CA2765395C - Full tension swaged connector - Google Patents
Full tension swaged connector Download PDFInfo
- Publication number
- CA2765395C CA2765395C CA2765395A CA2765395A CA2765395C CA 2765395 C CA2765395 C CA 2765395C CA 2765395 A CA2765395 A CA 2765395A CA 2765395 A CA2765395 A CA 2765395A CA 2765395 C CA2765395 C CA 2765395C
- Authority
- CA
- Canada
- Prior art keywords
- connector
- depth
- substantially cylindrical
- compression force
- compression
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 230000006835 compression Effects 0.000 claims abstract description 16
- 238000007906 compression Methods 0.000 claims abstract description 16
- 239000004020 conductor Substances 0.000 claims abstract 5
- 238000000034 method Methods 0.000 claims description 5
- 230000002250 progressing effect Effects 0.000 abstract description 2
- 230000005540 biological transmission Effects 0.000 description 4
- 238000009434 installation Methods 0.000 description 4
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 229910000755 6061-T6 aluminium alloy Inorganic materials 0.000 description 1
- 241001427367 Gardena Species 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000004323 axial length Effects 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
- H01R43/048—Crimping apparatus or processes
- H01R43/0486—Crimping apparatus or processes with force measuring means
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
Abstract
An improved full tension connector for electrical conductors has a substantially cylindrical outer surface and a stepped series of substantially cylindrical inner surfaces with progressively smaller inside diameters. The design of the connector allows for improved control of the compression of the cable inside the fitting. A series of swages, progressing successively from a light compression to a heavier compression, ensures that the connector will sustain the required tensile load.
Description
FULL TENSION SWAGED CONNECTOR
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0001] This invention relates to the field of power transmission and, more particularly, to connectors for high tension power transmission lines.
BACKGROUND
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0001] This invention relates to the field of power transmission and, more particularly, to connectors for high tension power transmission lines.
BACKGROUND
[0002] Connectors play a critical role in the efficiency and reliability of power transmission systems. Aluminum cables used for overhead transmission lines require connectors for splices and dead end assemblies. Currently available connectors are typically tubular aluminum devices that are crimped or swaged onto the cable. In order to achieve a full or nearly full tension fitting, prior art connectors require numerous crimps or swages and are therefore relatively long and heavy. In addition, the installation tools for prior art connectors are large and unwieldy. During the installation of prior art connectors, the length of the fitting and the size of the tooling may result in undesired bending of the connector.
SUMMARY OF INVENTION
SUMMARY OF INVENTION
[0003] The present invention provides an improved connector with a body having a substantially cylindrical outer surface and a stepped series of substantially cylindrical inner surfaces with progressively smaller inside diameters. The design of the connector allows for improved control of the compression of the cable inside the fitting. A series of swages, progressing successively from a light compression to a heavier compression, ensures that the connector will sustain the required tensile load.
[0004] In comparison to prior art connectors, the present invention provides a smaller, lighter full tension connector that can be installed with fewer swages. Installation of the connector is quicker and easier than prior art counterparts. Furthermore, the connector is less prone to bending during installation.
BRIEF DESCRIPTION OF THE DRAWINGS
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Figure 1 is a partial cross-sectional view of a connector in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
DETAILED DESCRIPTION OF THE INVENTION
[0006] In the following description, for purposes of explanation and not limitation, specific details are set forth in order to provide a thorough understanding of the present invention.
However, it will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of well-known methods and devices are omitted so as to not obscure the description of the present invention with unnecessary detail.
However, it will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of well-known methods and devices are omitted so as to not obscure the description of the present invention with unnecessary detail.
[0007] A connector 10 in accordance with one embodiment of the present invention is shown in Figure 1. The connector body 12 has a substantially cylindrical outer surface. A first substantially cylindrical inner surface 14 has an inside diameter d1 and extends axially from the end of connector body 12 to a depth A. A second substantially cylindrical inner surface 16 has an inside diameter d2, which is smaller than d1, and extends axially from depth A to depth B. A
third substantially cylindrical inner surface 18 has an inside diameter d3, which is smaller than d2, and extends axially from depth B to depth C.
third substantially cylindrical inner surface 18 has an inside diameter d3, which is smaller than d2, and extends axially from depth B to depth C.
[0008] To install the connector 10 onto a cable, the end of the cable is inserted into the connector body to depth C. The connector is compressed onto the cable using a hydraulic swaging tool. A suitable swaging tool may be, for example, the tool disclosed in U.S. Patent No.
7,299,674 and commercially available under the CableLok brand from Designed Metal Connections of Gardena, California. The design of connector 10 allows it to be installed on the cable using a single die set.
7,299,674 and commercially available under the CableLok brand from Designed Metal Connections of Gardena, California. The design of connector 10 allows it to be installed on the cable using a single die set.
