U.S. patent application number 10/930537 was filed with the patent office on 2006-03-23 for systems and methods for modular instrument design and fabrication.
Invention is credited to Hubert K. Yeung.
Application Number | 20060059790 10/930537 |
Document ID | / |
Family ID | 35198573 |
Filed Date | 2006-03-23 |
United States Patent
Application |
20060059790 |
Kind Code |
A1 |
Yeung; Hubert K. |
March 23, 2006 |
Systems and methods for modular instrument design and
fabrication
Abstract
Modular component mounting systems and methods employ a
plurality of members adapted to be interlocked with one another and
anchored to an instrument housing. Each of the members comprises a
central elongated body, cross-holes extending transversely through
the body, beads extending along corners of the body to a position
spaced apart from an end of the body defining a key at the end of
the body, a channel defined by a surface of the body and a pair of
the beads to receive and register with a key of another member, and
a fastener receptive orifice defined in the end of the body. A
fastener extends though one of the cross-holes of a first member to
be received by an end orifice of a second member, interlocking the
members and preventing torsional movement by the members relative
to one another.
Inventors: |
Yeung; Hubert K.; (Santa
Rosa, CA) |
Correspondence
Address: |
AGILENT TECHNOLOGIES, INC.;Legal Department, DL429
Intellectual Property Administration
P.O. Box 7599
Loveland
CO
80537-0599
US
|
Family ID: |
35198573 |
Appl. No.: |
10/930537 |
Filed: |
August 31, 2004 |
Current U.S.
Class: |
52/36.5 |
Current CPC
Class: |
E04C 2003/0452 20130101;
E04C 3/28 20130101; H05K 7/1418 20130101; E04C 2003/0465 20130101;
H05K 7/1425 20130101; E04C 2003/0439 20130101; E04C 3/06
20130101 |
Class at
Publication: |
052/036.5 |
International
Class: |
E04B 2/74 20060101
E04B002/74 |
Claims
1. A member comprising: a central elongated body portion; at least
one cross-hole extending transversely through said central body
portion; bead portions extending along at least a pair of corners
of said body portion, said bead portions extending to a position
along said body portion, spaced apart from an end of said body
portion, to provide a key portion of said body portion; a channel
portion defined by a surface of said body portion and a pair of
said bead portions, said channel portion adapted to receive an end
of another member and register with a key portion of said another
member; and a fastener receptive orifice defined in said end of
said body portion;
2. The member of claim 1, wherein said at least one cross-hole
comprises a plurality of cross-holes for indexing with component
mounting grids.
3. The member of claim 1, wherein at least one of said at least one
cross-hole is elongated along a length of said member, defining a
slot.
4. The member of claim 1, wherein said body portion has a generally
square cross section.
5. The member of claim 1, wherein said orifice is threaded to
threadably receive a fastener.
6. The member of claim 1, wherein said orifice is defined by a
central cannula extending through a length of said body
portion.
7. The member of claim 1, wherein said member is extruded.
8. The member of claim 1, wherein said member is adapted to be used
as a heat sink for at least one of said components.
9. A modular system comprising: a plurality of members adapted to
be interlocked with one another and anchored to an instrument
housing structure, each of said members comprising: a central
elongated body portion; at least one cross-hole extending
transversely through said central body portion; bead portions
extending along at least a pair of corners of said body portion,
said bead portions extending to a position spaced apart from an end
of said body portion to define a key portion at said end of said
body portion; a channel portion defined by a surface of said body
portion and a pair of said bead portions, said channel portion
receiving and registering with a key portion of another member; and
a fastener receptive orifice defined in said end of said body
portion; a fastener extending though one of said cross-holes of a
first of said members to be received by an end orifice of a second
of said members, interlocking said first and second members and
preventing torsional movement by said members relative to one
another.
10. The system of claim 9, wherein an orientation of said second
member are selected based on a desired orientation of said
cross-holes of said second member.
11. The system of claim 10, wherein said desired orientation of
said cross-holes of said second member are based on mounting
provisions provided by one or more of said components.
12. The system of claim 9, wherein said at least one cross-hole
comprises a plurality of cross-holes indexing with a component
mounting grid.
13. The system of claim 9, wherein at least one of said cross-holes
is elongated along a length of said member, defining a slot.
14. The system of claim 9, wherein at least one of said members is
adapted to be used as a heat sink for at least one of said
components.
