Abstract:
An improved banana jack adapter assembly is provided for use in connection with a test switch in a utility meter application. The banana jack adapter assembly improves connectability of testing equipment to a meter box test switch when a field operator desires to calibrate a meter of a utility box.

Description:
FIELD OF THE INVENTION 
       [0001]    An apparatus and method for aiding and conducting tests on utility devices and, more particularly, an improved banana jack adapter for use with a test switch that is in a utility meter box. 
       BACKGROUND AND BRIEF SUMMARY OF THE INVENTION 
       [0002]    It is well known to provide a meter box at various residential and commercial locations. A typical utility meter box assembly includes a test switch and a meter and the meter provides the function of measuring the amount of kilowatts that is being used by the consumer. Because the meter is an electromechanical device, it requires routine maintenance in order to assure the meter is operating properly and also to make certain it is properly calibrated. If the meter is not properly calibrated, then the utility company could be wasting energy and resources and reducing profits. 
         [0003]    There are various methods of calibrating a meter in the field in order to assure it is properly functioning. One such example is to provide a test switch, which is placed in communication with the meter. The test switch provides easy multi-circuit testing of switchboard relays, meters and other instruments that may be present in the meter box. 
         [0004]    Traditionally, a test switch includes a test switch ear that is nothing more than a post for a temporary attachment of alligator style test clips to a stud of the test switch. The alligator style test clips, once connected to the ear, allow an outside testing device, such as a voltage flow diagnostic tool, to be connected to the meter where diagnostic tests can be performed. The problem with the traditional test switch ear is that in use the alligator style test clips can be accidentally bumped, thus causing the clip to short against adjacent electrical components or even to become entirely dislodged from the ear. Such an event can be dangerous as up to 480 volts can run through the switch at any given time. If the alligator clip becomes dislodged, it could also cause an operator to become injured. Further, the test switch and the surrounding enclosure could be damaged if the alligator clips are somehow shorted against other switches that are within the switch housing. Also, there are other inefficiencies such as loss of employee time if the alligator clips disengage from the traditional test switch ear as it may require the operator to reconnect the alligator clips to the test ear. 
         [0005]    Thus, it would be desirable to provide an improved adapter for test switches that are used with utility boxes. It would also be desirable to provide an adapter for use with test switches that is operable to be utilized with banana jack style assemblies which in turn can be connected to test equipment. 
         [0006]    One such example includes a test jack adapter for use with a test switch, which can be used with a utility meter box. The adapter includes a bracket made of conductive material that is operable to be secured to a switch stud, an elongated hollow body that is made of conductive material, an insulated washer that slides over the elongated hollow body, an insulated member that is operable to receive a portion of the insulated washer, and a nut for securing the elongated hollow body to the bracket. It will be appreciated that the test jack adapter can be part of a test switch assembly that may have a test switch cover. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0007]      FIG. 1  illustrates a perspective view of a meter box for use in connection with a utility application; 
           [0008]      FIG. 2  illustrates a partially exploded view of a test switch with its cover removed, and a banana jack test cord is shown connecting the switch to test equipment; 
           [0009]      FIG. 3  illustrates an enlarged view taken from circle  3 , of  FIG. 2 ; 
           [0010]      FIG. 4  illustrates a perspective view of a single test switch, showing the banana jack adapter; 
           [0011]      FIG. 5  illustrates an exploded view of the banana jack adapter assembly; and 
           [0012]      FIG. 6  illustrates the banana jack adapter assembly with a banana jack that can be connected to said assembly. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0013]      FIG. 1  illustrates a meter box assembly  10  having a meter box  12 , a meter  14  and a test switch  16 . The test switch  16  assembly is shown in phantom because the lid of the meter box  12  is shown in a closed position. A latch  18  serves to close and help seal the meter box assembly  10  and keep intruders from the interior of the meter box  12 . 
