CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority of US Provisional Application No. 61/307,299, entitled "Power Source Roll Cage ", filed February 23, 2010, which is herein incorporated by reference and U.S. Patent Application No. 12/962,070 entitled "Welding Power Supply External Protective Support Structure ", filed December 7, 2010, which are herein incorporated by reference.

BACKGROUND

[0002] The present invention relates generally to the field of welding systems, and more particularly to an external support structure to house a welding system power supply to protect and transport the power supply, and that may allow for stacking the power supply with additional power supplies outfitted with similar external support structures.

[0003] Welding systems and power supplies are frequently used in harsh environments where they may be exposed to debris, dust and other deposits that can harm or damage the welding power supplies. Similarly, common welding environments may include exposure to vibrating and mechanical tools, contact with which could damage a welding power supply. Additionally, some welding tasks, such as those in boilers or power plants, regularly require the use of more than one welding power supply. In such circumstances, it can be inconvenient and hazardous for a welding environment to be cluttered with numerous welding power supplies. Furthermore, welding power supplies, which may weigh over 80 pounds, are frequently difficult and cumbersome to transport or reposition.

BRIEF DESCRIPTION

[0004] An external support structure, in certain embodiments, includes a cage-like assembly configured to receive a welding power supply. The cage-like assembly includes a number of tubular members defining an inner volume where the tubular members at least partially surround the base, top and lateral sides of the welding power supply. The cage-like assembly further includes a plurality of fastening points allowing for securement of the welding power supply within the cage-like assembly. The cage-like assembly also includes stacking members which allow the structure to be stacked with a self-similar structure. A sheet-like cover may be disposed over at least a part of the cage-like assembly to protect the welding power supply.

DRAWINGS

[0005] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0006] FIG. 1 is a perspective view showing an exemplary external support structure, a welding power supply and the manner in which a welding power supply may be placed within the external support structure, in accordance with certain embodiments of the present technique.

[0007] FIG. 2 is a front perspective view of a welding power supply within an exemplary external support structure, in accordance with certain embodiments of the present technique.

[0008] FIG. 3 is a rear perspective view of a welding power supply within an exemplary external support structure, in accordance with certain embodiments of the present technique.

[0009] FIG. 4 is a perspective view of two exemplary external support structures, each containing a welding power supply, that are stacked in accordance with certain embodiments of the present technique. DETAILED DESCRIPTION

[0010] As discussed further below, embodiments of the presently disclosed external support structure include a cage-like assembly configured to receive a welding power supply. The cage-like assembly includes a plurality of tubular members that at least partially surround the base, top and lateral sides of the welding power supply. The cage-like assembly may further include a number of fasteners for use in securing the welding power supply within the cage-like assembly. In order to facilitate the stacking of two or more self-similar external support structures, the cagelike assembly includes upper and lower support members configured to permit stacking. In addition, the cage-like assembly may include handles of a first configuration and handles of a second configuration such that the handles of a first configuration interlock with the handles of a second configuration when self- similar external support structures are stacked. The cage-like assembly may also include casters to facilitate the transportation or repositioning of the external support structure. The external support structure may also include an outer shell configured to at least partially extend over the top and lateral sides of the cage-like assembly, thereby protecting the welding power supply from contact with tools, debris, dust and other materials that could harm or damage the welding power supply.

[0011] Turning now to the drawings, FIG. 1 illustrates an external support structure 10 configured to receive a welding power supply 12 in accordance with aspects of the present disclosure. As discussed above, the external support structure 10 includes a cage-like assembly 14. In the exemplary embodiment depicted in FIG. 1, the cage-like assembly defines an inner volume 14 and has an open end 18 and a closed end 20. As shown in FIG. 1, the cage-like assembly 14 receives the welding power supply 12 through the open end 18 and at least partially surrounds the base, top and lateral sides of the welding power supply 12.

[0012] In certain embodiments of the present invention, the welding power supply 12 may be a power converter style welding power supply or an inverter welding power supply requiring a power source 22. In other embodiments, the welding power supply 12 may be a generator or alternator welding power supply which may include an internal combustion engine. The welding power supply 12 may also include a control panel (not shown) for adjusting various welding parameters such as voltage and current, and for connecting a power source 22, if required. The welding power supply 12 provides an electric current and voltage to welding leads 28 for a welding application 26.

[0013] In accordance with embodiments of the present invention, the cage- assembly 14 may be constructed with a metallic material such as aluminum or steel. As discussed in further detail below, the cage-like assembly 14 may be constructed by bending tubular members and/or by welding two or more tubular members together. As shown in FIG. 1, the cage-like assembly 14 includes a lower frame 28 as a base for the external support structure 10. For example, the lower frame 28 may be constructed by bending a single tubular member. For further example, the lower frame 28 may be constructed by welding a number of tubular members together. The cage-like assembly includes supports 30 attached to the lower frame 28. The supports 30 provide a platform for supporting the weight of the welding power supply 12 when the welding power supply 12 is placed within the cage-like assembly 14. The supports 30 further include securement pads 32 and fasteners 34. When placed in the cage-like assembly 14, the welding power supply 12 rests on the securement pads 32, which may serve as a cushion between the lower frame 28 and the welding power supply 12. In certain embodiments, the securement pads 32 may comprise a resilient material, such as rubber or polyurethane. The fasteners 34 operate to secure the welding power supply 12 within the cage-like assembly 14 and to prevent the welding power supply 12 from shifting or sliding within the cage-like assembly 14. In certain embodiments, the fasteners 34 may be pins, bolts or threaded bars which may be inserted into the base of the welding power supply 12.

