Extruded Enclosure Structural Members for Heavy Component Mounting
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Solution Overview
Problem
Existing enclosure designs face challenges in mounting large and heavy internal components, such as transformers or chokes, due to limited mounting space around the base, often resulting in structural issues like buckling of sheet metal covers and added weight from separate racks.
Innovation Solution
The use of extruded structural members with tubular cross-sections and radially spaced longitudinal fastener channels, made from metals like aluminum, which provide a rigid and flexible mounting system integrated into the enclosure shell, allowing for infinitely positionable threaded fasteners and angled U-shaped channels for secure component attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rack is erected within the enclosure to provide separate structure for mounting internal components, then mounting capability for heavy components is improved, but the overall weight of the unit increases and space within enclosure is consumed
Solution Approach 1:
The structural member combines the enclosure shell function with the mounting structure function into a single integrated component. The extruded member forms part of the enclosure shell while simultaneously providing mounting surfaces and attachment points for internal components, eliminating the need for separate racks and reducing overall weight.
Solution Approach 2:
The extruded structural member serves multiple functions: it provides structural support for the enclosure, creates mounting surfaces for internal components, and offers attachment points for covers and panels. This multi-functional design replaces what would traditionally require multiple separate components including racks.
2Ease of manufacture
If components are mounted directly to the sheet metal covers, then mounting simplicity is improved, but buckling of the sheet metal occurs resulting in dimples
Solution Approach 1:
The extruded structural member acts as an intermediary between the sheet metal covers and the components to be mounted. It provides a rigid mounting surface that can support component weight without deforming the sheet metal, while still allowing straightforward mounting operations.
Solution Approach 2:
The enclosure structure is segmented into functional zones: the sheet metal covers maintain their protective and aesthetic functions, while the extruded structural members provide the mounting functions. This segmentation allows each component to perform its optimal function without compromising the other.
3Area of stationary object
If mounting space is limited to the region around the base, then enclosure compactness is maintained, but mounting capability for large heavy components is insufficient
Solution Approach 1:
The extruded structural members extend the mounting space vertically and radially beyond the base region. By utilizing the vertical dimension and radial space around the enclosure, the design provides adequate mounting area for large heavy components without increasing the enclosure's footprint.
Solution Approach 2:
The extruded structural members are positioned at corners and edges of the enclosure, utilizing the three-dimensional space efficiently. This angular placement maximizes the use of available space while providing optimal mounting positions for heavy components.
Data Source
AI summary
An enclosure includes wall members connected together by structural members forming joints of the enclosure. The structural members may be extruded from aluminum or other generally rigid material and may comprise a series of mounting channels and fastener channels to which the internal components of the enclosure may be mounted.