Abstract:
A sealed switch assembly for use with a disconnect operator movable between an on state, a tripped state, and an off state. The disconnect operator housed within a sealed enclosure. The switch assembly includes a housing sealed to the enclosure to inhibit ingress of solids and liquids therebetween. A handle is coupled to the disconnect operator and is disposed at least partially within the housing. The handle is sealed to the housing to inhibit ingress of solids and liquids therebetween, and is moveable between an on position and an off position. A low-friction trip indicator mechanism operates independent of the handle to indicate when the disconnect operator is in the tripped state.

Description:
BACKGROUND 
       [0001]    The present invention is directed to disconnect operators. In particular the invention is directed to water resistant actuators or switches for disconnect operators. 
         [0002]    In industrial environments, electrical enclosures and related components need to meet various standards based on the environment the electrical enclosure will be subjected to. For example, an enclosure may be required to meet the UL50 type 4/IP67/IP69K standard. The UL50 type 4/IP67/IP69K standard provides strict guidelines within a rated device must function. The guidelines provide standards for ingress of solids and liquids. As a result, a UL50 type 4/IP67/IP69K rated device must meet a defined threshold or standard for repelling environmental conditions. Such a threshold or standard provides a challenge in adapting standard devices to meet the UL50 type 4/IP67/IP69K standard. 
         [0003]    Typical switch assemblies for disconnect operators include high friction, heavy duty o-rings or K-seals. These high friction seals provide the necessary rating for resistance to environmental ingress, but the switches are difficult to actuate. As a result, when an associated disconnect operator actuates to a tripped state, the switch assembly may resist the movement. Often, this problem is overcome by utilizing sealing grease or providing spring bias toward a tripped position. Typically, a handle of the switch assembly serves as the indicator of a tripped state. 
       BRIEF SUMMARY OF THE INVENTION 
       [0004]    The present embodiments overcome the aforementioned problems by providing a switch assembly for a disconnect operator that is easy to assemble and that meets the UL50 type 4/IP67/IP69K standard while providing a low friction tripped state indicator. 
         [0005]    In one construction, the invention provides a sealed switch assembly for use with a disconnect operator movable between an on state, a tripped state, and an off state. The disconnect operator housed within a sealed enclosure. The switch assembly includes a housing sealed to the enclosure to inhibit ingress of solids and liquids therebetween. A handle is coupled to the disconnect operator and is disposed at least partially within the housing. The handle is sealed to the housing to inhibit ingress of solids and liquids therebetween, and is moveable between an on position and an off position. A low-friction trip indicator mechanism operates independent of the handle to indicate when the disconnect operator is in the tripped state. 
         [0006]    In another construction, the invention provides a UL50 type 4/IP67/IP69K rated switch assembly for use with a disconnect operator that is movable between an on state, a tripped state, and an off state. The disconnect operator is housed within a sealed enclosure. The switch assembly includes a handle that is coupled to the disconnect operator and is movable between an on position and an off position. An indicator indicates when the disconnect operator is in the tripped state, and a latching mechanism is coupled between the handle and the disconnect operator such that when the disconnect operator actuates from the on state to the tripped state, the handle does not move. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0007]    The invention will be better understood and features, aspects and advantages other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such detailed description makes reference to the following drawings. 
           [0008]      FIG. 1  is an exploded view of a switch assembly according to one embodiment of the invention installed in an enclosure. 
           [0009]      FIG. 2  is a section view of the exploded switch assembly of  FIG. 1  taken along line  2 - 2  of  FIG. 1 . 
           [0010]      FIG. 3  is an exploded view of the switch assembly of  FIG. 1 . 
           [0011]      FIG. 4  is a section view of the exploded switch assembly of  FIG. 1  taken along line  4 - 4  of  FIG. 1 . 
           [0012]      FIG. 5  is a section view of the switch assembly of  FIG. 1  installed in the enclosure. 
           [0013]      FIG. 6  is a section view of the switch assembly of  FIG. 1  installed in the enclosure. 
           [0014]      FIG. 7  is a perspective view of a tag out base of the switch assembly of  FIG. 1 . 
           [0015]      FIG. 8  is a bottom perspective view of a disconnect handle shaft of the switch assembly of  FIG. 1 . 
           [0016]      FIG. 9  is a bottom perspective view of another disconnect handle shaft. 
           [0017]      FIG. 10  is a top perspective view of the disconnect handle shaft of  FIG. 8 . 
           [0018]      FIG. 11  is a top view of the disconnect handle shaft of  FIG. 8 . 
