TECHNICAL FIELD OF THE INVENTION
[001] The present invention relates to the field of electrical power distribution
centers and motor control centers, particularly with regard to plug-in connections
used to connect electrical equipment installed in functional units (withdrawable
5 and removable units) in low-voltage switchgear and controlgear assemblies, to
external cables.
BACKGROUND ART OF THE INVENTION
[002] Low-voltage switchgear and controlgear assemblies are intended to be
used for distribution of electric power to consumers. The assemblies are internally
10 separated into sections, sub-sections and compartments depending on the
requirements of the end user. There can be three types of compartments in a lowvoltage switchgear and controlgear assembly, as per the international standards
IEC 61439, i.e. functional unit compartments, busbar compartments and cable
compartments. The terminals for external conductors are accommodated in cable
15 compartments. The functional units of a low-voltage switchgear and controlgear
assembly can be of four different types, i.e. fixed, plug-in, removable and
withdrawable.
[003] The internal separation between sections, sub-sections or compartments
is carried out by barriers and/or partitions. The international standard IEC 61439-
20 2 classifies internal separation into 4 forms. Forms 2, 3 and 4 are sub-classified into
sub-forms “a” and “b”. All the forms of internal separation show how busbars,
functional units and terminals for external conductors are separated from each
other.
[004] The above described internal separations and types of functional units are
25 two important technical concerns of today’s low-voltage switchgear and
controlgear assembly manufacturers. The functional units need to be
interconnected with dropper busbars to supply current to incoming circuits in the
functional unit and need to be interconnected with terminals for external
conductors to distribute current to outgoing circuits through external conductors.
30 In order to facilitate these interconnections of a functional unit, various types of
devices and methods are used in low-voltage switchgear and controlgear
assemblies. One such method is a male plug plugging-in and contacting with a bare
conductor in a mating female plug using a plugging assembly. When a plugging
assembly is used to supply current to incoming circuits it is called as ‘incoming
3
plug’ When a plugging assembly is used to distribute current to outgoing circuits,
it is called as ‘outgoing plug’ Such plugging assemblies facilitate connection and
disconnection of current between the functional units and the conductors.
[005] It is also one of important requirements in the industry is that a functional
5 unit is removed from the low-voltage switchgear and controlgear assembly
without dismantling any external conductors from their terminal; the assembly is
not fully shut down at any time for repairs or maintenance.
[006] The plugging assembly closest to this invention, is disclosed in
PCT/IB2013/001597 and patented under EP2875551. In that invention a different
10 type of plugging technology is disclosed to make interconnections with respect to
power, control, and data connections. The operational current of that invention
was limited due to the size of the plug pins. Another such mechanism closest to
this invention, is disclosed in PCT/IB2019/061395 invented by this inventor. The
invention disclosed in PCT/IB2019/061395 is not capable of handling high
15 operational currents. Furthermore, it supports a maximum of two outgoing cables
per phase in a limited cable space.
[007] The present invention is an improvement of the invention disclosed in
PCT/IB2019/061395.
[008] When it comes to plugging assemblies used in a low-voltage switchgear
20 and controlgear assembly, the interconnections between incoming circuits and
outgoing circuits are achieved by plug-in and plug-out operations. These plugging
assemblies are found with many mechanical and electrical issues. The contact clips
of the male plug and the receiving terminals of the female plug need to be strong
enough to withstand greater number of plug-in and out operations. Furthermore,
25 the contact clips and receiving terminals wear-out when they are used for many
times and need to be adjusted mechanically to establish proper contact.
[009] The end users look for compact functional units having high operating
currents in order to save space. Since the space inside a functional unit and its
compartment are limited, the plugging assemblies cannot be designed as bulky
30 and sturdy plugs. On the contrary, the cross section of the conductor parts used
inside the male and female plugs should be increased corresponding to the
operational current. Apart from that, the space meant of terminal for external
conductors in the female plug determines the number of external conductors
which can be connected to the terminals. Therefore, designing a compact plugging
4
assembly with high operational current has become a challenging task.
[0010] On the other hand, the low-voltage switchgear and controlgear assembly
manufacturers cannot compromise the protection offered by internal separation,
since the safety of the personnel working around the switchgear and controlgear
5 assemblies are one of the most demanding requirements in the industry.
[0011] In case of maintenance or repair work on one of functional units, other
units should stay live. The removal of the functional unit should be as easy as
possible. The technicians are not expected to dismantle conductors inside the unit
before it is taken out or remove external conductors.
10 SUMMARY OF THE INVENTION
[0012] The invention is a plugging assembly with improved operational current,
comprising a male plug and a matching female plug used to interconnect incoming
circuits in a functional unit, with terminals for external conductors in a cable
compartment of a low-voltage switchgear and controlgear assembly. Depending
15 on the location and orientation where the male plug plugs-in the female plug and
the shape of the terminal to which the external conductors are connected to the
female plug, the invention discloses two variations namely side-access outgoing
plugging assembly and rear-access outgoing plugging assembly. The invention
consists specially shaped terminals for external conductors in the female plug to
20 increase the number of external conductors connected to a terminal for external
conductors.
[0013] The invention eliminates the requirement of dismantling external
conductors during removal of a functional unit from the switchgear or controlgear
assembly. The heavy-duty terminals for external conductors allow accommodating
25 external conductors with a greater cross-section asthere is enough space between
each terminal. The invention enables functional units to be taken out entirely from
a low-voltage switchgear or controlgear assembly and replace it while the
assembly is live.
[0014] The cable connections can be arranged as per the requirements of the
30 application as the invention supports alternative ways of cable connections from
rear or side cable compartments with respect to functional unit compartment,
where the external conductors are accessed from a separate compartment
achieving Form 4 in accordance with the international standard IEC 61439-2.
Accidental contact with terminals for external conductors is protected by
5
polycarbonate covers in this invention.
BRIEF DESCRIPTION OF DRAWINGS
[0015] Drawings do not appear in their correct scale. Some components of the
invention are illustrated comparatively larger or smaller than their actual
5 appearance.
[0016] Fig. 1 is an illustration of the first variation of the invention, i.e. side access
plugging assembly comprising male plug and female plug.
[0017] Fig. 2A is an illustration of the male plug of the side access plugging
assembly.
10 [0018] Fig. 2B is an illustration of bottom view of the male plug of the side access
plugging assembly.
[0019] Fig. 3 is an illustration of the female plug of the side access plugging
assembly and its sides as referenced in the description.
[0020] Fig. 4A is an illustration of the main components of the female plug.
15 [0021] Fig. 4B is an illustration of the top view of the female plug with its top cover
removed.
[0022] Fig. 5 is an illustration of the front isometric view of the terminal conductor
of side access plugging assembly.
[0023] Fig. 6 is an illustration of the configuration of the housing and the extended
20 base of the female plug.
[0024] Fig. 7A, 7B and 7C are illustrations of the upper supporting busbar holder
and the lower supporting busbar holder of the female plug.
[0025] Fig. 8A is an illustration of the front surface of the top cover of the female
plug.
25 [0026] Fig. 8B is an illustration of the back of the top cover of the female plug.
[0027] Fig. 8C is an illustration of the top side of the housing of the female plug
with its terminal conductors in.
6
[0028] Fig. 9 is an illustration of the bottom of the housing of the female plug.
[0029] Fig. 10 is an illustration of the horizontal mounting brackets, vertical
mounting bracket and how the female plug is mounted to those mounting
brackets.
5 [0030] Fig.11A and 11B are illustrations of how the horizontal mounting brackets
and vertical mounting bracket are mounted to frame member of switchgear or
controlgear assembly.
[0031] Fig. 12 is an illustration of how the female plug is mounted to a frame
member.
10 [0032] Fig. 13 is an illustration of how the female plug is mounted to a frame
member with transparent cover.
[0033] Fig. 14 is an illustration of the second variation of the invention, i.e. rear
access plugging assembly comprising male plug and female plug.
[0034] Fig. 15 is an illustration of the female plug of the rear access plugging
15 assembly and its sides as referenced in the description.
