Hot stick light

A light for use with a hot stick includes an elongate body having a first connector configured to connect to the hot stick and a second connector configured to connect to a tool associated with the hot stick. The light also includes a first light source supported by the elongate body and having a first light emitting diode configured to emit light in a first direction relative to a longitudinal axis of the body, a second light source supported by the elongate body and having a second light emitting diode configured to emit light in a second direction relative to the longitudinal axis that is different than the first direction, a power source positioned within the elongate body and electrically coupled to the first light source and the second light source, and a user interface supported on the elongate body to control operation of the first and second light sources.

BACKGROUND

The present invention relates to lights and, more particularly, to lights for use with hot sticks.

Power utility linemen, municipalities, and utility contractors work on high voltage power lines and equipment on a daily basis. Hot stick applications are common during outage situations at night, resulting in users needing light to perform their tasks. The most common light sources are headlamps, which do not provide enough light to illuminate the workspace, and spot lights, which are never in the right place and require a second user to spot the workspace. The tasks, equipment, and hot stick styles vary for outages so users need versatility of light spread and compatibility for different styles of hot sticks.

SUMMARY

In one aspect, the invention provides light for use with a hot stick. The light includes an elongate body having a first connector on a first end of the elongate body and a second connector on a second end of the elongate body. The first connector is configured to connect to the hot stick. The second connector is configured to connect to a tool associated with the hot stick. The elongate body defines a longitudinal axis extending through the first connector and the second connector. The light also includes a first light source supported by the elongate body and having a first light emitting diode configured to emit light in a first direction relative to the longitudinal axis, a second light source supported by the elongate body and having a second light emitting diode configured to emit light in a second direction relative to the longitudinal axis that is different than the first direction, a power source positioned within the elongate body and electrically coupled to the first light source and the second light source, and a user interface supported on the elongate body to control operation of the first and second light sources.

In another aspect, the invention provides a light for use with a hot stick. The light includes a body configured to be coupled to an end of the hot stick adjacent a tool associated with the hot stick. The body includes a battery compartment. The light also includes a light source supported by the body and having a light emitting diode configured to emit light toward the tool associated with the hot stick, a rechargeable battery pack positioned within the battery compartment, and a charging port supported by the body and electrically coupled to the rechargeable battery pack. The charging port is operable to recharge the rechargeable battery pack. The light further includes a power switch supported by the body and electrically coupled to the light source. The power switch is operable to control operation of the light source.

In yet another aspect, the invention provides a hot stick assembly including a hot stick, a tool associated with the hot stick, and a light including an elongate body having a first connector on a first end of the elongate body and a second connector on a second end of the elongate body. The first connector is connected to the hot stick light. The second connector is connected to the tool. The elongate body defines a longitudinal axis extending through the first connector and the second connector. The light also includes a first light source supported by the elongate body and having a first light emitting diode configured to emit light toward the tool in a first direction relative to the longitudinal axis, a second light source supported by the elongate body and having a second light emitting diode configured to emit light toward the tool in a second direction relative to the longitudinal axis that is different than the first direction, a power source positioned within the elongate body and electrically coupled to the first light source and the second light source, and a user interface supported on the elongate body to control operation of the first and second light sources.

Other aspects of the invention will e apparent by consideration of the detailed description and accompanying drawings.

DETAILED DESCRIPTION

Workers use hot sticks to service power lines. A hot stick is an insulated pole, usually made of fiberglass, used by electric utility workers when engaged on live-line working on energized high-voltage electric power lines, to protect them from electric shock. Depending on the tool attached to the end of the hot stick20, it is possible to test for voltage, tighten nuts and bolts, apply tie wires (twisted lengths of ductile wire which fasten the running cable to its supporting insulators), open and close switches, replace fuses, lay insulating sleeves on wires, and perform various other tasks while not exposing the crew to a large risk of electric shock.

