Modular Power Converter with Sliding Rail Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Large-sized or medium-sized power converters have bulky structures with complex wiring and fixed modules, making them difficult to transport, assemble, disassemble, and maintain due to their non-modular design and rigid construction.
Innovation Solution
A heat-dissipating power converter design featuring modular power modules with rails and main air duct modules that allow for easy plugging and unplugging, along with a radiator for improved dissipation efficiency, simplifying the structure and facilitating maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power converter is made into a whole with fixed modules, then the structure is stable and reliable, but the volume and weight increase, making it difficult to transport, disassemble, assemble and maintain
Solution Approach 1:
The power converter is divided into modular power modules that can be independently assembled and disassembled. Each power module includes a power unit, radiator, and mounting plate module, allowing selective replacement and maintenance without affecting the entire system.
Solution Approach 2:
The mounting structure transitions from fixed to dynamic/removable. The mounting plate module with rails and fasteners enables the power modules to be easily installed and removed, providing adaptability for maintenance and replacement while maintaining structural integrity during operation.
2Strength
If the power modules are fixed by traditional locking methods with multiple screws, then the connection is secure, but the structure becomes bulky and the wiring becomes messy
Solution Approach 1:
The mounting plate module integrates multiple functions: structural support, positioning rails, and fastening mechanisms are combined into a single integrated component. This reduces the number of separate parts and simplifies the overall structure while maintaining secure connections.
Solution Approach 2:
The mounting plate module serves multiple purposes: it provides mechanical support, guides the power module through rails, secures the connection with fasteners, and facilitates easy removal. This multi-functional design eliminates the need for separate mounting brackets, rails, and fastening hardware.
3Volume of stationary object
If the power converter has a large volume to accommodate all components, then all components can be housed, but the heat dissipation efficiency decreases
Solution Approach 1:
The radiator is designed with optimized fin structures and heat dissipation surfaces specifically positioned near the power unit. The mounting plate module integrates the radiator directly with the power unit, concentrating heat dissipation capabilities where needed rather than distributing volume uniformly throughout the converter.
Solution Approach 2:
The radiator is nested within or integrated with the mounting plate module structure. The air duct is positioned to flow directly over the radiator fins, creating a compact heat dissipation pathway that fits within the overall converter volume without requiring additional space.
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
This modular design enhances the assembly, disassembly, and maintenance of power converters while improving heat dissipation efficiency, making them more suitable for high-power applications with compact and efficient cooling systems.
Implementation Method 1
the power unit is fixed to the radiator
Implementation Method 2
main air duct module...provided between the pair of rails...improving heat dissipation efficiency
Data Source
AI summary
A heat-dissipating type of power converter comprises a support unit, at least one power module, at least one pair of rails and at least one main air duct module corresponding to the at least one power module. The pair of rails are fixed to the support unit and parallel to each other. The power module comprises a mounting plate module, a power unit and a radiator. wherein the power unit is fixed to the radiator, and the mounting plate module and the radiator are fixedly connected to each other. the main air duct module is fixed to the support unit and provided between the pair of rails, a second opening is defined in a side of the main air duct module toward the power module. The power module is assembled with or disassembled from the main air duct module by sliding along the pair of rails. Wherein after the power module is assembled with the main air duct module, the radiator is plugged into the main air duct module through the second opening, the power unit is positioned outside the main air duct module, and the main air duct with a sealed sidewall is defined by the mounting plate module, the radiator and the main air duct module.