Motor installation system

An installation system for use with a motor comprising a motor base coupled to the motor and having a first aperture through the motor base, and a first post coupled to a support structure and configured to cooperate with the first aperture, wherein the first post is configured to temporarily support the motor while the motor is removably coupled to the support structure. The present invention also provides a method of manufacturing the motor installation system.

TECHNICAL FIELD OF THE INVENTION

The present invention is directed, in general, to a system for attaching a motor to a support structure and, more specifically to a system for initially locating and supporting a motor on a support beam so that the installer has both hands free to fasten mounting/adjustment bolts and nuts.

BACKGROUND OF THE INVENTION

Electric motors are used in many applications to drive machinery or other devices. It is not uncommon to encounter heavy electric motors that, in order to install them, require the installer to support the motor in approximately the final location while mounting bolts are inserted through slots in a motor mount base and into or through a mounting structure which is part of a motor-driven device, e.g., air conditioning unit. Securing nuts are then coupled to the mounting bolts, the mounting bolts and nuts tightened to the point that motor alignment to the driven machinery can be accomplished and then the nuts are tightened to securely hold the motor in place. Frequently these motors, such as for powering large air conditioner installations, are quite heavy, requiring the installer to use both hands to position the motor and to perform a “juggling act” to insert the bolts and attach the nuts. Failure of the motor necessitates a similar juggling act to dismount the motor and to install a new one. Losing a grip on a heavy motor can be both painful and dangerous.

Accordingly, what is needed in the art is a motor mounting system that does not suffer the shortcomings of the prior art and frees the hands of the installer from the weight of the motor when inserting and coupling the mounting bolts and nuts, while still allowing for final alignment of the motor with the driven machinery.

SUMMARY OF THE INVENTION

To address the above-discussed deficiencies of the prior art, the present invention provides an installation system for use with a motor comprising: a motor base coupled to the motor and having a first aperture through the motor base, and a first post coupled to a support structure and configured to cooperate with the first aperture, wherein the first post is configured to temporarily support the motor while the motor is removably coupled to the support structure. The present invention also provides a method of manufacturing the motor installation system.

DETAILED DESCRIPTION

Referring initially toFIGS. 1A and 1B, illustrated is an isometric view of one embodiment of a motor installation system100constructed according to the principles of the present invention. The motor installation system100comprises a motor base110coupled to a motor120, and first and second posts131,132, (collectively: posts130), coupled to a support structure140. The motor base110may be coupled to the motor120by any conventional means, i.e., welding, strapping, keying, etc. In a preferred embodiment, the motor base110may be a conventional motor base having a plurality of elongated apertures150, each elongated aperture150having an aperture length151and an aperture width152. The elongated apertures150may have a flattened oval shape, i.e., racetrack, or a rectangular shape155as shown inFIG. 1B. For the purposes of this discussion, the support structure140may be the frame of an air conditioning unit (not shown) or other electric motor-powered device. One who is of skill in the art will readily list a significant number of other electric motor-powered devices that would benefit from the present invention. In a preferred embodiment, the elongated apertures150allow some vertical and lateral adjustment of the position of the motor120with respect to the support structure for aligning a drive belt (not shown) to the driven assembly. The support structure140further comprises mounting bolt apertures160therethrough. In one embodiment, the mounting bolt apertures160are unthreaded to receive mounting bolts170therethrough and to be fastened to nuts171. In an alternative embodiment, the mounting bolt apertures160are internally threaded to receive and cooperate with the mounting bolts170. In yet another embodiment, the mounting bolt apertures160have locknuts affixed, e.g., by welding, on a rear face141of the support structure140. One who is of skill in the art will conceive of other suitable bolt/nut fastener systems for mounting the motor120.

Refer now toFIGS. 2A through 2E.FIG. 2Aillustrates an end view of one embodiment, having a circular cross section, of the posts130ofFIG. 1A.FIGS. 2B,2C and2D are partial sectional views of three alternative embodiments of posts130installed in the support structure140along a plane2—2ofFIG. 1A. In a preferred embodiment the posts130may be shoulder screws130as inFIGS. 2A,2B,2C and2E. The posts130comprise a circular head201having an optional recessed socket202therein (FIGS. 2A and 2B), a body203, a threaded portion204and a shoulder205. The shoulder screw130is so-called because of having the shoulder205that prevents the body203from passing through a properly size unthreaded aperture210in the support structure140.FIG. 2Cis that of a shoulder screw threaded directly into the support structure140. In this embodiment, the shoulder screw may be mated with a threaded aperture in the support structure140. In an alternative of this embodiment, the shoulder screw may be a self-threading screw for coupling directly into an un-threaded aperture in the support structure140.FIG. 2Dillustrates a third embodiment that may be fashioned from a suitable material, e.g., machine steel, and then welded or riveted220in place. Alternatively,FIG. 2Eillustrates a shoulder screw130having a flanged head231suitable to be driven with a conventional hex socket or similar tool.

