Patent Publication Number: US-10326215-B1

Title: Pin aligning crimping fixture

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to electrical connectors, and more particularly to electrical connectors for submersible electric pumps. 
     In the oil and gas industry, submersible electric pumps are utilized to pump crude oil from within the well head. The environment within the well head in which the pumps and associated electrical conductors operate makes the electrical connections within the wellhead susceptible to corrosion, fatigue, and ultimately disruption of electrical conduction necessary to operate the pumps. The conductors within the well head must also effectively routed to the exterior of the well head to permit connection to an external power source outside to operate the pump. 
     From time to time, the conductor cables within the well head may require repair or replacement. At other times, the pump may be relocated to a different well head and the conductor cables may be replaced as a precaution to accomplish a fresh installation. The repairs will typically require a splice connection of the conductors. The individual conductors within the heavy gauge multi-conductor cables, typically electrical submersible pump (ESP) cables, are normally oriented in flat side by side configuration. Due to the heavy gauge, the individual conductors in the cables are typically very rigid. Accordingly, adequate separation of the conductors is needed in order to apply a splice with conventional splicing tools. It is also desirable that the crimp be accomplished with standard tools. 
     As can be seen, there is a need for an improved crimping fixture and method for joining the electrical conductors of and pin conductors of a well head. 
     SUMMARY OF THE INVENTION 
     In one aspect of the present invention a splice fixture to facilitate carriage of a plurality of power pins for application of a splice connection between the plurality of power pins and a corresponding conductor of a multi-strand conductor cable, is disclosed. The splice fixture includes an elongate rod to interconnect a first block, a second block, and a pin protector, the first and second block received on a first end of the elongate rod and the pin protector configured to be removably received on a second end of the elongate rod. The first block has a plurality of apertures defined in a radially disposed, spaced apart relation, the plurality of apertures extend through a longitudinal length of the first block. The second block has a plurality of corresponding apertures defined in a radially disposed spaced apart relation and extend through a longitudinal length of the second block. The pin protector also has a plurality of receiving apertures extending into the pin protector, with the plurality of receiving apertures defined in a radially disposed spaced apart relation. The first block and the second block are joinable to secure a crimp end of the plurality of power pins and the pin protector is configured secure a terminal end of the plurality of power pins. 
     In some embodiments, the plurality of apertures, the plurality of corresponding apertures, and the plurality of receiving apertures are configured to be coaxially aligned to receive the plurality of power pins. The pin protector may be adjustably carried on the elongate rod to accommodate a length of the power pin. The elongate rod may be received in a bore defined in a central axis of each of the first block, the second block, and the pin protector. 
     In some embodiments, a plurality of axially aligned joining holes are defined through a longitudinal length of each of the first block and the second block. The plurality of axially aligned joining holes are adapted to receive a fastener to join the first and the second blocks. A recess may be defined in an adjacent face of one of the plurality of apertures and the plurality of corresponding apertures. A retaining clip adapted to be received within the recess and have an interior diameter dimensioned to receive the power pin in a close fitting engagement. The plurality of apertures and the plurality of corresponding apertures compressively retain the retaining clip there between when the first block and the second block are joined. 
     In other embodiments, a fluted opening may be defined in each of the plurality of receiving apertures. The plurality of apertures, the plurality of corresponding apertures, and the plurality of receiving apertures are spaced apart to receive a jaws of a crimping tool. 
     These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of and embodiment of a crimping fixture; 
         FIG. 2  is an exploded view of the crimping fixture; 
         FIG. 3  is a section view of the crimping fixture, taken along line  3 - 3  in  FIG. 1 ; 
         FIG. 4  is a perspective view of the crimping fixture, illustrating the insertion of pins  44  into fixture  10  and the placement of the fixture and power pins into vise  60 ; 
         FIG. 5  is a perspective view of the crimping fixture, illustrating the insertion of conductors  54  into connectors  48 ; 
         FIG. 6  is a perspective view of the crimping fixture, illustrating the crimping of connectors  48  onto conductors  54 ; 
         FIG. 7  is a section view of the crimping fixture, taken along line  7 - 7  in  FIG. 6 ; 
         FIG. 7A  illustrates a view of a prior art crimping connector in use with a standard crimping tool; 
         FIG. 8  is a perspective view of the crimping fixture, illustrating the removal of fixture  10  from the cable  52  and pins  46  assembly; and 
         FIG. 9  is a perspective view of the crimping fixture, illustrating the fixture  10  applied to shorter length power pins  46 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims. 
     Broadly, embodiments of the present invention provide a fixture and method of crimping an electrical conductor with a pin connector for a wellhead. The fixture provides radial separation of a plurality of power pins for alignment with a corresponding power conductor so that a splice may be applied to conductively join the conductors and the power pin connector. The spliced connections may then be sealed and carried with the cartridge disclosed in co-pending U.S. Patent Application and mounted within a wellhead. 
     A preferred fixture according to embodiments of the invention is shown in reference to  FIGS. 1-3 . The fixture includes a first block  12  having a plurality of apertures  18  radially disposed in a spaced apart relationship through a longitudinal length of the block  12 . The radially disposed spaced apart relation defining an expanded conductor circle, permitting the jaws of an industry standard crimping tool, such as the to crimp a splice applied to one of the plurality of power pins and a corresponding conductor, without interference with another of the plurality of power pins or conductors. 
     Each of the plurality of apertures  18  are adapted to receive a power pin  46  for connection to an external power source to provide power to the wellhead pump. The first block  12  is configured to be threadingly carried on an elongate threaded rod  36  through a bore  16  defined through a central axis of the first block  12 . 
     The first block  12  is joined to a second block  20 , the second block  20  having a plurality of apertures  26  coaxially aligned with the plurality of apertures of the first block  12 . The first block  12  and the second block  20  may be coupled by a plurality of threaded fasteners  30  that are received through axially aligned joining holes  14 ,  22  in each of the first block  12  and the second block  20 . A washer  32  and a nut  34  may be utilized to join the first block  12  and the second block  20 . 
     A retaining clip  28  is provided for each of the power pins and is received in a recess defined in at least one of an adjacent face of the apertures  18 ,  26 . The retaining clip  28  is dimensioned for a close sealing fit around a circumference of the power pin. 
     As with the first block  12 , the second block  20  has a bore  24  defined through a central axis of the second block  20 , such that the first and second blocks may be adjustably carried on the elongate threaded rod  36 . The bores  16 ,  36  may be threaded. Alternatively, and adjustment jut  34  may be provided to secure the first and second blocks  12 ,  20  to a first end of the threaded rod  36 . 
     A pin protector  40  is adjustably carried along the elongate rod  36  from a second end of the rod  36 . The pin protector  40  has a plurality of receiving apertures  44  extending into the pin protector. The plurality of receiving apertures  44  are radially disposed in a spaced apart relation to coaxially align with the apertures  18  and  26  of the first and second block  12 ,  20 . The plurality of receiving apertures  44  are dimensioned to receive and protectively cover the ends of the power pins  46  to avoid damage to the ends while the power pins  46  are spliced to the conductors  54 . The pin protector  40  is adjustable along the length of the elongate rod  36  so that the crimp fixture may accommodate power pins  46  having differing lengths. The plurality of receiving apertures  46  may have a funneled or fluted opening to facilitate reception of the power pins  46  in the pin protector  40 . 
     A bore  42  extends through a longitudinal axis of the pin protector  46  and is dimensioned to slidingly receive the threaded rod  36 . The pin protector  46  is adjustable along the length of the threaded rod  36  via a nut  34 . 
     As seen in reference to  FIGS. 5-8 , showing the crimping fixture in use, the first block  12  and second block  20  are applied to a crimp end of the power pins  46 . The retaining clip  28  may be applied to the power pins  46  prior to assembly of the first and second blocks  12 ,  29 . The pin protector  40  is applied to the free ends of the power pins  46  within receiving apertures  44 . The pin protector  40  is adjusted along the length of the threaded rod  36  so that the power pins  46  are held in a radially disposed spaced apart relationship. The joined blocks  12 ,  20  may be secured in a vise  60  to hold the power pins  46  so that the ends of the conductors  54  of a multi stranded conductor cable  52  may be joined to the power pins  46 . 
     A crimp connector is applied to each of the crimping ends of the power pin  46  and the corresponding conductor  54  is received in each of the crimp connectors. With the power pins  46  and the conductors  54  held in the radially disposed spaced apart relation provided by the crimp fixture, a crimp may be applied by the jaws of a standard crimping tool  58  without interference from another of the plurality of power pins or conductors. 
     Once each of the crimp connectors have been crimped to join the respective power pin  46  and conductor  54 , the crimping fixture may be removed from the power pins  46 . The joined conductors  54  and power pins  46  may then be encased in a protective cartridge, such as that of our co-pending U.S. Patent Application. For shorter length power pins  46 , the threaded rod  36  may be omitted, as seen in reference to  FIG. 9 . Likewise, the pin protector  40  may be omitted for shorter length power pins  46 . 
     It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.