One-Piece Chassis for Welding Power Supply Assembly and Cooling
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Solution Overview
Problem
Welding power supplies occupy large spaces and generate significant heat, making it difficult to manufacture compact and efficient units due to the complexity of mounting multiple electrical components.
Innovation Solution
A one-piece chassis is used to house and mount electrical components such as transformers, rectifiers, inductors, and control circuitry, with integrated fan mounts and shrouds to facilitate efficient air flow and cooling, reducing the need for additional mounting structures and enhancing assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple electrical components are mounted using separate brackets and mounting structures, then the components can be securely fixed, but the device complexity and manufacturing time increase
Solution Approach 1:
The patent integrates multiple separate mounting structures into a single integrated chassis that serves as a common mounting platform for all electrical components. The chassis includes integrated mounting features such as recesses, tabs, and attachment points that securely fix transformers, rectifiers, inductors, and control circuitry without requiring separate brackets for each component.
Solution Approach 2:
The chassis performs multiple functions simultaneously: it provides structural support, serves as a mounting platform for all components, acts as a thermal management system with integrated heat sinks, and functions as a shield for electrical components. This multi-functional design eliminates the need for separate mounting structures.
2Adaptability or versatility
If traditional separate mounting structures are used for each component, then each component can be independently mounted, but the manufacturing time and cost increase
Solution Approach 1:
The chassis is pre-manufactured with all mounting features, recesses, and attachment points integrated into its structure before components are installed. This preliminary preparation of the mounting platform allows for rapid assembly of components without requiring separate mounting operations for each component.
Solution Approach 2:
Multiple mounting operations are combined into a single chassis manufacturing process, where all mounting features are created during chassis fabrication rather than being added separately during assembly. This merging of operations significantly reduces manufacturing time and complexity.
3Volume of moving object
If compact design is pursued, then the power supply size is reduced, but heat management becomes more difficult
Solution Approach 1:
The chassis is designed with nested thermal management features where heat sinks are integrated into the chassis structure itself, and components are positioned to utilize each other's thermal zones. The fan housing and air flow paths are nested within the chassis volume, maximizing cooling efficiency within a compact form factor.
Solution Approach 2:
The structural chassis and thermal management system are merged into a single integrated component. The chassis itself serves as the heat dissipation structure with integrated heat sinks and thermal pathways, eliminating the need for separate cooling systems and reducing overall size.
4Productivity
If integrated chassis is used, then manufacturing efficiency is improved, but the initial design complexity increases
Solution Approach 1:
The integrated chassis is designed as a modular platform with standardized mounting zones and features that can accommodate different component configurations. The chassis is segmented into functional zones for different component types, allowing for systematic design and easier manufacturing despite the integrated nature.
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 allows for a compact, cost-effective, and efficient manufacturing of welding power supplies by simplifying the assembly process, reducing manufacturing time and complexity, and improving heat management through optimized air flow paths.
Implementation Method 1
a fan configured to direct air across the electronic components and toward the panel
Data Source
AI summary
A welding power supply includes a housing and a one-piece chassis. The one-piece chassis is coupled to the housing and configured to be enclosed within the housing. Moreover, the one-piece chassis is configured to be selectively removable from the housing and the one-piece chassis is configured to have multiple components coupled thereto. The components include one or more transformers, a fan blade, one or more rectifiers, one or more inductors, and control circuitry.