Electrical Covers for Wired Devices

Abstract

An electrical cover is provided for a terminal block of a device that protects the terminal block from risks associated with stray wires. The electrical cover retains the desired wiring within the connection space of the terminal block while protecting other stray wires from entering the connection space.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of and priority to U.S. Provisional Application No. 62 / 982,162, filed February 27, 2020, the entirety of which is incorporated herein by reference.

[0002] TECHNICAL FIELD This application relates generally to electrical covers for wired devices, and more particularly to electrical covers for terminal blocks. [Background technology]

[0003] The terminal block can be connected to high voltage power (e.g., line power) of 120 volts or more. The terminal block can be associated with a controller or other electronic device that is powered by the high voltage power. The terminal block may have metal areas to which high voltage wires can be fastened. For example, screw-type fasteners are often used. Summary of the Invention

[0004] A brief summary will now be presented in order to provide a basic or general understanding of various aspects of the exemplary, non-limiting embodiments described below in the detailed description and accompanying drawings. However, this summary is not intended to be an extensive or exhaustive overview. The purpose of this summary is to present some concepts related to some exemplary, non-limiting embodiments in a concise manner as a prelude to the more detailed description of the various embodiments that follow.

[0005] In various non-limiting embodiments, an electrical cover for a terminal block of a device is provided that protects the terminal block from risks associated with stray wires. The electrical cover retains desired wires within the connection space of the terminal block while protecting other stray wires from entering the connection space.

[0006] These and other embodiments are described in detail below. [Brief explanation of the drawings]

[0007] Various non-limiting embodiments are further described below with reference to the drawings.

[0008] [Figure 1] FIG. 1 is a schematic block diagram of an exemplary, non-limiting embodiment of a well management system according to one or more aspects. [Figure 2] 2 is a top front right perspective view of an exemplary non-limiting embodiment of a controller of the well management system of FIG. 1. [Figure 3] 3 is a top front left perspective view of the controller of FIG. 2. FIG. [Figure 4] 4 is a lower front left perspective view of the controller of FIG. 2. FIG. [Figure 5] 5 is a top front right perspective view of the controller of FIG. 2 with the housing cap removed. [Figure 6] FIG. 6 is a top view of the controller of FIG. 2 with the housing cap removed. [Figure 7] FIG. 7 is a schematic diagram of the controller of FIG. 2 with exemplary wires according to one embodiment. [Figure 8] FIG. 8 is a schematic diagram of the controller of FIG. 2 with an electrical cover according to various embodiments. [Figure 9] FIG. 9 is an exemplary, non-limiting embodiment of an electrical cover according to various aspects. DETAILED DESCRIPTION OF THE INVENTION

[0009] Well systems typically have a water pump that draws water from the well into the structure's piping system. A pressure tank is often utilized to supply water under pressure to the piping system to supplement the water pump and allow the water pump to operate intermittently. Even if the pump can meet demand, a continuously operating pump may have a shorter operating lifespan.

[0010] The pressure switch allows the well pump to operate intermittently while also ensuring the system maintains pressure. A pressure switch is a device that opens and closes an electrical contact based on water pressure acting on the input of the pressure switch. The pressure switch is configured to close the electrical contact, thus operating the pump, when the pressure acting on the input drops to a predetermined cut-in pressure. Similarly, the pressure switch is configured to open the electrical contact (i.e., turn the pump off) when the pressure acting on the input rises to a predetermined cut-out pressure.

[0011] Pressure switches simply maintain system pressure within a configured range and do not provide pump protection. Such devices do not provide robust management, control, or protection of the well system. Furthermore, physical inspection of the well system (i.e., pressure tank and / or pump) is required to verify status and / or adjust the system.

[0012] The improved well management system can have a controller capable of communicating with a backend system via a communications network and capable of communicating with one or more client devices via the backend system.

[0013] 1 shows a schematic block diagram of an exemplary, non-limiting embodiment of an internet-enabled well management system. System 100 can include a controller 110 operably coupled to a pump 120 for moving fluid from a well. Pump 120 supplies fluid to a pressure tank 130 and / or a distribution system 140 (e.g., a structure's piping system). Tank 130 can be a pressure vessel having an internal diaphragm separating the interior volume into an air chamber from a water chamber. The air chamber includes an air pressure precharge to provide fluid under pressure to distribution system 140 even when pump 120 is not operating.

[0014] The controller 110 activates and deactivates the pump 120 according to the operating modes established for the system 100. More particularly, the controller 110 collects operational data associated with the various components of the system 100 and operates the pump 120 according to the operational data and operational configurations stored by the controller 110.

