Hybrid Self-Fixturing Frame Assembly for IT Enclosures

Solution Overview

Problem

Existing IT infrastructure enclosures either require skilled labor and increased assembly time due to fully welded frames or lack rigidity and strength with fully riveted frames.

Innovation Solution

A hybrid self-fixturing frame assembly that combines welded and riveted components, where individual components are self-fixtured via riveted points and then welded, to create a stronger and more rigid frame with reduced assembly complexity and labor requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If fully welded frames are used, then strength and rigidity are improved, but assembly time and complexity increase

Engineering Contradiction:

Improveframe strengthVSAvoidassembly time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

Components are pre-fixtured together using rivets before the welding process. This preliminary action holds components in the correct position and within tolerance specifications during assembly, eliminating the need for complex fixturing during welding and reducing overall assembly time while maintaining frame strength.

Inventive Principle:

Principle #10Preliminary action

2Strength

If fully welded frames are used, then strength and rigidity are improved, but skilled labor requirements increase

Engineering Contradiction:

Improveframe strengthVSAvoidlabor skill requirement

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Components are pre-fixtured together using rivets before the welding process. This preliminary action holds components in the correct position and within tolerance specifications during assembly, eliminating the need for complex fixturing during welding and reducing overall assembly time while maintaining frame strength.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If fully riveted frames are used, then assembly complexity is reduced, but strength and rigidity decrease

Engineering Contradiction:

Improveassembly complexityVSAvoidframe strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent combines two different joining methods: riveting and welding. Rivets are used for preliminary fixturing to simplify assembly and hold components in position, while welding is applied afterward to provide the necessary strength and rigidity. This hybrid approach merges the advantages of both methods while mitigating their individual disadvantages.

Inventive Principle:

Principle #5Merging (Combining)

4Loss of time

If fully riveted frames are used, then assembly time is reduced, but strength and rigidity decrease

Engineering Contradiction:

Improveassembly timeVSAvoidframe strength

Core Design Contradiction:

Loss of timeVSStrength

Solution Approach 1:

The patent combines two different joining methods: riveting and welding. Rivets are used for preliminary fixturing to simplify assembly and hold components in position, while welding is applied afterward to provide the necessary strength and rigidity. This hybrid approach merges the advantages of both methods while mitigating their individual disadvantages.

Inventive Principle:

Principle #5Merging (Combining)

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 hybrid self-fixturing frame assembly achieves increased strength and rigidity compared to fully riveted frames, reduces assembly time and skilled labor needs compared to fully welded frames, and allows for reduced paint booth dimensions.

Implementation Method 1

the individual components to be fixtured together to hold the components in the proper location and within the tolerance specification during the welding process

Methodology Applied

Scientific EffectMechanical Fastening: Mechanical Fastener

Implementation Method 2

upon coupling the at least one base frame member to the additional at least one base frame member, the at least one base frame member being welded to the additional at least one base frame member

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS20250142761A1Hybrid self-fixturing frame

Publication Date: 2025.05.01 VERTIV CORP

AI summary

A self-fixturing frame assembly includes a base sub-assembly, one or more side assemblies, and a top sub-assembly. The base sub-assembly may include a base frame member configured to be coupled to an additional base frame member via two or more fasteners. Upon coupling the base frame member to the additional base frame member, the base frame member may be welded to the additional base frame member. Each side sub-assembly may include a side frame member configured to be coupled to an additional side frame member via the two or more fasteners. Upon coupling the side frame member to the additional side frame member, the side frame member may be welded to the additional side frame member. The one or more side sub-assemblies may then be coupled to the base sub-assembly upon welding. The top sub-assembly may include top frame members couplable to the one or more side sub-assemblies.