[0009] The first swage area at the end of the connector (i.e., between the end of the connector body where the cable is inserted and depth A) carries the maximum load. This has the minimum compression, thereby minimizing damage to the cable. The second swage area (i.e., between depth A and depth B) holds the load that the first swage area cannot take and has a heavier compression to provide better electrical contact. The third swage area (i.e., between depth B and depth C) carries less load, but provides the best electrical contact. When properly installed, connector 10 can sustain a load of 95% or more of the rated strength of the cable, thereby meeting the requirements for class 1 full tension fittings of the C119.4 ANSI standard.
[0010] As will be appreciated, the specific dimensions of connector 10 are dependent upon the dimensions of the cable with which it will be used. The smallest inside diameter, in this case d3, is slightly greater than the nominal outside diameter of the cable. The inside diameter step sizes (i.e., the difference between d1 and d2 and the difference between d2 and d3) may be less than about 0.05 inches. The axial length of each step (i.e., the distance from the end of the connector body to depth A, from depth A to depth B, and from depth B to depth C) is determined primarily by the dimensions of the swaging tool head and may be approximately 1 inch.
Connector 10 has been described as having three swaging segments; however, it is to be understood that other embodiments of the invention may have more or fewer segments.
Connector 10 has been described as having three swaging segments; however, it is to be understood that other embodiments of the invention may have more or fewer segments.
[0011] Connector 10 may be configured either as a splice connector with a tubular body receiving a cable at each end or as a full tension dead end having a suitable structural coupling.
In one embodiment, connector 10 is fabricated with 6061-T6 aluminum alloy, although other alloys may be used. In this embodiment, the connector body is heat treated (annealed) after machining.
In one embodiment, connector 10 is fabricated with 6061-T6 aluminum alloy, although other alloys may be used. In this embodiment, the connector body is heat treated (annealed) after machining.
[0012] It will be recognized that the above-described invention may be embodied in other specific forms without departing from the spirit or essential characteristics of the disclosure.
Thus, it is understood that the invention is not to be limited by the foregoing illustrative details, but rather is to be defined by the appended claims.
Thus, it is understood that the invention is not to be limited by the foregoing illustrative details, but rather is to be defined by the appended claims.
Claims (9)
1. A connector for an electrical conductor comprising: a body having a substantially cylindrical outer surface; a first substantially cylindrical inner surface having a first inside diameter d1, the first inner surface extending axially from a first end of the body to a depth A; a second substantially cylindrical inner surface having a second inside diameter d2 smaller than d1, the second inner surface extending axially from the depth A
to a depth B; wherein d1-d 2 < 0.05".
to a depth B; wherein d1-d 2 < 0.05".
2. The connector of claim 1 further comprising a third substantially cylindrical inner surface having a third inside diameter d3 smaller than d2, the third inner surface extending axially from the depth B to a depth C; wherein d2-d 3 <
0.05".
0.05".
3. The connector of claim 2 further comprising a fourth substantially cylindrical inner surface having a fourth inside diameter d4 smaller than d3, the fourth inner surface extending axially from the depth C to a depth D; wherein d3- d. sub .4 < 0 .05".
4. The connector of claim 1 wherein the body is configured as a splice.
5. The connector of claim 1 wherein the body is configured as a dead end.
6. A method of attaching the connector of claim 1 to an electrical conductor comprising: inserting an electrical conductor into the connector to at least depth B;
compressing the outer surface of the connector between the first end and depth A with a first compression force; compressing the outer surface of the connector between depth A
and depth B with a second compression force greater than the first compression force.
compressing the outer surface of the connector between the first end and depth A with a first compression force; compressing the outer surface of the connector between depth A
and depth B with a second compression force greater than the first compression force.
7. A method of attaching the connector of claim 2 comprising: inserting an electrical conductor into the connector to at least depth B; compressing the outer surface of the connector between the first end and depth A with a first compression force;
compressing the outer surface of the connector between depth A and depth B with a second compression force greater than the first compression force; and compressing the outer surface of the connector between depth B and depth C with a third compression force greater than the second compression force.
compressing the outer surface of the connector between depth A and depth B with a second compression force greater than the first compression force; and compressing the outer surface of the connector between depth B and depth C with a third compression force greater than the second compression force.
8. The method of claim 6 wherein the steps of compressing are performed using a swaging tool.
9. The method of claim 7 wherein the steps of compressing are perforated using a swaging tool.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2765395A CA2765395C (en) | 2012-01-25 | 2012-01-25 | Full tension swaged connector |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2765395A CA2765395C (en) | 2012-01-25 | 2012-01-25 | Full tension swaged connector |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2765395A1 CA2765395A1 (en) | 2013-07-25 |
| CA2765395C true CA2765395C (en) | 2014-07-08 |
Family
ID=48868709
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2765395A Active CA2765395C (en) | 2012-01-25 | 2012-01-25 | Full tension swaged connector |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2765395C (en) |
-
2012
- 2012-01-25 CA CA2765395A patent/CA2765395C/en active Active
Also Published As
| Publication number | Publication date |
|---|---|
| CA2765395A1 (en) | 2013-07-25 |
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