Electrical probe and associated method

An electrical probe and associated method are provided to establish electrical contact with a wire. The electrical probe includes an elongate member extending between opposed first and second ends, and first and second needles connected to the elongate member and extending beyond the first end of the elongate member. The electrical probe also includes first and second conductors electrically connected to the first and second needles, respectively, and extending along the elongate member. The electrical probe also includes a bumper stop connected to the elongate member proximate the first end of the tube. Further, the electrical probe includes a movable engagement member extending lengthwise along the elongate member. The moveable engagement member includes a hook that extends beyond the first end of the elongate member and beyond the first and second needles. The hook may include a terminal portion configured to contact the bumper stop.

TECHNOLOGICAL FIELD

Embodiments of the present disclosure relate generally to an electrical probe and, more particularly, to an electrical probe and an associated method for penetrating a wire with first and second needles in order to reliably establish electrical contact therewith.

BACKGROUND

In a number of instances, it is desirable to establish electrical contact with a wire. For example, in applications that include a relatively large number of wires, it may be desired to establish electrical contact with a wire in order to identify the wire and to distinguish the wire from all other wires. Additionally, electrical contact may be established with wires in order to test the wires, such as by performing various electrical diagnostic and functional tests, such as measurements of the resistance of the wire, the voltage on the wire, etc., to replace a damaged wire or the like.

In order to make electrical contact with a wire, wires have conventionally been cut and the insulation covering the wire has then been stripped in order to access and make electrical contact with the wire. As will be apparent, this technique is quite invasive and requires physical access to receive. In some instances, wiring may be positioned in an area that is difficult to access. For example, wiring may extend through a cavity that is relatively small and deep, thereby significantly limiting the accessibility of a wire. In order to access and then make contact with a wire that is disposed in a region of limited accessibility, disassembly, sometimes on a large scale, may be required in order to provide increased accessibility to the wire so as to allow electrical contact to be established with the wire. Such disassembly may disadvantageously introduce delays and increase costs and, in some instances, may necessitate retesting to ensure that the assembly remains operational following the disassembly and subsequent re-assembly.

Establishing contact with a wire, such a wire disposed within a region of limited accessibility may be particularly challenging in instances in which the wire has a smaller gauge, such as 24 American wire gauge (awg) or thinner wires. In this regard, the reliable establishment of electrical contact with smaller wires may prove to be more difficult, particularly in regions of limited accessibility.

BRIEF SUMMARY

An electrical probe and associated method are provided according to an embodiment of the present disclosure in order to facilitate the establishment of electrical contact with a wire, such as for identifying the wire, testing the wire or the like. Although the electrical probe may establish contact with wires of any size, the electrical probe and associated method of one embodiment are configured to facilitate the establishment of electrical contact with smaller gauge wires, such as 24 awg wire. Additionally, while the electrical probe may establish contact with a wire in any of a number of different environments, the electrical probe and associated method of one embodiment are advantageously capable of establishing verifiable electrical contact with a wire that is disposed within a region of a limited accessibility.

In one embodiment, an electrical probe is provided that includes a tube formed, for example, of a non-conductive material extending between opposed first and second ends, first and second needles operably connected to the tube and extending beyond the first end of the tube and a bumper stop operably connected to the tube proximate the first end of the tube. The electrical probe of this embodiment also includes a moveable engagement member extending through the tube. The moveable engagement member includes a hook that extends beyond the first end of the tube and beyond the first and second needles. The hook includes a terminal portion configured to operably contact the bumper stop, thereby limiting retraction of one moveable engagement member relative to the tube.

The electrical probe of one embodiment may also include first and second conductors electrically connected to the first and second needles, respectively, and extending along the tube. In one embodiment, the bumper stop extends beyond the first end of the tube. In this embodiment, the first and second needles and the bumper stop are operably connected to the tube such that the first and second needles extend beyond the bumper stop. The electrical probe of one embodiment may also include a spring positioned proximate the second end of the tube and configured to draw the hook into operable engagement with the bumper stop. In this regard, the movable engagement member may include a plunger with the spring being positioned between the plunger and the second end of the tube. The electrical probe of this embodiment may also include an adjustment member that is adjustably positioned between the tube proximate the second end such that the spring extends between the plunger and the adjustment member.

