Orthogonal PCB Arrangement for Smart Meter Gateway Space Optimization
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Solution Overview
Problem
Communication units in top-hat rail housings face space bottlenecks due to the conventional parallel arrangement of printed circuit boards, which limits packing density and complicates the routing of conductor tracks, especially when additional interfaces are required, as per the FNN specifications for SmartMeter gateways.
Innovation Solution
The communication unit employs orthogonally arranged printed circuit boards, with a base board extending parallel to the mounting wall and module boards perpendicular to it, allowing for flexible space utilization and reduced complexity in EMC compliance, eliminating the need for stackable connectors and enabling more efficient use of housing space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If printed circuit boards are arranged parallel to the mounting wall, then the maximum combined area of each PCB is achieved, but the packing density is limited and routing of conductor tracks becomes complex
Solution Approach 1:
The patent transitions from a two-dimensional parallel arrangement of PCBs to a three-dimensional orthogonal arrangement. Module PCBs are mounted perpendicular to the base PCB, utilizing the vertical dimension within the housing. This dimensional change increases packing density without reducing the combined area of individual PCBs, while also simplifying conductor track routing by reducing the number of layers required.
2Adaptability or versatility
If additional interfaces are required per FNN specifications, then functionality is improved, but space bottlenecks and routing complexity increase
Solution Approach 1:
The patent segments the circuit board system into a base PCB and multiple module PCBs, where each module PCB can be independently configured to provide specific interfaces (HAN, WAN, LMN). This segmentation allows the system to be customized according to FNN specification requirements without increasing overall housing volume, as only the necessary modules are installed.
Solution Approach 2:
By mounting module PCBs orthogonally to the base PCB, the patent utilizes vertical space within the housing rather than horizontal space. This enables additional interfaces and modules to be integrated without increasing the housing footprint or creating space bottlenecks.
3Reliability
If stackable connectors are used for PCB connection, then electrical connection is achieved, but device complexity and cost increase
Solution Approach 1:
The patent merges the electrical connection function into the mechanical mounting structure itself. The module PCBs are electrically connected to the base PCB through contact elements that are integrated into the mounting brackets, eliminating the need for separate stackable connectors. This reduces device complexity and cost while maintaining reliable electrical connections.
4Adaptability or versatility
If DIN rail enclosure dimensions are constrained by DIN 43880, then standardization is achieved, but space for components and interfaces is limited
Solution Approach 1:
The patent exploits the vertical dimension within the constrained DIN rail enclosure by mounting module PCBs perpendicular to the base PCB. This orthogonal arrangement maximizes the use of available three-dimensional space, allowing sufficient room for components and interfaces while maintaining compliance with DIN 43880 dimensional standards.
Data Source
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AI summary
A communication unit, in particular a smart meter gateway, comprising several printed circuit boards and a housing (1) for mounting on a mounting rail (2), particularly a DIN rail, is disclosed. The several printed circuit boards comprise a base printed circuit board (16) and at least one module printed circuit board (17, 18, 19, 20) and are arranged in the housing (1). One wall of the housing (1) – mounting wall (5) – is designed as a receptacle for the mounting rail (2). The base printed circuit board (1) is arranged at a wall (5, 6, 7) of the housing (1) and extends in a plane parallel to this wall (5, 6, 7). The at least one module circuit board (17, 18, 19, 20) extends in a plane orthogonal to the base circuit board (16) and orthogonal to an extension direction of the receptacle (4) for the mounting rail (2) and is electrically connected to the base circuit board (16).