BACKGROUND AND FIELD OF THE PRESENT INVENTION

Field of the Present Invention

The present invention relates generally to electrical jumpers. More specifically, the present invention relates to a system, method and apparatus for positioning and training prefabricated, flexible jumpers.

Background of the Invention

Substations generally operate to transform voltages within electrical distribution systems. Substations are connected to electrical systems by connecting wires or jumpers. Jumpers attach between substation terminal mounts and terminal mounts electrically connected to larger electrical systems. Jumpers that can be repositioned and shaped are referred to as flexible jumpers.

Electrical substations are increasingly prefabricated and transported to a given location for installation. Once installed, flexible jumpers are attached. Commonly, the flexible jumpers are built on the finally erected substation structure. Alternatively, they are built on a work bench or “one ended” off-site and finished in the field on an erected substation. Each of these methods creates significant delays and extra costs during substation installation. Specifically, work benches don't allow for the jumpers to be positioned as they would be on the installed substation. This causes jumpers to be built out of position and with no means to train the cable between ends. Further, the alternative of building a one ended jumper and finishing it in the field requires more material and labor than building a jumper all at once.

Accordingly, what is needed is an improved system, method and apparatus for positioning and training flexible jumpers to overcome the limitations of the prior art. In particular, what is needed is a system that allows jumpers to be built without an erected substation, in a controlled production environment, and positioned on the substation taking into account cable routing, gravity and other factors.

SUMMARY OF THE DISCLOSURE

To minimize the limitations found in the prior art, and to minimize other limitations that will be apparent upon the reading of the specifications, the preferred embodiment of the present invention provides an improved system, method and apparatus for positioning and training prefabricated, flexible jumpers. According to a first preferred embodiment, the present invention includes a flexible jumper jig which is reconfigurable to replicate the end positions of a flexible jumper as it would be on an installed substation thus allowing for the flexible jumper to be completely fabricated off-site.

According to a further preferred embodiment, an exemplary system of the present invention may include a framework forming three orthogonal axes and repositionable tooling mounts for end fittings. According to another aspect of the present invention, an x-axis oriented rail may preferably hold a tooling mount which is configurable to be rotated about its axis to allow for alternate tooling mount orientations. Additionally, a y-axis oriented rail may be perpendicular to the x-axis rail and may be fixed. Still further, a z-axis oriented rail may be perpendicular to and slide along the y-axis rail. Additionally, a second tooling mount may be attached to the z-axis rail. Preferably, all tooling mounts and movable rails may be bolted and/or pinned in place once positioned.

According to further aspects of the present invention, a variety of tooling mounts and adapters may be used with the present invention. These may include offset, rotary angle, and compound angle tooling mount adapters which may preferably allow connection points and end fittings to be rotated, titled and positioned as needed.

These and other advantages and features of the present invention are described with specificity in the descriptions below to make the present invention understandable to one of ordinary skill in the art.

