CLIAMS:CLAIMS
What is claimed is:

1. A device (200) for assembling a wedge connector (100), the device (200) comprising:
a movable C-shaped collar (205) configured for being removably inserted with a spring member (102) of the wedge connector (100), the spring member (102) being held in predefined position by two clasps (208 and 210) provided at two ends of the C-shaped collar (205);
a mechanically operated drive member (215) coupled to an extension bar (217) of the C-shaped collar (205), the drive member (215) further coupled to the C-shaped collar (205) using a lever (218), such that movement of the drive member (215) causes motion of the C-shaped collar (205) thereby causing elastic deflection the spring member (102) positioned there within; and
a control unit (220) coupled to the extension bar (217) of the C-shaped collar (205) and configured for limiting movement of the drive member (215) so as to control the elastic deflection of the spring member (102).

2. The device (200) of claim 1, wherein the drive member (215) comprises a gear with a ball screw.

3. The device (200) of claim 1, wherein the linear motion of the drive member (215) is converted into curved motion of the C-shaped collar (205).

4. The device (200) of claim 1, wherein the drive member (215) is operated using an external tool that is configured for generating torque in order to drive the drive member (215).

5. The device (200) of claim 1, wherein the control unit (220) is set to be at a predefined position, the predefined position being proportional to the size of the spring member (102).

6. A method of assembling a wedge connector (100), the method comprising:
inserting a spring member (102) of the wedge connector (100) onto a device (200) for assembling the wedge connector (100);
elastically deflecting the spring member (102) by operating the device (200) in a first direction, the spring member (102) having a first hook portion (106), a second hook portion (108), and a central section (110) extending between the first hook portion (106) and the second hook portion (108), each of the first and second hook portions (106 and 108) being adapted to receive conductors (112 and 114);
inserting two electrical conductors (112 and 114) within the spring member (102) such that the first conductor (112) is positioned within the first hook portion (106) and the second conductor (114) is positioned within the second hook portion (108);
pushing a wedge (104) into the central section (110) by capturing the first conductor (112) between the first hook portion (106) and the wedge (104), and capturing the second conductor (114) between the second hook portion (108) and the wedge (104); and
releasing the spring member (102) by operating the device (200) in a second direction such that the spring member (102) imparts a clamping force on the conductors (112 and 114).

7. The method of claim 6, wherein operating the device (200) comprises mechanically operating a drive member (215), the drive member (215) being operably coupled to a movable C-shaped collar (205) such that movement of the drive member (215) causes motion of the C-shaped collar (205) thereby causing elastic motion of the spring member (102) positioned there within.

8. The method of claim 7, further comprising limiting movement of the drive member (215) so as to control the elastic deflection of the spring member (102).

9. A method of assembling a wedge connector (100) that includes a spring member (102) and a wedge (104), the method comprising:
inserting the spring member (102) into a C-shaped collar (205) of a device (200) for assembling the wedge connector (100);
setting a control unit (220) to be at a predefined position, the predefined position being proportional to the size of the spring member (102);
elastically deflecting the spring member (102) by operating the device (200) in a first direction, the spring member (102) having a first hook portion (106), a second hook portion (108), and a central section (110) extending between the first hook portion (106) and the second hook portion (108), each of the first and second hook portions (106 and 108) being adapted to receive conductors (112 and 114);
inserting two electrical conductors (112 and 114) within the spring member (102) such that the first conductor (112) is positioned within the first hook portion (106) and the second conductor (114) is positioned within the second hook portion (108);
pushing a wedge (104) into the central section (110) and thereby capturing the first conductor (112) between the first hook portion (106) and the wedge (104) and the second conductor (114) between the second hook portion (108) and the wedge (104); and
releasing the spring member (102) by operating the device (200) in a second direction such that the spring member (102) imparts a clamping force on the conductors (112 and 114).
,TagSPECI:
FORM 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules, 2003
COMPLETE SPECIFICATION
(SEE SECTION 10 AND RULE 13)

