Information
-
Patent Grant
-
6193563
-
Patent Number
6,193,563
-
Date Filed
Friday, May 28, 199925 years ago
-
Date Issued
Tuesday, February 27, 200123 years ago
-
Inventors
-
Original Assignees
-
Examiners
-
CPC
-
US Classifications
Field of Search
US
- 439 607
- 439 608
- 439 609
- 439 701
- 439 677
- 439 680
- 439 681
- 439 378
- 439 65
- 439 357
- 439 372
-
International Classifications
-
Abstract
An electrical connector assembly includes a receptacle connector having a housing defining a mating receptacle. A dielectric wafer is mounted in the housing. A plurality of terminal pins are mounted through the wafer with mating ends of the pins projecting from one side of the wafer into the mating receptacle and connector ends of the pins projecting from an opposite side of the wafer. A plurality of discrete first connector modules are mounted on the housing for termination to selected ones of the connector ends of the terminal pins. A plug connector includes a shell defining a mating plug for insertion into the mating receptacle of the receptacle connector. A plurality of discrete second connector modules are mounted on the shell for termination to selected ones of the mating ends of the terminal pins when the plug connector is mated with the receptacle connector.
Description
FIELD OF THE INVENTION
This invention generally relates to the art of electrical connectors and, particularly, to an electrical connector assembly for connecting a large number of electrical wires in a modular system.
BACKGROUND OF THE INVENTION
There are various applications in which a large number of electrical wires must be terminated in a single electrical connector which, in turn, is mated with a complementary connector that also is terminated to the same large number of electrical wires. One such example of this type of application is in machine tools and robotic applications, such as in the automotive industry. In a typical example, six electrical wires may be required for each axis of a hexaxial robot, resulting in a total of thirty-six wires having to be terminated to thirty-six terminals mounted on an insulative housing. These wires must be connected individually, and care must be taken that they are connected in their designated groups of six wires.
It can be understood from the above that problems often can be encountered in terminating such electrical connectors having such large numbers of wires and terminals. The connecting process may be difficult and inefficient. This is particularly true if the lengths of the respective wires, such as in a wiring harness, are different due to the difference in positions of the axes of a robot, for instance. Other problems are encountered in the inefficiency of using such wiring systems when maintenance or replacement must be performed. Other problems encountered with such connectors include the difficulty in polarizing such large connectors, in grounding such connectors and in ensuring that the connectors are fully mated. Often, lever-type assisting mechanisms are used to ensure that the connectors in a connector assembly are fully mated.
The present invention is directed to solving one or more of the problems discussed above.
SUMMARY OF THE INVENTION
An object, therefore, of the invention is to provide a new and improved electrical connector assembly which incorporates a modular termination system.
In the exemplary embodiment of the invention, a first connector, such as a receptacle connector, includes a housing defining a mating portion, such as a mating receptacle. A dielectric wafer is mounted in the housing. A plurality of terminal pins are mounted through the wafer. The terminal pins include mating ends projecting from one side of the wafer into the mating receptacle and connector ends projecting from an opposite side of the wafer. A plurality of discrete first connector modules are mounted on the housing for termination to selected ones of the connector ends of the terminal pins.
The connector assembly also includes a plug connector having a shell defining a mating plug for insertion into the receptacle of the receptacle connector. A plurality of discrete second connector modules are mounted on the shell for termination to selected ones of the mating ends of the terminal pins when the plug connector is mated with the receptacle connector.
As disclosed herein, both the first and second connector modules are substantially identical. The housing of the receptacle connector includes a plurality of discrete recesses within which the first connector modules are mounted. The shell of the plug connector also includes a plurality of discrete recesses within which the second connector modules are mounted.
The terminal pins are mounted through the wafer at locations defining a plurality of clusters of pins. One pin cluster corresponds to each of a plurality of pairs of the first and second connector modules. Each module includes a dielectric housing mounting a plurality of female terminals corresponding to one of the clusters of terminal pins. For instance, in relation to the robotic example set forth in the “Background”, above, there may be six clusters of six terminal pins, with each cluster of pins being provided for each axis in a hexaxial robot.
