U.S. patent application number 13/012612 was filed with the patent office on 2011-07-28 for panelized lightweight control enclosure.
Invention is credited to Victor Hugo Barragan Gonzalez, Luis Alberto Alfredo D'Acosta Anezin, Richard A. Schulz, Antonio Zaldivar Lelo de Larrea.
Application Number | 20110179722 13/012612 |
Document ID | / |
Family ID | 44307264 |
Filed Date | 2011-07-28 |
United States Patent
Application |
20110179722 |
Kind Code |
A1 |
Schulz; Richard A. ; et
al. |
July 28, 2011 |
PANELIZED LIGHTWEIGHT CONTROL ENCLOSURE
Abstract
The present invention relates to a panelized lightweight control
enclosure, capable of being substantially manufactured before
installation for housing power system devices of a power system
substation. Specifically, the control enclosure is comprised of a
structural frame including a plurality of vertical posts, a base, a
plurality of side panels for forming the walls thereof and defining
an interior space therein for housing the power system devices, and
a roof for covering the interior space. The structural frame
engages and provides support for the side panels and roof. To
facilitate engagement between the frame, side panels and roof, the
control enclosure includes a plurality of tongue-and-groove
fittings. As a result, the present invention control enclosure may
be constructed at and/or transported in an assembled state to an
installation site. The present invention further relates to a
method of making a composite material, for the panels of the
control enclosure, formulated for weight reduction, strength, and
resistance to cracking.
Inventors: |
Schulz; Richard A.; (Tega
Cay, SC) ; D'Acosta Anezin; Luis Alberto Alfredo;
(San Luis Potosi, MX) ; Barragan Gonzalez; Victor
Hugo; (San Luis Potosi, MX) ; Zaldivar Lelo de
Larrea; Antonio; (Corregidora, MX) |
Family ID: |
44307264 |
Appl. No.: |
13/012612 |
Filed: |
January 24, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61298147 |
Jan 25, 2010 |
|
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Current U.S.
Class: |
52/79.1 ;
52/588.1 |
Current CPC
Class: |
E04B 1/34315 20130101;
E04H 5/02 20130101 |
Class at
Publication: |
52/79.1 ;
52/588.1 |
International
Class: |
E04H 1/00 20060101
E04H001/00; E04C 2/38 20060101 E04C002/38 |
Claims
1. A portable panelized control enclosure for housing power system
devices of a power system substation, said enclosure comprising: a
structural frame including a plurality of vertical posts and a
base; a plurality of side panels forming walls of the control
enclosure and defining an interior space therein for housing the
power system devices, wherein the structural frame engages and
provides support for the side panels; at least one roof structure
for providing a covering for said the interior space, wherein said
the frame and side panels engage and provide support for the roof
panel; a plurality of tongue-shaped fittings formed on at least one
of the frame, side panel and roof panels; and a plurality of
groove-shaped fittings formed on at least one of the frame, side
panel, and roof panels each engaging a corresponding tongue-shaped
fitting to form an engagement between one of the frame, side panel
and roof panel.
2. The portable panelized control enclosure of claim 1, wherein the
panels are comprised of a combination of panels constructed of
metal and panels constructed of a composite material.
3. The portable panelized control enclosure of claim 1 further
including lifting yokes to facilitate transportation thereof.
4. The portable panelized control enclosure of claim 1, wherein at
least one of the groove-shaped fittings is in the form of parallel
rails affixed to at least one of the frame, side panel and roof
panels.
5. The portable panelized control enclosure of claim 1, wherein at
least one of the side panels, structural frame and roof panel are
prefabricated.
6. The portable panelized control enclosure of claim 2, wherein the
strength of the enclosure may be customized by the select
combination of metal panels and composite panels.
7. The portable panelized control enclosure of claim 1, wherein at
least one of the tongue-shaped fittings includes a pre-formed
tongue.
8. The portable panelized control enclosure of claim 1, wherein at
least one of the tongue-shaped fittings includes a support element
adapted to limit movement of the one of the roof panels with
respect to one of the side panels.
9. The portable panelized control enclosure of claim 1, wherein in
the plurality of lightweight panels are composed of a composite
material comprising: about 38 liters of LW coarse aggregate, about
38 liters of dust, about 9.5 liters of sand, about 50 kilograms of
cement, about 19 liters of water, about 9.5 liters of polystyrene
particle filler, about 400 milliliters of concrete consistency
regulating reslump admixture, about 200 grams of fiber, and about 2
liters of acrylic resin.
10. The portable panelized control enclosure of claim 9 wherein
said composite material is selectively altered to have a
compression strength of about 2500 psi.
11. The portable panelized control enclosure of claim 9, wherein
said composite material is selectively altered to have a density of
100 pcf.
