Patent Publication Number: US-2022239043-A1

Title: Connector alignment and retention panel for modular based system

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of co-pending U.S. application Ser. No. 16/925,322 filed on Jul. 9, 2020, now assigned U.S. Pat. No. 11,251,575, and the entire disclosure of said application is hereby expressly incorporated by reference into the present specification. 
    
    
     FIELD 
     The subject matter disclosed herein relates to a connector alignment and retention panel for an electronics housing. The connector alignment and retention panel can be used as part of a modular based system such as a modular, scalable linear motor system or any other system including one or more electronics housings assembled from at least two interconnected sections. 
     BACKGROUND INFORMATION 
     Historically, in power conversion products and other complex electrical systems, multiple internal pluggable connections are required during assembly as the different printed circuit board (PCB) subassemblies are brought together and enclosed within a housing having first or upper and second or lower portions that are interconnected. Typically, these internal pluggable connections are accomplished using “flying lead” type connector structures in which a mating connector is located at the end of plurality of wires that are loosely connected to a first (or lower) housing portion or a second (or upper) housing portion. During assembly, enough slack is present in the flying lead connectors to allow the plug connection to be completed before the first and second housing portions (or other housing portions) are connected together to complete construction of the housing in which the PCB subassemblies and other electrical component are contained. 
     These internal pluggable connections are difficult to implement in a compact product design in which space is limited because the flying leads, themselves, take up excessive space and the plug connections are difficult to complete or “make” when there is not enough room for an assembler to work. Also, each internal plug connection must be made separately. Furthermore, the required added length of the wires/cables of the flying lead connectors increase the amount of electromagnetic interference (EMI) generated which can cause interference with nearby electronic components, and the unrestrained, lengthy wires/cables can exhibit wear or “fretting” over time due to repeated movements from vibrations and the like. The foregoing issues and others can lead to failures resulting from incomplete connections and/or connections that are completely missed during the assembly process. Even if such failures are caught during quality control testing, costly and time-consuming reassembly must be carried out to correct the problem(s). Also, unrestrained flying lead connectors can lead to reliability problems due to EMI and also due to wire/cable fretting over time due to vibrations and other incidental movement of the connectors during use of the system. 
     BRIEF DESCRIPTION 
     In accordance with a first aspect of the present development, an electronics housing assembly includes a first housing portion and a second housing portion removably connected to the first housing portion to define an interior space that contains electronics components. A first group of said electronics components is connected to the first housing portion and a second group of said electronics components is connected to the second housing portion. A connector alignment and retention panel is connected to the first housing portion. The connector alignment and retention panel includes a connector support platform with a first connector mounting location. A first electrical connector that is part of said first group of said electronics components is operatively engaged with the first connector mounting location of said panel such that said first electrical connector is mounted on said panel and located in a select position relative to said first housing portion. A first corresponding electrical connector that is part of said second group of said electronics components is operatively secured to the second housing portion and is operatively engaged with the first electrical connector mounted on the panel. 
     In accordance with another aspect of the present disclosure, a connector alignment and retention panel for an electronics housing assembly includes a one-piece polymeric body including a connector support platform and a plurality of legs that extend outwardly relative to the connector support platform. Each of the legs comprising a foot located at an outer end spaced from said platform such that the platform is offset from each foot. Each foot defines a mounting opening for receiving a fastener. At least one electrical connector mounting location is located on said connector support platform of the body. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is an isometric view of a modular, scalable linear motor track system which is one example of a system in which a connector alignment and retention panel according to the present development can be used; 
         FIGS. 1B and 1C  are respective isometric views of first and second electronics housing assemblies of the system of  FIG. 1A  that can be used individually or connected together to define a system housing, with  FIG. 1B  showing a straight housing assembly and  FIG. 1C  showing a curved housing assembly; 
         FIGS. 2A and 2B  respectively show the first and second housing assemblies of  FIGS. 1B and 1C  with a second (upper) housing portion removed from the first (lower) housing portion to reveal a connector alignment and retention panel provided in accordance with a first embodiment ( FIG. 2A ) and a second embodiment ( FIG. 2B ) of the present development; 
