Abstract:
Embodiments described herein relate to a composite cross arm for use with a utility structure and a program for selecting a cross arm. The cross arm includes a composite member, a hardware plate, and a mounting bracket. The program includes a data subroutine where the user selects the type of cross arm and inputs the required data. Thereafter, the program provides the appropriate cross-arm for the user.

Description:
REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a conversion of U.S. Provisional Application No. 61/045,935 filed on Apr. 17, 2008 to a non-provisional U.S. patent application and claims benefit of that earlier filing date. That Provisional Application is incorporated herein in its entirety by this reference. 
     
    
     FIELD 
       [0002]    Embodiments described herein relate to cross arms, cross arm brackets, and programs for selecting cross arms and cross arm brackets. 
       BACKGROUND 
       [0003]    Cross arms and cross arm brackets are used by utility companies to position and support insulators and cable lines. Previously cross arms have been made of wood and steel. However, wood and steel cross arms have several disadvantages. 
         [0004]    Over time, wood cross arms deteriorate and can rot due to weather, thereby decreasing the strength of the wooden cross arm and necessitating replacement. A wooden cross arm can absorb moisture and become a poor electrical insulator. As such, there is a risk of electricity traveling though the wooden cross arm. This can pose a risk of electrocution to a line technician. Additionally, wooden cross arms can suffer from variations in strength do to inherent flaws within the wood. 
         [0005]    Others have proposed using steel cross arms; however, steel cross arms are insufficiently robust and end up corroding when exposed to the elements. Further, steel cross arms lack the electrical insulating properties that are desirable for electric power line applications. 
         [0006]    Still others have used fiberglass in the construction of cross arms, such as those disclosed in U.S. Pat. No. 6,834,469. The device of U.S. Pat. No. 6,834,469 utilizes a foam filled beam having transverse and vertical holes for mounting external structures. Accordingly, the locations of the external structures are limited to the transverse and vertical holes. 
         [0007]    U.S. Pat. No. 4,262,047 depicts a fiberglass cross arm including bores with sleeves telescoped therein. The bores are used to located the fiberglass cross arm to a support structure and to located the external structures to the cross arm. As such, the cross arm in U.S. Pat. No. 4,262,047 must be secured to a support structure via the bores, and the external structures must be located via the bores. Accordingly, there exists a need for an adjustable fiberglass cross arm that allows a technician to easily adjust the location of the cross arm relative to the support structure, and the location of the external structures. 
       SUMMARY 
       [0008]    Briefly stated, a composite cross arm described herein includes a composite member provided with a plurality of extensions. The cross arm includes an attachment assembly, a plurality of hardware plates, and clasping members. The hardware plates can be retained in sliding engagement to enable utility hardware to be placed in alignment with, for example, a utility line. 
         [0009]    A program that analyzes a user&#39;s input to select a utility product, such as a dead end cross arm application or a tangent cross arm application. The program includes an acquisition routine, an application subroutine, a data subroutine, and calculation routine, and a report routine. In one embodiment, the program is integrated with a product purchasing program. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0010]      FIG. 1  depicts a cross-sectional view of one embodiment of the cross arm and the attachment assembly; 
           [0011]      FIG. 2  depicts a perspective view of one embodiment of the cross arm; 
           [0012]      FIG. 3  depicts a cross-sectional view of one embodiment of the hardware plates in cooperation with the cross arm; 
           [0013]      FIG. 4  depicts a close up view of one embodiment of the internal surface of the hardware plate; 
           [0014]      FIG. 5  depicts a close up view of one embodiment of the external surface of the hardware plate; 
           [0015]      FIG. 6  depicts a close up view of one embodiment of the pole mount; 
           [0016]      FIG. 7  depicts a top-down view of one embodiment of the cross arm attached to a pole; 
           [0017]      FIG. 8  depicts a perspective view of one embodiment of the cross arm with an insulator attached thereto; 
           [0018]      FIG. 9  depicts a perspective view of one embodiment of the cross arm with an insulator attached thereto; 
           [0019]      FIG. 10  depicts a one embodiment of a program; 
           [0020]      FIG. 11  depicts an application subroutine; 
           [0021]      FIG. 12  depicts a data subroutine; 
           [0022]      FIG. 13  depicts a data subroutine; 
           [0023]      FIG. 14  depicts a result of the application subroutine; 
           [0024]      FIG. 15  depicts one embodiment of the user interface of the application subroutine; 
           [0025]      FIG. 16  depicts one embodiment of the user interface of the data subroutine; 
           [0026]      FIG. 17  depicts one embodiment of the user interface of the calculation routine; and 
           [0027]      FIG. 18  depicts one embodiment of the report generation. 
