U.S. patent number 3,582,575 [Application Number 04/838,558] was granted by the patent office on 1971-06-01 for composite conductor bar and method of manufacture.
This patent grant is currently assigned to Insul-8-Corp.. Invention is credited to Donald H. Scofield.
United States Patent |
3,582,575 |
Scofield |
June 1, 1971 |
COMPOSITE CONDUCTOR BAR AND METHOD OF MANUFACTURE
Abstract
An aluminum conductor bar is provided with a steel cap to form a
wearing surface for a slidable current collector. The cap is
secured to the bar by simultaneously punching the opposite side
legs of the cap to form tabs integral with the cap material which
extend into the aluminum to lock the cap securely onto the bar.
Inventors: |
Scofield; Donald H. (San
Carlos, CA) |
Assignee: |
Insul-8-Corp. (San Carlos,
CA)
|
Family
ID: |
25277424 |
Appl.
No.: |
04/838,558 |
Filed: |
July 2, 1969 |
Current U.S.
Class: |
191/29DM; 29/432;
29/515; 29/509; 29/857; 29/521 |
Current CPC
Class: |
A63H
21/04 (20130101); B60M 1/302 (20130101); B21D
49/00 (20130101); Y10T 29/49174 (20150115); Y10T
29/49925 (20150115); Y10T 29/49915 (20150115); Y10T
29/49833 (20150115); Y10T 29/49936 (20150115) |
Current International
Class: |
B60M
1/30 (20060101); B60M 1/00 (20060101); A63H
21/00 (20060101); A63H 21/04 (20060101); B21D
49/00 (20060101); B60m 001/30 () |
Field of
Search: |
;29/432,624,521
;191/23DM,33DM ;238/143,147,148 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: LaPoint; Arthur L.
Assistant Examiner: Libman; George H.
Claims
I claim:
1. A composite electric conductor adapted to be slidably engaged by
a current collector, said conductor comprising:
an elongate bar member made of good electrically conductive
material such as aluminum
a thin walled cap member for said bar member made of electrically
conductive material which is more wear resistant than said bar
member;
one of said members including a pair of side legs for engaging side
faces of the other member; and
tab lock means formed integral with the side legs of the said one
member including a portion cut away from each side leg and punched
into the said other member for positively securing the cap member
to the bar member, the tab lock means being the sole material
embedded in the said other member for securing the cap member to
the bar member.
2. The conductor bar of claim 1 wherein said one member is the cap
member and said other member is the bar member and wherein said tab
lock means are at spaced intervals along the cap member and the bar
member and each tab lock means includes a plurality of tabs
symmetrically arranged in close proximity to each other, each
having an edge joined to the cap member and a portion cut away from
the main body of the cap member and punched into the bar
member.
3. The conductor bar of claim 2 wherein the cut away portions of
the tabs extend away from each other.
4. The conductor bar of claim 2 wherein the cut away portion of the
tabs extend toward each other.
5. The conductor bar of claim 1 wherein the tab lock means on one
leg of said one member is transversely aligned with the tab lock
means on the other leg.
6. The conductor bar of claim 1 wherein said tab lock means
includes three tabs each having a generally triangular shape with
one side of each of the triangular tabs being joined to the main
body of said one member and the corner opposite said one side being
the point of the cut away portion which is forced into said other
member.
7. A composite electric conductor adapted to be slidably engaged by
a current collector, said conductor comprising:
an elongate bar made of aluminum alloy having a front face and
opposite side faces;
a stainless steel cap having side legs snugly engaging the side
faces of the bar adjacent the front face, and having an
intermediate contact face tightly engaging the front face of the
bar; and
tab lock means formed integral with the legs of the cap at spaced
intervals along the cap, the tab lock means in one leg being
transversely aligned with the tab lock means on the other leg, each
tab lock means including a plurality of tabs symmetrically arranged
in close proximity to each other, with each tab having an edge
joined to the cap and a tip portion cut away from the main body of
the cap and punched into the bar a distance about equal to the
thickness of the cap for positively locking the cap to the bar in
good electrical and mechanical contact with the bar.
8. A method of making a composite conductor comprising an
electrically conductive bar and a cap having side legs engaging the
side faces of the bar and having an intermediate wall engaging the
front face of the bar, the cap being made of electrically
conductive material which is harder than the bar material so as to
form a surface to be engaged by a slidable current collector, the
steps comprising:
placing the cap on the bar with the side legs engaging the side
faces of the bar;
simultaneously punching through the legs of the cap into the bar
with a pair of axially aligned sharpened punches to form tab means
on each leg integral with the cap and having a portion punched away
from the cap into the bar to lock securely the cap on the bar;
and
repeating the punching operation at spaced intervals along the
length of the bar to securely hold the cap on the bar.