15. The system of claim 9, wherein channels of a pair of spaced
apart members are adapted to be used as a card guide for a circuit
board of said instrument, said channels of said spaced apart
members each receiving and retaining an edge of said circuit
board.
16. The system of claim 9, further comprising a hinge assembly,
said hinge assembly comprising: an anchored member; a first
fastener extending through a cross-hole of said anchor member; a
generally tubular element adapted to receive said fastener in a
first end; a frame member; and a second fastener extending through
a cross-hole of said frame member, said second fastener received by
an opposite end of said generally tubular element; wherein said
frame member and any instrument component attached thereto pivots
at said generally tubular member, at least partially about said
anchor member.
17. The system of claim 9, further comprising a truss, said truss
comprising at least a pair of generally parallel, spaced apart,
cord members arranged with channel portions of said cord members
facing each other; at least one strut-tie members extending between
said cord members, key portions of said strut-tie members received
by said channel portions of said cord members; and fasteners
extending though cross-holes of each of said cords and received by
end orifices of said strut-tie members, torsionally interlocking
said cord members and said strut tie members in a truss
configuration.
18. A method comprising: keying an end of a first beam member with
a channel defined by a second beam member; receiving a fastener
through a hole defined by said second beam member into an orifice
defined in an end of said first beam member; securing said fastener
to torsionally interlock said first and second beam members; and
mounting instrument components to the interlocked beam members to
provide an instrument.
19. The method of claim 18, further comprising indexing component
mounting grids with said beam members for said mounting.
20. The method of claim 18, further comprising: selecting an
orientation of said first beam member based on a desired
orientation of said cross-holes of said first beam member for
mounting one or more of said components.
21. The method of claim 18, further comprising: anchoring said
second beam member to an instrument housing structure.
22. The method of claim 18, further comprising: threading said
fastener into said orifice.
23. The method of claim 18, further comprising: adjusting a
position of said components along said beam members.
24. A method comprising: anchoring modular beam members to an
instrument housing structure; interlocking beam members disposed in
said instrument housing structure with the anchored beam members;
mounting instrument components to the interlocked beam members; and
interconnecting said instrument components to provide an
instrument.
25. The method of claim 24, further comprising indexing: component
mounting grids with said beam members for said mounting.
26. The method of claim 24, further comprising: interlocking other
beam members disposed in said instrument housing structure with the
beam members interlocked with said anchored beam members.
27. The method of claim 24, further comprising: adjusting a
position of said components along said beam members.
Description
BACKGROUND OF THE INVENTION
[0001] Many electronic systems, instruments, and the like must be
custom designed and/or fabricated. Such instruments may include
processor-based systems, communications equipment, networking
equipment, switch matrixes, testing equipment, and the like. Such
equipment may be developed to meet specific requirements of a
customer and may be one of a kind or small production runs, such as
of fifteen or fewer units. However, these same customers expect, or
at least desire, an inexpensive solution to such custom
applications, provided in a timely manner.
[0002] Traditionally, even small run jobs are treated as truly
custom jobs that involve custom designing each part including
housing and mounting sheet metal, machined parts and the like. This
is time consuming and costly. Not only is the cost of a small run
of custom parts expensive, overhead related to these custom or
small production runs is relatively high as the resulting
instrument and its parts require many of the overhead processes and
procedures that a mass produced product requires. For example,
parts (sheet metal, machined parts, plastic parts, etc.) must be
assigned part numbers, documentation must be produced for the
instrument and parts, and Engineering Change Report(s) (ECR) and/or
Engineering Change Orders (ECO) must be produced and reviewed for
parts purchasing and product release. Also, it takes time to
fabricate custom parts and the time required to gather all of the
custom produced parts may also present problems, particularly where
multiple vendors are involved, as is often the case. Oftentimes, it
becomes necessary to "chase" after parts to start building a
product. When prototyping, or at the beginning of fabrication, it
is often found that a custom piece is missing or not made as
specified. At this time, it might be determined that a redesign of
the instrument is necessary causing further delay and cost. In such
cases, it may be necessary to have one or more new pieces
fabricated, causing a halt, or at least a delay, in the prototyping
process or in product production.