[0014] As shown in FIG. 1, the cage-like assembly 14 further includes a number of upright members 36. The upright members 36 are connected to the lower frame 28 and are generally oriented vertically to protect the lateral sides of the welding power supply 12. In certain embodiments, the upright members 36 may be welded to the lower frame 28. While the illustrated embodiment shows six upright members 36, the cage-like assembly 14 may include any number of upright members 36 depending on the requirements of a given application, economic considerations, etc. As shown, a number of the upright members 36 may be configured to receive casters 38 at the base of the cage-like assembly 14 to allow for the transportation of the external support structure 10 and the welding power supply 12. Still further, the cage-like assembly 14 includes cross braces 40. As shown in FIG. 1, the cross braces 40 are connected to a number of the upright members 36 to form the closed end 20 and to provide added structural stability to the cage-like assembly 14. The number of cross braces 40 may vary depending on the requirements of a given application, economic considerations, etc. As discussed above, in an exemplary embodiment of the present invention, the upright members 36 and the cross braces 40 may be tubular members and may be constructed of a metallic material such as aluminum or steel.

[0015] The lower frame 28 includes a recess 42 such that the recess 42 is configured to receive a handle 44 of a self-similar external support structure 10, as discussed in further detail below. In accordance with certain aspects of the invention, the recess 42 may be formed by machining or bending one or more of the tubular members that comprise the lower frame 28. In other embodiments, the recess 42 may be formed by welding additional tubular members onto the lower frame 28.

[0016] FIG. 2 is a front perspective view of an external support structure 10 containing a welding power supply 12. As shown in FIG. 2, when placed within the external support structure 10, the welding power supply 12 is at least partially enclosed by a lower frame 28, upright members 36 and cross braces 40. FIG. 2 also shows an end 20 defined by the upright members 36 and the cross braces 40.

[0017] Further, the cage-like assembly 14 includes two handles 44 that may be used for lifting, pushing or otherwise relocating the external support structure 10. In the illustrated embodiment, one handle 44 is located at the top of the closed end 20 of the cage-like assembly 14, and another handle 44 is located at the top of the open end 18 of the cage-like assembly 14. In other embodiments, the handles 44 may be located at other points on the cage-like assembly 14. The handles 44 may be formed by machining or bending the tubular members used to construct the cage-like assembly 14. As shown in FIG. 2, the cage-like assembly 14 further includes an arcuate lifting eye 46. As will be appreciated, the arcuate lifting eye 46 may be useful when lifting and stacking the external support structure 10 onto a second self- similar external support structure 10. The arcuate lifting eye 46, in certain embodiments, may be formed from a tubular member using a bending or other machining process. Further, the arcuate lifting eye 46 may then be welded onto the cage-like assembly 14. Additionally, while the illustrated embodiment includes one arcuate lifting eye 46, other embodiments may include more than one arcuate lifting eye 46.

[0018] Still further, the lower frame 28 of the cage-like assembly 14 includes a handle 48 defining a recess 50. The recess 50 is configured to receive a handle 44 of a second self-similar external support structure 10. In particular, as discussed in further detail below, when a first external support structure 10 is stacked on top of a second external support structure 10, a handle 44 of the second external support structure 10 interlocks with the handle 48 of the first external support structure 10. In one embodiment, the handle 48 may be formed by machining or bending one or more of the tubular members that comprise the lower frame 28. In another embodiment, the handle 48 and the recess 50 may be formed by welding additional tubular members onto the lower frame 28.

[0019] FIG. 3 is a rear perspective view of the external support structure 10 containing the welding power supply 12. As discussed above, when placed within external support structure 10 through the open end 18, the welding power supply 12 rests on the supports 30 and is at least partially surrounded by the upright members 36.

[0020] FIG. 4 is a front perspective view of a two stacked, self-similar external support structures 10. More particularly, a first external support structure 52 is stacked on top of a second external support structure 54. As previously discussed, when stacked, a handle 44 of the second external support structure 54 interlocks with a handle 48 of the first external support structure 52 and occupies a recess 50 formed by the handle 48. Furthermore, as previously discussed, a handle 44 of the second external support structure 54 occupies the recess 42 (shown in FIG. 2) of the first external support structure 52. As will be appreciated, the interlocking of the handle 44 and the handle 48 provides stability to the stacked external support structures 10 and helps prevent the shifting or sliding of the first external support structure 52 while stacked on top of the second external support structure 54. To provide additional stability, the first external support structure 52 and the second external support structure 54 may be bound together with straps or other fasteners (not shown).

[0021] Additionally, two or more external support structures 10 may be stacked horizontally, or side by side. More particularly, two or more external support structures 10 may be horizontally bound together with straps or other fasteners. In certain applications, it may be desirable to stack several external support structures 10 vertically and horizontally. For example, in an application requiring six welding power supplies 12, each welding power supply 12 may be placed within a respective external support structure 10, and the external support structures 10 may be stacked in two rows of three columns. As will be appreciated, such a configuration may further decrease clutter in a welding work environment and increase the mobility of the welding power supplies 12.

[0022] As shown in FIG. 4, the first external support structure 52 includes an outer shell 56 that extends over the top and a portion of the lateral sides of the first external support structure 52. In some embodiments, the outer shell 56 may extend to fully cover the top and lateral sides of the external support structure 10. By way of example, the outer shell 56 may be constructed of sheet metal. Alternatively, the outer shell 56 may be constructed of polyurethane, polyethylene or other type of plastic or hard, durable material. As will be appreciated, in some embodiments, the outer shell 56 may be attached to the external support structure 52 with fasteners such as bolts or screws (not shown). In other embodiments, the outer shell 56 may be attached to the external support structure 52 with clasps or other type of quick-release latch to allow for rapid removal of the outer shell 56. The outer shell 56 may also include an opening 58, as shown in FIG. 4, to allow an arcuate lifting eye 46 to protrude therethrough. [0023] While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.