A frequency converter replacement assistance device

Abstract

The utility model discloses a frequency converter replacement auxiliary equipment relates to frequency converter technical field. Frequency converter replacement auxiliary equipment includes base, frequency converter body, protective cover, the bottom of base is equipped with walking wheel, frequency converter body sets up on the base, and the frequency converter has the connecting portion, and the connecting portion sets up on one side of base, and the connecting portion includes a plurality of terminal blocks, the utility model provides frequency converter replacement auxiliary equipment, when the frequency converter of production equipment breaks down or is damaged, can disconnect the damaged frequency converter and production equipment first, then connects the connecting line corresponding to production equipment and frequency converter with the terminal block of frequency converter body, makes the frequency converter body replace the damaged frequency converter and carries out the temporary replacement work, ensures that the production line or production equipment can carry out the continuous work, and can give the repairman the sufficient time to the damaged frequency converter and carries out the repair or replacement, ensures the production capacity of production equipment.

Description

Technical Field

[0001] This utility model relates to the field of frequency converter technology, and in particular to an auxiliary device for frequency converter replacement. Background Technology

[0002] In traditional industrial production, frequency converters are commonly used in production workshops and assembly line systems. These power electronic devices control process parameters by adjusting motor speed and are one of the core components ensuring continuous operation of the production line. However, limited by early technical design standards and the characteristics of continuous high-load operation, after more than 2000 hours of continuous operation, the aging rate of key components such as power modules and electrolytic capacitors of frequency converters will accelerate significantly, leading to an exponential increase in equipment failure rate. When typical faults such as power unit overheating protection and drive circuit abnormalities occur, the production system must immediately initiate the equipment shutdown procedure.

[0003] The current inverter replacement process faces significant technical bottlenecks. During the power-off phase, the three-level distribution cabinet must be de-energized step-by-step according to regulations, and warning signs must be displayed to prevent accidental power restoration; this step takes an average of 25 minutes. During the disassembly of the main unit, specialized tools are required to remove 12 sets of connecting components, including the cooling fan and control terminals, while also addressing any rusted fixing screws; this process typically requires two technicians working together for 40 minutes. During the new equipment installation phase, technicians must perform secondary drilling and positioning based on the hole spacing on the equipment base, use M12 expansion bolts for mechanical fixing, and re-lay 15-20 meter lengths of power and control signal cables. Actual measurements show that the complete replacement process takes an average of 3.8 hours, during which the production line is completely halted.

[0004] Supporting management issues further exacerbate the risk of production interruptions. Currently, most companies employ a decentralized warehousing management model, storing spare frequency converters in three different warehouse areas, resulting in a 40% increase in equipment retrieval time after a failure. Mainstream frequency converter models typically weigh over 80 kg, requiring specialized equipment such as hydraulic pallet trucks and at least two people to operate them during handling. In emergency repair scenarios, the hoisting, transportation, and positioning of equipment can incur an additional 1.2 hours of time loss. This combined effect of "technical downtime + management delays" means that a single frequency converter failure results in an average production loss of 18%-25% of the planned output for the shift, posing a significant operational risk to continuous production companies. Utility Model Content

[0005] In view of this, the purpose of this utility model is to overcome the shortcomings in related technologies, and this utility model provides an auxiliary device for frequency converter replacement.

[0006] This utility model provides the following technical solution:

[0007] An auxiliary device for replacing a frequency converter includes a base, a frequency converter body, and a protective cover.

[0008] The base is provided with wheels at its bottom; the inverter body is mounted on the base, the inverter has a connection part located on one side of the base, the connection part includes multiple terminals; the protective cover is located on the outside of the connection part to provide protection for the connection part.

[0009] As a further improvement to the above technical solution, the protective cover has a connection port on the end face away from the inverter body, and the connection line of the equipment with inverter failure can pass through the connection port and connect to the corresponding terminal block.

[0010] As a further improvement to the above technical solution, a protective door is provided on the connection port, and one side of the protective door is hinged to the edge of the connection port.

[0011] As a further improvement to the above technical solution, the protective door is made of transparent material.

[0012] As a further improvement to the above technical solution, the protective cover is connected to the base through a snap-fit ​​assembly.

[0013] As a further improvement to the above technical solution, a protective frame is provided on the base, and the inverter body is installed inside the protective frame.

[0014] As a further improvement to the above technical solution, the inverter body is mounted on the protective frame by bolt connection, and the protective frame has multiple sets of mounting screw holes corresponding to different models of the inverter body.

[0015] As a further improvement to the above technical solution, a push handle is provided on the end face of the protective frame opposite to the connecting part.

[0016] As a further improvement to the above technical solution, a toolbox is installed on the end face of the protective frame near the connection part, and the toolbox is used to store the tools required for disassembling and assembling the frequency converter.