       
    
    
     DETAILED DESCRIPTION  
       [0028]      FIG. 1  depicts a cross-sectional view of a cross arm  10  constituting an embodiment described herein. As shown therein, a composite member  20  is provided. In one embodiment, a plurality of composite members  20 ,  21  are attached together via an attachment assembly  40 , a plurality of hardware plates  71 ,  72 , and clasping members  41 ,  42 ,  43 ,  44 . As  FIG. 1  also illustrates, the clamping force of the clasping members  41 ,  42 ,  43 ,  44  is distributed through the cross arm  10 . However, a single composite member  20  could be used as a cross arm  10 . Advantageously, each composite member  20 ,  21  represents the result of a single extruded tube of fiberglass being cut into identical (or substantially identical) halves. While one embodiment is a fiberglass material extruded into a tube, other materials can be employed. In an alternative embodiment, an armed fiber material is used. In yet another alternative embodiment, a polyester fiber is used. 
         [0029]    As stated above, one embodiment is fabricated by extrusion, alternative embodiments are fabricated through other processes. In one alternative embodiment, the tube  30  is fabricated by filament winding resin impregnated fibers around an approximately shaped mandrel. In yet another alternative embodiment, the tube  30  is fabricated by rolling a plurality of sheets of pre-impregnated unidirectional material around a mandrel. While fibers can be wound (or rolled as the case may be) around a mandrel, in an alternative embodiment, a braided or triaxial sock can be slipped over a mandrel, taped, and then cured in an oven. Alternatively, the epoxy resin can be cured by exposing the material to UV light. 
         [0030]    Referring now to  FIG. 2 , each of the composite members  20 ,  21  is provided with a plurality of extensions  22 ,  23 , each of which is specifically designated  22 - a,    22 - b,    23 - a,    23 - b.  Each of the extensions,  22 - a,    22 - b,    23 - a,    23 - b  terminates at an edge. Thus, as shown in  FIG. 1 , extension  22 - a  terminates at edge  20 - a;  extension  22 - b  terminates at edge  20 - b;  extension  23 - a  terminates at edge  21 - a,  and extension  23 - b  terminates at edge  21 - b.  Each of the extensions,  22 - a,    22 - b,    23 - a,    23 - b  is provided with an inner surface and an outer surface. As illustrated in  FIG. 2 , extension  22 - a  is provided with an inner surface  22 - c  that faces inner surface  22 - d  located on extension  22 - b.  Similarly, extension  23 - a  is provided with an inner surface  23 - c  that faces an inner surface  23 - d  located on extension  23 - b.    
         [0031]      FIG. 2  also illustrates each of the extensions  22 - a,    22 - b,    23 - a,    23 - b  provided with outer surfaces  22 - e,    22 - f,    23 - e,    23 - f.  Outer surface  22 - e  is, relative to inner surface  22 - c,  located on the opposite side of extension  22 - a  and faces away from inner surface  22 - d.  In the same vein, outer surface  22 - f  is, relative to inner surface  22 - d,  located on the opposite side of extension  22 - b  and faces away from inner surface  22 - c.  Similarly, outer surface  23 - e  is, relative to inner surface  23 - c,  located on the opposite side of extension  23 - a.  Lastly, outer surface  23 - f  is, relative to inner surface  23 - d,  located on the opposite side of extension  23 - b.    
         [0032]    As noted above, one embodiment uses an attachment assembly  40 , a plurality of hardware plates  71 ,  72 , and clasping members  41 ,  42 ,  43 ,  44  in attaching the composite members  20 ,  21  to the pole mount  90  or base. However, in alternative embodiments, the composite members  20 ,  21  are attached through the use of an adhesive. In yet another embodiment, an attachment assembly  40  is used.  FIG. 2  depicts a perspective view of the composite members  20 ,  21  attached to each other. 
         [0033]    The attachment assembly  40  is provided with a plurality of clasping members  41 ,  42 ,  43 ,  44 . The clasping members  41 ,  42 ,  43 ,  44  are each provided with a leg and a lip. The lip corresponding to each of the clasping members  41 ,  42 ,  43 ,  44  has been designated accordingly (the lip of clasping member  41  has been designated  41 - a  and so forth). In the same vein, the leg corresponding to each of the clasping members  41 ,  42 ,  43 ,  44  has been designated accordingly (the leg of clasping member  41  has been designated  41 - b  and so forth). 
