Assembly method of compact frequency converter

Abstract

The invention discloses an assembling method of a compact frequency converter, which is used for assembling the compact frequency converter comprising a main water pipe, a functional part, a water distribution pipe and a joint, a primary loop bus connecting end and a secondary loop wiring end, and comprises the following steps in sequence: mounting the main water pipe, pre-paying off the functional part, mounting the functional part, mounting the water distribution pipe and mounting a primary loop. And secondary circuit wiring and internal redundancy cleaning are carried out. By formulating a reasonable and optimized compact frequency converter assembly process, the production quality and reliability of the compact frequency converter are ensured by controlling the assembly quality of waterway installation, bus installation, wiring and the like in the frequency converter production process.

Description

Technical Field

[0001] The invention belongs to the field of frequency converter assembly technology, and in particular relates to an assembly method for a compact frequency converter. Background Art

[0002] The frequency converter is an energy control device that converts the industrial frequency power supply into another frequency by using the on-off function of power semiconductor devices. It has functions such as speed regulation, torque control, reducing starting impact, protecting equipment, achieving motor soft start, and saving energy and reducing consumption.

[0003] The inverter mainly includes a cooling water system composed of stainless steel water pipes and hoses, a control system composed of a rectifier unit, a filter unit, a brake unit, a drive unit, a detection unit, a microprocessor unit, etc., a primary circuit system composed of busbars, laminated busbars and insulating parts, and a secondary circuit system composed of cable connections and terminal blocks.

[0004] During operation, the inverter will encounter problems such as heat dissipation, electromagnetic interference, and water condensation. In particular, compact inverters have small maintenance space and are complex to disassemble. Once quality problems occur, they will have a great impact on the entire product. Therefore, during the inverter assembly process, it is necessary to control the quality of water installation, busbar installation, wiring, etc. In order to solve the above problems, it is necessary to adopt appropriate assembly process methods to ensure the assembly production quality of compact inverters. Summary of the invention

[0005] In view of this, the present invention provides an assembly method for a compact frequency converter, which ensures the installation quality and reliability of the compact frequency converter and improves production efficiency by optimizing the assembly steps.

[0006] The technical solution adopted by the present invention to solve the technical problem is: a method for assembling a compact frequency converter, which is used to assemble a compact frequency converter including a main water pipe, functional components, a water distribution pipe and a joint, a primary circuit busbar connection end and a secondary circuit connection end, and the steps are as follows: S1, installation of main water pipe: flush the main water pipe continuously with clean water to ensure that there are no impurities at the water outlet. After flushing, seal the water inlet and outlet with protective bags, wrap the exposed surface of the stainless steel pipe with anti-condensation foam sponge and tie it with cable ties; S2, pre-layout of functional components: Lay out the functional components according to their positions in the equipment. When laying out the functional components, consider the convenience of wiring, and keep an appropriate positive tolerance for the length of the wire, and do not allow negative tolerance; S3, installation of functional components: each functional component is installed layer by layer from inside to outside and from top to bottom; S4, installation of water distribution pipes and joints: use hoses, clamps, etc. to connect the water path between the water cooling device and the main water pipe through the pagoda joint interface. When installing the pagoda joint, use anaerobic thread sealant to seal the threads; S5, primary circuit installation: Before installation, clean the busbar installation surface with cotton gauze dipped in anhydrous alcohol, and then install the primary circuit consisting of the busbar, laminated busbar and insulation parts; S6, secondary circuit wiring: When wiring the secondary circuit, the wiring harness should be arranged neatly and beautifully, horizontally and vertically, and placed from the input end to the output end. The wire harness should have an arc transition at the bend. In the sections with holes and edges, it is necessary to use a wire protection sleeve to protect the wire insulation layer. The temperature of the electric soldering iron is set to 350±10℃. When the stripped cable core is tinned, the tinning time in the tin melting furnace is 1 to 2 seconds. The surface of the welded joint is smooth, the solder is full, and the cable surface is free of burns and aging deformation. The overall wiring of the functional components is completed; S7, cleaning of internal excess materials: Use a vacuum cleaner to clean the wire ends, cable ties and other excess materials generated during the internal assembly and wiring processes.

[0007] Furthermore, after the water distribution pipes and joints in step S4 are installed, the strength and sealing tests of the entire pipeline are carried out: first, the pressure is maintained for 30 minutes with 0.6MPa clean air, and the pressure does not drop during the test; then, the pressure is maintained for 30 minutes with 1.0MPa pure water, and the pressure does not drop during the test and there is no water leakage.

[0008] Furthermore, in step S5, the busbar connection screws are fastened by a cross-cross method according to the torques of M6: 3-6 N.m, M8: 8.8-10.8 Nm, M10: 17.7-22.6 Nm, and M12: 31.4-39.2 Nm.

