FIELD OF THE INVENTION

The present invention relates to carriage assemblies for fusing two ends of polymer pipe.

SUMMARY

The carriage of the present disclosure is part of a fusion system that is designed to be modular and light weight in order to easily use in tight spaces. The disclosure includes a modular carriage where the jaws are removable preferably without the requirement of tools in order to allow the carriage to be assembled on existing pipe that is in place in the rafters or running up a wall of a structure. For the purpose of exemplification, and not limitation, the carriage of the present disclosure may be sized to accommodate six different sizes of pipe for which butt fusion is required: 1) 355 mm; 2) 400 mm; 3) 450 mm; 4) 500 mm; 5) 560 mm; or 6) 630 mm.

Each of these exemplary sizes requires its own size jaws and guide rod support. The hydraulic cylinders and guide rods of the present disclosure are able to be used on all sizes of the carriage system for the above examples. This allows a cost reduction and increase in the flexibility of the fusion system. This increased flexibility is characterized by the ability to:1.) Break the unit down for easier storage and shipment;2.) Customize the particular carriage assembly for a particular work space size and pipe size requirement;3.) Customize the equipment sent to a job site in order to limit unnecessary parts;4.) Move the carriage with ease in buildings and other structures;5.) Assemble the carriage at the site of use of the carriage and particularly in work/pipe locations that are too tight for the use of a conventional fusion machine.

Additional benefits of the modular carriage of the present disclosure include:1.) Reduced weight of components that must be transported to/moved and/or lifted to the location of the pipe fusion;2.) The modular design allows for the carriage of the present disclosure to be assembled directly on existing pipes that are already in place;3.) Having a jaw for each size of pipe reduces the required spatial envelope for the carriage which allows the machine to fuse pipes that are spaced much closer to each other;4.) Allows the possibility for reduced shipping size as the component (modular) parts are able to be disassembled and nested in shipping packaging.

The carriage of the present disclosure is configurable so that the right size tools for any specific fusion requirement on a job site, even when different sizes of pipes are presented.

The carriage assembly of the present disclosure includes in one embodiment, generally, a fixed jaw; moveable inner jaw and moveable outer jaw, and a guide preferably for each size of pipe. In addition, a combined hydraulic carriage cylinder and associated guide rod may be included. In this embodiment the hydraulic carriage cylinder/guide rod; a guide rod cap, and a guide rod sleeve may also be provided and be the same and employed with all pipe and jaw sizes. In an alternate preferred embodiment, a fourth, fixed jaw is added for increased stability.

The modular carriage of the present disclosure is adaptable for varying spacing between ends of polymer pipe during fusion. The present modular design allows for many different sizes of pipe to be fused with the same fusion apparatus without the use of inserts. As set forth above, the modular carriage includes in a basic embodiment a fixed jaw; an inner and outer movable jaw; and a plurality of guide rods. The fixed jaw is adapted for tool free engagement with the plurality of guide rods. A carriage cylinder is associated with each of at least two of the guide rods. The carriage cylinder may be mounted for reciprocal travel on its associated guide rod. Each movable jaw is adapted for tool free engagement with a cylinder for reciprocal travel therewith. Each moveable jaw is preferably adapted for engagement with at least two carriage cylinders for alignment and stability purposes.

The guide rods each include a longitudinal axis. Each associate carriage cylinder also includes a longitudinal axis which is concentric with the longitudinal axis of its associated guide rod.

A guide rod support is adapted for tool free engagement preferably with at least two of the plurality of guide rods. A latching assembly is operable to secure the guide rod support to the guide rods by tool free engagement. The movable jaws include at least two latching assemblies being operable to secure each movable jaw to at least two carriage cylinders by tool free engagement.

The fixed jaw includes at least two latching assemblies being operable to secure the fixed jaw to at least two guide rods by tool free engagement.

The plurality of guide rods are each substantially cylindrical with an external surface and an internal surface. The guide rods each include a first end and a second end. A guide rod sleeve is positioned at least partially over the external surface of each guide rod adjacent its first end. The fixed jaw is secured to the plurality of guide rods adjacent their first end. A guide rod cap is in contact with (threaded into) the internal surface at the first end. The fixed jaw is positioned between the guide rod sleeve and the guide rod cap and secured by the latching mechanism.

