Layered control panel design to provide separation of high/low voltage

Solution Overview

Problem

Current HVACR control panels are space-inefficient and pose safety risks due to the co-location of high and low-voltage components, requiring shutdowns and protective equipment for servicing, which complicates maintenance and troubleshooting.

Innovation Solution

A layered control panel design separates high-voltage components from low-voltage components, with the latter on an outer layer that can be accessed while the former is protected on an inner layer, allowing for safe servicing and diagnosis without shutting down the HVACR unit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If high-voltage and low-voltage components are co-located on the same control panel, then the panel structure is simple and space utilization is maximized, but servicing high-voltage components requires system shutdown and protective equipment

Engineering Contradiction:

Improveservicing accessibilityVSAvoidelectrical safety risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The control panel is segmented into distinct high-voltage and low-voltage sections with separate access paths. The low-voltage section can be serviced independently through a dedicated access point without requiring shutdown or protective equipment, while the high-voltage section remains isolated and requires proper safety procedures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An intermediary barrier or isolation structure is introduced between high-voltage and low-voltage components. This intermediary element allows low-voltage servicing to proceed safely without direct exposure to high-voltage hazards, eliminating the need for system shutdown while maintaining safety.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If high-voltage components are placed in a separate protected compartment, then electrical safety is improved, but the control panel becomes space-inefficient

Engineering Contradiction:

Improveelectrical safety riskVSAvoidcontrol panel area

Core Design Contradiction:

Object-affected harmful factorsVSArea of stationary object

Solution Approach 1:

The control panel employs a nested layout where low-voltage components are positioned within or adjacent to the high-voltage compartment structure. This nesting allows low-voltage servicing access without requiring a completely separate external compartment, thereby reducing overall panel area while maintaining safety isolation.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

Instead of separating high and low-voltage components in the horizontal plane (which would increase panel area), the design utilizes vertical dimensionality or layered arrangement. Low-voltage components are accessible from a different spatial dimension or level, allowing safety isolation without increasing the footprint of the control panel.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Productivity

If low-voltage components are accessible without shutdown, then troubleshooting efficiency is improved, but safety risks increase if high-voltage components are also accessible

Engineering Contradiction:

Improvetroubleshooting efficiencyVSAvoidelectrical safety risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The control panel is segmented into distinct high-voltage and low-voltage sections with separate access paths. The low-voltage section can be serviced independently through a dedicated access point without requiring shutdown or protective equipment, while the high-voltage section remains isolated and requires proper safety procedures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An intermediary barrier or isolation structure is introduced between high-voltage and low-voltage components. This intermediary element allows low-voltage servicing to proceed safely without direct exposure to high-voltage hazards, eliminating the need for system shutdown while maintaining safety.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11774132B2Layered control panel design to provide separation of high/low voltage

Publication Date: 2023.10.03 TRANE INTERNATIONAL INC

AI summary

A layered control panel for a heating, ventilation, air conditioning, and refrigeration (HVACR) unit includes an outer layer on which low-voltage components are placed, and an inner layer on which high-voltage components are placed. The outer layer is capable of taking a closed position where it blocks access to the inner layer, and an open position where the outer layer does not block access to the inner layer. The outer layer can include a lock to keep the outer layer in the closed position. The outer layer can be one or two or more panels mounted on hinges that allow the outer layer to swing between closed and open positions.