[0035] Fig. 16A is an illustration of the main components of the female plug of the
rear access plugging assembly.
[0036] Fig. 16B is an illustration of the bottom view of the female plug of the rear
access plugging assembly.
20 [0037] Fig. 16C is an illustration of the female plug of the rear access plugging
assembly with its terminal conductors and upper and lower supporting busbar
holders.
[0038] Fig. 17 is an illustration of the female plug of the rear access plugging
assembly without its top cover.
25 [0039] Fig. 18 is an illustration of the terminal conductor of the female plug of the
rear access plugging assembly.
[0040] Fig. 19 is an illustration of the housing and the extended base of the female
plug of the rear access plugging assembly.
[0041] Fig. 20A, 20B and 20C are illustrations of the upper supporting busbar
7
holder and the lower supporting busbar holder of the female plug of the rear
access plugging assembly.
[0042] Fig. 21 is an illustration of the housing of the female plug without its top
cover.
5 [0043] Fig. 22A and 22B are illustrations of front view of the top cover of the
female plug.
[0044] Fig. 23 is an illustration of the back of the top cover of the female plug. Fig.
24 is an illustration of bottom view of the female plug.
[0045] Fig. 25 is an illustration of the arrangement of the horizontal mounting
10 brackets, vertical mounting bracket and female plug before mounting to a frame
member.
[0046] Fig. 26 is an illustration of how the horizontal mounting brackets and
vertical mounting bracket are mounted to a frame member.
[0047] Fig. 27A and 27B are illustrations of how the rear access plugging assembly
15 is mounted to a frame member.
DETAILED DESCRIPTION OF THE DRAWINGS
[0048] The invention is a plugging assembly which allows the power connections
coming from internal switching devices installed in functional units in electrical
switchgear and controlgear assemblies, to be connected or disconnected with
20 external cables connected with the load, by means of a plugging-in mechanism.
The plugging assembly comprises a male plug and a female plug. The ‘external
conductors’ and ‘terminals for external conductors’ mentioned in the above
sections, are respectively referred to as ‘external cables’ and ‘external cable
terminals’ in this detailed description.
25 [0049] The invention discloses two variations of such plugging assemblies in which
the variation between the two plugging assemblies lies in the manner which the
external cables are connected with the plugging assembly and the location where
the male plug is plugged into the female plug.
[0050] Fig. 1 shows the first variation of the invention which is a plugging assembly
30 (1) to which external cables are connected from its right side and the male plug is
plugged in on the top. This plugging assembly (1) is identified as ‘side access
8
outgoing plug’ by the inventor. The plugging assembly (1) is comprised of two
parts, i.e. male plug (2) and female plug (3).
[0051] As shown in Fig. 2A. The male plug (2) of the plugging assembly (1)consists
twelve ‘U’ shaped spring-loaded clips (4) and their corresponding four terminals
5 (5) meant for internal wiring, fixed on a rigid insulating housing (6), and is fixed in
a functional unit (“unit”) in a low-voltage switchgear or control gear assembly.
Since clips (4) are spring-loaded, they are expandable and
[0052] shrinkable when they are engaged and disengaged with solid matter. Each
‘U’ shaped spring- loaded clip(4)is accommodated in and supported by a base (7)
10 protruded downwards from the housing (6). It is fixed in manner which extendsout its ‘U’ shaped spring- loaded clips (4)towards the rear side of the unit allowing
the spring-loaded clips (4) to be mechanically inserted into the female plug (3)
when the unit is pushed into its compartment in the assembly.
[0053] As shown in Fig. 2B, each terminal (5) is fixed with three ‘U’ shaped spring15 loaded clips (4). These three clips (4) are designed in three different heights,
creating three levels of clips (4) to avoid connecting all clips (4) at the same time
to terminal connectors in the female plug (3).Thus, when the unit is pushed into
and removed from its compartment, the effort to be deployed against mechanical
force due to springs in the clips (4), is reduced. Furthermore, the ‘U’ shaped spring20 loaded clips (4) are covered and protected by their bases (7) in three sides to
increase clearances and creepage distance between two clips (4). The terminals
(5) are internally wired with the devices inside the unit. As shown in Fig. 2A, each
of the terminals (5) is covered from insulating barriers (8) protruded upwards from
the housing (6), which limit access to live parts— terminals (5). The terminals (5)
25 can be covered with a transparent cover having square shaped cutouts.
[0054] The female plug (3) of the plugging assembly (1) is the component which
receives the ‘U’ shaped spring-loaded clips (4) of the male plug (1) and makes the
power connection with the external cables to complete the outgoing circuits. For
the ease of description, the sides of the female plug (3) is referenced as top side
30 (9), bottom side (10), left side (11) and right side (12), as shown in Fig. 3.
[0055] As shown in Fig. 4A, the female plug (3) consists of four terminal
conductors (13), a part of which is placed inside a cuboid shaped rigid housing (14),
with an extended base (15) and a top cover (16) moulded out of an insulating
material. As shown in Fig. 4B, the housing (14) has insulating internal barriers (17)
9
with holders (18) and border walls (19) with holders (18), creating slots (20a) to
accommodate the terminal conductors (13) in the housing (14). The internal
barriers (17) separate each of the terminal conductors (13). The holders (18) hold
the terminal conductors (13) vertically and firmly in the slots (20a). The housing
5 (14) has five screw holes (21)of which two screw holes (21) are attached to border
walls (19) and the rest is on internal barriers (17) for fixing the top cover (16). The
top cover (16) is fixed to the housing (14) by driving five screws into the screw
holes (21).
[0056] As further shown in Fig. 4B, the four terminal conductors (13) are meant
10 for four poles, three phases and neutral. Each terminal conductor (13) is a solid
plate of conductive material, having a rectangular shaped longitudinal profile with
a substantial thickness, which runs from the left side (11) to the right side (12) of
the female plug (3).
[0057] As shown in Fig. 5, the terminal conductor (13) has three sections, i.e.
15 receiving terminal (22), insulated section (23) and external cable terminal (24).
One end of the terminal conductor (13) is identified and functions as receiving
terminal (22). The other end of the terminal conductor (13) has an ‘L’ shaped
section, identified and functions as external cable terminal (24).The in-between
section (23) of the terminal conductor (13) is covered with an insulator (25) and
20 identified as insulated section (23). The insulator covers the bare area of the
terminal conductor, the section of which is just inside from the housing (14)to the
beginning of the external cable terminal (24) and thereby provides protection
against risk of arc faults. As shown in Fig. 6, each terminal conductor (13)runs from
the left side to the right side of the female plug (3) and is placed with its larger face
25 vertically in slots (20a) in the housing (14) and in channels (20b) on the extended
base (15)of the female plug (3).The receiving terminal (22) is caught, from its top,
by the spring-loaded clip (4) in the male plug (2) when the male plug is plugged
into female plug (3). The external cable terminal (24) end of the terminal
conductor (13)is designed to have ‘L’ shape with holes (26), creating more space
30 to accommodate more cables, i.e. it increases the number of external cables
connectable to a terminal conductor (13). The holes (26) on the ‘L’ shaped external
cable terminal (24) are used to fix external cables. Each hole (26) can be connected
with two external cables. The terminal conductor (13), at its insulated section (23),
is outwardly bent at two points (27) in a manner which the receiving terminal (22)
35 and the external cable terminal (24) are offset to each other, creating required
clearances between the terminal conductors (13) when it is outside of the housing
10
(14). Thus, the distance between each external cable terminal (24) is increased;
the number of external cables connected to the female plug (3) per phase is
increased. Each terminal (5) in the male plug (2) has three ‘U’ shaped springloaded clips (4). The receiving terminal (22) of each terminal conductor (13) in the
5 female plug (3) receives three spring-loaded clips (4) in the male plug (2)and
connects them (4) from the top of the receiving terminal (22),and the external
cable terminal (24) of each terminal conductor (13) accommodates at least two
external cables connected to the load. The terminal conductor (13) could be of
Copper or Aluminum having cross-sectional area corresponding to operating
10 current. As a result, the operating current of the plugging assembly (1) and the
outgoing circuit are increased.
