Transfer switch assembly and method

• US 8,810,062 B2
• Filed: 05/23/2013
• Issued: 08/19/2014
• Est. Priority Date: 12/29/2006
• Status: Active Grant

• Current Assignee: Cummins Power Generation IP, Inc.
• Original Assignee: Cummins Power Generation IP, Inc.
• Inventors: Murray, Jerry, Carney, Allen B., Bax, Randall L., Ayana, Elias, Pautzke, Roger, McCarthy, John
• Primary Examiner(s): AMAYA, CARLOS DAVID
• Application Number:
  US13/900,813
• Publication Number:
  US 20130257148A1
• Time in Patent Office: 453 Days
• Field of Search: 307/9.1, 307/46, 307/64, 439/554
• US Class Current: 307/9.1
• CPC Class Codes: H01H 11/00 Apparatus or processes specially adapted for the manufacture of electric switches processes specially adapted for manufacture of rectilinearly movable switches having a plurality of operating members associated with different sets of contacts, e.g. keyboards, H01H13/88
• CPC Class Codes: H02J 2310/46 for ICE-powered road vehicles
• CPC Class Codes: H02J 4/00 Circuit arrangements for mains or distribution networks not specified as ac or dc
• CPC Class Codes: H02J 7/14 for charging batteries from dynamo-electric generators driven at varying speed, e.g. on vehicle
• CPC Class Codes: H02J 7/1415 with a generator driven by a prime mover other than the motor of a vehicle
• CPC Class Codes: H02J 7/34 Parallel operation in networks using both storage and other dc sources, e.g. providing buffering H02J7/14 takes precedence
• CPC Class Codes: H02M 5/458 using semiconductor devices only
• CPC Class Codes: Y10T 29/49105 Switch making

Abstract

A method for assembly of a transfer switch is disclosed that includes a power switch device with a number engagement landings and a printed circuit board defining an opening bordered by a number of tabs. The tabs engage the landings as the switch device extends through the openings, and can be fastened together.

Claims

1. A method, comprising:

operably coupling a power transfer switch unit with an interface to an external power source;

operably coupling the power transfer switch unit with a generator power source;

operably coupling the power transfer switch unit to an output power bus;

switching between the external power source and the generator power source with the power transfer switch to transfer electric power to the output power bus, wherein the power transfer switch unit includes;

a contactor defining a number of landings between a first end portion and a second end portion, the landings each being separated from one another by a corresponding one of a number of dividing walls;

a printed circuit board carrying a number of power electronic devices, the printed circuit board including a first side opposite a second side and defining an opening therethrough, the opening being bordered by several tabs each separated from one another by a corresponding one of several notches, the contactor being received through the opening to place each respective one of the dividing walls through a respective one of the notches, each respective one of the tabs being fastened to a respective one of the landings; and

an enclosure including a first enclosure wall opposite a second enclosure wall, the contactor and the printed circuit board being contained in the enclosure and at least one of the first end portion and the second end portion of the contactor engaging the enclosure to position the printed circuit board between the first enclosure wall and the second enclosure wall.

2. The method of claim 1, further comprising carrying the interface, the generator power source, and the power transfer switch unit on a vehicle.

3. The method of claim 1, further comprising stacking the printed circuit board next to another printed circuit board in a spaced apart relationship within the enclosure and between the first wall and the second wall.

4. A method for assembling a power switch unit, comprising:

connecting an electric power switching device to a printed circuit board by positioning the electric power switching device through an opening between first and second sides of the printed circuit board to engage a number of landings of the electric power switching device with different ones of a number of engagement fingers of the printed circuit board that border the opening so that a first end portion of the electric power switching device extends past the first side of the printed circuit board and a second end portion of the electric power switching device extends past the second side of the printed circuit board; and

positioning the electric power switching device and the printed circuit board in an enclosure that includes a first wall opposite a second wall so that at least one of the first end portion and the second end portion bear against the enclosure to support the printed circuit between the first wall and the second wall.

5. The method of claim 4, further connecting power transfer switch unit to a power bus and selectively switching between a shore power source and a generator power source to transfer electrical power to the power bus.

6. The method of claim 5, further comprising carrying the generator power source and the power transfer switch in a vehicle.

7. The method of claim 4, further comprising connecting each respective one of the fingers to a different one of the landings by a respective one of a number of fasteners.

8. The method of claim 7, wherein the fingers each define an aperture, the landings each define a threaded hole, and the fasteners are each in the form of a screw extending through the aperture of the respective one of the fingers and engaging the threaded hole of the respective one of the landings.

9. The method of claim 4, further comprising fastening the fingers to the landings.

10. The method of claim 4, further suspending the printed circuit board from the electric power switching device.

11. The method of claim 4, further comprising extending a contactor through a second opening in the printed circuit board so that a number of dividing walls of the contactor separate the landings of the electric power switching device from one another.

12. The method of claim 11, wherein the printed circuit board defines a number of notches each separating adjacent ones of the fingers from one another, and further comprising positioning the dividing walls of the contactor through respective ones of the notches.

13. A method for assembling an electric power transfer switch unit, comprising:

obtaining a power switching device defining a number of fastening landings each separated from one another by a corresponding one of a number of dividing walls;

obtaining a printed circuit board carrying a number of electrical power devices, the printed circuit board defining an opening therethrough that is bordered by a number of fastening fingers each separated from one another by a corresponding one of a number of notches, the fingers each configured to provide thermal and electrical conductivity;

positioning the power switching device through the opening to engage each respective one of the fingers with a respective one of the landings and receive a respective one of the dividing walls through a respective one of the notches; and

fastening the respective one of the fingers to the respective one of the landings.

14. The method of claim 13, further comprising positioning the power switching device in an enclosure including a first wall opposite a second wall.

15. The method of claim 13, further comprising engaging the enclosure with at least one of a first end portion and a second end portion of the power switching device to support the printed circuit board between the first wall and the second wall.

16. The method of claim 13, further comprising connecting the power transfer switch unit to a power bus in a vehicle.

17. The method of claim 13, wherein the vehicle includes an interface to selectively connect to a shore power source and a generator power source and the power switch unit is operable to select between the shore power source and the generator power source to transfer electrical power to the power bus.

18. The method of claim 13, further comprising suspending the printed circuit board from the electric power switching device.

19. The method of claim 13, wherein fastening the respective one of the fingers to the respective one of the landings includes positioning a fastener through an aperture defined by the finger into engagement with a threaded hole in the landing.

20. The method of claim 13, further comprising stacking a second printed circuit board carrying a number of semiconductor devices in relation to the printed circuit board.