This application is directed to product transfer equipment and modules, and more specifically, an electrical converter adapter that enables production transfer equipment to connect with equipment having incompatible electrical connectors.
Modern-day automated equipment comes equipped with wiring that facilitates applications such as power, controls, signals, data communication, telemetry etc. End electrical connectors are provided on individual equipment where the wiring terminates, commonly referred to as electrical terminations or end terminals. An electrical connector is an electro-mechanical device used to join electrical terminations to create an electrical circuit. Electrical connectors generally include plugs (male-ended) and jacks (female-ended). The connectors may be used to physically integrate different pieces of equipment that make up the system. The end connectors allow power, controls, signals and data to flow through the system thereby creating a virtual eco-system made of different pieces of equipment, where each performs its designated task(s). The electrical connection may be temporary, as for portable equipment, require a tool for assembly and removal, or serve as a permanent electrical joint between two wires or devices.
Different types and sizes of electrical connectors are available in market to meet different applications. However, certain Original Equipment Manufacturers (OEMs) commonly use only a certain type of connector across their different product lines. However, there may be a challenge to system integrators trying to build a system by connecting equipment from multiple OEMs. Equipment that needs to be physically coupled within a system may come in with different/incompatible electrical connectors, thus preventing them from being physically connected. What is needed is an adapter that may be used to effectively bring together electrically incompatible connectors.
Reference is now made to the following descriptions taken in conjunction with the accompanying drawings and illustrations in which:
Disclosed herein are aspects of a product transfer system and electrical adapters that may be used therein. Different OEMs for equipment, such as product transfer equipment, may prefer to use a specific type of electrical connector on their equipment. However, when an end customer tries to integrate equipment built by multiple OEMs into a product transfer system, the electrical connections of all of the equipment may not be compatible. As such, one or more electrical adapters may be needed to connect equipment that has heretofore been electrically incompatible. Being able to connect equipment with incompatible electrical connections in series may provide greater flexibility in at least the layout and installation of a product transfer system. Disclosed herein are embodiments of electrical adapters that may be used to couple together various components of a product transfer system that have been previously electrically incompatible.
In the disclosure, the terms “upstream,” downstream,” and similar terms are used in the context of a product flow stream, where product flows from “upstream” to “downstream.”
As used herein, the term “jack” may be used generally when describing to pins for a female connector and “plug” or “slot” may be used when describing pins for a male connector.
Referring now to
In this embodiment, the ports P2 and P4 may not include any plugs, but there may be other embodiments where P2 and P4 may be configured for various connector purposes. Similarly, jack 3235 and jack 4240 may not be used in this embodiment, but in some embodiments, jack 3235 and jack 4240 and ports P2 and P4 may be configured for various connector purposes. Further, the unused jacks, plugs, and ports of the adapter 200 may also be used to facilitate “serial communication” between adjacent equipment modules or conveyor segments. The serial communication may enable features such as “gapping” and a Zero Pressure Accumulation (ZPA) mode of functioning of an adjoining conveyor. Accordingly, the serial communication may facilitate programming intelligence or communication of operation into a dummy conveyor or similar conveyor segment that may not currently have at least the foregoing features. Other embodiments of an adapter having at least two additional jacks and ports beyond at least 6 may also include jacks or ports for enabling an Ethernet connection.
In some embodiments, the plugs of the male connector 315 may be positioned within a slot module. In this embodiment, the module may employ slots P1 and P3, and slots P1 and P4 may be empty or used for various other connector purposes such as discussed above. While the slots P1-P4 are shown in this configuration, alternative configurations for these slots P1-P4 may be employed. For example, a 2-plug male insert of the male connector 215 may be housed in slots P2, P3 or P4. Similarly, a 5-plug insert may be housed in either P1, P2, P3 or P4. One of the unique aspects of the adapter 300 is the wiring scheme where at least one of a selected jack of the 6 jacks 325-350 comprising the female connector 210 may be wired to one of a selected plug of the plugs 365-390 of the male connector 315.
Referring now to
Referring now to
The second connector 415 may also be a male connector, and may in some embodiments, have slots labeled as P1, P2, P3 and P4. In some embodiments, the slots P1-P4, and plug P5 may have the same, or similar electrical configuration construction as connector 410.
In some embodiments, the arrangement of plugs within the slots and ports may be altered or adjusted in order to meet an application for connecting a female connection with one of the male connectors 410 or 415. For example, slots J1 and P1 may in some embodiments include AC power plugs and in some embodiments, 10AWG wires may be used connect plug in J1-1 to P1-1 and J1-2 to P1-2. In some embodiments, the cables may include heavy gage wires. Slots J2 and P2 may, in some embodiments, include Ethernet plugs, such as, e.g. RJ45 Ethernet ports. The two Ethernet ports J2 and P2 may in some embodiments be connected by an Ethernet cable, such as a CAT 5E Ethernet cable. In this example, the cable may be specifically selected to facilitate IP based data transfer that allows different equipment within a data transfer system to communicate with each other.
Slots J3, J4, P3 and P4, in some embodiments, may each include 5-plug modules. The plugs, in some embodiments, may be connected by 18AWG wires. In some embodiments, the wires connecting the plugs in slots J3, J4, P3 and P4 may be configured to carry a control signals that allow a logic programs to operate and communicate between the various modules and segments in a product transfer system, such as product transfer system 100.
The two male connectors 410 and 415 may be joined, in some embodiments, by a cable conduit 420 configured to relay or carry the above-mentioned wiring. The length of the conduit may be varied according to the given application In some embodiments, such as the example shown, the length may be 20 inches, but there may be other embodiments with shorter or longer lengths such as, e,g., about 2 inches to about 48 inches, or even longer or shorter as needed.
