Abstract
An end product and system for connecting large aluminum tubular pipe segments into an Isolated Phase Bus comprising reducing the diameter (or increasing the same) of one end of a tubular segment and sliding it into (or over) the untreated end of an adjacent pipe or tubular segment, followed by a tubular and circumferential welding of the same. The outside or inside circumference of the connected segments are uniform from distal to proximal end of the overall length of the connected tubular segments. A structural integral, axially aligned, simplified set of connectable tubular segments allows for a grounded connection between power generators and step transformers. Preferably, the overall diameter change of the necked down flange (or outwardly flared flange) of one tubular segment is less than or only slightly greater than twice the material wall thickness of the tubular segment's initial pre-rolled flat aluminum sheet material.
Claims
1. An enclosure of an isolated phase bus comprising: at least two connectable, thin-walled, aluminum tubular segments, each tubular segment having two open ends at opposite sides of a longitudinal axis of said tubular segment, wherein the enclosure is engaged with a conductor disposed in an interior portion of the enclosure via an insulator connected to both the enclosure and the conductor, wherein a first open end of a first tubular segment of the at least two tubular segments has a forwardly projecting flange element, each tubular segment having the same outside surface diameter along a substantial length except as to a short length of said flange element of said first tubular segment, said flange element being formed and necked down from the outside surface diameter of said first tubular segment to a slightly smaller diameter than the outside surface diameter of said first tubular segment, said flange element including a connecting shoulder directed inwardly from the outside surface diameter of said first tubular segment and a slightly forwardly extending segment coaxial with a longitudinal axis of said first tubular segment, wherein a second open end of said first tubular segment, opposite to said first open end, defines a flat annular surface whose plane extends across said longitudinal axis of said first tubular segment, said annular surface facing away from said first open end and said flange element, wherein said flange element of said first tubular segment is configured to slide into a second open end of a second tubular segment of the at least two tubular segments, said second open end of said second tubular segment provided with a flat annular surface whose plane extends across a longitudinal axis of said second tubular segment, and said connecting shoulder of said first tubular segment is configured to engage and contact said annular surface of said second open end of said second tubular segment, and wherein a seam formed between said connecting shoulder of said first tubular segment engaging and contacting said annular surface of said second open end of said second tubular segment is welded with a weld, in which said flange element of said first tubular segment is a backing surface of the weld.
2. The enclosure of claim 1, wherein the at least two tubular segments are about inch in wall thickness.
3. The enclosure of claim 1, wherein said flange element extends from said first open end in an amount about equal to or only slightly greater than the wall thickness of the at least two tubular segments.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) FIG. 1A is an exploded view of a first prior art system of aligning and welding a pair of conductor cans or pipe or tubular segments together using a pair of exterior welding bands encircling the edges of the tubular segments which are then welded to the exterior of the ends of the adjacent segments;
(2) FIG. 1B shows the external welding bands of aluminum being placed around the two metal pipe segments in the prior art embodiment seen in FIG. 1A and demonstrates how tack welding of the bands to the exterior of the pipes is first accomplished;
(3) FIG. 1C shows the two pipe segments having been welded together in the prior art embodiment seen in FIGS. 1A and 1B, with the welding bands extending around the entire perimeter of both cans and showing exterior seams between the tubular segments and the exterior welding bands;
(4) FIG. 2A is an exploded view of a second prior art system of aligning and welding a pair of pipes, tubular segments or conductors using a pair of interiorly located welding bands;
(5) FIG. 2B shows the welding strips or bands of aluminum being connected to the inside end of a first metal pipe for sliding connection into the end of a second metal pipe in the prior art embodiment seen in FIG. 2A; the welding bands are tack welded to the first pipe and then, after the free end of the second pipe slid over the short exposed width of the bands, the bands are desirably tack welded to the inside of the second pipe segment;
(6) FIG. 2C shows the two pipe segments having been welded together;
(7) FIG. 3A is a front perspective view of a section of a tubular pipe segment, a can or a cylinder with a flaring mechanism for pinching or tapering inwardly the first and free end of the pipe segment and thereby creating an interior, diameter-reduced or offset flange of short longitudinal axial dimension with a shoulder for sliding connection into the untreated end of a second pipe using the system and method of the present invention;
(8) FIG. 3B is a front perspective view of a section of a tubular pipe segment shown in FIG. 3A, after the end has been provided with the inner, reduced in diameter, flange or inward tapering or flaring of the metal pipe created by using the system and method of the present invention shown in FIG. 3A; FIG. 3B also shows the exterior shoulder of the end of the pipe segment;
(9) FIG. 3C is a side elevational view of the coupling or connection of the untreated or free end of a second pipe segment onto the interior, reduced in diameter flange of the first pipe segment, shown in FIG. 3B, with the untreated end sliding over the reduced flange end until the shoulder of the reduced-in-diameter end comes into butting contact with the circular edge of the free end of the second tubular segment; the two segments can then be welded along the seam around the complete circumference of the pipe segments, with the formed flange serving as a backing surface for the weld;
(10) FIG. 3D is a close-up or enlarged partial, side view of the interior, necked down or diameter-reduced, offset flange of a first pipe segment as seen in FIG. 3B;
(11) FIG. 3E is a front perspective view of a section of a tubular pipe segment, a can or a cylinder with a flaring mechanism for pinching and drawing outwardly the first and free end of the pipe segment and thereby creating an enlarged in diameter, outwardly flared flange of short longitudinal axial dimension with a shoulder for sliding connection into and abutting with the untreated end of a second pipe segment using the system and method of the present invention;
(12) FIG. 3F is a front perspective view of a section of a tubular pipe segment shown in FIG. 3E, after the end has been provided with the outwardly flared flange created by using the system and method of the present invention shown in FIG. 3E; FIG. 3F also shows the interior shoulder of the treated end of the pipe segment;
(13) FIG. 3G is a side elevational view of the coupling or connection of the untreated or free end of a second pipe segment (on the right of the FIG.) slid into the outwardly flared or increased in diameter flange of the first pipe segment (on the left side of FIG. 3G) with the untreated end sliding within the enlarged flange end until the shoulder of the flange is engaged and comes into butting contact with the circular edge of the free end of the second tubular segment; the two segments can then be welded along the seam around the complete circumference of the pipe segments; and
(14) FIG. 3H is a close-up or enlarged partial, side view of the outwardly flared or increased in diameter flange of a first pipe segment as seen in FIG. 3F.
DETAILED DESCRIPTION OF THE DRAWINGS AND THE PREFERRED EMBODIMENT
(15) Description will now be given of the invention with reference to the attached FIGS. 1A-3H. It should be understood that these drawings and figures are exemplary in nature and in no way serve to limit the scope of the invention as the invention will be defined by the claims, as interpreted by the Courts in an issued US Patent.
(16) The prior art mechanism and system for connecting adjacent sections or open ended cans of aluminum into a long segment for connection between a power generator and a step transformer is set forth in FIGS. 1A, 1B and 1C. As can be seen, two identical pipe segments, cans, or tubular sections are aligned, end to free end and then a pair of semi-cylindrical welding bands placed over and around the adjoining edges. The inside of the welding strips are tack welded to the outside of the edges of the cans or tubular segments and a small length (in contrast to the circumferential dimension) of the dimension of the welding strips extends over and overlaps a small amount of the longitudinal length of the tubular segments. With the tack welding finished, the two circumferential seams of the welding strips are welded to the outside of the tubular segments to create a length (two segments end to end) of enclosure. The welding strips actually can be seen in FIG. 1C to be slightly greater in outside diameter than that of the tubular segments upon which they are placed so that the outside wall of the connected together tubular segments is not perfectly smooth.
(17) FIGS. 2A, 2B and 2C, also show a prior art method of connecting tubular segments but, here, a pair of inside, semi-cylindrical welding strips are placed inside the ends of the adjacent tubular segments, spot welded therein and then, the entire outside perimeter of the interface or seam of the adjacent pipe segments welded together.
(18) As seen in FIG. 3A, according to one embodiment of the present invention, one end of a first pipe segment 10 (sought to be joined to another pipe segment 24) is placed with its end or edge into a flaring machine (FM) or a jig intended to provide an inside or necked down or tapered flange 12 thereon. As can be seen in FIG. 3B, the necked down flange 12 has a leading edge 14, an outside circumferential wall 16 and a shoulder 18 extending substantially perpendicularly between the outside 20 of the pipe segment 10 and the necked down section or flange 12. FIG. 3D shows an alternate and preferred embodiment wherein the circumferential wall 16 does not extend fully perpendicularly to the outside circumferential wall 20 but, rather, shows a gradual taper, from outside 20 to the necked down flange 12. The perpendicular shoulder 18 (See FIG. 3D) is the point of contact with the circular end 22 of the untreated edge of the second tubular segment 24 (as seen in FIG. 3C). The taper shown in FIG. 3D facilitates the easy sliding of the second tubular segment 24 over the reduced in diameter flange up to the point that the shoulder 18 abuts against circular end 22 of second tubular segment 24. The taper also facilitates the process of manufacture and, by eliminating sharp angles, likely results in superior construction, i.e., more structural integrity.
(19) The necked down end of the first pipe segment shown in FIGS. 3B, 3C and 3D is intended to be slid into the untreated end of an adjacent pipe segment 24. Then, the full perimeter seam can be welded, between the circular end 22 of second pipe segment 24 and the shoulder 18 of the first pipe segment 20. This will result in a strong, axially aligned, length of pipe segments with excellent integrity, all made in a highly efficient manner. The flange of one segment is an integral backing strip for the weld, resulting in a superior surface are of weld and structural integrity. Of course, as mentioned, the other end of the pipe segment 24 (and, for that matter segment 20, too) are provided, as needed, with either a reduced in diameter end as shown in FIGS. 3B and 3C, 3D, or an untreated end (like tubular segment 24) or an enlarged in diameter outwardly flanged end as seen in FIGS. 3F, 3G and 3H. Preferably, one end of each segment is flared inwardly or outwardly and the other end untreated. The point is that only one end needs to be flanged inwardly (FIGS. 3B, 3C and 3D or flanged outwardly (FIGS. 3F, 3G and 3H) and the other end can be wholly untreated. In this manner, a long stretch of pipe segments can be laid, end to end, with the flanged ends either sliding into or over the untreated ends of adjacent segments to create a long and axially aligned length of tubular sections. Of course, the length of the flange 30 (See FIG. 3C), extending between shoulder 18 and free edge or circular wall or end 16 needs to be adequate such that some backing support is provided and axial alignment maintained, especially during the welding process. According to the preferred embodiment, the length of the flange's extension into the free or untreated end of the adjacent tubular section is enough to hold the two cans securely together and provide a backing to the seam joint.
(20) According to the embodiment shown in FIGS. 3E through 3H, a free end of a third tubular section 40 is brought into working contact with the outwardly Flaring Machine FM2 which will cause the end to have an outward in diameter flare. As seen in FIG. 3F, the outside wall 42 is provided, at its end 44, with an outwardly flared or increased in diameter end 46. The flared end 46 comprises a circular edge 48, an outside, circumferentially extending along a short longitudinal distance, flare wall 64, and an outwardly tapered connecting wall 52 (See FIG. 3H). A shoulder 54 on the inside of the flared head end will, when a second pipe segment 60 is slid within the flared end, have its edge 62 (see FIG. 3G) abut against and in contact with the shoulder 54. When the second pipe segment 60 is slid into and abuts the shoulder 54 of the first pipe segment 40, the two segments 40 and 60 are welded about the entire circumference of the seam to provide a secure, axially aligned and strong length of pipe segments. The seam is defined as the edge 64 of the flared out section and the outside of the second tubular pipe segment 60. The wall of the flange serves as a backing wall for the seam. Of course, the other end of the second pipe segment 60 can either be and is preferably untreated, provided with a flange as shown in FIGS. 3B, 3C and 3D or as that shown in FIGS. 3F, 3G and 3H. The important point, however, is to provide multiple lengths of pipe segments which can be laid, end to end, one flange either sliding within the free end of an adjacent pipe segment or over the adjacent pipe segment, with the seams then being welded from the outside. Here, too, the length of the extension of the wall 64 (FIG. 3H) from shoulder 54 to edge 48 is just slightly greater than the thickness of the pipe. As can be seen in FIG. 3H, an outwardly flared or outwardly tapered flange wall can be provided from outside wall 42 to wall 64 or, alternatively but not as preferred, the wall can be perpendicular to the longitudinal axis of the pipe segment. It has been found that a tapered wall between the shoulder and the free end 48 is structurally superior and, in addition, is easier to be manufactured without defects.
(21) It will be understood by those of ordinary skill in the art that various changes may be made and equivalents may be substituted for elements without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular feature or material to the teachings of the invention without departing from the scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed but that the invention will include all embodiments falling within the scope of the claims.