[0003] Custom designed instruments often have undesirable
qualities. For example the final product may be a relatively
"closed" system that requires tortuous cable routing and an
inflexibility limiting the ability to make changes or enhancements
to the instrument. Custom produced instruments are often cluttered
with long cable runs required or with cables routed through sheet
metal decks or the like. Additionally, design may be problematic in
that the instrument designers may be designing an instrument that
uses components that the designers do not have on-hand, and for
which the designers may not know the actual, final dimensions or
configuration. Although typical custom instrument casing and
housing designs employ formed or bent sheet metal parts, attempts
have been made to address problems encountered with such sheet
metal based structures through the use of open space-frames. These
space-frames are typically machined or welded from dimensional
metal. However, such frames are typically configured for use in a
single instrument design, are costly, and time consuming to
fabricate.
[0004] Finally, many printed circuit boards (PCBs) employ mounting
holes that are placed in a relatively arbitrary layout.
Problematically, custom fabricated sheet metal or manual drilling
of sheet metal elements must be used to mount PCBs for custom
instrument fabrication.
SUMMARY
[0005] Embodiments of systems and methods for modular instrument or
system design and fabrication may employ a plurality of members
adapted to be interlocked with one another and anchored to an
instrument housing structure. Each of these integral members has a
central elongated body portion, which might have a generally square
cross section. Cross-holes may extend transversely through the
central body portion, in at least one direction. Bead portions
extend along, at least, a pair of corners of the body, to a point
spaced apart from an end of the body portion this may result in a
key portion of the body being formed at an end of the body. A
channel portion is defined by a surface of the body and a pair of
the beads, the channel is adapted to register with a key of another
member. A fastener receptive threaded orifice is defined in the end
of the body. This orifice may be defined by a central cannula
extending through a length of the body. Embodiments of the present
systems and methods also employ fasteners extending though a
cross-hole of a first of the members to be received by an end
orifice of a second of the members, interlocking the first and
second members and preventing torsional movement by the members
relative to one another.
[0006] Thus, in use, embodiments of the present systems may be
employed by method embodiments that include keying an end of a
first member with a channel defined by a second member and
receiving a fastener through a cross-hole defined by the second
member into the orifice defined in an end of the first member.
Securing the fastener interlocks the first and second members,
torsionally. Instrument components may then be mounted to the
interlocked members to provide a custom fabricated instrument. An
orientation of the second member may be selected based on a desired
orientation of the cross-holes of the second member, such as may be
desired for mounting of the instrument components.
[0007] The profile of the present member might be extruded.
Alternatively, the present member may be cast. Advantageously, if
the present members are made from a heat transmissive material such
as aluminum, the member may be used as a heat sink for instrument
components. If a stronger member or the like is desired to support
a heavy component, such as a power supply, a double or triple
truss-like member, or the like, may be made using the present
members.
[0008] The foregoing has outlined rather broadly the features and
technical advantages of the present systems and methods in order
that the detailed description that follows may be better
understood. Additional features and advantages of the systems and
methods will be described hereinafter which form the subject of the
claims. It should be appreciated that the conception and specific
embodiment disclosed may be readily utilized as a basis for
modifying or designing other structures for carrying out the same
purposes of the present systems and methods. It should also be
realized that such equivalent constructions do not depart from the
systems and methods set forth in the appended claims. The novel
features which are believed to be characteristic of the invention,
both as to its organization and method of operation, together with
further objects and advantages will be better understood from the
following description when considered in connection with the
accompanying figures. It is to be expressly understood, however,
that each of the figures is provided for the purpose of
illustration and description only and is not intended as a
definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a more complete understanding of the present systems and
methods, reference is now made to the following descriptions taken
in conjunction with the accompanying drawing, in which:
[0010] FIGS. 1 through 3 are perspective views of various length
member embodiments of the present systems;
[0011] FIG. 4 is a perspective illustration of a slotted embodiment
of a two unit length member of the present systems;
[0012] FIG. 5 is an exploded view showing relative deployment of
embodiments of members of the present systems in accordance with
embodiments of the present methods;
[0013] FIG. 6 is a perspective view of an embodiment of a
two-member-truss constructed from member embodiments s of the
present systems in accordance with embodiments of the present
methods;
[0014] FIG. 7 is a perspective view of a method embodiment using
embodiments of the members of the present systems to act as a
circuit board or card guide;
[0015] FIG. 8 is a perspective view of a method embodiment using
embodiments of the members of the present systems to act as a
hinged circuit board mounting structure;
[0016] FIG. 9 is an environmental perspective illustration of an
instrument employing embodiments of the present systems and methods
to mount components; and
[0017] FIG. 10 is a flow chart of an embodiment of the present
methods.