[0017] As a further improvement to the above technical solution, the protective frame is symmetrically provided with protective frames on the end face near the connecting part, and the two protective frames are respectively located on both sides of the connecting part.

[0018] As a further improvement to the above technical solution, the bottom of the base is provided with multiple feet, which are threaded onto the base.

[0019] Compared with related technologies, the beneficial effects of this utility model are:

[0020] The auxiliary equipment for replacing the frequency converter provided by the present utility model is an emergency solution designed for the scenario of sudden failures of frequency converters in industrial production. On modern production lines, as the core component of the drive system, the operating stability of the frequency converter directly affects the equipment production capacity. When the frequency converter supporting the production equipment fails or suffers irreversible damage due to reasons such as overload, short circuit, or component aging, the conventional processing process often requires shutdown for maintenance, which will cause the entire production line to stop running, resulting in production capacity losses and even delays in order deliveries.

[0021] During the use of the present utility model, the operator can first safely cut off the electrical connection between the faulty frequency converter and the production equipment through the emergency stop switch of the equipment control cabinet, and then use the walking wheels configured at the bottom of the equipment to quickly push the present utility model to the installation position of the faulty frequency converter.

[0022] After the present utility model reaches the designated position, the operator needs to perform wiring operations according to the standardized process. First, remove the protective cover of the wiring terminal area of the frequency converter body, and then correspondingly connect the original power cable, control signal line, grounding wire and other connection harnesses of the production equipment to the wiring terminals of the frequency converter body.

[0023] After completing the electrical connection, the built-in frequency converter control system of the auxiliary equipment will automatically detect the wiring status and display the connection result through the human-machine interface. After confirmation, the operator can start the automatic frequency converter parameter matching function, and the equipment will read the original frequency converter parameter configuration through the built-in PLC module or call the preset process parameter package to achieve seamless adaptation to the production equipment. At this time, the present utility model will completely replace the faulty equipment and put it into operation, thus maintaining the continuous and stable operation of the production line.

[0024] During the period when the auxiliary equipment undertakes the temporary driving task, the maintenance personnel can obtain a sufficient maintenance window period. For the faulty frequency converter that can be repaired, professional maintenance can be carried out during the production gap; if a new equipment needs to be replaced, the spare parts deployment process can be started synchronously. According to the actual test data, the application of this equipment can reduce the average downtime of the production line by more than 70%, and reduce the production capacity loss of single fault handling to less than 15% of the conventional method.

[0025] When the fault handling is completed or the new frequency converter is in place, the operator needs to recycle the equipment according to the standard process. First, disconnect the power supply of the auxiliary frequency converter. After the capacitor is completely discharged, restore all wiring terminals to the initial state and reinstall the protective cover. During the equipment recycling process, the physical barrier formed by the protective cover can prevent the wiring terminals from being damaged due to collision, scratching or contact with corrosive media, ensuring the reliability of long-term storage of the equipment.

[0026] To make the above objects, features and advantages of the present utility model more obvious and understandable, the following specifically gives preferred embodiments and detailed descriptions in conjunction with the accompanying drawings as follows. Attached Figure Description

[0027] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of the inverter replacement auxiliary equipment from one perspective in one embodiment of the present invention;

[0029] Figure 2 This invention provides a schematic diagram of another perspective on the structure of the inverter replacement auxiliary equipment in one embodiment of the present invention.

[0030] Figure 3 This invention provides a schematic diagram of the structure of a frequency converter being replaced by removing the protective cover in one embodiment of the present invention.

[0031] Figure 4 A schematic diagram of the protective cover from one perspective is shown in one embodiment of the present invention.

[0032] Explanation of key component symbols:

[0033] 100-Base; 110-Walking wheel; 120-Protective frame; 121-Push handle; 130-Toolbox; 140-Protective frame; 150-Foot; 200-Inverter body; 210-Terminal block; 300-Protective cover; 310-Connection port; 311-Protective door; 320-Snap-on assembly. Detailed Implementation

[0034] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.

[0035] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0036] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0037] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0038] In this utility model, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0039] Combination Figure 1 , Figure 3 As shown, an embodiment of this utility model provides an auxiliary device for replacing a frequency converter, including a base 100, a frequency converter body 200, and a protective cover 300.

[0040] The bottom of the base 100 is provided with traveling wheels 110; the frequency converter body 200 is arranged on the base 100, the frequency converter has a connecting part, the connecting part is arranged on one side of the base 100, and the connecting part includes a plurality of wiring terminals 210; the protective cover 300 is arranged outside the connecting part to provide protection for the connecting part.

