Inverter Package Frame with U-Shaped Beams for Flexible Width
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional inverter apparatus package structures rely on aluminum die-cast members and flat-shaped side metal sheets, limiting width flexibility, increasing manufacturing costs, and risking damage to fragile components during assembly.
Innovation Solution
A package structure using aluminum die-cast supports at corners connected by U-shaped sheet-metal beams, eliminating the need for flat side metal sheets, allowing adjustable width, and enabling assembly of heavy components before side metal sheets, which reduces tool limitations and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum die-cast members having substantially the same length as the width of the inverter apparatus are used, then the package strength is secured, but the width of the inverter apparatus is limited and manufacturing costs increase
Solution Approach 1:
The aluminum die-cast member is divided into two separate members with different lengths. The first aluminum die-cast member has a length corresponding to the width of the inverter apparatus, while the second aluminum die-cast member has a length corresponding to the length of the inverter apparatus. This segmentation allows the package structure to maintain strength while adapting to different width requirements without requiring custom die-cast members for each width.
Solution Approach 2:
The first aluminum die-cast member serves multiple functions: it acts as both a support member for mounting side metal sheets and as a structural element defining the width of the inverter apparatus. By making this member universal with standardized dimensions, the package structure can accommodate different width requirements while maintaining consistent manufacturing processes and cost structures.
2Strength
If side metal sheets are mounted on aluminum die-cast members in the early stage of assembly, then the package strength is secured for installing heavy components, but there are limitations on tools for assembly
Solution Approach 1:
The side metal sheets are pre-mounted on the first aluminum die-cast member before the assembly of heavy components such as cooling fins and electrolytic capacitors. This preliminary action ensures that the package structure has adequate strength from the beginning to support heavy components, while the standardized dimensions of the first aluminum die-cast member ensure compatibility with standard assembly tools.
3Ease of manufacture
If built-in components are mounted on flat-shaped side metal sheets, then the assembly is simplified, but fragile components may be broken by resonance of the side metal sheets
Solution Approach 1:
The second aluminum die-cast member is specifically designed with enhanced structural properties to serve as a mounting base for fragile built-in components such as main circuit terminal blocks and printed-circuit boards. This localized quality improvement at the component mounting area provides better vibration resistance and structural support, protecting fragile components from resonance damage while maintaining simple assembly procedures.
Data Source
AI summary
A package structure of an inverter apparatus includes at least four metal column supports arranged vertically to be spaced apart from each other, and sheet-metal bent beams connecting the column supports in transverse direction and longitudinal direction to form rectangular package structure. The metal column support is an aluminum die-cast support, and the sheet-metal bent beam has a U-shape with sharp edges in cross section.