CA2378279C - Pole-mounted lighting system - Google Patents
Pole-mounted lighting system Download PDFInfo
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- CA2378279C CA2378279C CA002378279A CA2378279A CA2378279C CA 2378279 C CA2378279 C CA 2378279C CA 002378279 A CA002378279 A CA 002378279A CA 2378279 A CA2378279 A CA 2378279A CA 2378279 C CA2378279 C CA 2378279C
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Abstract
Pole mounted lighting system (10) including mounting components (44) to mount such things as an integrated multiple cross-arm assembly (16) to a pole (12), a remote ballast box (18) to the pole (12), or an integrated cross-arm ballast box (138) to the pole (12). The mounting structures (44) include adjustable connection members (46, 48, 50) which allow customization of fit to different size poles.
Description
POLE-MOUNTED LIGHTING SYSTEM
BACKGRODND OF THS INVENTION
Field of the Invention The present invention relates to pale-mounted lighting systems, and in particular, to means and methods for mounting on F>oles various structures related to elevated lighting fixtures !:or large area lighting.
B. Background of the Invention There are many examples of pole-mounted large area lighting systems. They include sports field lighting; such as softball, baseball, football, soccer fields and the like. It also includes tennis court lighting, and playground lighting; and could also include such things as parking lat lighting.
The most conventional way of elevating lighting fixtures to enable large scale lighting is to install poles in the ground and then secure structures to the poles to facilitate such lighting.
'' CA 02378279 2002-04-15 It is usually desirable to elevate the lighting fixtures as high as economically practical. The higher the light pole the costlier. Therefore there is usually a practical limit on the height of poles which is directly related to cost. Multiple fixtures normally are positioned on some sort of a cross-arm which is then secured to the pole» Multiple cross-arms on each pole are possible. Other structures, such as electrical boxes containing ballasts, circuit: breakers, fuses, switches, and other electrical components are also commonly suspended along the length of the pole. Such components can either be associated with the cross-arms, or be spaced apart from and usually lower on th.e pole.
While it may appear to be elementary to accomplish lighting systems of this type, a number of different design criteria and considerations are involved.. For example, it is not trivial to secure structures of substantial size and weight to a pole. The structures must be mounted securely and in a durable manner for long term use. The mounting structure must also be strong to support cross-arms, fixtures, and such things as ballast boxes;
particularly in light of wind loads that exist on outdoors s~~stems .
Another set of considerations involves cost of manufacturing arid installation. As with most commercial goods, the cost of making the goods impacts significantly on the cost of the goods to consumers. There is narrnally high incentive to be able to present the lowest price t:o consumers;. therefore there is high incentive to devise systems which are as inexpensive as possible to manufacture. This impacts on design and the type of materials utilized.
Another consideration is the shipping of these components from factory to installation site. Limits of size and weight come into play. For example, shipment via semi-trailer limits th.e maximum dimensions of pieces.
Still further, there is generally a high incentive to offer goods to consumers that are easy to install while meeting performance requirements for the 'types of components.
Still further, it is usually desirable that the goods be flexible and customizable to varying installation situations. In other words, it is most times advantageous to have, for example, mounting systems that are generally universal with the ability to work for different mounting situations such as, for example, different heights, diameter, and types of poles.
In the field of the present invention, these considerations a~>ply. There are practical limitations on the number of light fj.xtures that can be suspended from each pole. It depends on f~~ctors such as the type of pole (examples are wood, steel, concrete), the height of the pole, and the lighting requirements a:~sociated with that pole. As a general rule it is most cost-ei=fective to be able to elevate a maximum number of fixtures from each pole, as the poles and their installation comprise a s~Lgnificant amount of the cost for lighting systems.
In the same sense, because structures such as cross-arms, l:Lghting fixtures, and ballast boxes are substantial in size, and nE~ed to be installed at elevated positions from the ground, it is - 3. -. . ,-...
highly desirable that the mounting procedures be as simple and quick as possible. With this is t:he need for flexible, almost universal, mounting components that can be adapted easily by the installers for different situations.
Many consumers also take into consideration how a certain system visually looks from an attractiveness standpoint, in cooperation with its functionality.
There are currently many ways of suspending lighting fixtures and related structures on poles for accommodating large scale lighting. It is submitted, however, that there is room for improvement in this field of art. Two specific examples are set forth below.
As previously mentioned, it is highly desirable to suspend as many lighting fixtures per pole as possible, in most situations. Currently a conventional way to attach fixtures to a pole is to mount one or more cross-arms to the pole, each cross-arm bearing multiple light fixtures and having separate pole-attaching hardware. One time saver that exists in the art is to connect the light fixtures 1.o the cross-arm before raising the entire cross-arm assembly to its position at the top of the pole.
However, if more than one :bar of :Lights is required, significant time and effort must be utilized to position and then secure the first cross-arm, then the second, then any others.
Another example involvE~s ballast boxes. They are normally secured by brackets that surround the pole and connect to the top and bottom of the ballast box. However, when installing and cinching the box against thf~ pole, certain problems can exist. -~. ; --.
t ~ .
There are times when rotational or other forces can deform or even permanently warp the ballast box. This can significantly affect the ballast box in, for example, causing misalignment of any door on the box so that it does not fit securely, which in turn can lead to water leakage or other detrimental and potentially serious problems for the lighting system. For example, if the ballast box is not accurately aligned along the pale, when tightened, deformation or warping can occur. Another instance is if the pole is crooked. A still further example involves cases where wood poles are used and mounting brackets s3.nk into the wood at different rates. Knots or other dj.scontinuities in poles can also cause problems. It is to be understood that other situations can also cause problems resulting in the risk of deformation or warpage.
It is therefore the primary object of the present invention to provide a~pole-mounted lighting system which improves over some of the problems and deficiencies in the art.
Another object of the ;present invention is to provide a pole-mounted lighting system which securely and durably mounts sitructures to poles, but limits potentially damaging stresses on the structures when being mounted.
Another object of the present invention is to provide a pole-mounted lighting system which is easy to mount to the pole ~i:n a minimum amount of time and steps, A still further object of the present invention is to provide a pole-mounted lighting system which is flexible in the types of structure and poie~s with which it can be used.
Another object of the present invention is to provide a pole-mounted lighting system which deters or avoids mounting problems related to misalignment of structures with respect to the poles, crooked poles, poles having surface irregularities, and poles such as wood poles which are crooked or have varying wood density, knots, or other discontinuities.
Another object of the present invention is to provide a pole-mounted lighting system which allows a significant amount of neaeded structure, for example, lighting fixtures, ballasts, or other electrical components, to be mounted on an existing pole.
Another object of the present invention is to provide a light-mounted lighting system which allows for easy electrical interconnection of electrical components, even if they are spaced apart from one another on the pole.
These and other objects, features, and advantages of the present invention will become more apparent with reference to the a<:companying specification and claims.
Si~ARY OF THE INVENTION
The pole-mounted lighting system of the present invention includes an attachment system for structures, such as cross-arm assemblies and ballast boxes, to a pole. The cross-arm assemblies comprise either two or more cross-arms rigidly secured together, where the entire collection of cross-arms forms an integral structure that can then be mounted to a pole, or a cross-arm and ballast combination which can in one step be mounted to a pole.
- f> -,, A ballast box, containing multiple ballasts and other electrical components for a plurality of light fixtures, can be remotely positioned along the pole from the light fixtures but easily and quickly installed to the pole.
An aspect of the invention includes mounting components for these structures which can be customized to securely and easily mount the structures to a wide variety of pole types, shapes, and sizes. Another aspect of the invention involves mounting components which assist in keeping the structure centered on the pole without stress that could detrimentally deform the structure when tightened to the pole..
~F~IEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a perspective view of a light pole, cross-arm assembly, light fixtures, and remotely positioned ballast box, according to one embodiment of the present invention.
Fig. 2 is an enlarged perspective view of the cross-arm assembly of Fig. 1 showing mounting brackets in exploded fashion, the light pole in ghost lines, and an optional third cross-arm in ghost lines.
Fig. 3 is an enlarged sectional view taken along line 3-3 of F~Lg. 2.
Fig. 4 is an enlarged partial sectional view taken along line 4-4 of Fig. 2.
Fig. 5 is an isolated elevational view taken along line 5-5 o:E Fig . 4 .
_ i, Fig. 6 is an enlarged perspective view of the ballast box ~~hown at line 6-6 of Fig. 1, from a generally opposite direction from Fig.~l, showing the mounting components in exploded fashion a.nd the light pole in ghost lines.
Fig. 7 is an enlarged sectional view taken along line 7-7 of F'ig. 6 but showing the pole in solid lines.
Fig. 8 is an enlarged partial elevational and sectional view taken along line 8-8 of Fig. 6 but showing the pole in solid lines.
Fig. 9 is an isolated and still further enlarged partial elevational and sectional view taken along line 9-9 of Fig. 7.