In a preferred embodiment, the recessed socket202is configured to accept a hex key, often called by its original name: an Allen wrench, which was a trademark of the Allen Manufacturing Company of Hartford, Conn. The recessed socket202in combination with a hex key can screw the shoulder screw130into a threaded aperture212or alternatively hold the shoulder screw130in place while a nut206is affixed and tightened to the threaded portion204. The head201has a head diameter211while the body203has a body diameter213that is less than the head diameter211.

Referring now toFIG. 3, illustrated is an exploded top plan view of the motor installation system100ofFIG. 1Ajust prior to placement of the motor120with base110on the posts130. While the present discussion is directed toward the installation of a vertical-shaft motor, one who is of skill in the art will recognize that horizontal or even off-angle installations may likewise readily use the present invention. The posts130are separated along the support structure140by an inter-postal distance310measured between proximate edges of the two postal heads201. This inter-postal distance310is slightly greater than an inter-aperture distance320measured between the proximate edges of the two elongated apertures150. The head diameter211is slightly less than the aperture width152. This relationship of the inter-postal distance310and the inter-aperture distance320, together with the head diameter211being slightly less than the aperture width152, allows the motor base110to readily slip over the posts130. Furthermore, the body length223of the posts130is slightly greater than a base thickness330at the apertures150. This relationship of the body length223and the base thickness330allows the motor base110to easily slip over the heads201of the posts130and then rest on the bodies203of the posts130. The head thickness221and the body diameter213must be sufficient to hold, at least temporarily, the weight of the motor120and the motor base110during installation.

Referring now toFIG. 4, illustrated is an isometric, partial cutaway, view of the motor120and motor base110installed on the posts130. Bolts170are aligned for installation through elongated apertures150and into mounting bolt apertures160. When the motor base110has been placed upon the posts130, the posts130temporarily support all of the weight of the motor120and motor base110while the installer obtains the mounting bolts170and mounting nuts171. With the motor base110on the posts130, the first and second apertures substantially align with the mounting bolt apertures160, respectively.

Referring now toFIG. 5, illustrated is a partial sectional view of the motor120and motor base110along plane5—5ofFIG. 4. The plane5—5of the section passes vertically through one of the posts130and one of the elongated apertures150. As can be seen, the post head diameter211is slightly smaller than the aperture width152, thereby allowing the post head201to pass therethrough. InFIG. 5, the weight W of the motor120and motor base110are supported on the body203of the posts130. The post heads201prevent the motor120from falling off of the posts130. The base thickness330is less than the length223of the post body203. The posts130keep the motor120approximately positioned with respect to the intended driven machinery, e.g., fan blade (not shown).

Referring now toFIG. 6, illustrated is a partial sectional view of the motor base110and support structure140along plane6—6ofFIG. 4. The plane6—6of the section passes horizontally through the posts130and the elongated apertures150. Paired elongated apertures651,652have closest ends653,654, respectively and distal ends655,656, respectively. The inter-aperture distance320between the closest ends653,654is slightly less than the inter-post distance310, allowing the motor base110to be placed over the posts130. The posts130are located proximate the closest ends653,654of the paired elongated apertures651,652. The distal ends655,656of the paired elongated apertures651,652are therefore available to allow the mounting bolts170to pass therethrough.

Referring now toFIG. 7, illustrated is an isometric view of the motor120and motor base110installed on the support structure140. Once the mounting bolts170and nuts171have been coupled, the nuts171may be tightened to the point that the motor base110may be slid so as to align motor pulley710and drive belt720with a pulley730coupled to the driven machinery, e.g., a fan blade (not shown). One who is of skill in the art will understand how this is accomplished. When the motor pulley710, drive belt720and are properly aligned, mounting bolts170and nuts171are tightened so that a substantial portion of the weight W of the motor120and motor base110is carried by the mounting bolts170and nuts171through to the supporting structure140. The posts130may, in the course of aligning the pulleys710,730and drive belt720, contact a portion of the elongated apertures150, but any portion of the weight W of the motor120and motor base110carried by the post(s)130is inconsequential to the substantial portion of the weight W carried by the mounting bolts170and nuts171. One who is of skill in the art will understand that the posts130of the system100will likewise assist a repairman when removing the motor120and motor base110.

One who is of skill in the art will recognize that flat washers, lock washers, lock nuts, flange nuts and other similar hardware may be effectively used, as necessary, with both the posts130and the mounting bolts170.

Thus, a motor mounting system for use with a motor has been described that enables an installer to temporarily position a heavy motor while obtaining and installing mounting bolts and nuts that will ultimately bear the most significant portion of the weight of the motor. Although the present invention has been described in detail, those skilled in the art should understand that they can make various changes, substitutions and alterations herein without departing from the spirit and scope of the invention in its broadest form.