DETAILED DESCRIPTION
[0018] Embodiments of the present systems and methods provide a
modular component mounting system that may employ a minimum set of
elements. These elements include structural members described below
and typical fasteners such as screws, nuts, associated washers,
including lock washers, stand-offs and the like. FIGS. 1 through 3
are perspective views of various length member embodiments 100, 200
and 300, respectively, of the present systems. FIG. 1 is a
partially fragmented view of member 100 having a "unit" length of
at least nine. Herein, a "unit" is the distance between cross-holes
101 in a member, which also corresponds to the overall length of
single unit member 300. Also a "unit" as used herein may be viewed
as the distance from the mid-points between cross-holes 101, which
corresponds to the configuration of single unit member 300. For
purposes of illustration, members 100, 200 and 300 of FIGS. 1, 2
and 3 are illustrated as having lengths of at least nine units, two
units and one unit, respectively. However, as one of ordinary skill
in the art will appreciate, members of the present systems can be
of any number of units in length, or fractions thereof. FIG. 4 is a
perspective illustration of a slotted embodiment of a two unit
length member of the present systems. However, a slotted member may
also be of any length, with one or more slots being of any of
various lengths.
[0019] Each of integral component mounting members 100, 200, 300
and 400 comprise a central, generally elongated, body portion 102.
In embodiments of the present systems body portion 102 has a
generally square cross-section. Body 102 may be extruded from a
generally rigid material such as aluminum or steel. Advantageously,
aluminum can be extruded easily and it has other desirable
properties. For example, aluminum is lightweight, inexpensive, easy
to machine and has very good thermal conduction properties.
Relative to aluminum, steel is heavier, but it is stronger in the
sense of having a higher modulus of elasticity, but steel would, in
most cases more likely, be more difficult to extrude and machine.
Additionally, it is within the scope of the present systems and
methods that the member may be formed in a number of other manners.
For example, the members may be injection molded from plastics,
steel, other alloys or ceramics; formed from a composite material
using various methods as are known in the art of composite
materials; or cast from any number materials such as aluminum,
steel, or various plastics or from other materials not particularly
well suited for extrusion such as magnesium, epoxy or urethane.
Cast or molded members may require less machining than extruded
members, for example cross-holes 101 may be cast or molded into a
member. However, material that cannot be tapped or otherwise formed
or machined to provide relatively strong threads, such as discussed
in greater detail below, may make use of inserts or the like to
provide threaded orifices, such as those discussed below.
[0020] The aforementioned cross-holes 101 extend transversely
through central body portion of embodiments of members 100, 200 and
300. Cross-holes 101, are shown in FIGS. 1-3 as extending through
member body 102 in only one direction. However, it is within the
scope of the present systems and methods to employ members having
one or more additional cross-holes extending through the respective
member body, orthogonal to cross-holes 101. These orthogonal
cross-holes might be either aligned with cross-holes 101, or, in
the case of multi-unit members, such as illustrated members 100 and
200, disposed between cross-holes 101.
[0021] Slotted member 400 has a slot shaped cross-hole, referred to
herein as a "slot" (401). Through use of a slotted member, such as
member 400, off-grid component mounting holes may be flexibly
addressed. As noted above, slot 401 may be of any length. Also, a
member may have multiple slots, which may be of varying lengths.
FIG. 4 illustrates a one unit length slot defined in a two unit
long member. However, as will be appreciated from the description
appearing below and illustrated in the FIGURES, such a two unit
slotted member provides a versatility to embodiments of the present
systems and methods, which might be enhanced in certain situations
by a longer member with longer and/or multiple slots.
[0022] Embodiments of members 100, 200, 300 and 400 define bead
portions 103 extending from at least a pair of corners of body
portions 102 to define channel portions 104. As will be appreciated
upon inspection of FIGS. 1, 2, 3 and 4, channel portions 104 are
defined by a surface of body portion 102 and a pair of bead
portions 103. As will also be appreciated from inspection of FIGS.
1 2, 3 and 4, bead portions 103 may extend to a position spaced
from end 105 of respective member 100, 200, 300 or 400 to define
key portion 106, adapted to be received in channel 104 of another
member and secured thereto. Alternatively, to provide a more stable
end for member 100, 200, 300 or 400, beads 103, and thus channel
104, may extend to end 105, thereby providing a greater bearing
surface on such an end to better bear against a mounting structure
which does not provide a channel to receive the end.