Other objects, features and advantages of the invention will be apparent from the following detailed description taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of this invention which are believed to be novel are set forth with particularity in the appended claims. The invention, together with its objects and the advantages thereof, may be best understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements in the figures and in which:
FIG. 1
is a somewhat schematic or block diagram of a termination system provided by the connector assembly of the invention;
FIG. 2
is a plan view of the receptacle or mating end of the plug connector of the connector assembly;
FIG. 3
is a side elevational view of the plug connector;
FIG. 4
is an end elevational view of the plug connector;
FIG. 5
is a section taken generally along line A—A of
FIG. 2
;
FIG. 6
is a section taken generally along line B—B of
FIG. 2
;
FIG. 7
is a plan view looking at the termination face of one of the connector modules, on an enlarged scale;
FIG. 8
is a side elevational view of the connector module of
FIG. 7
;
FIG. 9
is a plan view of the mating face of the connector module;
FIG. 10
is an end elevational view of the connector module;
FIG. 11
is a plan view of the termination face of the plug shell of the plug connector of the connector assembly;
FIG. 12
is a side elevational view of the plug shell of
FIG. 11
;
FIG. 13
is a plan view of the mating face of the plug shell;
FIG. 14
is an end elevational view of the plug shell;
FIG. 15
is a section taken generally along line C—C in
FIG. 11
;
FIG. 16
is a section through the entire electrical connector assembly incorporating the concepts of the invention, taken in the mating direction of the connectors and with the connectors in unmated condition;
FIG. 17
is a sectional view similar to that of
FIG. 16
, but with the connectors in mated condition; and
FIG. 18
is a side elevational view of the mated connector assembly as shown in FIG.
17
.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in greater detail,
FIG. 1
shows a somewhat schematic or block diagram of the termination system afforded by the connector assembly of the invention.
FIGS. 2-6
show the receptacle connector of the connector assembly.
FIGS. 7-10
show one of the identical connector modules that are used in both the plug connector and the receptacle connector of the assembly.
FIGS. 11-15
show the plug shell of the plug connector.
FIGS. 16-18
show the entire connector assembly including both the receptacle connector and the plug connector.
Turning to first to
FIG. 1
, the connector assembly of the invention is readily applicable for use in such applications as robotic applications involving machine tools, assembly apparatus and the like, which may be encountered in the automotive industry, for instance. With that understanding, the left-hand side of
FIG. 1
might represent a controlled side of a machine tool such as a robot main body, and the right-hand side of
FIG. 1
might represent a control equipment side such as a controller. The controlled side at the left of
FIG. 1
includes a plurality of wires
1
divided into six groups “g
1
-g
6
”. The six groups of wires
1
are terminated to six identical connector modules, generally designated
2
. The right or control equipment side of
FIG. 1
shows a plurality of wires
3
in six groups “g
1
-g
6
”, with the wires in each group terminated to identical connector modules, generally designated
2
. All of connector modules
2
on both the left and right sides of the termination system can be identical in structure and configuration.
Still referring to
FIG. 1
, a first or receptacle connector, generally designated
4
, includes a plurality of terminal pins
5
mounted through an insulative or dielectric wafer
6
to form a wafer assembly
7
within receptacle connector
4
. The pins are arranged in six clusters “b
1
-b
6
”. The six connector modules
2
terminated to the six groups of wires
3
on the control equipment side are mounted in a plug shell
8
of a second or plug connector, generally designated
9
. With the termination system of
FIG. 1
, group “g
1
” of wires
1
terminated to connector module
2
on the left or controlled side of the system are connected through terminal pins “b
1
” of receptacle connector
4
to wires
3
in group “g
1
” terminated in one of the connector modules
2
of plug connector
9
, and so on through groups “g
2
-g
6
” of wires in the system.
FIGS. 2-6
show plug connector
4
(
FIG. 1
) with dielectric wafer
6
and terminal pins
5
mounted within a generally rectangular outer housing
10
. The housing is fabricated of die cast metal material, such as aluminum. Wafer assembly
7
, including wafer
6
and terminal pins
5
, is secured within the housing by locking pins
11
(FIG.
6
). The terminal pins are arranged in six clusters of six pins corresponding to clusters “b
1
-b
6
” as described above in relation to FIG.
1
.