Hot sticks are made in different lengths, from a few feet long up to telescoping types of 30 feet length. Because the fiberglass provides electrical insulation, the hot stick allows utility workers to perform operations on power lines safely without de-energizing the power lines or while the state of the power lines is not yet known. This is essential because certain operations (such as opening or closing combination fuse/switches) are occasionally performed on an energized line. Additionally, after a fault occurs, the exact state of a line may not be certain; in this case, for reasons of crew safety, the utility workers should treat the line as though it were energized until it can be proven that it is not and safety ground cables can he applied to the line (so that the line is guaranteed to remain grounded/earthed while maintenance is performed upon the line). The hot stick not only electrically insulates the worker from the energized conductor, but also provides physical separation from the device being operated to reduce the chances of burns which might result from electrical arcing if there is a malfunction of the device being operated.

FIGS. 1-5illustrate a light24for use with a hot stick. The illustrated light24includes a body28, a first light source32, a second light source36, a power source40(FIG. 4), and a user interface44. The body28is generally cylindrical and includes a central aperture48that receives the hot stick. In the illustrated embodiment, the body28is divided into two sections52,56that are connected together with a hinge60. The two sections52,56are also releasably secured together in a closed position by a clamp mechanism64. The hinged sections52,56and the clamp mechanism64allow the body28to be positioned around a portion of the hot stick and secured in place. The clamp mechanism64includes an over-center clamp. The clamp mechanism64is thereby adjustable to fit around different sizes (e.g., diameters and/or shapes) of hot sticks. For example, in some embodiments, the light24can attach to hot sticks having diameters between 1 inch and 2.5 inches. In addition, the light24can attach to hot stick having circular, triangular, or other shaped cross-sections.

As shown inFIG. 3, the body28also includes gripping sections68positioned on an inner surface of the body28. The illustrated gripping sections68are elastomeric members that deflect and deform to match the shape and size of the hot stick. The gripping sections68can be made of a single molded elastomeric piece, or can include two or more individual pieces. In some embodiments, the gripping sections68may include horizontal ribbing on surfaces that contact the hot stick to reduce vertical slipping along the stick. Additionally or alternatively, the gripping sections68can have other shapes and sizes.

Referring back toFIGS. 1 and 3, the first light source32is supported by the body28. The first light source32includes a light emitting diode72(LED) (FIG. 4) and is configured to provide a spot light to illuminate a finger on the end of the hot stick. In the illustrated embodiment, the first light source32includes a single LEI), but may alternatively include multiple LEDs or an array of LEDs.

The second light source36is also supported by the body28. The illustrated second light source36includes two LEDs76(FIG. 5) positioned on diametrically opposite sides of the body28. The second light source36is configured to provide a flood light to illuminate an area around the hot stick. The two LEDs76are positioned radially from each other to avoid making shadows. In other embodiments, the second light source36may include more than two LEDs and/or the LEDs76may be located elsewhere on the body28.

As shown inFIG. 4, the power source40is positioned within the body28and electrically coupled to the first light source32and the second light source36. In the illustrated embodiment, the power source40includes a single cell battery. More particularly, the power source40includes a removable power tool battery pack. The power source40is positioned within a battery compartment80of the body28so that the power source40can be removed. In the illustrated embodiment, the power source40is arranged generally parallel to a longitudinal axis of the hot stick to which the light24is attached. In other embodiments, the power source40may be arranged generally perpendicular to the longitudinal axis of the hot stick. In some embodiments, the battery compartment80is sealed to inhibit fluid and dust ingress.

As shown inFIGS. 2 and 4, the user interface44is supported on the body28and includes a power switch84, a mode switch88, and a charging port92. The power switch84is a button that can be depressed by a user to turn the light24on and off. The mode switch88is also a button that can be depressed by a user to change the operating mode of the light24. For example, the light24can operate in a first or spot mode where only the first light source32is illuminated, a second or flood mode where only the second light source36is illuminated, or a third or fill mode where both the first light source32and the second light source36are illuminated. In other words, the light sources32,36can be used individually or together by actuating the mode switch88. In other embodiments, the power switch84and the mode switch88may be combined into a single switch.

The charging port92is electrically coupled to the power source40. The charging port92allows the power source40to be recharged while the power source40remains in the battery compartment80of the body28. The power source40may also be removed from the battery compartment80for replacement or separate charging. In the illustrated embodiment, the charging port92includes a USB port94to charge the power source40. In other embodiments, the light24may include other suitable charging ports. In some embodiments, the user interface44may additionally include a charge status indicator to indicate the status of the power source40.