Each guide rod sleeve may include a shoulder for retaining the guide rod sleeve adjacent the first end of its respective guide rod.

Each carriage cylinder may be hydraulically actuated for reciprocal travel on its associated guide rod. Each of the plurality of guide rods has a length and each carriage cylinder has a length and two ends. Each carriage cylinder may surround its associated guide rod. The length of each carriage cylinder is less than the length of its associated guide rod so as to allow reciprocal hydraulic travel of each carriage cylinder along the length of its associated guide rod.

Each carriage cylinder may include a rod gland at each end. Each rod gland is operable to hydraulically seal the carriage cylinder at each end. The rod gland surrounds its associated guide rod. Each rod gland includes a channel for receiving and supporting a movable jaw. As stated previously, in one embodiment there are two moveable jaws, an inner moveable jaw and an outer moveable jaw. In a preferred embodiment each moveable jaw is supported.

A latching mechanism secures the moveable jaws. The movable jaw is secured in the channel by the latching mechanism. In a preferred arrangement the latching mechanism is a lock over (also known as a cam over) clamp. Thus, the movable jaws are secured to the rod glands by tool free engagement.

The rod glands are mounted on the carriage cylinder so as to maintain the first movable jaw and the second movable jaw in a parallel orientation. A movable jaw (inner or outer) is secured to a rod gland at each opposing end of each of at least two guide rods. In one embodiment, two carriage cylinders, one of each of the at least two guide rods are positioned substantially parallel to one another.

The carriage cylinder of the present invention may employ a cylinder assembly which may be of a known design. The cylinder may be powered in any known manner, such as pneumatically, or hydraulically.

One particularly suited cylinder design, however, includes a combination hydraulic cylinder/guide rod of the present disclosure. The cylinder includes in one embodiment a guide rod; cylinder tube; a rod gland on each end of the cylinder tube; and a plurality of the rods extending between the rod glands.

The piston includes an internally ported body with machined in sealing features for proper hydraulic functions.

The hydraulic cylinder tube is preferably a composite tube for encasing the hydraulic cylinder. The rod gland on each end of the cylinder tube seals on the cylinder rod and cylinder tube and seals the cylinder tube. The rod gland also pilots on the cylinder bore to properly align the carriage jaws. The tie rods connect the two rod glands at the ends of the cylinder tube.

The guide rod of the present disclosure in one embodiment includes three separate elements that are preferably threaded together to form the guide rod/cylinder rod and piston. This split embodiment allows for the hydraulic functions of the carriage to be routed through the piston as a manifold in order to move the associated (required) hydraulic connections away from the outside of the cylinder where they are more susceptible to damage.

The cylinder tube is adapted for reciprocal travel along a guide rod. As hydraulic fluid flows into an annular area defined between the hydraulic cylinder tube and the split guide rod, the hydraulic cylinder tube and rod glands (with jaws attached) will reciprocate back and forth. This is accomplished because one hydraulic fluid chamber (and port therefor) is separated from a second hydraulic fluid chamber (and port therefor) via a seal to separate the first and second annular hydraulic fluid chambers of the cylinder.

The combined hydraulic cylinder and guide rod of the present disclosure is self-contained and when adapted for the modular carriage described above, does not require bolts to be inserted through the jaws as is the case with certain prior art hydraulic cylinder designs. The present cylinders are attached to the moveable jaws with the clamp attachment assembly directly.

Each carriage cylinder may be hydraulically actuated for reciprocal travel on its associated guide rod. Each of the plurality of guide rods has a length and each carriage cylinder has a length and two ends. Each carriage cylinder may surround its associated guide rod. The length of each carriage cylinder is less than the length of its associated guide rod so as to allow reciprocal hydraulic travel of each carriage cylinder along the length of its associated guide rod.

Each carriage cylinder may include a rod gland at each end. Each rod gland is operable to hydraulically seal the carriage cylinder at each end. The rod gland surrounds its associated guide rod. Each rod gland includes a channel for receiving and supporting a movable jaw. As stated previously, in one embodiment there are two moveable jaws, an inner moveable jaw and an outer moveable jaw. In a preferred embodiment each moveable jaw is supported.

A latching mechanism secures the moveable jaws. The movable jaw is secured in the channel by the latching mechanism. In a preferred arrangement the latching mechanism is a lock over (also known as a cam over) clamp. Thus, the movable jaws are secured to the rod glands by tool free engagement.

The rod glands are mounted on the carriage cylinder so as to maintain the first movable jaw and the second movable jaw in a parallel orientation. A movable jaw (inner or outer) is secured to a rod gland at each opposing end of each of at least two guide rods. In one embodiment, two carriage cylinders, one of each of the at least two guide rods are positioned substantially parallel to one another.

It should be understood that carriage cylinders of the carriage of the present disclosure described above may employ a cylinder assembly which may be of a known design. The cylinder may be powered in any known manner, such as pneumatically, or hydraulically.

The cylinder tube is adapted for reciprocal travel along a guide rod. As hydraulic fluid flows into an annular area defined between the hydraulic cylinder tube and the split guide rod, the hydraulic cylinder tube and rod glands (with jaws attached) will reciprocate back and forth. This is accomplished because one hydraulic fluid chamber (and port therefor) is separated from a second hydraulic fluid chamber (and port therefor) via a seal to separate the first and second annular hydraulic fluid chambers of the cylinder.

The combined hydraulic cylinder and guide rod of the present disclosure is self-contained and when adapted for the modular carriage described above, does not require bolts to be inserted through the jaws as is the case with certain prior art hydraulic cylinder designs. The present cylinders are attached to the moveable jaws with the clamp attachment assembly directly.

Some, non-limiting benefits of the present combined hydraulic cylinder/guide rod assembly designs include:1.) The combination cylinder/guide rod assembles in the carriage without the use of any hand or power tools;2.) A self-contained design as described herein does not require the jaws (fixed and moveable) to be bolted to the ends to remain assembled.3.) The design of the present disclosure allows for a small annular area for the cylinder (as compared to other known piston attachment methods which take up considerable space);4.) A lower cost to manufacture is associated with the present design (lower cost than machining stock material down to add all of the piston features/required elements);5.) The piston is able to be easily machine as a manifold allowing the hydraulic porting to be done through the hollow cylindrical guide rods;6.) The hydraulic cylinder/guide rod assembly of the present disclosure includes features that ensure concentricity of the guide rod to provide jaw alignment for proper fusions and to reduce cylinder drag.

A fourth jaw and a skid, when used in conjunction with the three jaw skid, create a four jaw carriage that may be used when fusing on the ground in a traditional manner. The four jaw skid provides a stable base that allows precise alignment of pipe with minimum effort. The three jaw carriage and the outer fixed jaw attach to the skid in a tool less manner through the use of interlocking D-shaped cams. The outer fixed jaw (fourth jaw) is attached to the inner fixed jaw (third jaw) with the usage of two jaw braces.

The skid is comprised of two sections that can be folded flat and pinned rigidly in the flat configuration with the use of four detent pins, or can be folded in half and latched in the closed position using the same D-shaped cams that latch the carriage into the skid. The folding of the skid allows for shipping the carriage in a compact manner. The ability to fold the skid allows the entire package to be packed into four foot shipping pallets.

Benefits of the fourth jaw and skid include the following, without limitation:1.) A fourth jaw and a skid may be used in conjunction with a three jaw carriage.2.) The assembly/connection of the jaws to the skid, the jaws to the guide rod(s) and/or jaw(s) to each other is toolless.3.) The carriage, and particularly the carriage mounted to the skid, provides a stable base for conventional fusion of pipe.4.) The addition of a fourth jaw eases alignment of one pipe to another through the use of two jaws per side.5.) The carriage assembly, particularly with the additional fourth jaw, provides increased clamping force for retention of pipe during high force fusion.6.) D-shaped cams connect the jaws to the skid.7.) D-shaped cams lock the skid together when folded for shipping.8.) A Folding skid allows for compact shipment of the carriage assembly package.9.) A Folding skid can be pinned in a rigid configuration to provide a stable base for fusion.10.) A Spring plunger is used to ensure the D-shaped cam does not disengage during use
Attachment “A” is incorporated fully herein by reference.

