Mounting Strip With Locking Flange for Space-Saving Switchgear Layouts
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Solution Overview
Problem
Existing mounting systems for electric devices in industrial control technology are inefficient in utilizing space and require complex installation processes, limiting their versatility and ease of manipulation.
Innovation Solution
A mounting system featuring a horizontal mounting strip with a built-in standardized top hat rail and locking flange, allowing for easy attachment and organization of devices, with optional adapter elements and cable retainers that can be snapped or attached securely, forming a pre-assembled frame for efficient installation in electrical enclosures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional mounting systems are used with separate mounting rails and comb-shaped organizers, then devices can be arranged in electrical enclosures, but the installation process becomes complex and space utilization is inefficient
Solution Approach 1:
The mounting strip combines the mounting rail function and the organizer function into a single integrated component. The mounting strip has a mounting rail on its front surface for attaching devices and locking flanges on its back surface for securing cable bundles, eliminating the need for separate mounting rails and comb-shaped organizers. This merging reduces the number of components and simplifies the installation process.
Solution Approach 2:
The mounting strip serves multiple functions simultaneously: it provides a mounting surface for devices via the top hat rail on the front, organizes cable bundles via locking flanges on the back, and can be attached to profile bars to form mounting frames. This multi-functionality replaces multiple separate components with a single universal element, reducing complexity.
2Area of stationary object
If traditional separate components are used for mounting and cable organization, then devices can be secured, but space utilization in electrical enclosures is inefficient
Solution Approach 1:
By merging the mounting rail and organizer into a single mounting strip, the system reduces the number of separate components that need to be installed and positioned. The integrated design occupies less space than multiple separate components would require, improving space utilization in electrical enclosures.
Solution Approach 2:
The mounting strip utilizes both the front surface (with mounting rail) and back surface (with locking flanges) of a single component for different functions. This bidirectional utilization of the component's surfaces maximizes the functional output per unit of space occupied, improving space efficiency.
3Ease of operation
If locking flanges are made releasable without tools for ease of manipulation, then installation is simplified, but unintentional release of components may occur
Solution Approach 1:
The locking flange with self-locking locking edge automatically secures itself to the profile bar or mounting rail without requiring additional fastening actions. The undercut geometry creates a self-locking mechanism that prevents unintentional release while maintaining ease of initial installation, as the component locks itself upon attachment.
Solution Approach 2:
The locking edge with undercut creates an asymmetric geometry where insertion is easy but removal requires deliberate action. The undercut allows the locking flange to snap onto the profile bar easily, but the asymmetric shape prevents accidental release by requiring a specific removal motion, thus balancing ease of installation with secure attachment.
4Productivity
If mounting strips are pre-assembled into frames for efficient installation, then productivity is improved, but the initial assembly complexity increases
Solution Approach 1:
Mounting strips can be pre-assembled into mounting frames before installation in the electrical enclosure. This preliminary assembly allows the frame to be prepared in advance with all necessary mounting strips positioned and secured to the profile bars, reducing on-site installation time and improving productivity during the actual enclosure installation.
Solution Approach 2:
The mounting system is segmented into modular mounting strips that can be independently assembled into frames. This segmentation allows for flexible pre-assembly configurations where frames can be built in sections or completely pre-assembled, then installed as complete units, balancing preparation complexity with installation efficiency.
Data Source
AI summary
A mounting system (1) includes in switchgear cabinets a horizontal mounting strip (3) with a front face to which an electrical device (2) can be secured. The mounting strip (3) has a locking flange (63) on its rear side lying opposite the device (2) that is to be secured. The locking flange, onto which another component (65) of the mounting system (1) can be directly locked or can be indirectly secured by a lockable adapter element (66), extends in the longitudinal direction of the mounting strip (3).