[0023] A fastener receptive orifice 107 may be defined in member
end 105. Orifice 107 may be threaded to accept a screw, bolt or
similar fastener. Orifice 107 may be defined by a central cannula
extending through a length of body portion 102, such as may be
formed during extrusion or other forming of body 102.
Alternatively, orifice 107 may be defined in end 105 of body
portion 102 by drilling or otherwise forming orifice 107 in the end
of body portion 102.
[0024] FIG. 5 is an exploded view showing relative deployment 500
of embodiments of members of the present systems in accordance with
embodiments of the present methods. In use, key portion 106 of
members 100, 200, 300 or 400 may be received by channel 104 of
another member, and register therewith. As illustrated in FIG. 5,
key portions 106 of horizontally disposed members 501 and 502 are
shown as being received by channel 104 of vertical column member
503. A screw or similar fastener 505 may be used to rigidly secure
members. As shown in FIG. 5, fastener 505 may be disposed through a
cross-hole (101) of one member, such as vertical column member 503,
and treaded into end orifice 107 of another member, such as member
501 or 502. Lock washer 506 or a similar device may be used in
conjunction with fastener 505 to insure that screws 505 do not
back-out due to shock, vibration or the like. Registration between
key 106 of members 501 and 502 with channel 104 of column member
503 torsionally locks members 501 and 502, relative to column
member 503, in a generally perpendicular, torsionally rigid,
arrangement. Further, this torsional rigidity enables the use of a
single fastener (505) to secure two members together against
movement relative to one another. In other words, a second fastener
is not required to hold two members in position relative to one
another. Although the members of FIG. 5 are shown disposed in a
generally perpendicular fashion, it is within the scope of the
present systems and methods that members may be disposed at an
angle to one another. For example, key portion 106 of a member may
be disposed at an angle relative to the axis of a member.
Registration between such an angularly disposed key of a first
member and channel 104 of a second member would torsionally lock
the members, relative to one another, in an angularly disposed,
torsionally rigid, arrangement.
[0025] Embodiments of the present systems and methods provide a
strong structure for mounting instrument components. However, in
accordance with embodiments of the present systems and methods
members may be doubled, as shown in FIG. 6, tripled, or likewise
combined, to support heavy parts mounted thereto. Two-member-truss
embodiment 600 may be constructed from cord members 601 and 602,
joined by spanning strut-tie members 603-606 and secured by screws
607. Components of an instrument may be secured to or on such a
truss, such as by using fasteners and stand offs, or in other
manners discussed herein or as known in the art, for deployment in
the instrument.
[0026] Frames built using the present members may be used to mount
components and circuit boards and these frames may in turn be
mounted in a chassis, such as a housing or casing, which may in
turn be covered or deployed as a part of a rack system or the like.
In accordance with embodiments of the present systems and methods,
PCBs having "off-grid" mounting holes may be mounted to one or more
of the present members as illustrated in FIG. 9 below, using
standoffs or the like and the members secured within a housing or
case as appropriate.
[0027] Modular interlocking members 100, 200, 300 and 400, or other
length members may be adapted to work with standardized equipment
casing or rack systems such as AGILENT TECHNOLOGIES' SYSTEM II.TM.
modular cabinets. For example, half and/or full housing width
stretchers or beams, comprised of the present members, may be used
to span a SYSTEM II.TM. module. Modules and frames built using the
present members may be used to mount components and circuit boards
within the SYSTEM II.TM. modules. For example, the cast aluminum
front frames, rear frames, corner struts and/or side struts of the
aforementioned SYSTEM II.TM. modules may provide structure or
framework to which the present modular systems may be attached for
mounting components. For a custom instrument that needs to be
mounted in a test rack for example, the SYSTEM II.TM. front frame,
rear frame and struts extending therebetween, sized for the rack
that is to receive the instrument, may be outfitted with members of
the present system to provide an internal structure to mount the
components of the instrument, in an arrangement most conducive to
operation, maintenance and modification, of the resulting
instrument. The SYSTEM II.TM. or other standardized housing may
provide covers for the instrument, if desired. However, it is well
within the scope of the present systems and methods for the present
elements to be used to construct the entire framework for an
instrument. Further covering material such as sheet metal may be
secured to the present members.