Title of the Invention:
“LOCKING ARRANGEMENT FOR POWER DISTRIBUTION SYSTEM”

Applicant:
Name: Raychem RPG Pvt. Ltd.
Address: RPG House, 463, Dr. Annie Besant Road, Mumbai : 400 030, Maharashtra, India

The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed:-

DEVICE AND METHOD FOR ASSEMBLING WEDGE CONNECTOR

FIELD OF INVENTION

[0001] The invention generally relates to tools for assembling electrical connectors and more particularly to tools for assembling fired wedge connectors.

BACKGROUND OF THE INVENTION

[0002] Bare overhead electrical conductors often need be terminated or joined in various environments, such as underground or overhead electrical network system. Such conductors may be a part of electrical distribution or transmission systems. In order to form such connections, a connector may be employed. For example, in electrical power systems, it is necessary to tap from an electrical power line either to branch out or to feed a subsystem. One known system of tapping from an electrical power line is to use a wedge connector for electrically connecting two conductors.

[0003] Wedge connectors are typically installed by firing a wedge using a booster tool containing an explosive charge. One major limitation associated with such an installation is usage of hazardous chemicals that are subject to statutory regulation during logistics and usage. This adversely affects cost and on-time availability to the customer. Further, the installation procedure is complex as it involves usage of a charged booster by a trained and licensed operator.

[0004] Alternative solutions suggested in the prior art include usage of hydraulic tools. Disadvantages associated with hydraulic tools include problems with portability as the machinery is heavy, not user friendly, does not conform to ergonomical design and requires a skilled operator for installing the tool.

[0005] Yet another solution provided in the prior art describes pushing wedge into the wedge connector using a tool such as a hammer. However, usage of such tools may damage the conductor and moreover, quality of connection is inferior in such cases.

[0006] Hence there exists a long felt need for a light weight and ergonomically designed assembly tool that eliminates the usage of hazardous chemicals. Further, it is desired that such an assembly tool enables simple assembly mechanism that can be operated by a less skilled operator.

SUMMARY OF THE INVENTION

[0007] In one embodiment, a device for assembling a wedge connector is provided. The device comprises a movable C-shaped collar configured for being removably inserted with a spring member of the wedge connector, the spring member being held in predefined position by two clasps provided at two ends of the C-shaped collar, a mechanically operated drive member operably coupled to the movable C-shaped collar such that movement of the drive member causes motion of the C-shaped collar thereby causing elastic deflection the spring member positioned there within and a control unit operably coupled to the drive member and configured for limiting movement of the drive member so as to control the elastic deflection of the spring member.

[0008] In another embodiment, a method of assembling a wedge connector is provided. The method comprises steps of inserting a spring member of the wedge connector onto a device for assembling the wedge connector, elastically deflecting the spring member by operating the device in a first direction, the spring member having a first hook portion, a second hook portion, and a central section extending between the first hook portion and the second hook portion, each of the first and second hook portions being adapted to receive conductors, inserting two electrical conductors within the spring member such that a first conductor is positioned within the first hook portion and a second conductor is positioned within the second hook portion, pushing a wedge into the central section and thereby capturing the first conductor between the first hook portion and the wedge and the second conductor between the second hook portion and the wedge, and releasing the spring member by operating the device in a second direction such that the spring member imparts a clamping force on the conductors.

[0009] In yet another embodiment, a method of assembling a wedge connector that includes a spring member and a wedge is provided. The method comprises steps of, inserting the spring member into a C-shaped collar of a device for assembling the wedge connector, setting a control unit to be at a predefined position, the predefined position being proportional to the size of the spring member, elastically deflecting the spring member by operating the device in a first direction, the spring member having a first hook portion, a second hook portion, and a central section extending between the first hook portion and the second hook portion, each of the first and second hook portions being adapted to receive conductors, inserting two electrical conductors within the spring member such that a first conductor is positioned within the first hook portion and a second conductor is positioned within the second hook portion, pushing a wedge into the central section and thereby capturing the first conductor between the first hook portion and the wedge and the second conductor between the second hook portion and the wedge, and releasing the spring member by operating the device in a second direction such that the spring member imparts a clamping force on the conductors.

