Hinged Plug Lockout Ring for Connection and Disconnection Control
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Solution Overview
Problem
Existing access control devices fail to securely prevent both connection and disconnection of power cord plug ends to and from power outlets connected to power sources like power carts, posing risks of arc flashes and electrical shocks.
Innovation Solution
An improved access control assembly featuring a hinged ring with lockout holes and a cap attachment system, which locks the plug end in both plugged-in and unplugged positions, using locking elements to secure the hinged ring and prevent unauthorized connections or disconnections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If box-type plug lockout devices are used to lock out plug ends, then access control is provided, but the devices become bulky in size and only lock when the plug is disconnected
Solution Approach 1:
The access control device transitions from a static box-type structure to a dynamic hinged ring structure that can adapt its configuration. The hinged ring can open to allow plug insertion and close to provide lockout, enabling the same device to function in both plugged-in and disconnected states without requiring bulky fixed enclosures.
Solution Approach 2:
Instead of using a box-type structure that locks from the outside, the invention uses a hinged ring that locks around the plug from all sides when closed. The locking mechanism inverts the approach by having the ring conform to the plug shape and lock around it, rather than having a fixed box accommodate the plug.
2Reliability
If box-type plug lockout devices are used, then plug connection is prevented, but disconnection protection is not provided and arc flash risks remain
Solution Approach 1:
The hinged ring is positioned to lock around the plug end before disconnection occurs. The device includes a locking mechanism that secures the plug in the connected state, preventing unintended disconnection before it can happen. This preliminary locking action protects against arc flash by ensuring the plug cannot be accidentally pulled from the power outlet during power-down procedures.
Solution Approach 2:
The access control device is designed to perform multiple functions: preventing both connection and disconnection of the plug. The hinged ring structure can lock around the plug whether it is inserted or not, providing universal protection in both states. This multi-functionality eliminates the need for separate devices for connection prevention and disconnection protection.
3Volume of moving object
If a hinged ring structure is used to lock around the plug, then compact size is achieved, but clearance for hinged power outlet cover plate must be ensured
Solution Approach 1:
The hinged ring is divided into two portions connected by a hinge, allowing the ring to open sufficiently to clear the hinged power outlet cover plate when the plug is inserted. The segmented structure enables the ring to move out of the way during plug insertion while still providing effective lockout when closed around the plug end.
Solution Approach 2:
The hinged ring incorporates dynamic movement capability through its hinge connection, allowing it to adapt its position. The ring can open to provide clearance for the cover plate and then close to lock around the plug, dynamically adjusting to the operational requirements of both cover plate movement and secure lockout.
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2F
AI summary
There is provided an access control assembly for controlling access to a plug end of a power plug assembly. The access control assembly includes a hinged ring having a first portion pivotably connected to a second portion, so that the first portion pivots toward and away from the second portion to close and open the hinged ring. The first portion and the second portion each has one or more lockout holes. The access control assembly includes one or more locking elements, a cap having an internal cavity and an exterior lip, and a cap connector element. The access control assembly controls access to the plug end of the power plug assembly by preventing connection of the plug end when the plug end is in an unplugged position, and by preventing disconnection of the plug end when the plug end is plugged into a power outlet in a plugged-in position.