GB2138199A - An electrical cable - Google Patents

An electrical cable Download PDF

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Publication number
GB2138199A
GB2138199A GB08306544A GB8306544A GB2138199A GB 2138199 A GB2138199 A GB 2138199A GB 08306544 A GB08306544 A GB 08306544A GB 8306544 A GB8306544 A GB 8306544A GB 2138199 A GB2138199 A GB 2138199A
Authority
GB
United Kingdom
Prior art keywords
sleeve
cable
electrical connector
end termination
sheath
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.)
Withdrawn
Application number
GB08306544A
Other versions
GB8306544D0 (en
Inventor
Roy John Kirby
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Safran Electrical Components UK Ltd
Original Assignee
Icore International Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Icore International Ltd filed Critical Icore International Ltd
Priority to GB08306544A priority Critical patent/GB2138199A/en
Publication of GB8306544D0 publication Critical patent/GB8306544D0/en
Priority to DE19833346252 priority patent/DE3346252A1/en
Publication of GB2138199A publication Critical patent/GB2138199A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B9/00—Power cables
    • H01B9/001—Power supply cables for the electrodes of electric-welding apparatus or electric-arc furnaces
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
    • H01B5/12—Braided wires or the like
    • 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

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Abstract

An electrical cable comprises a plurality of strands 2 of electrically conductive metal wire having an outer sheath 3 of metal wire which holds the strands closely together while allowing the cable to flex under an imposed load. The wire of the strands and the sheath are preferably of copper and have the same the diameter. A metal sleeve 5 is swaged or crimped to the end of the cable and a metal termination 6 joined to the sleeve by swaging or soldering. The cable is used in the welding head of a welding robot. <IMAGE>

