Switchgear Frame Joining Element with External Alignment
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Solution Overview
Problem
Existing joining-devices for switchgear frames are complex to produce, difficult to assemble, and time-consuming, often requiring internal access to electrical components, which can lead to damage and alignment issues.
Innovation Solution
A joining-element with a coupling-base-part and locking-mating-part that allows for external alignment and secure connection of switchgear frames using a screwless mechanism, featuring a locking-pin system and aligning surfaces for precise positioning, enabling easy and quick assembly without internal access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a profiled bracket-plate is used for internal fixing to uprights, then the joining is mechanically secure, but the assembly operation becomes difficult and time-consuming due to internal access requirements
Solution Approach 1:
The joining element inverts the conventional approach by fixing to the external side of uprights rather than internally. The coupling base part engages with the external surface of the uprights, allowing assembly operations to be performed from outside the switchgear compartment, eliminating the need for internal access and avoiding damage to electrical components.
Solution Approach 2:
The coupling base part acts as an intermediary element that mediates between the joining requirement and the upright structure. It provides a mounting interface on the external side of uprights, enabling the bracket element to be securely fixed without penetrating into the internal compartment, thus resolving the conflict between secure joining and ease of operation.
2Ease of manufacture
If joining devices with complicated shapes are used for external mounting, then the structural connection is achieved, but the manufacturing complexity and alignment precision deteriorate
Solution Approach 1:
The first and second aligning surface portions are designed to be substantially parallel to each other, creating an equipotential alignment interface. This parallel configuration ensures that the bracket element and joining element align automatically during assembly, achieving precise positioning without requiring complex adjustment procedures or high-precision manufacturing tolerances.
Solution Approach 2:
The aligning surface portions change the geometric parameters of the joining interface by introducing inclined surfaces that guide the assembly process. These surfaces transform the alignment requirement from a precise point-to-point contact to a surface-to-surface engagement, allowing for self-alignment and reducing the impact of manufacturing tolerances.
3Strength
If multiple separate screws are used for fixing joining devices, then the secure attachment is achieved, but the assembly time and operational complexity increase
Solution Approach 1:
The fixing function is merged into the coupling base part itself, which integrates the mounting mechanism directly into the structure that attaches to the uprights. This consolidation eliminates the need for separate fixing screws, reducing the number of fastening operations while maintaining secure attachment through the integrated coupling mechanism.
Solution Approach 2:
The coupling base part provides self-service by incorporating its own fixing capability through the engagement with uprights. The design allows the bracket element to be securely attached through the coupling mechanism itself, without requiring additional external fixing elements, thereby simplifying the assembly process and reducing time consumption.
4Reliability
If internal access is required for fixing joining elements, then the mechanical connection is achieved, but the risk of damage to electrical components increases
Solution Approach 1:
The fixing operation is extracted from the internal compartment environment and relocated to the external side of the uprights. The coupling base part is designed to engage with the external surface, completely separating the joining operation from the electrical components housed inside the compartment, thus eliminating the risk of damage during assembly.
Solution Approach 2:
The coupling base part serves as an intermediary that enables mechanical connection without direct access to the internal compartment. It mediates between the joining requirement and the upright structure by providing an external mounting interface, allowing the bracket element to be secured to the frame without any tools or operations penetrating into the protected internal space.
Data Source
Figure 1~2
Figure 3~8
Figure 9~12
AI summary
A joining-element (1) for mechanically joining switchgear-frames (2, 3) to one other, comprises a coupling-base-part (4) having a resting-surface (5) suitable for resting on, and coupling with a profile-rod (6) of a first switchgear-frame (2); a locking-mating-part (7) protruding from the coupling-base-part (4) and configured for mating with a further locking-mating-part of a further joining-element connectable to a respective profile-rod (6') of a second switchgear-frame (3), the locking-mating-part (7) having a through-opening (8) extending along an insertion-axis (9) and suitable for cooperating with a further through-opening of the further locking-mating-part for receiving a locking-pin-element (10) parallely to longitudinal-axes (11) of the profile-rods (6, 6'). The locking-mating-part (7) comprises a first aligning-surface-portion (12, 23) tilted with respect to the insertion-axis (9) and configured for enabling achievement of a mutual alignment position of the switchgear-frames (2, 3) according to a first direction (F1) parallel to the longitudinal axes (11), and of a desired relative side position according to a second direction (F2) orthogonal to the longitudinal axes (11) and to said resting-surface (5). On the locking-mating-part (7) and coupling-base-part (4) there is included a second aligning-surface-portion (13, 14) parallel to the insertion-axis (9) and sloping relative to the resting-surface (5), and configured for ensuring a reciprocal alignment of the two switchgear-frames (2, 3) according to a third direction (F3) orthogonal to the insertion-axis (9) and parallel to the resting-surface (5).