Connector assembly for a plasma arc torch

1. A connection system for releasably coupling a plasma arc torch lead to a power supply receiver having a radially extending female keyway, the connection system comprising:

a connector assembly comprising:

a connector body having a distal end and a proximal end, the distal end configured to connect to the plasma arc torch lead; and

a plug secured within and extending from the proximal end of the connector body, the plug configured to be inserted into the power supply receiver, the plug defining a longitudinally oriented female keyseat; and

a locking key assembly including:

an adapter key configured to connect to the power supply receiver and including a first male portion configured to extend into the power supply receiver keyway, the adapter key including a longitudinally oriented second male portion configured to interfit with the plug female keyseat when the plug is inserted into the power supply receiver; and

a latch movably connected to the adapter key and configured to releasably engage the connector body to releasably lock the plug within the power supply receiver.

2. The connection system according to claim 1 wherein the adapter key includes a detent finger and a tab opposite the detent finger, wherein the tab is configured for receipt within a window formed in the power supply receiver keyway.

3. The connection system according to claim 2 wherein the detent finger is movable between a free state and a constrained state.

4. The connection system according to claim 3 wherein the tab is restrained within the window of the keyway when the plug is inserted into the power supply receiver.

5. The connection system according to claim 2 wherein the locking key assembly includes a mounting bracket and the latch is pivotally mounted to the mounting bracket with a hinge pin.

6. The connection system according to claim 2 wherein the latch includes a retention feature for retaining the latch to the connector body, and the connector body includes a complementary receiving feature.

7. The connection system according to claim 6 wherein the retention feature is one of a lip, a snap, a pin, and a screw.

8. A torch connection system for coupling a plasma arc torch lead and a power supply receiver having a radially extending female keyway, the torch connection system comprising:

a connector assembly including a connector body and a plug, the connector body having a distal end and a proximal end, the distal end configured to connect to the plasma arc torch lead, the plug secured within and extending from the proximal end of the connector body the plug defining a longitudinally oriented female keyseat, the plug configured for receipt within the power supply receiver; and

a locking key assembly including an adapter key and a latch, the adapter key including a first male portion configured to extend into and engage the power supply receiver female keyway, the adapter key including a second male portion configured to interfit with the plug female keyseat when the plug is inserted into the power supply receiver, the latch movably connected to the adapter key and configured to releasably engage the connector body to releasably lock the plug within the power supply receiver.

9. The torch connection system according to claim 8 wherein the adapter key is configured to connect to the power supply receiver and includes a tab, the tab biased into engagement within a window formed in the power supply receiver keyway.

10. The torch connection system according to claim 9 wherein the tab is biased by one of a screw-pin, a spring, a clip, a detent finger, a wedge, a ball detent, a cam, and a living hinge.

11. The torch connection system according to claim 9 wherein the tab is restrained within the keyway window when the plug is inserted into the power supply receiver.

12. The torch connection system according to claim 8 wherein the latch includes a retention feature for releasably engaging the latch to the connector body, and the connector body includes a complementary receiving feature.

13. The torch connection system according to claim 12 wherein the retention feature is one of a lip, a snap, a pin, and a screw.

14. A method of connecting a plasma arc torch lead to a power supply, the method comprising:

providing a power supply including a receiver disposed within or on the power supply, the power supply receiver including a radially extending female keyway with a window formed therethrough;

inserting a locking key assembly into the power supply receiver keyway, the locking key assembly including an adapter key including a tab and a male portion configured to extend into the power supply receiver female keyway, the locking key assembly including a latch movably connected to the adapter key, the tab biased into engagement within the power supply receiver keyway window;

providing a connector assembly connected to a plasma arc torch lead, the connector assembly having a connector body and a plug defining a longitudinally oriented female keyseat;

inserting the connector assembly into the power supply receiver such that the locking key assembly is interfit within the plug keyseat; and

releasably engaging the locking key assembly latch to the connector body to releasably lock the plug within the power supply receiver.

15. The method according to claim 14 wherein the adapter key tab is biased by one of a screw-pin, a spring, a clip, a detent finger, a wedge, a ball detent, a cam, and a living hinge.

16. The method according to claim 15 wherein the tab is restrained within the power supply receiver keyway window when the plug is inserted into the power supply receiver.

17. The method according to claim 14 wherein the latch includes a retention feature and the connector body includes a complementary receiving feature, wherein the retention feature is one of a lip, a snap, a pin, and a screw.

18. The method according to claim 17 including releasing the locking key assembly latch from the complementary receiving feature on the connector body and removing the connector assembly from the power supply receiver.

19. The method according to claim 18 including moving the tab out of engagement with the power supply receiver keyway window and removing the locking key assembly from within the power supply receiver.

20. The method according to claim 14 wherein adapter key aligns and joins the power supply receiver socket keyway and plug keyseat.