Electrical power distribution system

• US 7,819,676 B1
• Filed: 11/12/2009
• Issued: 10/26/2010
• Est. Priority Date: 11/12/2009
• Status: Active Grant

• Current Assignee: Power Distribution Incorporated (Eaton Corporation PLC.)
• Original Assignee: Power Distribution Incorporated (Eaton Corporation PLC.)
• Inventors: Katz, Alan, Cardoso, Roberto, Cortes, Timothy, Schmid, Keith, Horta, Enrique, Kammeter, John, Jauregui, Miguel
• Primary Examiner(s): TA, THO DAC
• Application Number:
  US12/617,289
• Time in Patent Office: 348 Days
• Field of Search: 439110-116, 439/259, 439/265
• US Class Current: 439/115
• CPC Class Codes: H01R 13/245 by stamped-out resilient contact arm
• CPC Class Codes: H01R 13/2457 consisting of at least two resilient arms contacting the same counterpart
• CPC Class Codes: H01R 25/145 Details, e.g. end pieces or joints H01R25/147 takes precedence
• CPC Class Codes: H02G 3/0431 Wall trunking
• CPC Class Codes: H02G 3/105 in association with a plinth, channel, raceway or similar
• CPC Class Codes: H02G 5/08 Connection boxes therefor

Abstract

An electrical power distribution system that can provide power to load equipment at any point along its length includes two main components: a power track housing assembly with current carrying conductors that can be mounted to the wall, ceiling or under the floor, and a plug-in power tap. The power track housing assembly includes a housing, insulators, and two or multiple conductors. In order to increase the housing assembly length, the housing assembly is preferably arranged such that multiple housing assemblies can be spliced together using cam operated splicing assemblies that form straight, “90 degree” and/or “T” splices to configure the system to match the equipment arrangement, and that allow all conductors in respective housing assemblies to be connected to each other simultaneously. The plug-in power taps also employ a system such as a shaft-cam mechanism that allows the assemblies to be electrically connected to all phase conductors within the power track housing assembly simultaneously. In addition, the power taps may include circuit breakers or other protective devices, and/or other sub-modules.

Claims

1. An electrical power distribution system, comprising:

a power track housing assembly including;

a housing;

a plurality of conductors extending from a first end of the housing to a second end of the housing;

an opening in a bottom of the housing assembly and extending continuously from the first end of the housing to the second end of the housing, said opening being arranged to receive a plug-in power tap anywhere along said length of said housing assembly; and

additional end openings at said first and second ends of said housing, said additional openings being arranged to receive splice assemblies for connecting together multiple said housing assemblies;

a plug-in power tap, a portion of which is arranged to be inserted into said power track housing assembly through said bottom opening, said plug-in power tap including;

a contact extending device including individual cams; and

a plurality of resilient spring members,

wherein said contact extending device is positioned to engage and press at least one of said resilient spring members against respective said conductors after said plug-in power tap has been inserted into said housing, to thereby establish an electrical connection between said resilient spring members and said conductors, said plug-in power tap further including at least one receptacle connected to at least one of said resilient spring members for supplying power to equipment upon rotation of said cams into engagement with said resilient spring members and connection of said equipment to said receptacle.

2. An electrical power distribution system as claimed in claim 1, wherein said cam mounted on a shaft arranged to be rotated after insertion of said plug-in power tap into said power track housing assembly.

3. An electrical power distribution system as claimed in claim 2, wherein resilient spring members are mounted on opposites sides of said cam such that rotation of said cam cause the resilient spring members on each side of said cam to engage a respective one of said conductors.

4. An electrical power distribution system as claimed in claim 3, wherein a plurality of said cams are mounted on said camshaft, with one cam for each pair of resilient spring members and conductors.

