JP2015103676A - Power Conditioner - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a power conditioner having a structure less likely to deform even for a relatively heavy good.SOLUTION: A housing 2 is formed of a first housing member 2a and a second housing member 2b. The first housing member 2a includes a top plate 21 and left and right side plates 23, 22, and flanges 211, 231, 221 are formed to project inward of the housing from each edge. Concave steps 224, 234 are formed at the tip corner of one flange 221, 231, and the tip corners 212, 213 of the other flange 211 are fitted in the abutting state or abuttable state. Lower end side of the left and right side plates 23, 22 bent from the top plate 21 are restricted not to open to the left and right, by attaching the second housing member 2b.

Description

  The present invention relates to a power conditioner, and more particularly to the structure of the casing.

  Conventionally, in Patent Document 1, in order to secure the same strength as that of the welded joint, an upper frame member for abutting and reinforcing each of the joint corners of the joint portion of the top plate and the side plate is added. A control panel housing in which a contact surface protruding from the top to the bottom on the side surface and a contact surface protruding in the left-right direction are overlapped to form a thick portion, and the thick portion and the top plate and the side plate are fastened with rivets. Has been proposed. Further, in Patent Document 2, a joint member is added to the left and right front corners of a control panel casing configured in a box shape with a top plate, left and right side plates, a bottom plate and a back plate, and the top plate and It has been proposed to secure rigidity and strength by screwing the side plate, the side plate and the bottom plate. Furthermore, in patent document 3, in the control panel housing integrated by welding, a front bent part whose edge is bent at a right angle on the side plate, and an inner bent part bent further at a right angle from the front bent part are provided. Forming the upper notch by notching the upper end of the front bent part and the inner bent part, and welding the corner member to the upper end of the side plate, When the top plate is attached to the side plate, the top plate is placed on the corner member of the side plate, and at the same time, the front bent portion and the inner bent portion of the top plate are placed on the upper notch of the side plate. It is proposed to perform main welding after spot welding in such an assembled state.

JP 2001-217574 A JP 2004-336946 A JP-A-7-274316

By the way, when forming a box-shaped housing, the top plate and a part or all of the left and right side plates are integrally formed by bending the plate material in order to omit the connection by welding means and screw means. It is possible. In this case, in order to increase the rigidity, as illustrated in FIG. 8, flange portions 611, 612, and 613 projecting inward from the respective edges to the top plate 601 and the side plates 602 and 603 may be formed. Adopted.
However, in the course of manufacturing or transporting a product using such a case, if an unexpected drop or the like occurs, there is a possibility that deformation (see an enlarged view of P part in FIG. 8) may occur particularly in the corners. It is necessary to take measures. If the product is a relatively heavy object such as a power conditioner, the risk of deformation will increase.

  The present invention has been made in view of such circumstances, and an object of the present invention is to provide a power conditioner having a structure that is difficult to deform even if it is relatively heavy.

  In order to achieve the above object, the present invention includes a top plate, left and right side plates, and a bottom plate, a housing having a substantially rectangular overall shape in front view, and between the power generator and the power system. The following specific items are provided for a power conditioner in which a power conversion unit for converting power is disposed in the casing. That is, the top plate or the bottom plate, and the left and right side plates are formed with flange portions projecting inward from the respective edges to the corners constituted by the top plate or the bottom plate and the left and right side plates. A concave step is formed on one of the front end corner of the flange portion of the top plate or the bottom plate and the front end corner of the flange on the side plate, and the corner is formed on the other side. As the portion, the corner portion is formed so as to be in contact with or in a contactable state with the concave step portion and abut each other (Claim 1).

  In the case of the present invention, even if a drop or the like occurs and a collision force or the like acts on the corner portion of the inverter, the butted portion of the flange portion at the corner portion and the corner portion of the flange portion are matched. Due to the fitting in the state, the occurrence of deformation is suppressed as much as possible and the deformation becomes difficult. For example, even if the operator slips one hand while carrying the power conditioner and the power conditioner falls and a collision force is applied, the collision force is caused by the contact between the concave step portion and the corner portion. As a result of being transmitted and supported, the shapes of the corner portions of the side plate and the top plate or the bottom plate are maintained, and the occurrence of deformation can be suppressed as much as possible.

  In the power conditioner of the present invention, the first casing member and the second casing member are assembled to each other so that the casing is configured, and the top panel and the left and right side plates are used as the first casing member. Partly or entirely, and part or all of the left and right side plates are bent from both sides of the top plate, and the bottom plate is provided as the second casing member. The both end portions can be attached to the first housing member in a state in which a part or all of the lower ends of the left and right side plates are constrained so as not to open in the left-right direction. . In this way, even if a springback that tends to open in the left-right direction due to part or all of the left and right side plates being bent from both sides of the top plate is generated, the first housing By attaching the second housing member to the member, it is possible to restrain the left and right side plates from being opened, and it is possible to reliably maintain the housing with an accurate shape and size.

  In the power conditioner of the present invention, the concave step portion can be formed with an end surface parallel to the top plate or the bottom plate and an end surface parallel to the side plate. By doing so, even if the power conditioner falls from the side plate side, the collision force is transmitted and supported by the contact between the end face parallel to the side plate and the corner portion, or the power conditioner. Even if na falls from the top plate or the bottom plate side, the collision force is transmitted and supported by the contact between the end face parallel to the top plate or the bottom plate and the corner.