         [0034]    As demonstrated in  FIG. 1 , each lip of the clasping members extends, at least in part, over each edge of the composite members  20 ,  21 . Thus, lip  41 - a  extends over edge  21 - a;  lip  42 - a  extends over edge  20 - a;  lip  43 - a  extends over edge  21 - b;  and lip  44 - a  extends over edge  20 - b.  Advantageously, the lips  41 - a,    42 - a,    43 - a,    44 - a  extend over the inner surfaces  23 - c,    22 - c,    23 - d,    22 - d,  at least a portion of the composite members  20 ,  21 . When used with the composite members  20 ,  21 , the lip of each of the clasping members  41 ,  42 ,  43 ,  44  engages at least a portion of each of the composite members. 
         [0035]    As stated above, each of the clasping members  41 ,  42 ,  43 ,  44  is provided with a leg. In one embodiment, the legs  41 - b,    42 - b,    43 - b,    44 - b  extend from the outer surfaces  23 - e,    22 - e,    23 - f,    22 - f  of the composite members. As  FIG. 1  illustrates, each leg extends from each outer surface so that the leg and the corresponding outer surface are generally orthogonal, an orientation suitable for a fastener. In one embodiment, a bolt extends parallel to the outer surfaces  22 - e,    23 - e  of the composite members  20 ,  21  through the respective legs  41 - b,    42 - b  of clasping members  41 ,  42  (as is shown in  FIG. 7 ). In similar fashion, a bolt extends parallel to the outer surfaces  22 - f,    23 - f  of the composite members  20 ,  21  through the respective legs  43 - b,    44 - b  of clasping members  43 ,  44 . Thus, the clasping members  41 ,  42 ,  43 ,  44  secure together the two composite members  41 ,  42 . 
         [0036]    Referring now to  FIG. 3 , the cross arm is  10  is provided with a plurality of hardware plates  71 ,  72 , which are referred to herein as a first plate  71  and a second plate  72 . The plates  71  and  72  are made of a metallic material such as steel or aluminum; however, other materials can be used, such as wood, phenolic, or a thermoplastic. The hardware plates  71 ,  72  are strapped to clamp together the composite members  20 ,  21 . As shown in  FIG. 3 , the first plate  71  engages the outer surfaces  23 - e,    22 - e  of composite members  20 ,  21 . Similarly, the second hardware plate  72  engages the outer surfaces  23 - f,    22 - f  of the composite members  20 ,  21 . The hardware plates  71 ,  72  are each provided with external and internal surfaces, which have been designated  73  and  74  respectively. 
         [0037]      FIG. 4  depicts the external surface  73  provided with a plurality of holes  73 - a,    73 - b  and  73 - c.  Holes  73 - a  and  73 - b  can be tapped so that a threaded bolt can be used to bring the plates  71  and  72  into clamping engagement with the composite members  20 ,  21 . Alternatively, a lock washer and nut combination may be used with the threaded bolt to bring the plates  71  and  72  into clamping engagement with the composite members  20 ,  21 . 
         [0038]    Referring now to  FIG. 5 , the internal surface  74  of the hardware plates  71  and  72  is shown. As illustrated therein, the internal surface is shaped according to the composite members  20  and  21 . The internal surface  74  of the hardware plates  71 ,  72  is provided with a spacing ridge  76 . The spacing ridge  76  extends down the central portion of the internal surface  74  and enables the hardware plates  71  and  72  to hold the composite members  20  and  21  in alignment, while, at the same time, providing a suitable location for a pin (not shown) for mounting an insulator (not shown) in  FIG. 8 , the spacing ridge  76  is provided with hole  73 - c  through which a pin may be placed for hardware mounting. Hole  73 - c  is located in the center of each of the plates  71 ,  72  and is so located to maximize the strength and aligning functions of the spacing ridge  76 . 
         [0039]    Opposing sides of the internal surface  74  are projections  77 - a  and  77 - b.  The projections  77 - a  and  77 - b  are located distances  78 - a  and  78 - b  which equal the width of the outer surfaces  23 - e -,  22 - e  of the composite members  20 ,  21 . The projections  77 - a,    77 - b  together with the spacing ridge  76 , hold the composite members  20 ,  21  in secure alignment. 
