Patent Publication Number: US-11024992-B2

Title: Tap clamp

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of prior-filed, co-pending U.S. patent application Ser. No. 16/323,141, filed on Feb. 4, 2019, which is a 371 of PCT/US2017/045235, filed on Aug. 3, 2017, which claims priority to Provisional Patent Application No. 62/370,918, filed Aug. 4, 2016, the entire contents of all are hereby incorporated by reference. 
    
    
     BACKGROUND 
     The present disclosure relates to connectors for electrical conductors, and particularly to conductor tap clamps. 
     SUMMARY 
     Conductor tap clamps are hot line connectors for providing electrical communication with or tapping a into main power line. In some applications, conductor tap clamps attach a first conductor to a second, energized, conductor engaged with a transformer. 
     In one aspect, a clamp for providing electrical communication between a first conductor and a second conductor includes a first housing portion having a first surface, a second surface, a first housing bore, and a cavity, the first housing bore extending along a longitudinal axis. The clamp further includes a clamp member at least partially disposed within the cavity of the first housing portion, the clamp member including a first clamp surface adjacent the second surface of the housing in a facing relationship. The clamp further includes a shaft oriented parallel to the longitudinal axis, the shaft coupling the first housing portion and the clamp member. The clamp further includes a second housing portion movably coupled to the first housing portion by the shaft, the second housing portion including a second housing bore and a second clamp surface, the second housing bore aligned with the longitudinal axis, the second clamp surface adjacent the first surface of the first housing portion in a facing relationship. 
     In another aspect, a method is provided for providing electrical communication between a first conductor and a second conductor. The method includes positioning the first conductor between a first surface of a first housing portion and a first clamp surface of a second housing portion; positioning the second conductor between a second surface of the first housing portion and a second clamp surface of a clamp member; actuating a shaft against a force of a biasing member to increase a distance between the first housing portion and the second housing portion to load the first conductor between the first surface of the first housing portion and the first clamp surface of the second housing portion; releasing the shaft to secure the first conductor between the first surface of the first housing portion and the first clamp surface of the second housing portion; actuating the shaft extending through the first housing portion, the second housing portion, and the clamp member to decrease a distance between the second surface of the first housing portion and the second clamp surface of the clamp member to secure the second conductor between the second surface of the first portion of the housing and the second clamp surface of the clamp member. 
     In yet another aspect, a clamp for providing electrical communication between a first conductor and a second conductor includes a first housing portion, a second housing portion, and a shaft. The first housing portion includes a first surface and a first housing bore extending along a longitudinal axis. The second housing portion includes a second surface and a second housing bore aligned with the longitudinal axis, the second clamp surface adjacent the first clamp surface in a facing relationship to cooperatively form a channel therebetween. The channel is configured to receive the first conductor. The shaft is oriented parallel to the longitudinal axis. The shaft couples the first housing portion and the second housing portion. The shaft is operable to change a spacing between the first surface and the second surface. 
     Other aspects will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a clamp engaged with a first conductor and a second conductor. 
         FIG. 2  is an exploded view of the clamp of  FIG. 1 . 
         FIG. 3  is a side view of a main housing. 
         FIG. 4  is a first end view of the main housing of  FIG. 3 . 
         FIG. 5  is a second end view of the main housing of  FIG. 3 . 
         FIG. 6  is a side view of a gripper. 
         FIG. 7  is a perspective view of a keeper. 
         FIG. 8  is a section view of the clamp of  FIG. 1  viewed along section  8 - 8 , with the first conductor and second conductor removed. 
         FIG. 9  is a section view of the clamp of  FIG. 1  engaged with the first conductor and viewed along section  9 - 9 . 
         FIG. 10  is a section view of the clamp of  FIG. 1  engaged with the first conductor and the second conductor and viewed along section  9 - 9 . 
     
    
    
     DETAILED DESCRIPTION 
     Before any embodiments are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “mounted,” “connected” and “coupled” are used broadly and encompass both direct and indirect mounting, connecting and coupling. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include electrical or hydraulic connections or couplings, whether direct or indirect. Also, electronic communications and notifications may be performed using any known means including direct connections, wireless connections, etc. 
       FIG. 1  illustrates a clamp  10  for electrically connecting a first conductor  14  and a second conductor  18 . In the illustrated embodiment, the clamp  10  is a tap clamp or a hot line clamp, and the clamp  10  includes a first housing portion or main housing  22 , a second housing portion or gripper  26 , a clamp member or keeper  30 , a linear actuator  34 , a resilient member  38  ( FIG. 2 ), and a nut  42  ( FIG. 2 ). 
     As shown in  FIGS. 2-5 and 8 , the main housing  22  includes a first bore or main housing bore  46 , a first channel  50  ( FIG. 4 ), a second channel  54  ( FIG. 5 ), a first surface  58 , and a second surface  62 . In the illustrated embodiment, the main housing  22  is made from a conductive material; in other embodiments, only a portion of the main housing  22  is made from a conductive material. As shown in  FIG. 3 , the main housing bore  46  extends along a longitudinal axis  66 . 
     As shown in  FIG. 4 , the first channel  50  is adjacent the housing bore  46  and aligned along the longitudinal axis  66 . In the illustrated embodiment, the first channel  50  is substantially U-shaped, although the first channel may have a different shape in other embodiments. The first channel  50  is positioned between a first upper surface  86 , a second upper surface  90 , and a wall  92 . In the illustrated embodiment, a first track  78  and a second track  82  extend along the sides of the first channel  50 , adjacent the upper surfaces  86 ,  90 . The first track  78  and the second track  82  are spaced apart laterally from one another across the longitudinal axis  66  and extend along a length of the first channel  50 , parallel to the longitudinal axis  66 . The first track  78  is positioned opposite the first upper surface  86  and the second track  82  is positioned opposite the second upper surface  90 . In other embodiments, the main housing  22  may include fewer or more tracks, and the tracks may be positioned in a different manner. 
     As best shown in  FIG. 8 , the second channel  54  is spaced from the first channel  50  and extends in a direction generally parallel to the longitudinal axis  66 . In the illustrated embodiment, the second channel  54  has a generally circular shape and extends between a rear wall  110  and an end surface  112  ( FIG. 3 ) that is oriented at an angle relative to the longitudinal axis  66 . As discussed in further detail below, the second channel  54  is sized to receive at least a portion of the gripper  26 . 
     Referring again to  FIG. 5 , in the illustrated embodiment the first surface  58  includes an upper portion  114  and a lower portion  118  and is positioned adjacent the second channel  54 . The upper portion  114  is formed as a bore extending along a first axis  126  that is substantially perpendicular to the longitudinal axis  66 . The upper portion  114  and the lower portion  118  are aligned along the first axis  126 . The upper portion  114  and the lower portion  118  are sized to receive the first conductor  14  ( FIG. 1 ). In other embodiments, the first surface  58  may be formed in another shape, such as a partially curved or non-enclosed surface. 
     As shown in  FIG. 3 , the second surface  62  is positioned between an inclined surface  130  of the main housing  22  and the upper surfaces  86 ,  90 . The second surface  62  is a curved surface and is sized to receive a portion of the second conductor  18  ( FIG. 1 ). In the illustrated embodiment, the second surface  62  extends along a direction that is substantially perpendicular to both the first surface  58  and the longitudinal axis  66 , and partially defines a passage for the second conductor  18  ( FIG. 10 ). In other constructions, the second surface  62 , the first surface  58 , and the longitudinal axis  66  may have a different geometric relationship. For example, the first surface  58 , the second surface  62 , and the longitudinal axis  66  may be formed at an angle relative to one another, but not mutually perpendicular. 
     As shown in  FIGS. 6 and 8 , the gripper  26  includes an aperture  134 , a first portion  138 , a surface  142  ( FIG. 6 ), a second portion  146 , and a gripper channel or cavity  150  ( FIG. 8 ). The aperture  134  is aligned along the longitudinal axis  66 . In the illustrated embodiment, the surface  142  ( FIG. 2 ) is curved and cooperates with the first surface  58  of the main housing  22  ( FIG. 2 ) to form a passage for receiving the first conductor  14 . The second portion  146  may have a profile that complements the profile of the housing end surface  112 . For example, in the illustrated embodiment the second portion  146  includes peripheral surfaces  162  that are inclined to mate with the end surface  112  of the second channel  54 . 
     As shown in  FIG. 8 , the cavity  150  is aligned with the aperture  134  along the longitudinal axis  66 . The cavity  150  receives the nut  42 . A rear wall  170  of the cavity  150  forms a seat abutting the nut  42  and provides a reaction surface. In the illustrated embodiment, the nut  42  has a non-circular cross section. The cavity  150  may have a non-circular cross section in a similar shape as the nut  42  so that the nut  42  does not rotate with respect to the gripper  26 . The nut  42  is secured to (e.g. by in-casting, peening, or welding) or axially fixed with respect to the gripper  26 . In other embodiments, the nut may have a circular or round cross-section. 
     As shown in  FIG. 7 , the keeper  30  includes a first portion  174  and a second portion  178  coupled to the first portion  174 . The first portion  174  of the keeper  30  includes a clamp surface or keeper surface  182 , a first slide portion  186 , and a second slide portion  190 . The keeper surface  182  extends laterally relative to the axis  66  ( FIG. 8 ). The keeper surface  182  is a curved surface and is sized to engage a portion of the second conductor  18  ( FIG. 1 ). The first slide portion  186  and the second slide portion  190  are spaced apart laterally and oriented perpendicular to the keeper surface  182 . In the illustrated embodiment, the first slide portion  186  and the second slide portion  190  have flat lower surfaces. As shown in  FIG. 2 , the first slide portion  186  and the second slide portion  190  engage the first upper surface  86  and the second upper surface  90  of the main housing  22 , respectively. 
     Referring again to  FIG. 7 , in the illustrated embodiment, the second portion  178  includes an opening  194 , a first guide  198  and a second guide  202 . The opening  194  is aligned along the longitudinal axis  66  ( FIG. 8 ). The first guide  198  and the second guide  202  are laterally spaced apart and protrude from opposite sides of the second portion  178 . In the illustrated embodiment, the first guide  198  and the second guide  202  are substantially triangular. The first guide  198  is disposed within the first track  78  ( FIG. 9 ) and the second guide  202  is disposed within the second track  82 , respectively, of the main housing  22 . In other embodiments, the guides  198 ,  202  may be formed in a different manner or may engage the main housing  22  in a different manner. In other embodiments, the keeper  30  may engage the main housing  22  in a different manner. 
     As shown in  FIG. 2 , the linear actuator  34  includes a shaft  210  and a flange  214 . The shaft  210  may include a threaded portion  218  and a non-threaded portion  222 . The flange  214  is positioned at one end of the shaft  210 . In the illustrated embodiment, the actuator  34  is an eyebolt, and the flange  214  is positioned between the threaded portion  218  and an eye stem  206 . In the illustrated embodiment, the flange  214  is circular and sized to be at least partially received by the first channel  50  of the main housing  22  ( FIG. 10 ). 
     As shown in  FIG. 2 , the resilient member  38  in the present embodiment is a coiled compression spring. The coils of the compression spring define an opening  230  therebetween. The resilient member  38  is at least partially positioned within the first channel  50  of the main housing  22 . 
       FIG. 8  shows a section view of the clamp  10 . The opening  194  of the keeper  30 , the opening  230  of the resilient member  38 , the main housing bore  46 , and the aperture  134  of the gripper  26  are aligned along the longitudinal axis  66 , and the linear actuator  34  extends therethrough. The opening  194  of the keeper  30  and the resilient member  38  are disposed along the non-threaded portion  222  of the shaft  210 . The resilient member  38  is seated against a first wall  196  of the keeper  30  and abuts the wall  92  of the first channel  50  of the main housing  22 . The flange  214  abuts a second surface  197  of the second portion  178  of the keeper  30 . The main housing bore  46  and the aperture  134  are disposed along the threaded portion  218  of the shaft  210 . The threaded portion  218  is threadably engaged with the nut  42  disposed within the cavity  150  of the gripper  26 . The nut  42  is seated against the rear wall  170  of the cavity  150  of the gripper  26 , so that the linear actuator  34  and the gripper  26  move together along the axis  66 . 
     As shown in  FIG. 2 , the first surface  58  of the main housing  22  and the surface  142  of the gripper  26  are aligned in a facing relationship to co-operatively define a first channel  234  ( FIG. 9 ) therebetween extending along the first axis  126 . Because the gripper  26  is movable relative to the main housing  22 , the first channel  234  has a variable width to accommodate a variety of sizes of conductor. As shown in  FIG. 9 , the second surface  62  of the main housing  22  and the keeper surface  182  of the keeper  30  are aligned in a facing relationship to co-operatively define a second channel  242  therebetween extending along a second axis  238 . Because the keeper  30  is movable relative to the main housing  22 , the second channel  242  has a variable width to accommodate a variety of sizes of conductor. 
     Referring to  FIG. 8 , before installing the first conductor  14 , an operator may immobilize the main housing  22  and push the linear actuator  34  against the bias of the resilient member  38  in a first direction  246  along the longitudinal axis  66 . The flange  214  engages the second portion  178  of the keeper  30  and pushes the keeper  30  towards the main housing  22 . As the keeper  30  slides towards the main housing  22 , the first guide  198  ( FIG. 7 ) and the second guide  202  of the keeper  30  travel along the first track  78  and the second track  82 , respectively, of the main housing  22 . As the linear actuator  34  is pushed in the first direction  246 , the gripper  26  moves away from the main housing  22 , creating a space between the main housing  22  and the gripper  26 . 
     As shown in  FIG. 9 , the operator aligns the first surface  58  of the main housing  22  with the surface  142  of the gripper  26  along the first axis  126  to form the first channel  234  therebetween. The operator then inserts the first conductor  14  into the first channel  234 . The operator releases the linear actuator  34 , and the resilient member  38  urges the keeper  30  away from the main housing  22  in a second direction  250  along the longitudinal axis  66 . As the resilient member  38  urges the keeper  30  away from the main housing  22 , the gripper  26  is pulled towards the main housing  22  to hold the first conductor  14  within the first channel  234 . 
     To insert the second conductor  18 , the operator aligns the second conductor  18  along the inclined surface  130  of the main housing  22  and slides the second conductor  18  into the second channel  242  defined between the keeper surface  182  and the second surface  62 . The operator threads the linear actuator  34  relative to the nut  42  ( FIG. 8 ), pulling the keeper  30  and the gripper  26  towards the main housing  22  and decreasing a distance between the keeper surface  182  and the second surface  62  of the main housing  22 . As the keeper  30  slides towards the main housing  22 , the first guide  198  and the second guide  202  of the keeper  30  travel along the first track  78  and the second track  82 , respectively, of the main housing  22  ( FIGS. 9 and 10 ). The positioning of the guides  198 ,  202  of the keeper  30  within the tracks  78 ,  82  of the main housing  22  prevents the keeper  30  from rotating with respect to the main housing  22  as the linear actuator  34  is rotated, and maintains the keeper surface  182  in a parallel orientation with respect to the second surface  62  of the main housing  22 . The rotation of the linear actuator  34  compresses the resilient member  38 , thereby also decreasing a distance between the main housing  22  and the gripper  26  until the first conductor  14  and the second conductor  18  are held tightly by the clamp  10  as shown in  FIG. 10 . 
     In the embodiment shown in  FIG. 10 , the second conductor  18  is a live conductor. An electric current travels from the second conductor  18  through the main housing  22  and into the first conductor  14 . 
     Although some aspects have been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects as described. Various features and advantages are set forth in the following claims.