12. The portable panelized control enclosure of claim 9, wherein
said composite material is reinforced with steel reinforcement
comprised of wire mesh 6.times.6-6/6 (complying with ASTM A-185 and
ASTM A-496) and with fiber reinforcement comprised of
macro-synthetic reinforcing fiber (complying with ASTM C1116 0.26
lb/ft.sup.3).
13. A panelized control enclosure capable of being substantially
manufactured before installation for housing power system devices
of a power system substation, said enclosure comprising: a
structural frame including a plurality of vertical posts and a
base; a plurality of prefabricated side panels forming walls of the
control enclosure and defining an interior space therein for
housing the power system devices, wherein the structural frame
engages and provides support for the side panels; and at least one
roof structure for providing a covering for said the interior
space, wherein said the frame and side panels engage and provide
support for the roof panel.
14. The panelized control enclosure of claim 13, wherein the panels
are comprised of a combination of panels constructed of metal and
panels constructed of a composite material.
15. The panelized control enclosure of claim 14, wherein the
strength of the enclosure may be customized by the select
combination of metal panels and composite panels.
16. The panelized control enclosure of claim 13, further including
a plurality of tongue-shaped fittings formed on at least one of the
frame, side panel and roof panels and a plurality of groove-shaped
fittings formed on at least one of the frame, side panel, and roof
panels each engaging a corresponding tongue-shaped fitting to form
an engagement between one of the frame, side panel and roof
panel.
17. The panelized control enclosure of claim 16, wherein at least
one of the groove-shaped fittings is in the form of parallel rails
affixed to at least one of the frame, side panel and roof
panels.
18. The panelized control enclosure of claim 16, wherein at least
one of the tongue-shaped fittings includes a pre-formed tongue.
19. The panelized control enclosure of claim 16, wherein at least
one of the tongue-shaped fittings includes a support element
adapted to limit movement of the one of the roof panels with
respect to one of the side panels.
20. The panelized control enclosure of claim 13, wherein in the
plurality of lightweight panels are composed of a composite
material comprising: about 38 liters of LW coarse aggregate, about
38 liters of dust, about 9.5 liters of sand, about 50 kilograms of
cement, about 19 liters of water, about 9.5 liters of polystyrene
particle filler, about 400 milliliters of concrete consistency
regulating reslump admixture, about 200 grams of fiber, and about 2
liters acrylic resin.
21. The panelized control enclosure of claim 21 wherein said
composite material is selectively altered to have a compression
strength of about 2500 psi.
22. The panelized control enclosure of claim 21, wherein said
composite material is selectively altered to have a density of 100
pcf.
23. The panelized control enclosure of claim 21, wherein said
composite material is reinforced with steel reinforcement comprised
of wire mesh 6.times.6-6/6 (complying with ASTM A-185 and ASTM
A-496) and with fiber reinforcement comprised of macro-synthetic
reinforcing fiber (complying with ASTM C1116 0.26 lb/ft.sup.3).
Description
RELATED APPLICATION
[0001] This application claims benefit under 35 U.S.C. .sctn.119(e)
of U.S. Provisional Application Ser. No. 61/298,147, entitled
"Panelized and Lightweight Control Enclosure," filed on Jan. 25,
2010, naming Rick A. Schulz, Luis Alberto Alfredo D'Acosta Anezia,
and Antonio Zaldivar Lelo de Larrea Corregidora as inventors, the
complete disclosure thereof being incorporated herein by
reference.
TECHNICAL FIELD
[0002] This disclosure relates to electric power control and
monitoring stations. More particularly, this disclosure relates to
outdoor electric power control and monitoring stations and systems
for enclosing such.
BACKGROUND OF THE INVENTION
[0003] Effective electric power transmission and distribution
requires equipment and devices for the control, monitoring,
automation and protection of the electric power transmission or
distribution systems. Examples of equipment that may be used on
electric power transmission and/or distribution systems include
switches, circuit breakers, capacitor banks, transformers,
conductors, fuses, generators, current transformers (CTs),
potential transformers (PTs), and the like. Devices may be in
communication with such equipment for the monitoring, control,
automation, and/or protection of the electric power system.
Examples of these devices include the following: intelligent
electronic devices (IEDs) such as protective relays, bay
controllers, differential relays, distance relays, synchrophasor
measurement units, synchrophasor measurement and control units,
communications processors, synchrophasor vector processors, meters,
programmable logic controllers, switches, generator relays,
transformer relays, faulted circuit indicators, clocks, and the
like. Devices may receive information from the equipment and act
accordingly, based on the information received. Devices may also
send control commands to the equipment. For example, a protective
relay may be capable of receiving electric power system information
(i.e. switch or breaker status from a switch or breaker, current
from a CT, and/or voltage from a PT), process the gathered power
system information, make a decision based on the information, and
send a control command to the breaker to change status.