           [0019]      FIG. 12  is a top perspective view of a reset flag of the switch assembly of  FIG. 1 . 
           [0020]      FIG. 13  is another top perspective view of the reset flag of  FIG. 12 . 
           [0021]      FIG. 14  is a top perspective view of a latching mechanism of the switch assembly of  FIG. 1 . 
           [0022]      FIG. 15  is a bottom perspective view of the latching mechanism of  FIG. 14 . 
           [0023]      FIG. 16  is a top view of the latching mechanism of  FIG. 14 . 
           [0024]      FIG. 17  is a bottom view of the latching mechanism of  FIG. 14 . 
           [0025]      FIG. 18  is a top perspective view of a cam element of the switch assembly of  FIG. 1 . 
           [0026]      FIG. 19  is a bottom view of the cam element of  FIG. 18 . 
           [0027]      FIG. 20  is a top view of the cam element of  FIG. 18 . 
           [0028]      FIG. 21  is a top perspective view of a handle of the switch assembly of  FIG. 1 . 
           [0029]      FIG. 22  is a bottom perspective view of the handle of  FIG. 21 . 
           [0030]      FIG. 23  is a top view of the handle of  FIG. 21 . 
           [0031]      FIG. 24  is a plan view showing the switch assembly of  FIG. 1  in an ON position. 
           [0032]      FIG. 25  is a plan view showing the switch assembly of  FIG. 1  in a TRIPPED position. 
           [0033]      FIG. 26  is a plan view showing the switch assembly of  FIG. 1  in an OFF position. 
           [0034]      FIG. 27  is a plan view showing the switch assembly of  FIG. 1  in a RESET position. 
           [0035]      FIG. 28  is a perspective view of a disconnect operator. 
           [0036]      FIG. 29  is a detail view of a connection point of the enclosure of  FIG. 1 . 
       
    
    
       [0037]    While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0038]    The present invention will be described in terms of one or more preferred embodiments, and it should be appreciated that many equivalents, alternatives, variations, and modifications, aside from those expressly stated, are possible and within the scope of the invention. 
         [0039]      FIGS. 1 and 2  show a switch assembly  10  mounted to an enclosure  14  for operating a disconnect operator  18  located within the enclosure  14 . As shown in  FIG. 29 , the enclosure  14  defines an aperture  15 , and a wall  16  that defines two apertures  17 . As shown in  FIG. 28 , the disconnect operator  18  includes a disconnect switch  22  that is moveable between an ON position, an OFF position, and a TRIPPED position (i.e., on state, off state, and tripped state). It is to be appreciated that a variety of devices are operable with the switch assembly  10 . 
         [0040]    Turning to  FIGS. 3-6 , the switch assembly  10  includes a disconnect handle shaft  26 , a reset flag  30 , a cam element  34 , a latching mechanism  38 , a base seal  42 , a tagout base  46 , a handle seal  50 , and a handle  54 . 
         [0041]    With reference to  FIG. 7 , the tagout base  46  includes a flange  58  that defines four apertures  62  (three are visible) sized to receive fasteners for coupling the tagout base  46  to the enclosure  14  and an annular recess  66  (see  FIGS. 5 and 6 ) sized to receive the base seal  42 . The illustrated base seal  42  is an o-ring, although other seal types are contemplated. The base seal  42  provides a static seal between the tagout base  46  and the enclosure  14  to inhibit the ingress of solids and liquid into the interior of the switch assembly  10 . 
         [0042]    The tagout base  46  further defines an annular wall  70  surrounding a central aperture  74  arranged to align with the aperture  15  in the enclosure  14  when the tagout base  46  is installed on the enclosure  14 . A sealing surface  78  is defined on an inner periphery of the annular wall  70  and two tagout apertures  82  are defined through the annular wall  70 . A cutout section  86  is defined over about ninety degrees (90°) of the annular wall  70 . 
         [0043]    With reference to  FIGS. 8 ,  10 , and  11 , the disconnect handle shaft  26  includes a base  90  defining a switch interface in the form of a recess  94  shaped to receive the disconnect switch  22  of the disconnect operator  18  when the switch assembly  10  is installed. A shaft  98  extends upward from the base  90  and terminates in a coupling feature in the form of two flats  102  and two keyways  106  (see  FIGS. 10 and 11 ). 
         [0044]      FIG. 9  shows an alternative disconnect handle shaft  26 ′ with similar parts to disconnect handle shaft  26  but with a differently shaped recess  94 ′. Other profiles and switch interface features are possible and contemplated and will depend on the particular disconnect operator  18  used with the switch assembly  10 . 
