Abstract:
An adjustable rail support system for a variable frequency drive module enclosure includes a subpanel adapter plate mounted to a subpanel of the enclosure, a front clamp assembly, a main rail, the main rail slidably suspended from the subpanel adapter plate and the front clamp assembly, and a drive lift assembly slidably suspended from the main rail, the drive lift assembly configured to slidably suspend a variable frequency drive module at a position outside of the enclosure and an installation position on the main drive panel.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of Provisional Application No. 62/213,845, filed Sep. 3, 2015, the disclosure of which is incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    1. Field 
         [0003]    Support systems for variable frequency drives in enclosures. 
         [0004]    2. Description of the Related Art 
         [0005]    Current enclosures require the use of heavy equipment to assist in locating Variable Frequency Drive (VFD) modules into enclosures. These devices help eliminate the need to have such equipment present. Usually space is restricted, which can cause a physical hazard to equipment and individuals handling these heavy VFD modules. 
         [0006]    Current enclosures in this technical field have the low voltage controls and high voltage components combined together inside one enclosure. With space being limited this can place the service technician in a hazardous Arc Flash environment and requires special equipment and training for servicing of low voltage issues. By moving the controls to a separate enclosure, mounted to the exterior of the main enclosure, the risk of accidently coming in contact with high voltage and Arc Flash is reduced. 
       SUMMARY 
       [0007]    In one aspect, a fixed rail support system for a variable frequency drive module enclosure includes a main drive panel, a top ceiling panel fixed to the main drive panel, a right-hand and a left-hand drive support rails fastened to the main drive panel and the top ceiling panel, the right-hand and left-hand drive support rails configured to slidably suspend a variable frequency drive module at a position outside of the enclosure and an installation position on the main drive panel. 
         [0008]    In a second aspect, an adjustable rail support system for a variable frequency drive module enclosure includes a subpanel adapter plate mounted to a subpanel of the enclosure, a front clamp assembly, a main rail, the main rail slidably suspended from the subpanel adapter plate and the front clamp assembly, and a drive lift assembly slidably suspended from the main rail, the drive lift assembly configured to slidably suspend a variable frequency drive module at a position outside of the enclosure and an installation position on the main drive panel. 
         [0009]    Additional aspects and/or advantages will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    These and/or other aspects and advantages will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which: 
           [0011]      FIG. 1  shows drive support rails for use with an embodiment; 
           [0012]      FIG. 2  shows a top variable frequency drive bolt on bracket for use with an embodiment; 
           [0013]      FIG. 3  shows a bottom variable frequency drive bolt on bracket for use with an embodiment; 
           [0014]      FIG. 4  shows a front view of a fixed rail support system according to an embodiment; 
           [0015]      FIG. 5  shows a back view of a fixed rail support system according to an embodiment; 
           [0016]      FIG. 6  shows an open enclosure for a variable frequency drive; 
           [0017]      FIG. 7  shows an open enclosure for a variable frequency drive; 
           [0018]      FIG. 8  shows an open enclosure for a variable frequency drive; 
           [0019]      FIG. 9  shows a subpanel adapter plate for use with an embodiment; 
           [0020]      FIG. 10A  shows a rail hanger for use with an embodiment; 
           [0021]      FIG. 10B  shows a main rail for use with an embodiment; 
           [0022]      FIG. 10C  shows a rail hanger pad for use with an embodiment; 
           [0023]      FIG. 11A  shows a pin lock  50  for use with an embodiment; 
           [0024]      FIG. 11B  shows a strut beam and a front clamp tube for use with an embodiment; 
           [0025]      FIG. 11C  shows a support assembly for use with an embodiment; 
           [0026]      FIG. 12  shows an adjustable arm for use with an embodiment; 
           [0027]      FIG. 13  shows an adjustable rail support system according to an embodiment; 
           [0028]      FIG. 14  shows a main rail assembly for use with an embodiment; 
           [0029]      FIG. 15  shows a front clamp assembly for use with an embodiment; 
           [0030]      FIG. 16  shows a drive lift assembly for use with an embodiment; and 
           [0031]      FIG. 17  shows an anchor Block for use with an embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0032]    Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below to explain the present invention by referring to the figures. 
         [0033]    1. Fixed Rail Support System: 
         [0034]    The Fixed Rail Support System will be described with reference to  FIG. 1-5 . This Device contains 1 right-hand and left-hand Drive support rails  10  and  12 , as shown in  FIG. 1 , 1 Top VFD bolt on bracket  14 , as shown in  FIG. 2 , and 1 bottom VFD bolt on bracket  16 , as shown in  FIG. 3 . 