Accordingly, the adapter 400 may facilitate more flexibility in arrangement of certain equipment on a manufacturing, warehouse, or product transfer area. Additional examples and details will be shown and described herein.
Referring now to
Various embodiments of a product transfer system, components therein, and electrical adapters have been disclosed herein. In some aspects, there may be a product transfer system comprising a plurality of conveyors, wherein the conveyors may include one or more flexible conveyors, one or more expandable conveyors, one or more gapper conveyors, or one or more 90° curved conveyor segments; wherein the plurality of conveyors may be connected in series and may also be coupled with a scanning module. In some embodiments, at least two of the conveyors placed in series may not be electrically compatible with the adjacent conveyor in the series. As such, the system may further include at least one electrical adapter, wherein the electrical adapter is one of a first adapter or a second adapter. The first adapter may include a female connector at one end and a male connector at an opposing end. The second adapter may include a male adapter at one end and another make adapter at an opposing end. In one embodiment, the first adapter may include an EPIC 9-pin female connector at one end and a Phoenix 6 pin male connector at the opposing end. In another embodiment, the second adapter may include a male Phoenix 9-pin connector at both ends. In other embodiments, the second adapter may include a female connector at both ends.
In some aspects, an electrical adapter includes an EPIC female connector and Phoenix male connector. The two connectors may be held together by a pigtail conduit of re-determined wiring. The adapter may allow electrical compatibility between equipment from various manufacturers to be connected in series with each other. While connectors and electrical connections have been discussed in some embodiments using certain manufacturers as examples, including Epic and Phoenix, embodiments of the adapters according to the disclosure are not limited to these manufacturers and may include connectors and connections may be made by any manufacturer of male and female connectors and electrical connections.
In another aspect, a gender conversion adapter may include a male connector at each ends thereof. The two male connectors may be held together by a pigtail conduit of pre-determined wiring as explained above. This gender conversion adapter may be applied, in some embodiments, where a curved conveyor segment may be installed into a product transfer system.
In other aspects, there may be a curved conveyor segment which may toggle between two flow directions, such that in a first setting, product may flow from right to left. In a second setting, product may flow from left to right. In one embodiment, at least one adapter according to the disclosure may connect the curve connector with at least one adjacent piece of equipment in the product transfer system.
The adapters according to the disclosure allow for improved modularity in a product transfer system irrespective of the manufacturers of each piece of equipment incorporated into the system.
Aspects disclosed herein include:
Aspect A: An electrical adapter, the adapter comprising: a female connector at one end; and a male connector at an opposing end, the male connector coupled with the female connector via wiring; wherein the female connector is a six jack connector wherein at least a first of the six jacks is configured for AC power, and at least a second of the six jacks is configured for relaying control signals; and wherein the male connector is a nine plug connector having at least a first of the nine plugs is configured for AC power, and at least a second and third plug of the nine plugs are configured for relaying control signals.
Aspect B: an electrical adapter, the adapter comprising: a first male connector at one end and a second male connector at an opposing end, the male connectors coupled via wiring; wherein each male connector is a nine plug connector having at least one plug configured for AC power, and two or more plugs configured for relaying control signals.
Aspect C: a product transfer system, the system comprising: a curved conveyor segment, the curved conveyor segment configured to switch between at least a first product flow direction and a second product flow direction, and having at least a first electrical connection at one end thereof; a product handling segment adjacent to the curved conveyor segment, the product handling segment having an electrical connector at one end thereof; and at least one electrical adapter for connecting the curved conveyor segment with product handling segment, wherein the at least the first electrical connection of the curved conveyor segment is incompatible for connection with the electrical connector of the product handling segment; wherein the at least one electrical adapter includes a first electrical adapter connector at one end thereof and a second adapter connector at an opposing end.
Aspects A, B, and C may have one or more of the following additional elements in combination: Element 1: wherein at least another of the six jacks is an Interlock IN connection; Element 2: wherein at least another of the six jacks is an Interlock OUT connection; Element 3: wherein at least another of the six jacks is configured for an Ethernet port; Element 4: wherein at least another of the nine plugs is an Interlock IN connection; Element 5: wherein at least another of the nine plugs is an Interlock OUT connection; Element 6: wherein the nine plugs are positioned in four-slot module carrier frame; Element 7: wherein five of the nine plugs are positioned in a same slot of the four-slot module carrier frame; Element 8: wherein the female connector includes 9 jacks; Element 9: wherein the male connector includes only 6 plugs; Element 10: wherein the first electrical adapter connector is a six jack female connector, wherein at least a first of the six jacks is configured for AC power, at least a second of the six jacks is configured for relaying control signals; Element 11: wherein the first electrical adapter connector is a nine jack female connector, wherein at least a first of the jacks is configured for AC power, at least a second of the jacks is configured for relaying control signals; Element 12: wherein at least another of the jacks is configured for an Ethernet port; Element 13: wherein the first electrical adapter connector is a nine plug connector having at least one plug configured for AC power, and two or more plugs configured for relaying control signals; Element 14: wherein the second electrical adapter connector is a nine plug connector having at least one plug configured for AC power, and two or more plugs configured for relaying control signals; Element 15: wherein the plugs are positioned in four-slot module carrier frame; and Element 16: wherein five of the plugs are positioned in a same slot of the four-slot module carrier frame.
Further additions, deletions, substitutions and modifications may be made to the described embodiments
This application claims the benefit of U.S. Provisional Application Ser. No. 62/870,838, filed by Tom Karol, et al. on Jul. 5, 2019, entitled “ELECTRICAL CONVERTER ADAPTERS FOR INCREASED MODULARITY IN A PRODUCT TRANSFER SYSTEM,” commonly assigned with this application and incorporated herein by reference in its entirety.
Number | Date | Country | |
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62870838 | Jul 2019 | US |