Additive Manufacturing Backplane for Switchgear
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Solution Overview
Problem
Conventional switchgear cabinets require extensive manual cabling for electrical component interconnection, leading to high cabling outlay and costs, especially with a large number of components.
Innovation Solution
A backplane with integrated actuator units and conductor paths produced using additive manufacturing, such as 3D printing, which automates individual wiring and reduces manual intervention, allowing for customized configurations with minimized conductor length and electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If manual cabling is used to electrically interconnect electrical components in switchgear cabinets, then flexibility in component arrangement is maintained, but cabling outlay and costs increase significantly with a large number of components
Solution Approach 1:
The patent merges the carrier plate and conductor paths into a single integrated backplane structure produced by additive manufacturing. The conductor paths are directly printed onto the carrier plate, eliminating the need for separate manual cabling between electrical components. This consolidation reduces both the quantity of cable material required and the manual labor involved in cabling operations.
Solution Approach 2:
The invention changes the manufacturing parameter from traditional manual assembly to additive manufacturing (3D printing). This enables complex conductor path geometries to be produced automatically with minimal manual intervention, significantly reducing both cabling outlay and manufacturing effort while maintaining design flexibility.
2Productivity
If conventional manual cabling methods are used, then existing manufacturing processes are maintained, but productivity and automation level remain low
Solution Approach 1:
The patent replaces manual mechanical cabling operations with an automated additive manufacturing process. The 3D printer automatically deposits conductive material to create conductor paths on the carrier plate, eliminating the need for manual cable routing, stripping, and connection operations. This substitution dramatically increases productivity and automation level.
Solution Approach 2:
The conductor paths are pre-integrated into the carrier plate during the additive manufacturing process before electrical components are mounted. This preliminary integration of electrical connections eliminates subsequent manual cabling steps, thereby increasing overall production efficiency and automation.
3Adaptability or versatility
If standardized backplanes are used, then manufacturing simplicity is maintained, but adaptability to different electrical component configurations is limited
Solution Approach 1:
The additive manufacturing process enables dynamic adaptation of the backplane design to match specific electrical component configurations. The conductor paths can be customized for each application by programming the 3D printer, allowing the same manufacturing process to produce different backplane layouts without requiring complex tooling changes or manual reconfiguration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces cabling costs and complexity, enabling efficient, automated electrical connections and improved operational safety through integrated sensors and shielding, while allowing for flexible production of backplanes for various configurations.
Implementation Method 1
the carrier plate being produced, at least in a region surrounding the actuator unit, using a 3D printing which embeds the actuator unit into the carrier plate
Data Source
AI summary
A backplane is for electrically connecting electrical components and a method is for producing a backplane. The backplane includes a base board, conducting tracks arranged on and/or in the base board, and at least one actuator unit arranged on or in the base board.