Fig. 10 is an exploded perspective view of an alternative embodiment for the mounting brackets of Fig. 6.
Fig. 11 is an enlarged elevational view taken along line 11-11 of Fig. 10.
Fig. 12 is a sectional. view taken along line 12-12 of Fig.
11.
Fig. 13 is a still further embodiment of the mounting brackets for Fig. 6 shown in perspective exploded form.
Fig. 14 is an enlarged partial elevational view taken along line 14-14 of Fig. 13.
Fig. 15 is a sectional view taken along line 15-15 of Fig.
1 ~4 .
Fig. 16 is an enlarged sectional view taken along line 16-16 o:E Fig. 13.
_ g _ -... r~~
;;
Fig. 17 is a still further enlarged sectional view taken along line 17-17 of Fig. lfi..
Fig. 18 is a perspective view of a cross-arm and ballast box combination with mounting brackets for a light pole shown in exploded fashion.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
A. Overview To assist in an understanding of the invention, a detailed description of preferred embodiments wil3. now be set forth. It is to be understood that these embodiments are examples of some farms the invention can take, but do not define all the forms the invention can take.
B. General Configuration -- Fig. 1 This description will refer to the drawing figures, and will reference certain parts and locations in the figures by reference numerals or characters. The same reference numerals or characters will be used to .identify the same or similar parts and locations in all of the figures unless otherwise explained.
Fig. 1 illustrates in ;perspective form one preferred embodiment of the invention (which will be generally designated a~; embodiment 10) on a light pole 12.
It is to be understood for purposes of this description that light pole 12 consists of a pole several tens of feet tall and made of wood (solid concrete would be another example). It is to be understood that the invention could be used with a variety of tropes of poles, including hollow metal or concrete poles, and ' ,.-~ r.~,., even tapered poles. The pale 12 3.s secured in the ground by methods known in the art.
In Fig. 1, what will be called a cross-arm assembly 16 is mounted at the top of pole 1.2 and what will be called a remote ballast box 18 is mounted near the bottom of pole 12.
Light fixtures 20 are positioned on cross-arm assembly 16.
In this case six such fixtures 20 exist. On each bar, in this embodiment, a fixture 20 is mounted on opposite sides of the bar, and a fixture 20 is mounted in between. As is shown in Fig. 1, an electrical conduit 22 extends from ballast box 18 up to cross-arm assembly 16 for purposes of providing electrical power and control wires to fixtures 20. It is to be understood that such wiring could be alternatively routed inside of pale 12, if hollow metal or concrete, for example, and that electrical power is received by ballast box from an electrical power source (not shown).
Fig. 1 also illustrates that conventionally ballast box 18 hays a door 24 which can be opened for access to components such as. ballasts, fuses, circuit breakers, switches, etc. Such a door 29: needs to seal securely to box 18 to prevent water leakage and protect the components inside box 18.
C. Cross-arm Assembly -- Figs. 2-5 Fig. 2 shows in more detail the exact structure of cross-arm a:~sembly 16. Top cross-ar°m 26 and bottom cross-arm 28 are parallel and spaced apart by interconnecting member 30. Assembly 1(i is unitary and basically "I" shaped. Each component 26, 28, and 30 is at least partially hollow to allow interior wiring to - 1(7 -fixtures 20. It is to be understood that the underside of cross-arms 26 and 28 have spaced apart openings and apertures which allow fixtures 20 to be bolted onto the underside of arms 26 and 28.
As shown in Fig. 2, arms 26 and 28 are two inches in height and three inches in depth. Component 30 is four inches wide by three inches in depth. Other sizes are possible. The length of arms 26 and 28 can be made to desired lengths, within practical constraints. For example, the wind load on fixtures such as fixtures 20 limits the number of fixtures and therefore the maximum length of arms 26 and 28. Fig. 2 shows that additional cross-arms (such as cross-arm 32 in ghost lines) can be added by also adding an appropriate interconnecting member (see member 34 ir,~ ghost lines in Fig. 2). It is preferred that assembly 16 consist either of two or three cross-arms because any more cross-a~~ms would make it difficult to ship on standard-sized trucks.
It; is further to be understood that the number of fixtures 20 that can be suspended from each cross-arm assembly 16 is selectable. Fig. 1 shows s:ix such fixtures as an example only.
By extending the length of cross-arm, up to, for example, seven fj_xtures per cross-arm are :reasonable. Therefore, with three cz~oss-arms, assembly 16 could utilize up to twenty-one or so f9_xtures 20.
Cross-arm assembly 16 of Fig. 2 has several other features.
A short arm 36 extends from cross-arms 26 and 28 (and 32 if used) orthogonally (mutually perpendicular) with respect to each cross-arm and interconnecting member at their junction. Each arm 36 ' - 1:1 -has on its bottom surface the appropriate openings or structures to mount a fixture 20, as shown in Fig. 1. Without this arm 36, it would not be possible to mount fixture 20 in that manner at the junction of cross-arm and interconnecting member, and which in this case is generally at: the center of the cross-arm.
Cover plates 38 in Fig. 2 sealingly close off openings in interconnecting member 30 which allow access to the interior wiring of assembly 16. "L" brackE~ts 40, on top and bottom cross-ar~m 26 and 28, and on opposite sides of interconnecting member 30, have apertures 42 which cooperate with what will be referred to as the mounting brackets 44 of Fig. 2, to secure cross-arm assembly 16 to pole 12. Note that different sets of holes 42 exist to assist in mounting for different sized poles.
In Fig. 2 mounting brackets 44 consist of threaded rods 46 which are securable through apertures 42 in "L" brackets 40, and "W" brackets 48 which cooperate with threaded rod 50 and threaded rods 46 to surround and there allow tightening of assembly 16 against pole 12 by threadably securing the nuts and washers (as shown) onto threaded rods 4fi and 50. These arrangements allow the secure and strong attachment of assembly 16 to pole 12 but with a high degree of adjustability and flexibility for different sizes of pole 12. Other arrangements are possible.
Fig. 2 also shows that a wiring harness 52 can be utilized to extend into assembly 16 to allow pre-wired, pre-attachment of fixtures 20 to cross-arm assembly 16 prior to raising it up on pole 12 for securement in place. The work required to wire up fixtures 20 can all be done on the ground or at a factory which _ 1~> _ '~'~ ~ L
a eliminates such critical and time consuming work which would otherwise have to be done at the 'top of light pole 12.
In the preferred embodiment, interconnecting member 30 is welded to top and bottom cross-arms 26 and 28, which are made of steel or similar material. Other ways of securing these components into an integral unit are possible.
Figs. 3 and 4 depict cross-arm assembly 16 as secured to light pole 12. As can be understood, by selectively tightening nets 54 on the threaded rods 46 and 50, serves to bring "W"
brackets 48 and cross-arm assembly 16 into abutment with pole 12, and cinch or clamp assembly 16 to pole 12. By watching "W"
brackets 48, the installer can accurately turn nuts 54 upon threaded rods 46 and 50 to .accurately position "W" brackets 48 so that the whole mounting bracket 44 (including "L" brackets 42, threaded rods 46 and 50, and "W" brackets 48) is centered and in that condition offers the best clamping action.
Fig. 4 illustrates that utilization of mounting brackets 44 a1: both the top and bottom of assembly 16 will hold the entire assembly 16, with fixtures 20 mounted thereon, in place at the top of pole 12. Fig. 4 also illustrates wiring harness 52 with a quick connect connector 56 which can be positioned inside a:~sembly 16 and allows the wiring going to fixtures 20 to be quickly connected up. The opposite end of wiring harness 52 can e:Ktend out of the bottom c~f cross-arm assembly 16 through conduit 2:z and be cut to length once assembly 16 is in place to match up with the position of a remote ballast box. Note in Fig. 4 that t)ze wiring bundle or harness 52 Extends through conduit 22 (which ,.--..
j is connected to assembly 16 at connection 23) up into.component 30. A J-hook 25 is secured by welding or otherwise to the interior of 30. A kellum-grip 27 surrounds harness 52 and is used to hang harness 52 fram hook 25 so that plug 56 can then be easily assessable through the openings which are covered by cover plates 38.
Fig. 5 illustrates a cover plate 38. A top ear 58 is bolted to interconnecting member 30. A bottom ear 60 has a C-shaped cutout 62 which allows cover 38 to be swung away around the pivot axis of bolt 64, for access into the interior of assembly 16.
Comer 38 can then be easily swung back into position and secured into place by bolt 66. It i_s to be understood that this arrangement eliminates the need to completely remove cover 38 and also utilizes gravity to an extent to swing cover 38 back into position when released. A gasket or O-ring can be placed between cover 38 and member 30 to seal the opening.
D. Mounting System Figs. 6-9 Figs. 6-9 illustrate an embodiment for a mounting system for seacuring structures to a pole 12. In particular,, this embodiment depicts the mounting of a ballast box 18. The system can be of>ed, however, for mounting other structures or components.