[0009] Furthermore, the busbar after the screws are tightened is inspected with a 0.1mm feeler gauge, and the size of the feeler gauge inserted into the busbar contact surface is no greater than 5mm.

[0010] Furthermore, in step S6, the bending radius of the wire harness must not be less than twice the outer diameter of the harness.

[0011] The beneficial effect of the present invention is that the assembly method of the present invention ensures the production quality and reliability of the compact frequency converter by controlling the assembly quality of water channel installation, busbar installation, wiring, etc. during the frequency converter production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a schematic diagram of the structure of a compact frequency converter assembled in the present invention; Figure 2 It is a flow chart of the assembly process of the compact frequency converter of the present invention.

[0013] The figures are marked as follows: 1—main water pipe, 2—functional component, 3—water distribution pipe and joint, 4—primary circuit busbar connection end, 5—secondary circuit connection terminal. DETAILED DESCRIPTION

[0014] The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments.

[0015] Before describing the embodiments of the present invention in detail, the application environment of the present invention is described first.

[0016] The technology of the present invention is mainly applied to the assembly process of compact frequency converters. Frequency converters will encounter problems such as heat dissipation, electromagnetic interference, and water channel condensation during operation. For compact frequency converters, the maintenance space is small and the disassembly is complicated. Once a quality problem occurs, it will have a great impact on the entire product. Therefore, a reasonably optimized compact frequency converter assembly process is formulated. During the frequency converter production process, the assembly quality of water channel installation, busbar installation, wiring, etc. is controlled to ensure the production quality and reliability of the compact frequency converter.

[0017] Figure 1 The figure shows the assembly object of the embodiment of the present invention, and the compact frequency converter includes a main water pipe 1, a functional component 2, a water distribution pipe and a joint 3, a primary circuit bus connection terminal 4, a secondary circuit connection terminal 5, etc. The functional component 2 includes a rectifier unit, a filter unit, a brake unit, a drive unit, a detection unit, a microprocessor unit, etc. The frequency converter realizes speed regulation, torque control, reduction of start-up impact, protection of equipment, realization of motor soft start, energy saving and consumption reduction, etc. through these functional components.

[0018] Figure 2 The assembly method of the compact frequency converter of the embodiment of the present invention is shown, including: installation of the main water pipe 1, pre-laying of the functional component 2, installation of the functional component 2, installation of the water distribution pipe, installation of the primary circuit, wiring of the secondary circuit, and cleaning of the internal excess. The steps are described in detail through this embodiment as follows.

[0019] S1, installation of main water pipe 1.

[0020] As a power device, the inverter will generate a lot of heat in its internal components during operation. If the heat cannot be removed in time, it will affect the power of the inverter. Therefore, the inverter is cooled by water. The flowing cooling water in the water pipe takes away the heat generated by the equipment. The temperature difference between the water pipe and the equipment can easily cause condensation on the surface of the water pipe. The condensed water droplets on the electronic components of the equipment may cause short circuit damage to the components. Therefore, it is necessary to prevent condensation in the water pipe. Therefore, when installing the main water pipe 1, the focus is on controlling the cleaning of impurities inside the water pipe and the generation of condensation in the waterproof pipe. The installation process is as follows: flush the main water pipe 1 continuously with clean water to ensure that there are no impurities at the water outlet. After flushing, use a protective bag to block the water inlet and outlet for protection. Wrap the exposed surface of the stainless steel pipe with anti-condensation foam sponge and tie it with cable ties.

[0021] S2, pre-release of functional component 2.

[0022] The compact inverter has a compact internal space, so the functional components 2 need to be wired first. Lay out the wires according to the positions of the functional components 2 in the device. When laying out the wires, consider the convenience of wiring, and keep an appropriate positive tolerance for the wire length. Negative tolerance is not allowed.

[0023] S3, installation of functional component 2.

[0024] The internal space of the frequency converter is compact, and the installation space of each functional component 2 is narrow, so each functional component 2 is installed layer by layer from the inside to the outside and from the top to the bottom.

[0025] S4, water distribution pipe installation.

[0026] There are some water-cooling devices in the functional component 2, and it is necessary to use hoses, clamps, etc. to connect the water path between the water-cooling devices and the main water pipe 1 through the pagoda joint interface. When installing the pagoda joint, anaerobic thread sealant is used to seal the threads.

[0027] After the water distribution pipe is installed, the strength and sealing test of the entire pipeline is carried out: first, the pressure is maintained for 30 minutes with 0.6MPa clean air, and the pressure does not drop during the test; then, the pressure is maintained for 30 minutes with 1.0MPa pure water, and the pressure does not drop and there is no water leakage during the test.