[0004] Power system substations are sites where several components
of the electric power system converge in a single location, such as
a yard. For example, a substation may be formed at the interface
between an electric power transmission system and an electric power
distribution system. The substation may include several step-down
transformers where the relatively high-voltage from the
transmission system is stepped down to the lower voltage of the
distribution system. Substations may further be formed along
various points of electric power transmission or distribution
systems, such as where several lines of a particular system
meet.
[0005] Substations often also house several devices for control,
monitoring, automation and protection of an electric power
transmission or distribution system. Such devices are typically
mounted in panels and housed in a free-standing structure such as a
building. Substation buildings may include some means of physical
security such as locked doors, intruder alarm systems, and the like
such that the devices are not easily accessed by unauthorized
persons.
[0006] Substation buildings are permanent, often bulky, require
significant amount of time to build and use large amounts of energy
to maintain adequate internal environmental conditions for
personnel that may be working therein. Further, substations are
often placed in locations away from populated areas and may be
difficult to access. Often, the need to access the devices occurs
only periodically. As a result, some substation buildings are built
and maintained for only a small amount of time that a person
requires the benefits of the structure. Construction of such
substation buildings requires transport of building materials,
personnel, and equipment to the site, time in construction, and the
associated costs.
[0007] Therefore, it is an object of the present invention to
provide portable control enclosures, which may be used to house
power system devices and equipment at a substation. Such enclosures
may be manufactured, fitted with the appropriate equipment and
devices (which may also be tested before the control enclosure is
installed), wired, and later stored and/or installed at the
appropriate location. It is specifically desirable that components
of the portable control enclosure be prefabricated. Collectively,
the prefabricated components may comprise a kit for assembling the
control enclosure. Such a kit would not require additional
construction materials and would be easily transportable. The
prefabricated components may be sent to an installation site and
easily configured thereon to form a control enclosure. Thus, the
present invention control enclosure overcomes the problems
associated with traditional, permanent building structures at
substations by providing a prefabricated control enclosure.
SUMMARY OF THE INVENTION
[0008] The present invention relates to a panelized lightweight
control enclosure, for housing the power system devices of a power
system substation, which may be constructed, outfitted, and
transported to an installation site in an assembled or unassembled
state. Specifically, the control enclosure is comprised of a
structural frame including a plurality of vertical posts, a base, a
plurality of side panels for forming the walls thereof and defining
an interior space therein for housing the power system devices, and
a roof for covering the interior space. The structural frame
engages and provides support for the side panels and roof. To
facilitate engagement between the frame, side panels and roof, the
control enclosure includes a plurality of tongue-and-groove
fittings. More particularly, the control enclosure includes a
plurality of tongue-shaped fittings formed on at least one of the
frame, side panel and roof panel, each engaging a corresponding
groove-shaped fitting formed on at least one of the frame, side
panel and roof panel to form an engagement between one of the
frame, side panel and roof panel. It is not required that the
control enclosure be constructed at the site of the substation, or
other storage site, but rather it may be transported to the site
already intact and installed thereon. The present invention further
relates to a method of making a composite material, for the panels
of the control enclosure, formulated for weight reduction,
strength, and resistance to cracking. Moreover, the present
invention relates to a panelized control enclosure designed to meet
the International Building Code (IBC) Live Load requirement
standard for the industry.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of an embodiment of the present
invention portable control enclosure.
[0010] FIG. 2A is a disassembled perspective view of the embodiment
of FIG. 1, showing the frame and the floor panel being
installed.
[0011] FIG. 2B is a disassembled perspective view of the embodiment
of FIG. 1, showing the frame and floor panel in an assembled
state.
[0012] FIG. 2C is a disassembled perspective view of the embodiment
of FIG. 1, showing the side panels being installed.
[0013] FIG. 2D is a disassembled perspective view of the embodiment
of FIG. 1, showing the roof panels being installed.
[0014] FIG. 2E is a fully assembled perspective view of the
embodiment of FIG. 1.
[0015] FIG. 2F is a disassembled perspective view of a second
embodiment of the present invention portable control enclosure,
showing roof supports being installed.
[0016] FIG. 2G is a disassembled perspective view of the embodiment
of FIG. 2F, showing roof supports in an assembled state and the
roof panels being installed.
[0017] FIG. 2H is a fully assembled perspective view of the
embodiment of FIG. 2F.
[0018] FIG. 3A is a cross-sectional view of an embodiment of a
fitting of a tongue-and-groove engagement.
[0019] FIG. 3B is a cross-sectional view of an embodiment of a
fitting of a tongue-and-groove engagement.
[0020] FIG. 3C is a cross-sectional view of an embodiment of a
fitting of a tongue-and-groove engagement.
[0021] FIG. 3D is a cross-sectional view of a corner of a control
enclosure, illustrating two joints between a vertical post and two
side panels.
[0022] FIG. 3E is a cross-sectional view of a joint between two
side panels.
[0023] FIG. 3F is a cross-sectional view of an embodiment of a
fitting of a tongue-and-groove engagement.
[0024] FIG. 3G is a cross-sectional view of a joint between two
side panels.
[0025] FIG. 3H is a cross-sectional view of a joint between a side
panel and a floor panel.
[0026] FIG. 4A is a cross-sectional view of an embodiment of a
metal fitting piece of a tongue-and-groove engagement.
[0027] FIG. 4B is a cross-sectional view of an embodiment of a
fitting of a tongue-and-groove engagement.
[0028] FIG. 4C is a cross-sectional view of a joint between a
vertical post and a roof panel.
[0029] FIG. 4D is a top perspective view of a portable control
enclosure.
[0030] FIG. 5A is an exploded side view of a composite side panel
of an embodiment of the present invention portable control
enclosure.
[0031] FIG. 5B is an exploded side view of a metal side panel of an
embodiment of the present invention portable control enclosure.
[0032] FIG. 5C is another exploded side view of a metal side panel
of an embodiment of the present invention portable control
enclosure.
[0033] FIG. 5D is an exploded side view of a composite side panel,
defining an aperture therein, of an embodiment of the present
invention portable control enclosure.
[0034] FIG. 5E is an exploded side view of a metal side panel,
defining an aperture therein, of an embodiment of the present
invention portable control enclosure.
[0035] FIG. 6A is a front view of an embodiment of the present
invention portable control enclosure.
[0036] FIG. 6B is a side view of the embodiment of FIG. 6A.
[0037] FIG. 6C is a rear view of the embodiment of FIG. 6A.
[0038] FIG. 6D is a top view of the embodiment of FIG. 6A.
[0039] FIG. 6E is a top view of the floor panel of the embodiment
of FIG. 6A.
[0040] FIG. 6F is a cross-sectional view of the embodiment of FIG.
6A.
[0041] FIG. 6G is a cross-sectional view of a joint between a side
panel and a roof panel.
[0042] FIG. 6H is a cross-sectional view of a joint between a side
panel and a floor panel.
[0043] FIG. 6I is a cross-sectional view of a joint between two
side panels and a vertical post.
[0044] FIG. 6J is a perspective view of the embodiment of FIG.
6A.
DETAILED DESCRIPTION OF THE DRAWINGS
[0045] The various embodiments of the disclosure will be best
understood by reference to the drawings, wherein like parts are
designated by like numerals throughout. It will be readily
understood that the components of the disclosed embodiments, as
generally described and illustrated in the figures herein, could be
arranged and designed in a wide variety of configurations. Thus,
the following detailed description of the embodiments of the
systems and methods of the disclosure is not intended to limit the
scope of the disclosure, as claimed, but is merely representative
of possible embodiments of the disclosure.
[0046] In some cases, well-known features, structures or operations
are not shown or described in detail. Furthermore, the described
features, structures, or operations may be combined in any suitable
manner in one or more embodiment. It will also be readily
understood that the components of the embodiments as generally
described and illustrated in the figures herein could be arranged
and designed in a wide variety of different configurations.
[0047] As illustrated in FIGS. 1 and 2A-F, the present invention
relates to a panelized control enclosure 100 that may be used for
enclosing power system devices and equipment at a substation.
Specifically, the panelized control enclosure 100 includes a
plurality of side panels 102, each engaging each other to form the
walls of the enclosure 100, thereby defining an interior space
within. Additionally, the control enclosure 100 includes a floor
panel 108 and at least one roof panel 106 for protecting the
interior space from the environment. At least one side panel 102
may define an aperture for routing a connection from the power
system devices and/or equipment housed within the chamber to the
power system devices and/or equipment external to the panelized
control enclosure 100. External equipment may include the
following: switchgear, circuit breakers, conductors, transformers,
buses, capacitor banks, reclosers, tap changers, current
transformers, potential transformers, grounding mats, Rogowski
coils, sensing equipment, and the like.
[0048] The control enclosure 100 further includes a structural
frame 109 for supporting the side panels 102 and securing the floor
108, roof 106 and side panels 102 to each other. The frame
comprises four vertical posts 110 and a base 112. The frame 109 may
be constructed of metal beams, such as steel beams.
[0049] Each of the above mentioned components of the portable
control enclosure may be prefabricated. Collectively, the
prefabricated components may comprise a kit for assembling the
control enclosure 100 at an installation site. This kit may not
require additional construction materials and may be easily
transportable. The prefabricated components may be sent to an
installation site and easily configured thereon to form a control
enclosure.