         FIGS. 3A and 3B  are respective isometric views of the first (straight) and second (curved) embodiments of a connector alignment and retention panel provided in accordance with the present development; 
         FIGS. 4,5, and 6  are respective top, bottom, and isometric views of the first embodiment of the connector alignment and retention panel, including first and second motor connectors and first and second control signal connectors operatively secured thereto, with a ribbon cable extending between the first and second control signal connectors; and, 
         FIG. 7  is a section view of the housing shown in  FIG. 1A  that illustrates operative use of the connector alignment and retention panel to connect one or more electronic elements connected to the first (upper) housing portion to one or more electronic elements connected to the second (lower) housing portion. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1A  is an isometric view of a modular, scalable linear motor track system TS which is one example of a system in which a connector alignment and retention panel according to the present development can be used as described below. One example of such a linear motor track system TS is available commercially from Rockwell Automation under the registered trademark ITRAK®. The linear motor track system TS is a modular, scalable and linear motor system including a system housing SH in which electronic components are enclosed. The system housing SH comprises a plurality of modular housing assemblies including one or more straight housing assemblies HA and one or more curved housing assemblies HB that are interconnected to construct and define the system housing SH. The system housing SH comprises a rail R and the linear motor track system TS comprises at least one and typically multiple movers M (only one shown) that are operably movably engaged with the rail R. The one or more movers move bi-directionally along the rail R as indicated by the arrow A in a feedback-controlled manner as controlled by the motor electronics in the system housing SH. When multiple movers M are operably installed, they can be synchronized to move in unison with respect to each other or they can be independently controlled and move independently with respect to each other, depending on programming. 
       FIGS. 1B and 1C  are respective isometric views of the straight (first) and curved (second) electronics housing assemblies HA,HB (generally housing assemblies H) shown in  FIG. 1A  that can be used individually or that can be connected together with one or more other housing assemblies as described above to define a housing enclosure such as the system housing SH. 
     In either case HA,HB, the housing assembly H comprises at least two sections or portions including a first (lower) housing or housing portion H 1  and a second (upper) housing or housing portion H 2  that are interconnected by fasteners (screws, pins, clips, rivets, etc.), mating projections, adhesive, welding/bonding, and/or other suitable devices, structures and/or means. When operably interconnected as shown in  FIGS. 1A and 1B  to define a housing assembly HA,HB, the first (lower) and second (upper) housing portions H 1 ,H 2  define and at least partially enclose an internal space S ( FIGS. 2A &amp; 2B ) that contains electronic components such as electronic devices, motors, fans, printed circuit boards (PCBs), switches, and the like. 
       FIGS. 2A and 2B  respectively show the first and second housing assemblies HA,HB with their second (upper) housing portion H 2  removed from the first (lower) housing portion H 1  to reveal a connector alignment and retention panel P (P 1  for the housing HA of  FIG. 2A , P 2  for the housing HB of  FIG. 2B ). The connector alignment and retention panel P (P 1 ,P 2 ) is fixedly secured to the first (lower) housing portion H 1  and is operatively engaged with and retains one or more flying lead connectors C of the first housing portion H 1  in a select position so that the panel P operatively locates and retains the flying lead connectors C in a select location and orientation with respect to the first housing portion H 1  to which the panel P is connected. In particular, each connector C engaged with and retained by the panel P is operatively located in a select, predetermined position relative to the first housing portion H 1  with respect to all of the X,Y,Z axes of a conventional three-dimensional axis coordinate system, wherein axis Z is parallel to a connection axis CX ( FIG. 7 ) along which the connector C mates with a mating connector and the axes X and Y being coplanar with each other and arranged perpendicular with respect to each other and each also being perpendicular to the Z axis. The connectors C held by the panel P are operatively positioned to mate with corresponding connectors CMCa,CMCb (see  FIG. 7 ) connected to and carried by the second (upper) housing portion H 2  when the second (upper) housing portion H 2  is connected to the first (lower) housing portion H 1  when the first and second housing portions H 1 ,H 2  are aligned and connected to each other. This mating of the connectors C (MCa,MCb) held by the panel P with the corresponding connectors CMCa,CMCb carried by the second housing portion H 2  occurs in a single step as part of the process of connecting the second housing portion H 2  to the first housing portion H 1  and does not require an assembler to mate the connectors MCa,CMCa and MCb,CMCb prior to connecting the second (upper) housing portion H 2  to the first (lower) housing portion H 1 , i.e., the connectors MCa,CMCa and MCb,CMCb are mated in a single-step when the second (upper) housing portion H 2  is moved axially along the Z axis in a connection direction CD toward and into mating abutment with the first (lower) housing portion H 1 . 