Description

SPECIFICATION An electrical connector Technical field ofinvention The invention relates to an electrical connector, and to a method of terminating same, which connectors are highly flexible and for carrying a high electrical current.
The need for highly flexible low force to bend high current cables has become particularly important since the widespread adoption of welding robots in high volume manufacturing industries, as the rapidly moving welding heads of the robots require electrical connectors or connections that do not restrict the movement of the welding heads.
A solution to this need has been to make the electrical connecting cables or connectors from multiple strands of fine copper wire laid up in a rope-lay configuration. This type of cable gives the required flexibility and low force to bend but, owing to a combination of high inertial loads that result from the rapid changes of movement of the welding head, and cable distorting loads that result from the rapid switching on and off of the electrical current, the cables generally last only a very short time.
Disclosure of invention It is an object of the invention to seek to mitigate these disadvantages of the prior art.
According to a first aspect of the invention there is provided an electrical connector comprising a plurality of individual strands of electrically conductive metal wire laid up in a desired configuration to form a cable and an outer sheath of metal wire which holds the strands of the cable closely together while allowing the cable to flex under an imposed load.
Using the invention it is possible to provide a connector in which the sheath does not affect detrimentally the bend radius orforce required to bend the cable and in which the wires of the cable are nevertheless held closely together, thereby making it possible for the cable to react as a single entity to imposed mechanical loads rather than as individual wires which would soon rupture if the sheath was not present. This constraining of the cable thus increase the life of the connector underflexure.
The desired configuration may comprise a ropelay configuration. This provides a relatively simple way of forming the individual wires into an electrically conductive cable.
The sheath may be a braid of woven wires, This construction is relatively easy to make, by interweaving the wires of the sheath, while ensuring that the cable is constrained.
The individual wires of the cable and the individual wires of the sheath may each have substantially the same diameter. This providing for a relatively inexpensive instruction in which a uniform or standard diameter of wire may be used.
The metal wire of the cable and of the sheath may be copper wire. This provides for good electrical conductivity.
According to a second aspect of the invention there is provided a method of terminating an electrical connector as hereinbefore defined, comprising the steps of securing a sleeve mechanically to the connector at the end to be terminated without the use of heat, and then connecting the sleeve with the cable secured to it to an end termination.
The step of securing the sleeve and connector may be by swaging, which step provides a positive mechanical connection without the use of heat.
The step of connecting the sleeve with the end termination may comprise inserting the sleeve in a socket of the end termination, and then securing the sleeve and end termination together by use of solder or the like, or by swaging. These alternative methods comprise relatively simple yet effective means for effecting a positive electrical and mechanical connection with an end termination.
According to a third aspect of the invention there is provide a welding head such as a robot welding head including an electrical connector as hereinbefore defined or terminated in a method as hereinbefore defined.
An electrical connector embodying the invention is hereinafter describe by way of example, with reference to the accompanying drawings.
Brief description of drawings Figure 1 is side elevational, part sectional, view of an electrical connector according to the invention; Figure 2 is a side elevational, part sectional, view of an end of the connector of Figure 1 during a first step in a method of terminating same; and Figure 3 is a side elevational, part sectional, view of an end of the connector of Figure 2 during a second step in a method of terminating same.
Referring to the drawings, in which like parts are referred to by like reference numerals, there is shown in Figure 1 an electrical connector 1 for a robot welding head (not shown) comprising a piurality of strands of copper wire laid up in a rope-lay configuration to form a cable 2 which is constrained within an outer sheath of copper wire which is woven to form a braid 3. The individual copper wires of the cable 2 and braid 3 are of substantially the same diameter.
Although only one braid 3 is shown in Figure 1, it will be understood that there may be more than one.
The addition of the braid(s) does not substantially detrimentally affect the bend radius of the cable 2 nor the force required to bend, or flex, the cable 2.
However, the strands of copper wire of the cable 2 are held closely together, in other words in contact, by the braid(s) 3 thus enabling the cable 2 to react as a single entity under mechanical loading rather than as individual wires, which does not happen when there is or are no braids. A connector 1 according to the invention thus has an increased flexing load life as compared with prior connectors.
A method for connecting the connector 1 of Figure 1 with an end termination 4 is a two step method (Figures 2 and 3).
The first step, shown in figure 2, is the mechanical swaging or crimping of a tubular metal sleeve 5 onto the end of the electrical connector 1.
Generous radii are allowed in the sleeve 5 at the swage diameter (A) and at the connector 1 outside diameter (B) such that a rapid change in section of the connector wires, which is a prime cause of metal fatigue, is avoided. It can further be seen that the swage diameter (C) is just above the diameter whereby all of the individual wires of the connector 1 are compressed into a solid copper rod. This swage diameter (C) ensures that the electrical joint or connector is as good as possible without overstressing the individual wires at the radius (A).
At the connector end of the sleeve 5, the sleeve 5 is belled out (D) to allow for flexing of the connector 1, with the belling out being equal to or slightly more than the minimum bend radius of the connector.
This belling out further increases the flexing life of the connector 1.
The second step, shown in Figure 3 is connecting the sleeve with the electrical termination 4 selected, in the case a metal one with a socket 6 in which the sleeve is inserted.
The sleeve 5 swaged on the connector 1 is inserted into the socket 6 (Figure 3) with the joint between the sleeve 5 and socket of the end termination 4 being made either by soldering, or by mechanical swaging of the termination.
The advantage of soldering is the "sureness" of the joint and that the termination 4 can be made from any solderable mterial.
The advantage of swaging of this joint is that heat is not required thus eliminating any possible heat problem.
When swaging is used, it will be understood that the metal of end termination 4 should be sufficiently malleable to be mechanically deformed without cracking, or subsequently being liable to fatigue failure.