5. An electrical power distribution system as claimed in claim 1, wherein a number of said conductors is four.

6. An electrical power distribution system as claimed in claim 1, further comprising a splice assembly arranged to be received in one of said end openings of said power track housing assembly to extend a length of said housing assembly by connecting the housing assembly to another said power track housing assembly, said splice assembly including a plurality of conductors arranged to engage said resilient conductors of said housing assembly.

7. An electrical power distribution system as claimed in claim 6, wherein said splice assembly includes a contact-extending mechanism arranged to engage and push said resilient conductors into engagement with said plurality of conductors of said power track housing assembly after insertion of said splice assembly into said one of said end openings of said power track housing assembly.

8. An electrical power distribution system as claimed in claim 7, wherein said contact-extending mechanism is a cam mechanism.

9. An electrical power distribution system as claimed in claim 7, wherein said splice assembly further includes voltage and/or temperature monitoring components.

10. An electrical power distribution system as claimed in claim 1, wherein said plug-in power tap includes circuit breakers or fuses.

11. An electrical power distribution system as claimed in claim 1, wherein said plug-in power tap includes at least one of a DC power supply, a transformer, a voltage inverter/converter, transfer switch, and a frequency inverter/converter.

12. An electrical power distribution system as claimed in claim 1, wherein said plug-in power tap includes monitoring circuitry including at least one of a power monitoring circuit and a temperature monitoring circuit.

13. An electrical power distribution system as claimed in claim 12, further comprising a cable carried by said power track housing assembly for carrying electrical signals from said monitoring circuitry to remote monitoring or display equipment.

14. An electrical power distribution system as claimed in claim 13, wherein said cable is a fiber optic cable.

15. An electrical power distribution system as claimed in claim 12, wherein said plug-in power tap, and/or a splice assembly for said power track housing assembly to another power track housing assembly, includes a transceiver for communicating with remote monitoring or display equipment.

16. An electrical power distribution system as claimed in claim 15, wherein said transceiver is connected to an antenna extending from said plug-in power tap, said antenna being inserted into said power track housing assembly when said portion of said plug-in power tap is inserted into said power track housing assembly.

17. An electrical power distribution system as claimed in claim 1, wherein said plug-in power tap further comprises a bracket for securing said plug-in power tap to said power track housing assembly following insertion of said portion into said power track housing assembly.

18. An electrical power distribution system as claimed in claim 1, wherein said plug-in power tap further comprises a locking slide arranged to be movable to a locking position in which said contact-extending device is prevented from moving to engage or disengage said at least one resilient spring member, and to be movable to an unlocking position in which said cam is free to be manually moved to engage or disengage said at least one resilient spring member.

19. An electrical power distribution system as claimed in claim 1, wherein said plug-in power tap includes:

a tower sub-assembly including said portion arranged to be inserted into said power track housing assembly, said portion including said contact-extending device and resilient spring members;

a distribution sub-assembly including said at least one receptacle; and

an electronics sub-assembly including monitoring circuitry.

20. An electrical power distribution system as claimed in claim 1, wherein said plug-in power tap includes at least one grounding member extending from a top of said plug-in power tap and arranged to contact a grounded element of said power track housing assembly when said portion of said plug-in power tap is inserted into said power track housing assembly.

21. An electrical power distribution system as claimed in claim 1, further comprising an internal mechanical support arranged to be inserted into said power track housing assembly and to engage said conductors in order to prevent said conductors from deforming upon occurrence of a short circuit.

22. An electrical power distribution system as claimed in claim 1, wherein said housing of said power track housing assembly is made of an EMI shielding material.

23. An electrical power distribution system as claimed in claim 1, wherein said housing of said power track housing assembly is made of an electrically conductive material.

24. An electrical power distribution system as claimed in claim 1, wherein said housing of said power track housing assembly includes exterior grooves for receiving EMI shielding plates.

25. An electrical power distribution system as claimed in claim 1, wherein said housing of said power track housing assembly includes interior grooves for accommodating insulators that surround said conductors.