         [0045]    With reference to  FIGS. 12 and 13 , the reset flag  30  includes a generally circular platform  110  arranged to be supported by the enclosure, a hollow shaft  114  that extends into the enclosure  14  through the aperture  15 , three engaging elements  118  arranged to engage the aperture  15  of the enclosure  14  and maintain the reset flag  30  therein, a central pole  122  extending upward from the circular platform  110 , and a flag  126 . The flag  126  defines an indication surface  130  that may be brightly colored, include text, or other indicating features, as desired. The flag  126  further defines a cut away portion  134 . 
         [0046]    The interior of the hollow shaft  114  is shaped to matingly receive the coupling feature of the disconnect handle shaft  26 . In the present embodiment, the hollow shaft  114  is arranged to engage the two flats  102  and two keyways  106  defined on the shaft  98  of the disconnect handle shaft  26 . In other embodiments, the hollow shaft  114  may be received within the coupling feature of the disconnect handle shaft  26  or may not be hollow. 
         [0047]    With reference to  FIGS. 14-17 , the latching mechanism  38  includes an upper surface  138 , a first cam  142  defining a clockwise (CW) surface  146  and a counterclockwise (CCW) surface  150 , a second cam  154  defining a CW surface  158  and a CCW surface  162 , a first arm  166  defining a CW surface  170  and a CCW surface  174 , a second arm  178  defining a CW surface  182  and a CCW surface  186 , and two biasing elements in the form of living springs  190  depending downwardly from the upper surface  138 , each living spring  190  defining an end face  194 . The first arm  166  further defines a contact feature in the form of a projection or tab  198  and the second arm  178  further defines a contact feature in the form of a projection or tab  202 . 
         [0048]    With reference to  FIGS. 18-20 , the cam element  34  includes an outer wall  206  that defines two projections  210  sized to be received within the apertures  17  formed in the wall  16  of the enclosure  14  and a ridge  214  on an interior surface. The cam element  34  also includes a bottom wall  218  configured to rest on top of the circular platform  110  of the reset flag  30  when the switch assembly  10  is installed. The bottom wall  218  defines a stop element  222 . A first arm  226  extends upward from the bottom wall  218  and defines a cam surface  230 . A second arm  234  extends upward from the bottom wall  218  and defines a cam surface  238 . The cam element  34  further defines an OFF surface  242  and an ON surface  246 . 
         [0049]    With reference to  FIGS. 21-23 , the handle  54  includes a hand grip portion  250 , an outer wall  254  that defines two tagout channels  258 ,  262  positioned to cooperate with the apertures  17  of the enclosure  14  for tagging out the disconnect operator  18  in the OFF position. The handle  54  further includes top wall  266  with a window  270  formed therethrough. The window  270  is formed of a clear material that may have magnifying properties. A recess  274  is formed in the handle  54  and arranged to receive the handle seal  50  (e.g., an o-ring) and hold it in place against the sealing surface  78  of the tagout base  46 . Four engagement elements  278  are configured to maintain the handle  54  installed within the tagout base  46 . The handle seal  50  provides a continuous radial seal, allowing the handle  54  to rotate while maintaining a seal. The base seal  42  and the handle seal  50  cooperate to provide environmental protection that meets the UL50 type 4/IP67/IP69K standard. 
         [0050]    Turning to  FIG. 22 , the handle  54  further includes a first tab  282  formed on the underside of the top wall  266  and defining a CW ramp  286  and a CCW surface  290 , a second tab  294  that defines a CW surface  298  and a CCW surface  302 , and a third tab  306  that defines a CW surface  310  and a CCW surface  314 . 
         [0051]    Operation of the switch assembly  10  will be discussed below with reference to  FIGS. 24-27 . Turning particularly to  FIG. 24 , the disconnect operator  18  is in the ON position and, correspondingly, the switch assembly  10  is in an ON position. When the switch assembly  10  is in the ON position, the disconnect handle shaft  26  is rotated fully CW. As a result, the flag  126  of the reset flag  30  is rotated CW until the flag  126  abuts the ON surface  246  of the cam element  34 . The flag  30  abuts and holds the CCW surface  290  of the handle&#39;s  54  first tab  282  rotated fully CW. When the switch assembly  10  is in the ON position, the tabs  198 ,  202  of the latching mechanism  38  are engaged with the cam surfaces  230 ,  238  of the cam element  34  such that the upper surface  138  of the latching mechanism  38  is forced downward out of engagement with the tabs  282 ,  294 ,  306  of the handle  54 . Additionally, the end face  194  one living spring  190  abuts the stop element  222  of the cam element  34 . 