     With continuing reference to  FIGS. 2A and 2B , and also referring to  FIGS. 3A and 3B , the panel P (P 1 ,P 2 ) comprises a one-piece polymeric body  10  defined by an injection molding process, an additive manufacturing process, extrusion process, thermoforming process, and/or other polymeric forming process. The panel P is electrically non-conductive and thus exhibits electrical insulation properties. 
     The panel body  10  comprises a connector support platform  12  and a plurality of support legs  14  that are connected to a peripheral edge of the connector support platform  12  and that extend transversely outwardly away from the connector support platform  12 . At least one leg  14  includes, and preferably two or more of the legs  14  include, an outer end  14   a  that comprises a foot  14   b  that extends transversely outward from the outer end  14   a  of the leg  14  and that includes a mounting opening  14   c  such as an aperture, slot, or notch defined therein that is adapted to receive a screw or other fastener. The panel P is fixedly secured to one of the housing portions H 1 ,H 2  (the first housing portion H 1  as shown in the present example) by fasteners F installed through the mounting opening  14   c  of each foot  14   b  ( FIG. 7 ). Alternatively, the feet  14   b  can be inserted into notches or other receiving locations included in the first housing portion H 1  by resilient flexing of the legs  14  such that the panel P is fixedly secured to the housing portion H 1  without using fasteners. 
       FIGS. 4-6  are respective top, bottom, and isometric views of the connector alignment and retention panel P(P 1 ) of the present embodiment.  FIG. 7  is a section view as taken at section line  7 - 7  of  FIG. 1A  that illustrates operative use of the panel P to connect one or more PCBs or other electronic elements E 1  connected to the first (lower) housing portion H 1  to one or more PCBs or other electronic elements E 2  connected to the second (upper) housing portion H 2 . It can be seen in these views that that the connector support platform  12  includes opposite first (inner) and second (outer) surfaces  12   a , 12   b . The first (inner) surface  12   a  is oriented inwardly toward the first housing portion H 1  while the second (outer) surface  12   b  is oriented outwardly away from the first housing portion H 1 . The connector support platform  12  of the panel P is raised or vertically offset along the Z axis relative to the feet  14   b  to position to connectors C at a proper location along the Z axis for mating with the corresponding connectors MCa,MCb carried by the second (upper) housing portion H 2 . Accordingly, a panel space PS is defined under the first (inner) surface  12   a  between the inner surface  12   a  of the raised connector support platform  12  of the panel P and the first housing portion H 1  to accommodate PCBs and other electronic devices E 1  carried by the first housing portion H 1 . The panel P includes voids, openings, and other panel openings PO defined through the connector support platform  12  and also defined in the body  10  adjacent the legs  14  and around a peripheral edge of the connector support platform  12  so that the panel space PS is in fluid communication with the space S defined in the housing HA,HB so that air can flow freely into and out of the panel space PS to cool the PCBs and other electronic components carried by the first (lower) housing H 1  and located in the panel space PS. 
     The panel P may include one or more partition walls PW that are connected to and that extend transversely outward from the inner and/or outer surfaces  12   a , 12   b  of the connector support platform  12  and that each provide or define an air baffle to block air flow, direct or deflect air flow, and/or route air flow in a desired direction and with a desired air flow velocity relative to the panel P. One or more of such partition walls PW can also be used to physically isolate, protect and/or electrically insulate/isolate or shield one or more electronic components E 1  in the panel space PS and/or supported on the connector support platform  12  from other such electrical components. The connector support platform  12  of the panel P also includes or defines one or more component mounting locations  16  ( FIGS. 3A &amp; 3B ) such as recesses or flat surfaces that each provide a mounting location for any desired electrical component such as a fan, a switch, an indicator LED, a heat sink, or any other desired component. 
