This invention relates to apparatus, systems, and methods for connecting drive controls to motors and more particularly, although not necessarily exclusively, to devices providing mechanical and electrical connections between drive controllers and motors of pumps of water-circulation systems of swimming pools and spas.
Multi-speed motors are configured to change rotational speed upon command. Such commands may originate with a computerized controller capable of transmitting the commands to a motor. Although transmission may occur wirelessly, often commands are transmitted via wire from controllers to motors.
Pumps used as parts of outdoor pool- and spa-water circulation systems frequently are positioned outdoors, near their associated pools or spas. Consequently, they are subject to being contacted by water, which may damage motors of the pumps. To minimize risk of water-intrusion damage, the motors typically are contained within waterproof housings. However, because the motors require electrical power to operate, at least some penetration of the housings typically is necessary to route electrical wires to the motors.
Moreover, at least some controllers are configured to mount onto the motor housings. These controllers, then, require both mechanical connections to the housings and electrical connections to the internal motors. At least some controllers, further, are designed or rated for use with motors of particular output, so that some method of ensuring that a controller and motor are compatible prior to attempted operation would be beneficial. Standardization of the connectors across a line of pumps of a manufacturer likewise may be advantageous.
The present invention seeks to satisfy some of these requirements in beneficial manners. In some versions of the invention, alignment and keying of connectors may be intuitive and designed to reduce, if not minimize (or wholly prevent), errors in attaching drive controllers to motor housings. An installer may position a controller adjacent—and preferably above—a motor housing so that a tower of the housing aligns and fits snugly within a chimney-like opening of the controller. As the installer lowers the drive controller, a keying pin of the controller aligns with a mating hole of the motor housing. Continued lowering of the controller causes male electrical terminals of the controller to fit into female terminals of the motor housing configured to convey electricity to the motor inside the housing.
Proceeding in this manner results in mechanically and electrically connecting the drive controller to the motor housing while protecting the male terminals from misalignments that could causes breaking or bending. Female terminals too are protected from these misalignments. Proceeding in this way also permits keying of controllers to motor housings to ensure their operational compatibility and may effectively supply a seal between the two components to prevent ingress of debris and moisture. Additional benefits of the present invention may include its modular nature and capability of providing complete sealing between the printed circuit boards (PCBs) and housings of the drive controllers so that drive electronics can be encapsulated without leaking or contaminating the electrical terminals. Accordingly, the present invention may provide robust mechanical guidance and alignment, solid electrical connections, and inherent keying of drive controllers and motor housings.
It thus is an optional, non-exclusive object of the present invention to provide apparatus and methods for connecting components of, e.g., water-circulation systems of swimming pools or spas.
It is another optional, non-exclusive object of the present invention to provide systems and techniques for mechanically and electrically connecting drive controllers to motor housings.
It is a further optional, non-exclusive object of the present invention to provide robust connection mechanisms with alignment, sealing, and keying capabilities.
Other objects, features, and advantages of the present invention will be apparent to those skilled in the art with reference to the remaining text and the drawings of this application.
Shown too in
First gasket 26 further is illustrated in
Tower 34 is configured to fit snugly within chimney 14, thereby supplying initial alignment of the controller and motor housing before pin 22 reaches hole 46. Assuming pin 22 is sized, shaped, and positioned (i.e. keyed) so as to be received into hole 46, further tightening of the alignment may occur. These alignments facilitate mating of male terminals 18 and female terminals 42, hence reducing the possibility of the terminals being damaged by any misalignments that otherwise might exist. Alternatively, pin 22 may protrude sufficiently so that it engages hole 46 prior to contact between tower 34 and chimney 14, although this alternative approach presently is not preferred.
Supplemental gaskets may, if desired, be used. A second gasket, for example, may be placed at the base of tower 34 and function to seal space between tower 34 and chimney 14 to reduce ingress of debris and moisture into the space. A third gasket may be positioned under tower 34 to prevent ingress of debris and moisture into the motor within the motor housing.
The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of the present invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of the invention. Additionally, the word “pool” and phrase “swimming pool” as used herein may include vessels such as spas and hot tubs within its definition.
This application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 62/635,630, filed Feb. 27, 2018, and having the same title as appears above, the entire contents of which application are hereby incorporated herein by this reference.
Number | Date | Country | |
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62635630 | Feb 2018 | US |