[0058] As further shown in Fig. 6, the housing (14) of the female plug (3) has an
extended base (15) with channels (20b) to support and hold the terminal
conductors (13).The channels (20b) on the extended base (15) are spread
15 outwards from the housing (14)and has the same longitudinal bended shape of
the insulated section of the terminal conductor (13).As the part of the terminal
conductor which is outside of the housing (14), i.e. the insulated section (23)and
the external cable terminal (24), is longer than the part of the terminal conductor
which is inside the housing (14), i.e. receiving terminal (22), the extended base
20 (15)is required to hold and support the terminal conductors in proper positions.
The receiving terminal end (22) of the terminal conductor (13) resides in slots (20a)
in the housing (14) of the female plug (3) whereas the insulated section (23) of the
terminal conductor (13) resides outside of the housing (14)in the channels (20b)
on the extended base (15). The slot (20a) in the housing (14)and a channel (20b)
25 on the extended base (15) combine and create one single path which continues
until the second outward bend (27) of the extended base (15).The depth of
channels (20b) on the extended base (15) is lower than that of the slots (20a) in
the housing (14). The extended base (15) is strengthened by the ribs (28) on its
surface.
30 [0059] As shown in Fig. 7A, the stability and the distance between each external
terminal (26) is maintained by a pair of supporting busbar holders — upper
supporting busbar holder (29a) and lower supporting busbar holder (29b),which
are placed on and under, and closer to the end of the insulated section (23)of the
terminal conductors (13),and are tightened by screws (30) inserted through upper
35 holes (31a) in the upper supporting busbar holder (29a) and driven through selftapping screw holes (31b)on the lower supporting busbar holder (29b).The
11
supporting busbar holders(29a and 29b) bind and avoid terminal conductors (13)
leaning sideways, deforming or moving due to the weight of external cables
connected to each terminal conductor (13).As shown in Fig. 7B, the lower
supporting busbar holder (29b) has lower holes (32b) to insert screws (33) and fix
5 the lower supporting busbar holder (29b) to vertical mounting bracket which is
described under Fig. 12. As shown in Fig. 7C, the upper supporting busbar holder
(29a) has upper holes (32a) to insert through a screwdriver to reach screws (33)
when fixing the female plug (3) with supporting busbar holders (29a and 29b) to a
vertical mounting bracket.
10 [0060] As shown in Fig. 8A, the top cover (16) is configured to have a set of
openings (35) for ‘U’ shaped spring-loaded clips (4) and set of screw holes (36) for
top cover fixing screws. The openings (35)for spring-loaded clips (4) are shaped
into thin rectangular with rounded corners, which resembles the shape of the base
(7) of ‘U’ shaped spring-loaded clip (4).The size of the opening (35) is slightly
15 greater than the size of the base (7) of the spring-loaded clip (4); thus, allowing
the spring-loaded clips (4) and its base (7) to enter into the opening (35) and the
spring- loaded clips (4) to reach and catch the terminal conductor (13) in the
housing (14) of the female (12) plug (3).The shape of the base (7) is designed to
have an inwardly tapered top. Similarly, the opening (35) for spring-loaded clip (4)
20 is designed to have the same shape with a tapered bottom. Hence, the tapered
top of the base (7) of the clip (4) reaches the tapered bottom of the opening (35)
and stops at a distance to maintain a gap between the housing (6) of the male plug
(2) and the front surface of the top cover (16) of the female plug (3) to protect the
female plug (3) being hit by the male plug (2), while the clips (4) fully engage with
25 the terminal conductor (13) and stops without imposing extra force to the terminal
conductor (13).
[0061] Further shown in Fig. 8B, the back of the top cover (16) has a configuration
of channels (37) designed to be sunk into the internal barriers (17) and the three
border walls (19) in the housing (14) of the female plug (3) when the top cover (16)
30 is placed on the top of the housing (14). As shown in Figs 8B and 8C, at the top
edges of the three border walls (19) of the housing (14), the border walls (19) have
an inward step (38) on the outside of the border walls (19). When the cover (16)
is placed on top of the housing (14), the top edges of the internal barriers (17) and
that of border walls (19) sink into their respective channels (37)at the back of the
35 top cover, until the bottom of edges (39) of the top cover (16) hit the inward step
(38) on the border walls (19) of the housing (14).The cover (16) is fixed to the
12
housing (14) with screws driven into cover fixing screw holes (36).
[0062] As shown in Fig. 9, at the bottom side (10) of the housing (14) has a spring
clip (40) with a notch (41) and four mounting channels (43) on the two long edges
and at the center, which are used to mount the female plug (3), and two square5 shaped knobs (49). The spring clip (40) is positioned in the bottom side (10) of the
housing (14) along the center line of the width of the housing (14), keeping one
end of the spring clip (40) as a free end (42).
[0063] As shown in Fig. 10, two rectangular steel horizontal mounting brackets
(44) and a rectangular steel vertical mounting bracket (50) are used to mount the
10 female plug (3) to the low-voltage switchgear or controlgear assembly. Each of the
two horizontal mounting brackets (44) has a slide stopper (45) and mounting
screw holes (46) and its two long edges are formed as flanged edges (47) to allow
sliding-in mounting channels (43) on the bottom side (10) of the housing (14) of
female plug (3).The vertical mounting bracket (50) is a steel plate of which the two
15 vertical edges (54a and 54b) have been folded in opposite directions at right-angle
and the surface has been twice vertically folded to have a step-down level creating
an upper level (51) and lower level (52) on the surface, which in turn increases
creepage clearance on the vertical mounting bracket (50).The vertical mounting
bracket (50) has cutout-holes (53) on one folded edge (54a); openings (55),
20 mounting-cutouts (56), lock hole (59)and lower supporting busbar holder
mounting holes (57) on the upper level (51); and cover fixing holes (58) on both
upper level (51) and lower level (52)and on vertical edge (54b).
[0064] As shown in Fig. 11A, the vertical mounting bracket (50) is mounted
vertically to left or right side of a vertical frame member (60), depending on the
25 requirement, by inserting the cutout- holes (53) into half-way pre-fixed screws on
the vertical frame member (60); the screws are fully tightened by screwdriver
inserted through mounting-cutouts (56) while the tightening operation is viewed
through openings (55).The vertical mounting bracket (50) is mounted in a direction
to which the bracket (50) and its vertical edge (54b) extends-out towards the
30 adjoining compartment, i.e. cable compartment, at left or right side of the
functional unit compartment. As shown in Fig. 11B, once the vertical mounting
bracket (50) is mounted to frame member (60) of switchgear or controlgear
assembly, the two horizontal mounting brackets (44) are mounted horizontally to
the front side of the same frame member, in the same direction of which the
35 vertical mounting bracket (50) is mounted, locating the flanged edges (47) in the
functional unit compartment using mounting screw holes (46).The female plug (3)
13
is mounted in the functional unit compartment facing its (3) top side (9) towards
the front side of the low-voltage switchgear or control gear and keeping its
openings (35) for ‘U’ shaped spring-loaded clips (4) in the functional unit
compartment.
5 [0065] Referring to Figs 9, 10, 11A and 11B, in order to mount the female plug (3),
it is inserted through the four mounting channels (43) on its back along the flanged
edges (47) of the two horizontal mounting brackets (44), from the side of the
vertical mounting bracket (50), and slided-in until the two knobs (49) on the
bottom side of the female plug (3) hit the two slide stoppers (45) on the two
10 horizontal mounting brackets (44) and the notch (41) on the free end (42) of the
spring clip (40) reaches the middle opening (55) on the vertical mounting bracket
(50) and locks making a “click” sound. The middle opening (55) provides space to
accommodate the notch (41) on the spring clip (40) at the time of the female plug
(3) is fully inserted into the two horizontal mounting brackets (44).The middle
15 opening (55) is connected with lock hole (59) on the vertical mounting bracket
(50), through which a tool is inserted to press the free end (42) to release the notch
(41) from the middle opening (55) when the female plug (3) is dismantled by
sliding-out from the horizontal mounting brackets (44).
