the first, second and third pairs is connected to S1 (see
Operation:
Advantages:
The invention disclosed here uses a single ring for establishing all conduction paths. As a result, the mating surface and contacts have several desirable features: (i) The individual contacts can be made larger by taking advantage of the space saving design of single ring of contacts. This is particularly important for handling very high currents as the larger contacts not only allow for good sized contact surface and a large conductive body, but are also capable for dissipating any heat generated. (ii) This invention allows mating connector halves to tolerate rotational misalignment. This is important to be able to reduce the number of actuators required if the two mating halves are brought together mechanically.
Refinement1:
The embodiment in
Refinement2:
In order to configure the group of switches 2A, 2B, 3A, 3B, 4A, 4B or the group of switches 8A, 8B-1, 8B-2, 8C; one needs to know which contacts 6A, 6B and 6C from the first group have connected with which particular contacts 5A or 5B from the second group. One approach is the use an encoder or an equivalent orientation sensor to measure relative orientation between 10 and 20. However, this could be expensive. Instead this invention teaches a novel approach of adding two switches 9A and 9B to signal paths for L1 and L2 as shown in
- Step 1: Disconnect 6A, 6B and 6C from S1 as well as S2. This means opening all of the switches 2A, 2B, 3A, 3B, 4A, 4B or 8A, 8B-1, 8B-2, 8C. Also disconnect 5A and 5B from load or from each other. This means open 9A and 9B. See
FIG. 11 . Please note that the switch 9A is optional if (i) load 7 is capable of withstanding the small voltage used during the continuity checks used during this procedure and (ii) offers a low resistance that is detectable by continuity checks used during this procedure and in that case circuit ofFIG. 11 can be simplified to circuit ofFIG. 14 - Step 2: Perform pairwise continuity check on 6A, 6B and 6C. The outcomes are all contacts are open, or two of them show short circuit. This represents the orientation shown in
FIG. 7 , where 6A and 6B are electrically connected by 5A. - Step 3: Close the switch 9A. See
FIG. 12 . - Step 4: Perform pairwise continuity check on 6A, 6B and 6C. The outcomes are:
- i. all contacts short circuited to each other (when 10 and 20 are oriented as shown in
FIG. 7 i.e. when 6A and 6B are shorted through 5A and 6C is shorted to 5A through the pathway: 6C->5B->9A->5A->{6A and 6B}). - ii. one pair is short circuited (when 10 and 20 are oriented as shown in
FIG. 6 orFIG. 8 ). The short circuit is through 9A only.
- i. all contacts short circuited to each other (when 10 and 20 are oriented as shown in
- Step 5: Open switch 9A. Close switch 9B. See
FIG. 13 . - Step 6: Combining the results of Step 2 and Step 4, one can understand which of the 6A, 6B or 6C are connected to 5A and 5B. Configure switches 2A, 2B, 3A, 3B, 4A, 4B or switch 8A, 8B-1, 8B-2, 8C appropriately.
Application:
One of the important application of this technology is in the field of robotic hands-free charging of electric vehicles (EVs). In this application, a robot end effector would be installed with one half of an EV charging connector, and the other half would be installed on the electric vehicle. When the EV is to be charged, the robot would move its end effector and the attached connector half to bring it next to the connector half mounted on the EV. If this connector is to be designed as described in this invention, the Robot would not need to angularly align the two connector halves. This way, the robot end effector complexity can be reduced.
Another application is in the field of slip rings. In the traditional design of slip rings, each individual connection being transmitted across has its own dedicated ring. With the principle described in in this invention, multiple connections can be integrated into single slip ring that is peripherally segmented. This does add the complication of extra switching, as well as continuous monitoring of slip ring configuration. However, it allows for a significantly smaller slip ring design to be realized.
A third application is in the field of aerial drone recharging stations. The drone can simple land on the charging pad and not worry about the rotational alignment. The drone's landing gear will be fashioned as a ring, forming one half of the charging connector, and the charging pad surface will have appropriate mating connector embedded in it.
SUMMARYThe invention teaches how to establish 1 to 1 connection between a first group of n electrical signals to a second group of n electrical signals. A first connector half with a first group of n1 contacts equally spaced around a circle and a second connector half with a second group n2 connectors, also equally spaced around a circle, with n1−1=n2≥n. The angular extent of the individual contacts from the first group is e1, and that from the second group is e2. The angular extent of the gap between individual contacts from the second group is g2. Following relationship must be satisfied: e1<g2 and e2>(360/n1−e1).
A switch interconnect means for connecting arbitrarily selected n contacts out of a first group of n1 contacts where (n1−1) n to n signals from a first group of n signals. The minimum number of signals required for doing this is n+(n1−n)*n. A single pole switch is connected from each of the n signals from the first group to each of the n arbitrarily selected contacts from the first group of n1 contacts. Each of the remaining n1−n contacts from first group, is connected to one end of a group of n switches. The other end of each switch from this group of switches is connected to each of the n signals from second group.
What is presented in this patent application are only few representative embodiments of the core innovation. There are countless situations where this innovation can be applied. Any variant embodiments of this innovation are anticipated by this disclosure and hence are to be considered as part of this patent.
Claims
1. A method of establishing an electrical power connection across potentially misaligned a first and a second power connector bodies, the first connector body carries a first set of contactors and the second connector body carries a second set of contactors, comprising:
- a. providing first circuitry that identifies at least first and second electrically mating pairs that are electrically isolated from each other, from among the first and second sets of contactors; and
- b. providing second circuitry that establishes the power connection using the at least first and second electrically mating pairs.
2. The method of claim 1, wherein the first set of contactors has at least two contactor members, and the second set of contactors has at least three contactor members.
3. The method of claim 1, wherein the first set of contactors has n contactor members, and the second set of contactors has at least n+1 members.
4. The method of claim 1, wherein the first circuit identifies a third electrically mating pair that is electrically isolated from the first and the second electrically mating pairs, from among the first and second sets of contactors, and wherein the second circuitry establishes a power connection using the third electrically mating pair.
5. The method of claim 4, wherein the first circuit identifies a fourth electrically mating pair that is electrically isolated from the first, the second and the third electrically mating pairs, from among the first and second sets of contactors, and wherein the second circuitry establishes a power connection using the fourth electrically mating pair.
6. The method of claim 1, wherein the first and the second connector bodies are shaped to meet along a planer interface.
7. The method of claim 1, further comprising utilizing the power connection to charge an electric vehicle.
Type: Application
Filed: Nov 2, 2019
Publication Date: Mar 26, 2020
Inventor: Satyajit Patwardhan (Fremont, CA)
Application Number: 16/672,444