[0041] The frequency converter replacement auxiliary equipment provided in this embodiment is an emergency solution designed for the sudden failure scenario of the frequency converter in industrial production. On a modern production line, as the core component of the drive system, the stable operation of the frequency converter directly affects the equipment production capacity. When the frequency converter supporting the production equipment fails or is irreversibly damaged due to reasons such as overload, short circuit or component aging, the conventional processing process often requires shutdown for maintenance, which will cause the entire production line to stop running, resulting in production capacity loss and even order delivery delays.

[0042] During the use of this embodiment, the operator can first safely cut off the electrical connection between the faulty frequency converter and the production equipment through the emergency stop switch of the equipment control cabinet, and then use the traveling wheels 110 configured at the bottom of the equipment to quickly push the utility model to the installation position of the faulty frequency converter.

[0043] After this embodiment reaches the designated position, the operator needs to perform wiring operations according to the standardized process. First, remove the protective cover 300 in the area of the wiring terminals 210 of the frequency converter body 200, and then connect the original power cable, control signal line, grounding wire and other connecting wire bundles of the production equipment to the wiring terminals 210 of the frequency converter body 200 correspondingly.

[0044] After completing the electrical connection, the built-in frequency converter control system of the auxiliary equipment will automatically detect the wiring status and display the connection result through the human-machine interaction interface. After confirmation, the operator can start the automatic frequency converter parameter matching function, and the equipment will read the original frequency converter parameter configuration through the built-in PLC module or call the preset process parameter package to achieve seamless adaptation to the production equipment. At this time, this embodiment will completely replace the faulty equipment and put it into operation, so as to maintain the continuous and stable operation of the production line.

[0045] During the period when this embodiment undertakes the temporary driving task, the maintenance personnel can obtain a sufficient maintenance window period. For the repairable faulty frequency converter, professional maintenance can be carried out during the production gap; if a new equipment needs to be replaced, the spare parts allocation process can be started synchronously. According to the actual test data, the application of this embodiment can shorten the average downtime of the production line by more than 70%, and reduce the production capacity loss of single fault handling to less than 15% of the conventional method.

[0046] After troubleshooting is complete or the new frequency converter is in place, operators must follow the standard procedure for equipment recovery. First, disconnect the power supply to the auxiliary frequency converter. After the capacitors are fully discharged, restore all terminals 210 to their initial state and reinstall the protective cover 300. During equipment recovery, the physical barrier formed by the protective cover 300 prevents the terminals 210 from being damaged by impact, scratches, or contact with corrosive media, ensuring the reliability of the equipment during long-term storage.

[0047] In some specific embodiments, the protective cover 300 is made of flame-retardant ABS engineering plastic, and the inner side of the protective cover 300 is specially designed with a silicone sealing strip to achieve a sealed connection with the base 100, effectively isolating environmental pollutants such as metal debris, oil stains and water vapor.

[0048] Combination Figure 2 , Figure 4 As shown, in some specific embodiments, the protective cover 300 has a connection port 310 on the end face away from the inverter body 200. The connection wire of the equipment with inverter failure can pass through the connection port 310 and connect to the corresponding terminal block 210. When the inverter of the production equipment experiences a sudden failure, the on-site maintenance personnel do not need to perform the overall disassembly of the protective cover 300. They only need to insert the connection wire harness of the equipment to be connected along the axial direction of the connection port 310, which makes it easy to ensure the reliability of the protective cover 300 in protecting the terminal block 210.

[0049] In some specific embodiments, the connection port 310 is provided with a protective door 311. One side of the protective door 311 is hinged to the edge of the connection port 310. When the connection port 310 is to be stored after use in this embodiment, closing the protective door 311 can provide complete protection for the connection part composed of the terminal block 210.

[0050] In some specific embodiments, the protective door 311 is made of transparent material, so that the operator can directly observe the arrangement and assembly of the wiring terminals 210 inside the protective cover 300 without opening the protective door 311.

[0051] In some specific embodiments, the protective cover 300 is connected to the base 100 via a snap-fit ​​assembly 320, which facilitates quick assembly and disassembly of the protective cover 300 relative to the base 100 and makes it easier for operators to perform regular maintenance and repair on the wiring terminal 210.

[0052] In some specific embodiments, the base 100 is provided with a protective frame 120, and the inverter body 200 is installed in the protective frame 120. The protective frame 120 is formed by welding multiple steel pipes to ensure reliable support and protection for the inverter body 200.

[0053] In some specific embodiments, the inverter body 200 is bolted to the protective frame 120. The protective frame 120 has multiple sets of mounting screw holes corresponding to different models of the inverter body 200. Specifically, the inverter body 200 is rigidly connected to the protective frame 120 using high-strength internal hexagonal bolts (M8×30, grade 8.8). The bolt holes adopt a composite design of slotted grooves and circular holes. Three sets of slotted adjustment holes (40mm in length and 12mm in width) are pre-set on the inner side of the protective frame 120 columns, which can achieve a horizontal position adjustment of ±20mm for the inverter body. At the same time, each column is also equipped with eight sets of M8 standard threaded holes with a spacing of 50mm. The arrangement conforms to the ISO 898-1 standard, and the hole tolerance is controlled at H7 level to ensure compatibility with the mounting hole systems of different brands of inverters.