To illustrate some of the advantages of the mounting system oiE Figs. 6-9, the previously discussed problems with mounting ballast boxes will be referred to. Ballast boxes like box l8 are gE~nerally made of relatively thin metal. If such a box were to bE~ connected to pole 12 by mounting components such as those shown in Fig. 44, there is the risk that when tightening down i-~.~ ,.....
nuts 54, uneven pressure or stress will be created at one corner or portion of ballast box 18. This in turn could cause the warping of box 18. If the warping is severe enough, it could affect the performance of the box 18; for example, the door 24 may not close, water leakage may occur through the door or a seam in. the box, or other environmental conditions may adversely affect box i8 or the contents of box 18. As previously discussed, such warpage can be caused by the box being originally mi.saligned or mis-centered on the pole before tightening of the mounting hardware.
Still further, mounting components such as brackets 44 of Fi.g. 2, are time consuming in their installation because of all the nuts 54 that must be secured, and the skill required to position and center the structure while being mounted.
In Fig. 6 there is shown a mounting system which includes top strap 70, bottom strap 72, fixed connection bracket 74, and pivoting connection bracket 76, Fixed connection bracket 74 is rigidly secured to the top beck side of ballast box 1.8. It is C-shaped in cross section (with its open side facing out), has apertures 78 at opposite side ends, and V-shaped cutouts or recesses 80 along its center to facilitate reception arid centering of pole 12 in bracket 74.
C--shaped receptors 82 are attachable by bolts 84 to opposite ends oj° bracket 74. Adjustment connectors 86 are fixable to opposite ends of top strap 70 by balts 88. Adjustment connectors 86 include threaded ends 90 which can be inserted into apertures 92 ojF C-shaped receptors 82. The corresponding nuts 94 for threaded 1~~ _ i ends 90 are then turned down to tighten top strap 70 and the top of ballast box 18 to pole 12.
It is to be understood that top strap 70 can be initially of a :Longer length and then cut to a length which approximates that needed to surround the portion of pole 12 selected to clamp ballast box 18 to pole 12. It can then be attached to adjustment connectors 86 by bolts 88 through selected holes in strap 70.
Adjustment connectors 86 can be used for the final and fine adjustment and clamping action of box 18 to pole 12. Essentially this arrangement would only require the tightening down of nuts 94 once box is positioned on pole 12. All other connections of the brackets of Fig. 6 could be previously made. The V-shaped cut outs 80 of bracket 74 help center the pole and then nuts 94, ca.n be tightened to provide the clamping action. Strap 70 is made preferably of stainless steel and serves to grip pole 12 and clamp the top of box 18 in place.
The arrangement of bottom strap 72 is similar to top strap 7C1, with the following differences. To eliminate as much as possible the potential for warpage of box 18, pivoting connection bracket 76 is connected to box 18 by bolt 96 and pivot bracket 9E3. Resilient pads 100 and 102 (in the preferred embodiment made oi= medium density foam rubber) are attached to ballast box 18 on opposite lateral sides of pivot bracket 98. The opposite sides o:E bracket 74 therefore extend across pads 100 and 102.
This arrangement functions as follows. In normal-installation, the length of straps 70 and 72 are cut to as close t~~ size as is possible for the particular pole diameter at the - 1~6 --.
selected location of installation of ballast box 18. Adjustment connectors 86 are bolted by bolts 88 to the free ends of straps 70 and 72. C-shaped receptors 82 are bolted by bolts 84 to the opposite ends of bracket 74. C-shaped receptors 82 are connected by bolts 84 to the opposite ends of pivoting connection bracket 76, and bracket 76 is pivotably connected to pivot bracket 98.
Ballast box 18 is brought to pole 12 and roughly positioned at th.e location of intended installation. V-shaped recesses 80 in brackets 74 and 76 assist in this positioning. Threaded ends 90 of: adjustment connectors 86 are then inserted into apertures 92 iri C-shaped receptors 82 in bracket 74, and nuts 94 are tightened down to pull the top of ballast box 18 to pole 12. The bottom pivoting bracket ?6 and pads 100 and 102 on box 18 cooperate to deter deformation or warpage of box 18 as follows. Pads 100 and 1t12 extend from the back of box 18 and hold bracket 76 in basically a parallel orientation with respect to the back of box 18 when it is being installed. If any rotation or misalignment, or any force or structure attempts to pivot bracket 76 away from this prefer-red position, pads 100, 102 will resist the same and urge bracket to remain parallel. One or the other of pads 100 or 102 may come into contact with one side of pivoting connection bracket 76 and will resiliently urge bracket 76 back to a parallel position (meaning a generally parallel orientation to the back of box 18). This will then present bracket 76 in this intended position when threaded ends 90 of adjustment connectors 86 on strap 72 are inserted into C-shaped receptors 82 on pivoting bracket 76. This positioning of bracket 76 assists k~racket 76 in transferring stress to the center of box 18 (as opposed to its bottom side edges) when nuts 94 are tightened down on threaded portions 90 of adjustment connectors 86 of bottom strap 72. This, avoids placement of tension on the bottom corners of box 18, which would cause tension on box 18. Thus, it will then deter any deformation or permanent warping of box 18 during and after box 18 is all tightened down to pole 12. It will also tend to keep box 18 centered. Again, the clamping of the bottom of box 18 with bottom strap 72 requires a tightening of only two nuts 94 which is quick, easy, and also deters tension on the corners of box 18. Alternative ways of keeping bracket 72 resiliently positioned parallel are possible. An examp3e would be spring clips between the ends of bracket 72 and box 18.
Figs. 7 and 8 show botaom strap 72 and pivoting connection bracket 76 in an installed position. It can be seen that adjustment connectors 86 allow for a range of tightening adjustment by virtue of their threaded length which exceeds that need to initially position nuts 94 on threaded ends 90. Fig. 7 also illustrates the centering nature of pole 12 in V-shaped cut outs 80 and how the centered (parallel) bracket 72 concentrates stress at the center back ~f box 18.
Fig. 8 shows in more detail the connection of C-shaped receptors 82 to pivoting connection bracket 76, and also the configuration of adjustment: connectors 86 and bottom strap 72.
Fig. 9 illustrates in more detail the structure of pivot bracket 98 and its connection to pivoting connecting brackets 76.
t E. Alternate Mounting System Figs, 10-12 By referring to Figs. 10-12, an alternative embodiment of a mounting system for that shown in Figs. 6-9 is illustrated. It is similar to that shown in Figs. 6-9 except as follows. Strap 106 has tear-drop shaped or corn kernel shaped apertures 108 in two rows along its length (instead of the two rows of square holes in straps 70 and 72 of Fig. 6). Note that the two rows of apertures can extend the length of strap 106 (as indicated by dashed lines). As shown in Fig. 11, a smaller diameter portion 130 of each aperture 108 expands to a larger diameter portion 112 to make the tear-drop shape. It is to be understood that the smaller diameter portions 1:10 point towards the ends of strap iCl6. Thus, the apertures 108 are mirror images of one another at the opposite ends of strap :106.
In direct comparison, ;similar tear-drop shape apertures 114 e~!:ist in adjustment connectors 86 but have the smaller portions (Like portions 110) point towards the portions 110 of apertures 1C)8 of strap 106. Two headed pins 116 having a large flat head 11.8 of a diameter greater than any portion of apertures 108 or 17.4, and a small or tapered head 120, having a diameter which can pass through large portion 112 of apertures 108 and 114 but will not pass through small portions 110 of apertures 108 and 114, are used to quickly connect the opposite ends of straps 106 to adjustment connectors 86.
It is to be understood that like previously described, strap 106 is first cut to approximate length for the pole diameter at the installation location. C-shaped receptors 92, having been 1.9 previously connected to bracket 74, for example, and bracket 74 being connected to a structure (far example, ballast box, cross-arm assembly, etc.), await connection of strap 106.
This can be done by either cannecting adjustment connections 86 to the ends of strap 106 and then inserting and securing threaded ends 90 of connections 86 into C-shaped receptors 82, or visa versa. In either case, Figs. 11 and 12 show that the ends of strap 106 would be inserted between sides of adjustment connections 86 (which in original condition are sprung open).
Th.e large portions of apertures 114 in connections 86 are aligned with the large portions of apertures 108 in strap 106. The s~rualler tapered heads 120 of pins 116 are inserted thxough the aligned large portions of the apertures. When longitudinal ts~nsion is applied pulling the ends of strap 106 oppositely from connections 86 the smaller portions of apertures 108 and 114 be pulled to the pin. This essentially shearing action will cooperate with the caroming action of tapered heads 120 to close down the sides of connections 86 to sandwich the ends of strap 106 as well as to effectively lock pins 1.16 in place, and lock strap 106 to connections 86. Strap 106 in the preferred embodiment is only thirty-thousandths of an inch thick. This connection of strap 106 ends to connections 86 capture the thin si~rap ends so they do not tear.
Therefore, shown in Figs. 11 and 12, by first appropriately aligning selected apertures 108 and 114 and inserting small heads 120 of two headed pins 116 through corresponding large ends 110 o:E apertures 108 and 114 of strap 106 and adjustment connector 86 ,.
~l (at either end of strap 106), the strap 106 and adjustment connectors 86 are then pulled in opposite directions so that pin 116 is captured in the small portions of apertures 110 and can not be removed laterally. Nuts 99: can then be turned down to finish the tightening of the mounting system.
The embodiment of Figs. 10-12 can be used with either fixed connection bracket 74 or pivoting connection bracket 76.
F. Alternative Mounting System Figs. 13-17 A still further alternative mounting system is shown at Figs. 13-17. It essentially functions similarly to those shown in Figs. 6-9 and Figs. 10-12 except as follows. In this embodiment strap 122 has a first piece 124 and a second piece 126. Apertures 128, in one row, are contained in embossments 130A in piece 124 and embossments 130B in piece 126 of strap 122 (a.s better shown in Figs. 15 and 16). These embossments 130A and lf~OB include cavities 123A and 1238 on the back of strap 122 and raised portions 125A and 125B on the front of strap i22; with apertures 128 centered therein.
It is to be understood, as shown in Figs. 15 and 16 that embossments 130A are sized to be .larger then embossments 130B so that raised portions 125B of embossments 130B effectively fit within cavities 123A of embossments 130A. This allows embossments 130B to essentially matingly nest within embossments 130A, so facing surfaces of strap pieces 122 and 124 can abut one another and lock into place.
Strap 122 can be easi.l:y coarsely positioned by first connecting adjustment connectors 86 to C-shaped receptors 82 (see - 2:L -/"~
Figs. 14 and 15), which in turn have been installed on bracket 74 (or 76) (see Figs. 14 and 15), connecting adjustment members 86 to the free ends of strap 122, and then extending first and second pieces 124 and 126 of strap 122 around pole 12. The pieces 124 and 126 are overlapped and bolts 132 and clamps 134 are used to connect the overlapping ends of pieces 124 and 126 in place as shown in Figs. 13, 16, and 17. Alternatively, strap pieces 124 and 126 could be connected together prior to connecting adjustment connections 86 to bracket 74.
As shown in Fig. 17, threaded inserts 136 can be press-fitted or otherwise secured in selected cavities 123B of the embossments 130H of piece 126 so 'that bolts 132 can simply be threaded in place through pieces 124 and 126 from the outside of strap 122 to lock them in place.
Once strap pieces 124 .and 126 are connected and adjustment connections 86 are connected to C-shaped receptors 82 on bracket 79'r, nuts 94 can then be turned down with respect to adjustment connectors 86 (see Fig. 14 and 15) to finally secure and cinch this clamp system in place on pole 12.
G. Merged Ballast Box and Cross-arm Assembly -- Fig. 18 Fig. 18 illustrates what will be called a merged ballast box/cross-arm assembly 38. Cross-arm 140 (like cross-arm 26 or 28) is welded to the top c:~f ballast box 18 (or attached by some oi~her means). In this embodiment, "L" brackets 142, secured to cross-arm 140, allow connecting structures such as threaded rods 4fi and 50 and "W" bracket: 48 to be used to secure the top of the a:~sembly 138 to pole 12. In this; example, threaded rods 46 and r~-. ; -...
k 50, and "W" brackets 48 could also be used with pivoting connection bracket 76 to connect the bottom of ballast box 18 to poJLe 12 .
Obviously, the different types of alternate strap systems of Figs. 6-17 could also be used with. this embodiment.
H. Alternatives, Features, and Options As can be appreciated, the invention can take many forms and embodiments. The true essence and spirit of this invention are de:Fined in the appended claims, and it is not intended that the emlbodiment of the invention presented herein should limit the scope thereof.
- 2:3 -
BACKGRODND OF THS INVENTION
Field of the Invention The present invention relates to pale-mounted lighting systems, and in particular, to means and methods for mounting on F>oles various structures related to elevated lighting fixtures !:or large area lighting.
B. Background of the Invention There are many examples of pole-mounted large area lighting systems. They include sports field lighting; such as softball, baseball, football, soccer fields and the like. It also includes tennis court lighting, and playground lighting; and could also include such things as parking lat lighting.
The most conventional way of elevating lighting fixtures to enable large scale lighting is to install poles in the ground and then secure structures to the poles to facilitate such lighting.
'' CA 02378279 2002-04-15 It is usually desirable to elevate the lighting fixtures as high as economically practical. The higher the light pole the costlier. Therefore there is usually a practical limit on the height of poles which is directly related to cost. Multiple fixtures normally are positioned on some sort of a cross-arm which is then secured to the pole» Multiple cross-arms on each pole are possible. Other structures, such as electrical boxes containing ballasts, circuit: breakers, fuses, switches, and other electrical components are also commonly suspended along the length of the pole. Such components can either be associated with the cross-arms, or be spaced apart from and usually lower on th.e pole.
While it may appear to be elementary to accomplish lighting systems of this type, a number of different design criteria and considerations are involved.. For example, it is not trivial to secure structures of substantial size and weight to a pole. The structures must be mounted securely and in a durable manner for long term use. The mounting structure must also be strong to support cross-arms, fixtures, and such things as ballast boxes;
particularly in light of wind loads that exist on outdoors s~~stems .
Another set of considerations involves cost of manufacturing arid installation. As with most commercial goods, the cost of making the goods impacts significantly on the cost of the goods to consumers. There is narrnally high incentive to be able to present the lowest price t:o consumers;. therefore there is high incentive to devise systems which are as inexpensive as possible to manufacture. This impacts on design and the type of materials utilized.
Another consideration is the shipping of these components from factory to installation site. Limits of size and weight come into play. For example, shipment via semi-trailer limits th.e maximum dimensions of pieces.
Still further, there is generally a high incentive to offer goods to consumers that are easy to install while meeting performance requirements for the 'types of components.
Still further, it is usually desirable that the goods be flexible and customizable to varying installation situations. In other words, it is most times advantageous to have, for example, mounting systems that are generally universal with the ability to work for different mounting situations such as, for example, different heights, diameter, and types of poles.
In the field of the present invention, these considerations a~>ply. There are practical limitations on the number of light fj.xtures that can be suspended from each pole. It depends on f~~ctors such as the type of pole (examples are wood, steel, concrete), the height of the pole, and the lighting requirements a:~sociated with that pole. As a general rule it is most cost-ei=fective to be able to elevate a maximum number of fixtures from each pole, as the poles and their installation comprise a s~Lgnificant amount of the cost for lighting systems.
In the same sense, because structures such as cross-arms, l:Lghting fixtures, and ballast boxes are substantial in size, and nE~ed to be installed at elevated positions from the ground, it is - 3. -. . ,-...
highly desirable that the mounting procedures be as simple and quick as possible. With this is t:he need for flexible, almost universal, mounting components that can be adapted easily by the installers for different situations.
Many consumers also take into consideration how a certain system visually looks from an attractiveness standpoint, in cooperation with its functionality.
There are currently many ways of suspending lighting fixtures and related structures on poles for accommodating large scale lighting. It is submitted, however, that there is room for improvement in this field of art. Two specific examples are set forth below.
As previously mentioned, it is highly desirable to suspend as many lighting fixtures per pole as possible, in most situations. Currently a conventional way to attach fixtures to a pole is to mount one or more cross-arms to the pole, each cross-arm bearing multiple light fixtures and having separate pole-attaching hardware. One time saver that exists in the art is to connect the light fixtures 1.o the cross-arm before raising the entire cross-arm assembly to its position at the top of the pole.
However, if more than one :bar of :Lights is required, significant time and effort must be utilized to position and then secure the first cross-arm, then the second, then any others.
Another example involvE~s ballast boxes. They are normally secured by brackets that surround the pole and connect to the top and bottom of the ballast box. However, when installing and cinching the box against thf~ pole, certain problems can exist. -~. ; --.
t ~ .
There are times when rotational or other forces can deform or even permanently warp the ballast box. This can significantly affect the ballast box in, for example, causing misalignment of any door on the box so that it does not fit securely, which in turn can lead to water leakage or other detrimental and potentially serious problems for the lighting system. For example, if the ballast box is not accurately aligned along the pale, when tightened, deformation or warping can occur. Another instance is if the pole is crooked. A still further example involves cases where wood poles are used and mounting brackets s3.nk into the wood at different rates. Knots or other dj.scontinuities in poles can also cause problems. It is to be understood that other situations can also cause problems resulting in the risk of deformation or warpage.
It is therefore the primary object of the present invention to provide a~pole-mounted lighting system which improves over some of the problems and deficiencies in the art.
Another object of the ;present invention is to provide a pole-mounted lighting system which securely and durably mounts sitructures to poles, but limits potentially damaging stresses on the structures when being mounted.
Another object of the present invention is to provide a pole-mounted lighting system which is easy to mount to the pole ~i:n a minimum amount of time and steps, A still further object of the present invention is to provide a pole-mounted lighting system which is flexible in the types of structure and poie~s with which it can be used.
Another object of the present invention is to provide a pole-mounted lighting system which deters or avoids mounting problems related to misalignment of structures with respect to the poles, crooked poles, poles having surface irregularities, and poles such as wood poles which are crooked or have varying wood density, knots, or other discontinuities.
Another object of the present invention is to provide a pole-mounted lighting system which allows a significant amount of neaeded structure, for example, lighting fixtures, ballasts, or other electrical components, to be mounted on an existing pole.
Another object of the present invention is to provide a light-mounted lighting system which allows for easy electrical interconnection of electrical components, even if they are spaced apart from one another on the pole.
These and other objects, features, and advantages of the present invention will become more apparent with reference to the a<:companying specification and claims.
Si~ARY OF THE INVENTION
The pole-mounted lighting system of the present invention includes an attachment system for structures, such as cross-arm assemblies and ballast boxes, to a pole. The cross-arm assemblies comprise either two or more cross-arms rigidly secured together, where the entire collection of cross-arms forms an integral structure that can then be mounted to a pole, or a cross-arm and ballast combination which can in one step be mounted to a pole.
- f> -,, A ballast box, containing multiple ballasts and other electrical components for a plurality of light fixtures, can be remotely positioned along the pole from the light fixtures but easily and quickly installed to the pole.
An aspect of the invention includes mounting components for these structures which can be customized to securely and easily mount the structures to a wide variety of pole types, shapes, and sizes. Another aspect of the invention involves mounting components which assist in keeping the structure centered on the pole without stress that could detrimentally deform the structure when tightened to the pole..
~F~IEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a perspective view of a light pole, cross-arm assembly, light fixtures, and remotely positioned ballast box, according to one embodiment of the present invention.
Fig. 2 is an enlarged perspective view of the cross-arm assembly of Fig. 1 showing mounting brackets in exploded fashion, the light pole in ghost lines, and an optional third cross-arm in ghost lines.
Fig. 3 is an enlarged sectional view taken along line 3-3 of F~Lg. 2.
Fig. 4 is an enlarged partial sectional view taken along line 4-4 of Fig. 2.
Fig. 5 is an isolated elevational view taken along line 5-5 o:E Fig . 4 .
_ i, Fig. 6 is an enlarged perspective view of the ballast box ~~hown at line 6-6 of Fig. 1, from a generally opposite direction from Fig.~l, showing the mounting components in exploded fashion a.nd the light pole in ghost lines.
Fig. 7 is an enlarged sectional view taken along line 7-7 of F'ig. 6 but showing the pole in solid lines.
Fig. 8 is an enlarged partial elevational and sectional view taken along line 8-8 of Fig. 6 but showing the pole in solid lines.
Fig. 9 is an isolated and still further enlarged partial elevational and sectional view taken along line 9-9 of Fig. 7.
Fig. 10 is an exploded perspective view of an alternative embodiment for the mounting brackets of Fig. 6.
Fig. 11 is an enlarged elevational view taken along line 11-11 of Fig. 10.
Fig. 12 is a sectional. view taken along line 12-12 of Fig.
11.
Fig. 13 is a still further embodiment of the mounting brackets for Fig. 6 shown in perspective exploded form.
Fig. 14 is an enlarged partial elevational view taken along line 14-14 of Fig. 13.
Fig. 15 is a sectional view taken along line 15-15 of Fig.
1 ~4 .
Fig. 16 is an enlarged sectional view taken along line 16-16 o:E Fig. 13.
_ g _ -... r~~
;;
Fig. 17 is a still further enlarged sectional view taken along line 17-17 of Fig. lfi..
Fig. 18 is a perspective view of a cross-arm and ballast box combination with mounting brackets for a light pole shown in exploded fashion.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
A. Overview To assist in an understanding of the invention, a detailed description of preferred embodiments wil3. now be set forth. It is to be understood that these embodiments are examples of some farms the invention can take, but do not define all the forms the invention can take.
B. General Configuration -- Fig. 1 This description will refer to the drawing figures, and will reference certain parts and locations in the figures by reference numerals or characters. The same reference numerals or characters will be used to .identify the same or similar parts and locations in all of the figures unless otherwise explained.
Fig. 1 illustrates in ;perspective form one preferred embodiment of the invention (which will be generally designated a~; embodiment 10) on a light pole 12.
It is to be understood for purposes of this description that light pole 12 consists of a pole several tens of feet tall and made of wood (solid concrete would be another example). It is to be understood that the invention could be used with a variety of tropes of poles, including hollow metal or concrete poles, and ' ,.-~ r.~,., even tapered poles. The pale 12 3.s secured in the ground by methods known in the art.
In Fig. 1, what will be called a cross-arm assembly 16 is mounted at the top of pole 1.2 and what will be called a remote ballast box 18 is mounted near the bottom of pole 12.
Light fixtures 20 are positioned on cross-arm assembly 16.
In this case six such fixtures 20 exist. On each bar, in this embodiment, a fixture 20 is mounted on opposite sides of the bar, and a fixture 20 is mounted in between. As is shown in Fig. 1, an electrical conduit 22 extends from ballast box 18 up to cross-arm assembly 16 for purposes of providing electrical power and control wires to fixtures 20. It is to be understood that such wiring could be alternatively routed inside of pale 12, if hollow metal or concrete, for example, and that electrical power is received by ballast box from an electrical power source (not shown).
Fig. 1 also illustrates that conventionally ballast box 18 hays a door 24 which can be opened for access to components such as. ballasts, fuses, circuit breakers, switches, etc. Such a door 29: needs to seal securely to box 18 to prevent water leakage and protect the components inside box 18.
C. Cross-arm Assembly -- Figs. 2-5 Fig. 2 shows in more detail the exact structure of cross-arm a:~sembly 16. Top cross-ar°m 26 and bottom cross-arm 28 are parallel and spaced apart by interconnecting member 30. Assembly 1(i is unitary and basically "I" shaped. Each component 26, 28, and 30 is at least partially hollow to allow interior wiring to - 1(7 -fixtures 20. It is to be understood that the underside of cross-arms 26 and 28 have spaced apart openings and apertures which allow fixtures 20 to be bolted onto the underside of arms 26 and 28.
As shown in Fig. 2, arms 26 and 28 are two inches in height and three inches in depth. Component 30 is four inches wide by three inches in depth. Other sizes are possible. The length of arms 26 and 28 can be made to desired lengths, within practical constraints. For example, the wind load on fixtures such as fixtures 20 limits the number of fixtures and therefore the maximum length of arms 26 and 28. Fig. 2 shows that additional cross-arms (such as cross-arm 32 in ghost lines) can be added by also adding an appropriate interconnecting member (see member 34 ir,~ ghost lines in Fig. 2). It is preferred that assembly 16 consist either of two or three cross-arms because any more cross-a~~ms would make it difficult to ship on standard-sized trucks.
It; is further to be understood that the number of fixtures 20 that can be suspended from each cross-arm assembly 16 is selectable. Fig. 1 shows s:ix such fixtures as an example only.
By extending the length of cross-arm, up to, for example, seven fj_xtures per cross-arm are :reasonable. Therefore, with three cz~oss-arms, assembly 16 could utilize up to twenty-one or so f9_xtures 20.
Cross-arm assembly 16 of Fig. 2 has several other features.
A short arm 36 extends from cross-arms 26 and 28 (and 32 if used) orthogonally (mutually perpendicular) with respect to each cross-arm and interconnecting member at their junction. Each arm 36 ' - 1:1 -has on its bottom surface the appropriate openings or structures to mount a fixture 20, as shown in Fig. 1. Without this arm 36, it would not be possible to mount fixture 20 in that manner at the junction of cross-arm and interconnecting member, and which in this case is generally at: the center of the cross-arm.
Cover plates 38 in Fig. 2 sealingly close off openings in interconnecting member 30 which allow access to the interior wiring of assembly 16. "L" brackE~ts 40, on top and bottom cross-ar~m 26 and 28, and on opposite sides of interconnecting member 30, have apertures 42 which cooperate with what will be referred to as the mounting brackets 44 of Fig. 2, to secure cross-arm assembly 16 to pole 12. Note that different sets of holes 42 exist to assist in mounting for different sized poles.
In Fig. 2 mounting brackets 44 consist of threaded rods 46 which are securable through apertures 42 in "L" brackets 40, and "W" brackets 48 which cooperate with threaded rod 50 and threaded rods 46 to surround and there allow tightening of assembly 16 against pole 12 by threadably securing the nuts and washers (as shown) onto threaded rods 4fi and 50. These arrangements allow the secure and strong attachment of assembly 16 to pole 12 but with a high degree of adjustability and flexibility for different sizes of pole 12. Other arrangements are possible.