Still referring to
FIGS. 2-6
, housing
10
of receptacle connector
4
defines a terminal face
10
a
and a mating face
10
b
. Six identical module-receiving receptacles
12
(
FIG. 5
) are formed in termination face
10
a
for receiving six connector modules
2
(FIG.
1
). A generally rectangular plug-receiving receptacle
13
is formed in mating face
10
b
for receiving a plug portion of plug shell
8
(
FIG. 1
) of plug connector
9
, as described hereinafter. Terminal pins
5
are mounted through wafer
6
as best seen in
FIGS. 5 and 6
and include mating ends
5
a
projecting into plug-receiving receptacle
13
and connector ends
5
b
projecting into module-receiving receptacles
12
.
Finally, a latch post
15
projects outwardly from each opposite side of housing
10
of receptacle connector
4
for purposes described hereinafter. A polarizing recess
16
is formed in three corners of receptacle
13
. The recesses are in the form of grooves extending in the mating direction of the connectors. A grounding clip
17
(
FIG. 2
) is mounted at each opposite end of housing
10
of receptacle connector
4
as will be described in greater detail hereinafter.
FIGS. 7-10
show one of the connector modules
2
(
FIG. 1
) which are inserted into receptacles
12
(
FIG. 5
) of receptacle connector
4
. The connector modules also are mounted in plug shell
8
(
FIG. 1
) of plug connector
9
as described hereinafter. It should be understood that the terminals have been removed from module
2
in
FIGS. 7-10
to avoid cluttering the illustration.
More particularly, each module
2
(
FIGS. 7-10
) includes an insulative or dielectric housing, generally designated
18
. The housing includes a plurality of terminal-receiving passages
19
. Six passages are provided corresponding to the six terminal pins in each of the clusters of pins “b
1
-b
6
” (FIGS.
1
and
2
). Housing
18
defines a connecting or mating end
20
and a termination end
21
. The mating end is inserted into one of the module-receiving receptacles
12
(
FIG. 5
) of receptacle connector
4
, and electrical wires
1
(
FIG. 1
) are terminated to female terminals inserted into passages
19
through termination end
21
. A pair of cantilevered latch arms
23
are provided at opposite ends of housing
18
. The latch arms have chamfered latch projections
24
which latch behind latch shoulders
25
(
FIG. 5
) within receptacles
12
of receptacle connector
4
. Key grooves
26
are formed in opposite sides of housing
18
for receiving keying ribs
27
(
FIG. 5
) within receptacles
12
of receptacle connector
4
to polarize the modules and the receptacles so that the modules can be inserted into the receptacles in only given preselected orientations.
Referring to
FIGS. 11-15
, plug shell
8
of plug connector
9
(
FIG. 1
) is shown in detail. The plug shell is formed of die cast metal, such as aluminum, similar to housing
10
of receptacle connector
4
. The plug shell includes a generally rectangular body
8
a
having a peripheral flange
28
thereabout, along with a grounding pole
29
projecting from the flange opposite body
8
a
. The body has a plurality of partitions
30
which form a plurality of module-receiving receptacles
31
. Receptacles
31
are similar to receptacles
12
(
FIG. 5
) of receptacle connector
4
for receiving identical connector modules
2
. Similarly, polarizing keys
32
are provided within receptacles
31
for positioning in key grooves
26
of the connector modules. Latch shoulders
33
(
FIG. 15
) are provided for engaging latch projections
24
of cantilevered latch arms
23
of the connector modules.
As best seen in
FIGS. 11 and 13
, mounting holes
34
are formed through flange
28
at the four corners thereof, for purposes described hereinafter. Finally, as best seen in
FIG. 13
, three polarizing ribs
35
are provided at three corners of rectangular body
8
a
. The polarizing ribs extend in the mating direction of plug connector
9
and are sized for insertion into polarizing grooves
16
(
FIG. 2
) of receptacle connector
4
to ensure that the plug connector can be inserted into the receptacle connector in only one given orientation.
Referring to
FIG. 16
in conjunction with
FIGS. 11-15
, the housing of plug connector
9
is a two-part housing including plug shell
8
and a cover
36
. Plug shell
8
is mounted within the bottom of cover
36
by means of fasteners
37
extending through mounting holes
34
(
FIGS. 11 and 13
) of the plug shell and into a lower peripheral edge of the cover. A wiring harness (not shown) extends through an entrance
38
to the inside of cover
36
. A sealing gasket
39
may be compressed by a nut
40
about the wiring harness. The wiring harness will include electrical wires
3
(
FIG. 1
) for terminating to a plurality of female terminals
41
mounted within passages
19
of connector modules
2
mounted within plug shell
8
.