In another embodiment, an electrical probe is provided that includes an elongate member extending between opposed first and second ends, and first and second needles operably connected to the elongate member and extending beyond the first end of the elongate member. The electrical probe of this embodiment also includes first and second conductors electrically connected to the first and second needles, respectively, and extending along the elongate member. The electrical probe also includes a bumper stop operably connected to the elongate member proximate the first end of the tube. Further, the electrical probe of this embodiment includes a movable engagement member extending lengthwise along the elongate member. The moveable engagement member includes a hook that extends beyond the first end of the elongate member and beyond the first and second needles. In one embodiment the hook may include a terminal portion configured to operably contact the bumper stop.

In one embodiment, the bumper stop extends beyond the first end of the elongate member. In this embodiment, the first and second needles and the bumper stop are operably connected to the elongate member such that the first and second needles extend beyond the bumper stop. The electrical probe of one embodiment may also include a spring positioned proximate the second end of the elongate member and configured to draw the hook into operable engagement with the bumper stop. In this regard, the movable engagement member may include a plunger with the spring being positioned between the plunger and the second end of the elongate member. The electrical probe of this embodiment may also include an adjustment member that is adjustably positioned between the elongate member proximate the second end such that the spring extends between the plunger and the adjustment member.

A method is provided according to yet another embodiment that includes actuating a movable elongate member of an electrical probe relative to an elongate member such that a hook proximate one end of the moveable engagement member extends and provides access to first and second needles that are operably connected to and extend beyond a first end of the elongate member. The method of this embodiment also positions the electrical probe such that a wire is positioned proximate to the first and second needles. The moveable engagement member is then retracted relative to the elongate member such that the hook contacts the wire and urges the first and second needles to penetrate the wire. The method of this embodiment also prevents further retraction of the moveable engagement member relative to the elongate member as a result of contact by a terminal portion of the hook with a bumper that is operably connected to the elongate member proximate to the first end of the elongate member.

In one embodiment, the method also establishes electrical contact with the first and second needles via first and second conductors, respectively, that extend along the elongate member. The method of this embodiment may also include electrically testing the wire via the first and second conductors and the first and second needles. In one embodiment in which the elongate member comprises a tube through which the moveable engagement member extends, actuation of the moveable engagement member includes sliding the moveable engagement member in a first direction through the tube, while retracting the moveable engagement member comprises sliding the moveable engagement member in a second direction, opposite the first direction, through the tube. In one embodiment in which a spring is positioned proximate a second end of the elongate member, opposite the first end, retraction of the moveable engagement member includes biasing the moveable engagement member with the spring so as to retract relative to the elongate member. In this embodiment, the moveable engagement member may include a plunger with the spring being positioned between the plunger and the second end of the elongate member such that actuation of the moveable engagement member may include depression of the plunger relative to the elongate member.

In accordance with embodiments of the electrical probe and associated method, verifiable establishment of contact with a wire is facilitated, even in instances in which the wire is small and disposed in a region having limited accessibility. However, the features, functions and advantages that have been discussed may be achieved independently in various embodiments of the present disclosure may be combined in yet other embodiments, further details of which may be seen with reference to the following description and drawings.

DETAILED DESCRIPTION

As shown inFIG. 1, an electrical probe10in accordance with one embodiment is configured to establish electrical contact with a wire12. In one embodiment the electrical probe10is configured to establish electrical contact with wires of a relatively small gauge, such as 24 AWG. However, the electrical probe10may establish electrical contact with wires of any size and any gauge. The wire12is generally insulated so as to include a conductor surrounded by an insulating coating. The electrical probe10may be configured to contact other types of wires, such as uncoated wires, if so desired.

The electrical probe10is configured to establish electrical contact with wires12in a variety of environments or situations. As shown inFIG. 1, however, the electrical probe10may advantageously establish electrical contact with wires12that are disposed within regions of limited accessibility, such as wires disposed within cavities14that are relatively small and deep or that otherwise have limited accessibility. By permitting electrical contact to be established with wires12within these regions of limited accessibility, the electrical probe10and associated method of one embodiment may permit wires to be identified without requiring any significant disassembly, therefore avoiding the time delays and costs associated with such disassembly.

As shown inFIG. 2A, the electrical probe10of one embodiment includes an elongate member16extending between opposed first and second ends18,20. In the illustrated elongate member, the elongate member16is a tube that defines an internal passage that extends between the opposed first and second ends18,20. The elongate member16may have a length that is selected based upon the reach that is desired for the electrical probe10. In this regard, an electrical probe10that is designed to establish electrical contact with wires12disposed within a cavity14having a depth of 12 inches may have a length of about 14 inches in order to allow the electrical probe to comfortably access the wire. However, the elongate member10may be longer or shorter in other embodiments depending upon the environment intended to be serviced. The elongate member16, such as the tube, may generally formed of a non-conductive material, such as a Delron® material. Alternatively, the elongate member16may be formed of a conductive material, such as brass. In an instance in which the elongate member16is formed of a conductive material, the elongate member may also include an insulative coating, such as an insulative shrink sleeve that covers the conductive material, or the conductors24that extend along the elongate member and are described below may include an insulative coating so as to be electrically isolated from the elongate member.

As shown inFIG. 2A, and, in more detail inFIG. 2B, the electrical probe10includes a plurality of needles22, such as first and second needles positioned proximate the first end18of the elongate member16. The needles22are formed of a conductive material, such as steel, and have a pointed end. In one embodiment, the first and second needles22are sewing needles. The needles22may be attached to the elongate member in various manners including, for example, by an epoxy adhesive. Regardless of the manner in which the needles22are attached to the elongate member16, the pointed ends of the needles extend beyond the first end18of the elongate member. Although the needles22may extend beyond the first end18of the elongate member16by the same distance, the needles are advantageously spaced from one another by predetermined spacing, such as between about 5 and 8 mils.

The electrical probe10may also include conductors24that are attached at one end to respective ones of the needles22and that extend lengthwise along the elongate member16. The conductors24are generally relatively small, such as 24 awg sense wires, and may include an insulative coating, at least on that portion of the conductors that extend along the elongate member.

The electrical probe10also includes a mechanical bumper stop26positioned proximate the first end18of the elongate member16and also proximate the needles22. In the illustrated embodiment, the bumper stop26is attached to the first end18of the elongate member16so as to extend beyond the elongate member. However, the needles22advantageously extend further beyond the first end18of the elongate member16than the bumper stop26. As shown in the illustrated embodiment, the bumper stop26may be operably attached to the first end18of the elongate member16so as to be positioned between the needles22. The bumper stop26may also be attached to the first end18of the elongate member16in a variety of manners including, for example, by an adhesive. Additionally, a non-conductive sleeve28, such as a sleeve formed of a heat shrinkable material, such as Kynar® shrink sleeving, may surround the elongate member16and the conductors24as well as those portions of the needles22and bumper stop26that are operably attached to the elongate member. The shrink sleeve may therefore serve to maintain the conductors24in position relative to the elongate member16, and may also serve to further secure at least the bumper stop26to the elongate member.

The electrical probe10can also include a movable engagement member30as shown inFIGS. 3A and 3B. The movable engagement member30may be formed in various manners, but, in one embodiment, is formed of rod wire, such as steel. The movable engagement member30extends lengthwise along the elongate member16and protrudes beyond the first end18of the elongate member. In the embodiment in which the elongate member16is comprised of a tube, the movable engagement member30is advantageously sized such that the movable engagement member extends through the tube from one end of the tube to the other. The movable engagement member30includes a hook32proximate one end. As shown inFIGS. 4A and 4B, the movable engagement member30is positioned relative to the elongate member16such that the hook32extends beyond the first end18of the elongate member and beyond the needles22. In this regard, the hook32is shaped so as to extend over and about the pointed ends of the needles22. The hook32has a terminal portion34that is configured to operably contact the bumper stop26so as to limit the retraction of the hook relative to the elongate member16. As shown, the hook32is spaced from the pointed ends of the needles22by a predefined distance in an instance in which the terminal portion34of the hook operably contacts the bumper stop26. The predefined distance by which the hook32is spaced from the pointed ends of the needles22is advantageously no larger than the diameter of the largest wires12to be inspected by the electrical probe10and, more particularly, is generally somewhat smaller than the largest wires to be inspected by the electrical probe.

Opposite the hook32, the movable engagement member30may include a plunger36or other head. The electrical probe10may also include a spring38positioned between the second end20of the elongate member16and the plunger36or other head of the movable engagement member30. The spring38biases the plunger36or other head of the movable engagement member30such the movable engagement member is positioned relative to the elongate member16such that the terminal portion34of the hook32is moved into operable contact with the bumper stop26in the absence of other forces, such as a wire12disposed between the hook and the needles22. In the illustrated embodiment, the electrical probe10also includes an adjustment member40that is adjustably positioned upon the elongate member16proximate the second end20of the elongate member. In the embodiment in which the elongate member16is a tube, the portion of the tube proximate the second end20may be threaded such that the adjustment member, such as a nut, may be threadably positioned relative to the second end of the tube. In this embodiment, the spring38extends between the plunger36or other head of the moveable engagement member30and the adjustment member40in order to bias the movable engagement member relative to the elongate member16. By controllably positioning the adjustment member40in a lengthwise direction relative to the elongate member16, the tension or force applied by the spring may be controlled in order to draw the movable engagement member30rearward relative to the elongate member such that the terminal portion34of the hook32operably contacts the bumper stop26.

In operation, the electrical probe10may be positioned relative to a wire12to be identified inspected, tested or the like such that the wire is proximate the first end16of the elongate member16. As shown in operation50ofFIG. 6, the plunger36may be actuated, such as by being depressed or otherwise urged towards the second end20of the elongate member16, such that the hook32extends further from the first end18of the elongate member and a space is opened between the pointed ends of the needles22and the hook. The elongate probe10may be further positioned relative to the wire12such that the wire is positioned so as to extend within the hook32and across the needles22, as shown inFIG. 5Aand in operation52ofFIG. 6. The plunger36may then be released such that the spring38retracts the movable engagement member30relative to the elongate member16. See operation54ofFIG. 6. In this regard, the hook32pulls the wire12towards the first end18of the elongate member16such that the pointed ends of the needles22pierce the insulative coating of the wire and penetrates the conductive member of the wire, thereby establishing electrical contact between the conductive member of the wire and the needles, as shown in operation56ofFIG. 6. See alsoFIG. 5Band, in more detail,FIG. 5C. The retraction of the movable engagement member30relative to the elongate member16is limited, however, by the operable contact or the terminal portion34of the hook30with bumper stop26. See operation58ofFIG. 6. By limiting the retraction of the movable engagement member30relative to the elongate member16, the electrical probe10of one embodiment may insure that the needles22penetrate the conductive member42of the wire12, but do not extend through the conductive member into the insulative member44on the far side of the wire or even further, as shown inFIG. 5C.

As such, electrical contact is established in a reliable fashion with the wire12. In this regard, electrical contact may be established with the wire12via the needles22and the conductors24that extend lengthwise along the elongate member16. Since the electrical probe10includes two or more needles22that are spaced apart from one another and that each make electrical contact with the wire12, it may be initially verified that the needles have made electrical contact with the wire, since the wire may be located within a cavity or other region of limited accessibility such that it may not be practical to visually confirm that the needles have each made contact with the wire. In this regard, a current may be passed through the conductors24from one needle22to the other needle such that the electrical conductivity and/or resistivity may be measured. Based on the conductivity and/or resistivity measurement, the needles22may be verified to have established electrical contact with the same wire12. The wire12may then be identified or tested in a variety of fashions including continuity measurements, resistance measurements and/or voltage measurements utilizing current passed through either one or both needles24. See operation60ofFIG. 6. For example, resistance may be determined via Ohms law by applying a small current via the conductors24and, in turn, the pair of needles22. By increasing the amperes of the current that is provided via the conductors24, the accuracy of the resistance measurement increases and the resistance reading could be utilized to determine the wire length if multiple wires in the same harness routing path have different juncture points. The electrical probe10may be employed for other electrical diagnostic test procedures including circuit/signal monitoring, two-point resistance measurement, four-wire milli-ohm resistance measurements, voltage sense and the like. Once the wire12has been appropriately identified or otherwise tested, the process may be reversed. In this regard, the plunger36may be depressed such that the hook32is again spaced further from the first end18of the elongate member16and from the needles22. The electrical probe10may then be disengaged from the wire12and the electrical probe withdrawn or otherwise moved so as to engage another wire.

As a result of the length of the electrical probe10, the electrical probe may reliably identify and test wires12that are in regions that are relatively inaccessible, such as wires that are disposed within relatively small and deep cavities as shown inFIG. 1. In this regard, the electrical probe10may have any desired length depending upon the location of the wires12to be identified and tested. In one embodiment, however, the elongate probe10is about 14 inches in length.