Powered bender

An assembly for bending a conduit and a portable conduit bender. The assembly may generally include a portable bender including a base having a base surface supportable on a work surface, a housing supported by the base and defining a housing axis, the housing including a handle engageable by an operator to carry the bender, and a shoe supported by the housing for pivoting movement about the housing axis, the shoe defining a channel for supporting a conduit to be bent; and a pipe threader removably supported by the housing, the threader being operable to pivotably drive the shoe relative to the housing to bend the conduit.

FIELD

The present invention generally relates to a conduit bender and, more particularly, to a powered bender.

SUMMARY

Conduit is used to protect electrical wiring and provides a rigid member for pliable wires to extend through and connect components located on opposite ends of the conduit. Conduit is also used in plumbing lines, gas and compressed air lines, food, pharmaceutical, petrochemical operations, etc. In such operations, solids (e.g., wires) or fluids (e.g., water) pass through the conduit or pipe. In many applications, conduit is bent at least once to extend between the components to be connected.

Conduits of various sizes and materials are used based on design requirements for a given application. A conduit (of a material and size) may be selected based on, for example, the number and size of wires to pass through the conduit, environmental factors regarding the location of the conduit, the number and radius of bends to connect the electrical components, etc.

There are a number of standards for installation of wiring and conduit. For example, Underwriters Laboratories 797, American National Standards Institute C80.3, and National Fire Protection Agency 70 (i.e., National Electrical Code) provide requirements for the manufacturing, size, use, bending of conduit in construction. Other standards for conduits and pipes include, but are not limited to, the following: UL 6 Electrical Rigid Metal Conduit—Steel; UL 6A Electrical Rigid Metal Conduit—Aluminum, Red Brass, and Stainless; UL 797 Electrical Metal Tubing—Steel; UL 797A Electrical Metallic Tubing—Aluminum and Stainless Steel; UL 1242 Electrical Intermediate Metal Conduit—Steel; ANSI/ASME B36.10M Welded and Seamless Steel Pipe; ANSI/ASME 36.19M—Stainless Steel Pipe. Other related standards may apply.

Conduit bending tools provide utility when they are able to make bends with the conduit oriented level to a support surface (e.g., the ground). An operator, knowing the exact starting configuration of the conduit, can make an accurate bend with the bending tool without having to make an adjustment of the desired bend. Thus, the resulting bending operation requires less time and effort, saving time and money.

For example, for some bends, such as kick bends, it is desirable to bend the conduit in a vertical direction relative to a level work surface. This allows the conduit to be inclined from the work surface to provide an additional measurement to confirm that the bend is appropriate for the given application.

For other bending jobs, it may be desirable to bend a conduit in a horizontal direction (e.g., parallel to the work surface). A conduit bending tool that is operable in a number of different orientations (e.g., to bend a conduit in a vertical direction or in a horizontal direction) may be desirable.

Conduit bending tools should be usable by many operators (e.g., require a reasonable amount of force for operation and transport). Manual bending tools require significant force and associated torque to provide bends for certain size/material conduit which some operators are not able to supply. This inhibits certain operators from using such manual bending tools.

Existing motorized bending tools permit use by operators who cannot power the manual bending tools. However, such motorized bending tools are typically heavy and/or require wheeled structures for transport between and around jobsites.

In one independent aspect, an assembly for bending a conduit may be provided. The assembly may generally include a portable bender and a pipe threader. The bender may include a base having a base surface supportable on a work surface, a housing supported by the base and defining a housing axis, the housing including a handle engageable by an operator to carry the bender, and a shoe supported by the housing for pivoting movement about the housing axis, the shoe defining a channel for supporting a conduit to be bent. The pipe threader may be removably supported by the housing, the threader being operable to pivotably drive the shoe relative to the housing to bend the conduit.

In another independent aspect, a portable conduit bender may generally include a base supportable on a work surface; a housing defining a housing axis and supported for movement relative to the base to adjust a position of the housing axis relative to the base; a roller supported by the housing and extending along a roller axis parallel to the housing axis, the roller having a roller surface; and a shoe supported by the housing for pivoting movement about the housing axis, the shoe defining a first channel for supporting a first conduit up to a first diameter and a second channel for supporting a different second conduit up to a second diameter, the second diameter being greater than the first diameter. The housing may be movable relative to the base to selectively align one of the first channel and the second channel relative to the roller surface to support a corresponding one of the first conduit and the second conduit between the roller surface and the one of the first channel and the second channel. The shoe may be pivotable about the housing axis to bend the corresponding one of the first conduit and the second conduit when supported by the shoe.

In yet another independent aspect, a portable bender may generally include a base supportable on a work surface; a housing supported by the base, the housing including a hollow spindle having an outer surface and defining a housing axis; and an annular shoe extending from an inner surface supported by the outer surface of the spindle for pivoting movement about the housing axis, the shoe defining a channel for supporting a conduit to be bent, the shoe being pivotable about the housing axis to bend the conduit.

In a further independent aspect, a conduit bender may generally include a base having a base surface; a housing supported by the base and defining a housing axis; a roller supported by the housing and defining a roller axis, the roller having a roller surface operable to support a portion of a conduit to be bent; and a shoe supported by the housing for pivoting movement about the housing axis, the shoe defining a channel for supporting another portion of the conduit, the shoe including a first portion defining a radially-inner channel surface and a second portion providing a radially-outer surface, the shoe being pivotable about the housing axis to bend the conduit. At least one of the housing and the roller may be supported for relative movement to arrange a line intersecting the roller surface and the radially-outer surface to be substantially parallel to the base surface.

In some constructions, the housing is pivotable about the roller axis relative to the base to arrange the line to be substantially parallel to the base surface. The bender may include a mounting plate connecting the housing and the base, and the housing may be fixed to the base via the mounting plate at a desired angular position. In the desired angular position, a distance between a first line intersecting the radially-inner surface of the channel and parallel to the base surface and a second line intersecting the roller surface and parallel to the base surface is substantially equal to a diameter of the conduit.

In another independent aspect, a conduit bender may generally include a base having a base support surface; a housing supported by the base; a shoe supported by the housing for pivoting movement to bend a conduit; and a support member defining a member support surface extending transverse to the base support surface. The bender may be selectively and alternatively supported and operated to bend a conduit in a first configuration on the base surface and in a second configuration on the member support surface.

In some constructions, the support member may include a number of legs connected to the housing. The housing may define a housing axis, and the legs may extend parallel to the housing axis.

In yet another independent aspect, a conduit bender may generally include a base; a housing supported by the base and defining a housing axis; a shoe supported by the housing for pivoting movement about the housing axis to bend a conduit; and a drive mechanism operable to pivotably drive the shoe, the drive mechanism including an input drive shaft having a shaft axis and supporting a spur gear and a ring gear meshed with the spur gear, the shaft axis being offset from the housing axis.

In a further independent aspect, a conduit bender may generally include a base; a housing supported by the base and having a spindle defining a housing axis, the spindle defining an open central space; a shoe supported by the spindle for pivoting movement about the housing axis to bend a conduit; and a drive mechanism operable to pivotably drive the shoe, the drive mechanism including an input drive shaft having a shaft axis offset from the housing axis.

In another independent aspect, a conduit bender may generally include a base; a housing supported by the base and defining a housing axis; a shoe supported by the housing for pivoting movement about the housing axis to bend a conduit; and a pipe threader removably supportable by the housing and operable to drive the shoe.

In yet another independent aspect, a conduit bender assembly may generally include a base; a housing supported by the base and defining a housing axis; a shoe supported by the housing for pivoting movement about the housing axis to bend a conduit; a pipe threader operable to pivotably drive the shoe; and a remote pendant in communication with the pipe threader and operable to control the pipe threader to drive the shoe.

In a further independent aspect, a conduit bender may generally include a base; a housing supported by the base and defining a housing axis; a shoe supported by the housing for pivoting movement about the housing axis to bend a conduit; a drive member operable to pivot the shoe; a pipe threader removably supportable by the housing and operable to drive the shoe through the drive member; and an adapter removably supportable between the drive member and the pipe threader to transmit driving motion of the pipe threader to drive the shoe.

Other independent aspects of the disclosure may become apparent by consideration of the detailed description, claims and accompanying drawings.

DETAILED DESCRIPTION

Use of “including” and “comprising” and variations thereof as used herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Use of “consisting of” and variations thereof as used herein is meant to encompass only the items listed thereafter and equivalents thereof. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.

Also, the functionality described herein as being performed by one component may be performed by multiple components in a distributed manner. Likewise, functionality performed by multiple components may be consolidated and performed by a single component. Similarly, a component described as performing particular functionality may also perform additional functionality not described herein. For example, a device or structure that is “configured” in a certain way is configured in at least that way but may also be configured in ways that are not listed.

It should also be noted that a plurality of hardware and software-based devices, as well as a plurality of different structural components may be used to implement the embodiments. In addition, it should be understood that embodiments may include hardware, software, and electronic components or modules that, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary skill in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, the electronic-based aspects of the invention may be implemented in software (for example, stored on non-transitory computer-readable medium) executable by one or more processors. As such, it should be noted that a plurality of hardware and software-based devices, as well as a plurality of different structural components may be utilized to implement the invention. For example, “control units” and “controllers” described in the specification can include one or more processors, one or more memory modules including non-transitory computer-readable medium, one or more input/output interfaces, and various connections (for example, a system bus) connecting the components.

For ease of description, some or all of the example systems presented herein are illustrated with a single exemplar of each of its component parts. Some examples may not describe or illustrate all components of the systems. Other example embodiments may include more or fewer of each of the illustrated components, may combine some components, or may include additional or alternative components.

A powered bender assembly10is illustrated in the figures. In some aspects, the bender assembly10may be operable to bend a number of different types of conduits having different bending requirements (e.g., with an adjustable shoe having multiple channels) and, for each type of conduit, may be adjustable to orient a supported conduit C to be level relative to a work surface W. The bender assembly10is operable to bend conduits used in electrical construction, plumbing, gas, or compressed air lines, food, pharmaceutical or petrochemical industries, etc. The bender assembly10may include a bend indicator that is adjustable to “zero” the indicator (e.g., to accommodate adjustment of the bender assembly10), select between different bend angle measurement indications.

In some aspects, the bender assembly10may be operable to bend a conduit C in multiple different orientations relative to a work surface W (e.g., a vertical orientation and a horizontal orientation). The bender assembly10may include an adjustable support assembly operable between an extended support position and a retracted position.

In some aspects, the bender assembly10may have a drive input which is offset from the pivot axis of the bender assembly10. The drive mechanism (e.g., a ring gear driven by a spur gear) of the bender may be arranged with an open central space to house various components, tools, material, etc.

The bender assembly10is relatively lightweight and compact when compared to existing powered benders and manual benders (e.g., considering the size and weight of the components of the manual benders required to provide the same bending capabilities of the bender assembly10).

FIGS.1-32illustrate a powered bender assembly10in one orientation (e.g., a vertical orientation) with respect to a work surface W.FIGS.33-34illustrate the bender assembly10in a different orientation (e.g., a horizontal orientation) with respect to the work surface W. The illustrated bender assembly10includes a combination of a bender12and a power mechanism13(e.g., a portable, motorized pipe threader182, an on-board motor (not shown), etc.).

A pipe threader182is commonly used on the jobsite and is a convenient and economical power mechanism for the bender assembly10. Because the pipe threader182is removable, the size and weight of the bender12itself is reduced, and these components can be separated for transport. Also, after use to power the bender12, the pipe threader182may be used to thread the bent conduit C.

The bender12includes a housing14and a base18movably connected by a mounting plate22. In the illustrated construction, a hollow cylindrical portion19on the housing14extends through a hole in the plate22to pivotably connect the housing14and the base18. A roller26is supported on the portion19which defines a roller axis30. The illustrated arrangement of the portion19on the housing14results in a simple rigid construction. A driven shoe34engages the housing14for pivoting movement relative to the housing14about a housing axis38. In the illustrated embodiment, the axes30,38are parallel to each other and extend transverse to a longitudinal axis42of the base18.

The housing14and the shoe34are adjustable (e.g., pivotable) relative to the base18such that the housing axis38is adjustable relative to the base axis42between a number of positions for bending of different types of conduit C (e.g., different size, material, etc.). In the illustrated embodiment, the roller axis30is fixed relative to the base18and the base axis42and defines a pivot axis of the housing14and the shoe34relative to the base18.

In other constructions (not shown), the roller axis30may not be fixed relative to the base18and may not define the pivot axis of the housing14and the shoe34relative to the base18. In such constructions, the roller axis30and the roller26may be adjustable relative to the base18.

The roller26may include (seeFIGS.51-52) a conduit engagement groove27which may serve to spread the load during bending over a larger surface area to inhibit damage to the plastic roller26and/or to a thin-walled conduit C. The roller26“floats” (e.g., is slidable along the portion19) to align the groove27with the conduit C. A conduit C engages both the shoe34and the conduit engagement groove27of the roller26.

In the vertical orientation (seeFIGS.1-32), the bender assembly10is supported on a work surface W via the base18. In this orientation, the bender assembly10is operable to bend the conduit C in a plane perpendicular to the work surface W.

The illustrated bender12also includes a number of (three shown) laterally-extending legs50,54,58which extend parallel to the axis30,38. In the horizontal orientation (seeFIGS.33-34), the housing14is supported on the work surface W via legs50,54,58and with the base18spaced from the work surface W. The housing14may include (seeFIG.55) ribs46extending between, the legs50,54,58, and the wall defining the open space242of the housing14. The support ribs46also extend between, the wall defining the open space242of the housing14and the exterior of the housing14. The leg(s)50,54,58may be used as a handle to transport the bender assembly10to, from or around a jobsite. To facilitate carrying, an ergonomic gripping member (not shown) may be provided on a leg (e.g., on the leg58).

The illustrated legs50,54,58are threaded and received by corresponding threaded leg receiving portions62of the housing14. Each illustrated leg50,54,58is dimensioned to be provided by or replaced with a length of threaded ¾″ conduit C. Such threaded conduit C may be readily available to an operator due to the bender assembly10being capable of bending ¾″ conduit C and a pipe threader182being usable as the power mechanism13. The illustrated legs50,54,58are removable for example, for storage or replacement but, in other constructions (not shown), may be non-removable. In other embodiments (not shown), the legs50,54,58and the leg receiving portions62may be dimensioned larger or smaller than ¾″ conduit.

The legs50,54,58may be formed of machined steel, injection molded glass-filled nylon, or another suitable material. Injection molded glass-filled nylon legs50,54,58may be cheaper than machined steel legs while still being able to support the housing14and be threaded to engage the threaded leg portions62.

One leg50engages a leg receiving portion62and the mounting plate22and is aligned along the roller axis30. As shown inFIG.34, a collar66and a set screw70retain the mounting plate22between the leg50and the housing14. In another construction (seeFIG.52), the leg50is an injection-molded part and has a shoulder engaging the mounting plate22. A cap51is fixed to (e.g., glued to) the end of the leg50.

The mounting plate22includes portions74,78,82,86. The first portion74extends parallel to the base18and includes openings90to receive fasteners to connect to the base18. The second portion78extends substantially perpendicular to the first portion74, is retained with the set screw70between the leg50and the housing14and defines an arcuate slot94. The third and fourth portions82,86extend between and are substantially orthogonal to the first and second portions74,78and provide additional support to the mounting plate22.

The mounting plate22may be formed integrally as one piece including the portions74,78,82,86or may be assembled from two or more separate pieces. In the illustrated embodiment, the mounting plate portions78,82,86are integrally formed as a unit and mechanically fastened (e.g., welded) to the first portion74.

A rod98protrudes from receiving portion102of the housing14and through the arcuate slot94of the mounting plate22. A nut106, a washer110and a lever114are supported on the rod98. The lever114is operable to selectively tighten (a locking condition) and loosen (a release condition) the clamping engagement of the mounting plate22between the nut106and the washer110on one side and the housing14on the opposite side. In the release condition, the rod98is movable in the slot94and the housing14is movable relative to the base18(e.g., pivotable about the roller axis30in the illustrated construction). In the locking condition, the rod98and the mounting plate22are releasably fixed to retain the housing14in a selected position relative to the base18.

In other constructions (not shown), another type of locking arrangement may be provided to releasably retain the housing14in a selected position. For example, additionally or alternatively, a positive locking arrangement (e.g., a selectively engageable detent arrangement) may include a projection engageable in one or more recesses, each corresponding to a selected position of the housing14.

In a given position of the housing14relative to the base18, a distance or clearance118is defined in a direction perpendicular to the base axis42between a line parallel to the axis42intersecting a surface (e.g., an upper surface in the vertical orientation) of the roller26supporting a portion of a conduit C and a line parallel to the axis42and intersecting a portion (e.g., a channel surface) of the shoe34supporting another portion of the conduit C. The clearance118is adjustable by adjusting the position of the housing14(and the supported shoe34) relative to the base18. When adjusted to an appropriate position, the clearance118will be substantially equal to a diameter of a supported conduit C.

FIGS.20-21illustrate the shoe34in more detail. The shoe34may be formed of aluminum (e.g., cast A380-F aluminum as illustrated). In other embodiments, the shoe34is formed of a different material, such as, for example, A356-T6 aluminum, cast iron, a zinc-aluminum alloy (e.g., ZA-27), steel, etc. In the illustrated construction, the shoe34is annular and defines a number of (four in the illustrated construction) grooves or channels122,126,130,134dimensioned to fit various sizes of conduit C. The channels122,126are formed integrally in a first segment138of the shoe34, and the channels130,134are formed integrally in an opposite second segment142of the shoe34. The channels122,126and130,134in each pair are spaced apart along the housing axis38.

A first shoe hook146is mounted to the shoe34proximate an end of the first segment, and a second shoe hook150is mounted to the shoe34proximate an end of the second segment142. Holes222in the shoe34receive fasteners to connect the shoe hooks146,150to the shoe34. In some embodiments, the fasteners may include a bolt and a nut that engage the holes222. In other embodiments, the holes222may be tapped such that threads of the holes222engage fasteners received in the shoe34and the shoe hooks146,150.

The shoe34may be “roughly” adjusted (e.g., pivoted about 180° by the drive mechanism178or manually if a clutch is provided) relative to the housing14to bring a segment138or142into an “operational” position to bend a given conduit C. In the operational position, the conduit C supportable in each channel122,126or130,134of the operational segment138,142, respectively, may be bent by operation of the bender assembly10(e.g., by pivoting movement of the shoe34and the hook146,150relative to the housing14).

Each channel122,126,130,134has a radial inner channel surface intersected by the line defining the upper extent (in the vertical orientation) of the clearance118. The hook146defines a hook surface146a,146bassociated with each channel122,126to define a radial outer surface proximate the channel122,126. The hook150defines a hook surface150a,150bassociated with each channel130,134to define a radial outer surface proximate the channel130,134.

The distance between the channel surface of a channel122,126and130,134and the corresponding hook surface146a,146band150a,150bof the associated hook146,150, respectively, is substantially equal to the diameter of the conduit C to be supported in the channel122,126,130,134and to the clearance between the channel surface and the roller surface when the housing14is adjusted to the appropriate position for a given conduit C. In such a position, the corresponding hook surface146a,146bor150a,150bwill be aligned with the roller surface along a line parallel to the base axis42. The roller26cooperates with each channel122,126,130,134to support an associated conduit C to be bent and does not require adjustment or replacement for use of the bender12.

As illustrated, the bender assembly10is operable to bend conduits C of different materials, types, sizes, for example, due to the multiple channels122,126,130,134of the shoe34, the adjustability of the housing14relative to the base18to provide a number of clearances118, etc. The illustrated bender assembly10is operable to bend at least intermediate metal conduit (IMC), rigid (i.e., galvanized steel) conduit (RMC), electrical metallic tubing (EMT) conduit, etc., of certain nominal sizes used for electrical wiring.

The bender assembly10is also capable of bending conduits formed of other materials, such as, Polyvinyl Carbonate (PVC) coated RMC, carbon steel pipe used for plumbing, gas lines, or compressed air lines, stainless steel pipe used in food, pharmaceutical, or petrochemical industries. The following is a non-exhaustive listing of standards for conduits and pipes that the bender assembly10can bend: UL 6 Electrical Rigid Metal Conduit—Steel; UL 6A Electrical Rigid Metal Conduit—Aluminum, Red Brass, and Stainless; UL 797 Electrical Metal Tubing—Steel; UL 797A Electrical Metallic Tubing—Aluminum and Stainless Steel; UL 1242 Electrical Intermediate Metal Conduit—Steel; ANSI/ASME B36.10M Welded and Seamless Steel Pipe; ANSI/ASME 36.19M—Stainless Steel Pipe. Other related standards for conduits and pipes may apply.

Table 1 below illustrates various type(s) and nominal size(s) of conduit C to be supported and bent in the specified channel122,126,130,134of the shoe34. Other combinations of conduit C size and material may be bent in a given channel122,126,130,134. Table 1 also notes the actual outer diameter of each nominal conduit size. It should be understood that, in other constructions (not shown), the bender assembly10may be constructed to bend conduits of materials, types, sizes, etc., other than those listed. It should also be understood that, in other constructions (not shown), the bender assembly10may be constructed such that the channel(s)122,126,130,134are capable of engaging and bending conduit C of a non-standard size. A conduit C may be positioned in a channel122,126,130,134to determine whether bending is possible and, if not, moved to another channel122,126,130,134appropriate for bending.

In the illustrated embodiment, each channel122,126,130,134is dimensioned to allow for manufacturing tolerances in the conduit C and the bending shoe34. The UL standards listed above allow the diameter to vary ±0.005″ for EMT and ±0.015″ for RMC. In the illustrated embodiment, the channel126measures 0.716″—which is 0.01″ larger than the 0.706″ outer diameter of an EMT conduit of a ½″ in. trade size. Likewise, the channel134measures 0.932″, the channel130measures 1.173″, and the channel122measures 1.335″. Other adjustments may be made to the size of each channel122,126,130,134to account for manufacturing tolerances.

An indicator arrangement is provided to indicate a bend measurement. Indicia154(e.g., a line, an arrow, etc.) on the shoe34is alignable with indicia158(e.g., a line, an arrow, text, etc.) on a face plate162supported by the housing14. As the bender assembly10is operated, the indicia154,158are brought into alignment to indicate a bend measurement.

The illustrated faceplate162includes different types of indicia (e.g., angular indicia170and “bend multiplier” indicia174), each type cooperating with the indicia154on the shoe34to indicate a bend measurement. Depending on a given bending job, an operator may want to reference one indicia rather than the other. For example, in kick bends in which a conduit C is bent to avoid an obstacle and then bent back to its original axis, bending multipliers are commonly used to avoid calculation of exact bending angles. The indicia154,158allow simultaneous indication of bend angle and bend multiplier such that an operator can cross-check the measurement, if desired. Common bending multipliers are provided on the multiplier indicia174. Table 2 below lists some corresponding bend angles and bend multipliers which may be indicated with the indicia154,158.

In the illustrated construction, the faceplate162is selectively movably supported by the housing14. During bending operations, to provide the bend indication, the faceplate162is fixed with and remains stationary relative to the housing14while the shoe34pivots. As desired by the operator (e.g., to select a set of indicia (bend angle or bend multiplier) to be used) or for accurate indication of the bending operation, the faceplate162is pivoted relative to the housing14and the shoe34to relatively orient the indicia158,162. Once in the selected position, the faceplate162is again fixed to the housing14(e.g., by a frictional and/or positive locking engagement). The illustrated faceplate162is also removably mounted to an annular portion the housing14, as discussed below in more detail.

In another embodiment (not shown), an auxiliary device may be supported for movement with the shoe34(e.g., mounted to the shoe34). The auxiliary device may include a mechanical level or measurement device or an electronic device, such as, for example, a smart phone, a tablet, etc. Such an electronic device may include a level which can provide another bend measurement and indication to the operator. The level can be zeroed or reset when a conduit C is supported for bending, and, as the conduit C is bent, the level will indicate the amount of bend with respect to the zeroed position. By initially being zeroed, the level accounts for any angular adjustment if the conduit C is not level.

A drive mechanism178pivotably drives the shoe34relative to the housing14and the roller26to bend a conduit C. The drive mechanism178may be driven by an on-board motor or, as illustrated, by an external motorized device, such as, for example, a portable pipe threader182, a drill, etc. The motor, if provided, or the motorized device may be powered by an external power source (e.g., AC line power) or by a supported power source (e.g., a battery, an engine, etc.).