[0050] FIGS. 2A through 2E specifically illustrate the process of
assembling the components detailed above to form an embodiment of
the present invention panelized control enclosure 100. As shown in
FIG. 2A, the vertical posts 110 of the frame are affixed to the
base 112. The floor panel 108 defines corner indentations to allow
the floor panel 108 to engage the four vertical posts 110 of the
structural frame 109. Specifically, each corner indentation of the
floor panel 108 corresponds to a vertical post 110 such that the
floor panel 108, via the corner indentations, may be slid down and
engage the vertical posts 110, while fitting securely onto the
frame base 112. In another embodiment, the floor panel 108 may be
constructed of concrete, metal, wood, or another material and may
include a metal tread plate, such as a steel tread plate. Once the
floor panel 108 and vertical posts 110 are securely in place, as
shown in FIG. 2B, the side panels 102 may be installed. The side
panels 102 may be formed from a number of pre-formed composite or
metal materials. The composite material may be composed of
concrete, wood, fibers and resin, polymeric, reinforced concrete or
the like. The metal panels may also be corrugated.
[0051] As shown in FIG. 2B, the vertical posts 110 and frame base
112 may include tongue-and-groove fittings 104, for receiving the
side panels 102. In this embodiment, the tongue-and-groove fittings
104 extend the vertical length of the vertical posts 110 and side
panel 102 such that the sides of the vertical posts 110 engage the
side panels 102 via the tongue-and-groove fittings 104. Each side
panel 102 may also include tongue-and-groove fittings 104 for
connection to each other as well as the frame 109 and roof panel
106. In this embodiment, the tongue-and-groove fittings 104 are
affixed to all four sides of each side panel 102 such that the
panels may engage each other, the vertical posts 110, the base 112,
and the roof 106 of the enclosure. The tongue-and-groove
engagements 104 are illustrated in detail in FIGS. 3A-3H.
[0052] As illustrated in FIG. 2C, the tongue-and-groove fittings
104 are installed on the base 112 and vertical posts 110 after the
floor panel 108 is in place. The tongue-and-groove fittings 104
affixed to the side panels 102 are fitted into the corresponding
tongue-and-groove fittings 104 affixed to the vertical posts 110.
The tongue-and-groove fittings 104 allow the side panels 102 to
slide downwards until the tongue-and-groove fittings 104 affixed to
the base of the side panels 102 engage the corresponding
tongue-and-groove fittings 104 affixed to the floor panel 108
and/or frame base 112. Alternatively, the side panels 102 may be
set into the tongue-and-groove fitting 104 of the floor panel 108
and/or frame base 112 first and then slid outward to engage the
tongue-and-groove fittings 104 positioned on the vertical posts
110. FIG. 2D illustrates the side panels 102 as fully extended and
installed.
[0053] As further illustrated in FIG. 2D, the panelized control
enclosure 100 may also include roof supports in the form of
integrated non-prismatic beams in the roof panels 106. FIG. 2E
illustrates the first embodiment of the panelized control enclosure
100 fully assembled.
[0054] In a second embodiment, illustrated in FIGS. 2F-2H, the roof
supports may be in the form of non-integrated, angled supports 114
(i.e., triangles) situated at opposite ends of the control
enclosure 100 on top of two opposing side-paneled 102 walls to
define the shape and slope of the roof. The roof supports 114 in
that embodiment allow the roof panels 106 to meet at an angle. As
shown in FIG. 2G, the roof panels 106 are installed on top of the
roof supports 114 on the two remaining side-paneled 102 walls. In
both embodiments, the roof panels 106 and roof supports are affixed
to the side panels 102, and each other, via tongue-and-groove
fittings 104. The roof panels 106 may meet at a gradual peak in the
middle, and slope downward toward the sides at a constant slope.
FIG. 2H illustrates the second embodiment of the panelized control
enclosure 100 fully assembled.
[0055] The tongue-and-groove fittings 104 described above are
illustrated in FIGS. 3A-4C. The tongue-and-groove fittings 104 are
generally comprised of individual corresponding fittings (shown at
204, 206, 208, 210, 212, 214, and 216). Each fitting joins with a
corresponding fitting to form a tongue-and-groove type fitting 104,
thereby forming a joint between the parts of the control enclosure
100 discussed above. The various tongue-groove type fittings are
illustrated in detail in FIGS. 3A-3C, 3F, and 4A-4C. These fittings
may be applied to form joints between any one of the vertical posts
110, side panels 102 or roof structures 106 of the enclosure.
[0056] For instance, as illustrated in FIG. 3D, a vertical post 110
may be connected to a side panel 102a by a tongue-and-groove
fitting 104 comprised of a tongue-shaped fitting 204 and another
corresponding groove-shaped fitting 206a. In the embodiment of FIG.