[0015] By way of example, the operating configuration can include a pressure setpoint, and the operating data can include a pressure measurement from a sensor 112. The sensor 112 can be coupled to a fluid line between the pump 120 and the tank 130 or the distribution system 140. The sensor 112 provides a pressure measurement in the fluid line and communicates the pressure measurement to the controller 110. In accordance with a normal mode of operation, the controller 110 activates the pump 120 when the pressure measurement is below a cutout pressure and deactivates the pump 120 when the pressure measurement is at or above the cutout pressure. While illustrated as separate from the controller 110, it should be understood that the sensor 112 can be integrated with the controller 110. For example, the sensor 112 can be at least partially integrated with a circuit board of the controller 110 and / or encased in a common housing. Furthermore, the common housing with the controller 110 and / or the sensor 112 can be mounted on or attached to the tank 130.

[0016] The controller 110 may obtain operational data related to the pump 120. For example, the electrical characteristics (e.g., current, voltage, resistance) and cycle time of the pump 120 may be recorded by the controller 110. Additional operational data may include the water level in the tank 130, system output history, and / or data from other sensors (e.g., water usage sensors, temperature sensors, etc.). In addition, the operational data may also include user input such as, but not limited to, images of the physical setup of the system 100, maintenance notes, etc.

[0017] The operational configuration of the controller 110 can have alarm conditions or event triggers. The controller 110 can respond with a preconfigured action when operational data acquired by the controller 110 meets an alarm condition or event trigger. For example, the controller 110 may deviate from a normal operating mode in response to an alarm condition or event trigger. The deviation can include shutting off the pump for a period of time and / or until the condition is resolved.

[0018] The controller 110 may also send notification or alert messages to inform the homeowner or service contractor of the system status. To enable this operation, the controller 110 may be configured to communicate with a backend system 150 and / or a client device 160. The communication may be performed over a communication network, or in some examples, the communication may be direct device-to-device communication.

[0019] According to one embodiment, backend system 150 can register one or more users with controller 110. These users can utilize client devices 160 to communicate with controller 110 through backend system 150 according to their configured access levels. For example, a homeowner has full access to all information. A homeowner can designate service subscribers and register the service subscribers with backend system 150. The level of information access granted to service agents is adjustably controlled by the homeowner.

[0020] The controller 110 can obtain information through the backend system 150. Alternatively, the controller 110 can be configured to periodically transmit information. In one embodiment, the backend system 150 can act as a relay between the controller 110 and the client device 160. For example, the backend system 150 can forward information transmitted by the controller 110 to the client device 160 and can forward commands and requests from the client device 160 to the controller 110. In another embodiment, operational data and other historical operational information can be transmitted by the controller 110 to the backend system 150 for storage. The backend system 150 can provide stored information to the client device 160 independently of the controller 110 depending on the access level. It should be understood that the system 100 can operate along a continuum between the two approaches described above. For example, the controller 110 can retain certain information while the backend system 150 stores other information to enable efficient utilization of storage on the controller 110.

[0021] In another aspect, the controller 110 can utilize direct device-to-device communication. For example, the client device 160 may be in close proximity to the controller 110 (i.e., the same structure, the same room, etc.). In such a case, a wired or wireless connection (e.g., Bluetooth, wireless USB, ad-hoc WiFi, etc.) can be established between the client device 160 and the controller 110.

[0022] The operational configuration of the controller 110 can specify one of several operating modes or states in which the controller 110 is currently operating. As previously described, the controller 110 utilizes pressure setpoints and pressure measurements to activate and deactivate the pump 120 in normal operating mode. When the controller 110 is first powered on, it can enter an initial startup mode. In the initial startup mode, the controller 110 can activate the pump 120 to fill the tank 130, determine a pre-fill for the tank 130, and establish pressure settings based on the pre-fill. These pressure settings can then be utilized in normal operating mode.

[0023] Additional modes may include a setup mode, a vacation mode, a storm mode, and a maintenance mode. In the setup mode, the controller 110 may initially utilize direct device-to-device communication with the client device 160 to register with and configure communication with the backend system 150. In the vacation mode, the controller 110 is configured to prevent operation of the pump 120. In the storm mode, the controller 110 overrides the pressure setpoint to maximize the amount of water stored in the tank 130. In the maintenance mode, the controller 110 may recheck the charge of the tank 130. This value may be compared to an initial reading to determine charge degradation. In this manner, the maintenance mode provides a health status check of the system 100. Furthermore, the maintenance view on the client device 160 may provide health status information such as, but not limited to, charge degradation, current precharge reading, and electrical input to the pump 120. Furthermore, a protection mode is available when the controller 110 detects an alarm condition or other event that warrants a deviation from normal operating mode.

