Modular Compressor Mounting Rack for Expandable HVAC Systems
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Solution Overview
Problem
Climate control system racks often require remanufacturing when components, such as compressors, need to be added or modified, as they are typically designed for specific configurations and sizes, limiting flexibility and efficiency in accommodating changes.
Innovation Solution
A modular metal rack design with customizable metal beams featuring differently shaped cavities for compressor mounting, allowing for expansion and modification of the compressor section without affecting other parts, enabling the accommodation of various compressor sizes and manufacturers without full rack remanufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If racks are manufactured in specific configurations and sizes for specific components, then the rack structure is stable and reliable, but the rack cannot be modified when components need to be added or changed
Solution Approach 1:
The rack beam is designed with multiple cavities of different shapes (round, oval, square, rectangular) and different spacing configurations along its length. This universal design allows the same rack beam to accommodate various compressor sizes, types, and manufacturers by selecting appropriate cavities, eliminating the need for custom racks for each component configuration.
Solution Approach 2:
The rack beam is segmented into multiple discrete cavities rather than a continuous structure. Each cavity can be independently selected and used based on the specific compressor mounting requirements. This segmentation allows flexible combination of cavities to match different compressor footprints and mounting patterns.
2Ease of manufacture
If racks are designed for specific configurations, then manufacturing is simplified for that specific use, but remanufacturing is required when components need to be added or modified
Solution Approach 1:
The rack beam is pre-manufactured with multiple cavities of different shapes and spacing configurations before deployment. This preliminary action ensures that when components need to be added or modified, the rack is already prepared with the necessary mounting options, eliminating the need for time-consuming remanufacturing operations.
Solution Approach 2:
By incorporating multiple cavity types and spacing variations in the initial manufacturing, the rack becomes a universal mounting solution that can adapt to various component configurations without requiring remanufacturing, thus saving time when system changes are needed.
3Manufacturing precision
If racks are manufactured to exact specifications for specific components, then mounting precision is high, but flexibility to accommodate various compressor sizes is reduced
Solution Approach 1:
Different cavities along the rack beam have different shapes (round, oval, square, rectangular) and different spacing configurations. Each cavity is precisely manufactured for its specific function, and the selection of appropriate cavities allows adaptation to various compressor sizes while maintaining high mounting precision for each specific application.
Data Source
AI summary
An apparatus includes a first metal beam and a mounting bracket. The first metal beam is arranged in a linearly horizontal direction and defines a plurality of first and second cavities along a top surface of the first metal beam. Each first cavity is of a first shape and is separated from another first cavity by a first distance. Each second cavity is of a second shape different from the first shape and is separated from another second cavity by a second distance greater than the first distance. The mounting bracket couples to the top surface of the first metal beam at a first mounting cavity of the plurality of second cavities and the top surface of the second metal beam at a second mounting cavity of the plurality of fourth cavities. The mounting bracket further couples to a compressor.