[0054] To adapt to mainstream inverter models in the market, the protective frame 120 has undergone systematic design optimization: the mounting screw hole layout on its vertical columns covers three typical hole spacing specifications (190×170mm, 250×210mm, and 320×260mm), corresponding to micro general-purpose, medium-sized vector, and heavy-duty engineering inverter products, respectively. Each set of screw holes is processed using laser cutting technology, with a C1.5 chamfer at the hole opening to prevent scratching the threads when tightening the bolts. For non-standard hole spacings (such as 220×195mm) used in some imported equipment, compatibility can be achieved by combining oblong holes with the adapter bracket. The adapter bracket is made of 2mm thick galvanized steel plate, bent and formed, with RAL7035 anti-rust paint sprayed on the surface. The torque of the connecting bolts between the adapter bracket and the protective frame 120 is set at 25N·m±2N·m to ensure that the connection strength meets the safety factor requirement of twice the weight of the inverter body (15-80kg).

[0055] This modular installation design significantly improves the equipment's applicability to various scenarios: in electronic component processing workshops, it can be quickly replaced with a miniature frequency converter with high-precision control functions; in heavy machinery production lines, it can be seamlessly upgraded to a heavy-duty frequency converter that supports high torque output.

[0056] In some specific embodiments, the end face of the protective frame 120 opposite to the connecting part is provided with a push handle 121; this makes it easier and more efficient for the operator to push this embodiment by holding the push handle 121.

[0057] In some specific embodiments, a toolbox 130 is installed on the end face of the protective frame 120 near the connection part. The toolbox 130 is used to store the tools required for disassembling and assembling the frequency converter, which facilitates further improvement of the maintenance efficiency of the frequency converter on the production equipment and the connection efficiency between this embodiment and the production equipment.

[0058] In some specific embodiments, the protective frame 120 is symmetrically provided with protective brackets 140 on the end face near the connection part, and the two protective brackets 140 are respectively located on both sides of the connection part to provide protection for the wiring terminal 210 and the toolbox 130.

[0059] In some specific embodiments, the bottom of the base 100 is provided with a plurality of feet 150. The feet 150 are threaded through the base 100. Each foot 150 can abut against the ground by relative rotation with the base 100, so as to fix the whole embodiment when it is stored or when it is moved to a designated position for work, thereby preventing relative movement of the embodiment during use or storage and ensuring the reliability of the embodiment.

[0060] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0061] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. An auxiliary device for replacing a frequency converter, characterized in that, include: A base (100) is provided with wheels (110) at the bottom of the base (100); The inverter body (200) is mounted on the base (100). The inverter has a connection part, which is located on one side of the base (100). The connection part includes a plurality of terminals (210). A protective cover (300) is disposed on the outside of the connection portion to provide protection for the connection portion.

2. The inverter replacement auxiliary equipment according to claim 1, characterized in that, The protective cover (300) has a connection port (310) on the end face away from the inverter body (200), and the connection line of the device with inverter failure can pass through the connection port (310) and connect to the corresponding terminal block (210).

3. The inverter replacement auxiliary equipment according to claim 2, characterized in that, The connection port (310) is provided with a protective door (311), and one side of the protective door (311) is hinged to the edge of the connection port (310).

4. The inverter replacement auxiliary equipment according to claim 3, characterized in that, The protective door (311) is made of transparent material.

5. The inverter replacement auxiliary equipment according to claim 2, characterized in that, The protective cover (300) is connected to the base (100) via a snap-fit ​​assembly (320).

6. The inverter replacement auxiliary equipment according to claim 1, characterized in that, The base (100) is provided with a protective frame (120), and the inverter body (200) is installed inside the protective frame (120).

7. The inverter replacement auxiliary equipment according to claim 6, characterized in that, The protective frame (120) is provided with a push handle (121) on the end face away from the connecting part.

8. The inverter replacement auxiliary equipment according to claim 6, characterized in that, A toolbox (130) is installed on the end face of the protective frame (120) near the connection part. The toolbox (130) is used to store the tools required for disassembling and assembling the frequency converter.

9. The inverter replacement auxiliary equipment according to claim 6, characterized in that, The protective frame (120) has a protective frame (140) symmetrically provided on the end face near the connecting part, and the two protective frames (140) are respectively located on both sides of the connecting part.

10. The inverter replacement auxiliary equipment according to any one of claims 1 to 9, characterized in that, The base (100) has a plurality of feet (150) at its bottom, and the feet (150) are threaded onto the base (100).

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