[0010] Various other features and advantages of the invention will be made apparent from the following detailed description and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Embodiments are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings in which like reference numerals refer to similar elements and in which:

[0012] FIG. 1 shows top view of a wedge connector in a mated position;

[0013] FIG. 2 shows a schematic diagram representing a device for assembling a wedge connector as described in one embodiment of the invention;

[0014] FIG. 3 shows a flow diagram representing a method for assembling a wedge connector as described in one embodiment of the invention; and

[0015] FIG. 4 shows a flow diagram representing a method for assembling a wedge connector as described in another embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0016] It shall be observed that system and method components described in accordance with exemplary embodiments have been represented by known symbols in the figures, showing only specific details that are relevant for an understanding of the present disclosure. Further, details that are readily apparent to those skilled in the art may not have been disclosed.

[0017] FIG.1 shows an exemplary representation of a wedge connector 100 that includes an electrically conductive C-shaped spring member 102 and a wedge 104. The spring member 102 is structured to include a first hook portion 106, a second hook portion 108 and a central section 110 extending between the first hook portion 106 and the second hook portion 108. Each of the first and second hook portions 106 and 108 are adapted to receive conductors 112 and 114 respectively. The conductors 112 and 114 are positioned at opposite sides of the spring member 102 and the wedge 104 is driven between the two conductors 112 and 114. The insertion of the wedge 104 forces the conductors 112 and 114 against the hook portions 106 and 108, such that the conductors 112 and 114 are captured between the wedge 104 and the hook portions 106 and 108 respectively.

[0018] In one embodiment, as shown in FIG. 2, a device 200 for assembling the wedge connector 100 is provided. The device 200 comprises a movable C-shaped collar 205 configured for being removably inserted with the spring member 102 of the wedge connector 100. The spring member 102 is held in predefined position by two clasps 208 and 210 provided at two ends of the C-shaped collar 205 thereby matching the surface profile of the wedge connector 100. The device 200 further comprises a mechanically operated drive member 215 operably coupled to the movable C-shaped collar 205.
[0019] The C-shaped collar 205 comprises an extension bar 217. The drive member 215 is coupled to the C-shaped collar 205 via the extension bar 217 and a lever 218, such that movement of the drive member 215 causes motion of the C-shaped collar 205. Further, the lever 218 forms a part of the C-shaped collar 205. This in turn causes elastic deflection of the spring member 102 positioned within the C-shaped collar 205. The device 200 further comprises a control unit 220 coupled to the extension bar 217 and configured for limiting the movement of the drive member 215. The control unit 220 is positioned adjacent to the drive member 215 on the extension bar 217. The control unit 220 when set at a predefined position halts the movement of the drive member 215 beyond the predefined position and thus controls the elastic deflection of the spring member 102.

[0020] The device 200 for assembling wedge connector 100 can be adapted for various sizes of the spring member 102. The size of the spring member 102 depends on the size of the conductors 112 and 114 to be inserted and that, as is known in the art, is dependent on the current carrying capacity of the conductors 112 and 114.

[0021] Further, multiple extension links 222 and 223 can be mechanically coupled to the two clasps 208 and 210 provided at two ends of the C-shaped collar 205 so as to accommodate the varying size of the spring member 102.

[0022] The control unit 220 is set to be at a predefined position, the predefined position being proportional to the size of the spring member 102. The setting of the control unit 220 based on the size of the spring member 102 helps in limiting the deflection of the spring member 102 within its elastic limits.