FIGS. 6-8illustrate the light24being attached to a hot stick96. InFIG. 6, the clamp mechanism64is unsecured and the two sections52,56of the body28are pivoted apart from each other to receive the hot stick96. InFIG. 7, the two sections52,56of the body28are pivoted together to wrap around the hot stick96. InFIG. 8, the clamp mechanism64is closed to secure the light24to the hot stick96.

FIGS. 9 and 10illustrate the light24operating in the spot mode. In this mode, the first light source32is illuminated.

FIGS. 11 and 12illustrate the light24operating in the flood mode. In this mode, the second light source36is illuminated.

The illustrated light24provides a relatively compact and lightweight light that can be attached to a hot stick. For example, the light24can have an overall length of less than 120 mm (e.g., between 90 mm and 120 mm) and an overall diameter of less than 100 mm (e.g., between 75 mm and 95 mm). In addition, the battery compartment80can have a width of less than 45 mm (e.g., between 25 mm and 40 mm), such that the power source40only projects from the body28a relatively small amount. In embodiments where the power source40is oriented perpendicular to the hot stick (rather than parallel to the hot stick), the overall diameter could then be less than 120 mm to accommodate the length of the power source40, but the overall length could be the same or smaller. The overall length may be related to the amount of gripping area required for the particular elastomeric material selected for the gripping sections68.

FIGS. 13-18illustrate another embodiment of a light100for use with a hot stick154. The light100includes an elongate body104having a first connector108aand a second connector108b.More specifically, the first and second connectors108a,108bare a portion of a backbone106of the light100. The backbone106may be formed of a material (e.g., aluminum) capable of withstanding axial load when fuses are detached from a fuse cut-off. Therefore, the backbone106undergoes the axial load, removes stress from the housing104and a battery door160, and distributes the axial load throughout the light100. The first connector108ais positioned on a first end104aof the body104. The illustrated first connector108ais generally cylindrical and includes a threaded aperture112. The first connector108aalso includes a plurality of circumferentially-spaced projections116extending from one side120bof the first end104a.The projections116engage corresponding grooves and projections on a tool124aof the hot stick154(FIG. 18) to connect the light100to the tool124a.Although one specific embodiment of the tool124ais shown in the figures, other types of tools may additionally or alternatively be connected to the light100. In some embodiments, the projections116may extend from both sides120a,120bof the first end104a,allowing the tool124ato be connected to either or both sides120a,120bof the light100. As shown inFIG. 16, a fastener128extends through the threaded aperture112and a corresponding aperture in the tool124ato secure the light100to the hot stick154. In the illustrated embodiment, the fastener128is a threaded fastener, such as a thumb screw. More specifically, the illustrated fastener128includes a flat, planar surface which may supply additional leverage than a traditional wing thumbscrew. As such, the fastener128may be tightened via a tool (e.g., pliers) or a user's hands.

Referring back toFIGS. 13-15, the second connector108bis positioned on a second end104bof the body104. The body104further defines a longitudinal axis A extending through the first connector108aand the second connector108b.The illustrated second connector108bis generally cylindrical and includes an elongate aperture130extending through the connector108b.The second connector108balso includes a plurality of circumferentially-spaced projections116extending from one side120aof the second end104b,In the illustrated embodiment, the other side120bof the second connector108bincludes a beveled surface134. The projections116on the second connector108bengage corresponding grooves and projections on an end124bof the hot stick154(FIG. 18) to connect the light100to the hot stick154. As shown inFIG. 18, a fastener128extends through the elongate aperture130and a corresponding aperture in the end124bof the hot stick154to secure the light100to the hot stick154. In the illustrated embodiment, the fastener128is a threaded fastener, such as a thumb screw. The elongate aperture130allows the light100to be slid off of the end124bof the hot stick154by loosening the fastener128, but without completely disconnecting the fastener128from the hot stick154.

The projections116on the connectors108a,108ballow the light100to be secured to the hot stick154and to the tool124ain different orientations (e.g., at a variety of angles). For example, in the illustrated embodiments, the connectors108a,108bcouple to the hot stick154such that the longitudinal axis A of the light100is generally parallel to collinear to a longitudinal axis A′ of the hot stick154. Each connector108a,108b,however, defines a pivot axis136a,136b.The pivot axes136a,136bare perpendicular to the longitudinal axes A, A′ and are collinear with longitudinal axes of the corresponding fasteners128. When the fasteners128are loosened, the hot stick154and the tool124amay be rotated about the pivot axes136a,136bto different orientations relative to the light100. For example, the connectors108a,108bmay couple to the hot stick154such that the longitudinal axis A of the light100is substantially perpendicular to the longitudinal axis A′ of the hot stick154. Additionally, the connectors108a,108ballow the light100to couple to the hot stick154at oblique angles relative to the longitudinal axis A′. The connectors108a,108balso allow the tool124ato be connected to the light100at a different angle than how the hot stick154is connected to the light100. In other words, the angle of the tool124arelative to the light100is independent of the angle of the hot stick154relative to the light100.

As shown inFIG. 17, the elongate body104includes a first light source142aand a second light source142b.In the illustrated embodiment, the light sources142a,142bare closer to the second connector108b(and thereby the hot stick) than to the first connector108a.The first light source142ais positioned on a first side of the longitudinal axis A, and the second light source142bis positioned on a second side of the longitudinal axis A opposite the first light source142a.In the illustrated embodiment, the light sources142a,142binclude first and second LEDs144a,144bcovered by first and second lenses148a,148b.The LEDs148a,148bare configured to provide a spot light to illuminate the first connector108aand/or the tool124aassociated with the hot stick154. More specifically, the first LED148aemits light in a first direction relative to the longitudinal axis A, and the second148bemits light in a second direction relative to the longitudinal axis A. The second direction is different than the first direction, although both LEDs148a,148bemit light generally toward the first connector108a.By providing the light sources1142a,142bon opposite sides of the longitudinal axis A, the light sources142a,142bcan better illuminate both ends of the tool124a.in the illustrated embodiment, the light sources142a,142binclude an array of LEDs which illuminate the entire hot stick154and eliminate shadows. In alternative embodiments, the light sources142a,142bmay alternatively include a single LED. In still further embodiments, a ramped surface138of the light100may also or alternatively include a light source to direct light toward the tool142aof the hot stick154. In the illustrated embodiment, the light sources142a,142bare co-molded such that they are substantially waterproof. As such, the light100is capable of being stored in inclement weather and/or being submerged in water without causing damage to the light sources142a,142b.

A power source152is positioned within the body104and electrically coupled to the light sources142a,142b.In the illustrated embodiment, the power source152includes a single cell battery. More particularly, the power source152includes a removable power tool battery pack. The power source152is positioned within a battery compartment158of the body104. In some embodiments, the power source152is removable from the battery compartment158. The battery compartment158includes the sealed battery door160. In the illustrated embodiment, the battery door160is a sealed battery door having, for example, a gasket extending around an inner perimeter of the battery door160to inhibit fluid and dust ingress. The illustrated battery door160also includes a thumb screw162. The thumb screw162includes a semi-circular portion164attached to the screw162and rotatable in a horizontal orientation and a vertical orientation. The screw162may be unscrewed using a tool (e.g., a screwdriver) or via a user's hands. In order to remove the power source152from the battery compartment158, the semi-circular portion164may be rotated in the vertical direction and then in the horizontal direction, which then allows the user to pivot the battery door160open about a pivot point166. In other embodiments, the power source152is not removable from the battery compartment158. In the illustrated embodiment, the power source152is arranged generally parallel to the longitudinal axis A′ of the hot stick154to which the light100is attached. In other embodiments, the power source152may be arranged generally perpendicular to the longitudinal axis A′ of the hot stick154. In the illustrated embodiment, the battery door160and the housing104are gasketed to the backbone106in order to protect the internal components (e.g., power source152) from external conditions. For example, the light100may be exposed to inclement weather (e.g., rain, snow, etc.), submerged in water, etc. without causing damage to the light100. These aspects provide the light100with an IP67 rating for waterproofing.

As shown inFIGS. 13-18, the body104also supports a power switch146and a USB port150. The illustrated power switch146is a button that can be depressed by a user to turn the light100on and off. The USB port150is electrically coupled to the battery compartment158to charge the power source152. The body104further supports a charge status indicator156to indicate a charge status of the power source152. The illustrated charge status indicator156is positioned adjacent the USB port150. When the power source152is turning on, the charge status indicator156may emit a colored (e.g., red, yellow, green, etc.) light. Additionally, when the power source152is charging, the charge status indicator156may emit a first colored light (e.g., red), and when the power source152is fully charged, the charge status indicator156may emit a second colored light (e.g., green). In still further embodiments, the charge status indicator156may flash to indicate that the power source152is charging or to indicate an error in the charging process. In other embodiments, the light100may include other suitable charging ports and/or a mode switch to change an operating characteristic (e.g., brightness) of the light sources142a,142b.In the illustrated embodiments, the power switch146, USB port150, and charge status indicator156are co-molded such that they are substantially waterproof. As such, the light100is capable of being stored in inclement weather and/or being submerged in water without causing damage to the light sources power switch146, USB port150, and charge status indicator156. Furthermore, the light100may include additional components on the body104which are waterproof.

In the illustrated embodiments, the power switch146operates the first light source142aand/or the second light source142bin at least two modes: a first mode where the first and/or second light sources142a,142bemit light having a first intensity, and a second mode where the first and/or second light sources142a,142bemit light having a second intensity different from the first intensity. In some embodiments, the first intensity is at least 200 lumens, or is between 200 lumens and 400 lumens. Additionally, the second intensity is at least 75 lumens, or is between 75 lumens and 150 lumens. In the illustrated embodiments, the first intensity is at least 350 lumens, and the second intensity is approximately 107 lumens. The illustrated light100has a sufficient voltage to power the first and second light sources142a,142bfor an extended period of time. For example, when operating in the second mode, the light sources142a,142bcan emit light for at least 6 hours. In the illustrated embodiment, the light can operate in the second mode for approximately 8.5 hours. In alternative embodiments, the power switch146may operate the first and second light sources142a,142bin additional modes.

As shown inFIGS. 19 and 20, the illustrated light100includes the USB port150, a charging circuit202, the power source (e.g., battery)152, a controller206, the charge status indicator156, the first light source142a,and the second light source142b.The USB port150provides DC power to the charging circuit02to charge the battery152. The battery152sends a control signal to the controller206to indicate that power is provided through the battery152. The battery152is additionally configured to output DC power from the battery152to the first light source142aand/or the second light source142bto start or stop emitting light. InFIG. 19, the first and second light sources142a,142bare shown in parallel. However, in alternative embodiments (FIG. 20), the light sources142a,142bmay be arranged in series.

The charging circuit202is electrically connected to the USB port150, the battery152, and the controller206. The charging circuit202receives DC power from the USB port150and then controls the charging current202provided to the battery152. The charging circuit202sends and receives information regarding the battery152to and from the controller206. The battery152may be connected to the controller206and directly with a DC power source such as, for example, the USB port150. For example, the charging circuit202may communicate to the controller206the charge status of the battery152. If the battery152includes a charge level below a threshold voltage, the controller206may send control signals to the charging circuit202to charge the battery152via the USB port150, while still providing power to the first and/or second light sources142a,142b.The illustrated light100may additionally include a switching circuit, an LED driver circuit, etc. as illustrated inFIG. 20.

The controller206is electrically connected to the battery152, the state of charge indicator156, the charging circuit202, the first light source142a,and the second light source142b.The controller206receives indication signals from the charging circuit202. The controller206sends control signals to the charge status indicator156, communicating the state of charge of the battery152and allowing the indicator156to emit a signal to indicate the state of the charge. The controller206also sends control signals (e.g., PWM signals) to the first light source142aand/or the second light source142bto start or stop emitting light. In the illustrated embodiment, the first and second light sources142a,142bare configured to receive DC power from the battery152. If the state of charge of the battery152is insufficient (e.g., the state of charge of the battery152is below a voltage threshold), the controller206may send control signals to the charging circuit202to charge the battery152. The controller206includes a processor and memory storing software executed by the processor to affect the functionality of the controller206described herein.