3D, the side panels 102a, 102b are composed of a composite
material, such as concrete, and formed so as to define a groove
130a, 130b or tongue 132a, 132b, respectively, along their edges.
As shown in FIG. 3D, one side panel 102b is configured to include a
tongue 132b shape along its edge. The tongue 132b shape may be
formed by tongue-shaped fitting 208 of FIG. 3C. The other side
panel 102a is shaped to define a groove 130a along its
corresponding edge. The groove 130a shape may be formed by a
groove-shaped fitting similar to the groove-shaped fitting 206 of
FIG. 3B. The groove-shaped fitting 206a may be affixed to the side
panel 102a and the tongue-shaped fitting 208b may be affixed to the
side panel 102b with sealant or welding.
[0057] The vertical post 110 may define either a groove or a tongue
to facilitate engagement with the side panels through machining.
Otherwise, the tongue or groove shape may be constructed to the
vertical post 110 via other fittings. Specifically, the fitting 204
of FIG. 3A, including a tongue shape 132a, may be affixed to the
vertical post 110. As shown in FIG. 3D, the tongue 132a of fitting
204 fits into the groove 130a of the side panel 102a to form a
joint between the side panel 102a and the vertical post 110.
Fittings 204 and 206 may be secured to each other with structural
adhesive 138, sealant, or welding.
[0058] Furthermore, in the embodiment of FIG. 3D, the vertical post
110 engages the side panel 102b via a tongue-and-groove fitting 104
comprised of parallel rails 210 situated on the vertical post 110
forming a groove-shaped engagement and a corresponding
tongue-shaped fitting 208b formed on a side panel 102b.
Specifically, the tongue shape 132b may be formed by tongue-shaped
fitting 208b (e.g. similar to tongue-shaped fitting 208 of FIG.
3C). The groove shape 130b may be formed by affixing two rails 210
to the vertical post 110 with sealant or welding. The space defined
between the rails 210 forms a groove shape 130b. As shown in FIG.
3D, the tongue 132b of tongue-shaped fitting 208b fits into the
groove 130b formed by the rails 210 to form a joint between the
side panel 102b and the vertical post 110.
[0059] FIG. 3E illustrates a cross-sectional view of an embodiment
of side panels 102c, 102d fitted together, via a tongue-and-groove
fitting 104, to form part of a wall of the control enclosure.
Specifically, one side panel 102c is shaped to define a groove 130c
in its lateral edge and is fitted with a groove-shaped fitting 206c
(e.g., similar to groove-shaped fitting 206 of FIG. 3B). The
adjacent side panel 102d is shaped such that it includes a tongue
shape 132d to engage the grooved side panel 102c. The fitting 208d
(e.g., similar to fitting 208 of FIG. 3C), which has a
corresponding tongue shape 132d to side panel 102d, is fitted over
the lateral edge of side panel 102d and may be affixed thereto with
sealant or may be welded thereto. The tongue 132d fits into the
groove 130c to form a joint between the side panels 102c and 102d.
The fittings 206c and 208d may be secured to each other with
structural adhesive 138 or welding. In another embodiment shown in
FIG. 3G, the side panel 102f is composed of a material that cannot
easily define a groove or tongue. In this embodiment, the
tongue-shaped fitting 212 of FIG. 3F including a pre-formed tongue
shape 132 is used and applied as shown.
[0060] As illustrated in FIG. 3H, the connection between the side
panel 102 and the floor panel 108 may also include a
tongue-and-groove engagement 104. The floor panel 108 may be formed
so as to define a groove or tongue, respectively, along its top
perimeter edges to facilitate engagement with the vertical posts
and the side panels. The floor panel 108 may be configured to
include a tongue shape 132 along one of its edges. The tongue shape
132 may be formed by fitting 204 of FIG. 3A or fitting 212 of FIG.
3F. The side panel 102 may be formed to define a groove 130 along
its corresponding bottom surface. The groove shape 130 may be
formed by the fitting 206 of FIG. 3B. As shown in FIG. 3H, the
tongue 132 of fitting 204 fits into the groove 130 of fitting 206
to form a joint between the floor panel 108 and the side panel 102.
Fittings 202 and 206 may be secured to each other with structural
adhesive 138. The fittings 204, 206 may also be welded to each
other.
