Modular Compressor Rack with Multi-Cavity Beams for Flexible Mounting
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Solution Overview
Problem
Climate control system racks are often manufactured to specific sizes and configurations, making it necessary to produce new racks when components, such as compressors, are added or modified, rather than allowing for modular expansion or accommodation of different compressor sizes and manufacturers.
Innovation Solution
A modular metal rack design featuring metal beams with differently shaped cavities for compressor mounting, allowing for flexible expansion and accommodation of various compressor sizes and manufacturers without requiring a new rack, and using mounting brackets to secure compressors to these beams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If racks are manufactured in specific sizes and configurations to accommodate particular compressors, then the initial mounting requirement is satisfied, but the rack cannot accommodate additional or different compressors without remanufacturing
Solution Approach 1:
The rack is divided into modular sections with standardized mounting positions. Each section can be independently configured and replaced, allowing the rack to be reconfigured for different compressor sizes and types without remanufacturing the entire structure.
Solution Approach 2:
The rack incorporates universal mounting features including multiple cavity types (first shape and second shape) at standardized intervals, allowing a single rack design to accommodate various compressor configurations and manufacturers through selective use of different mounting positions.
2Adaptability or versatility
If a rack is designed to accommodate specific compressor sizes, then those compressors can be securely mounted, but compressors of different sizes cannot be accommodated
Solution Approach 1:
Different sections of the rack have different local characteristics with various cavity shapes and spacing patterns. This allows each local area to be optimized for specific compressor types while the overall rack maintains a simple modular structure that doesn't require complex redesign for different applications.
Solution Approach 2:
The rack allows for parameter changes in compressor accommodation by providing multiple cavity types (first shape with first distance, second shape with second distance) that can be selected based on the specific compressor size and mounting requirements, without changing the fundamental rack structure.
3Adaptability or versatility
If the entire rack is remanufactured to add or modify compressor mounting, then the new configuration is achieved, but time and resources are wasted
Solution Approach 1:
The rack is designed in advance with multiple pre-positioned mounting cavities of different shapes and spacings. This preliminary preparation allows compressors to be mounted or reconfigured by simply selecting appropriate pre-existing positions rather than remanufacturing the rack structure.
Solution Approach 2:
The rack provides dynamic reconfiguration capability through its modular design with multiple mounting options. The system can adapt to changing requirements by repositioning compressors to different cavities or adding/removing rack sections, enabling modification without complete remanufacturing.
4Area of stationary object
If mounting positions are closely spaced to maximize rack utilization, then space efficiency is improved, but access and removal of compressors becomes difficult
Solution Approach 1:
The rack employs asymmetric cavity placement patterns where different cavity shapes are positioned at different intervals. This asymmetric arrangement allows optimal spacing for access and removal operations while maintaining high space utilization through strategic positioning of mounting positions.
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
An apparatus includes a first metal beam (205) and a mounting bracket (245). The first metal beam (205) is arranged in a linearly horizontal direction and defines a plurality of first and second cavities (225, 230) along a top surface of the first metal beam (205). Each first cavity (225) is of a first shape and is separated from another first cavity by a first distance (235). Each second cavity (230) is of a second shape different from the first shape and is separated from another second cavity by a second distance (240) greater than the first distance. The mounting bracket (245) couples to the top surface of the first metal beam (205) at a first mounting cavity of the plurality of second cavities (225, 230) and the top surface of the second metal beam (210) at a second mounting cavity of the plurality of fourth cavities (225, 230). The mounting bracket further couples to a compressor (120).