FIG. 16
also shows identical female terminals
41
mounted within passages
19
of a plurality of connector modules
2
mounted within housing
10
of receptacle connector
4
. It can be seen in
FIG. 16
that connector ends
5
b
of terminal pins
5
are engaged by female terminals
41
mounted within housing
10
of receptacle connector
4
. Mating ends
5
a
of terminal pins
5
which extend through wafer
6
of the receptacle connector, are aligned with female terminals
41
of connector modules
2
mounted within plug shell
8
of plug connector
4
.
FIG. 17
shows plug connector
9
inserted into receptacle
13
of receptacle connector
4
in the direction of arrow “A”. When fully mated, mating ends
5
a
of terminal pins
5
move into female terminals
41
mounted within connector modules
2
which, in turn, are mounted within plug shell
8
of plug connector
9
.
FIGS. 16 and 17
also show the details of grounding clips
17
. Specifically, each grounding clip is generally U-shaped to embrace a wall
42
of housing
10
of receptacle connector
4
. Each U-shaped grounding clip is stamped and formed of conductive sheet metal material and has a first leg
17
a
disposed within receptacle
13
(
FIG. 16
) of the receptacle connector. A second leg
17
b
of the clip is positioned along the outside of wall
42
and terminates in an outwardly projecting flange
17
c
. The flange includes a mounting hole
43
(
FIG. 2
) aligned with a mounting hole
44
(FIGS.
16
and
17
). Conductive fasteners are inserted through mounting holes
44
to mount the receptacle connector to a conductive chassis. Because of the tolerances involved in die casting housing
10
of receptacle connector
4
and plug shell
8
of plug connector
9
, grounding clips
17
may be fabricated of material such as stainless steel to provide good positive engagement between the two connectors for grounding purposes. In fact, it can be seen in comparing
FIG. 16
with
FIG. 17
that legs
17
a
of the grounding clips within receptacle
13
of the receptacle connector form spring fingers for engaging the outside of plug shell
8
. Grounding pole
29
of the plug shell also might be used for attachment to a ground wire from the wiring harness extending through entrance
38
of cover
36
.
Referring to
FIG. 18
in conjunction with
FIGS. 16 and 17
, a mating assist system is provided to ensure that receptacle connector
4
and plug receptacle
9
are fully mated. More particularly, a generally U-shaped lever, generally designated
50
(
FIG. 18
) is mounted for pivoting about a pivot post
51
which is fixed to and projects outwardly from each opposite side of cover
36
. The U-shaped lever defines a lever arm
52
on each opposite side of the cover
36
, joined by a bight portion
53
. The bight portion has a flange
54
which defines a tab for facilitating manual grasping and manipulation of the lever. Each lever arm
52
has an aperture
55
which embraces a respective one of the pivot posts
51
, and the aperture is larger than the pivot post to allow for lost motion between the lever and the posts. Each pivot post
51
includes a head portion
51
a
which is larger in diameter than aperture
55
so that the lever arms are maintained on the posts.
Each lever arm
52
of lever
50
includes a latch portion in the form of a hook
56
for engaging one of the latch posts
15
of receptacle connector
4
. A generally U-shaped spring
57
defines a pair of legs
58
and
59
. The distal end of leg
58
of the spring is anchored in lever arm
52
. The distal end of leg
57
of the spring is wrapped around pivot post
51
. With lost motion being provided between the lever and the pivot posts because of enlarged apertures
55
, springs
51
are effective to bias the lever in the direction of arrow “B” which is generally in the mating direction of the connectors. Therefore, when lever
50
is pivoted about pivot posts
51
in the direction of arrow “C”, latch hook
56
draws receptacle connector
4
into mating engagement with plug connector
9
through the interengagement of the latch hook with latch posts
15
of the receptacle connector. Springs
50
are effective to further draw lever
50
upwardly in the direction of arrow “B” which, in turn, draws receptacle connector
4
therewith to ensure that the connectors are fully mated.
