HVAC Support Unit with Angled Pocket Assembly for Reduced Material Use
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Solution Overview
Problem
Existing HVAC systems face challenges in efficient support during transportation and installation, particularly with heavy components like compressors, requiring significant material and labor for support structures that must withstand enhanced loading and lateral accelerations.
Innovation Solution
A support unit comprising a base rail frame with angled pockets and compressor beams that mate securely without additional fasteners, providing a stable and efficient assembly method for HVAC systems, allowing for surface-to-surface contact and weight-driven engagement, which reduces assembly complexity and enhances stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional box steel arrangements are used to support heavy HVAC components, then structural strength and stability are achieved, but material usage and assembly complexity increase significantly
Solution Approach 1:
The support structure is segmented into modular components: a base rail frame with integrated pockets and separate compressor beams that mate together. This segmentation allows for optimized material distribution and easier assembly while maintaining structural strength for supporting heavy components like compressors weighing over 120 pounds.
Solution Approach 2:
The pockets are directly formed as integral features of the base rail frame, merging the support function into the primary structure. This eliminates the need for separate support brackets or additional box steel arrangements, reducing material usage while maintaining the required structural strength.
2Stability of the object's composition
If traditional box steel arrangements with multiple fasteners are used, then structural stability is achieved, but assembly time and labor requirements increase
Solution Approach 1:
The compressor beams are designed to self-position and self-lock into the pockets through their complementary angled faces. The beams automatically align and secure themselves without requiring multiple fasteners or complex assembly procedures, significantly reducing assembly time while maintaining assembly stability.
Solution Approach 2:
The angled faces of the pockets and compressor beams act as intermediaries that facilitate automatic alignment and secure engagement. This geometric interface serves as a mediator that enables stable assembly without requiring additional fastening hardware or complex alignment procedures.
3Force
If heavy components like compressors are supported with traditional arrangements, then load-bearing capacity is achieved, but structural complexity and labor requirements increase
Solution Approach 1:
The base rail frame features locally optimized pockets with specific geometric properties at critical load-bearing positions. These pockets are strategically formed on the longitudinal sides to provide enhanced support exactly where heavy components like compressors need to be mounted, achieving high load-bearing capacity without increasing overall structural complexity.
Data Source
AI summary
In one instance a support unit for supporting a portion of a heating, ventilation, and air conditioning system is provided that includes a base rail frame that on two sides has at least a first pocket and second pocket for receiving the ends of a compressor beam. The compressor beam has angled faces on both ends that interface with angled faces in the pockets. In this way, when assembled and loaded, the compressor beam will fit in the pockets and remain in place. Others systems and methods are presented.