Method and apparatus for mounting a power converter

• US 9,142,939 B2
• Filed: 12/14/2012
• Issued: 09/22/2015
• Est. Priority Date: 11/07/2008
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Inventors: Weiss, Bruce W., Brubaker, John R., Alwardt, Keith A., Grosskreuz, Paul J., Michalski, Robert M., Tobias, Wayne O.
• Primary Examiner(s): Norris, Jeremy C
• Assistant Examiner(s): MILAKOVICH, NATHAN J
• Application Number:
  US13/715,033
• Publication Number:
  US 20130097851A1
• Time in Patent Office: 1,012 Days
• Field of Search: 361/728, 361/730, 361/752, 361/796, 361/800, 361/825
• US Class Current: 1/1
• 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 method of mounting a power converter to a mounting surface, wherein the mounting surface has a front side, a rear side, and an opening extending between the front side and the rear side, the opening configured to allow at least a portion of the power converter to extend therethrough, the method comprising the steps of:

attaching a flange to the mounting surface with one or more fasteners operable from the front side of the mounting surface, the flange having a front surface, a rear surface, and an opening configured to allow at least the portion of the power converter to extend therethrough; and

securing the power converter to the flange with one or more fastening members operable from the front side of the mounting surface.

2. The method of claim 1 wherein the step of securing the power converter further comprises the steps of:

attaching the fastening members to the front surface of the flange;

positioning a sealing member along a mating surface of the flange;

inserting the portion of the power converter through the openings of the flange and of the mounting surface thereby positioning the sealing member between the mating surface of the flange and a lip of the power converter; and

attaching the fastening members to the power converter.

3. The method of claim 2 further comprising the steps of:

positioning a second sealing member around at least a portion of the front surface of the flange;

positioning a third sealing member on the front surface of the flange and generally along one end of the flange wherein the combination of the second and third sealing members extend substantially around the front surface of the flange;

attaching a cover for the power converter to the front surface of the flange wherein the second sealing member and at least a portion of the third sealing member are positioned between a rim of the cover and the flange; and

attaching a conduit plate to the front surface of the flange along the end of the flange having the third sealing member wherein the third sealing member is positioned between the conduit plate and the flange.

4. The method of claim 3 wherein the cover, the conduit plate, the second sealing member, and the third sealing member work together to satisfy one of UL type 12, IP5X, and NEMA type 12 sealing requirements for the converter.

5. The method of claim 1 wherein:

the power converter is mounted in an enclosure,

the enclosure includes a rear surface, a plurality of side surfaces, a front surface, an access opening extending through at least a portion of the front surface, and an access panel removably covering the access opening, and

the mounting surface is the rear surface of the enclosure.

6. A method of securing a power converter to a flange with a plurality of fastening members, wherein the flange includes a front surface, a rear surface opposite the front surface, an opening which defines an inner periphery of the flange and which extends between the front surface and the rear surface, a mating surface recessed below the front surface and extending around the inner periphery of the flange, and a plurality of fastener openings proximate to the mating surface, each fastener opening in the front surface of the flange and extending through at least a portion of a thickness of the flange, the method comprising the steps of:

positioning a sealing member generally along the mating surface of the flange;

inserting the power converter through the opening in the flange until a portion of the power converter engages the sealing member;

orienting a second portion of each of the fastening members to engage the power converter; and

securing a first portion of each of the fastening members to one of the fastener openings, thereby compressing the sealing member between the mating surface of the flange and the power converter.

7. The method of claim 6 wherein each fastening member includes a threaded member and a clip, and wherein the clip includes a first end having an opening configured to receive the threaded member and a second end configured to engage the power converter.

8. The method of claim 6 including the initial steps of:

aligning the opening in the flange to an opening in a mounting surface; and

securing the flange to the mounting surface from the front of the flange.

9. The method of claim 8 wherein the flange is secured to the mounting surface with a plurality of fasteners, each of the fasteners engaging one of a second set of fastener openings extending through the flange.

10. The method of claim 8 wherein the power converter is mounted in an enclosure having a rear surface, a plurality of side surfaces, a front surface, an access opening extending through at least a portion of the front surface, and an access panel removably covering the access opening and wherein the mounting surface is the rear surface of the enclosure.

11. The method of claim 6 further comprising the steps of:

positioning a second sealing member around at least a portion of the front surface of the flange;

positioning a third sealing member on the front surface of the flange and generally along one end of the flange wherein the combination of the second and third sealing members extend substantially around the front surface of the flange;

attaching a cover for the power converter to the front surface of the flange wherein the second sealing member and at least a portion of the third sealing member are positioned between a rim of the cover and the flange; and

attaching a conduit plate to the front surface of the flange along the end of the flange having the third sealing member wherein the third sealing member is positioned between the conduit plate and the flange.

12. The method of claim 11 wherein the cover, the conduit plate, the second sealing member, and the third sealing member work together to satisfy one of UL type 12, IP5X, and NEMA type 12 sealing requirements for the converter.

13. A method of mounting a power converter to a mounting surface, wherein the mounting surface has a front side, a rear side, and an opening extending between the front side and the rear side, the opening configured to allow at least a portion of the power converter to extend therethrough, the method comprising the steps of:

connecting a flange to the mounting surface from the front side of the mounting surface, wherein the flange includes a mating surface extending around an opening in the flange and wherein the opening in the flange is generally aligned with the opening in the mounting surface;

positioning a sealing member along the mating surface of the flange;

inserting the power converter through the opening in both the flange and the mounting surface such that a portion of the power converter engages the sealing member; and

securing the power converter to the flange with a plurality of fastening members from the front side of the flange.

14. The method of claim 13 wherein the flange further includes a front surface, a rear surface, a thickness, and a plurality of fastener openings in the front surface extending through at least a portion of the thickness of the flange, and wherein each of the plurality of fastening members engages one of the fastener openings to secure the power converter to the flange.

15. The method of claim 14 further comprising the steps of:

positioning a second sealing member around at least a portion of the front surface of the flange;

positioning a third sealing member on the front surface of the flange and generally along one end of the flange wherein the combination of the second and third sealing members extend substantially around the front surface of the flange;

attaching a cover for the power converter to the front surface of the flange wherein the second sealing member and at least a portion of the third sealing member are positioned between a rim of the cover and the flange; and

attaching a conduit plate to the front surface of the flange along the end of the flange having the third sealing member wherein the third sealing member is positioned between the conduit plate and the flange.

16. The method of claim 15 wherein the cover, the conduit plate, the second sealing member, and the third sealing member work together to satisfy one of UL type 12, IP5X, and NEMA type 12 sealing requirements for the converter.

17. The method of claim 13 wherein:

the power converter is mounted in an enclosure,

the enclosure includes a rear surface, a plurality of side surfaces, a front surface, an access opening extending through at least a portion of the front surface, and an access panel removably covering the access opening, and

the mounting surface is the rear surface of the enclosure.