[0024] Further aspects of the well management system can be found in US Patent Application No. 16 / 046,441, which is incorporated herein by reference in its entirety.

[0025] 2-6, exemplary, non-limiting embodiments of a controller 110 according to various aspects are shown. As shown, the controller 110 includes a controller housing 200. In one embodiment, the controller housing 200 includes a housing body 202 and a housing cap 204. The housing cap 204, in some embodiments, covers and protects a wire section 212 (FIGS. 5 and 6). The housing body 202 contains, for example, control and communication electronics and / or a pressure switch.

[0026] The housing 200 further has a first opening 206 ( FIG. 2 ) and a second opening 208 ( FIG. 3 ) disposed on opposite sides of the housing 200. The first opening 206 and the second opening 208 provide access to a wire compartment 212 while the housing cap 204 is installed. Wires may pass through the openings 206, 208. Additionally, the openings 206, 208 can facilitate connection with conduits through which the wires pass. In some embodiments, a controller opening 210 ( FIG. 4 ) can be disposed at the bottom of the controller housing 200. The controller opening 210 can provide access to wired or other connectors for coupling with control, communication, and / or pressure switch electronics.

[0027] According to one embodiment, wire section 212 can have one or more terminal blocks, such as terminal block 214 and terminal block 216. Terminal blocks 214, 216 provide externally accessible connections to control electronics (e.g., pressure switches, etc.) within housing body 202. As best shown in FIG. 6 , terminal blocks 214, 216, in one embodiment, allow for connections to high voltage (e.g., 120 volts or greater) for powering controller 110 and external devices (e.g., pumps). In one embodiment, terminal block 214 connects to input line power, and terminal block 216 connects to the pump. These connections, in one embodiment, allow controller 110 to operate the pump according to one or more control processes that can selectively turn power to the pump on or off.

[0028] 7, an exemplary, non-limiting schematic diagram of the controller with wiring is shown. Terminal blocks 214, 216 provide metal areas onto which high voltage wires 218, 220, respectively, are fastened in place with threaded fasteners. A ground wire 222 covers the top and passes through openings 206, 208.

[0029] In some situations, during installation or repair, a fastener may come loose or another bare wire may contact a portion of the terminal block. Such a situation may result in a tripped breaker, electric shock, or damage to system components. The likelihood of a wire accidentally contacting the terminal block may depend on the layout (e.g., relative placement) of the terminal blocks 214, 216 and / or the amount of wiring pushed into the wire compartment 212.

[0030] In consideration of the above situation, an electrical cover is described herein. The electrical cover is configured to protect the terminal blocks (e.g., terminal blocks 214, 216) and prevent stray wires from entering the connection space. The electrical cover also keeps desired wires, such as wire 218 connected to terminal block 214, within the connection space. Thus, the electrical cover protects the device, the user, and the system from potential loose wires.

[0031] Referring to FIG. 8, a schematic diagram of controller 110 includes at least one electrical cover for the terminal block. In the embodiment shown in FIG. 8, electrical cover 224 is installed over terminal block 214, and electrical cover 226 is installed over terminal block 216. In some embodiments, electrical covers 224 and 226 may be vinyl, rubber, or other electrically insulating material. In another embodiment, electrical covers 224, 226 are deformable and can stretch over the terminal blocks. Furthermore, electrical covers 224, 226 are elastic after stretching and rebound to fit snugly around the side walls of the terminal blocks when installed. Therefore, once installed, electrical covers 224, 226 will not pop out due to system movement or vibration.

[0032] As shown in Figures 7 and 8, a pass-through ground wire 222 is used. The pass-through ground wire 222 can reduce the overall footprint of the device and streamline the circuit board layout of the controller 110. Thus, while a separate ground wire connection on the terminal block can mitigate the possibility of stray wire contacts, the benefits noted above (e.g., reducing the overall footprint and simplifying the circuit board layout) are lost. However, the electrical covers 224, 226 also mitigate the possibility of stray wire contacts, like separate connections, but without losing these benefits. Additionally, the pass-through ground wire 222 can make it easier to hold the electrical covers 224, 226 in place.

[0033] In yet another embodiment, the electrical covers 224, 226 may be monolithic components. For example, in a device with multiple terminal blocks, a single electrical cover configured to cover all of the terminal blocks minimizes the risk of improper installation. Thus, the monolithic component has a shape that corresponds to the relative positioning of the terminal blocks. The monolithic embodiment further improves the retention characteristics of the ground wire 222.