9. The method of claim 8 including the step of compressing the
intermediate wall of the cap against the front face of the cap to
the bar while the punching operation is occurring.
10. The method of claim 9 including the steps of:
positioning the bar on its side on a spring loaded plate having one
of the sharpened punches fixed to a base member beneath the plate
with the sharpened tip of the punch extending upwardly through an
opening in the plate aligned with the lower leg of the cap;
driving the other sharpened tip of the punch against the upper leg
of the cap to drive the bar downwardly against the lower punch and
simultaneously drive the punches into the opposite legs of the cap
and sides of the bar; and
retracting the upper tool so as to permit the bar to be raised away
from the lower punch by the spring loaded plate.
11. The method of claim 8 including the step of restraining the bar
along its rear edge, which is remote from the cap so as to prevent
the bar from curling as a result of the elongation to the bar
occurring during the punching operations.
12. The method of claim 11 wherein the means for restraining the
bar is positioned to engage the rear edge of the bar after it has
passed through the punching station.
13. The method of claim 8 wherein the punching step is formed by
punches, each of which is balanced around its longitudinal axis
such that the forces received by the punches during the punching
operation are balanced in a direction radial to the punch axis.
Description
RELATED APPLICATIONS
This application is related to application Ser. No. 771,931, filed
Oct. 30, 1968 and assigned to the same assignee.
BACKGROUND OF THE INVENTION
This invention relates to electrical distribution systems wherein a
current collector slides in contact with an electrical conductor;
and more particularly, relates to an improved composite conductor
for such a system and a method of manufacturing such a
conductor.
Sliding contact electrification systems are used extensively in
industry to provide electrical power to mobile apparatus such as
cranes, monorails, overhead hoists, etc. Generally, such systems
include a high amperage conductor extending along the path of the
mobile apparatus, and a current collector mounted to move with the
apparatus slidably engages an exposed face of the conductor to
supply power to the apparatus.
In addition to low electrical resistance, a satisfactory conductor
for such sliding contact systems must have a surface which makes a
good electrical connection with the collector shoe and must be able
to withstand the constant wear of the sliding collector shoe.
Adequate structural strength is, of course, essential, and low cost
is particularly significant in view of the large quantities of
conductor bars required for many electrification systems.
Aluminum conductor bars have a relatively good combination of high
structural strength, low electrical resistance, and low cost in
comparison with conductor bars of other metals and are especially
suitable for heavy duty installation wherein current requirements
on the order of 500 or more amperes are needed. However, aluminum
has severe disadvantages in a sliding contact system because
aluminum oxide which forms on its surface is a very poor electrical
conductor. Moreover, aluminum is a relatively soft metal and has a
relatively high coefficient of friction. Hence, it affords a poor
wearing surface for sliding contact.
To overcome these shortcomings of aluminum while still having the
benefit of its many advantages, composite conductor bars have been
employed wherein a steel cap is attached to the aluminum bar so
that the steel forms the contacting surface for the current
collector. Steel, being much harder than aluminum, can, of course,
withstand the constant wear of sliding contact much better than
aluminum and also has a lower coefficient of friction.
Various approaches have been utilized to secure the cap to the
aluminum bar with a minimum of increased resistance being
introduced by the steel cap. In one approach the holes are
predrilled in the steel cap and aluminum plugs are then welded
through the holes into the aluminum bar so that the welded plug
securely attaches the cap to the bar. The welded aluminum plugs
also make good electrical contact with the steel cap without having
any undesirable oxidation of the aluminum. Consequently, most of
the electrical transfer between the conductor bar and cap is
through the aluminum welds. While this approach has met with
considerable success, it is still naturally desirable that the cost
for attaching the cap to the bar be reduced, in that the
predrilling and the actual welding process requires skilled labor.
Also, adding to the cost is the fact that the cap has to be
carefully cleaned prior to the welding operation so as not to
contaminate the welds. As a result of this, there is also some
danger of bad welds occuring which may cause failure of the welded
connection. Moreover, even with a good weld, there is some tendency
for the weld to weaken after extended usage since most of the
current flow is through the spot welds. Hence the cap may not
remain securely attached to the conductor bar.
In other approaches steel caps have been bolted onto an aluminum
bar, or nailed onto the bar by means of explosively driven nails.
While these approaches have many advantages, they are still
relatively expensive in view of the labor involved and the cost of
the materials used in assembly. Hence, improvements in this regard
are highly desirable.
SUMMARY OF THE INVENTION
Briefly stated, the composite conductor bar of the invention
includes an elongated bar of good electrically conductive material,
such as aluminum, with the bar having a front face and a pair of
opposite sidewalls. A cap made of a conductive material such as
stainless steel which is harder than the bar is forcefully pressed
onto the conductor bar with its inner surface engaging the front
and sidewalls of the bar. The cap is then securely attached to the
bar by punching the side legs of the cap with a sharp punch or
similar tool to form one or more tabs on the cap which are integral
with the cap and have a portion which is cut away from the cap
material and embedded in the softer aluminum to lock the cap onto
the bar. Such tabs are employed at spaced intervals on both sides
of the cap, and upon withdrawal of the punches form the sole
material embedded in the bar to attach the cap to the bar.
Preferably, the tabs on one side of the bar are aligned with those
on the other side.
In accordance with the method of the invention, the tabs are formed
in the steel cap on opposite legs of the cap at the same time so
that the forces are balanced. This decreases the cost of the
operation and also prevents bending of the bar out of the flat
planes defined by the cap legs. Preferably, the aluminum bar is
positioned on one side supported on a spring loaded plate with the
cap held under pressure against the face of the bar. An upper punch
is driven against the upper leg of the cap forcing the bar and the
spring loaded support plate downwardly against a lower punch
aligned with the upper punch and extending through an opening in
the plate. By continued pressure through the upper punch, the
punches are driven into the cap, simultaneously forming in a single
operation tabs forced into the conductor bar. By withdrawing the
upper punch, the lower support plate raises the bar away from the
lower punch and by releasing the force clamping the cap onto the
bar, the bar may be moved longitudinally to the position where an
additional punching operation is to be performed.
Punching a series of tabs into the edge of a conductor bar deforms
that edge of the bar slightly, causing it to elongate a slight
amount. Over a long length of bar, this slight elongation can cause
the bar to curl about an axis parallel to the punches used to form
the tabs. To prevent this, the bar is restrained during the
punching operation by positioning a restraining element downstream
from the punching apparatus to engage the edge of the bar which is
opposite from the steel cap.
With this method the cap is securely and permanently mechanically
locked to the conductor bar, thus providing good electrical
conductivity between the bar and the cap. The method of manufacture
is relatively simple and inexpensive when compared to previous
methods employed. The fact that basically only a single type of
manufacturing step is utilized and this step may be performed by
relatively unskilled operators, adds greatly to the low cost of the
operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of the apparatus employed in
fabricating the composite bar of the invention, with a bar being
shown in endwise cross section and the apparatus in position to
perform a punching operation;
FIG. 2 is a view similar to FIG. 1 with the apparatus shown
performing a punching operation in accordance with the
invention;
FIG. 3 is an exploded perspective view of the die set apparatus
used to employ the punching operation; and
FIGS. 4--7 are enlarged views of a portion of the bar and cap
showing various forms of tabs punched into the cap and conductor
bar.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
Referring first to FIGS. 1 and 2, an aluminum conductor bar 10 is
shown positioned in endwise cross-sectional view supported on its
lower side 10a and having an upper side 10b, a front face 10c and a
rear edge 10d. The conductor bar 10 may extend longitudinally for a
considerable distance, perhaps up to 30 ft. in length. A steel cap
12 is positioned on the front end of the bar with the cap having a
lower side leg 12a engaging the lower side 10a of the conductor bar
and an upper side leg 10b engaging the upper side 10b of the
conductor bar while an intermediate wall 12c engages the front face
10c of the bar. The cap has a generally U-shaped cross section, but
with a slight depression in its intermediate wall to conform to the
shape of the bar such that the cap may be termed as having a
W-shaped cross section.
The composite conductor bar and cap is positioned with a die set
generally indicated at 14 and including in its lower half a
stripper plate 16 supporting the conductor bar. As may be seen from
FIGS. 1 and 3, the stripper is supported by a plurality of coil
springs 18 extending between the lower surface of the plate and the
upper surface of a base member 20. Each spring surrounds a bolt 21
extending through the base member 20 and threaded into the stripper
plate 16. As may be seen from FIG. 1, the stripper plate 16 is
normally spaced from the base member 20 by the springs 18.
A lower punch 22 having a sharp upper end, is positioned in a
holder 22a clamped to the base member 20 by means of a setscrew 24
extending through the front edge of the base member 20. The punch
22 extends upwardly through an aperture 23 in the stripper plate 16
and is vertically aligned with the lower leg 12a of the steel cap
12, as viewed in FIG. 1. The base member 20 is secured to a large
supporting die plate 25.
The upper half of the die set 14 includes an upper support member
26 which is comparable to the support member 20 and is attached to
a hydraulic press 28. A clamp bar 30 is attached to the upper
support member 26 by means of a plurality of bolts 32 extending
through the support member 26 and threaded into the clamp bar 30. A
plurality of springs 33 each surrounding one of the bolts 32 load
the clamp bar 30 downwardly so that it is normally spaced from the
support member 26 as shown in FIG. 1.
An upper punch 34 positioned in a holder 34a which is clamped to
the upper support member 26 by means of a suitable setscrew 36
extends downwardly through an opening 37 in the clamp bar 30. The
punch 34 has a pointed lower end like the lower punch 22 and
vertically aligned with the lower punch.
Attached to the front of the stripper plate 16 by suitable bolts 38
is a guide bar 40. As seen from FIG. 1, the front face of the steel
cap 12 engages the rear surface of the guide bar. A slide plate 42
is supported on the back side of the stripper plate 16 for slidable
movement along the upper surface of the stripper plate as guided by
the brackets 44 clamped to opposite sides of the rear of the
stripper plate by suitable bolts 26. Lugs 48 attached to the rear
edge of the stripper plate are connected by a pin 50 extending
through a clevis 51 attached to the piston 52, which extends
horizontally outwardly from a pneumatic ram cylinder 54.
The upper half of the die set 14 is aligned with the lower half by
a pair of guide pins 56 which are secured to the lower support
member 20 and are slidably received in the upper support member 26.
Alternatively, such guide pins can be attached to the upper support
member to slide into the lower member 20.
Referring to FIGS. 1 and 3, the rear edge of the conductor bar 10
engages a restraining roller 57 horizontally mounted on a shaft 58
extending upwardly from the die plate 25. The roller is spring
biased by the springs 59 so that it can move vertically with the
bar 10. The remainder of the conductor bar which extends beyond the
die set apparatus is supported by roller tables or other suitable
means (not shown).
In operation, the steel cap 12 is initially positioned on the
conductor bar 10 by hand and positioned within the die set as shown
in FIG. 1. Air pressure is then applied to the ram cylinder 54
driving the piston 52 forwardly, which in turn drives the slide
plate 42 forwardly against the rear edge 10d of the conductor bar
10. The steel cap 12 is pressed against the guide bar 40 and hence
the inner surface 12c of the cap forcefully engages the front face
10c of the conductor bar 10. In one successful example of this step
of the operation, air pressure of approximately 100 pounds per
square inch is applied to the piston 52.
While the steel cap 12 is thus held forcefully in good electrical
and mechanical contact with the conductor bar 10, the press 28 is
actuated, moving the upper half of the die set downwardly. The
clamp bar 30 contacts the upper leg 12b of the steel cap and pushes
the bar and cap together with the stripper plate 16 downwardly
until the cap lower leg 12a engages the sharpened upper end of the
lower punch 22. Continued application of pressure forces the steel
cap and the conductor bar onto the punch 22 until the lower surface
of the stripper plate 16 engages the upper surface of the base
member 20, as illustrated in FIG. 2 thus punching the lower punch
22 into the adjacent side leg of the steel cap and the side of the
conductor bar. Simultaneously, the clamp bar 30 is forced against
the upper member 26 so that the upper punch 34 protrudes beyond the
clamp bar 30 and punches into the upper leg 12b of the steel cap
into the conductor bar, also as illustrated in FIG. 2. This action
causes the sharpened punches to penetrate the steel cap and cut
tabs integral with the cap which are punched into the conductor
bar.
Upon raising the press 28, the clamp bar 30 is withdrawn and once
more is urged away from the upper member 36 by its springs 33.
Simultaneously, the stripper plate 16 is forced upwardly by its
springs 18, raising the conductor bar 10 away from the lower punch
22. The air pressure on the ram 52 is reversed such that the
stripper plate 42 is withdrawn, thus releasing the conductor. The
bar is then drawn endwise to the succeeding punching position so
that the punching step may be repeated. The number of operations
necessary may vary with the dimensions of the materials employed;
however, it has been found that punching locking tabs into the
steel cap about every 6 inches along the longitudinal length of the
bar provides a composite conductor with the cap tightly locked to
the aluminum in good electrical contact. Simultaneously, punching
the tabs on opposite sides of the bar balances the punching forces
and prevents bending out of the planes defined by the legs of the
cap.
Due to the repeated punching along the front edge of the conductor
bar, there is a tendency for that edge of the bar to elongate,
which in turn creates forces to cause the bar to curl in a
horizontal plane, as viewed in FIG. 1, towards the rear edge 10d of
the bar about an axis parallel to the punches. That is, the end of
the conductor bar which has been through the punching operation
tends to curl towards the rear edge 10d. After the bar passes the
punching operation, its rear edge 10d engages the restraining
roller 57 which prevents this curling action. If necessary,
additional rollers may be spaced further downstream from the die
set to assist in preventing any such curling. Although the bar
forcefully engages the roller, a minimum of friction is introduced
to interfere with the longitudinal feeding of the conductor bar.
Since the roller is spring-loaded, it can move up and down with the
bar 10 as it is moved during the punching operation.
Refer now to FIGS. 4--7 for a more detailed discussion of the lock
tabs which are formed in the steel cap for securing the cap to the
bar. Punching tools of various shapes may be employed for the tab
forming operation, and they may be oriented in different manners.
In FIG. 4a and 4b, there is shown an enlargement of the lock tab 60
formed with the punches 22 and 34. The sharp end of these punches
has a triangular cross section tapering to a sharp point at about a
60.degree. angle. Such a punch cuts three generally triangular
shaped tabs 60 forming three points or barbs 60a which cut into the
aluminum bar. Note that the tabs extend a considerable distance
into the bar. For example with a cap of about one-sixteenth of an
inch a tab penetration depth into the bar about equal to the cap
thickness has been found satisfactory. The point of the punch
actually extends further as it penetrates through the cap. The tab
edges 60opposite the points 60a of course remain attached to the
cap as may be best seen from FIG. 4b. It can be realized that with
the triangular arrangement at least one of the points 60a of the
tabs tends to be gouged further into the aluminum in resisting any
sliding relative movement between the cap and the bar, which might
be introduced, for example, by expansion and contraction of the
material.
It should be pointed out that typically the edges of the tabs, as
shown in the drawing, are extruded somewhat to a tapered thickness
and are somewhat rounded due to the resistance to deformation of
the metals. However, the exact configurations will, of course, vary
with the thickness of the cap and characteristics of the cap and
bar materials.
In this regard the cap will typically be made of -302 or 304
stainless steel having a thickness of about one-sixteenth of an
inch, or as thick as three thirty-seconds of an inch. As an
example, the conductor bar could be made of extruded aluminum alloy
-6063-T6.
An advantage of the punches 22 and 34 having triangular cross
section points is that the point is centrally located on the tool
longitudinal axis, and the cross section is balanced such that the
forces encountered by the punches are balanced. This minimizes wear
and breakage of the punches. FIGS. 5, 6 and 7 illustrate locking
tabs formed from other symmetrical or balanced punches. In FIGS. 5a
and 5b, four tabs 62 are formed in the cap by the use of a
four-sided punch having its sharp point on the punch longitudinal
axis. As can be seen, each of the tabs formed gouge into the
aluminum to create four separate barbs 62a which tend to hold the
cap on the aluminum.
In FIGS. 6a and 6b, a pair of opposing tabs 64 are formed in the
steel cap by utilizing a punch having a V-shape as viewed from the
side, so that the sharp point is in the center of the punch. These
tabs 64 tend to prevent movement of the cap in either direction
relative to the conductor bar in view of the opposing edges 64a of
the tabs. This tab is very effective when oriented in either the
longitudinal direction of the conductor bar or perpendicular
thereto.
In FIGS. 7a and 7b, a pair of tabs 66 are formed extending
downwardly from a central section 68 which is not displaced by the
punch. The tool for forming these tabs had a pair of sharp edges on
opposite edges with a V-shaped slot or groove between the edges
when viewed from the side. Consequently, the forces again are
balanced so that tool life is enhanced. As with the tabs
illustrated in FIGS. 6a and 6b, the tabs 66 in FIGS. 7a and 7b tend
to resist relative movement of the cap and bar although the free
ends 66a extend away from each other, while in FIGS. 6a and 6b, the
free ends extend towards each other.
* * * * *