         [0035]    The 2 Drive Support Rails  10  and  12 , shown in  FIG. 1 , act as a slide rail for the VFD Module  24 , shown in  FIGS. 4 and 5 . The Top VFD bolt on Bracket  14 , shown in  FIG. 2 , and the Bottom VFD bolt on Bracket  16 , shown in  FIG. 3 , mount to the VFD Module  24  using the 2 pressed in PEM studs at the back of each bracket, and 4 screws on the side of each bracket. The 2 Drive Support Rails  10  and  12 , shown in  FIG. 1 , are bolted to the main Drive panel  18 , shown in  FIG. 5 , with the 4 press in studs that are pressed into the panel. The Drive Support Rails  10  and  12 , shown in  FIG. 1 , top lip has a clearance hole that is used to hold the 2 Drive Support Rails  10  and  12 , shown in  FIG. 1 , spacing and are bolted onto the enclosure&#39;s top ceiling panel  20 , shown in  FIG. 5 , using 2) ¼-20 bolts. The VFD drive is loaded on to the bottom lip of the Drive Support Rails  10  and  12 , shown in  FIG. 1 , and slid into location. The Top VFD bolt on Bracket  14 , shown in  FIG. 2 , and the Bottom VFD bolt on Bracket  16  is secured to the Main Drive Panel  22 , shown in  FIG. 5 ), by 2 machine nuts each, through the formed mounting holes. 
         [0036]    The right-hand and left-hand Support rails  10  and  12 , shown in  FIG. 1 , are constructed using 12 gauge galvanized sheet-metal. The Support rails  10  and  12 , shown in  FIG. 1 ) are laser cut and formed in a “C” channel shape with a lip turned down 90 degrees on the bottom lip using a sheet-metal forming machine. The back side of the support rails  10  and  12 , shown in  FIG. 1 , have 3 clearance holes and is bent back toward the inside “C” channel and then welded to provide a ridged form. 
         [0037]    The Top VFD Bracket  14 , shown in  FIG. 2 , is constructed using 12 gauge galvanized sheet-metal that is laser cut and formed in “C” channel shape on a sheet-metal forming machine. The Top VFD Bracket  14 , shown in  FIG. 2 , has 2 pressed in press in studs on the back wall and 4 clearance holes (2 each side wall) that mate with the VFD module. The top lip is bent to the outside of the bracket and extends to the back with a lip turned up. The lip that turns up at the back has a clearance hole that is used to mount to the Main Drive Panel  22 , shown in  FIG. 5 . 
         [0038]    The Bottom VFD Bracket  16 , shown in  FIG. 3 , is constructed using 12 gauge galvanized sheet-metal that is laser cut and formed in “C” channel shape on a sheet-metal forming machine. The Bottom VFD Bracket  16 , shown in  FIG. 3 , has 2 pressed in press in studs on the back wall and 4 clearance holes (2 each side wall) that mate with the VFD module  24 . The side lip is bent to the outside of the bracket and extends outward. The lip that turns out at the back has a clearance hole that is used to mount to the Main Drive Panel  22 , shown in  FIG. 5 . 
         [0039]    2. Adjustable Rail Support System: 
         [0040]    The Adjustable Rail Support System will be described with reference to  FIG. 9-21 . The Adjustable Rail Support System is made up of 4 main components. 
         [0041]    1. Sub Panel Adapter Plate  26 , shown in  FIGS. 9 and 13 . 
         [0042]    2. Main Rail  28  and Rail Hanger  30 , shown in  FIGS. 10A and 10B . 
         [0043]    3. Front Clamp Assembly  56 , shown in  FIG. 13 . 
         [0044]    4. Drive Lift Assembly  54 , shown in  FIGS. 13 and 16 . 
         [0045]    The purpose of the Adjustable Rail System is to help with the removal and re-installation of existing VFD Drives that may need to be serviced in the field. The Adjustable Rail System is designed to fit larger enclosures and a multiple of different size VFD Modules. 
         [0046]    The Subpanel Adapter plate  26 , shown in  FIGS. 9 and 13 , has 5 slotted holes that mount to the enclosure sub-panel studs. The adapter plate  26  is used when clearance is an issue between the sub-panel and the back wall of the enclosure. The Sub-Panel Adapter Plate  26 , shown in  FIGS. 9 and 13 , allows the Main Rail  28 , shown in  FIG. 10B , to have lateral side to side movement so it can be positioned over the center of the VFD Module. 
         [0047]    The Sub-Panel Adapter Plate  26  is a 14 gauge steel sheet-metal component that is laser cut with 5 slots and a relief on the right hand side, this relief is for mounting the Rail Hanger Adapter  30 , shown in  FIG. 10A , and formed with a 90 degree lip on the top side using a sheet-metal forming machine. 
         [0048]    The Main Rail Assembly, shown in  FIG. 14 , contains 6 components. 
         [0049]    Rail Hanger Adapter  30 , shown in  FIG. 10A . 
