Power Module Exchange Rack With Rolling Lift for Tight Converter Spaces
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Solution Overview
Problem
Existing systems for replacing power modules in high-voltage converters are cumbersome, heavy, and require significant space, making them difficult and costly to operate safely and efficiently.
Innovation Solution
A modular holding and exchanging system with a lightweight lifting tool that uses rolling bodies and a lever device to raise power modules vertically, allowing for easy removal and replacement without additional transverse elements, reducing weight and space requirements, and incorporating a locking mechanism for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a series-changing device with a longitudinally extended fixed receiving frame and a holding frame is used, then power modules can be received and exchanged, but the device adds high additional weight and requires relatively high total space
Solution Approach 1:
The receiving frame is divided into multiple receiving spaces, each capable of independently receiving a power module. The holding frames are segmented to correspond with individual receiving spaces, allowing selective engagement and exchange of power modules without requiring the entire device to be moved or reconfigured.
Solution Approach 2:
The holding frames are designed with universal applicability to engage with power modules across different receiving spaces. The same holding frame structure can be used for any power module position, and the device can handle both reception and exchange functions using the same basic mechanism, reducing the need for specialized components for each function.
2Ease of operation
If a ball bearing platform changing device is used, then power modules can be lifted and pushed out, but the device has very high weight and requires relatively high vertical space due to L-shaped pillars
Solution Approach 1:
Instead of using vertical L-shaped pillars that consume significant vertical space, the invention uses horizontal carrier elements that extend laterally within the receiving frame. The holding frames move horizontally along these carrier elements, transforming the space requirement from vertical to horizontal dimension, thereby reducing the vertical profile of the device.
Solution Approach 2:
The conventional approach uses vertical support structures (L-shaped pillars) to enable horizontal movement. The invention inverts this by using horizontal carrier elements to support and guide the holding frames, reversing the traditional orientation of support and movement directions to achieve compact vertical dimensions.
3Weight of stationary object
If a modular holding and exchanging system with rolling bodies is used, then power modules can be raised with reduced weight and space, but a locking mechanism is required to ensure safety during the raising process
Solution Approach 1:
The locking mechanism acts as an intermediary between the rolling bodies and the power module. It provides an additional securing function that mediates the interaction between the lifting mechanism and the load, ensuring that the power module remains securely held during the raising process even with the reduced-weight rolling body design.
Solution Approach 2:
The locking mechanism engages beforehand to secure the power module before the raising operation begins. This pre-engagement ensures that safety measures are in place prior to the critical lifting action, preventing accidental disengagement or dropping during the operation.
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
Facilitates quick, safe, and cost-effective power module changes with reduced weight and space usage, improving accessibility and operational efficiency while meeting insulation and explosion prevention requirements.
Implementation Method 1
at least one rolling body, preferably at least two rolling bodies, which can be raised and/or moved between a rest position and a support and/or service position
Implementation Method 2
a lever device for adjusting, in each case, at least one rolling body, preferably two rolling bodies spaced apart from one another in the longitudinal direction, from the rest position into the service position
Implementation Method 3
The lifting tool is configured so as to be insertable, in the rest position, into the profile element of the carrier element and comprises a longitudinally extended profile body, preferably hollow body, in which a lever device for adjusting, in each case, at least one rolling body
Data Source
AI summary
The invention relates to a method and a modular holding and exchanging system (1) for medium or high voltage converters, preferably a modular multilevel converter, comprising a rack (2) for receiving at least two power modules (3) arranged on top of one another in receiving spaces (4), wherein the rack (2) has at least two pairs of vertical standing elements (5) and at least two carrier elements (6) connecting the vertical standing elements (5) in a longitudinal direction (10) of the rack (2) in a horizontal support plane (9), a lifting tool (7) that can be coupled with the rack (2), which lifting tool (7) comprises at least one, preferably at least two, rolling bodies (19) that can be adjusted between a rest position (13) and a support and/or service position (14) for temporarily raising and/or moving a power module (4), wherein the power modules (4) have support surfaces (16) projecting in a transverse direction (11) with respect to a housing width (15) for being supported on the carrier elements (6), and the carrier elements (6) have an upper side (17) provided for at least parts of the support surface (16) of the respective power module (4) to rest on, and are configured as a profile element such that every carrier element (6) has at least one, preferably at least two passages (18), each, that are spaced apart from one another in the longitudinal direction (10), for at least one rolling body (19) to pass through in the service position (14) of the lifting tool (7), and wherein the lifting tool (7) comprises a longitudinally extended profile body (21), preferably a hollow body, configured so as to be insertable into the profile element of the carrier element (6) in the rest position (13), in which profile body (21) a lever device (20) is formed for adjusting the at least one rolling body (19), preferably of the at least two rolling bodies (19), which are spaced apart from one another in the longitudinal direction (10), from the rest position (13) into the service position (14).