[0066] As shown in Fig. 12, once the female plug (3) is fully inserted into horizontal
20 mounting brackets (44), the lower supporting busbar holder (29b) of the female
plug (3) is fixed to vertical mounting bracket (50) using screws (33) inserted
through lower holes (32b) in the lower supporting busbar holder (29b). The screws
(33) are fastened by inserting a screwdriver through upper holes (32a) on the
upper supporting busbar holder (29a). Thus, the female plug (3) is installed in a
25 manner which the top side (9) of the female plug (3) stays in the functional unit
compartment and keeping its (3) openings (35) for spring-loaded clips (4) in the
functional unit compartment while the external cable terminals (24) for external
cables extend-out to adjoining left or right cable compartment of the switchgear
or controlgear assembly.
30 [0067] Once the female plug is (3) is mounted to the horizontal mounting bracket
(44) and to the vertical mounting bracket (50), lugged external cables, which
supply power to the load in the outgoing circuit, are connected to external cable
terminals (24), using nuts and bolts fasten through holes (26). The increased
distance between two external cable terminals (24) due to the outward bends (27)
35 and the ‘L’ shaped design of the external cable terminals (24), creates considerable
amount of space to accommodate more than one external cable per phase. Thus,
14
the current carrying capacity of the plugging assembly (1) is increased. Finally, the
external cable terminals (24) are covered by a transparent cover (61) which is
identified as Form 4B cover. The cover (61) comprises square-shaped cutouts (62)
on all sides of the cover and fixing brackets (63). The cover (61) guards against
5 accidental contact with live parts in the female plug (3), i.e. cable lugs and external
cable terminals. The square-shaped cutouts (62) allows ventilation to reduce the
temperature generated inside the cover when current passes in the circuits. The
cutouts (62) can be removed from anywhere on the cover (61) in any shape to
create external cable entry holes for external cables extended towards external
10 circuits. Lugged external cables are passed through such cable entry holes on the
transparent cover (61). Fig. 13 shows the way it appears when it is fully installed
in switchgear or controlgear assembly without connecting external cables.
[0068] The female plug (3) is dismantled from the horizontal mounting bracket
(44) by first removing the (61), disconnecting external cables from external cable
15 terminals (24), removing screws (33) from lower holes (32b) on the lower
supporting busbar holder (29b) and pressing the free end (42) on the spring clip
(40) to release the notch (41) from the middle opening (55) by a tool inserted
through lock hole (59), while sliding-out the female plug (3) from the horizontal
mounting bracket (44).
20 [0069] When the functional unit is fully inserted into its compartment, the male
plug (2) fixed in the unit engages its ‘U’ shaped spring-loaded clips (4) with the
terminal conductors (13) in the female plug (3) making power connections with
female plug (3) mounted on the frame members of the switchgear or controlgear
assembly. When the unit is removed from its compartment, the male plug (2)
25 disengages its spring-loaded clips (4) from the terminal conductors (13) and
withdraws from the female plug (3) disconnecting the power connections.
[0070] The above described variation of the invention — side access outgoing plug
— makes the interconnection between the internal circuit in the functional unit
and the outgoing circuit in the switchgear or controlgear assembly, i.e. it connects
30 the devices in functional units with the external cables which supply power to load
in the downstream, where the external cables are connected to the female plug
(3) from the compartment which is adjacent to the functional unit compartment
on the right or left. As shown in Fig. 13, the female plug (3) is mounted horizontally
on two adjoining vertical frame members (60) in the low-voltage switchgear or
35 controlgear assembly, facing its top side (9) towards the front of the assembly,
keeping its openings (35) for ‘U’ shaped spring-loaded clips (4) extended out from
15
male plug (2), in the functional unit compartment and the external cable terminals
(24)for external cables extending- out to the cable compartment located on the
left or right of the functional unit compartment. As a result, the external cable
terminals (24) and holes (26) meant for external cables are accessed from the
5 adjacent cable compartment located on the left or right of the functional unit
compartment when connecting external cables to the female plug (3).
[0071] The Fig.14 shows another variation of the invention which is identified as
‘rear-access outgoing plug’ This plugging assembly (80) has the exactly same
functionality as the first variation of the invention which was described above as
10 the side-access outgoing plug (1). The same male plug
[0072] (2) in the first variation of the invention is used as the male plug for female
plug (81) in the second variation. What mainly differs from the first variation is the
openings for U-shaped clips and holes in the top cover; openings, holes and
internal barriers in the housing, the side from which receiving terminal is caught
15 by ‘U’ shaped clips and configuration of the terminal conductor of the female plug
(81).
[0073] For easy description, the female plug (81) of the second variation (rearaccess outgoing plug) is referenced as top side (85), bottom side (86), left side (87)
and right side (88) as shown in Fig. 15.
20 [0074] As shown in Fig. 16A, Fig. 16B and Fig. 16C, the female plug (81) consists of
a cuboid shaped rigid housing (100) with an extended base (106) and four terminal
conductors (90), a top cover (110), upper supporting busbar holder(120a), lower
supporting busbar holder(120b), vertical mounting bracket (50), two horizontal
mounting brackets (44) and transparent cover (61).
25 [0075] As further shown in Fig. 16C, the female plug (81) of the second variation
consists of four terminal conductors (90), a part of which is placed inside the
cuboid shaped rigid housing (100) with an extended base (106) and a top cover
(110) which are moulded with insulating material.
[0076] As shown in Fig. 17, the housing (100) has insulating internal barriers (101)
30 with holders (102)and border walls (103) with holders (102), creating slots (104a)
to accommodate the receiving terminal (91) of the terminal conductors (90) in the
housing (100). The internal barriers (101) in the housing (100) separate each of the
terminal conductors (90). The holders (102) hold the terminal conductors (90)
vertically and firmly in the slots (104a) with their larger face vertical. The housing
16
(100) has five top cover fixing screw holes (105) on the internal barriers (101) and
close to border walls (103) to fix top cover (110). The top cover (110) is fixed to
the housing (100) by driving five screws into the screw holes (105). The extended
base (106) has channels (104b) to hold terminal conductors (90) as described
5 below under Fig. 19.
[0077] As shown in Fig. 18, the terminal conductor (90) has three sections, i.e.
receiving terminal (91), insulated section (94) and external cable terminal (92).
Same as in the first variation (1) of the invention, the four terminal conductors (90)
meant for four poles, i.e. three phases and the neutral, provide the same
10 functionality and has a rectangular shaped longitudinal profile of which one end is
identified and functions as receiving terminal (91)and the other end is identified
and functions as external cable terminal (92) with two holes (93) to connect
external cables. The in between section (94) of the terminal conductor (90) is
covered with an insulator (95) and identified as insulated section (94).The
15 insulator (95) covers the bare area of the terminal conductor just inside from the
housing (100) to the beginning of the external cable terminal (92) and thereby
provides protection against risk of arc faults. As shown in Fig. 19, each terminal
conductor (90) is a solid plate of conductive material, with a substantial thickness,
runs from the left side (87) to the right side (88) of the female plug (81) and is
20 placed with its larger face vertically in slots (104a) in the housing (100) and in
channels (104b) on the extended base (106) of the female plug (81). The external
cable terminal (92) of the terminal conductor (90) is different from that of the first
variation. The external cable terminal (92) of the terminal conductor (90) is
designed to be long enough to provide cable connecting space to connect at least
25 two external cables. The holes (93) are used to fix external cables. Depending on
the size of the external cables, two external cables can be connected to each hole
(93) on the external cable terminal (92).
