Structural frame cooling manifold
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Solution Overview
Problem
Existing cooling systems for variable speed drives, which rely on hoses for coolant distribution and steel members for structural support, are prone to hose failures that can lead to short circuits and equipment shutdowns due to liquid contacting energized components.
Innovation Solution
A dual-function cooling manifold that integrates cooling fluid passages with structural members, providing support to the electrical cabinet and electronic components while minimizing the use of hoses by acting as both a conduit for cooling fluid and a structural support system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If hoses are used for coolant distribution, then the cooling system is flexible and easy to install, but the reliability deteriorates due to hose failures causing short circuits
Solution Approach 1:
The patent combines the structural support function and coolant distribution function into a single integrated manifold structure. The manifold serves dual purposes: providing mechanical support for mounting power electronics modules and simultaneously distributing coolant through integrated passages. This eliminates the need for separate hoses, thereby improving reliability while maintaining installation efficiency.
Solution Approach 2:
The manifold is designed as a multi-functional component that performs both structural support and fluid distribution functions. By making the manifold universal in its capabilities, the system eliminates the need for separate dedicated hoses for coolant distribution, thereby reducing failure points while maintaining ease of installation through the single integrated component.
2Adaptability or versatility
If separate hoses and structural members are used, then the functions are clearly separated, but the device complexity increases
Solution Approach 1:
The patent merges the structural support members and coolant distribution hoses into a single integrated manifold structure. This consolidation reduces the total number of components and connections required, thereby reducing device complexity while maintaining the necessary functional separation through the integrated design of the manifold itself.
3Ease of operation
If hoses are used for coolant distribution, then the installation is simple, but the risk of liquid contacting energized components increases
Solution Approach 1:
The patent combines structural support and coolant distribution into an integrated manifold, eliminating separate hoses that could fail and leak coolant onto energized components. The manifold's integrated design ensures coolant is distributed through controlled passages within the structural element itself, reducing the risk of harmful liquid contact while maintaining installation simplicity.
Solution Approach 2:
The manifold acts as an intermediary structure that safely contains and directs coolant flow through integrated passages. By serving as both the structural element and the coolant conduit, it mediates between the need for simple installation and the need to prevent liquid contact with energized components, eliminating the intermediate hoses that could fail.
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 manifold reduces complexity in cooling fluid distribution, minimizes the risk of hose failures, and provides additional space within the variable speed drive system by using the same structural framework for both support and fluid conduction, thereby enhancing reliability and efficiency.
Implementation Method 1
a heat sink in thermal communication with the power electronics module and in cooling fluid communication with a manifold
Implementation Method 2
cooling fluid communication with a manifold
Data Source
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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.