Abstract: A 1/16 DIN power controller configuration is provided that includes a housing, a circuit board carrier disposed within the housing and capable of engaging at least three circuit boards within the housing, a power supply circuit board disposed within the housing and engaged by the circuit board carrier, and a communications circuit board disposed adjacent the power supply circuit board within the housing and engaged by the circuit board carrier. The communications circuit board includes Ethernet/IP and/or Modbus TCP protocols, and in alternate forms includes RS-232 and RS-485 with Modbus RTU protocol, DeviceNet, Profibus DP, CanOpen, and/or EtherCat.

Abstract: A housing assembly is provided that has a case including an open end and a flange extending around at least a portion of the open end. The flange defines at least one reduced area extending into a portion of the flange, and a gasket is disposed around the flange. Preferably, the gasket includes a first sealing portion, a second sealing portion, an internal groove for receiving the flange, and at least one member extending into the internal groove and into the at least one reduced area of the flange. In one form, the reduced area is an aperture, and the member of the gasket is a support that extends all the way through the flanges, thereby providing a secure engagement between the gasket and the case during operation. Methods of manufacturing the housing assembly are also provided.

Abstract: A gasket is provided that includes a first sealing portion defining an angled profile and a second sealing portion. A plurality of beads are disposed along the angled profile of the first sealing portion, and a plurality of ribs are disposed along the second sealing portion, thus providing a dual action sealing gasket. The gasket is preferably employed in an electrical housing assembly for a power controller system, wherein the housing assembly comprises a case having an open end, a cover for closing the open end of the case, and a mounting collar disposed around the case for mounting the case to a panel. The gasket is secured to the case proximate the open end such that when the cover is mounted to the open end of the case, the plurality of beads are elastically deformed by the cover and the plurality of ribs are compressed against the panel.

Abstract: An assembly includes a circuit board, a terminal and a pin. The circuit board is for a controller and includes terminal mounting holes. The terminal mounting holes include a first mounting hole and a second mounting hole. The terminal includes a first mounting post that has an interference fit with said first mounting hole. The terminal also includes a second mounting post that has a transitional fit with the second mounting hole. A pin is electrically coupled to one or more of the first mounting post and the second mounting post and couples to a block connector.

Abstract: A power control assembly for use in an integrated power control system has a base with a housing that defines a cavity adapted for receiving a power switch. The control assembly includes a control module configured for generating control signals for controlling the power switch for selectively providing power to a load. A control housing houses the control module and is adapted to be releasably coupled to the base housing and is configured for electrically coupling to control couplers on the base housing for providing the generated control signals to the power switch within the housing cavity upon coupling the control housing to the base housing.

Abstract: A power control system includes a base having a housing configured for releasably receiving a control unit and a cavity within the housing for receiving a solid state relay having a hockey puck configuration. The base includes an input power terminal for coupling to an input power source, an output power terminal for coupling to a power receiving load, and coupling fixtures for fixedly and electrically coupling to input and output power terminals and control terminals of the received solid state relay. A control unit is configured to control the solid state relay for selectively providing, at least a portion of, the power received at the input power terminal to the output power terminal. The control unit has a housing adapted to be releasably coupled to the base housing. The control unit and base each configured to electrically couple the control unit to the control terminals of the received solid state relay as a function of the control unit being coupled to the base.