[0028] Embodiments of the present systems and methods may make use
of standardized sized fasteners and unit lengths. For example,
cross-holes 101 and slots 401 may be sized for three millimeter, or
M3 screws, spaced at a 3/8 of an inch pitch, with end orifices 107
sized and tapped to receive such M3 screws. Cooperatively, channels
104 may be sized for the pan head of standard M3 screws, with lock
washers. Thus, in this sample embodiment, a unit is 3/8 of an inch,
the spacing between cross-holes 101. Such 3/8 inch spacing provides
embodiments of the present systems and methods a large degree of
versatility. For example, mounting hole spacings on SYSTEM II.TM.
modular cabinet frames and the like are based on a 3/4 of an inch
grid.
[0029] As noted above members used in embodiments of the present
systems and methods may be extruded or otherwise formed from metal,
such as aluminum and steel. Such metal members may, in accordance
with embodiments of the present systems and methods be used as a
heat sink. The member's main body provides a substantial surface
area for heat dissipation, which is increased by the member's
functional features such as the aforementioned beads and unused
cross-holes. In accordance with some embodiments of the present
systems a member's heat dissipation surface area is comparable to,
or greater than, the heat dissipation surface of a conventional
finned heat sink. The cross-holes may also provide an avenue to
attach heat transmission mediums and/or heat convecting surface of
components.
[0030] In accordance with embodiments of the present systems and
methods members may be deployed for use as a card guide. FIG. 7 is
a perspective view of embodiment 700 using embodiments of members
701 and 702 of the present systems to act as a PCB or card guide.
Illustrated card guide 700 is comprised of a pair of spaced apart
members 701 and 702 disposed in relation to a card location in an
instrument, spaced apart a distance appropriate to receive edges of
card 703 and support the card in a deployed configuration in the
instrument, for example, in a card slot of another PCB, such as a
processor board, of the instrument.
[0031] In accordance with embodiments of the present systems and
methods members may be deployed in a hinged swing assembly
configuration. FIG. 8 is a perspective view of an embodiment using
embodiments of the members of the present systems to act as hinged
circuit board mounting structure 800. Members 801-815 are shown
interconnected in an arrangement to support and mount (such as
using screws, nuts and stand-offs) PCB 820. Hinge structures 822
are provided by anchor members 825, anchored to housing corner
strut 830, with tubular elements 826 threadably receiving screws
extending through cross-holes of anchor members 825 and screws
extending through cross-holes of PCB mounting members 801 and 802.
Stand-offs sized to threadably receive these screws may be used as
tubular members 826. Tubular members 826, in conjunction with the
screws they receive, provide a pivot for hinging of mounted PCB
820. PCB 820 and mounting members 801-815 may be releasably secured
from swinging by screws (not shown) passing through holes in
housing corner strut 832 into end orifices of PCB mounting members
803, 804 and 805.
[0032] Employment of embodiments of the present systems and methods
for design and fabrication of an instrument, whether it be a custom
instrument or a mass produced product results in an instrument that
has an open structure, facilitating the routing of cables. Further,
unused member cross-holes may be used to anchor cable ties used to
restrain and/or route loose cabling and cable harnesses.
Additionally, embodiments of the present systems and methods
facilitate design changes and enhancements, as such changes and
enhancements can be readily incorporated into the instrument though
the addition or replacement of system members.
[0033] The present systems and methods provide significant
versatility in mounting components. For example slotted members
such as member 400 may be used to provide a flexibility in
receiving mounting hardware for a PCB or the like. As another
example, embodiments of the present systems and methods enable the
suspension of components that might need airflow around them for
cooling. For example, a power supply might be mounted on or
suspended from a framework of members. Embodiments of the present
systems and methods may also be advantageously employed in
conjunction with sheet metal components that may used on a repeated
basis. For example a facility that commonly used a set of switches
and a few PCBs in custom designed instruments might have sheet
metal components on hand that would be tailored to these
components. However, the facility might employ embodiments of the
present systems and methods to mount the components that vary
between instruments or to provide enhanced functionality such as
the aforementioned hinged PCB mount or heat sink functionality.