26. An electrical power distribution system as claimed in claim 1, further comprising a termination sub-assembly including a power termination junction box for connecting said conductors to an input power supply, said termination sub-assembly being arranged to be connected to said power track housing assembly by a splice assembly having one end that fits into one of said end openings of the power track housing assembly and a second end that fits into a corresponding opening in the termination sub-assembly.

27. An electrical power distribution system as claimed in claim 26, wherein said termination sub-assembly further includes an electronics section for housing monitoring circuitry connected to monitoring circuits in said plug-in power tap by a cable or by a wireless connection, and which is further connected to a remote monitor or display by a cable, wireless connection, or network.

28. An electrical power distribution system as claimed in claim 1, wherein said power track housing assembly is linear.

29. An electrical power distribution system as claimed in claim 1, wherein said power track housing assembly is “

L”

shaped.

30. An electrical power distribution system as claimed in claim 1, wherein said power track housing assembly is “

T”

shaped.

31. An electrical power distribution system as claimed in claim 1, wherein said power track housing assembly is “

X”

shaped.

32. A power track housing assembly for an electrical power distribution system, comprising:

a housing;

a plurality of conductors extending from a first end of the housing to a second end of the housing;

a opening in a bottom of the housing assembly and extending continuously from the first end of the housing to the second end of the housing, said opening being arranged to receive a plug-in power tap anywhere along said length of said housing assembly; and

additional end openings at said first and second ends of said housing, said additional openings being arranged to receive splice assemblies for connecting together multiple said housing assemblies,

wherein said power track housing assembly is adapted to receive a portion of a plug-in power tap through said bottom opening, said plug-in power tap including a contact-extending device and a plurality of resilient spring members, said contact-extending device being positioned to engage and press at least one of said resilient spring members against respective said conductors after said plug-in power tap has been inserted into said housing to thereby establish an electrical connection between said resilient spring members and said conductors, and

wherein said power track housing assembly further includes a compartment for carrying at least one data bus for establishing communications between a monitoring circuit in said plug-in power tap and a remote monitor or display.

33. A power track housing assembly as claimed in claim 32, wherein said cable is a fiber optic cable.

34. A power track housing assembly as claimed in claim 32, wherein said housing of said power track housing assembly is made of an EMI shielding material.

35. A power track housing assembly as claimed in claim 32, wherein said housing of said power track housing assembly is made of an electrically conductive material.

36. A power track housing assembly as claimed in claim 32, wherein said housing of said power track housing assembly includes exterior grooves for receiving EMI shielding plates.

37. A power track housing assembly as claimed in claim 32, wherein said housing of said power track housing assembly includes interior grooves for accommodating insulators that surround said conductors.

38. A power track housing assembly as claimed in claim 32, wherein said housing of said power track housing assembly is adapted to receive an antenna extending from said plug-in power tap, said antenna being connected to monitoring circuitry in said plug-in power tap, and said antenna being shielded by said housing upon insertion of said plug-in power tap portion into said housing.

39. An electrical power distribution system as claimed in claim 32, wherein said power track housing assembly is “

L”

shaped.

40. A power track housing assembly as claimed in claim 32, wherein said power track housing assembly is “

T”

shaped.

41. A power track housing assembly as claimed in claim 32, wherein said power track housing assembly is “

X”

shaped.

42. A plug-in power tap for an electrical power distribution system including a power track housing assembly having a housing;

a plurality of conductors extending from a first end of the housing to a second end of the housing; and

an opening in a bottom of the housing assembly and extending continuously from the first end of the housing to the second end of the housing, said opening being arranged to receive said plug-in power tap anywhere along said length of said housing assembly, said plug-in power tap comprising;

a contact-extending device including individual cams; and

a plurality of resilient spring members,

wherein said contact-extending device is positioned to engage and press at least one of said resilient spring members against respective said conductors after said plug-in power tap has been inserted into said housing, to thereby establish an electrical connection between said resilient spring members and said conductors, said plug-in power tap further including at least one receptacle connected to at least one of said resilient spring members for supplying power to equipment upon rotation of said cams into engagement with said resilient spring members and connection of said equipment to said receptacle.

43. A plug-in power tap as claimed in claim 42, wherein said cam is mounted on a camshaft arranged to be rotated after insertion of said plug-in power tap into said power track housing assembly.

44. A plug-in power tap as claimed in claim 43, wherein said resilient spring members are mounted on opposites sides of said cam such that rotation of said cam cause the resilient spring members on each side of said cam to engage a respective one of said conductors.

45. A plug-in power tap as claimed in claim 43, wherein a plurality of said cams are mounted on said camshaft, with one cam for each pair of resilient spring members and conductors.

46. A plug-in power tap as claimed in claim 42, a number of said conductors is four.

47. A plug-in power tap as claimed in claim 42, wherein said plug-in power tap includes circuit breakers.

48. A plug-in power tap as claimed in claim 42, wherein said plug-in power tap includes at least one of a DC power supply, a transformer, a voltage inverter/converter, transfer switch, and a frequency inverter/converter.

49. A plug-in power tap as claimed in claim 42, wherein said plug-in power tap includes monitoring circuitry including at least one of a power monitoring circuit and a temperature monitoring circuit.

50. A plug-in power tap as claimed in claim 42, wherein said plug-in power tap includes a transceiver for communicating with remote monitoring or display equipment.

51. A plug-in power tap as claimed in claim 50, wherein said transceiver is connected to an antenna extending from said plug-in power tap, said antenna being inserted into said power track housing assembly when said portion of said plug-in power tap is inserted into said power track housing assembly.

52. A plug-in power tap as claimed in claim 42, wherein said plug-in power tap further comprises a bracket for securing said plug-in power tap to said power track housing assembly following insertion of said portion into said power track housing assembly.

53. A plug-in power tap as claimed in claim 42, wherein said plug-in power tap further comprises a locking slide arranged to be movable to a locking position in which said contact-extending device is prevented from moving to engage or disengage said at least one resilient spring member, and to be movable to an unlocking position in which said cam is free to be manually moved to engage or disengage said at least one resilient spring member.

54. A plug-in power tap as claimed in claim 42, wherein said plug-in power tap includes:

a tower sub-assembly including said portion arranged to be inserted into said power track housing assembly, said portion including said cam and resilient spring members;

a distribution sub-assembly including said at least one receptacle; and

an electronics sub-assembly including monitoring circuitry.

55. A plug-in power tap as claimed in claim 42, wherein said plug-in power tap includes at least one grounding member extending from a top of said plug-in power tap and arranged to contact a grounded element of said power track housing assembly when said portion of said plug-in power tap is inserted into said power track housing assembly.

56. A splice assembly for an electrical power distribution system including a power track housing assembly having a housing;

a plurality of conductors extending from a first end of the housing to a second end of the housing;

an opening in a bottom of the housing assembly and extending continuously from the first end of the housing to the second end of the housing, said opening being arranged to receive a plug-in power tap anywhere along said length of said housing assembly; and

end openings for receiving said splice assembly, said splice assembly comprising;

a plurality of resilient conductors;

a support for supporting said plurality of resilient conductors; and

a contact-extending mechanism arranged to engage and push said resilient conductors into engagement with said plurality of conductors of said power track housing assembly after insertion of said splice assembly into said one of said end openings of said power track housing assembly,

wherein said splice assembly is arranged to be received in one of said end openings of said power track housing assembly to extend a length of said housing assembly by connecting the housing assembly to another said power track housing assembly.

57. A splice assembly as claimed in claim 56, wherein said contact-extending mechanism is a cam mechanism.

58. A splice assembly as claimed in claim 56, further comprising voltage and/or temperature monitoring components.