Claims (13)

1. An electrical connector comprising a plurality of individual strands of electrically conductive metal wire laid up in a desired configuration to form a cable and an outer sheath of metal wire which holds the strands of the cable closely together while allowing the cable to flex under an imposed load.
2. Electrical connector according to Claim 1,the desired configuration comprising a rope-lay configuration.
3. An electrical connector according to Claim 1 or Claim 2, in which the sheath is a braid of woven wires.
4. An electrical connector according to any preceding Claim, in which the individual wires of the cable and the individual wires of the sheath each have substantially the same diameter.
5. An electrical connector according to any preceding claim, the metal wire of the cable and of the sheath being copper wire.
6. An electrical connector, substantially as hereinbefore described with reference to and as shown in the accompanying drawings.
7. A method of terminating an electrical connector according to any preceding claim, comprising the steps of securing a sleeve mechanically to the connector at the end to be terminated without the use of heat, and then connecting the sleeve with the cable secured to itto an end termination.
8. A method according to Claim 7, the step of securing the sleeve and connector being by swaging.
9. A method according to Claim 7 or Claim 8, the step of connecting the sleeve with the end termination comprising inserting the sleeve in a socket of the end termination, and then securing the sleeve and end termination together by use ofsolderorthe like.
10. A method according to Claim 7 of Claim 8, the step of connecting the sleeve with the end termination comprising inserting the sleeve in a socket of the end termination, and then securing the sleeve and end termination together byswaging.
11. A method of terminating an electrical connector according to Claim 1, substantially as hereinbefore described with reference to and as shown in the accompanying drawings.
12. Awelding head including an electrical connector according to any of Claims 1 to 6 or terminated using a method according to any one of Claims 7to 11.
13. A welding head according to Claim 12, which is a robot welding head.
GB08306544A 1983-03-09 1983-03-09 An electrical cable Withdrawn GB2138199A (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB08306544A GB2138199A (en) 1983-03-09 1983-03-09 An electrical cable
DE19833346252 DE3346252A1 (en) 1983-03-09 1983-12-21 ELECTRICAL CONNECTOR AND METHOD FOR PRODUCING AN END CONNECTION TO THE SAME

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB08306544A GB2138199A (en) 1983-03-09 1983-03-09 An electrical cable

Publications (2)

Publication Number Publication Date
GB8306544D0 GB8306544D0 (en) 1983-04-13
GB2138199A true GB2138199A (en) 1984-10-17

Family

ID=10539282

Family Applications (1)

Application Number Title Priority Date Filing Date
GB08306544A Withdrawn GB2138199A (en) 1983-03-09 1983-03-09 An electrical cable

Country Status (2)

Country Link
DE (1) DE3346252A1 (en)
GB (1) GB2138199A (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1056098A2 (en) * 1999-05-26 2000-11-29 Casa Masfarné, S.A. Self-supporting conductor cable
EP1383201A1 (en) * 2002-07-17 2004-01-21 Souriau Improvement method for a binding a contact to stands of a cable
CN100423365C (en) * 2004-01-09 2008-10-01 矢崎总业株式会社 Electric wire terminal connecting structure and wire terminal connecting method
WO2011066054A1 (en) * 2009-11-25 2011-06-03 Griplock Systems, Llc Conductive cable system for suspending a low voltage luminaire assembly

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102004010779B4 (en) * 2004-03-05 2012-03-22 A. + E. Keller Gmbh & Co. Kg Sleeve for end-on sliding onto a cable or rope, and method for making a sleeve for receiving the end of a cable or rope
CN108321556B (en) * 2017-12-11 2020-01-31 北京交通大学 Welding device for superconducting cable joint

