DIN Rail Mounting System for Controller PCB Cooling and Stability
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Solution Overview
Problem
Low-cost consumer-grade controllers used in industrial settings face challenges with reliable mounting and power connection, as they lack secure attachment mechanisms and adequate ventilation, leading to potential disconnection and downtime.
Innovation Solution
A DIN rail mounting system with clips and standoffs is used to securely attach the controller PCB, along with a strain relief feature for the USB power connector using tie wraps, ensuring reliable installation and cooling, and optionally grounding the PCB for added stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a low-cost consumer controller with USB power connection is used in an industrial setting, then cost is reduced, but reliability deteriorates due to accidental unplugging of USB cables
Solution Approach 1:
The mounting system is divided into separate functional components: DIN rail clips for mechanical attachment, strain relief features for cable protection, and grounding elements for electrical safety. This segmentation allows each component to address specific reliability issues independently while maintaining overall system integrity.
Solution Approach 2:
The strain relief feature is designed to prevent cable disconnection before it can cause system failure. By providing built-in cable management and securing mechanisms, the system cushions against the harmful effect of accidental unplugging, ensuring continuous operation without manual intervention.
2Ease of manufacture
If a standard USB-powered consumer controller is used, then cost is reduced, but reliability deteriorates due to lack of secure mounting mechanism
Solution Approach 1:
The mounting system is designed to be universally compatible with standard DIN rails used across industrial applications. The DIN rail clips provide both mechanical support and electrical grounding through a single integrated component, demonstrating multi-functionality that enhances reliability without adding complexity.
Solution Approach 2:
The mounting system transitions from simple adhesive or screw-based attachment to a three-dimensional DIN rail clip mechanism that engages with the rail structure. This dimensional change provides superior mechanical stability by distributing mounting forces across multiple contact points along the rail.
3Area of stationary object
If the controller PCB is mounted close to the mounting surface, then space utilization is improved, but temperature increases due to inadequate ventilation
Solution Approach 1:
The PCB mounting system utilizes the vertical dimension by elevating the board above the mounting surface using standoffs. This creates sufficient clearance for air circulation and heat dissipation while maintaining compact horizontal footprint, effectively resolving the contradiction between space utilization and thermal management.
4Ease of operation
If the USB cable is allowed to move freely, then ease of connection is improved, but reliability deteriorates due to accidental disconnection
Solution Approach 1:
The strain relief feature provides beforehand protection against cable disconnection by securing the USB cable to the mounting surface. This cushioning mechanism allows the cable to remain accessible for connection while preventing accidental unplugging, thus maintaining both ease of operation and connection stability.
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
The solution provides a reliable and space-efficient mounting solution that minimizes downtime by preventing accidental disconnection and ensuring adequate cooling, while allowing for easy installation and management of cables, thus enhancing the usability of consumer-grade controllers in industrial environments.
Implementation Method 1
The position of the PCB is extended relative to the substantially planar mounting surface the PCB further away from the substantially planar mounting surface to allow for more ventilation and convection of heat generated by the board components
Implementation Method 2
the surface of the board opposite with respect to the side facing the mount is optionally also exposed for additional cooling through unrestricted convection
Data Source
AI summary
A mounting device for a consumer grade controller that allows for installation in an industrial application with reliability improvement features. The consumer grade controller is mounted to the mounting device using screws and standoffs, which securely fasten the consumer grade controller to the mounting device. The mounting device is compatible with an industry standard DIN rail allowing for easy installation and removal. The mounting device positions the consumer grade controller vertically with respect to the DIN rail to provide improved cooling and reduce DIN rail space. A power cable is secured with a built-in strain relief feature and held in place with a tie wrap to maintain pressure on the cable and preventing it from accidentally releasing. The mounting device, standoffs, and strain relief feature can be injected molded in one assembly for low cost manufacturing while still providing all the benefits that an industrial application requires.