[0078] Further to Fig. 18, the terminal conductor (90), at its insulated section (94),
is outwardly bent at two points (96) in a manner which the receiving terminal (91)
30 and the external cable terminal (92) are offset to each other, creating required
clearances between the terminal conductors (90). Thus, the distance between
each external cable terminal (92) is increased; the number of external cables
connected to the female plug (81) per phase is increased. As shown in Fig. 2A, each
terminal (5) in the male plug (2) has three ‘U’ shaped spring-loaded clips (4).The
35 receiving terminal (91) is caught, from the side of the receiving terminal (91), by
the spring-loaded clip (4) in the male plug (2) when the male plug is plugged into
17
female plug (81). The receiving terminal (91) of each terminal conductor (90) in
the female plug (81) receives three spring-loaded clips (4) in the male plug (2),and
the external cable terminal (92) of each terminal conductor (90) accommodates at
least two external cables connected to the load. The terminal conductor (90) could
5 be of Copper or Aluminum having cross-sectional area corresponding to operating
current. As a result, the operating current of the plugging assembly (80) and of the
outgoing circuit is increased.
[0079] As shown in Fig. 19, the housing (100) of the female plug (81) has an
extended base (106) with channels (104b) to support and hold the terminal
10 conductors (90). The channels (104b) on the extended base (106) are spread
outwards from the housing (100) and has the same longitudinal bent shape of the
insulated section of the terminal conductor (90). As the part of the terminal
conductor which is outside of the housing (100), i.e. the insulated section (94) and
the external cable terminal (92), is longer than the part of the terminal conductor
15 which is inside the housing (100), i.e. receiving terminal (91), the extended base
(106) is required to hold and support the terminal conductors in proper positions.
The receiving terminal (91) of the terminal conductor (90) resides in slots (104a)
in the housing (100) of the female plug (81)whereas the insulated section (94) of
the terminal conductor (90) resides outside of the housing (100) in the channels
20 (104b) on the extended base (106). A slot (104a) in the housing (100) and a channel
(104b) on the extended base (106) combine and create one single path which
continues until after the second outward bend (96) of the extended base (106).
The depth of channels (104b) on the extended base (106) is lower than that of the
slots (104a) in the housing (100). The extended base (106) is strengthened by the
25 ribs (107) on its surface.
[0080] As shown in Fig. 20A, the stability and the distance between each external
cable terminal (92) is maintained by a pair of supporting busbar holders, i.e. upper
supporting busbar holder (120a) and lower supporting busbar holder (120b),
which are placed on and under, and closer to the end of the insulated section (94)
30 of the terminal conductors (90), and are tightened by screws (121) inserted
through upper holes (122a) in the upper supporting busbar holder (120a) and
driven through self-tapping screw holes (122b) on the lower supporting busbar
holder (120b). The supporting busbar holders (120a and 120b) bind and avoid
terminal conductors (90) leaning sideways, deforming, or moving due to the
35 weight of external cables connected to each terminal conductor (90). As shown in
Figs 20A, 20B and Fig. 20C, the lower supporting busbar holder (120b) has lower
18
holes (123b) to insert screws (124) and fix the lower supporting busbar holder
(120b) to vertical mounting bracket. The upper supporting busbar holder (120a)
has upper holes (123a) to insert through a screwdriver to reach screws (124) when
fixing the female plug (81) with supporting busbar holders (120a and 120b) to
5 vertical mounting bracket, as shown in Fig. 27A.
[0081] As shown in Fig. 21, the left side (87) of the housing (100) is configured to
have a set of openings (108) for ‘U’ shaped spring-loaded clips (4). The openings
(108) for spring-loaded clips (4) are shaped into thin rectangular with rounded
corners, which resemble the shape of the base (7) of ‘U’ shaped spring-loaded clip
10 (4). The size of the opening (108) is slightly greater than the size of the base (7) of
the spring-loaded clip (4); thus, allowing the spring-loaded clips (4) and its base (7)
to enter into the opening (108) and the spring-loaded clips (4) to reach and catch
the terminal conductor (90) in the housing (100) of the female plug (3). The shape
of the base (7) is designed to have an inwardly tapered top. Similarly, the opening
15 (108) for spring- loaded clip (4) is designed to have the same shape with a tapered
bottom. Hence, the tapered top of the base (7) of the clip (4) reaches the tapered
bottom of the opening (108) and stops at a distance to maintain a gap between
the housing (6) of the male plug (2) and the left side (87) wall of the housing (100)
of the female plug (81) to protect the female plug (81) being hit by the male plug
20 (2), while the clips (4) fully engages with the terminal conductor (90), from its side,
and stops without imposing extra force to the terminal conductor (90).
[0082] As shown in Fig. 22A, the top cover (110) is configured to have a set of
screw holes (111) for top cover fixing screws on its top surface. One long border
wall (112a) of the top cover (110) has another set of openings (108) for ‘U’ shaped
25 spring-loaded clips (4). As shown in Fig. 22B, the other long border wall (112b) of
the top cover (110) has openings (114) into which top part of terminal conductors
(90) are sunk when the top cover (110) is fixed to the housing (100). As shown in
Fig. 22A and Fig. 22B, the edge of border walls(112a, 112b, 113a and 113b) of the
top cover (110) is designed to have an inward step (118) on the outside of the
30 boarder walls (112a, 112b, 113a and 113b).
[0083] As further shown in Fig. 21 and Fig. 23, the back of the top cover (110) has
a configuration of holders (115) connected to border walls (113a and 113b) and
internal barriers (117). The holders (115) are designed to be sunk into top part of
terminal conductors (90) and held tightly inside the housing (100). The inward step
35 (118) at the edge of the border walls (112a, 112b, 113a and 113b) of the top cover
(110) rests on the top of border walls (103) of the housing (100) when the top
19
cover (110) is fixed. The top cover (110) is strengthened by ribs (119) with a set of
slots (120) which are sunk into respective top edges of the internal barriers (101)
in the housing (100) when the top cover (110) is fixed to the housing (100). As
shown in Fig. 21, the top cover (110) is fixed to the housing (100) with screws
5 driven into screw holes (105) on the housing (100) through screw holes (111) on
the top cover (110). The border walls (103) of the housing (100) has a step (109)
closer to top edge and inside to the boarder walls (103) on which the edges of
boarder walls (112a, 113a and 113b)of the top cover (110) stop when the top
cover (110) is placed on the housing (100).
10 [0084] As shown in Fig. 24 and as described for the first variation, at the bottom
side (86) of the housing (100) has a spring clip (130) with a notch (131) and four
mounting channels (132) on the two long edges and at the center, which are used
to mount the female plug (81), and two square shaped knobs (133). The spring clip
(130) is positioned in the bottom side (86) of the housing (100) along the center
15 line of the width of the housing (100), keeping one end of the spring clip (130) as
a free end (134).
[0085] Similar to first variation, the same two rectangular steel horizontal
mounting brackets (44) and the same rectangular steel vertical mounting bracket
(50), as shown in Fig. 25, are used to mount the female plug (81) to the low-voltage
20 switchgear or controlgear assembly.
[0086] As shown in Fig. 26, the vertical mounting bracket (50) is mounted
vertically to rear side of a vertical frame member (116) of the assembly, in the
same manner described under the first variation of the invention. The vertical
mounting bracket (50) is mounted in a direction which the bracket (50) and its
25 vertical edge (54b) extend-out towards the adjoining compartment, i.e. cable
compartment, at the back of the functional unit compartment. The two horizontal
mounting brackets (44) are horizontally mounted to left or right side of the same
frame member (116), depending on the requirement, in the same direction of
which the vertical mounting bracket (50) is mounted, locating the flanged edges
30 (47) in the functional unit compartment, in the same manner described under the
first variation of the invention.
[0087] As shown in Fig. 27A, the female plug (81) is mounted to the horizontal
mounting brackets (44) by inserting the female plug (81) through the four
mounting channels (132), from the side of the vertical mounting bracket (50),
35 along the flanged edges (47) of the two horizontal mounting brackets, facing the
20
left side (87) of the female plug (81) towards the front side of the low- voltage
switchgear or controlgear assembly in the functional unit compartment, in the
same manner as described under the first variation. Thus, the female plug (81) is
mounted in a manner which the left side (87) of the female plug (81) stays in the
5 functional unit compartment, keeping its (81) openings (108) for spring-loaded
clips (4) in the functional unit compartment, while the external cable terminals
(92) for external cables extend-out to adjoining rear cable compartment of the
switchgear or controlgear assembly, as shown in Fig. 27A.
[0088] Once the female plug is (81) is mounted to the horizontal mounting
10 brackets (44), it is fixed to vertical mounting bracket (50) by screws (124) inserted
through lower holes (123b) on the lower supporting busbar holder (120b) and
tightened by a screwdriver inserted through upper holes (123a) on the upper
supporting busbar holder (120a). Thereafter, lugged external cables, which supply
power to the load in the outgoing circuit, are connected to external cable
15 terminals (92), using nuts and bolts fasten through holes (93). The increased
distance between two external cable terminals (92) due to the outward bends (95)
creates considerable amount of space to accommodate more than one external
cable per phase. Thus, the current carrying capacity of the plugging assembly (81)
is increased. Finally, the external cable terminals (92) are covered by the same
20 cover (61) which is identified as Form 4B cover, in the same manner described
under the first variation of the invention.
[0089] Fig. 27B shows the way it appears when the female plug (81) is fully
installed to a vertical frame member (116) of a switchgear or controlgear assembly
without connecting external cables. The cut-outs (62) on the transparent cover
25 (61) can be removed from anywhere on the cover (61) in any shape to create cable
entry holes for external cables. Lugged external cables are passed through such
cable entry holes on the transparent cover (61).
[0090] The female plug (81) is dismantled from the horizontal mounting bracket
(44) by first removing the transparent cover (61), disconnecting external cables
30 from external cable terminals (92), removing screws(124) from lower holes (123b)
on the lower supporting busbar holder (120b) and pressing the free end (134) on
the spring clip (130) to release the notch (131) from the middle opening (55) by a
tool inserted through lock hole (59), while sliding-out the female plug (81) from
the horizontal mounting bracket (44).

We Claim:
1. A plugging assembly adapted for making electrical interconnections between
the devices installed in a functional unit compartment, and external cables of
a low-voltage switchgear or controlgear assembly, comprising:
5 a male plug (2) to which internal wires coming from devices installed in
thefunctional unit are connected, comprising:
a rigid insulating housing (6) having insulating barriers (8)
protruded upwards from the housing (6) and bases (7)
protruded downwards from the housing (6),
10 a plurality of ‘U’ shaped spring-loaded clips (4) which expand and
shrink when the clips are engaged with and disengaged from a
terminal conductor and
a plurality of terminals (5) for internal wiring, each connected
with ‘U-shaped spring-loaded clips (4) having different heights
15 creating different height levels;
a female plug (3) of which ‘U’ shaped spring-loaded clips (4) of the male
plug (2)are received from the top (9) and external cables are connected
from the right side (12), comprising:
a cuboid shaped rigid insulating housing (14) with an extended
20 base (15), whereby the cuboid shaped housing having a plurality
of insulating border walls (19) with holders (18), a plurality of
insulating internal barriers (17) with holders (18), a plurality of
slots (20a), a plurality of cover fixing screw holes (21) attached to
border walls (19) and on internal barriers (17), and the extended
25 base (15) having outward spreading channels (20b) and ribs (28),
a plurality of terminal conductors(13) having a rectangularshaped
longitudinal profile of which one end functioning as receiving
terminal(22) caught from its top by ‘U’ shaped spring-loaded
clips (4) in male plug (2), the other end functioning as external
30 cable terminal (24) having an ‘L’ shape with a plurality of holes
(26) to which external cables are connected, and insulated middle
section (23) with two bends (27) which outwardly bend the
23
terminal conductor off-setting the receiving terminal (22) and the
external cable terminal (24),
upper supporting busbar holder (29a) having upper holes (31a
and 32a) and lower supporting busbar holder (29b) having self5 tapping screw holes (31b) and lower holes (32b), placed on and
under and closer to the end of the insulated section (23) of the
terminal conductors (13)and tightened by screws (30) keeping
certain fixed distance among terminal conductors (13),
a top cover (16) having a plurality of openings (35) for spring10 loaded clips (4) and a plurality screw holes (36) for cover fixing
screws on the top surface, and a configuration of channels (37) at
the back of the cover (16) whereby the channels (37) are
designed to be sunk into the top edges of the internal barriers
(17) and that of the three border walls (19) in the housing (14) of
15 the female plug (3), and
a spring clip (40) with a free end (42), positioned in the bottom
(10) of the housing (14) along the center line of the width of the
housing (14), with a notch (41) and four mounting channels (43)
on two long edges and at the center, and two square-shaped
20 knobs (49);
two rectangular steel horizontal mounting brackets (44) each having a
slidestopper (45) and mounting screw holes (46) with its two long
edges formed as flanged edges (47);
a rectangular steel vertical mounting bracket (50) of which two
25 vertical edges(54a and 54b) folded in opposite directions at right-angles
and the surface twice vertically folded to have a step-down level
creating an upper level (51) and lower level (52) on the surface,
whereby cutout-holes (53) on the folded edge (54a); openings (55),
mounting cutouts (56), lock hole (59) and lower supporting busbar
30 holder mounting holes (57) on the upper level (51); and cover fixing
holes (58) on both upper level (51) and lower level (52) of the surface
and on vertical edge (54b); and
a transparent cover (61) having square-shaped cutouts (62) on all sides
of the cover and fixing brackets (63), which covers external cable
24
terminals.
2. A plugging assembly adapted for making electrical interconnections between
the devices installed in a functional unit compartment, and external cables
of a low-voltage switchgear or controlgear assembly, comprising:
5 a male plug (2) to which internal wires coming from devices installed in
a functional unit are connected, comprising:
a rigid insulating housing (6) having insulating barriers (8)
protruded upwards from the housing (6) and bases (7) protruded
downwards from the housing (6),
10 a plurality of ‘U’ shaped spring-loaded clips (4) which expand and
shrink when the clips are engaged with and disengaged from a
terminal conductor and
a plurality of terminals(5) for internal wiring, each connected with
different corresponding ‘U’ shaped spring-loaded clips (4) having
15 different heights creating different height levels;
a female plug (81) of which ‘U’ shaped spring-loaded clips (4) of
the male plug (2) are received from the leftside (87) and external cables
are connected from the right side (88), comprising:
a cuboid shaped rigid insulating housing (100) with an
20 extended base (106) whereby the cuboid shaped housing having
a plurality of insulating border walls (103) with holders (102) and
a step (109), a plurality of insulating internal barriers (101) with
holders (102), a plurality of slots (104a), a plurality of top cover
fixing screw holes (105) on the internal barriers (101) and close
25 to the border walls (103), and the extended base (106) having
outward spreading channels (104b) and ribs (107),
a plurality of terminal conductors(90) having a rectangularshaped
longitudinal profile of which one end functioning as receiving
terminal (91) caught from its side by ‘U’ shaped spring-loaded
30 clips (4) in male plug (2), the other end functioning as external
cable terminal (92) long enough to connect external cables with
plurality of holes (93) to which external cables are connected and
25
insulated middle section (94) with two bends (96) which
outwardly bend the terminal conductor off-setting the receiving
terminal (91) and the external cable terminal (92),
upper supporting busbar holder (120a) having upper holes (122a
5 and 123a) and lower supporting busbar holder (120b) having selftapping screw holes(122b) and lower holes (123b), placed on and
under and closer to the end of the insulated section (94) of the
terminal conductors (90) and tightened by screws (121) keeping
certain fixed distance among terminal conductors (90),
10 a top cover (110) having a plurality of openings (108) for springloadedclips (4) on one long border wall (112a), a plurality of
openings (114) on the other long border wall (112b), a plurality
screw holes (111) for cover fixing screws on the top surface, a
configuration of holders (115) connected to border walls (113a
15 and 113b) and internal walls (117) at the back of the cover, an
inward step (118) at the edge of and on the outside of the border
walls (112a, 112b, 113a and 113b), and
a spring clip (130) with a free end (134), positioned in the
bottom side (86) of the housing (100) along the center line of the
20 width of the housing (100), with a notch (131) and four mounting
channels (132) on two long edges at the center, two squareshaped knobs (133);
two rectangular steel horizontal mounting brackets (44) each having a
slide stopper (45) and mounting screw holes (46) with its two long edges
25 formed as flanged edges (47);
a rectangular steel vertical mounting bracket (50) of which two vertical
edges(54a and 54b) folded in opposite directions at right-angles and the
surface twice vertically folded to have a step-down level creating an
upper level (51) and lower level (52) on the surface, whereby cutout30 holes (53) on the folded edge (54a); openings (55), mounting cutouts
(56), lock hole (59) and lower supporting busbar holder mounting holes
(57) on the upper level (51); and cover fixing holes (58) on both upper
level (51) and lower level (52) of the surface and on vertical edge (54b);
and
26
a transparent cover (61) having square-shaped cutouts (62) on all
sides of the cover and fixing brackets, which covers external cable
terminals.