As illustrated, the pipe threader182transmits torque via an adapter (i.e., a primary adapter186) having an input (e.g., an octagonal input). Vertices of the input may include grooves187engageable with correspondingly dimensioned ribs of the pipe threader182. A secondary adapter266(seeFIGS.39-41) may be fastened to the primary adapter186for engagement with a different sized pipe threader182.

Each illustrated adapter182,266is generally a hollow extrusion having radially extending support ribs270between an interior engagement surface274and an exterior engagement surface278. The secondary adapter266and the adapter186are shown assembled inFIGS.45-48. To assemble, fasteners282extend through the secondary adapter266and engage and an exterior surface278of the adapter182.

FIGS.42-44illustrate an alternative construction for a secondary adapter266′ which may be fastened to the primary adapter186for engagement with the pipe threader182. The secondary adapter266′ is fastened to the primary adapter186through a circlip267retained in a circlip groove268defined in an inner periphery of the alternate secondary adapter266′. The circlip groove268has a depth generally corresponding to the radial dimension of the circlip267. When the circlip267is retained in the circlip groove268, the primary adapter186is positioned within the annular alternate secondary adapter266′. As such, the circlip267retains the primary adapter186with the secondary adapter266′.

A rear plate190of the housing14supports (seeFIGS.17-18and25-26) a support pin or rod194positioned to engage the pipe threader182to inhibit relative rotation of the pipe threader182as torque is supplied. In the illustrated embodiment, the rod194is retained on the rear plate190with a bolt198. The rear plate190defines (seeFIGS.17-18) arcuate slots202to receive fasteners so that the rear plate190can be attached to the housing14in a number positions to allow different types of power mechanisms (e.g., different pipe threaders) to be supported and engage the adapter186. In another embodiment (seeFIG.55), the rear plate190may include multiple holes202′ which receive fasteners so that the rear place190and the rod194may be attached to the housing14in a number of positions. The holes202′ may be circumferentially spaced near the outer periphery of the rear plate190.FIGS.55-57illustrate the rear plate190defining multiple holes202′.

FIGS.18-19illustrate the drive mechanism178in more detail. The drive mechanism178includes a shaft206with a shaft axis210is parallel to and offset from the housing axis38. The shaft206is drivingly rotated by the pipe threader182through the adapter186. A spur gear214, supported on the shaft206for rotation therewith, meshes with an internal ring gear218. The internal ring gear218is connected to the shoe34, and the ring gear218and the shoe34are supported by the housing14for rotation about the housing axis38. Rotation of the shaft206and the spur gear214causes rotation of the internal ring gear218and, therewith, the shoe34. Rotation of the shoe34bends the supported conduit C. After bending, the pipe threader182can be removed from the bender12and used to thread the bent conduit C.

A gear ratio between the spur gear214and the internal ring gear218increases the torque transmitted from the power mechanism13to the shoe34. In the illustrated embodiment, the ring gear218is an approximately 12″ diameter gear, and the gear ratio between the internal ring gear218and the spur gear214is about 9:1. In other embodiments, the gear ratio may be less than or greater than this ratio (e.g., between about 5:1 and about 15:1). In other embodiments (not shown), the gear assembly may include one or more additional gears.

The gear ratio between the spur gear214and the internal ring gear218allows for the use of a pipe threader182to bend conduit C. It has been found that bending 1″ rigid metal conduit C may require about 850 ft-lbs. (e.g., 848 ft-lbs.) of torque. The pipe threader182may provide about 100 ft-lbs. of torque. With the gear ratio between the spur gear214and the internal ring gear218being 9:1, the pipe threader182, through the spur gear214and the internal ring gear218, provides 900 ft-lbs. of torque, sufficient to bend 1″ rigid metal conduit C.

In the illustrated construction, the factor of safety between torque supplied by the pipe threader182and torque required to bend 1″ rigid metal conduit C is around 1.06 (greater than one to provide adequate torque to bend the conduit C). Conduit C that is smaller and/or of a different material may require less torque to bend and, thus, may have a higher factor of safety.

The gear ratio between the spur gear214and the internal ring gear218slows down the rotation of the pipe threader182to an appropriate speed for bending conduit C. The pipe threader182may rotate at around 30 RPM. With the gear ratio between the spur gear214and the internal ring gear218, the shoe34may be rotated at 30/9 RPM to bend the conduit C. This slower speed may allow for more control and accurate stopping of the rotation of the powered bender assembly10at a desired bend of conduit C.

The arrangement of the drive mechanism178, with the drive shaft206offset from the housing axis38, results in a smaller profile assembly10in which the opposite ends266,270of the pipe threader182are on opposite sides of the housing axis38. In comparison, with a drive shaft206along the housing axis38, the pipe threader182would extend further to one side of the assembly10.

As shown inFIGS.19and22, the structure of the shoe34and the arrangement of the drive mechanism178, with the offset drive shaft206and spur gear214and annular ring gear218, allows for an open space242in the housing14. The space242may serve as a compartment, closed by the removable faceplate162, operable to house any component, tool, material, etc., which an operator may need on a jobsite. For example, a power cord to supply power to or a remote pendant346and control electronics358to control the bender assembly10may be stored in the space242. Alternatively, in an embodiment in which the drive mechanism178is driven by an onboard motor, the motor (not shown) and power source (e.g., the power cord, a battery) may be housed within the space242. Additionally, the space242may provide a location for control electronics to monitor and control operation of the bender assembly10.

As shown inFIG.60, a latching mechanism286may be provided to removably engage the faceplate162and the housing14so that the open space242may be selectively closed and opened. The latching mechanism286includes a latch arm290(e.g., on the faceplate162) and a latch receiving aperture294(e.g., in the faceplate162) through which a portion of the latch arm290extends. The latch arm290is biased towards engagement with the aperture294(e.g., towards the inner surface of the housing wall defining the open space242) to retain the faceplate162in a closed position in which the open space242is covered. An operator engages the latch arm290to disengage it from the aperture294to remove the faceplate162and uncover the open space242.

The illustrated faceplate162has a handle298which is generally recessed from an exterior surface of the faceplate162. In the event that the bender assembly10is dropped onto a flat surface, the recessed handle298would not contact the flat surface. The handle298is also operable to move the latch arm290out of the aperture294, permitting an operator to remove the faceplate162only by engaging the handle290. In the illustrated embodiment, the handle298and the latch arm290include biased leaf-spring type springs. In other constructions (not shown), other mechanisms may be provided.

FIGS.23-24illustrate an adjustable support assembly for the bender assembly10. As illustrated, a relatively long conduit C is supported by the bender assembly10. The base18includes an extension254capable of increasing the length of the base18along the longitudinal axis42.

InFIG.23, the extension254is retracted into the base18for storage and/or use with relatively shorter conduit C. InFIG.24, the extension254is in the extended support position with the base foot258separated from the base18. In this position, the center of gravity250of the assembly is between the base foot258and a base cap262at the opposite end of the base18. The assembly has increased stability, and an operator does not have to apply additional downward force to maintain contact between the base18and the work surface W.

The extension tube254is retained within the base18with a fastener which engages a magnet housed within a base foot258. In other embodiments, the extension tube254is retained within the base foot258with a molded latch (not shown) at an end of the extension tubes254and engageable with the base foot258. Other retaining mechanisms may be provided.

The base foot258engages a distal end of the extension tubes254. The base foot258also includes at least one through hole to receive a fastener to further secure the base foot258with the work surface W. At the other end of the base18, the base cap262is retained with fasteners received in fastener receiving channels of the base18.

FIGS.11A,12A and13illustrate operation of the bender assembly10to bend one type and size of conduit C (e.g., a ½″ EMT conduit C). As shown inFIG.11A, the shoe34is oriented relative to the housing14with the first segment138(with the channels122,126) in the operational condition.FIG.11Aillustrates the bender assembly10and the conduit C before bending, and the illustrated ½″ EMT conduit C contacts the roller26, the portion146aof the first shoe hook146, and the channel126of the shoe34. In the position shown inFIG.11A, the housing14is positioned relative to the base18with the hook surface146aaligned with the roller surface along a line parallel to the base axis42.

FIG.12Aillustrates the bender assembly10operated to bend the conduit C to a bend angle (e.g., about 30°) with the faceplate162oriented to use the bend angle indicia170.FIG.13illustrates the bender assembly10operated to bend the conduit C with the faceplate162oriented to use the bend multiplier indicia174.

FIGS.11B and12Billustrate operation of the bender assembly10to bend another different type and/or size of conduit C (e.g., a 1″ RMC). As shown inFIG.11B, the shoe34is oriented relative to the housing14with the first segment138(with the channels122,126) in the operational condition.FIG.11Billustrates the bender assembly10and the conduit C before bending, and the illustrated 1″ RMC conduit C contacts the roller26, the portion146bof the first shoe hook146, and the channel122of the shoe34.

From the position shown inFIG.11A, the housing14is adjusted (e.g., pivoted) relative to the base18to, as shown inFIG.11B, align the hook surface146bwith the roller surface along a line parallel to the base axis42. To pivot the housing14, the lever114is released, and, as the housing14is moved, the rod98moves in the slot94(to the position shown inFIG.16C). When the housing14is in the position shown inFIG.11B, the lever114is tightened to lock the housing14relative to the base18so that the bender assembly10can be operated to bend the conduit C.FIG.12Billustrates the bender assembly10operated to bend the conduit C to a bend angle (e.g., about 30°).

FIGS.14-15illustrate operation of the bender assembly10to bend yet another different type and/or size of conduit C (e.g., a ¾″ RMC). As shown inFIG.14, the shoe34is pivoted relative to the housing14to place the second segment142(with the channels130,134) in the operational condition.

FIG.14illustrates the bender assembly10and the conduit C before bending, and the illustrated ¾″ RMC conduit C contacts the roller26, the portion150bof the second shoe hook150, and the channel130of the shoe34. As shown inFIG.16B, the rod98, the nut106and the washer110are at a position in the arcuate slot94spaced from the base18(when compared to the position shown inFIG.16A).FIG.15illustrates the bender assembly10operated to bend the conduit C to a bend angle (e.g., about 30°).

FIGS.25-26illustrate comparative views of the bender assembly10supporting different conduits C. InFIG.25, ½″ EMT conduit C is supported by the bender assembly10and the rod98is positioned in the arcuate slot94relatively close to the base18. InFIG.26, 1″ RMC conduit C is supported, and, notably, the rod98is positioned in the arcuate slot94relatively farther from the base18.

FIGS.49-53illustrate an alternative construction of a bender assembly10′ with additional indicia including, but are not limited to shoe hook indicia302, shoe channel indicia306, a bend angle indicator310, indicia314, and conduit markings318. The shoe hook indicia302indicates at least one of the size and type of conduit which each hook146,150is dimensioned to engage. The illustrated shoe hook indicia302is located directly adjacent each hook surface146a,146b,150a,150b, and optionally may be positioned on each hook146,150.

As illustrated inFIG.49A, the bender assembly10′ includes a base18engaging a base foot258. A base extension254telescopically engages the base18at an end opposite the foot258. Another foot258is provided at the end of the extension254opposite the foot258which directly engages the base18. Both feet258are also illustrated in at leastFIGS.49B and54-55.

The shoe channel indicia306indicate at least one of the cross-sectional size and type of conduit which each channel122,126,130,134is dimensioned to engage. The shoe channel indicia306may indicate more than one size and type of conduit which the particular channel122,126,130,134can engage. The illustrated shoe channel indicia306is positioned on the shoe34at an end of each channel122,126,130,134opposite the hook146,150.

The illustrated conduit markings318include a deduct arrow322which indicates a start location of a bend in conduit C as a turn is formed in the conduit C. As illustrated, the start location is offset from the hook146,150in a direction along the base axis42and towards the roller axis30. In other words, the start location is between the hook146,150and the roller26prior to bending. The illustrated conduit markings318also include a back of bend indicia326which indicates a terminal angle for a desired bend. In the illustrated embodiment, the back of bend indicia326are positioned on the shoe34adjacent the channels122,126,130,134at a location indicating a back of bend of a common bend angle (e.g., 90 degrees).

The illustrated indicia314indicates a distance from the deduct arrow322to the outside of a 90° bend in the conduit C after bending when using a given channel122,126,130,134. The indicia314is positioned on the shoe34adjacent the deduct arrow322. In the illustrated construction, the positions of the arrows322are shifted slightly from a centerline323of the shoe34so that calculating a “stub up” height is made easier.

For example, if an 11″ stub-up bend is desired, the value of the indicia314(e.g., 8″) is subtracted from 11″ to determine the location for a mark on the conduit C (e.g., 11″−8″=3″ from the end of the conduit C). The mark on the conduit C is aligned with the arrow322, and a 90° bend is made in the conduit C. For reference, such a “stub up” bend, as made by a manual bender, is illustrated inFIG.50C.

The illustrated conduit markings318also include at least one center of bend angle marking334indicating a common bend angle for a desired three-point saddle bend. As illustrated, the center of bend angle marking334is positioned on the shoe34adjacent the channels122,126,130,134at a location indicating a center of bend of at least two common bend angles (e.g., 30, 45, 60 degrees).

FIGS.51-52illustrate a bend angle scale338positioned on a side face of the shoe34. The housing14includes a bend angle indicator310which cooperates with the scale338. As the shoe34is rotated, the scale338rotates to the corresponding bend angle which is indicated by the bend angle indicator310. The scale338and the bend angle indicator310provide means for an operator to view the present bend angle of the shoe34relative to the housing14from an operating position parallel to the base axis42. As illustrated, the bend angle indicator310and scales338may be provided adjacent each of the channels122,126,130,134.

Each of the additional indicia may be formed using various methods. The additional indicia may be provided by, for example, one of pad printing, laser engraving, casting, sheet printing and applying a sticker, or subtractive detenting or holing.

The additional indicia may be shaped to accurately depict a specific point on the bender assembly10′. For example, the deduct arrow322may point at a specific location on the shoe34, the bend angle indicator310may be a cylindrical notch positioned at a specific location on the shoe34, and the back of bend indicia326may be an irregular pointed star with the irregular point positioned adjacent a specific location on the shoe34. The bend angle scale338may be positioned in a raceway342of the shoe such that the scale338does not protrude radially outwardly from the housing axis38and from within the raceway342.

FIGS.51-52illustrate an alternate roller26′ including at least one conduit engagement groove27which serves to center the conduit C on the roller26′ relative to the shoe34prior to, during, and after bending. In the illustrated embodiment, the roller26′ includes one conduit engagement groove27corresponding with the channels122,130and another conduit engagement groove27corresponding with the channels126,134. The conduit C engages the hook246,250, the shoe34, and the conduit engagement groove27of the roller26′ which fixes the position of the conduit C in a direction parallel to the housing axis38(seeFIG.1).

FIG.61illustrates a remote pendant346and a housing350with control electronics358operable to remotely control the bender assembly10,10′. In other embodiments (not shown), the remote pendant346and the control electronics358may be combined as a single structure.

The pendant346includes a trigger354which can be depressed to send a signal via a communication link (e.g., a wire362(illustrated as a light gauge cable for carrying a low voltage control signal)) to the control electronics358. The control electronics358receives the signal from the trigger354of the pendant346, receives power from an external source (through a heavy gauge cable for carrying higher voltages), and, based on the signal from the trigger354, provides power to the pipe threader182(through the heavy gauge cable). In the illustrated embodiment, the control electronics358include at least one transistor which outputs the signal based on the position of the trigger354. In other embodiments, the control electronics358may include a potentiometer or similar device to influence the output signal based on the position of the trigger354.

The wire362between the pendant346and the control electronics housing350is lightweight, coiled, and optionally has a stress reducing feature366. In the illustrated embodiment, with the lightweight wire362, the pendant346can be placed on the work surface W without falling from or otherwise moving on the work surface W. The wire362may have an outlet end370configured as a standard male audio jack such as a 3.5 mm audio jack, etc.

In some embodiments, the coiled segment374of the wire362shortens the length of the wire362when not tensioned while allowing an increased distance when tensioned from the control electronics housing350. In the illustrated embodiment, the un-coiled length (e.g., when under tension) of the wire362is about 6 feet and, when relaxed, about 4 or 5 feet long. Other lengths of wire362may also be appropriate.

As illustrated, the wire362includes a stress reducing feature366positioned adjacent the control electronics housing350and/or the outlet end370(as shown). The stress reducing feature366may reduce damage on the wire362due to tension, tensile stress, or other stresses.

The pipe threader182can be operated remotely from the bender assembly10,10′. In some embodiments, as illustrated inFIG.62, the pipe threader182has a trigger lock378operable to maintain a pipe threader trigger382in the engaged (i.e., “ON”) position. With the trigger lock378engaged, an operator can operate the trigger354of the pendant346remotely from the assembly10to supply power to the pipe threader182, turn the shoe34, and bend the conduit C between the hook146,150and the roller26.

As shown inFIGS.63-64, the shoe34has a radially-inner cylinder34aand a radially-outer cylinder34bconnected by ribs34c. The cylinders34a,34bdefine therebetween an annular space accommodating the structure and avoiding inhibiting operation of the drive mechanism178(e.g., the spur gear214and the ring gear218or another drive mechanism).

FIGS.65-66illustrate the housing14as having complementary inner and outer cylinders14a,14brotatably supporting the shoe cylinders34a,34b(seeFIGS.67-68) through bearings. The housing inner cylinder14agenerally defines the perimeter of the space242. The housing inner cylinder14aincludes a spindle surface14cdimensioned to correspond with the size of the shoe inner cylinder34a. As such, the shoe inner cylinder34ais operable to rotate about the spindle surface14cwhen the spur gear214and, thus, the ring gear218are rotated.

The relative size in diameter between the inner cylinder14aand the spindle surface14cdefine a thickness of the spindle wall. The illustrated spindle is relatively thin walled, thereby reducing the weight of the housing14. In the illustrated embodiment, the inner cylinder14ahas a diameter of between about 4 inches (in.) and about 6 in. (e.g., about 5.3 in.), and the spindle surface14chas a diameter of between about 5 in. and about 7 in. (e.g., about 6.1 in.). In the illustrated embodiment, the wall thickness is between about 0.1 in. and about 1.5 in. (e.g., about 0.4 in.). The ratio of the wall thickness to the radius of the inner cylinder14a(e.g., about 3.05 inches, as illustrated) is between about 1:12 and 1:2 (e.g., about 1:8). As illustrated, the wall thickness is about 13.1% of the radius, to avoid distortion under load.

In other constructions (not shown), the wall thickness may be decreased for a larger radius inner cylinder14aand may be increased for a smaller radius inner cylinder14a. The ratio of the wall thickness to the radius of the inner cylinder14amay be determined based on, for example, the material of the housing, expected loading, a desired factor of safety, the outer diameter of the spindle surface14c, and a variety of other factors.

With a large spindle surface14c, the hollow spindle defines a large open space242(e.g., as a storage compartment) and also reduces the weight of the housing14. The larger spindle also reduces the material and weight of the annular shoe34, eliminating excess material of the shoe34extending inwardly to the housing axis38. In the illustrated embodiment, the shoe34has an inner diameter generally corresponding to the outer diameter of the spindle surface14c(e.g., about 6.1 in.). The shoe34extends to an outer diameter of between about 10 in. and about 15 in. (e.g., about 12.9 in.). In the illustrated construction, the ratio of the diameter of the spindle surface14cto the diameter of the shoe outer surface is between about 1:4 to about 1:1.5 (e.g., about 1:2 as illustrated). As illustrated, the spindle diameter is about 45% to about 50% (e.g., about 47.29%) the outer diameter of the shoe34.

To, for example, maintain desired bending capabilities of 1″ EMT without changing the radius of the channel126, the ratio of the diameter of the spindle surface14cto the diameter of the shoe outer surface may be between about 1:1.7 and about 1:7.5. It should be understood, however, that other ratios may be possible.

The arrangement of the drive mechanism178(of the spur gear214and the ring gear218), the size of the shoe inner cylinder34aand the size of the housing inner cylinder14aallows for the space242to have a sufficient size for storage (e.g., to hold the remote pendant346, a power cord, other devices, supplies, etc.). In other constructions (not shown), the space242may accommodate other structure (e.g., a motor).

The structure of the hollow spindle/inner cylinder14amay reduce material of the housing14and allow the spindle to be made as a cast part (e.g., a cast aluminum housing14) compared to a separate shaft or tube. The illustrated roller support portion19is formed with the housing14. The inner cylinder14aand the support portion19are cast with the housing14and thereafter machined to have the desired precise dimensions. The inner cylinder14a and the support portion14are hard anodized. In the illustrated embodiment, the housing14is formed of cast A380-F aluminum.

In other embodiments, the housing14may be formed of a different material, such as, for example, A356-T6 aluminum, cast iron, a zinc-aluminum alloy (e.g., ZA-27), etc. A polymer spindle bearing may be used between the shoe34and the housing14. In other constructions (not shown), the housing14may include a smaller-diameter solid spindle.

In the illustrated construction, the shoe34and the housing14are connected for relative pivoting movement during bending operations but are otherwise fixed. In some embodiments (not shown), the shoe34may be removable from the housing14(e.g., for substitution with a different shoe34to bend different types of conduits C, for replacement of the shoe34/the housing14due to wear or damage, for transport/storage, etc.). In yet other embodiments (not shown), one or more portions of the shoe34(e.g., portions defining the channels122,126,130,134, the hooks150,154) may be removable and replaceable.

FIGS.18-19,63and69-71illustrate the drive assembly of the bender assembly10. In the illustrated embodiment, the drive assembly includes the primary adapter186, the shaft206, and the spur gear214, supported on the housing14, and the ring gear218fixed to the shoe34. The pipe threader182provides drive input to the adapter186, causing the shaft206and spur gear214to rotatably drive the ring gear218and the shoe34.

In other embodiments (not shown), the bender assembly10may include a different drive assembly for rotating the shoe34. Such other drive assemblies may include different gear assemblies (e.g., an external ring gear, bevel gears, a face gears, roller chains, etc.). As described above, an onboard motor and gearbox and power source may be housed within the space242.

The bender assembly10,10′ is configured to receive commands from an electronic controller of the control system to conduct a bending process. The unit is communicatively connected to the electronic controller via one or more communication links and, in this example, via a wired connection; however, in some embodiments, the bender assembly10,10′ may be communicatively connected over a wireless network or a short-range wireless connection.

The electronic controller includes a plurality of electrical and electronic components that provide power, operation control, and protection to the components and modules within the electronic controller. The illustrated electronic controller includes, among other things, an electronic processor (such as a programmable electronic microprocessor, microcontroller, or similar device), a memory, a communication interface, and a display. In some embodiments, the electronic controller is incorporated into the unit or may be a separate computing device, such as a laptop computer, a tablet computer, a smart phone, a smart watch, etc.

The memory is, for example, a non-transitory, machine-readable memory. The communication interface is communicatively connected to the bender assembly10,10′. The electronic processor is communicatively connected to the memory, and the communication interface. The memory includes a bender engine (for example, software or a set of computer-readable instructions that determines commands to be sent to the bender assembly10,10′).

The electronic controller may be implemented in several independent controllers each configured to perform specific functions or sub-functions. Additionally, the electronic controller may contain sub-modules that include additional electronic processors, memory, or application specific integrated circuits (ASICs) for handling communication functions, processing of signals, and application of the methods listed below. In other embodiments, the electronic controller includes additional, fewer, or different components.

The communication interface coordinates the communication of information between the electronic processor and the bender assembly10,10′. In the example illustrated, information received from the display is provided to the electronic processor to assist in determining what commands will be executed by the bender engine. The determined commands are then provided from the electronic processor to the communication interface where the commands are transmitted to the bender assembly10,10′. In other embodiments, the information received from the display may be provided without a display and may be, for example, transmitted from a remote server where the information is stored in a storage medium, such as a database.

The memory can include one or more non-transitory machine-readable media, and includes a program storage area and a data storage area. The program storage area and the data storage area can include combinations of different types of memory, as described herein. In some embodiments, data is stored in a non-volatile random-access memory (NVRAM) of the memory. Furthermore, in some embodiments, the memory stores predetermined factors with which to adjust commands for the bender assembly10,10′.

The control system may include a user interface provided on a display to operate with the bender assembly10,10′ with various parameters (set bend angle, current bend angle, etc.) being output/displayed to an operator and various inputs (e.g., bend angle, type of bend, start/stop operation, etc.) being received from the operator.

The embodiment(s) described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present disclosure. As such, it will be appreciated that variations and modifications to the elements and their configuration and/or arrangement exist within the spirit and scope of one or more independent aspects as described.