Structural frame cooling manifold
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Solution Overview
Problem
Electrical panels in variable speed drives generate significant heat, and traditional hose-based coolant distribution systems are prone to failure, risking short circuits and equipment shutdowns due to liquid contacting energized components.
Innovation Solution
A cooling manifold integrated with structural members, constructed from hollow stainless steel tubing, provides both cooling fluid distribution and structural support, minimizing the use of hoses and integrating cooling passages within the electrical cabinet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional hose-based coolant distribution systems are used, then cooling fluid can be distributed to components, but the system is prone to failure causing short circuits and equipment shutdowns
Solution Approach 1:
The patent merges the structural support function with the coolant distribution function into a single integrated manifold structure. The manifold is constructed as a rigid structural member that simultaneously provides mechanical support for electrical components and serves as the coolant distribution network, eliminating the need for separate flexible hoses that are prone to failure and leakage.
Solution Approach 2:
The manifold structure performs multiple functions: it provides structural support for mounting electrical components, distributes coolant to various heat-generating components, and serves as a rigid framework within the electrical enclosure. This multi-functionality replaces the traditional separate hose-based cooling system with a more reliable integrated structure.
2Ease of operation
If separate hoses are used for coolant distribution, then flexible cooling connections can be made, but the system complexity increases and reliability decreases
Solution Approach 1:
The patent combines the structural framework and coolant distribution system into a single manifold component. This integration eliminates multiple separate hoses, connectors, and mounting hardware, thereby reducing system complexity while maintaining the necessary flexibility for coolant distribution through the integrated manifold design.
Solution Approach 2:
The manifold serves as both the structural support framework and the coolant distribution network, performing multiple functions with a single component. This multi-functionality reduces the overall number of parts and simplifies the system architecture compared to traditional hose-based systems that require separate structural and cooling components.
3Strength
If traditional steel members and hoses are used separately, then structural support and cooling can be provided, but the overall system complexity increases
Solution Approach 1:
The patent merges the structural support function traditionally performed by separate steel members with the coolant distribution function performed by hoses into a single integrated manifold. This consolidation reduces the total number of components while maintaining both structural integrity and cooling capability through the multi-functional manifold design.
Solution Approach 2:
The manifold is designed to simultaneously provide structural support for mounting electrical components and serve as the coolant distribution network. This multi-functionality eliminates the need for separate structural members and hoses, thereby reducing system complexity while maintaining both mechanical strength and thermal management capabilities.
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
The solution reduces complexity in cooling fluid distribution, provides structural support, and prevents short circuits by eliminating hoses, ensuring reliable heat management and equipment operation in variable speed drives.
Implementation Method 1
a nonconductive heat sink in thermal communication with the power electronics module and in fluid communication with a manifold
Implementation Method 2
circulating a liquid coolant through hollow stainless steel tubing
Data Source
AI summary
A variable speed drive includes a converter connected to an AC power source, a DC link connected to the converter, and an inverter connected to the DC link. The inverter converts DC voltage into an output AC power having a variable voltage and frequency. The inverter includes at least one power electronics module and associated control circuitry; a heat sink in thermal communication with the power electronics module and in fluid communication with a manifold. The manifold includes a tubular member having at least one vertical member portion and at least one horizontal member portion in fluid communication. A plurality of ports conduct cooling fluid into and out of the manifold. A bracket attaches the manifold to a structural frame. Brackets are provided for attachment of power electronics modules to the manifold.