     The panel P can include first and second high frequency signal connectors SCa,SCb connected thereto. The first and second signal connectors SCa,SCb are operably electrically interconnected by a cable such as the illustrated ribbon cable RC. The second (outer) surface  12   b  of the connector support platform  12  includes a second signal connector mounting locations  40   b  (see also  FIGS. 3A and 3B ). The second signal connector mounting location  40   b  is dimensioned and conformed to closely receive and retain the second control signal connector SCb such as with a snap-fit, friction fit, or other mechanical engagement. In the illustrated embodiment, the second signal connector mounting location  40   b  includes one or more resilient tabs  40   t  ( FIGS. 3A and 3B ) that retain the respective signal connector SCb in an operative position on the panel P with a snap fit. Preferably, the signal connector mounting location  40   b  is dimensioned to retain the signal connector SCb while also allowing limited movement of the connector SCb relative to the panel P along both the X and Y axes which are oriented transverse relative to the Z axis along which the connector SCb mates with a corresponding connector. This limited movement of the connector SCb relative to the panel P along both the X and Y axes allows the second signal connector SCb to move as required during the process of mating with a corresponding signal connector to accommodate or adapt to any misalignment between the connector SCb and the corresponding mating connector. The first high frequency signal connector SCa can be secured to the first side  12   a  of the connector support platform  12  in the same manner that the second signal connector  14   b  is secured to the second side  14   b  of the platform  12  but, as shown herein, the first signal connector SCa is not directly fixedly secured to the panel P. Instead, the first signal connector SCa is indirectly connected to the platform  12  of the panel P by way of its connection to the second signal connector  40   b  via cable RC. Thus, the first signal connector SCa is indirectly connected to the panel P via cable RC and is movable relative to the panel P. 
     As shown herein, the first and second control signal connectors SCa,SCb are high frequency signal connectors operatively electrically connected to each other by a cable such as the illustrated ribbon cable RC that extends through the panel space PS between the first and second signal connectors SCa,SCb to electrically interconnect the control signal connectors SCa,SCb. The panel P includes one or more slots or passages  42  for receiving and retaining the ribbon cable RC as it extends between and operatively interconnects the first and second signal connectors SCa,SCb. 
     The outer surface  12   b  of the connector support platform  12  further includes at least one and preferably two or more motor (or other) connector mounting locations  50   a , 50   b  (generally  50 ). Each motor connector mounting location  50   a , 50   b  is dimensioned and conformed to closely receive and retain a motor (or other) connector MC (MCa,MCb) such as the illustrated  10  pin motor plugs with a snap-fit, friction fit, or other engagement. In the illustrated example, the motor connector mounting locations  50   a , 50   b  thus each include one or more resilient tabs  50   t  that retain the respective motor connector MCa,MCb with a snap fit. Preferably, the motor connector mounting locations  50   a , 50   b  are dimensioned to retain the respective connectors MCa,MCb while also allowing limited movement of the connector MCa,MCb along both the X and Y axes which are oriented transverse relative to the Z axis along which the connector MC mates with a corresponding connector. This limited movement of the connectors MCa,MCb along both the X and Y axes allows the connectors MCa,MCb to “float” or move as required during the process of mating with a corresponding connector CMCa,CMCb to accommodate or adapt to any misalignment between the connector MC and the mating connector CMCa,CMCb. 
     As shown in the present embodiment, each connector mounting location  50  includes four corner regions  52   a , 52   b , 52   c , 52   d  that extending perpendicularly outward from the upper surface  12   b  of the platform  12  to define a rectangular connector receiving region that receives and retains the connector MCa,MCb while allowing for limited movement of the connector MCa,MCb in the connector receiving region along the X and Y axes (the corner regions  52  can be separate from each other and provided as post structures or the corner regions can be interconnected to define a wall structure between themselves, both of which arrangements are shown in  FIG. 4 ). 
     As best seen in  FIGS. 2A, 2B, and 7 , each panel P (P 1 ,P 2 ) includes one or more cable routing channels CC in communication with the connector mounting locations  50   a , 50   b  that receive and retain the cables or wires CB connected to the motor connectors MC. These cable routing channels CC each provide a groove, channel, or other recessed location that receives the connector cables CB to provide space for the cables CB, to protect the cables CB prevent contact between the cables CB and adjacent components, and locate the cables CB in their optimum positions to allow the second (upper) housing H 2  to be connected to the first (lower) housing H 1  without interference between one or more of the cables CB and the second (upper) housing H 2 . These cable routing channels CC ensure that the cables CB are always positioned as desired for optimum assembly of the housings HA,HB and to protect the cables CB from wear over time during use due to repeated shocks and vibrations. 