[0061] As described above, the engagement between the side panel
102 and the roof 106 may also include a tongue-and-groove
engagement 104. As illustrated in FIGS. 4C-4D, the roof panels 106
are formed so as to define a groove or tongue, respectively, along
their edges to allow for engagement with each other and the side
panels 102. As specifically illustrated in FIG. 4C, a roof panel
106 may be configured to include a tongue shape 132 along one of
its edges. The tongue shape 132 may be formed by fitting 214 of
FIG. 4A. Moreover, fitting 214 may further provide an additional
support element 170 for the roof panel. Specifically, as
illustrated in FIG. 4C, the support element 170 of fitting 214
borders the outer lateral edge of the roof panel 106, which limits
movement of the roof panel 106 with respect to the side panels 102
to ensure that the roof panel 106 stays in place above the side
panels 102. The side panel 102 may be formed to define a groove 130
along its corresponding top surface. The groove shape 130 may be
formed by the fitting 216 of FIG. 4B. The fitting 214 is affixed to
the roof panel 106 and the fitting 216 may be affixed to the side
panel 102 with sealant or through welding. As shown in FIGS. 4C and
4D, the tongue 132 of fitting 214 fits into the groove 130 of
fitting 216 to form a joint between the roof panel 106 and the side
panel 102. Fittings 214 and 216 may be secured to each other with
structural adhesive 138. Additionally, the fittings 214, 216 may be
welded to each other.
[0062] The fittings may be comprised of 12-gauge, ASTM 1011, HSLA
Gr 55 tongue-and-grooved shaped steel. Additionally, the metal
fitting pieces may be hot dipped galvanized, complying with ASTM
A123/A123M.
[0063] FIGS. 5A through 5E illustrate various embodiments of side
panels 102 for the panelized control enclosure 100. As discussed
above, the side panels 102 may be constructed of various materials.
For example, in FIGS. 5A-5E, the control enclosure 100 may include
side panels 102 constructed of composite materials 120 in
combination with other side panels 102 constructed of metal 122.
The metal 122 side panels 102 may be formed from a light metal
(i.e., 24-gauge steel with polystyrene filler) that is pre-coated
in 20-yr Kynar finish. Moreover, the metal panels 122 may be
corrugated. FIGS. 5B, 5C and 5E show side panels comprised of metal
material 122. The composite material 120 may be a concrete, wood,
fibers and resin, polymeric, reinforced concrete or the like. FIGS.
5A and 5D show side panels 102 comprised of a composite material
120. The strength of the enclosure may be customized by the select
combination of metal panels and composite panels.
[0064] In one embodiment, the composite material consists of a
novel concrete formula, designed for weight reduction, strength and
resistance to cracking. The composite material may be selectively
altered to maximize one or more of these attributes. In one
embodiment, the composite material may be formed from the
ingredients and in the proportions as listed in the following
Table:
TABLE-US-00001 Ingredient Amount LW Coarse Aggregate 38 L Dust 38 L
Sand 9.5 Liters Cement 50 Kg Water 19 L Pre-expanded mineral bead
9.5 L Concrete consistency regulating 400 mL reslump admixture MS
Fiber (macro synthetic 200 g reinforcing fiber Acrylic resin 2
L
[0065] Moreover, in one embodiment, the composite concrete has
compression strength of 2500 psi and density of 100 pcf
(lb/ft.sup.3). Additionally, the concrete is reinforced with steel
reinforcement comprised of wire mesh 6.times.6-6/6 (complying with
ASTM A-185 and ASTM A-496) and with fiber reinforcement comprised
of macro-synthetic reinforcing fiber (complying with ASTM C1116
0.26 lb/ft.sup.3). The formula includes fiber and wire reinforced
concrete with pre-expanded mineral bead, such as Perla.TM.
(manufactured by Fanosa, located in Sinaloa, Mexico). In one
embodiment, the concrete consistency regulating reslump admixture
is Sikament-100, manufactured by Sika.RTM. Corp. USA, located in
Lyndhurst, N.J. Additionally, in one embodiment, the abovementioned
MS fiber is Sika.RTM. Fiber MS, manufactured by Sika.RTM. Corp.
USA.
[0066] As discussed above, the walls may be constructed of a number
of pre-formed composite material or metal panels. In a single
control enclosure, the panels may be constructed of the same or
different material. That is, a single control enclosure may include
a combination of metal panels and composite panels, or only metal
panels, or only composite panels. The metal panels may be comprised
of 12-gauge, ASTM 1011, HSLA Gr 55 tongue-and-grooved shaped steel.
Additionally, the metal panels may be hot dipped galvanized,
complying with ASTM A123/A123M.
[0067] The side panels 102 may comprise one of the following
configurations:
TABLE-US-00002 Description Dimension Frame: Steel HSLA 55 Gr.
sheet, gauge 12, tongue and 2'-9'' .times. 10'-6'' groove shape
Filler: synthetic fiber and steel wire mesh reinforced light weight
concrete Finishing: Stained and sealed concrete Frame: Steel A-36
sheet, gauge 12, tongue and groove 2'-9'' .times. 10'-6'' shape
Filler: polystyrene Finishing: pre-coated steel sheet, gauge 24
Frame: Steel HSLA 55 Gr sheet, gauge 12, tongue and 2'-9'' .times.
