GB2415835A

GB2415835A - Cable end alignment for connection

Info

Publication number: GB2415835A
Application number: GB0414671A
Authority: GB
Inventors: David Charles Peter Harrison
Original assignee: CONTACTUM Ltd
Current assignee: CONTACTUM Ltd
Priority date: 2004-06-30
Filing date: 2004-06-30
Publication date: 2006-01-04
Anticipated expiration: 2024-06-30
Also published as: GB0414671D0; GB2415835B

Abstract

Bared cable cores 11,12,13 are aligned for connection to terminals 3,26,28,30 by a locator. In one embodiment, figure 1, live cores 11 are fixed in position on a locator plate 15 so as to align with live terminals 3 of circuit protection devices 2 of a distribution board 1. The neutral cores 12 are fixed to a bar 18 with the bar being connected to a neutral terminal 18b of the circuit protection device. Likewise earth cores 13 are fixed to an earth bar 19 connected to an earth terminal 19b. In an alternative embodiment, figure 3, locator blocks 31 are aligned with the terminal blocks 20. Locator blocks each receive bared ends 17,12a,13a of cable cores 11, 12, 13 and align the bared ends 17,12a,13a with terminals of corresponding terminal block 20.

Description

24 1 5835 Cable Connection Method

Description

lights toveuttotl relates to a method for easily and quickly connecting the cable s ends of a multi-core cable to the terminals of one or more electrical components.

lithe mventlorl Is primarily but not exclusively c-'ncerncd with providing a method of connecting the cable ends of the multi-core cable to a plurality of fixedly positlorlcd electrical components such as a number of circuit protection lo devices or isolators mounted in a distribution board. However, it will be appreciated that the invention Is applicable to the connection of electrical cables or wiring to any electrical device or accessory.

Although the cable connection method of the invention is not restricted to Is distribution boards enclosing a number of circuit protection devices, tints will be used hereafter as an illustration to describe the problems to be solved by the method of the prescut invention.

When wiring up an electrical Installation which includes a distribution board with a number of circuit protection devices or isolators in it, the Installing electrician normally has to individually connect each of the live cable ends coming from all the frxcd electrical circuits extending throughout an entire budding, and which arc wired up to Itghts, plugs, sockets, switches, etc., to the circuit protection dcvrces. Similarly, each of the earth and neutral cable ends must be Individually collected to respective earth and neutral terminals In the distribution board.

Similar conuccttons must be tnaclc to interconnect the distribution board with any sub-dstrrbution boards and/or interconnect distribution boards with any consumer units.

A problem with the aforementioned procedure is that it is complicated and very time consuming. An attctnpt has beers made to alleviate tints problem by fitting plugs to the end of the multt-corc CalJIC, the plugs then being c:>nuccted to - 2 spccfcally designed dedicated sockets on the distribution board which are pre- wre<l and connectecl to the circuit protection devices, earth and neutral terminals in the distribut-'n board at the factory as part of the manufacturing process.

Whilst this substantially reduces the wiring up time that must be carried out on s site, the cost of manufacturing these dedicated plugs and sockets Is very expeosivc, cspccally In circumstances where they need to be capable of withstanding high current loads in the region of between 100 to 200amps, as this requires very large plugs and sockets possessing a high short-crcuit withstand in the rcgon of 16141. It will also be appreciated that the manufacturing process takes considerably longer because of all the pre-wiring within the distribution board that must be completed at the factory.

It is an object of the present invention to overcome or substantially reduce these problems without any significant cost penalty.

According to the invention there Is provided a method of connecting the cable ends of a mult-core cable to the terminals of a plurality of fixedly positioned clectucal c-'mponcuts cornpristug the steps of: a) taking a multi-c<:'re cable in which individual cables have been mounted to a locator element with the live cable ends protruding from the locator element, the live cable ends being mounted to the locator element in predetermined spaced relationships relative to each other, the predetcrmincd spaced relationships corresponding to the locations of 2s electrical terminals on the electrical components to receive them, and b) simultaneously Inserting said pre-positioncd cable ends into the electrical terminals of the elcctrcal components to electrically connect them thereto.

In a preferred embodiment, the method includes the step of mounting individual cables of the mult-core cable to the locator clcmcut with the live cable cods - 3 protruding from the locator element in predetermined spaced relationships to each otller, prior to carrying out step (a) above.

l'refcrahly all the live calyle ends are mounted on a locator plate. (conveniently, s the cable ends are attachecl to fingers extending therefrom.

In a preferred metllcd of the invention, all the neutral cable ends are connected to a neutral bar attached to the locator plate. I'reEerably, all the earth cable ends are also connected to an earth bar attached to the locator plate.