     The section view of  FIG. 7  illustrates operative use of a panel P to connect a first group of one or more PCBs or other electronic elements E 1  carried by the first (lower) housing portion H 1  to a second group of one or more PCBs or other electronic elements E 2  carried by the second (upper) housing portion H 2 .  FIG. 7  shows the straight panel P 1 , but those of ordinary skill in the art will recognize that the curved panel P 2  operates in a corresponding manner. In  FIG. 7 , it can be seen that the panel P is fixedly secured to the first (lower) housing H 1  by a plurality of screws or other fasteners F respectively installed through the mounting opening  14   c  of a corresponding plurality of feet  14   b  and engaged with the housing H 1 . As such, the open panel space PS is defined between the inner surface  12   a  of the platform  12  of the panel and the housing H 1 . At least some of the first group of electronic elements E 1  carried by the first (lower) housing portion H 1  are located in the panel space PS. 
     As noted above, the first and second signal connectors SCa,SCb are connected to the panel P and are interconnected by a ribbon cable RC (the ribbon cable RC is omitted from  FIG. 7  but is shown in  FIGS. 4-6 ). The panel P positions the first and second signal connectors SCa,SCb in their respective required positions to mate respectively with corresponding signal connectors CSCa,CSCb that are part of the electronic elements E 1 ,E 2  carried by the first and second housings H 1 ,H 2  when the first and second housings H 1 ,H 2  are connected together during assembly. As such, it can be seen that the first signal connector SCa located in the panel space PS is operatively mated with a first corresponding signal connector CSCa carried by a PCB in the first (lower) housing H 1  as part of the first group of electronic elements E 1 , and the second signal connector SCb located on the outer side  12   b  of the connector support platform  12  of the panel P is operatively mated with a second corresponding signal connector CSCb carried by a PCB in the second (upper) housing H 2  as part of the second group E 2  of electronic elements. This results in the first and second corresponding signal connectors CSCa,CSCb of the first and second housings H 1 ,H 2  being operatively electrically connected to each other by way of the ribbon cable RC and the signal connectors SCa,SCb located on the opposite ends of the ribbon cable RC (the cable RC need not be a ribbon cable and can be any other electrical signal cable). 
     Similarly, the first and second motor connectors MCa,MCb are operatively connected to the panel P via the first and second connector mounting locations  50  such that the first and second connectors MCa,MCb are operatively positioned to mate respectively with the corresponding connectors CMCa,CMCb carried by the second (upper) housing H 2  as part of the second group of electronic elements E 2 . Those of ordinary skill in the art will recognize that the connectors MCa,MCb are positioned by the panel P such that they are properly operatively positioned to mate with their respective corresponding connectors CMCa,CMCb along their connection axis CX when the second (upper) housing H 2  is mated with the first (lower) housing H 1  during assembly of the overall housing HA,HB. In the illustrated embodiment, the first and second connectors MCa,MCb are located at the distal ends of respective flying lead cable bundles FLa,FLb each comprising a plurality (bundle) of the wires CB that originate at respective plugs PG or other electronic elements E 1  carried by the first (lower) housing H 1 . The flying lead cable bundles FLa,FLb are safely retained by the panel P in the cable routing channels CC of the panel P to prevent movement of and otherwise control the position of the cables CB relative to the panel P and housing H 1  and to protect the cables CB from fretting or other damage. 
     It should be noted that during disassembly, the second (upper) housing H 2  is separated from the first (lower) housing H 1  by movement of the second (upper) housing H 2  along the Z axis away from the first (lower) housing H 1 . Such movement of the second (upper) housing H 2  away from the first (lower) housing H 1  along the Z axis causes disconnection of the first and second connectors MCa,MCb secured to the panel P from their respective first and second corresponding connectors CMCa,CMCb carried by the second (upper) housing H 2  and also causes disconnection of the second signal connector SCb secured to the panel P from its corresponding signal connector CSCb carried by the second (upper) housing H 2 . 
     In the preceding specification, various embodiments have been described with reference to the accompanying drawings. It will, however, be evident that various modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense.