Modular Sheet Metal Inverter Rack with Interchangeable Supports
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional inverter racks for rooftop solar installations are often expensive, structurally weak, and require time-intensive assembly processes, posing safety hazards and risks to high-cost equipment due to potential failures.
Innovation Solution
A robust rack system formed from folded metal sheets with interchangeable triangular support members and cross struts, designed to securely mount inverters and load centers at acute and orthogonal angles, featuring a shade cover for heat dissipation and sun protection, and anchor attachments for secure rooftop installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional inverter racks are used, then installation can be performed, but the structural strength and reliability are insufficient
Solution Approach 1:
The rack is divided into multiple modular components including leg assemblies, cross members, and support structures that can be independently assembled and configured. Each segment is designed with specific load-bearing characteristics, allowing the overall structure to achieve high strength through proper distribution of forces across multiple connection points.
Solution Approach 2:
The rack components are pre-configured with attachment features, pre-drilled holes, and pre-assembled connection elements during manufacturing. This preliminary preparation enables rapid on-site assembly while ensuring that all critical structural connections are properly established before the inverter is mounted, eliminating the need for time-consuming field modifications.
2Productivity
If conventional inverter racks are used, then mounting can be achieved, but assembly time is excessive
Solution Approach 1:
The rack is divided into multiple modular components including leg assemblies, cross members, and support structures that can be independently assembled and configured. This segmentation allows for parallel assembly of different sections and reduces the overall assembly time compared to monolithic rack designs.
Solution Approach 2:
The rack components are pre-configured with attachment features, pre-drilled holes, and pre-assembled connection elements during manufacturing. This preliminary preparation enables rapid on-site assembly while ensuring that all critical structural connections are properly established before the inverter is mounted, eliminating the need for time-consuming field modifications.
3Ease of manufacture
If conventional inverter racks are used, then installation can proceed, but cost is high
Solution Approach 1:
The rack is divided into multiple modular components that can be manufactured using standard fabrication processes and assembled on-site. This modular approach reduces manufacturing complexity and material waste compared to custom-built monolithic racks, while maintaining structural integrity through engineered connection details.
Solution Approach 2:
The rack utilizes standardized metal components and connection elements that can be manufactured cost-effectively through conventional fabrication methods. The design accepts that individual components may need replacement over time, so each element is optimized for cost-effective manufacturing while the overall system achieves the required reliability through redundancy and proper load distribution.
4Adaptability or versatility
If fixed support structures are used, then structural stability is achieved, but adaptability to different inverter types is limited
Solution Approach 1:
The rack incorporates universal mounting plates with multiple pre-drilled holes arranged in various patterns, allowing accommodation of different inverter sizes, weights, and attachment configurations. The leg assemblies and cross members are designed with standardized connection interfaces that can adapt to different structural requirements while maintaining overall system stability through proper load path design.
Data Source
AI summary
A multi-component inverter rack formed from sheet metal is disclosed. Some of the sheet metal derived parts used to form the multi-component inverter rack can be interchangeable. The multi-component inverter rack can include attachment points for an inverter, a load center and other supporting electrical components.