         [0050]    Main Rail  28 , shown in  FIG. 10B . 
         [0051]    Main Rail Socket  32 . 
         [0052]    Rail Hanger Pad  34 , shown in  FIG. 10C . 
         [0053]     5/16 dia. Pin And Clevis  36 . 
         [0054]    ½ dia. Pin and Clevis  38 . 
         [0055]    The Main Rail  28 , shown in  FIGS. 10B and 14 , is designed to give the Adjustable Rail System motion front to back. The Rail Hanger Adapter  30 , shown in  FIGS. 10A and 14 , will fit over the enclosure sub-panel or mount to the Sub-Panel Adapter Plate  26 , shown in  FIG. 9 . The Rail Hanger Adapter  30  gives the Main Rail  28 , shown in  FIGS. 10B and 14 , lateral side to side motion so the Main Rail  28  can be centered over the VFD module. The Rail Hanger Pad  34 , shown in  FIGS. 10C and 14 , is mounted to the Rail Hanger Adapter  30 , shown in  FIGS. 10A and 14 , using 2 screws, the Rail Hanger Pad  34  is used as a spacer and reduces scratching to the enclosure sub-panel. Main Rail  28 , shown in  FIGS. 10B and 14 , is mounted to the Rail Hanger  30 , shown in  FIGS. 10A and 14 , using the Main Rail Socket  32 , shown in  FIG. 14 . The Main Rail Socket  32  has 2 positions and is located with studs depending on the height of the VFD Module. The Main Rail Socket  32  is and is held in place with the Clevis and Pin  38 , shown in  FIG. 14 . The Main Rail  28 , shown in  FIGS. 10B and 14 , is designed to give the Adjustable Rail System front to back motion so the VFD module can be removed and re-installed. A stop Pin and Clevis  36 , shown in  FIG. 14 , is located at the free end of the Main Rail  28  and act as a positive stop. The Main Rail  28 , shown in  FIGS. 10B and 14 , is the carrier for the Drive lift Assembly. 
         [0056]    The Rail Hanger Adapter  30 , shown in  FIGS. 10A and 14 , is made from 14 gauge steel sheet-metal, it is machine 3 clearance holes and has 4 studs for the Main Rail Socket  32 , shown in  FIG. 14 , to mount. The shape is then formed with a “C” shaped hook at the top to fit over the Sub-Panel Adapter Plate, shown in  FIG. 9 , with an offset at the bottom to give clearance for the panel studs. 
         [0057]    The Main Rail  28 , shown in  FIGS. 10B and 14 , is a length of strut beam that is modified on each end. One end has a ½ slotted hole machine to accept the Pin and Clevis  36 , shown in  FIG. 14 , for mounting to the Main Rail Socket  32 , shown in  FIG. 14 , the opposite end is machined with a 5/16 diameter hole for the Pin and Clevis  36 , shown in  FIG. 14 , that is used for the positive stop. 
         [0058]    The Main Rail Socket  32 , shown in  FIG. 14 , is a channel strut connector and is not modified and is an off the shelf item. 
         [0059]    The Rail Hanger Pad  34 , shown in  FIGS. 10C and 14 , is made from a rectangular piece of UHMW plastic, with 2 large clearance hole and 3 tapped holes machined and attaches to the Main Rail Adapter  30 , shown in  FIGS. 10A and 14 . 
         [0060]    The Front Clamp Assembly  28 , shown in  FIG. 15 , consists of 9 components. 
         [0061]    DE.STA.CO Clamp  36 . 
         [0062]    Strut Beam  38 , shown in  FIG. 11B . 
         [0063]    Front Clamp Tube  40 , shown in  FIG. 11B . 
         [0064]    Front Rail Support  42 , shown in  FIG. 11C . 
         [0065]    Strut Beam Support  44 , shown in  FIG. 11C . 
         [0066]    Pin and Clevis  46 , shown in  FIG. 11C . 
         [0067]    Strut Key  48 , shown in  FIG. 11C . 
         [0068]    3 Pin Lock  50 , shown in  FIG. 11A . 
         [0069]    Adjustment Screw  52 , shown in  FIG. 11C . 
         [0070]    The Front Clamp Assembly  56 , shown in  FIGS. 13 and 15 , is designed to give the Main Rail Assembly, shown in  FIG. 14 , support, lateral movement, and Height adjustment. 
         [0071]    The Front Clamp Assembly, shown in  FIGS. 13 and 15 , is held in place by fitting into the rain guard lip at the top of the enclosure door and clamped using the 2 DE STA CO Clamps  36 . The Clamps have been modified to lock in the clamped position with 3 Pin Lock Assembly  50 . The lock assembly  50  shown in  FIG. 11A  is constructed with 3 pins welded to a “L” shaped steel form the center pin has a groove cut for a “E” clip to retain the spring. This prevents the clamps from accidently being unlocked during use. 