[0023] The drive member 215 is operated using an external tool (not shown) that may be manual or powered. The external tool (not shown) is configured for generating torque in order to drive the drive member 215. The operation of the external tool (not shown) causes linear motion of the drive member 215. In one embodiment, the drive member 215 comprises a gear with a ball screw that together exhibit a mechanism to limit the elastic deflection of the spring member 102 by isolating the applied torque. Other mechanical arrangements can however be envisaged by those skilled in the art.

[0024] The device 200 may further comprise a handle 225 mechanically coupled to the C-shaped collar 205 that facilitates operating the device 200. In one embodiment, the device 200 is made of metal selected from a group comprising iron, aluminum, copper and the like.

[0025] Turning now to FIG. 3, a method 300 for assembling a wedge connector 100 is provided. The method 300 comprises steps of inserting the spring member 102 onto the device 200 at step 302, elastically deflecting the spring member 102 by operating the device 200 in a first direction at step 304, inserting two electrical conductors 112 and 114 within the spring member 102 such that the first conductor is positioned within the first hook portion 106 and the second conductor is positioned within the second hook portion 108 at step 306, pushing a wedge 104 into the central section 110 by capturing the first conductor 112 between the first hook portion 106 and the wedge 104, and the second conductor 114 between the second hook portion 108 and the wedge 104 at step 308 and releasing the spring member 102 by operating the device 200 in a second direction such that the spring member 102 imparts a clamping force on the conductors 112 and 114, at step 310.

[0026] Operating the device 200 comprises mechanically operating the drive member 215 in one of the directions such that movement of the drive member 215 causes motion of the C-shaped collar 205.

[0027] Accordingly, mechanically operating the drive member 215 in a first direction causes the C-shaped collar 205 to open up thereby causing elastic deflection of the spring member 102. In contrast, operating the drive member 215 in a second direction causes the C-shaped collar 205 to move closer thereby causing the spring member 102 to regain its original position.

[0028] The method further comprises limiting movement of the drive member 215 so as to control the elastic deflection of the spring member 102. The motion of the drive member 215 is limited by setting the control unit 220. The control unit 220 is set to be at a predefined position based on the size of the spring member 102. As a result, the control unit 220 halts the movement of the drive member 215 beyond the predefined position and thus controls the elastic deflection of the spring member 102.
[0029] In yet another embodiment described using FIG. 4, a method 400 for assembling a wedge connector 100 is provided. The method 400 comprises steps of inserting the spring member 102 into the C-shaped collar 205 of the device 200 at step 402, setting the control unit 220 to be at a predefined position at step 404, the predefined position being proportional to the size of the spring member 102, elastically deflecting the spring member 102 by operating the device 200 in a first direction at step 406, inserting two electrical conductors 112 and 114 within the spring member 102 at step 408, pushing the wedge 104 into the central section 110 and thereby capturing the conductors 112 and 114 within the wedge 104 at step 410, and releasing the spring member 102 by operating the device 200 in a second direction such that the spring member 102 imparts a clamping force on the conductors 112 and 114 at step 412.

[0030] Some of the advantages of using the device 200 include increased portability due to reduction in weight. The device 200 is ergonomically designed and simple in structure. The weight of the device 200 is such that it can be carried in air for establishing connections with overhead arial conductors.

[0031] Usage of the device 200 warrants no skilled operation and hence the device 200 eliminates the need for a highly skilled and licensed operator for installation.

[0032] Further, transport and usage of the device 200 are not subject to statutory regulations as there is no involvement of hazardous chemicals. This reduces the time taken for installation and reduces the cost of installation.

[0033] The device 200 is configured for converting the linear motion of the drive member 215 into curved motion of the C-shaped collar 205. However, the application of the device 200 can be extended to other areas for example for changing linear motion of a drive member into a curved motion of a connected member.

[0034] It will be appreciated by those skilled in the art that the present invention can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restricted. The scope of the invention is indicated by the appended claims rather than the foregoing description and all changes that come within the meaning and range and equivalence thereof are intended to be embraced therein.