         [0040]    In operation, the threaded bolts (not shown) that are passed through the tapped holes  73 - a  and  73 - b  can be loosened; thus, the hardware plates  70 ,  71  can be retained in sliding engagement on the composite members  20 ,  21 . This sliding engagement enables the hardware plates to slide along the composite members  20 ,  21 . Because electrical lines extend across the composite members  20  and  21 , (as shown in  FIG. 8 ), the sliding engagement enables hardware (such as an insulator) to be placed in alignment with the appropriate electrical line. 
         [0041]      FIG. 8  depicts a side view of a portion of the cross arm  10  with a composite member  20  and an insulator  96  attached to the hardware plates  71 ,  72  via a pin through hole  73 - c.  As  FIG. 8  illustrates, when the fasteners placed through holes  73 - a  and  73 - b  are loosened, the insulator  96  can slide along the composite member  20  and be aligned with a utility line (not shown) 
         [0042]      FIG. 9  depicts a side view of another embodiment of the cross arm  10  with a composite member  20  and an insulator  96  attached to the hardware plates  71 ,  72  via a pin  97  through hole  73 - c.  As  FIG. 9  illustrates, when the fasteners placed through holes  73 - a  and  73 - b  are loosened, the insulator  96  can slide along the composite member  20  and be aligned with a utility line (not shown). As depicted therein, the pin  97  is secured to the cross arm by way of a fastener  99 , such as a washer, nut, and nut retainer. 
         [0043]    Referring now to  FIG. 6 , the cross arm  10  is provided with a pole mount  90 . The pole mount  90  is provided with a plurality of holes. As shown in  FIG. 6 , the pole mount  90  is provided with a plurality of mounting holes  91 - a,    91 - b,    91 - c.  The mounting holes  91 - a,    91 - b,    91 - c  are shaped to accept a fastener, such as a bolt (not shown) with a shank and a head. The mounting holes  91 - a,    91 - b,    91 - c  accept the shank of the bolt while the head of the bolt clamps the pole mount. In an alternative embodiment, a simple washer (not shown) may also be employed. The mounting holes  91 - a,    91 - b,    91 - c  are shaped so that the pole mount can be adjusted by loosening the mounting bolts; the pole mount  90  can be moved up or down so that the cross arm  10  can be placed at the correct height. 
         [0044]    The pole mount  90  is also provided with a plurality of clamp holes  92 - a,    92 - b,    92 - c,  and  92 - d.  The clamp holes  92 - a,    92 - b,    92 - c,  and  92 - d  are positioned to line up with holes located on the clamping members  41 ,  42 ,  43 ,  44 . In one embodiment, the pole mount  90  is fabricated from a cast iron in a sand mold. 
         [0045]    Referring now to  FIG. 7 , the cross arm  10  is shown in a top-down view attached to a pole, designated  95 . As shown therein, the clasping members are shown on opposing sides of the pole mount  90 . Hidden from view in  FIG. 2 , a second pair of clasping members is shown in  FIG. 7 . To distinguish one pair of clasping members from the other, the clasping members shown in  FIG. 7  shall be designated  41 - a,    42 - a,    41 - b,  and  42 - b.  As  FIG. 7  illustrates, the clasping members  41 - a,    42 - a,  are aligned with hole  92 - a  in the pole mount  90 . While clasping members  41 - b,    42 - b  are aligned with hole  92 - b  in the pole mount  90 . 
         [0046]      FIG. 10  depicts one embodiment of a program  110  that analyzes user input in order to select a product. Advantageously, the program  110  analyzes user input to select a utility product, such as a cross arm. While one embodiment is a program that selects a cross arm, the program  110  can be adapted to analyze user input for other types of products, such as an insulator. In one embodiment, the program  110  is software run on a computer. As shown in  FIG. 10 , the program  110  begins by running an acquisition routine  112  that obtains application data via an application subroutine  113 . In the case of a cross arm product, the application subroutine  113  obtains user input by indicating whether the application is a cross arm application (such as when a conductor is terminated on a utility pole), also referred to herein as a “Deadend Application,” or whether the application is a tangent cross arm application (such as when a conductor extends from one cross arm to another), also referred to herein as a “Tangent Application.” 
         [0047]      FIG. 11  depicts the application subroutine  113  obtaining application data; as shown therein, the application subroutine  113  obtains application data by prompting the user to select whether the application is a “Tangent Application” or a “Deadend Application.”  FIG. 15  depicts the user interface of the application subroutine  113 , wherein the user is prompted to select whether the application is a “Tangent Application” or a “Deadend Application.” As  FIG. 15  also illustrates, the program  110  enables the user to exit by clicking an “Exit Application” button. After the application subroutine  113  obtains application data, the acquisition routine  112  obtains numeric data via a data subroutine  114 . In the case of a utility product, the data subroutine  114  obtains user input indicating the loads that the product must withstand. After the application data has been obtained, the data subroutine  114  obtains numeric data and data relating to the loads imposed upon the product. 