         [0072]    The Front Clamp Tube  40 , shown in  FIG. 11B , is a part of a weldment that has 2 tabs for mounting the DE STA CO Clamps  36 , and the 1×1⅝ Strut Beam  38 . 
         [0073]    The Front Rail Support  42  is a housing for the Strut Beam Support  44  and has vertical height adjustment by turning the adjustment Screw  52 . The Front Rail Support  42  is mounted to the Strut Beam Support  44  with a Strut Key  48  and has lateral side to side movement. The Pin and Clevis  46  is used to limit the stroke of the Strut Beam Support  44 . 
         [0074]    The Front Rail Support  42  is a weldment that has 3 parts. It is 14 gauge sheet-metal with 1 piece bent at a 90 degree angle with 2 holes, the 2 legs have a slot laser cut. 
         [0075]    The Strut Beam Support  44  is a piece of 2×3× 3/16 rectangular tubing that has 3 clearance holes and a slot cut through the opposite end creating “C” shaped bracket. 
         [0076]    The Strut Key  48  is made of steel bar machined in a “T” shape with a tapped hole in the center. 
         [0077]    The Drive Lift Assembly  54 , shown in  FIGS. 13 and 16 , consists of 9 components. 
         [0078]    Adjustable Arm  58 . 
         [0079]    Anchor Block  60 . 
         [0080]    Split Clevis  62 . 
         [0081]    Jackscrew  64 . 
         [0082]    Threaded Barrel Nut  66 . 
         [0083]    Pin and Clip  68 . 
         [0084]    4 Roller Trolley Assembly  70 . 
         [0085]    Pin and Clevis  72 . 
         [0086]    Hook Clevis  74 . 
         [0087]    Hook  76 . 
         [0088]    The Drive Lift Assembly  54 , shown in  FIGS. 13 and 16 , provides vertical lift To the VFD Module to clear the mounting studs on the enclosure Sub-panel. It then allows the service technician to move the module forward and clear the enclosure where it can be lowered onto a lift table or the tailgate of a service truck for service or replacement. 
         [0089]    The 2 Adjustable Arms  58 , shown in  FIGS. 12, 13 and 16 , are made of 1045 steel plate and machined to give clearance inside the enclosure and offset the Main Rail  60 . It has 3 holes for Hook  76  placement and 1 hole for the Pin and Clips  68  that is the pivot pin for raising and lowering the arm. The lower section has a machined relief on both sides with a hole cut in the center for attaching Split Clevis  62 . The 3 larger holes are to remove weight. 
         [0090]    The Anchor Block  60 , shown in  FIGS. 16 and 17 , is made from 1045 steel and is CNC machined across the top with a slot and 2 holes to accept the 4 Bearing Trolley  70  using Pin and Clevis  72 . The 2 sides are machined with a slot and 2 holes to accept the 2 Adjustment Arms  58 . The Adjustment Arms  58  are held in place by the Pin and Clip  68 , the bottom 2 holes are to mount the Threaded Barrel Nut  66 . The Threaded Barrel Nut  66  is machined from ½ round stock and threaded ⅜-24 LH to accept the 2 purchased RH/LH threaded Jackscrew  64 . The Threaded Barrel Nuts  66  allow of some rotation while adjustment is made raise the 2 Adjustable Arms  58 . The RH/LH Jackscrews  64  mount to the Split Clevis  62  and tie to the Adjustment Arm  58 . 
         [0091]    Description Low Voltage Electrical Controls: 
         [0092]    Current enclosures in this technical field have the low voltage controls and high voltage components combined together inside one enclosure. With space being limited this can place the service technician in a hazardous Arc Flash environment which requires special PPE Clothing, equipment, and training for servicing of low voltage issues. By moving the controls to a separate enclosure, mounted to the exterior of the main enclosure, the risk of accidently coming in contact with high voltage and ARC Flash is reduced and moves the technician away from the front of the enclosure, thus protecting him/her from potential ARC Flash in the High Voltage section of the equipment. 
         [0093]    Reduces risk of High Voltage or ARC Flash exposure while performing maintenance task, as shown in  FIG. 6 . 
         [0094]    Improves troubleshooting by having controls and display accessible for side by side viewing, as shown in  FIGS. 7 and 8 . 
         [0095]    Controls environment is better maintained by being isolated from possible dust in main enclosure. 
         [0096]    By having controls separated it reduces risk of control and power wiring being ran in same conduit. 
         [0097]    Metal barrier in separate enclosures adds to less risk of inducing noise or voltage spikes in signal and low voltage control wiring. 
         [0098]    The low voltage control enclosure and operator interface enclosure doors open opposite allowing an easy view of and access to both during start up and servicing, as shown in  FIG. 8 . 
         [0099]    Although a few embodiments have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.