In an alternative method of the invention, the ends of a live, neutral and earth wire of the multi-core cable are received In an islclivdual locator which fixes the position of said wire ends to correspond to the terminals in the electrical component Into which they are to be inserted. Conveniently the wire ends are Is fixed In a staggered relationship relative to each other.

According to another aspect of the invention, there is provided a locator element to pre-postion the live cable ends of individual cables of a multcore cable in a pre-determmed spaced relationship to each other, the locator element comprising a plurality of spaced mounting locations configured so that the live cable ends are positioned in the predetermined spaced relationship when a cable is attached to each mounting location.

In a preferred embodiment, each mounting location comprises a finger. The locator element may comprise a plate to which the cables are tethered or otherwise attached with their ends protruding beyond the end of the plate. The cables are insulated and only a portion of each cable extending beyond the plate is stripper of its Insulation and prepared ready for electrical connection. In another embodiment, the locator element may be a block through which the so cables extend. Again, the cables are insulated and only a portion of each cable that protrudes from the block Is stepped of its insulation and prepared ready for electrical conNcction to an electrical component.

I;,mbodiments of the invention will now be descubetl, by way of example only, with reference to the accompanying drawings in whch: s Figure 1 Is a schematic plan view of a distribution board to which a multt-core cable can be connected using the method of the invention.

Figure 2 Is a schematic plan view of an alternative method for connecting a mult-core cable to an electrical component such as a dstnbution board using lo the method of the Invention, and Figure 3 is a schematic perspective view of the Installation shown In l:;igure 2.

Figure 1 shows a distribution board comprising a cabinet 1 in which a plurality Is of Juxtaposed circuit protection devotees or isolators 2a 2e are fixedly mounted.

l'he circuit protection devices are of known design so they will not be described further. However, each one has a screw terminal 3 to receive a live electrical eonduetc>r 17 emerging from a live cable 11 of a known mult-eore cable 10. 'I'he multt-eore cable 10 is of known type and the cables therein are connected at its end remote from the cabinet 1 to other eleetreal components such as other distribution boards, distribution hubs and/or plugs and sockets eta. (not shown).

The cable 10 also carries a plurality of neutral wires 12 and earth wires 13, each respectively connected to a neutral bar 18 and an earth bar 19. Neutral bar 18 is connected by electrical connector 18a to terminal 1Sb In a terminal block 4 in the Consumer unit and earth bar 19 is connected by electrical connector 19a to terminal 19b In a terminal block 5 in consumer unit.

Electrical power Is supplied to the cabinet 1 from a three-phase cable 6 which is connected to an Isolation device or mcomer (not shown). The live supply wire 7 Is fed from the isolation device to a common terminal 7a where it is then fed to the other terminals.. Neutral stpply wire X Is fed from the Isolation clevce to a - 5 neutral terminal block 4 and the earth supply wire 91S fed from the isolation device to the earth terrmmal block 5.

In prior art connection methods, once the consumer unit has been installed on s site, the mstallmg electrician individually connects each live wire 11 from mult'- core cable 10 to the terminals 3 of respective circuit breakers 2 one-by- one, each earth wire 13 to a terminal on a multi-term1nal earth bar and each neutral wire 12 to a terminal of a mult1-tetmlual neutral bar. 'thus proceclure Is very time consuming.

In accordance with the method of the present mvent1on, the live electrical conductors 17 are pre-mounted in fixed positions relative to each other which correspond to the positions of the terminals 3 on the circuit protection devices 2a - 2e into which they are to be inserted. '[this is achieved by attaching the live 7s cables 11 to a former or locator plate 15 to hold the cables in pre- determ1ned spaced relative positions. 'l'he locator plate 15 may have a number of fingers 16 which are spaced from each other by the appropriate distance so that if one cable I 1 IS attached to each finger 16, they will each be spaced from each other by the required distance corresponding to the distance between the terminals of the circuit protection devices. The cables 11 may be attached to the locator plate 15 so that the bared live electrical conductors 17 at the end of each cable 11 protrude from the end of each finger 16. The exposed wire ends of neutral cables 12 are pre-wired by connecting them to terminals in neutral bar IX attached to one side of the locator plate 15. Similarly, the exposed wire ends of earth cables is 13 are pre-w1red by connecting them to terminals in earth bar 19 secured to the opposite stale of the locator plate 15. As this work can be earned out in the factory or at least away from the installation site and/or cabinet 1, the task is much easier and quicker to complete. The cables 11, 12, 13 may be attached or tethered to the locator plate 15 using standard plastic te-wraps or the like. 'lthe plate may IJC made front metal or plastics material and it will be noted that the live cables 11 are insulated from the plate 15 because the exposed wire ends

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protrude beyond the ends of the fingers 16 and so do not come mto direct contact with the plate 15.

All the wire ends 11, 12, 13 emerging from the end of the multi-core cabic 1() are now fixedly mounted in place on the locator plate 15 so It Is very quick and easy for the electrician to push the live wire ends 17 Into the terminals 3 at the same time and secure them thereto. A single wire 19a is then used to connect the earth bar 1') to earth bar terminal 19b of earth terminal block 5 in the consumer unit. Similarly, a single wire Ida Is used to connect the neutral bar 18 to the lo terminal 18b on the neutral terminal block 4 in the consumer unit.

It will be appreciated that the shape of the locator plate 15 shown in the drawings is not critical as the number of fingers 16 will clepeod on the number of live cables in the multi-core cable 1() which are to be connected to the circuit Is protection devices In the dtstrtbutton board.

Although the supply cable G Illustrated in Figures 1 and 2 shows only single Itve, neutral and earth wires, such as would be the case if supply cable 6 extends directly from the mains supply, It will be appreciated that the cable 6 could be an interconnecting cable between distribution boards and/or consumer units and therefore include multiple live, earth and neutral wires. In this case, a plate or former similar or identical to the plate 15 could be attached to the wires of cable 6 and connected to the distribution board in the same way.

As Instead of mounting the cable ends 11, 12, and 13 on a single locator plate 15 as described with reference to Figure 1, a plurality of individual locator members can be used as will now be described with reference to Figures 2 and 3.

In the tostallatton shown in l;tgures 2 and 3, the mates electrical po\ver supply Is fed by cable 6 to a row of circuit protection crevices 2() mounted m the cabmet 1.

I.ach circuit protection device 2(:) has a hole 25 to receive a live wire therein and l clamping means such as a screw 2G is mounted in the circuit protection device to clamp the \vre therein and electrically connect it to the circuit protection crevice.

An earth bar 21 is mounted above the row of circuit protection devices 20 but s staggered relative thereto as illustrated. I'he earth bar 21 has a plurality of holes 27 therein in which a wire can be secured using some form of clamping means such as a screw 28. Neutral bar 22 is mounted above the earth her 21 but in staggered relationship thereto as illustrated, said bar 21 having holes 2') therein to receive a wire end which can be secured therein using some form of clamping lo means such as a screw 30.

F,arth wire 9 and neutral wire 8 of supply cable 6 are electrically connected respectively to bars 21 and 22 In known manner.

Is 'I'he groups of wire ends 11, 12 and 13 emerging from the mult-core cable I () which are connected to the electrical components such as plugs and sockets are each mounted in a stepped locator 31 as llustratecl, the portion of the wires between the end cuff the cable 10 and the locator 31 having a V-shaped kink in them to prevent stress arising in the cables. 'l'he cables pass through holes and to emerge from the stepped locator 31 to terminate in wire ends 12a, 13a, 17 which are preferably bared but may also be crimped or otherwise prepared for electrical connection. Although Figure 2 illustrates an arrangement in which there are 5 locators 31 tc> getller, each locator 31 receiving an earth, live and neutral wire, it Will IJC appreciated that the locators may be separate and discrete from each 2s other so that the earth, live and neutral wires passing through one locator 31 are connected separately to each of the live, earth and neutral wires passing through each of the other locators 31.

As the cable ends 12a, 13a and 17 preposition in their locators 31, they are then m their correct posttcns, both physically and electrically, to be received in t}lC holes 2), 27 and 25 m their respective circuit protection devices 20, earth bar 21 and neutral bar 22 so it Is simple for the electrician to offer the locator 31 UP {0 the circuit protcctron devices 20 and push the cable ends 12a, 13a and 17 into the holes 29, 27 and 25 where they are secured using clamping means such as scrc\vs 30, 28 and 2G.

s It will be appreciated that fitting the wire ends In Iccators 3I makes the connection of the cable entls 11, 12 and 13 to the circuit protcctron dcvccs 20 much simpler and quicker than would have been possrblc than using prior art methods.

Claims

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Claims 1. A method of connecting the lvc cable ends of a mult-core cable to respective terminals of a plurality of fixedly positioned clectacal components s comprising the steps of: c) taking a multi-core cable m which individual cables have beck mounted to a locator clement with the live cable cods protruding from the locator element, the live cable ends being mounted to the locator clement in prcdetctmined spaced relationships relative to each other, the predetermined spaced relationships corresponding to the locations of electrical terminals on the electrical components to receive them, and d) simultaneously inserting said propositioned cable ends mto the electrical terminals of the electrical components to electrically connect them thereto.
2. A method according to claim 1, wherein the method includes the step of mounting individual cables of the multi-core cable to the locator clerncut with the live cable ends protruding front the locator element In predetctmined spaced relationships to each other, prior to carrying out step (a) above.
3. A method as claimed in claim 1 or claim 2, whcren the live cable cods are all mounted or a locator element.
4. A method as claimed in claim 3, whctcm the live cable ends arc mounted 2s on fingers extcodng from said locator clement.
5. A method as claimed in claim 4, wherein all the neutral cable ends are rcccved in a bar attached to the locator clement.
6. A method as clamcd In claim 4, wherein all the earth cable cocls arc rcccvcd in a liar attached to the locator clement.

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7. A method as claimed In claim 1, wherein the locator element Is an mdtvdual locator, the ends of a live, neutral and earth wire of the mult'- core cable acing rcccvcd m the individual locator which fixes the position of said wire ends to correspond to the terminals In the electrical component into which s they arc to be inserted.
8. A method according to claim 7, wherein the individual locator Is a block, the live, neutral and earth wires passing through apertures in the block.
9. A method according to claim 8, wherein the individual locator Is a plate, the live, neutral and earth wires being attached to the plate.
10. A method as claimed in claim 9, wherein the wire ends are fixed in a staggered relationship relative to each other.
11. A locator element to pre-position the ends of individual wires of a multi- core cable in a pre-detcrmned spaced relationship to each other for connccton to an electrical component, the locator clemcut comprising a plurality of spaced mounting locations configured so that the ends of individual wires are positioned in a predetcrmincd spaced relationship when an individual wire is attached to each mounting location.
12. A locator clement according to claim 11, wherein each mounting location comprises a finecr, a cable being attachal>le to each huger with its end 2s protruding beyond the end of the huger.
13. A locator element according to claim 11, comprising a block, the spaced mounting locations being defined by apertures in the block through which each wire passes to attach it to the block, the ends of each wire protruding from the block
14. ,A method substantially as hcreinbcfore clescnhed l
15. A locator clement substantially as hcrenbefore described

13. A locator clemcut according to claim 11, comprising a block, the spaced mounting locations being defined by apertures m the block through which each wire passes to attach it to the block, the ends of each wire protruding from the block.

14. method substantially as hcrembefore describe l - 11 15. A locator clement substantially as hercinbeforc dcscribcd.

Amendments to the claims have been filed as follows 1. A rmethocl -:,f connecting a plur,ilty of TIN C' neutral and earth cable ends of a mult-cc->re cable to respective live, neutral and earth terminals of a F>lur-alty of s fixecll: post:oncd electrical coinponens, cornprsrlg the steps of.

a) taking a mult--cor-e cable in whcl1 ncliNTiclual live cables have heen mounted to a locator element with the five cable ends protruding from the k>catc>r element, the hve cable ends long mounted tc> the locator element In predetermined spaced relationships relative to each other, the lo predetermined spaced relationships c<-:rrespondrlg to the locations of the live electrical terminals of the eiectrrcai components to receive therm, anti in which the neutral cable ends of the multi-core cable are located in a comm<>n neutral liar and the earth cable ends are located in a common earth bar, the neutral and earth hers both being attached to the locator element, h) simultaneously inserting said pre-positoned five cable ends into the electrical terminals of the electrical components to electrically connect the live cal:>le ends thereto, and c) connecting said neutral and earth bars tc> correspoflcling neutral and earth terminals respectively of the electrical components to electrically connect them t' n ereto 2. A method according to chain 1, wllcrcin the method uncouples the step of mounting ndvclual cables of the multi-core cable to the locator elementwith 2s the live cable ends Protruding from the k>catc>r element in predetermined spaced relationships to each other, prior to carrying out step (a) above 3. A method as claimed in claim 1 or claim 2, wlerer1 the live cable ends are all rn<->unted on a locator element 4. A method as claimed In claim 3, wherein the live cable ends are mounted on fingers extending from said locator elcrnert 3 5. A method as claimed in claim 4, wherein all the neutral cable ends are received in a bar attached to the locator element.

do 6 A method as claimed in claim 4, wherein all the earth cable ends are recevecl In a bar attached to the locator element 7. A method as claimed in claim 1, wherein the locator element is an individual locator, the ends of a live, neutral and earth wire of the rnult-core cable being received in the individual locator which fixes the position of said wire ends to correspond to the terminals in the electrical component into which s they are to be inserted.

8. A method according to claim 7, wherem the individual locator is a 1:1ock, the live, neutral and earth wires passing through apertures in the block.

lo 9. A method according to claim 8, wherein the individual locator is a plate, the live, neutral and earth wires being attached to the plate.

10. method as claimed in claim 9, wherein the wire ends are fixed in a staggered relationship relative to each other.

11. A locator element to pre-position the ends of individual wires of a multi- core cable in a pre-determined spaced relationship to each other for connection to an electrical component, the locator element comprising a plurality of spaced mounting locations configured so that the ends of individual wires are positioned in a predetermined spaced relationship when an individual wire is attached to each mounting location.

12. A locator element according to claim 11, wherein each mounting location comprises a finger, a cable being attachable to each finger with its end 2s protruding beyond the end of the finger.