Cable connection systems and methods

• US 8,961,061 B2
• Filed: 08/07/2010
• Issued: 02/24/2015
• Est. Priority Date: 08/07/2010
• Status: Expired due to Fees

• Current Assignee: Gulf Copper
• Original Assignee: Gulf Copper
• Inventors: Wahlberg, Michael, Callarman, Eric Shane, Colvin, Jesse Justin
• Primary Examiner(s): Kennedy, Joshua
• Assistant Examiner(s): McMahon, Matthew R
• Application Number:
  US12/852,462
• Publication Number:
  US 20120034025A1
• Time in Patent Office: 1,662 Days
• Field of Search: 403/72, 403/78, 403/275, 403/276, 403/282, 403/300, 403/269, 403/212, 403/278, 403/376, 166/351, 166/354, 166/77.2, 166/352, 166/77.1, 441/24, 441/25, 441/26, 441/27, 441/23, 439/461, 439/462, 439/463
• US Class Current: 403/275
• CPC Class Codes: F16G 11/025 Fastening means which engage a sleeve or the like fixed on the cable, e.g. caps F16G11/143 and F16G11/146 take precedence
• CPC Class Codes: F16G 11/05 by using conical plugs insertable between the strands
• CPC Class Codes: F16G 11/08 Fastenings for securing ends of driving-cables to one another, the fastenings having approximately the same diameter as the cables
• CPC Class Codes: Y10T 29/49908 Joining by deforming
• CPC Class Codes: Y10T 403/32213 Articulate joint is a swivel
• CPC Class Codes: Y10T 403/4933 by separate, deformable element
• CPC Class Codes: Y10T 403/7075 including discrete retainer

Abstract

A system for connecting two wire ropes includes first and second wire rope connectors, a swivel, and first and second connecting cables. The first wire rope connector includes a base defining a chamber for receiving an end of a first wire rope, a plug, and a cap that secures to the base to compress the plug and first wire rope end within the chamber. Similarly, the second wire rope connector includes a base defining a chamber for receiving an end of a second wire rope, a plug, and a cap that secures to the base to compress the plug and second wire rope end within the chamber. The swivel includes a first portion rotationally coupled to a second portion. The first connecting cable is coupled between the first wire rope connector and the first portion of the swivel, and the second connecting cable is coupled between the second wire rope connector and the second portion of the swivel.

Claims

1. A wire connector comprising:

a connector base comprising;

a mating structure; and

a rigid body defining an internal passage for receiving an end portion of a wire rope to be secured therein;

the internal passage including;

a cylindrical wire rope receptacle extending from a first end to a second end and having an inner diameter; and

a tapered compression chamber extending from (a) a first end extending from the second end of the cylindrical wire rope receptacle and having a smaller inner diameter than the inner diameter of the cylindrical wire rope receptacle to (b) a second end having a larger inner diameter than the first end of the compression chamber;

wherein the internal passage is configured to receive the end portion of the wire rope through the cylindrical wire rope receptacle and into the compression chamber;

a deformable plug configured for insertion in the tapered compression chamber;

a connector cap comprising;

a mating structure configured for mating with the mating structure of the connector base to secure the connector cap with the connector base;

a compression portion configured for compressing strands of the wire rope and the deformable plug within the compression chamber of the connector base upon securing of the connector cap with the connector base;

wherein the connector cap and the connector base define cylindrical outer surfaces having the same common diameter, and wherein the cylindrical outer surface of the connector cap and the connector base provide a flush cylindrical transition region when the connector cap is secured to the connector base;

wherein, in a fully assembled state of the wire connector, the connector cap extends over a portion of the tapered compression chamber but not over the cylindrical wire rope receptacle of the connector base; and

wherein the common diameter of the cylindrical outer surfaces of the connector cap and connector base is not more than 10% larger than the inner diameter of the cylindrical wire rope receptacle of the connector base.

2. A system, comprising:

a first wire rope connector including a rigid first connector base defining a first passage including a cylindrical wire rope receptacle and a tapered compression chamber for receiving an end portion of a first wire rope, a first plug configured for insertion in the compression chamber of the first connector base and a first connector cap configured for securing to the first connector base to compress the first plug and the end portion of the first wire rope within the compression chamber of the first connector base;

a second wire rope connector including a rigid second connector base defining a second passage including a cylindrical wire rope receptacle and a tapered compression chamber for receiving an end portion of a second wire rope, a second plug configured for insertion in the compression chamber of the second connector base, and a second connector cap configured for securing to the second connector base to compress the second plug and the end portion of the second wire rope within the compression chamber of the second connector base;

wherein the first connector base and the first connector cap define cylindrical outer surfaces having the same diameter, which diameter is not more than 10% larger than an inner diameter of the cylindrical wire rope receptacle of the first connector base, and

wherein the second connector base and the second connector cap define cylindrical outer surfaces having the same diameter, which diameter is not more than 10% larger than an inner diameter of the cylindrical wire rope receptacle of the second connector base,

a swivel device including a first portion rotationally coupled to a second portion;

a first connecting cable coupled between the first wire rope connector and the first portion of the swivel device; and

a second connecting cable coupled between the second wire rope connector and the second portion of the swivel device;

wherein for each of the first and second passages of the respective first and second connector bases;

the cylindrical wire rope receptacle extends from a first end to a second end; and

the tapered compression chamber extends from (a) a first end extending from the second end of the cylindrical wire rope receptacle and having a smaller inner diameter than the inner diameter of the cylindrical wire rope receptacle to (b) a second end having a larger inner diameter than the first end of the compression chamber; and

wherein, in a fully assembled state of the system, the first connector cap extends over a portion of the tapered compression chamber but not over the cylindrical wire rope receptacle of the first connector base, and the second connector cap extends over a portion of the tapered compression chamber but not over the cylindrical wire rope receptacle of the second connector base.

3. A system according to claim 2, wherein the first connecting cable is coupled to the first wire rope connector by a first swage fitting, and coupled to the first portion of the swivel device by a second swage fitting.

4. A system according to claim 2, wherein the first and second connecting cables comprise either chains or wire rope.

5. A system according to claim 2, wherein the first plug is deformable such that the first plug is deformed due to compressive forces in the compression chamber of the first connector base caused by securing the connector cap with the connector base, wherein the deformation of the first plug increases a connection strength between the plug and the end of the first wire rope within the compression chamber of the first connector base.

6. A system according to claim 3, wherein the first plug is more ductile than both the first connector base and the first connector cap.

7. A system according to claim 2, wherein for the first connector base, the first end of the compression chamber that extends from the cylindrical wire rope receptacle is sized to receive a radially inner portion of the first wire rope but not a radially outer portion of the first wire rope, the radially inner portion of the first wire rope including multiple wire rope strands extending into the compression chamber of the first connector base, the radially outer portion of the wire rope including additional wire rope strands that are cut back and received in the cylindrical wire rope receptacle to allow insertion of the inner portion of the first wire rope into the compression chamber of the first connector base;

and

an outer diameter of the first connector base is not more than 10% larger than an outer diameter of the radially outer portion of the first wire rope received in the cylindrical wire rope receptacle.

8. A system according to claim 2, wherein the deformable plug is configured such that during threaded securing of the connector cap with the connector base, twisted elements of the multiple wire rope strands form indentations in the deformable plug, the indentations extending generally diagonally with respect to a longitudinal direction of the plug.

9. A system according to claim 2, wherein the inner diameter of the second end of the compression chamber is smaller than the inner diameter of the cylindrical wire rope receptacle.

10. A system, comprising:

a connector base including;

a mating structure; and

a passage for receiving an end portion of a wire rope, the passage including;

a cylindrical wire rope receptacle extending from a first end to a second end and having an inner diameter sized to form a tight fit with the outer diameter of the wire rope received therein; and

a single tapered compression chamber extending from (a) a first end extending from the second end of the cylindrical wire rope receptacle and having a smaller inner diameter than the inner diameter of the cylindrical wire rope receptacle to (b) a second end having a larger inner diameter than the first end of the compression chamber but smaller than the inner diameter of the cylindrical wire rope receptacle;

a deformable plug configured for insertion between multiple strands of the wire rope extending at least partially through the passage of the connector base; and

a connector cap including;

a mating structure;

a compression portion; and

a coupling portion;

wherein the mating structure of the connector cap is configured for mating with the mating structure of the connector base to secure the connector cap with the connector base;

wherein the compression portion of the connector cap is configured for compressing the multiple wire rope strands and the deformable plug within the compression chamber of the connector base upon securing of the connector cap with the connector base;

wherein upon fully securing the connector cap with the connector base;

the deformable plug extends only partially through an axial length of the compression chamber due to the cylindrical shape of the second end of the wire rope receptacle from which the compression chamber extends; and

the connector cap extends over a portion of the tapered compression chamber but not over the cylindrical wire rope receptacle of the first connector base;

wherein the coupling portion of the connector cap is configured for coupling the connector cap to a separate structure;

wherein the deformable plug is more ductile than both the connector base and the connector cap such that the compression caused by the compression portion of the connector cap during securing of the connector cap with the connector base causes deformation of the deformable plug, but not the connector base or the connector cap; and

wherein the deformation of the deformable plug increases a connection strength between the deformable plug and the multiple wire rope strands within the compression chamber of the connector base.

11. A system according to claim 10, wherein the deformable plug includes a longitudinal passage for receiving a central strand of the wire rope during insertion of the deformable plug between the multiple strands of the wire rope.

12. A system according to claim 10, wherein the connector base and the connector cap are formed from steel, and the deformable plug is formed from bronze.

13. A system according to claim 10, wherein each of the deformable plug and the connector base compression chamber have a tapered conical shape.

14. A system according to claim 13, wherein the deformable plug and the connector base compression chamber have the same angle of taper.

15. A system according to claim 10, wherein:

the first end of the compression chamber that extends from the cylindrical wire rope receptacle is sized to receive a radially inner portion of the wire rope but not a radially outer portion of the wire rope, the radially inner portion of the wire rope including the multiple wire rope strands extending through the passage and into the compression chamber, the radially outer portion of the wire rope including additional wire rope strands that are cut back and received in the cylindrical wire rope receptacle to allow insertion of the inner portion of the wire rope into the compression chamber; and

an outer diameter of the connector base is not more than 10% larger than an outer diameter of the radially outer portion of the wire rope received in the cylindrical wire rope receptacle.

16. A system according to claim 10, wherein securing the connector cap with the connector base causes at least one of the multiple wire rope strands to physically embed within the deformable plug.

17. A system according to claim 10, wherein the inner diameter of the second end of the compression chamber is smaller than the inner diameter of the cylindrical wire rope receptacle.