3. The plugging assembly of Claim 1, wherein the spring-loaded clips (4) and their
5 bases (7) enter into the openings (35) and the spring-loaded clips (4) reach
and catch the terminal conductors (13) in the housing (14) of the female plug
(3), from their top.
4. The plugging assembly of Claim 2, wherein the spring-loaded clips (4) and their
bases (7) enter into the openings (108) and the spring-loaded clips (4) reach
10 and catch the terminal conductors (90) in the housing (100) of the female
plug (81), from their left side.
5. The plugging assembly of Claim l, wherein the tapered top of the base (7) of
the male plug (2) reaches the tapered bottom of the opening (35) for springloaded clip (4) and stops at a distance maintaining a gap between the housing
15 (6) of the male plug (2) and the front surface of the top cover (16) of the
female plug (3) while the clips (4) fully engage with the terminal conductor
(13).
6. The plugging assembly of Claim 2, wherein the tapered top of the (7) of the
male plug (2) reaches the tapered bottom of the opening (108) for spring20 loaded clip (4) and stops at a distance maintaining a gap between the housing
(6) of the male plug (2) and the left side (86) wall of the housing (100) of the
female plug (81).
7. The plugging assembly of Claims 1 or 2, wherein the terminals (5) can be
covered with a transparent cover having square shaped cutouts.
25 8. The plugging assembly of Claims 1 or 2, wherein the insulating border walls
(19 or 103) with holders (18 or 102) and insulating internal barriers (17 or 101)
with holders (18 or 102) create slots (20a or 104a) and separate terminal
conductors (13 or 90) in the housing of the female plug (3 or 81).
9. The plugging assembly of Claims 1 or 2 and 8, wherein the slots (20a or
30 104a) in the housing (14 or 100) of the female plug (3 or 81) accommodate
the terminal conductors (13 or 90) and hold the terminal conductors (13 or
90) vertically and firmly with the holders (18 or 102) in the slots (20a or 104a).
27
10.The plugging assembly of Claims 1 or 2, wherein the slot (20a or 104a) in
the housing (14 or 100) and the channel (20b or 104b) on the extended base
(15 or 106) combine andcreate one single path which continues until the
second outward bend (27 or 96) of the terminal conductor (13 or 90), in
5 which the depth of channels (20b or 104b) on the extended base (15 or 106)
is lower than that of the slots (20a or 104a) in the housing (14 or 100).
11.The plugging assembly of Claims 1 or 2, wherein the terminal conductor (13
or 90) accommodated in the housing (14 or 100) and extended base (15 or
106) of the female plug (3 or 81) is a single solid block of conductive material
10 which is placed in the slot (20a or 104a) in the housing (100) and in the
channel (20b or 104b) on the extended base (15 or 106).
12.The plugging assembly of Claims 1 or 2 and 11, wherein the receiving terminal
end of the terminal conductor (13 or 90) resides in slots (20a or 104a) in the
housing (14 or 100) of the female plug (3 or 81) and the insulated section (23
15 or 94) of the terminal conductor resides in the channels (20b or 104b) on the
extended base (15 or 106).
13.The plugging assembly of Claims 1 and 11, wherein the ‘L’ shaped design of
the external cable terminals (24), creates space to accommodate more than
one external cable per phase.
20 14.The plugging assembly of Claims 1 and 11, wherein the ‘L’ shaped design of
the external cable terminal (24), number of holes (26) on the external cable
terminal (24) and outward bends (27) of the terminal conductor (13) increase
the number of external cables which can be connectable to external cable
terminal (24).
25 15.The plugging assembly of Claims 2 and 11, wherein the length and the
number of holeson the external cable terminal (92), and outward bends
(96) of the terminal conductor (90) increase the number of external cables
which can be connectable to external cableterminal (92).
16.The plugging assembly of Claims 1 or 2 and 11, wherein the part of
30 the terminal conductor (13 or 90) which is outside of the housing (14 or 100)
is longer than the part ofthe terminal conductor (14 or 100) which is inside
the housing (14 or 100).
17.The plugging assembly of Claims 1 or 2, wherein the distance between two
28
external cable terminals (24 or 92) is increased by the outward bends (27 or
96) in the middle section of the terminal conductor and is maintained by
supporting busbar holders (29a, 29b or 120a, 120b) which are tightened by
screws (30 or 121) inserted through upper holes (31a or 122a) in the upper
5 supporting busbar holder (29a or 120a) and driven through self- tapping
screw holes (31b or 122b) on the lower supporting busbar holder (29b or
120b).
18.The plugging assembly of Claims 1 or 2, wherein the extended base (15 or
106) in the female plug (3 or 81) supports and holds terminal conductors (13
10 or 90) in outward spreading channels (20b or 104b) which has the same
longitudinal bended shape of the insulated section (23 or 94) of the terminal
conductors (13 or 90).
19.The plugging assembly of Claims 1 or 2, wherein the insulated section (23
or 94) of the terminal conductor (13 or 90) starts from inside the housing (14
15 or 100) to the beginning of the external cable terminal (24 or 92).
20.The plugging assembly of Claims 1 or 2, wherein the extended base (15 or 106)
has a configuration of ribs.
21.The plugging assembly of Claims 1 or 2, wherein each external cable terminal
(24 or 92)of the terminal conductor (13 or 90) has at least two holes to connect
20 at least two external cables.
22.The plugging assembly of Claims 1 or 2, wherein the lower supporting busbar
holder (29b or 120b) has lower holes (32b or 123b) to insert screws (33 or 124)
and fix the lower supporting busbar holder (29b or 120b) to vertical mounting
bracket (50) by means of a screwdriver inserted through upper holes (32a or
25 123a) on the upper supporting busbar holder (29a or 120a).
23.The plugging assembly of Claim 1, wherein the openings (35) for ‘U’ shaped
spring- loaded clips (4) on the top cover (16) of the female plug (3) are shaped
into thin rectangular with rounded corners with a tapered bottom
resembling the shape of the base (7) of ‘U’ shaped spring-loaded clip (4) and
30 are sized slightly greater than the size of the base (7) of the ‘U’ shaped spring
loaded clip (4).
24.The plugging assembly of Claim 2, wherein the top part of terminal conductors
(90) are sunk into the plurality of openings (114) on the long border wall
29
(112b) when the top cover (110) is fixed to the housing (100) of the female
plug (81).
25.The plugging assembly of Claim 2, wherein the (87) for ‘U’ shaped springloaded clips (4) on the left side of the housing (100) are shaped into thin
5 rectangular with rounded corners with a tapered bottom resembling the
shape of the base (7) of ‘U’ shaped spring loaded clip (4) and are sized
slightly greater than the size of the base (7) of the ‘U-shaped spring loaded
clip (4).
26.The plugging assembly of Claim 1, wherein the border walls (19) of the
10 housing (14) have an inward step (38), at the top edges, on the outside of the
border walls (19) of the housing (14), whereby the bottom of edges (39) of
the top cover (16) hit the inward step (38) on the border walls (19).
