Modular Frequency Converter With Interchangeable Circuit Boards
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Solution Overview
Problem
Existing frequency converters for construction sites are large, heavy, and permanently installed, making them unsuitable for use on construction sites, and they require a variety of different components for different operating parameters, leading to high costs and complexity.
Innovation Solution
A compact frequency conversion module composed of interchangeable frequency converters with standardized housings, allowing for modular combination and sharing of spare parts, featuring a circuit board with transformer and frequency conversion circuits, and a housing with cooling and signaling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If frequency converters are designed with different sizes for different operating parameters, then they can meet diverse construction site requirements, but they cannot be arranged in a modular, space-saving manner and require separate spare parts for each type
Solution Approach 1:
The patent implements a universal housing design that can accommodate different circuit board variants, allowing a single housing type to serve multiple frequency converter configurations. This enables modular stacking and standardized spare parts while maintaining adaptability to different operating parameters through circuit board selection rather than housing variation.
Solution Approach 2:
The frequency converter is divided into distinct functional modules: a standardized housing containing common components (cooling system, control electronics, display) and a replaceable circuit board module that handles parameter-specific transformations. This segmentation allows independent replacement of circuit boards while retaining the housing, achieving both versatility and modularity.
2Reliability
If frequency converters are designed as large, heavy units with all components integrated, then they are robust and self-contained, but they are not suitable for use on construction sites and cannot be easily assembled or disassembled
Solution Approach 1:
The frequency converter is segmented into a standardized housing and replaceable circuit board modules, enabling easy assembly and disassembly of specific components without affecting the entire unit. This modular structure maintains robustness through the standardized housing while improving portability and ease of operation through component-level replaceability.
Solution Approach 2:
The system transitions from a static, fully-integrated design to a dynamic, reconfigurable architecture where circuit boards can be swapped based on operational requirements. This allows the frequency converter to adapt its configuration while maintaining the robust standardized housing, balancing reliability with operational flexibility.
3Adaptability or versatility
If different frequency converters use different components for different operating parameters, then they can be optimized for specific tasks, but purchasing and maintaining spare parts becomes expensive and complex
Solution Approach 1:
A universal housing design is implemented that can accommodate multiple circuit board variants through standardized mounting and connection interfaces. This allows the same housing and associated components (cooling systems, control electronics, displays) to serve multiple frequency converter configurations, significantly reducing the variety of spare parts needed while maintaining task-specific optimization through circuit board selection.
Solution Approach 2:
Common components across different frequency converter types are merged into a single standardized housing design. The housing, cooling system, control electronics, and display are combined into a universal platform that supports multiple circuit board variants, consolidating spare parts inventory and reducing purchasing costs while preserving task-specific functionality.
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 solution enables a compact, efficient, and cost-effective use of frequency converters on construction sites, allowing for easy assembly and disassembly, reduced spare parts inventory, and effective cooling and monitoring of the converters.
Implementation Method 1
a circuit board (120), which is suitable for transforming an electrical current (200) applied to the circuit board (120) with regard to its frequency, voltage, and/or number of phases
Implementation Method 2
The housing has a cooling device for cooling the circuit board, with at least one fan capable of directing air from an air inlet of the housing via an air duct running along the converter mount to an air outlet of the housing
Implementation Method 3
The circuit board can have a transformer circuit for transforming the voltage of the applied current, preferably from a mains voltage of, in particular, 400V, 230V, or 120V to a lower voltage
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
A frequency converter (100) for converting a mains frequency to a higher frequency, comprising a converter housing (110) in which a circuit board (120) is hermetically encapsulated. This circuit board is suitable for transforming an electric current applied to the circuit board (120) with respect to its frequency, voltage, and/or number of phases, and for outputting the transformed electric current. The frequency converter (100) further comprises a housing (130) for receiving the converter housing (110), the housing (130) being designed such that it can be positively connected to a housing (130) of a similarly constructed frequency converter (100).