[0034] Referring now to Figure 8, an exemplary, non-limiting embodiment of an electrical cover 300 is shown. The electrical covers 224, 226 described above may be similar to the electrical cover 300 shown in Figure 9. The electrical cover 300 has a cover surface 302 and a plurality of side walls 304 extending downwardly from the cover surface 302. As shown in Figure 9, one side wall may be a notched side wall 306 having an opening 308 therein to accommodate wires connected to a terminal block.

[0035] As described above, the electrical cover 300 is formed from a flexible material. In some embodiments, the electrical cover 300 may be a vinyl material, a rubber material, or other flexible and electrically insulating material. That is, if the electrical cover 300 comes into contact with exposed wires, the material of the electrical cover 300 should be selected to allow a small current to pass through. As used herein, a small current is a current low enough not to pose a safety risk to people or equipment, low enough not to damage the equipment, and / or low enough not to trip fuses or circuit breakers.

[0036] The electrical cover 300 may be sized according to the terminal block. For example, the area of ​​the cover surface 302 may generally correspond to the area of ​​the footprint of the terminal block. Furthermore, the height of the side walls 304 may substantially correspond to the height of the terminal block. Furthermore, the lengths of the side walls 304 may each be set to correspond to the horizontal dimensions of the terminal block.

[0037] As described above, the electrical cover 300 is flexible and deformable, but may also be resilient. The side walls 304 may be deflected or stretched outward by the application of a force. The side walls 304 return to their undeformed state when the force is removed. This allows the cover 300 to flex and slide over the terminal block. The side walls 304 then return to their resting state, exerting a force against the terminal block to secure the cover 300 in place.

[0038] As used herein, the term "or" is intended to mean an inclusive "or" rather than an exclusive "or," i.e., unless otherwise specified or clear from the context, the phrase "X uses A or B" is intended to mean any of the natural inclusive permutations. That is, the phrase "X uses A or B" is satisfied by any of the following examples: X uses A, X uses B, or X uses both A and B. Additionally, the singular forms used in this application and the appended claims should generally be construed to mean "one or more" unless otherwise specified or clear from the context directed to the singular form.

[0039] Moreover, the word "exemplary" as used herein is intended to mean "serving as an illustration or example of something."

[0040] Illustrative embodiments have been described above. It will be apparent to those skilled in the art that the above-described devices and methods can incorporate changes and modifications without departing from the general scope of the claimed subject matter. It is intended to include all such modifications and variations within the scope of the claimed subject matter. Furthermore, the term "comprising," whether used in the detailed description or in the claims, is intended to be inclusive, similar to the interpretation of the term "comprising" when used as a claim transition term.

Claims

1. a controller, a housing body having an enclosed compartment containing control and communication electronics and a wire compartment; a housing cap removably attached to the housing body and enclosing the wire section; at least one terminal block disposed within the wire compartment providing one or more connection points for wiring, the at least one terminal block electrically coupling the control and communication electronics within the enclosed compartment to the one or more connection points; and at least one cover removably attached to the at least one terminal block.

2. The controller of claim 1 , wherein the at least one cover is formed from an electrically insulating material.

3. The controller of claim 1 , wherein the at least one cover is deformable to slide over the at least one terminal block.

4. The controller of claim 1 , wherein the at least one cover surrounds the one or more connection points of the at least one terminal block.

5. The controller of claim 1 , wherein the at least one cover comprises a cover surface and a plurality of side walls extending from the cover surface.

6. The controller of claim 5 , wherein the side walls are deflectable outwardly by the application of a force to allow attachment to the at least one terminal block.

7. The controller of claim 6 , wherein the side walls are resilient and return to a resting shape after removal of the force.

8. The controller of claim 7 , wherein the plurality of side walls exert a retention force on the at least one terminal block in the rest configuration to hold the cover in place on the at least one terminal block.

9. 2. The controller of claim 1, wherein the at least one cover is a monolithic part molded according to the respective sizes and relative arrangements of the at least two terminal blocks, the monolithic part being configured to be attached to all of the at least two terminal blocks.

10. the housing body has a pair of openings on either side of the wire compartment for receiving wiring, the wiring including wiring for line power, wiring for a load, and a pass-through ground wire; The controller of claim 1 , wherein the at least one cover electrically insulates the at least one terminal block from the pass-through ground wire.

11. The terminal block cover of claim 5 , wherein at least one of said plurality of side walls has an opening therein.

12. 12. The terminal block cover of claim 11, wherein said openings receive wires therethrough for connection to said at least one terminal block.

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