27.The plugging assembly of Claim 2, wherein the configuration of holders (115)
at the back of the top cover (110) are sunk into top part of terminal conductors
15 (90) and held them tightly inside the housing (100) and the inward step (118)
at the edge of the border walls (112a, 112b, 113a and 113b) of the top cover
(110) rests on the top of border walls (103)of the housing (100) when the top
cover (110) is fixed with screws driven into screw holes (105) on the housing
(100) through screw holes (111) on the top cover (110).
20 28.The plugging assembly of Claim 2, wherein the top cover (110) is
strengthened by ribs (119) with a set of slots (120) which are sunk into
respective top edges of the internalbarriers (101) in the housing (100) when
the top cover (110) is fixed to the housing (100).
29.The plugging assembly of Claims 1 or 2, wherein the lock hole (59) on the
25 upper level of the vertical mounting bracket (50), is designed to accommodate
the notch (41) on the spring clip (40) at the time of the female plug (3 or 81)
is fully inserted into the two horizontal mounting brackets (44).
30.The plugging assembly of Claims 1 or 2, wherein the vertical mounting bracket
(50) and the two horizontal mounting brackets (44) are mounted, both
30 towards one direction, on different sides of the same vertical frame member
of a switchgear and controlgear assembly in order to mount the female plug
(3 or 81) in a functional unit compartment of the low-voltage switchgear or
controlgear assembly.
30
31.The plugging assembly of Claims 1 or 2 and 30, wherein the vertical
mounting bracket (50) is mounted vertically to left or right side, or rear
side of a vertical frame member,depending on the female plug being used
(3 or 81), extending the vertical edge (54b) towards adjoining compartment
5 on the left or right, or rear side of the functional unitcompartment.
32.The plugging assembly of Claims 1 or 2 and 30, wherein the two horizontal
mounting brackets (44) are mounted horizontally to front side, or left or
right of a vertical frame member, depending on the female plug being used
(3 or 81), in the same direction of which the vertical mounting bracket (50) is
10 mounted, locating the flanged edges (47) in the functional unit
compartment.
33.The plugging assembly of Claims 1 or 2 and 30, wherein the vertical
mounting bracket (50) is mounted to a vertical frame member of a lowvoltage switchgear or controlgear assembly by inserting itself into half-way
15 pre-fixed screws on the vertical frame member and fully tightening the
screws by a screwdriver inserted through the mounting-cutouts (56) while
viewing the tightening operation through the openings (55).
34.The plugging assembly of Claims 1 or 2, wherein the middle opening (55) of
the vertical mounting bracket (50) provides space to accommodate the
20 notch (41) on the spring clip(40) at the time of the female plug (3 or 81)
is fully inserted into the two horizontalmounting brackets (44).
35.The plugging assembly of Claim 1, wherein the female plug (3) is
installed in a functional unit compartment of a switchgear or controlgear
assembly, facing its (3) top side (9) towards the front side of the switchgear or
25 controlgear assembly and keeping its openings (35) for ‘U’ shaped springloaded clips (4) in the functional unit compartment while the external cable
terminals (24) extending out to adjoining left or right cable compartment in
the switchgear or controlgear assembly.0
36.The plugging assembly of Claim 2, wherein the female plug (81) is installed in
30 a functional unit compartment of a switchgear or controlgear assembly, facing
its (81) left side (87) towards the front side of the switchgear or controlgear
assembly and keeping its openings (108) for ‘U’ shaped spring-loaded clips
in the functional unit compartment while the external cable terminals (92)
extending out to adjoining rear cable compartment in the switchgear or
31
controlgear assembly.
37.The plugging assembly of Claim 1 or 2, wherein the long edges of the
horizontalmounting bracket (44) are formed as flanged edges (47) to allow
sliding-in mounting channels (43 or 132) on the bottom of the housing of the
5 female plug (3 or 81).
38.The plugging assembly of Claims 1 or 2, wherein the square-shaped cutouts
(62) in the transparent cover (61) are removable in any shape to create cable
entry holes for external cables extended towards external circuits.
39.A method adapted for dismantling the female plug (3 or 81) as claimed in
10 Claim 1 or 2, wherein the female plug (3 or 81) is dismantled from the
horizontal mounting bracket (44) by first removing the transparent cover
(61), disconnecting external cables fromexternal cable terminals (24 or 92),
removing screws (33 or 124) from lower holes (32b or 123b) on the
lower supporting busbar holder (29b or 120b) and pressing the free end(42
15 or 134) on the spring clip (40 or 130) to release the notch (41 or 131),
from the middle opening (55) by a tool inserted through lock hole (59),
while sliding-out thefemale plug (3 or 81) from the horizontal mounting
bracket (44).
40.A method adapted for connecting and disconnecting electrical
20 interconnections betweenthe devices installed in a functional unit
compartment, and external cables of a low- voltage switchgear or
controlgear assembly, as claimed in Claims 1 or 2, such method comprising
steps of:
Fixing male plug (2) in a functional unit of a switchgear or controlgear
25 assembly in a manner which extends out the ‘U’ shaped spring loaded
clips (4) towards rearside of the functional unit allowing the spring loaded
clips (4) to be mechanically inserted into the female plug (3 or 81) when
the functional unit is pushed into its compartment in a low-voltage
switchgear or controlgear assembly;
30 Wiring the terminals (5) of the male plug (2) internally with the switching
devicesinstalled inside the functional unit;
Fixing the vertical mounting bracket (50) vertically to left or right, or
rear side ofa vertical frame member, depending on the requirement and
32
the female plug (3 or 81) being used, in a direction to which the vertical
mounting bracket (50) extending out its vertical edge (54b) towards the
adjoining compartment, by inserting the cutout-holes (53) into half-way
pre-fixed screws on the vertical frame member; the screws are fully
5 tightened by screwdriver inserted through mounting-cutouts (56) while
the tightening operation is viewed through openings (55);
Fixing the two horizontal mounting brackets (44) horizontally to the
front, or left of right side of the same frame member and the same
direction to which vertical mounting bracket (50) is mounted, depending
10 on the requirement and the female plug (3 or 81) being used, locating
the flanged edges (47) in the functional unit compartment using
mounting screw holes (46);
Mounting the female plug (3 or 81) in the functional unit compartment
facing its (3 or 81) openings (35 or 108) towards the front side of the
15 switchgear or controlgear assembly and keeping the openings (35 or 108)
for ‘U’ shaped spring-loaded clips (4) in the functional unit compartment,
by inserting through the four mounting channels (43 or 132) on its back
along the flanged edges (47) of the two horizontal mounting brackets
(44), from the side of the vertical mounting bracket (50), and sliding-in
20 until the two knobs (49 or 133) on the bottom side of the female plug (3
or 81) hitting the two slide stoppers (45) on the two horizontal
mounting brackets (44) and the notch (41) on the free end (42) of the
spring clip (40) reaching the middle opening (55) on the vertical mounting
bracket (50) and locks making a “click” sound;
25 Fixing the lower supporting bracket (29b or 120b) of the female plug (3
or 81) to vertical mounting bracket (50) using screws (33 or 124)
inserted through lowerholes (32b or 123b) in the lower supporting
busbar holder (29b or 120b) and fastening the screws (33 or 124) by
inserting a screwdriver through upper holes (32a or 123a) on the upper
30 supporting busbar holder (29a or 120a);
Creating external cable entry holes on transparent cover (61) for lugged
external cables by removing square-shaped cutouts (62) from
transparent cover (61) and inserting lugged external cables through the
external cable entry holes created on the transparent cover (61);
33
Fixing lugged external cables to female plug (3 or 81) by connecting them
to the external cable terminals (24 or 92), using nuts and bolts fastening
through holes (26 or 93);
Fixing the transparent cover (61) to the vertical mounting bracket
5 (50) using fixing brackets (63);
Fully inserting the functional unit into its compartment enabling the ‘U’
shaped spring-loaded clips (4) to be engaged with the receiving terminals
(22 or 91) in the female plug (3 or 81) to make the electrical
interconnections; and
10 Removing the functional unit from its compartment enabling the ‘U’
shaped spring-loaded clips (4) to be disengaged with the receiving
terminals (22 or 91) in the female plug (3 or 81) to remove the electrical
interconnections