         [0052]    Turning to  FIG. 25 , the switch assembly  10  is shown in a TRIPPED position. When the disconnect operator  18  moves from the ON position to the TRIPPED position, switch  22  rotates forty-five degrees) (45°) CCW. The flag  126  is likewise rotated CCW forty-five degrees) (45°) and rotates the latching mechanism  38  therewith by abutting the CW surface  146  of the first cam  142 . The CCW rotation of the latching mechanism  38  frees the tabs  198 ,  202  from the cam surfaces  230 ,  238  of the cam element  34  and the living springs  190  bias the upper surface  138  upward toward the handle  54 . In moving from the ON position to the TRIPPED position, the handle  54  does not move. However, a user is given a clear indication that the disconnect operator  18  is in the TRIPPED position via the indicator surface  130  of the flag  126  showing clearly through the window  270  of the handle  54 . 
         [0053]    Turning to  FIG. 26 , the switch assembly  10  is shown in an OFF position. After the disconnect operator  18  has moved to the TRIPPED position, it must be forced into the OFF position before it can be reset to the ON position. To move the disconnect operator  18  to the OFF position, the handle  54  is rotated CCW ninety degrees (90°). The handle  54  rotates freely for the first forty-five degrees (45°) until the first tab  282  abuts the flag  126 . Further CCW rotation of the handle  54  forces the flag  126  to the position shown in  FIG. 26  wherein the flag  126  is fully rotated CCW and the cut away portion  134  abuts the OFF surface  242  of the cam element  34 . The rotation of the flag  126  forces the latching mechanism  38  to continue rotating to the position shown in  FIG. 26  wherein the cams  142 ,  154  and arms  166 ,  178  are no longer positioned directly underneath the tabs  282 ,  294 ,  302  of the handle  54  and the living springs  190  bias the upper surface  138  upward into the same plane as the tabs  282 ,  294 ,  302 . 
         [0054]    Turning to  FIG. 27 , the switch assembly  10  is shown in a RESET position in which the components are in the same positions as in the ON position. After the disconnect operator  18  is moved to the OFF position, it may be reset to the ON position. With the tabs  282 ,  294 ,  302  of the handle  54 , the flag  126 , and the cams  142 ,  154  of the latching mechanism  38  engaged and the tabs  198 ,  202  of the latching mechanism  38  removed from the cam surfaces  230 ,  238  of the cam element  34 , the handle  54  is rotated CW ninety degrees (90°) such that the second tab  294  pushes on the CCW surface  150  of the latching mechanism&#39;s  38  first cam  142 , the third tab  306  pushes on the CCW surface  162  of the latching mechanism&#39;s  38  second cam  154 , and the CW surface  146  of the first cam  142  pushes on the flag  126 . In this way, the switching assembly  10  moved back into the ON position, or, in this case, the RESET position. While the latching mechanism  38  is being rotated, the tabs  198 ,  202  reengage the cam surfaces  230   238  of the cam element  34  such that the upper surface  138  of the latching mechanism  38  is again lowered below the plane of the tabs  282 ,  294 ,  302  against the bias of the living springs  190 . 
         [0055]    The invention offers several advantages. First, the switch assembly  10  may be assembled without k-seals, sealing grease and still maintain a UL50 type 4/IP67/IP69K standard rating. Second, the switch assembly  10  is assembled via snap fit to trap the internal components without the use of screws, staking, sealing greases, springs, or any other mechanical fastening methods. Third, the switch assembly  10  can be turned off, reset, and turned back on while maintaining the required environmental seal. Fourth, by using the indicator surface  130  visible through the window  270 , the switching assembly  10  provides a user with a clear indication that the disconnect operator  18  is in the TRIPPED position while maintaining the required environmental seal. Fifth, because the handle  54  does not move when the disconnect operator  18  moves from the ON position to the TRIPPED position, there is very little resistance to movement of the disconnect operator  18  or the components that indicate a tripped state. The components that indicate a tripped state provide an indication of a tripped disconnect operator  18  substantially instantly. In other words, the spring force of the disconnect operator&#39;s  18  switch  22  operates the trip mechanism (e.g., the indication surface  130  of the flag  126  and the window  270 ) of the switch assembly  10  freely. Sixth, the switch assembly  10  provides a lockout tagout ability while maintaining the required environmental seal. 
         [0056]    Other embodiments are possible in view of the following claims.