         [0014]    The meter box  12  includes a top panel  20 , side panels  22  and  24 , a lower or bottom panel  26 , and a back panel  28 . The box  12  is preferably made of heavy gauge steel. The box includes mounting features for securely mounting the box  12  in residential and commercial settings. It will be appreciated that the meter box assembly  10  can be used in various utility settings, and is not limited to electrical utility applications, for example, wherever a utility application may utilize a test switch. The improvements herein are contemplated to be utilized. 
         [0015]    The test switch  16  is connected to the meter  14  and the meter  14  is operable to transmit signals  30  to an outside sensor node that may be remote from the meter box assembly  10 . Thus, the meter box assembly  10  is contemplated to be utilized where it is desired to transmit signals via telemetry, or other measures, which in turn may be picked up by a network where the signal can be received and processed. 
         [0016]    With reference to  FIG. 2 , the test switch assembly  16  includes a cover  34 , a switch housing  36 , a non-conductive barrier  38  and a plurality of individual test switches  40 . It will be appreciated that while the present example discloses ten test switches  40  ganged in a common switch housing  36 , other quantities of test switches  40  can be arranged, depending upon the desire and the current needs of a utility. 
         [0017]    With reference to  FIGS. 2 and 3 , the switch housing  36  is preferably made of non-conductive polymer material and is sufficiently rigid and durable to properly support each of the switches  40 . The switch housing  36  includes a plurality of studs  42 , one for each of the test switches  40 . The stud  42  extends up through or is formed as a part of the base of the switch housing  36  and provides a mounting member for each banana jack adapter assembly to be secured thereto. The stud  42  in the present embodiment is threaded which permits a nut  44  to rigidly mount each banana jack adapter assembly  46  to each such stud  42 . The switch housing  36  further includes a mounting member  48  with an upwardly extending threaded portion  50  for receiving wing nuts  52 . The threaded portion  50  extends through an opening  54  of the cover  34 . The cover  34  preferably is made of nonconductive polymer material and is sufficiently rigid to withstand the environmental conditions to which it is exposed. The cover is of traditional size and has not been specially configured to accommodate the improved banana jack adapter assemblies  46 . The banana jack adapter assembly  46  can be retro-fit to an existing test switch assembly  16 . A kit of banana jack assemblies  46  could be sold or provided where a number of assemblies  46  can be provided that are equivalent to the number of test switches  40  that are housed within the test switch assembly  16 . 
         [0018]    With continued reference to  FIG. 2 , the test switch assembly  16  is shown connected to testing equipment  56  via a banana jack test cord  58 . The test cord has banana jacks  60  at both ends thereof. This allows a field technician to easily connect the testing equipment  56  to a test switch  40  so that the testing of the meter  14  can be performed. The cover  34  is removed from the switch housing  36  during these testing operations. It will be appreciated that a plurality of cords  58  may be provided for connecting the test equipment  56  to a number of test switches  40 . 
         [0019]      FIG. 3  illustrates an enlarged perspective view of several test switches  40  that have been positioned on the switch housing  36 . It will be appreciated that each test switch  40  has a stud  42  and a nut  44 .  FIG. 3  illustrates a banana jack adapter assembly  46  mounted to a corresponding switch stud  42  of one of the switches  40 . It will be appreciated that a banana jack assembly  46  may be employed with each individual test switch  40 , or as is desired by the utility. Alternatively, an assembly  46  may be used on only certain test switches, which is what is shown in  FIG. 3 . The banana jack adapter assembly  46  operates to replace a test switch ear by now providing a more positive connection arrangement that is operable to receive one end of the banana jack test cord  58  (shown in  FIG. 2 ). 
         [0020]      FIG. 4  illustrates a perspective view of one improved test switch  40  and its various components. Each test switch  40  includes a molded polymer base  62 , a plastic handle  64 , a metal switch blade  66 , a metal hinge jaw  68 , a metal contact jaw  70 , and the banana jack adapter assembly  46  that is secured to the switch stud  42  by a nut  44 . The test switch  40  also may include a test ear  72  at a location on the base  62  that is opposite the adapter assembly  46 . 
         [0021]    With reference to  FIG. 5 , an exploded view of the banana jack adapter assembly  46  is depicted. The banana jack adapter assembly  46  includes a Z-shaped metal bracket  74 , an elongated threaded body  76 , a nut  78 , an insulated washer  80 , and an insulated head or guide bushing  82 . The components share a common central axis to which they are axially aligned. Collectively these components mate together to form a rigid structure that is sufficiently rigid  50  as to allow a technician to insert a jack  60  axially, relative to the central axis, without much movement. Thus, the assembly is robust so as to provide a positive connection point for a field technician to insert and easily remove a test cord  58  having a banana jack. 
         [0022]    The Z-shaped bracket  74  could also be L-shaped or other geometric configurations, and is preferably made of highly conductive material such as, but not limited to, copper. The bracket  74  includes a first portion  84 , a vertically extending second portion  86  and a horizontally extending third portion  88 . The first  84  and third  88  portions have a apertures  90  and  92 . The aperture  90  has a diameter sufficiently large to receive the outside diameter  94  of the threaded body  76 . Thus, the threaded body  76  can pass through the first portion  84 . The aperture  92  is sufficiently large to receive the switch stud  42 . The insulated washer  80  has an inside diameter  96  that is operable to receive the outside diameter  94  of the threaded body  76 . The insulated washer  80  further has a first outside diameter  98  and a second outside diameter  100 , thus creating a stepped type configuration for receiving a corresponding stepped type female configuration  102  that is found on the underside of the guide bushing  82 . The guide bushing  82  has internal threads  104  that are operable to receive threads  106  of the threaded body  76 . Thus, the nut  78  and the guide bushing  82  tend to thread towards one another, thus causing the threaded body  76  to be sandwiched and firmly secured to the first portion  84  of the bracket  74 . It will be appreciated that the bracket  74  can take on other geometric configurations, apart from those exemplaries shown herein. It will also be appreciated that the bushing  82  and washer  80  could be a single component. 
         [0023]      FIG. 6  illustrates the banana jack assembly  46  shown assembled with a banana jack assembly  60  ready to be deployed into the banana jack assembly  46 . The centerlines of the banana jack assembly  60  and the adapter assembly  46  are aligned. The banana jack assembly  60  includes a test cord  58  extending from a housing  108  that is preferably made of molded plastic. A male member  110  extends from the housing  108  and a plurality of pliable members  112  are provided for engagement with an internal diameter  114  of the threaded body  76 . As the jack assembly  60  enters the adapter assembly  46 , the pliable members  112  engage the internal diameter of the guide bushing  82  as they traverse downwardly into the threaded body  76 . This arrangement creates a strong positive electrical connection between the banana jack assembly  60  and the bracket  72  which in turn is connected to a particular test switch  40 . 
         [0024]    It will be appreciated that the adapter assembly  46  could encompass other configurations. For example, the bracket  74  could be made of an extruded member, with an internal bore for receiving the male member  110  of the banana jack assembly  60 . Further, it is contemplated that the body  76  could be press fit within, or relative to, the bracket  74  so as to create a press fit arrangement between these two components, thus removing the need for some of the other aforementioned components that have been employed for securing the member  76  to the bracket  74 . It will be appreciated that other arrangements are contemplated for providing an improved test switch ear that is operable to receive a banana jack assembly  60 . 
         [0025]    It will be appreciated that the aforementioned process and devices may be modified to have some steps or features removed, or may have additional steps or features added, all of which are deemed to be within the spirit of the disclosure. Even though the disclosure has been described in detail with reference to specific embodiments, it will be appreciated that various modifications and changes can be made to these embodiments without departing from the scope of the present invention as set forth in the claims. Accordingly, the specification and the drawings are to be regarded as an illustrative thought instead of merely a restrictive thought of the scope of the disclosure.