Fig. 2 also shows that a wiring harness 52 can be utilized to extend into assembly 16 to allow pre-wired, pre-attachment of fixtures 20 to cross-arm assembly 16 prior to raising it up on pole 12 for securement in place. The work required to wire up fixtures 20 can all be done on the ground or at a factory which _ 1~> _ '~'~ ~ L
a eliminates such critical and time consuming work which would otherwise have to be done at the 'top of light pole 12.
In the preferred embodiment, interconnecting member 30 is welded to top and bottom cross-arms 26 and 28, which are made of steel or similar material. Other ways of securing these components into an integral unit are possible.
Figs. 3 and 4 depict cross-arm assembly 16 as secured to light pole 12. As can be understood, by selectively tightening nets 54 on the threaded rods 46 and 50, serves to bring "W"
brackets 48 and cross-arm assembly 16 into abutment with pole 12, and cinch or clamp assembly 16 to pole 12. By watching "W"
brackets 48, the installer can accurately turn nuts 54 upon threaded rods 46 and 50 to .accurately position "W" brackets 48 so that the whole mounting bracket 44 (including "L" brackets 42, threaded rods 46 and 50, and "W" brackets 48) is centered and in that condition offers the best clamping action.
Fig. 4 illustrates that utilization of mounting brackets 44 a1: both the top and bottom of assembly 16 will hold the entire assembly 16, with fixtures 20 mounted thereon, in place at the top of pole 12. Fig. 4 also illustrates wiring harness 52 with a quick connect connector 56 which can be positioned inside a:~sembly 16 and allows the wiring going to fixtures 20 to be quickly connected up. The opposite end of wiring harness 52 can e:Ktend out of the bottom c~f cross-arm assembly 16 through conduit 2:z and be cut to length once assembly 16 is in place to match up with the position of a remote ballast box. Note in Fig. 4 that t)ze wiring bundle or harness 52 Extends through conduit 22 (which ,.--..
j is connected to assembly 16 at connection 23) up into.component 30. A J-hook 25 is secured by welding or otherwise to the interior of 30. A kellum-grip 27 surrounds harness 52 and is used to hang harness 52 fram hook 25 so that plug 56 can then be easily assessable through the openings which are covered by cover plates 38.
Fig. 5 illustrates a cover plate 38. A top ear 58 is bolted to interconnecting member 30. A bottom ear 60 has a C-shaped cutout 62 which allows cover 38 to be swung away around the pivot axis of bolt 64, for access into the interior of assembly 16.
Comer 38 can then be easily swung back into position and secured into place by bolt 66. It i_s to be understood that this arrangement eliminates the need to completely remove cover 38 and also utilizes gravity to an extent to swing cover 38 back into position when released. A gasket or O-ring can be placed between cover 38 and member 30 to seal the opening.
D. Mounting System Figs. 6-9 Figs. 6-9 illustrate an embodiment for a mounting system for seacuring structures to a pole 12. In particular,, this embodiment depicts the mounting of a ballast box 18. The system can be of>ed, however, for mounting other structures or components.
To illustrate some of the advantages of the mounting system oiE Figs. 6-9, the previously discussed problems with mounting ballast boxes will be referred to. Ballast boxes like box l8 are gE~nerally made of relatively thin metal. If such a box were to bE~ connected to pole 12 by mounting components such as those shown in Fig. 44, there is the risk that when tightening down i-~.~ ,.....
nuts 54, uneven pressure or stress will be created at one corner or portion of ballast box 18. This in turn could cause the warping of box 18. If the warping is severe enough, it could affect the performance of the box 18; for example, the door 24 may not close, water leakage may occur through the door or a seam in. the box, or other environmental conditions may adversely affect box i8 or the contents of box 18. As previously discussed, such warpage can be caused by the box being originally mi.saligned or mis-centered on the pole before tightening of the mounting hardware.
Still further, mounting components such as brackets 44 of Fi.g. 2, are time consuming in their installation because of all the nuts 54 that must be secured, and the skill required to position and center the structure while being mounted.
In Fig. 6 there is shown a mounting system which includes top strap 70, bottom strap 72, fixed connection bracket 74, and pivoting connection bracket 76, Fixed connection bracket 74 is rigidly secured to the top beck side of ballast box 1.8. It is C-shaped in cross section (with its open side facing out), has apertures 78 at opposite side ends, and V-shaped cutouts or recesses 80 along its center to facilitate reception arid centering of pole 12 in bracket 74.
C--shaped receptors 82 are attachable by bolts 84 to opposite ends oj° bracket 74. Adjustment connectors 86 are fixable to opposite ends of top strap 70 by balts 88. Adjustment connectors 86 include threaded ends 90 which can be inserted into apertures 92 ojF C-shaped receptors 82. The corresponding nuts 94 for threaded 1~~ _ i ends 90 are then turned down to tighten top strap 70 and the top of ballast box 18 to pole 12.
It is to be understood that top strap 70 can be initially of a :Longer length and then cut to a length which approximates that needed to surround the portion of pole 12 selected to clamp ballast box 18 to pole 12. It can then be attached to adjustment connectors 86 by bolts 88 through selected holes in strap 70.
Adjustment connectors 86 can be used for the final and fine adjustment and clamping action of box 18 to pole 12. Essentially this arrangement would only require the tightening down of nuts 94 once box is positioned on pole 12. All other connections of the brackets of Fig. 6 could be previously made. The V-shaped cut outs 80 of bracket 74 help center the pole and then nuts 94, ca.n be tightened to provide the clamping action. Strap 70 is made preferably of stainless steel and serves to grip pole 12 and clamp the top of box 18 in place.
The arrangement of bottom strap 72 is similar to top strap 7C1, with the following differences. To eliminate as much as possible the potential for warpage of box 18, pivoting connection bracket 76 is connected to box 18 by bolt 96 and pivot bracket 9E3. Resilient pads 100 and 102 (in the preferred embodiment made oi= medium density foam rubber) are attached to ballast box 18 on opposite lateral sides of pivot bracket 98. The opposite sides o:E bracket 74 therefore extend across pads 100 and 102.
This arrangement functions as follows. In normal-installation, the length of straps 70 and 72 are cut to as close t~~ size as is possible for the particular pole diameter at the - 1~6 --.
selected location of installation of ballast box 18. Adjustment connectors 86 are bolted by bolts 88 to the free ends of straps 70 and 72. C-shaped receptors 82 are bolted by bolts 84 to the opposite ends of bracket 74. C-shaped receptors 82 are connected by bolts 84 to the opposite ends of pivoting connection bracket 76, and bracket 76 is pivotably connected to pivot bracket 98.
Ballast box 18 is brought to pole 12 and roughly positioned at th.e location of intended installation. V-shaped recesses 80 in brackets 74 and 76 assist in this positioning. Threaded ends 90 of: adjustment connectors 86 are then inserted into apertures 92 iri C-shaped receptors 82 in bracket 74, and nuts 94 are tightened down to pull the top of ballast box 18 to pole 12. The bottom pivoting bracket ?6 and pads 100 and 102 on box 18 cooperate to deter deformation or warpage of box 18 as follows. Pads 100 and 1t12 extend from the back of box 18 and hold bracket 76 in basically a parallel orientation with respect to the back of box 18 when it is being installed. If any rotation or misalignment, or any force or structure attempts to pivot bracket 76 away from this prefer-red position, pads 100, 102 will resist the same and urge bracket to remain parallel. One or the other of pads 100 or 102 may come into contact with one side of pivoting connection bracket 76 and will resiliently urge bracket 76 back to a parallel position (meaning a generally parallel orientation to the back of box 18). This will then present bracket 76 in this intended position when threaded ends 90 of adjustment connectors 86 on strap 72 are inserted into C-shaped receptors 82 on pivoting bracket 76. This positioning of bracket 76 assists k~racket 76 in transferring stress to the center of box 18 (as opposed to its bottom side edges) when nuts 94 are tightened down on threaded portions 90 of adjustment connectors 86 of bottom strap 72. This, avoids placement of tension on the bottom corners of box 18, which would cause tension on box 18. Thus, it will then deter any deformation or permanent warping of box 18 during and after box 18 is all tightened down to pole 12. It will also tend to keep box 18 centered. Again, the clamping of the bottom of box 18 with bottom strap 72 requires a tightening of only two nuts 94 which is quick, easy, and also deters tension on the corners of box 18. Alternative ways of keeping bracket 72 resiliently positioned parallel are possible. An examp3e would be spring clips between the ends of bracket 72 and box 18.
Figs. 7 and 8 show botaom strap 72 and pivoting connection bracket 76 in an installed position. It can be seen that adjustment connectors 86 allow for a range of tightening adjustment by virtue of their threaded length which exceeds that need to initially position nuts 94 on threaded ends 90. Fig. 7 also illustrates the centering nature of pole 12 in V-shaped cut outs 80 and how the centered (parallel) bracket 72 concentrates stress at the center back ~f box 18.