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB346005A (en) * 1930-01-01 1931-04-01 Louis Van Thyn Improvements in or relating to electrical conductors
GB687084A (en) * 1950-08-29 1953-02-04 British Insulated Callenders An improved overhead electric line and conductor therefor
GB916905A (en) * 1959-09-25 1963-01-30 Edison Soc Conductor for very high voltage overhead power lines
GB1051267A (en) * 1963-02-20 1966-12-14
GB1413665A (en) * 1971-12-09 1975-11-12 Reynolds Metals Co Steel-supported aluminium overhead onductors
GB1469916A (en) * 1974-08-01 1977-04-06 Southwire Co Aluminum alloy composite electrical conductor
GB1537188A (en) * 1976-05-25 1978-12-29 Cables De Lyon Geoffroy Delore Sub-marine telephone cable
EP0009060A1 (en) * 1978-09-06 1980-04-02 AMP INCORPORATED (a New Jersey corporation) Eccentric bore electrical terminal
EP0018863A1 (en) * 1979-05-07 1980-11-12 The Bendix Corporation Electrical crimp type termination for aluminium wire
GB2052891A (en) * 1979-06-27 1981-01-28 Kabel Metallwerke Ghh Method of attaching a contact element to an electric line
GB2106308A (en) * 1981-01-28 1983-04-07 Tolyattinsk Polt Inst Double-pole water cooled flexible cable

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB346005A (en) * 1930-01-01 1931-04-01 Louis Van Thyn Improvements in or relating to electrical conductors
GB687084A (en) * 1950-08-29 1953-02-04 British Insulated Callenders An improved overhead electric line and conductor therefor
GB916905A (en) * 1959-09-25 1963-01-30 Edison Soc Conductor for very high voltage overhead power lines
GB1051267A (en) * 1963-02-20 1966-12-14
GB1413665A (en) * 1971-12-09 1975-11-12 Reynolds Metals Co Steel-supported aluminium overhead onductors
GB1469916A (en) * 1974-08-01 1977-04-06 Southwire Co Aluminum alloy composite electrical conductor
GB1537188A (en) * 1976-05-25 1978-12-29 Cables De Lyon Geoffroy Delore Sub-marine telephone cable
EP0009060A1 (en) * 1978-09-06 1980-04-02 AMP INCORPORATED (a New Jersey corporation) Eccentric bore electrical terminal
EP0018863A1 (en) * 1979-05-07 1980-11-12 The Bendix Corporation Electrical crimp type termination for aluminium wire
GB2052891A (en) * 1979-06-27 1981-01-28 Kabel Metallwerke Ghh Method of attaching a contact element to an electric line
GB2106308A (en) * 1981-01-28 1983-04-07 Tolyattinsk Polt Inst Double-pole water cooled flexible cable

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1056098A2 (en) * 1999-05-26 2000-11-29 Casa Masfarné, S.A. Self-supporting conductor cable
EP1056098A3 (en) * 1999-05-26 2001-11-28 Casa Masfarné, S.A. Self-supporting conductor cable
EP1383201A1 (en) * 2002-07-17 2004-01-21 Souriau Improvement method for a binding a contact to stands of a cable
FR2842659A1 (en) * 2002-07-17 2004-01-23 Framatome Connectors Int METHOD FOR IMPROVING A LINK BETWEEN A CONTACT AND STRANDS OF A CABLE
CN100423365C (en) * 2004-01-09 2008-10-01 矢崎总业株式会社 Electric wire terminal connecting structure and wire terminal connecting method
WO2011066054A1 (en) * 2009-11-25 2011-06-03 Griplock Systems, Llc Conductive cable system for suspending a low voltage luminaire assembly
CN102741942A (en) * 2009-11-25 2012-10-17 格瑞普锁系统有限公司 Conductive cable system for suspending a low voltage luminaire assembly
US8403519B2 (en) 2009-11-25 2013-03-26 Griplock Systems, Llc Conductive cable system for suspending a low voltage luminaire assembly
US8807780B2 (en) 2009-11-25 2014-08-19 Griplock Systems, Llc Conductive cable system for suspending a low voltage luminaire assembly
TWI474344B (en) * 2009-11-25 2015-02-21 Griplock Systems Llc Conductive cable system for suspending a low voltage luminaire assembly

Also Published As

Publication number Publication date
DE3346252A1 (en) 1984-09-13
GB8306544D0 (en) 1983-04-13

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Legal Events

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WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)