         [0048]      FIG. 12  involves a case in which the user has provided application data indicating that the cross arm product will be used in a “Tangent Application.” The data subroutine  114  thus prompts the user to provide the conductor type, the span length, the dimensions for pin holes, the utility safety factor, the conductor load type (such as the NESC conductor load type), and the construction grade (such as the NESC construction grade). The data subroutine  114  can prompt the user to provide the required data in any order. 
         [0049]      FIG. 13  involves a case in which the user has provided application data indicating that the cross arm product will be used in a “Deadend Application.” The data subroutine  114  thus prompts the user to provide the conductor type, the span length, the conductor span sag, the dimensions for pin holes, the utility safety factor, the conductor load type (such as the NESC conductor load type), and the construction grade (such as the NESC construction grade). 
         [0050]    After the data subroutine  114  obtains the numeric data, the program  110  executes a calculation routine  115 . The calculation routine  115  uses the numeric data that the data subroutine  114  has obtained as well as the application data that the application subroutine  113  has obtained and performs a plurality of mathematical operations. In the case of a utility application, the calculation routine  115  calculates the loads the product should withstand. 
         [0051]    Referring now to  FIG. 14 , the case of a tangent cross arm application is shown. As illustrated therein, the calculation routine  115  calculates a plurality of loads. First, the calculation routine  115  uses the application data from the application subroutine  113  to determine whether the cross arm is a tangent cross arm or deadend cross arm. Then, in the case of a tangent cross arm application, the calculation routine  115  calculates the loads corresponding to a tangent cross arm product. As shown in  FIG. 14 , the calculation routine  115  calculates the application moment load, the application load per phase with a safety factor (both a NESC safety factor and a utility safety factor), and an ultimate load per phase. The calculation routine  115  can calculate the plurality of loads in any order, 
         [0052]    Referring now to  FIG. 14 , the case of a deadend cross arm application is shown. As in the case of a tangent cross arm application, the calculation routine  115  calculates a plurality of loads and uses the application data from the application subroutine to determine whether the cross arm is a tangent cross arm or deadend cross arm. Then, after the program  110  establishes that a deadend cross arm application has been selected, the calculation routine  115  calculates the loads corresponding to a deadend cross arm application. As shown in  FIG. 14 , the calculation routine  115  calculates the horizontal tension, the vertical tension, the resultant tension load or load per phase, the tension moment load, the application load per phase with a safety factor (both a NESC safety factor and a utility safety factor), and an ultimate load per phase. 
         [0053]    In one embodiment, the program  110  is available over the world wide web. In another embodiment, the program  110  is able to interact with other programs. By way of an example and not a limitation, the program  110  may cooperate with, or be integrated to, another program, such as a product purchasing program. In one embodiment, the appropriate product may be ordered, for example, over the world-wide-web. In another embodiment, the program  110  is loaded onto a computer, such as a desktop or laptop computer. 
         [0054]    As depicted in  FIG. 15 , one embodiment, of the program  110  is depicted. A shown therein, the acquisition routine  112  obtains data through the application subroutine  113 . Here, the user inputs whether the application is a “Tangent Application” or a “Deadend Application.” 
         [0055]    Referring now to  FIG. 16 , one embodiment of the user interface of the data subroutine  114  is shown.  FIG. 16  depicts the data subroutine  114  for a “Tangent Application,” wherein the user inputs the conductor type, the span length, the dimensions for pin holes, the utility safety factor, the conductor load type (such as the NESC conductor load type), and the construction grade (such as the NESC construction grade).  FIG. 17  depicts the data subroutine  114  for a “Deadend Application,” wherein the user inputs the conductor type, the span length, the conductor span sag, the dimensions for pin_holes, the utility safety factor, the conductor load type (such as the NESC conductor load type), and the construction grade (such as the NESC construction grade). 
         [0056]    Referring now to  FIG. 10 , after the calculation routine  115  calculates the plurality of loads for either the “Tangent Application” or the “Deadend Application,” the report routine  116  determines if product is available to support the user&#39;s requirements by the product available  117  search. If product is available that supports the user&#39;s requirements, the report generation  118  of the program  110  generates a report of the available products for the user. One embodiment, of the report is depicted in  FIG. 18 .