[0034] FIG. 9 is a perspective illustration of instrument 900
employing embodiments of the present systems and methods to mount
instrument components. Illustrated instrument 900 is a switch
matrix, which includes transfer switches 901. Members 902-906 are
shown as mounting switches 901, with members 902 and 903 traversing
instrument housing 910 and members 904-906 (with a fourth member
hidden behind corner strut 911 of housing 910) extending between
transverse members 902 and 903 to provide struts for mounting
switches 901. Although, switches 901 may be directly mounted to
various ones of members 902-906, switches 901 may be mounted to one
or more preformed sheet metal parts, which in turn may be mounted
to various ones of members 902-906. Strut members 904-906 may be
secured to, transverse members 902 and 903 using screws extending
through cross-holes of transverse members 902 and 903 and secured
in end orifices of strut members 904-906. Lock washers, patch
locks, or other locking mechanisms may be used in conjunction with
these nuts and/or screws. This mounting of switches 901 allows for
an optimal cable run to front panel 945, such as by enabling
convenient and easy placement of switches 901 in close proximity to
front panels 945 or in a position mid-way between two components
connected to switches 901. This may also aid in avoiding cable loss
and allow repositioning of the components if desired. Another strut
member (912) is shown as extending from transverse member 903 to a
third transverse member 913. Short members 914 and 915 are shown in
use as spacers between the transverse members and strut member 912.
Member 922 is shown extending downwardly from strut 912 and PCB 920
is shown as mounted to strut member 912 and member 922. PCB 925 is
shown as mounted to corner struts 911 and 927 of housing 910 using
members 930-933 as adapters to suspend PCB 925 between housing
struts 911 and 927. Hinge structure 935, similar to hinge structure
800 of FIG. 8, is shown as mounting PCB 937 in housing 910 for
swing-down access for maintenance, upgrade or diagnostics.
[0035] A beam member framework may be assembled outside of an
instrument housing and components mounted to this framework, which
may them be anchored in the instrument housing. Alternatively, the
beam member framework may be built within the housing and then the
components mounted to the framework. Embodiment 1000 of the present
methods illustrated in the flow chart of FIG. 10 might be used to
deploy embodiments of the present systems, such as illustrated in
FIG. 9. At 1001 first beam members to be disposed in the instrument
housing structure, such as members 905 and 906 of FIG. 9, may be
interlocked with second beam members to be disposed in the
instrument housing, such as beam members 902, 903 and 913 of FIG.
9, to provide a framework. The members may be interlocked at 1001
by keying an end (key 106) of a first beam member with a channel
(104) defined by a second beam member at 1002; receiving a fastener
through a cross-hole (101) of the second member into an end orifice
(107) of the first beam member at 1003; and securing the fastener
to torsionally interlock the members, relative to one another, at
1004. An orientation of the first beam member may be based on a
desired orientation of the cross-holes of that beam member for
mounting one or more components. Instrument components, such as
switches 901 and PCBs 920 and 925 of FIG. 9, are indexed to and
mounted to the interlocked members of the framework at 1005. The
indexing might include indexing component mounting grids with the
cross-holes of beam members prior to mounting. At 1006 the
interlocked framework, and components mounted thereon, may be
anchored in an instrument housing or the like. Alternatively,
members, such as beam members 902, 903 and 913 of FIG. 9 may
initially be anchored to the housing, with other beam members, such
as beam members 905 and 906 of FIG. 9, interlocked with the
anchored members at 1001, within the housing, prior to mounting the
components on the resulting framework at 1005. Instrument
components may also be mounted directly to the instrument housing
structure at 1005, before or after the framework is anchored in the
housing. A position of the components may be adjusted along the
beam members by mounting to other cross-holes or through the use of
slot members 400. To complete the instrument the mounted components
are interconnected at 1007, such as through the use of cables, edge
connectors and the like.
[0036] As will be appreciated upon review of the above description
by one of ordinarily skill in the art, embodiments of the present
systems and methods are conducive to a variety of new designs. It
is anticipated by the present disclosure that as those of ordinary
skill in the art use the present systems and methods for designing
and constructing custom instruments, enhancements and new features
not specifically disclosed herein will result.
[0037] Although the present systems and methods and their
advantages have been described in detail, it should be understood
that various changes, substitutions and alterations can be made
herein without departing from the invention as defined by the
appended claims. Moreover, the scope of the present application is
not intended to be limited to the particular embodiments of the
process, machine, manufacture, composition of matter, means,
methods and steps described in the specification. As one will
readily appreciate from the disclosure, processes, machines,
manufacture, compositions of matter, means, methods, or steps,
presently existing or later to be developed that perform
substantially the same function or achieve substantially the same
result as the corresponding embodiments described herein may be
utilized. Accordingly, the appended claims are intended to include
within their scope such processes, machines, manufacture,
compositions of matter, means, methods, or steps.
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