This invention relates generally to the assembly of an electrical whip that electrically connects an electrical device or appliance to a power supply.
An electrical whip assembly is a generally a connector assembly to connect electrical power to an electrical appliance. It usually includes a flexible conduit, connector fittings on each end of the conduit for attaching the conduit to a panel or enclosure, and electrical conductors inside the conduit to carry power to the appliance. The connector fittings are usually attached to the flexible conduit via a threaded mechanical connection and allow the electrical whip to be connected to a knockout in a junction box. The fitting is typically mechanically threaded or pressed onto the conduit through manual human effort.
Disclosed herein are embodiments of apparatuses and methods pertaining to a connection device for use in assembling an electrical whip. This description includes drawings, wherein:
Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention. Certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. The terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.
Generally speaking, pursuant to various embodiments, systems, apparatuses and methods arc provided herein useful to assemble an electrical whip including the connection of a fitting or connector to a metal clad cable having electrical wiring extending therefrom. In some embodiments, a connection device for use in assembling an electrical whip comprising: a block portion fixed in position and having a cable engagement portion configured to engage an end portion of a metal clad cable having electrical wiring extending therefrom; a retaining device coupled to the block portion and configured to releasably retain the end portion of the metal clad cable against the cable engagement portion; a piston portion having a connector alignment portion and an end wall portion, wherein the connector alignment portion is configured to receive a connector with the electrical wiring extending therethrough, and wherein the end wall portion is configured to contact the connector while allowing the electrical wiring to extend therethrough; a handle; and a hinge assembly pivotally coupling the handle to the block portion and to the piston portion, wherein upon a manipulation of the handle, the piston portion including the connector alignment portion and the end wall portion slide linearly toward the block portion pressing the connector onto the end of the metal clad cable as it is retained against the cable engagement portion by the retaining device.
Accordingly, several embodiments provide connection devices and methods of connection for assembling an electrical whip. Throughout this specification, concurrent reference will be made to
Referring to
Generally, the connection device 300 has a first position or first orientation in which the cable 102 and connector 106 are positioned to be assembled. This open orientation is illustrated in
Turning to further details of the connection device 300, reference is made to
In the illustrated embodiments, the hinge assembly 310 and the handle 308 allow the piston 304 to move linearly about the x-axis. That is, as the handle 308 is moved in the direction of arrow 330, the piston is moved through a portion of the channel 332. This causes the end wall 314 and the connector alignment portion 316 to move toward (when transitioning to the closed orientation) and away from (when transitioning to the open orientation) the block 302. With the first pivot assembly 320, the handle is pivotally and rotatably coupled to one end of the piston 304 that extends through a back side (side opposite the end wall 314) of the block 302. With the second pivot assembly 322, the handle 308 is also pivotally and rotatably coupled to one portion (e.g., end) of the pivot component 324 which takes the form of a plate. With the third pivot assembly 326, another portion (e.g., other end) of the pivot component 324 is pivotally and rotatably coupled to the block portion 328 fixed to the block 302. All of the first, second and third pivot assemblies provide a rigid connection between components but allow rotation between the various connected components. When the handle 308 is in the open orientation (see
In some embodiments, the connector alignment portion 316 takes the form of a U-shaped member having two opposing sides extending upward in the shape of a letter U. The U-shaped member has an inner curvature substantially corresponding to an outer diameter of the connector 106. The U-shape allows the connector 106 to be easily positioned therein (e.g., see
In some embodiments, the end wall 314 includes the wire channel 318 to allow the electrical wires extending from the connector 106 to continue extending therethrough so as not to interfere with the compression fit of the connector to the cable by the end wall 314. In some embodiments, the wire channel 318 includes a narrow slot to allow insertion of the wires 104 and widens to an opening having to accommodate all wires together.
In some embodiments, as is best seen in
It is understood that the cable 102 may be jacketed (see cable 112 in
In some embodiments, one or more of the components of the connection device 300 are made of a metal or metallic material to enhance the strength of the connection device. For example, one or more of the block 302, the retainer 306, the piston 304, the connector alignment portion 316, the end wall 314, the handle 308, and the hinge assembly 310 comprise a metal or metallic material.
In some embodiments, a handle return 346 (generically referred to as a handle return device) is coupled to a portion of the handle 308 and is configured to introduce a resistance force on the handle 308 during the manipulation of the handle when the connection device is transitioned to the closed orientation. Some embodiments of the handle return 346 are illustrated in
Generally, the connection device of several embodiments provides for easier assembly of electrical whips without the use of manual force and holding pieces by hand which has proven time consuming and difficult, in particular with jacketed cables. Embodiments of the connection device allow the connector to be fit to the cable with little manual force due to the leverage created by the handle and the block/piston allow for quick installation, while securing the components being fit together. For example, in some embodiments, an operator may apply as little as about 10-15 pounds of force to the handle 308, and in some embodiments, the operator may apply as little as about 12-13 pounds of force to the handle 308 in order to press the connector onto a jacketed cable 112. Again doing so by hand without a connection device such as described herein is very difficult in that a user must hold both components by hand or press on component against the other and apply significantly more force than when using a connection device such as described herein. For example, due to the mechanical structure of the connection device including the handle, hinge mechanism, block and piston, less operator force on the handle is translated into a greater force by the end wall on the connector. In some cases, due to the manual force needed without a connection device, the operator rests the connector against a stationary Object and uses both hands to force the cable onto the connector, but if the connector is not held securely or the cable not pressed evenly, the cable may not align well with the connector. It may take 30 seconds to one minute or longer to assemble one electrical whip and it may be difficult to properly align the connector onto the cable. In some embodiments of the connection device, an electrical whip can be assembled in less than 10 seconds, and in some cases, less than 5 seconds. Further, electrical whips may be assembled with less force applied by the operator, resulting in less fatigue to the operator and less risk of injury. Additionally, electrical whips may be assembled with better alignment due to the guided linear movement of the piston and secure placement of components, relative to manual assembly techniques. Thus, in some embodiments, the process of assembling an electrical whip is more efficient, faster and requires less operator force application. In manufacturing processes where tens or hundreds of electrical whips are assembled by a single operator in a day, the connection device greatly improves assembly output and connection quality and reliability.
Reference is now made to the flow diagram of
Next, the cable and connector are positioned to a connection device (e.g., connection device 300) having a block (e.g., block 302) and a piston (e.g., piston 304) such that the cable contacts or engages a cable engagement portion (e.g., cable engagement portion 312) of the block, the connector contacts the connector alignment portion (e.g., connector alignment portion 316) and the end wall (e.g., end wall 314) of the piston, and such that the wires extend through the end wall (Step 1604). The block is fixed in position and the piston is linearly moveable toward and away from the block portion. In some embodiments, the piston extends through a hollow channel formed in the block such that the end wall and the connector alignment portion move toward and away from the block with movement of the piston. Next, the cable is retained against the cable engagement portion with a retainer (e.g., retainer 306) (Step 1606). This fixes the position of the cable during use of the connection device.
Next, a handle (e.g., handle 308) pivotally coupled to the block and to the piston (e.g. via hinge assembly 310) is manipulated (e.g., moved in the direction of arrow 330) such that the piston including the connector alignment portion and the end wall slide linearly toward the block pressing the connector onto an end of the cable as it is retained against the cable engagement portion (Step 1608).
And then the cable with attached connector is released from the retainer and removed from the connection device (Step 1610). Some embodiments of the assembled electrical whip 100 are shown in
It is understood that this method may differ according to any of the variations described herein with respect to
In some embodiments, apparatuses and methods are provided herein useful to assemble an electrical whip. In some embodiments, a connection device for use in assembling an electrical whip comprising: a block portion fixed in position and having a cable engagement portion configured to engage an end portion of a metal clad cable having electrical wiring extending therefrom; a retaining device coupled to the block portion and configured to releasably retain the end portion of the metal clad cable against the cable engagement portion; a piston portion having a connector alignment portion and an end wall portion, wherein the connector alignment portion is configured to receive a connector with the electrical wiring extending therethrough, and wherein the end wall portion is configured to contact the connector while allowing the electrical wiring to extend therethrough; a handle; and a hinge assembly pivotally coupling the handle to the block portion and to the piston portion, wherein upon a manipulation of the handle, the piston portion including the connector alignment portion and the end wall portion slide linearly toward the block portion pressing the connector onto the end of the metal clad cable as it is retained against the cable engagement portion by the retaining device.
In some embodiments, a method of assembling an electrical whip, comprises: positioning a metal clad cable having electrical wiring extending therefrom through a connector to be pressed onto an end of the metal clad cable against a cable engagement portion of a block portion of a connection device such that a portion of the metal clad cable engages the cable engagement portion, such that the connector is received in a connector alignment portion of a piston portion of the connection device and such that the electrical wiring extends through an end wall portion of the piston portion, wherein the block portion is fixed in position and the piston portion is linearly moveable toward and away from the block portion; retaining the metal clad cable against the cable engagement portion with a retaining device coupled to the block portion; manipulating a handle pivotally coupled to the block portion and to the piston portion via a hinge assembly such that the piston portion including the connector alignment portion and the end wall portion slide linearly toward the block portion pressing the connector onto the end of the metal clad cable as it is retained against the cable engagement portion by the retaining device; and releasing the metal clad cable having the connector pressed thereon from the retaining device and removing the metal clad cable and connector from the connection device
Those skilled in the art will recognize that a wide variety of other modifications, alterations, and combinations can also be made with respect to the above described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.
This application claims the benefit of U.S. Provisional Application No. 62/029,749, filed Jul. 28, 2014, which is incorporated by reference in its entirety herein.
Filing Document | Filing Date | Country | Kind |
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PCT/US15/42382 | 7/28/2015 | WO | 00 |
Number | Date | Country | |
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62029749 | Jul 2014 | US |