An additional feature of mating assist lever
50
is that an enlarged detent recess
60
is formed at the base of each lever arm
52
and latch hook
56
. These detent recesses allow latch posts
15
of receptacle connector
4
to “snap” into the recesses and render an audible and tactile indication that the connectors are fully mated.
Finally, a lock pin
61
(
FIGS. 16-18
) extends through bight portion
53
of lever
50
. The lock pin is spring loaded by a spring
62
for biasing inwardly in the direction of arrow “D”. When lever
50
is rotated to its complete mating position, lock pin
61
is biased by spring
62
into a locking hole
63
at the top of cover
36
to hold the lever in its full mating position.
It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein.
Claims
- 1. An electrical connector assembly, comprising:a receptacle connector including a housing defining a mating receptacle, a dielectric wafer mounted in the housing, a plurality of terminal pins mounted through the wafer with mating ends of the pins projecting from one side of the wafer into the mating receptacle and connector ends of the pins projecting from an opposite side of the wafer, and a plurality of discrete first connector modules mounted on the housing for termination to selected ones of the connector ends of the terminal pins; and a plug connector including a shell defining a mating plug for insertion into the mating receptacle of the receptacle connector, and a plurality of discrete second connector modules mounted on the shell for termination to selected ones of the mating ends of the terminal pins when the plug connector is mated with the receptacle connector.
- 2. The electrical connector assembly of claim 1 wherein the housing of said receptacle connector and the shell of said plug connector are fabricated of die-cast metal material.
- 3. The electrical connector assembly of claim 1 wherein said first connector modules are substantially identical.
- 4. The electrical connector assembly of claim 3 wherein the housing of said receptacle connector includes a plurality of discrete recesses within which the first connector modules are mounted.
- 5. The electrical connector assembly of claim 1 wherein said second connector modules are substantially identical.
- 6. The electrical connector assembly of claim 5 wherein the shell of said plug connector includes a plurality of discrete recesses within which the second connector modules are mounted.
- 7. The electrical connector assembly of claim 5 wherein said first connector modules are substantially identical.
- 8. The electrical connector assembly of claim 7 wherein the housing of said receptacle connector includes a plurality of discrete recesses within which the first connector modules are mounted.
- 9. The electrical connector assembly of claim 1 wherein said terminal pins are mounted through the wafer at locations defining a plurality of clusters of pins, with one pin cluster corresponding to each of a plurality of pairs of said first and second connector modules.
- 10. The electrical connector assembly of claim 9 wherein said first and second connector modules are identical and each module includes a dielectric housing mounting a plurality of female terminals corresponding to one of said clusters of terminal pins.
- 11. An electrical connector, comprising:a housing defining a receptacle for receiving a complementary mating plug connector; a dielectric wafer mounted in the housing; a plurality of terminal pins mounted through the wafer with mating ends of the pins projecting from one side of the wafer into the receptacle for connection to appropriate terminals of the plug connector, and connector ends of the pins projecting from an opposite side of the wafer, said terminal pins being mounted through the wafer at locations defining a plurality of spaced apart clusters of pins, each said cluster of pins being spaced from an adjacent cluster of pins by a first predetermined distance each said cluster including a plurality of spaced apart terminal pins the pins of each said cluster being spaced apart a second predetermined distance, the first predetermined distance being greater than said second predetermined distance; and a plurality of discrete connector modules mounted on the housing for termination to selected ones of the connector ends of the terminal pins each of the discrete connector modules corresponding to a predetermined one of said plurality of pin clusters.
- 12. The electrical connector of claim 11 wherein the housing is fabricated of die-cast metal material.
- 13. The electrical connector of claim 11 wherein said discrete connector modules are substantially identical.
- 14. The electrical connector of claim 13 wherein the housing includes a plurality of discrete recesses within which the connector modules are mounted.
- 15. The electrical connector of claim 11 wherein said connector modules are identical and each module includes a dielectric housing mounting a plurality of female terminals corresponding to one of said clusters of terminal pins.
Priority Claims (1)
Number |
Date |
Country |
Kind |
10-166391 |
May 1998 |
JP |
|
US Referenced Citations (9)
Foreign Referenced Citations (1)
Number |
Date |
Country |
736932 |
Oct 1996 |
EP |