Patent Application
20060009086
1. Field of the Invention
The present invention relates to electrical clamps and, more particularly, to a wedge connector assembly.
2. Background Information
U.S. Pat. No. 4,339,942 discloses an electric tap connector with a wedge that is moved into the shell by a bolt. U.S. Pat. No. 5,367,251 discloses a tool for grasping an electrical power conductor. The tool has a plurality of pointed pins mounted on a movable platform to pierce cable sheathing and insulation and contact a conductor of a cable held in place by the tool. U.S. Pat. No. 5,916,001 discloses a wedge connector with a shell and a wedge. The shell has insulation piercing sections to pierce through insulation of electrical conductor cables.
Despite the above advances, there is a desire for an improved wedge hot line clamp or wedge connector assembly suitable for connecting an overhead distribution current carrying conductor to another. The present invention addresses this need and others.
In accordance with one aspect of the present invention, an electrical wedge connector assembly is disclosed. The assembly comprises a shell, an eye bolt and a wedge sized and shaped to be inserted into the shell for connecting two conductors to each other. The eye bolt comprises a swivel joint adapted to be inserted into the wedge.
In accordance with another aspect of the present invention, an electrical wedge connector assembly is disclosed. The assembly comprises a shell, a wedge and an eye bolt. The shell is a one-piece member having a general “0” shaped cross-section and tapers from a first end to a more narrow second end. The wedge is sized and shaped to be inserted into the shell for connecting two conductors to each other. The eye bolt comprises a swivel joint adapted to be inserted into the wedge.
In accordance with a further aspect of the invention, a method of connecting two conductors using a wedge connector assembly is disclosed. The method comprises providing an electrical wedge connector. The wedge connector comprises a shell and a wedge sized and shaped to be inserted into the shell for connecting the two conductors to each other, wherein the shell comprises a protrusion having a first end and a second end. The method also comprises providing an eye bolt comprising a first end and second end and inserting the second end of the eye bolt through the protrusion so that the second end of the eye bolt extends from the second end of the protrusion. The method further comprises securing a first end of a swivel joint to the second end of the eye bolt and securing a second end of the swivel joint to the wedge; and rotating the eye bolt to position the wedge between the two conductors. Advantageously, the wedge rubs against the conductors creating a wiping action in which surface oxides are removed.
The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein:
Referring to
The wedge connector assembly 10 comprises a shell 12 and a wedge 14. The shell 12 is typically a one-piece member that may be made of any suitable material of significant strength to withhold the clamping forces during operation, including sheet metal. The shell 12 may also be a cast, drawn or extruded member. Preferably, shell 12 is a cast, copper body. The shell 12 has two opposing channel sections 16 and 18 interconnected by a middle section, or cavity 20 to form a general “0” or oval shape with a receiving area 22 for receiving the wedge 14 and the cables A, B. The “0” shape tapers from a first end 24 to a more narrow second end 26, as shown in
Located at the first end 24 typically is a protrusion 28, which is preferably cast with the shell 12 as part of the one-piece member. The protrusion 28 may be of any suitable shape and size having a threaded aperture 30 therein through which an eye bolt 32 may be inserted. Preferably, the protrusion 28 is of a width larger that the diameter of the eye bolt 32, as shown in
The eye bolt 32 has a first end 34, a second end 36 and a ring 38, as also shown in
The second end 36 of the eye bolt 32 may be inserted into a first end 37 of the protrusion or threaded block 28 such that the second end 36 of the eye bolt 32 protrudes through a second end 39 of the protrusion, or threaded block 28, as shown in
The first end 44 of swivel joint 42 may be secured to the eye bolt 32 by insertion into the threaded aperture 40, as shown in
The wedge 14 generally comprises a frame 50 and is preferably a one-piece copper member with two cable contact surfaces 52, 54. The wedge 14 preferably comprises a threaded aperture 58 into which the second end 46 of the swivel joint 42 may be inserted.
As shown in
During operation, the wedge connector assembly 10 may be conventionally mounted on an elongated pole (not shown). Similarly, a non-conductive material may be used for turning of the eye bolt 32 by an operator working at a distance from an overhead cable. For example, an elongated pole of non-conductive material, such as glass fiber reinforced plastic, may be employed for manipulating the wedge connector assembly 10. The elongated pole typically has a retractable hook for engaging the ring 38 or eye. Rotation of the elongated pole serves to rotate the hook on the pole and to screw the eye bolt 32 typically upwards or downwards for positioning the wedge 14, which may also move in an upwards or downwards position, in the receiving area 22.
As also shown in
The cable A or lead conductor may also be securely attached to the channel section 16 of the shell 12 by any suitable device prior to operation of the eye bolt 32. For example, as shown in
The design of the wedge connector assembly 10 offers many advantages. For example, use of swivel joint 42 reduces friction and transfers more torque from the eye bolt 32 to the wedge 14 creating a greater clamping force. The eye bolt 32 also advantageously transfers torque from a hot stick or other conventional elongated pole through the swivel joint 42 to directly drive the wedge 14 tightly between the cables, such as a bail and lead wire or conductor.
Additionally, use of wedge 14 mechanically driven between the afore-described cables with use of swivel joint 42 provides oxide removing abrasion action or a wiping action on both of the cables. This is particularly advantageous when a copper cast wedge 14 is mechanically driven between a bail and lead conductor. Often, conductors must be wire brushed prior to application of a clamping mechanism to remove surface oxides. Surface oxides are known to increase electrical resistance at contacts points. Such oxide films may cause poor electrical contact and result in disadvantageous overheating. The afore-described wiping action provided by embodiments of the invention provides a much needed solution to a problem encountered with some prior clamping mechanisms.
Another advantage of embodiments of the invention is that Applicant's hot line clamp or wedge connector assembly may be used by operators to efficiently mechanically connect an overhead distribution current carrying conductor to another.
Further advantages of embodiments of the invention include use of a fully enclosed copper case housing or shell 12 that may produce secureness properties greater then a “C” shaped housing, which is advantageous during high mechanical stress periods created by fault current on the electrical distribution lines.
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.