[0028] S5, primary circuit installation.

[0029] The primary circuit in the compact inverter is mainly composed of busbar, laminated busbar and insulating parts. Before installing the busbar, clean the busbar installation surface with cotton gauze dipped in anhydrous alcohol. The busbar connection screws are connected by cross-cross method according to the torque of M6: 3-6N.m, M8: 8.8-10.8Nm, M10: 17.7-22.6Nm, M12: 31.4-39.2Nm. After the screws are tightened, the busbar is guaranteed to be inspected with a 0.1mm feeler gauge, and the size of the feeler gauge inserted into the busbar contact surface is not greater than 5mm.

[0030] S6, secondary circuit wiring.

[0031] The wiring of the secondary circuit is mainly to complete the overall wiring of functional component 2. When wiring, place the harness from the input end to the output end according to the principle of neat and beautiful arrangement of the harness, horizontal and vertical; the wire harness should have an arc transition at the turning point, and its bending radius should not be less than twice the outer diameter of the harness; in the sections with holes, edges, etc., it is necessary to use a wire sheath to protect it to avoid damaging the insulation layer of the wire; when welding the joint, the temperature of the electric soldering iron is set to 350±10℃, and the stripped cable core is tinned. The core is immersed in the tin melting furnace for 1 to 2 seconds. The surface of the cable is smooth after welding, the solder is full, the tin cannot flow out of the joint, there must be no holes, desoldering, cold welding, etc., and the surface of the wire must not be burned and aging and deformed.

[0032] S7, clean up the excess internal materials.

[0033] Use a vacuum cleaner to clean up the wire ends, cable ties and other excess materials generated during the internal assembly and wiring processes.

[0034] In summary, the assembly method of the compact inverter of the present invention ensures the production quality and reliability of the compact inverter by controlling the assembly quality of water channel installation, busbar installation, wiring, etc. during the inverter production process.

[0035] Those skilled in the art can intuitively understand other advantages and effects of the present invention from the contents described in this specification. The details of this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention.

Claims

1. A method for assembling a compact frequency converter, for use with a compact frequency converter comprising a main water pipe (1), a functional component (2), a water distribution pipe and a joint (3), a primary circuit busbar connection terminal (4) and a secondary circuit connection terminal (5), characterized in that: The steps are as follows S1, flush the main water pipe (1) continuously with clean water to ensure that the water outlet is free of impurities, then seal the water inlet and outlet with a protective bag, wrap the exposed surface of the pipe with a foam sponge and tie it with a cable tie; S2, laying out the functional components (2) according to the positions of the functional components (2), and retaining the positive tolerance when laying out the functional components; S3, each functional component (2) is installed layer by layer from inside to outside and from top to bottom; S4, using a hose and a clamp to connect the water path between the water cooling device and the main water pipe (1) through a pagoda joint interface, and using an anaerobic thread sealant to seal the threads; S5, first clean the busbar installation surface with cotton gauze dipped in anhydrous alcohol, and then install the busbar, laminated busbar and insulation parts to form a primary circuit; S6, when wiring the secondary circuit, place the wire harness from the input end to the output end. The wire harness has an arc transition at the bend. Use a wire sheath to protect the holes and edge sections. Set the temperature of the electric soldering iron to 350±10℃. When tinning the stripped cable core, immerse it in a tin melting furnace for 1 to 2 seconds. After welding, the surface of the joint is smooth, the solder is full, and the cable surface is free of burns and aging deformation. Complete the overall wiring of each functional component (2); S7, use a vacuum cleaner to clean the wire ends and cable ties generated during the assembly and wiring processes.

2. The method for assembling a compact frequency converter according to claim 1, characterized in that: After the water distribution pipe and the joint (3) are installed in step S4, the strength and sealing test of the entire pipeline is carried out: first, the pressure is maintained for 30 minutes with 0.6 MPa clean air, and the pressure does not drop during the test; then, the pressure is maintained for 30 minutes with 1.0 MPa pure water, and the pressure does not drop during the test and there is no water drop leakage.

3. A method for assembling a compact frequency converter according to claim 1 or 2, characterized in that: In the step S5, the busbar connection screws are fastened by the cross-cross method according to the torques of M6: 3-6N.m, M8: 8.8-10.8Nm, M10: 17.7-22.6Nm, and M12: 31.4-39.2Nm.

4. The method for assembling a compact frequency converter according to claim 3, characterized in that: After the screws are tightened, the busbar is inspected with a 0.1mm feeler gauge. The size of the feeler gauge inserted into the busbar contact surface should not exceed 5mm.

5. The method for assembling a compact frequency converter according to claim 4, characterized in that: In step S6, the bending radius of the wire harness is not less than twice the outer diameter of the harness.

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