10'-6'' groove shape Filler: synthetic fiber and steel wire mesh
reinforced light weight concrete Finishing: Stained and sealed
Concrete Special: hole (aperture) Frame: Steel HSLA 55 Gr sheet,
gauge 12, tongue and 2'-9'' .times. 10'-6'' groove shape Filler:
polystyrene Finishing: pre-coated steel sheet, gauge 26 Special:
hole (aperture)
[0068] Additionally, as shown in FIGS. 5D and 5E, the side panels
102, whether composed of composite or metal material, may define an
aperture 128. The aperture 128 may be a window or an access port
for the devices or equipment within the control enclosure.
[0069] As shown in FIGS. 6A-6C, in a single panelized control
enclosure 100, the panels may be formed of different material. That
is, a single control enclosure 100 may include a combination of
metal panels 122 and composite panels 120. FIG. 6A illustrates a
panelized control enclosure 100 including both metal panels 122 and
composite panels 120, as well as a door 118. The door 118 may be
comprised of 18-gauge face sheet with 7-gauge hinge reinforcement
and may be thermally insulated. Moreover, the door 118 may include
a hydraulic closure and a key lock exterior handle with an interior
panic bar.
[0070] The embodiment of FIG. 6A includes further an additional
metal panel, the door cover 116, situated above the door 118. FIG.
6B depicts a side view of the panelized control enclosure of FIG.
6A, including composite panels and lifting yokes 148 situated on
the frame base 112. FIG. 6C shows the rear of the panelized control
enclosure 100, where the side panels 102 are comprised of both
composite panels 120 and metal panels 122. FIG. 6D provides a top
view of the panelized control enclosure 100. FIG. 6E illustrates a
floor panel 108 for the control enclosure 100. The floor panel 108
may be formed from concrete, metal, wood, or another material and
may include a metal tread plate 150 such as a steel tread plate.
FIG. 6F illustrates a cross-sectional view of the embodiment of the
panelized control enclosure 100 of FIGS. 6A-6E.
[0071] As illustrated in FIGS. 6G-61, the side panels 100, whether
composed of composite material or metal, may be coated in a casing
primed and finished with a top coat of Acrylic Polyurethane marine
coating. Moreover, the panels 102 may be joined utilizing a 2-part
methacrylic or acrylic construction adhesive and sealed with a
25-year marine sealant. The interior ceiling and side panels 102
may be comprised of plywood and/or polystyrene foam installation,
sheathed with white pre-coated steel sheet, gauge 24 or plastic
liner 142. FIG. 6G details the joint between the roof and the wall,
and shows in detail the P.V.C. waterproofing membrane 130, adhesive
132, hot-air welded sheet 134, sealer 136, structural adhesive 138
(such as, Plexus MA310, available from ITW Plexus with a location
in Rushden, UK, MAXLOK MX/T18 CART RP375 from LORD), side panel
102, roof panel 106, tongue-and-groove joint 104, polystyrene inner
insulation 140, pre-coated steel sheet, gauge 24 or plastic inner
liner 142, and the like. FIG. 6H illustrates a cross-sectional view
of a joint between a side panel 102 and a floor panel 108,
detailing the side panel 102, sealer 136, structural adhesive 138,
and steel floor plate 108. FIG. 6I illustrates a top
cross-sectional view of the joint between two side panels 102a,
102b and a vertical post 110 including a pre-coated steel sheet,
gauge 24 or plastic liner 142.
[0072] Furthermore, as previously mentioned with respect to in FIG.
6F the panelized control enclosure 100 may include lifting yokes
148 which are installed on the frame base 112 to facilitate moving
of the panelized control enclosure 100. As discussed above, it is
an object of the present invention to provide a panelized control
enclosure 100 that may be constructed and outfitted at a
manufacturing site, and later shipped to and installed at a
substation. The panelized control enclosure 100 may be stored
during the time between its construction and installation. In order
to move the control enclosure 100, it may be lifted onto a moving
device, such as a crane, truck or train. To facilitate the lifting
thereof, the panelized control enclosure 100 is fitted with lifting
yokes 148. FIG. 6F illustrates the configuration of the lifting
yokes 148 positioned on the base 112 of the panelized control
enclosure 100.
[0073] While this invention has been described with reference to
certain illustrative aspects, it will be understood that this
description shall not be construed in a limiting sense. Rather,
various changes and modifications can be made to the illustrative
embodiments without departing from the true spirit, central
characteristics and scope of the invention, including those
combinations of features that are individually disclosed or claimed
herein. Furthermore, it will be appreciated that any such changes
and modifications will be recognized by those skilled in the art as
an equivalent to one or more elements of the following claims, and
shall be covered by such claims to the fullest extent permitted by
law.
* * * * *