Fig. 8 shows in more detail the connection of C-shaped receptors 82 to pivoting connection bracket 76, and also the configuration of adjustment: connectors 86 and bottom strap 72.
Fig. 9 illustrates in more detail the structure of pivot bracket 98 and its connection to pivoting connecting brackets 76.
t E. Alternate Mounting System Figs, 10-12 By referring to Figs. 10-12, an alternative embodiment of a mounting system for that shown in Figs. 6-9 is illustrated. It is similar to that shown in Figs. 6-9 except as follows. Strap 106 has tear-drop shaped or corn kernel shaped apertures 108 in two rows along its length (instead of the two rows of square holes in straps 70 and 72 of Fig. 6). Note that the two rows of apertures can extend the length of strap 106 (as indicated by dashed lines). As shown in Fig. 11, a smaller diameter portion 130 of each aperture 108 expands to a larger diameter portion 112 to make the tear-drop shape. It is to be understood that the smaller diameter portions 1:10 point towards the ends of strap iCl6. Thus, the apertures 108 are mirror images of one another at the opposite ends of strap :106.
In direct comparison, ;similar tear-drop shape apertures 114 e~!:ist in adjustment connectors 86 but have the smaller portions (Like portions 110) point towards the portions 110 of apertures 1C)8 of strap 106. Two headed pins 116 having a large flat head 11.8 of a diameter greater than any portion of apertures 108 or 17.4, and a small or tapered head 120, having a diameter which can pass through large portion 112 of apertures 108 and 114 but will not pass through small portions 110 of apertures 108 and 114, are used to quickly connect the opposite ends of straps 106 to adjustment connectors 86.
It is to be understood that like previously described, strap 106 is first cut to approximate length for the pole diameter at the installation location. C-shaped receptors 92, having been 1.9 previously connected to bracket 74, for example, and bracket 74 being connected to a structure (far example, ballast box, cross-arm assembly, etc.), await connection of strap 106.
This can be done by either cannecting adjustment connections 86 to the ends of strap 106 and then inserting and securing threaded ends 90 of connections 86 into C-shaped receptors 82, or visa versa. In either case, Figs. 11 and 12 show that the ends of strap 106 would be inserted between sides of adjustment connections 86 (which in original condition are sprung open).
Th.e large portions of apertures 114 in connections 86 are aligned with the large portions of apertures 108 in strap 106. The s~rualler tapered heads 120 of pins 116 are inserted thxough the aligned large portions of the apertures. When longitudinal ts~nsion is applied pulling the ends of strap 106 oppositely from connections 86 the smaller portions of apertures 108 and 114 be pulled to the pin. This essentially shearing action will cooperate with the caroming action of tapered heads 120 to close down the sides of connections 86 to sandwich the ends of strap 106 as well as to effectively lock pins 1.16 in place, and lock strap 106 to connections 86. Strap 106 in the preferred embodiment is only thirty-thousandths of an inch thick. This connection of strap 106 ends to connections 86 capture the thin si~rap ends so they do not tear.
Therefore, shown in Figs. 11 and 12, by first appropriately aligning selected apertures 108 and 114 and inserting small heads 120 of two headed pins 116 through corresponding large ends 110 o:E apertures 108 and 114 of strap 106 and adjustment connector 86 ,.
~l (at either end of strap 106), the strap 106 and adjustment connectors 86 are then pulled in opposite directions so that pin 116 is captured in the small portions of apertures 110 and can not be removed laterally. Nuts 99: can then be turned down to finish the tightening of the mounting system.
The embodiment of Figs. 10-12 can be used with either fixed connection bracket 74 or pivoting connection bracket 76.
F. Alternative Mounting System Figs. 13-17 A still further alternative mounting system is shown at Figs. 13-17. It essentially functions similarly to those shown in Figs. 6-9 and Figs. 10-12 except as follows. In this embodiment strap 122 has a first piece 124 and a second piece 126. Apertures 128, in one row, are contained in embossments 130A in piece 124 and embossments 130B in piece 126 of strap 122 (a.s better shown in Figs. 15 and 16). These embossments 130A and lf~OB include cavities 123A and 1238 on the back of strap 122 and raised portions 125A and 125B on the front of strap i22; with apertures 128 centered therein.
It is to be understood, as shown in Figs. 15 and 16 that embossments 130A are sized to be .larger then embossments 130B so that raised portions 125B of embossments 130B effectively fit within cavities 123A of embossments 130A. This allows embossments 130B to essentially matingly nest within embossments 130A, so facing surfaces of strap pieces 122 and 124 can abut one another and lock into place.
Strap 122 can be easi.l:y coarsely positioned by first connecting adjustment connectors 86 to C-shaped receptors 82 (see - 2:L -/"~
Figs. 14 and 15), which in turn have been installed on bracket 74 (or 76) (see Figs. 14 and 15), connecting adjustment members 86 to the free ends of strap 122, and then extending first and second pieces 124 and 126 of strap 122 around pole 12. The pieces 124 and 126 are overlapped and bolts 132 and clamps 134 are used to connect the overlapping ends of pieces 124 and 126 in place as shown in Figs. 13, 16, and 17. Alternatively, strap pieces 124 and 126 could be connected together prior to connecting adjustment connections 86 to bracket 74.
As shown in Fig. 17, threaded inserts 136 can be press-fitted or otherwise secured in selected cavities 123B of the embossments 130H of piece 126 so 'that bolts 132 can simply be threaded in place through pieces 124 and 126 from the outside of strap 122 to lock them in place.
Once strap pieces 124 .and 126 are connected and adjustment connections 86 are connected to C-shaped receptors 82 on bracket 79'r, nuts 94 can then be turned down with respect to adjustment connectors 86 (see Fig. 14 and 15) to finally secure and cinch this clamp system in place on pole 12.
G. Merged Ballast Box and Cross-arm Assembly -- Fig. 18 Fig. 18 illustrates what will be called a merged ballast box/cross-arm assembly 38. Cross-arm 140 (like cross-arm 26 or 28) is welded to the top c:~f ballast box 18 (or attached by some oi~her means). In this embodiment, "L" brackets 142, secured to cross-arm 140, allow connecting structures such as threaded rods 4fi and 50 and "W" bracket: 48 to be used to secure the top of the a:~sembly 138 to pole 12. In this; example, threaded rods 46 and r~-. ; -...
k 50, and "W" brackets 48 could also be used with pivoting connection bracket 76 to connect the bottom of ballast box 18 to poJLe 12 .
Obviously, the different types of alternate strap systems of Figs. 6-17 could also be used with. this embodiment.
H. Alternatives, Features, and Options As can be appreciated, the invention can take many forms and embodiments. The true essence and spirit of this invention are de:Fined in the appended claims, and it is not intended that the emlbodiment of the invention presented herein should limit the scope thereof.
- 2:3 -
Claims
CLAIMS:
1.
A ballast box and cross-arm assembly comprising:
an elongated cross-arm;
a ballast box having a top end;
the cross-arm secured and centered to the ballast box; and an attachment means for attaching the combined cross-arm and ballast box to a pole, the attachment means comprises a pivot bracket having a base attached to a side of the ballast box, the pivot bracket having a pivot axis generally parallel with the pole when the structure is installed on the pole upon which the pivot bracket and ballast box pivot about the pole; resilient members secured to the side of the ballast box facing the pole positioned on lateral opposite sides of the pivot bracket; an elongated member pivotably connected to the pivot axis of the pivot bracket and having portions extending in opposite directions from the pivot axis transverse to the pole and extending over the resilient members;
a securing member attachable at opposite ends of the elongated member and extending around the pole and including adjustable cinching devices to pull the elongated member to the pole.
2.
The assembly of claim 1 including mounting openings in the bottom of the crossarm for attachment of lighting fixtures.
3.
The assembly of claim 1 wherein the attachment means comprises a brackets connected to the ballast box and cross-arm assembly; adjustable securement devices connected to each bracket to surround a portion of the perimeter of the pole and including a tightening mechanism to clamp the securement device and bracket to the pole.
4.
The assembly of claim 3 wherein the adjustable securement devices comprise threaded rods and "W" brackets.
5.
The assembly of claim 1 further comprising a wiring harness, the assembly having openings through which the wiring harness can be inserted and accessed.
6.
The assembly of claim 5 further comprising a quick connect device for connecting the wiring harness to other wires.
7.
The assembly of claim 1 wherein the attachment means comprises:
a pivot bracket having a base attached to at a side of the ballast box, the pivot bracket having a pivot axis generally parallel with the pole when the structure is installed on the pole upon which the pivot bracket and ballast box pivot about the pole;
resilient members secured to the side of the ballast box facing the pole positioned on lateral opposite sides of the pivot bracket;
an elongated member pivotably connected to the pivot axis of the pivot bracket and having portions extending in opposite directions from the pivot axis transverse to the pole and extending over the resilient members;
a securing member attachable at opposite ends of the elongated member and extending around the pole and including adjustable cinching devices to pull the elongated member to the pole.
8.
The assembly of claim 7 wherein the resilient member comprises a pad member.
9.
The assembly of claim 7 wherein the resilient member comprises a spring loaded device.
10.
The assembly of claim 7 wherein the elongated member comprises a pivoting arm with a V-shaped recess generally centered along its length near a pivot axis, the V-shaped recess being adapted to receive a portion of the perimeter of the pole.
11.
The assembly of claim 7 wherein the securing member comprises a flexible strap, and first connections at opposite ends of the strap to the adjustable cinching devices.
12.
The assembly of claim 11 wherein the strap is stainless steel.
13.
The assembly of claim 11 wherein the snap includes first and second generally parallel rows of apertures to allow selection of a point of attachment of the strap to the first connections.
14.
The assembly of claim 7 further comprising a second securing member spaced from the first a securing member on the ballast box.
15.
The assembly of claim 14 wherein the second securing member is substantially identical to the first securing member.
16.
The assembly of claim 14 wherein the second attachment device includes an elongated member nonpivotably attached to the structure.
17.
The assembly of claim 7 wherein the ballast box has basically a box shape with one side including a door.
18.
The assembly of claim 14 wherein the first securing member is located towards the bottom of the ballast box and the second securing member is located near the top of the ballast box.
19.
The assembly of claim 11 wherein the securing member comprises a flexible elongated strap having one or more rows of apertures along its length, each aperture asymmetrical in nature having a larger portion decreasing in diameter to a smaller portion in the direction of elongation of the strap.
20.
The assembly of claim 19 wherein the flexible strap connects to the first connection through openings in slightly spread apart walls of a clip attached to each end of the elongated member, the opening of the innermost wall having a diameter larger than the opening of the outermost wall, and including a two headed pin having a first head that is larger in diameter than both of the openings in the clip walls and second head including a tapered portion that fits through the larger diameter of the clip wall by camming action and causes convergence of the walls when tension is placed on the strap, securing the pin in place.
21.
The assembly of claim 19 wherein the securing member comprises a flexible elongated strap made of two pieces, at least one row of openings along the strap positioned in embossments in the strap, each end of the strap connecting to adjustable connector means, the pieces sized for the diameter of the pole and having different sized embossments so that when overlapped the pieces secured to one another by nesting the embossments of one piece into those in the other piece.
22.
The assembly of claim 7 wherein the securing member comprises rods with treaded ends threadably connectable to and extending from receivers connected on opposite sides of the elongated member to "w" brackets, and comprising a third rod with threaded ends threadably connectable to the "w" brackets.
23.
The assembly of the claim 22 further comprising a second securing member connectable to the ballast box.
1.
A ballast box and cross-arm assembly comprising:
an elongated cross-arm;
a ballast box having a top end;
the cross-arm secured and centered to the ballast box; and an attachment means for attaching the combined cross-arm and ballast box to a pole, the attachment means comprises a pivot bracket having a base attached to a side of the ballast box, the pivot bracket having a pivot axis generally parallel with the pole when the structure is installed on the pole upon which the pivot bracket and ballast box pivot about the pole; resilient members secured to the side of the ballast box facing the pole positioned on lateral opposite sides of the pivot bracket; an elongated member pivotably connected to the pivot axis of the pivot bracket and having portions extending in opposite directions from the pivot axis transverse to the pole and extending over the resilient members;
a securing member attachable at opposite ends of the elongated member and extending around the pole and including adjustable cinching devices to pull the elongated member to the pole.
2.
The assembly of claim 1 including mounting openings in the bottom of the crossarm for attachment of lighting fixtures.
3.
The assembly of claim 1 wherein the attachment means comprises a brackets connected to the ballast box and cross-arm assembly; adjustable securement devices connected to each bracket to surround a portion of the perimeter of the pole and including a tightening mechanism to clamp the securement device and bracket to the pole.
4.
The assembly of claim 3 wherein the adjustable securement devices comprise threaded rods and "W" brackets.
5.
The assembly of claim 1 further comprising a wiring harness, the assembly having openings through which the wiring harness can be inserted and accessed.
6.
The assembly of claim 5 further comprising a quick connect device for connecting the wiring harness to other wires.
7.
The assembly of claim 1 wherein the attachment means comprises:
a pivot bracket having a base attached to at a side of the ballast box, the pivot bracket having a pivot axis generally parallel with the pole when the structure is installed on the pole upon which the pivot bracket and ballast box pivot about the pole;
resilient members secured to the side of the ballast box facing the pole positioned on lateral opposite sides of the pivot bracket;
an elongated member pivotably connected to the pivot axis of the pivot bracket and having portions extending in opposite directions from the pivot axis transverse to the pole and extending over the resilient members;
a securing member attachable at opposite ends of the elongated member and extending around the pole and including adjustable cinching devices to pull the elongated member to the pole.
8.
The assembly of claim 7 wherein the resilient member comprises a pad member.
9.
The assembly of claim 7 wherein the resilient member comprises a spring loaded device.
10.
The assembly of claim 7 wherein the elongated member comprises a pivoting arm with a V-shaped recess generally centered along its length near a pivot axis, the V-shaped recess being adapted to receive a portion of the perimeter of the pole.
11.
The assembly of claim 7 wherein the securing member comprises a flexible strap, and first connections at opposite ends of the strap to the adjustable cinching devices.
12.
The assembly of claim 11 wherein the strap is stainless steel.
13.
The assembly of claim 11 wherein the snap includes first and second generally parallel rows of apertures to allow selection of a point of attachment of the strap to the first connections.
14.
The assembly of claim 7 further comprising a second securing member spaced from the first a securing member on the ballast box.
15.
The assembly of claim 14 wherein the second securing member is substantially identical to the first securing member.
16.
The assembly of claim 14 wherein the second attachment device includes an elongated member nonpivotably attached to the structure.
17.
The assembly of claim 7 wherein the ballast box has basically a box shape with one side including a door.
18.
The assembly of claim 14 wherein the first securing member is located towards the bottom of the ballast box and the second securing member is located near the top of the ballast box.
19.
The assembly of claim 11 wherein the securing member comprises a flexible elongated strap having one or more rows of apertures along its length, each aperture asymmetrical in nature having a larger portion decreasing in diameter to a smaller portion in the direction of elongation of the strap.
20.
The assembly of claim 19 wherein the flexible strap connects to the first connection through openings in slightly spread apart walls of a clip attached to each end of the elongated member, the opening of the innermost wall having a diameter larger than the opening of the outermost wall, and including a two headed pin having a first head that is larger in diameter than both of the openings in the clip walls and second head including a tapered portion that fits through the larger diameter of the clip wall by camming action and causes convergence of the walls when tension is placed on the strap, securing the pin in place.
21.
The assembly of claim 19 wherein the securing member comprises a flexible elongated strap made of two pieces, at least one row of openings along the strap positioned in embossments in the strap, each end of the strap connecting to adjustable connector means, the pieces sized for the diameter of the pole and having different sized embossments so that when overlapped the pieces secured to one another by nesting the embossments of one piece into those in the other piece.
22.
The assembly of claim 7 wherein the securing member comprises rods with treaded ends threadably connectable to and extending from receivers connected on opposite sides of the elongated member to "w" brackets, and comprising a third rod with threaded ends threadably connectable to the "w" brackets.
23.
The assembly of the claim 22 further comprising a second securing member connectable to the ballast box.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US08/021,497 US5426577A (en) | 1993-02-23 | 1993-02-23 | Pole-mounted lighting system |
| US08/021,497 | 1993-02-23 | ||
| CA002110014A CA2110014C (en) | 1993-02-23 | 1993-11-25 | Pole-mounted lighting system |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002110014A Division CA2110014C (en) | 1993-02-23 | 1993-11-25 | Pole-mounted lighting system |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2378279A1 CA2378279A1 (en) | 1994-08-24 |
| CA2378279C true CA2378279C (en) | 2003-09-16 |
Family
ID=25676814
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002378283A Expired - Fee Related CA2378283C (en) | 1993-02-23 | 1993-11-25 | Pole-mounted lighting system |
| CA002378279A Expired - Fee Related CA2378279C (en) | 1993-02-23 | 1993-11-25 | Pole-mounted lighting system |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002378283A Expired - Fee Related CA2378283C (en) | 1993-02-23 | 1993-11-25 | Pole-mounted lighting system |
Country Status (1)
| Country | Link |
|---|---|
| CA (2) | CA2378283C (en) |
-
1993
- 1993-11-25 CA CA002378283A patent/CA2378283C/en not_active Expired - Fee Related
- 1993-11-25 CA CA002378279A patent/CA2378279C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2378283C (en) | 2004-01-13 |
| CA2378283A1 (en) | 1994-08-24 |
| CA2378279A1 (en) | 1994-08-24 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |