Method and apparatus for mounting a power converter

• US 8,358,516 B2
• Filed: 10/30/2009
• Issued: 01/22/2013
• Est. Priority Date: 11/07/2008
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Weiss, Bruce W., Brubaker, John R., Alwardt, Keith A., Grosskreuz, Paul J., Michalski, Robert M.
• Primary Examiner(s): Thompson, Timothy
• Assistant Examiner(s): MILAKOVICH, NATHAN J
• Application Number:
  US12/609,240
• Publication Number:
  US 20100118507A1
• Time in Patent Office: 1,180 Days
• Field of Search: 361/728, 361/730, 361/752, 361/796, 361/800, 361/825
• US Class Current: 361/825
• CPC Class Codes: H02B 1/48 Mounting of devices therein
• CPC Class Codes: H02G 3/081 Bases, casings or covers
• CPC Class Codes: H05K 5/0204 Mounting supporting structures on the outside of casings
• CPC Class Codes: H05K 7/14322 wherein the control and power circuits of a power converter are arranged within the same casing
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

The present invention provides a power converter mounting system including a flange that cooperates with a power converter and an enclosure. The flange includes a through hole that cooperates with an opening in the enclosure to permit the power converter to extend therethrough. A number of fasteners connect to the flange and overhang a portion of the power converter. The fasteners are configured to be manipulated from a front side of the power converter. An outer perimeter of the flange extends beyond the opening in the enclosure. The flange is secured to the enclosure with a number of fasteners that are also operable from the front side of the power converter. The power converter mounting assembly is configured to secure a power converter to an enclosure so as to satisfy a variety of sealing requirements as well as allowing convenient servicing of the power converter system.

Claims

1. A mounting assembly for a power converter having a housing with outer sidewalls and a lip extending outwardly from at least a portion of the outer sidewalls, the mounting assembly comprising:

a generally planar flange having;

a front and a rear surface and an opening configured to allow passage of the sidewalls of the converter therethrough;

the front surface of the flange having a mating surface extending substantially around the opening to receive a rear face of the lip of the power converter;

the rear surface of the flange configured to engage a generally planar mounting surface; and

a plurality of fastener openings displaced from the mating surface to clear the lip of the power converter when the lip is positioned against the mating surface;

a sealing member fitting between the mating surface of the flange and the rear face of the lip; and

a plurality of fastening members, each fastening member engaging one of the fastener openings from the front surface of the flange and having an edge engaging a front face of the lip when the lip is positioned against the mating surface to sealingly compress the sealing member between the mating surface and the rear face of the lip.

2. The mounting assembly of claim 1 wherein each fastening member engages a cavity in the housing of the power converter.

3. The mounting assembly of claim 2 wherein:

the lip extends generally around the outer periphery of the power converter; and

the mating surface of the flange is recessed below the front surface such that the front face of the lip is generally coplanar to the front surface of the flange when the lip is positioned against the mating surface with the sealing member positioned therebetween.

4. The mounting assembly of claim 1 wherein the sealing member is an o-ring.

5. The mounting assembly of claim 1 further comprising:

a ridge on the flange extending away from the front surface and around at least a portion of the flange;

a cover for the power converter having a front surface, a plurality of side surfaces, and a rim extending generally outward from a bottom edge of at least a portion of the side surfaces; and

a second sealing member engaging the ridge and fitting between the rim and the front surface of the flange.

6. The mounting assembly of claim 5 wherein the cover has an opening in one of the side surfaces at one end the converter, the mounting assembly further comprising:

a conduit plate sized to fit the opening in the cover and removably connected to the front surface of the flange; and

a third sealing member fitting between the conduit plate and the front surface of the flange, a portion of the third sealing member extending beyond each side of the conduit plate and under the cover adjacent to the conduit plate.

7. The mounting assembly of claim 1 wherein the mounting surface is the inner surface of an industrial enclosure.

8. In a mounting system for a power converter having a housing with outer sidewalls, the mounting system having an enclosure and a mounting assembly operable with the enclosure, wherein the enclosure includes a plurality of sides, a rear surface, a front surface, an access opening extending through at least a portion of the front surface, a mounting opening extending through at least a portion of the rear surface, and an access panel removably covering the opening in the front surface of the enclosure, the mounting assembly comprising:

a generally planar flange having;

a front and a rear surface and an opening configured to allow passage of the sidewalls of the converter therethrough;

the front surface of the flange having a mating surface extending substantially around the opening to receive a rear face of a lip of the power converter;

the rear surface of the flange configured to engage a generally planar mounting surface; and

a plurality of fastener openings displaced from the mating surface to clear the lip of the power converter when the lip is positioned against the mating surface;

a sealing member fitting between the mating surface of the flange and the rear face of the lip; and

a plurality of fastening members, each fastening member engaging one of the fastener openings from the front surface of the flange and having an edge engaging a front face of the lip when the lip is positioned against the mating surface to sealingly compress the sealing member between the mating surface and the rear face of the lip.

9. The mounting system of claim 8 wherein the generally planar flange is positioned on the rear surface of the enclosure such that the mounting opening in the enclosure and the opening in the flange are generally aligned, the mounting assembly further comprising:

a plurality of second fastener openings displaced from an outer edge of the flange; and

a plurality of second fastening members, each second fastening member engaging one of the second openings from the front surface of the flange to connect the flange to the rear surface of the enclosure.

10. The mounting system of claim 9 wherein the plurality of fastening members may be disengaged from the power converter such that the power converter may be removed from the enclosure without disengaging the second fastening members.

11. The mounting system of claim 9 further comprising:

a ridge on the flange extending away from the front surface and around at least a portion of the flange;

a cover for the power converter having a front surface, a plurality of side surfaces, and a rim extending generally outward from a bottom edge of at least a portion of the side surfaces; and

a second sealing member engaging the ridge and fitting between the rim and the front surface of the flange.

12. The mounting system of claim 11 wherein the cover has an opening in one of the side surfaces at one end the converter, the mounting assembly further comprising:

a conduit plate sized to fit the opening in the cover and removably connected to the front surface of the flange; and

a third sealing member fitting between the conduit plate and the front surface of the flange, a portion of the third sealing member extending beyond each side of the conduit plate and under the cover adjacent to the conduit plate.

13. The mounting system of claim 12 wherein the enclosure complies with one of UL type 12, NEMA type 12, NEMA type 4, NEMA type 4X, IP5x, and IP6x mounting requirements.

14. A mounting assembly for a power converter, the mounting assembly comprising:

a flange including;

a front surface;

a rear surface, opposite the front surface, wherein the rear surface is configured to engage a generally planar mounting surface;

an opening defining an inner periphery of the flange, the inner periphery extending between the front and rear surfaces;

a mating surface recessed below the front surface and extending around the inner periphery of the flange, wherein the mating surface is configured to receive the power converter; and

a plurality of fastener openings proximate to the mating surface;

a sealing member configured to engage the mating surface and be retained between the mating surface and the power converter; and

a plurality of fastening members, each fastening member operatively engaging one of the fastener openings and the power converter to positively retain the power converter to the flange and to compress the sealing member between the power converter and the mating surface, thereby retaining the sealing member.

15. The mounting assembly of claim 14 wherein the generally planar mounting surface is an interior surface of an industrial enclosure.

16. The mounting assembly of claim 15 wherein the flange further includes a plurality of second fastener openings proximate to an outer periphery of the flange, the mounting assembly further comprising a second set of fastening members, each fastening member operatively engaging one of the second fastener openings and a corresponding opening in the mounting surface.

17. The mounting assembly of claim 16 wherein each of the fastening members and each of the second fastening members operatively engage and disengage the flange member from the front surface of the flange member.

18. The mounting assembly of claim 16 further comprising a ridge protruding from the front surface of the flange member, the ridge disposed between the fastener openings and the second fastener openings.

19. The mounting assembly of claim 18 further comprising a cover configured to enclose a portion of the power converter, the cover including:

a front surface,

a plurality of side surfaces, each side surface having a first edge joined to the front surface and a second edge distal from the front surface,

a rim extending around the periphery of the cover proximate to the second edge of the side surfaces, and

a plurality of openings extending through the rim, each opening in the rim corresponding to one of the plurality of second fastener openings, wherein the plurality of second fastening members operatively engage the cover, the flange, and the mounting surface.