  As described above, according to the power conditioner of the present invention, even if a drop or the like occurs and a collision force or the like acts on the corner portion of the power conditioner, the concave portion of the flange portion at the corner portion. By fitting the stepped portion with the corner portion of the flange portion, it is possible to suppress the occurrence of deformation as much as possible and make it difficult to deform. For example, even if an operator slides one hand while the power conditioner is being transported and the power conditioner falls and a collision force is applied, the collision force is transmitted by the contact between the concave step portion and the corner portion. As a result, the shape of the corner portion between the side plate and the top plate or the bottom plate can be maintained, and the occurrence of deformation can be suppressed as much as possible.

  In particular, according to the power conditioner of the second aspect, the first housing member and the second housing member are assembled to each other to form the housing, and the second housing member is attached to the first housing member. In this way, a part or all of the left and right side plates are folded from both sides of the top plate by restraining the lower ends of all or part of the left and right side plates so as not to open in the left and right direction. Even if a springback that tends to open in the right-and-left direction occurs due to the fact, the left and right side plates are restrained from opening by attaching the second housing member to the first housing member. Can be reliably maintained in a housing having an accurate shape and dimensions.

  According to the power conditioner of the third aspect, the power conditioner is formed from the side of the side plate by forming the concave step portion with an end surface parallel to the top plate or the bottom plate and an end surface parallel to the side plate. Even if it falls, the collision force can be transmitted and supported by the contact between the end face parallel to the side plate and the corner, or even if the inverter is dropped from the top plate or bottom plate side The force can be transmitted and supported by the contact between the end face parallel to the top plate or the bottom plate and the corner portion.

Fig.1 (a) is the perspective view seen from the front side of the power conditioner which concerns on embodiment of this invention, FIG.1 (b) is the perspective view seen from the back side of the power conditioner. It is the disassembled perspective view seen from the front side of the state which removed the front cover of the power conditioner of FIG. It is the perspective view seen from the front side of the state which removed the power converter part etc. from the inside of the power conditioner of FIG. It is the disassembled perspective view which decomposed | disassembled the thing of FIG. It is front explanatory drawing of the principal part of a housing | casing. It is explanatory drawing which concerns on the formation method of a 1st housing member. FIG. 7A is a correspondence diagram showing another embodiment corresponding to the enlarged view of the part A in FIG. 3, and FIG. 7B is a diagram showing another embodiment different from FIG. 7A in FIG. It is a correspondence diagram shown in correspondence with a part enlarged view. FIG. 6 is a view corresponding to FIG. 5 illustrating an example of a housing for explaining the problem of the present invention.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is a perspective view showing an appearance of a power conditioner according to an embodiment of the present invention. This power conditioner is used, for example, to connect a photovoltaic power generation unit to a commercial power system, and its rear side (see FIG. 1B) is installed in a wall-mounted state on an indoor or outdoor wall surface. It has become so. In this embodiment, an indoor installation type is shown, and in the case of an outdoor installation type, measures against rain and the like are further taken. In the following description, the description will be made using the top, bottom, left and right or front and rear with reference to the wall hanging state (the state shown in FIG. 1A).

  The power conditioner includes a housing 2 having a predetermined thickness and a substantially rectangular overall shape when viewed from the front. A rear opening 11 (see FIG. 1B) is drawn on the rear surface of the housing 2 for drawing various wirings that pass through the wall surface to be installed. The housing 2 is provided with a front cover (front cover) 3 that detachably covers the front opening on the front side. In addition, the housing 2 includes a wiring cover 4, and is configured such that the overall shape is rectangular in a state where the wiring cover 4 is attached to the housing 2. Specifically, the casing 2 includes a peripheral frame 20 including a top plate 21, a right plate 22, a left plate 23, a bottom plate 24, partition plates 24a and 24b described later, and the frame 20 and the back plate. The face plate 25 is configured in a box shape whose front surface is opened. A part of the casing body 2 in the circumferential direction, specifically, the lower right corner is partitioned by the partition plates 24a and 24b so as to be recessed inward to form the wiring connection portion 5 (see FIGS. 1 and 2). By attaching the wiring cover 4 having a L-shaped cross section, the wiring connection portion 5 is partitioned and shielded from the surroundings, and the entire shape of the housing body 2 is rectangular. It is configured. In addition, inside the casing body 2, devices that should normally be provided in order to fulfill the function as a power conditioner are housed. For example, it is composed of a converter that rectifies and boosts the generated power supplied from the solar power generation unit, and an inverter that converts the output of this converter into AC power that is connected to the commercial power system and outputs it. A power converter E (shown only in FIG. 2) is installed in the housing 2. In addition, illustration about the details of apparatuses, such as the power conversion part E, is abbreviate | omitted in drawing.

  Here, both the front cover 3 and the wiring cover 4 are configured to be detachable. However, the front cover 3 covers both front surfaces with the wiring cover 4 attached to the housing body 2. The wiring cover 4 cannot be attached or detached unless the front cover 3 is removed. In other words, by preventing the wiring cover 4 from being removed alone, the wiring cover 4 is prevented from being accidentally or unintentionally removed.

  Reference numeral 7 in FIG. 2 is an operation base including the display monitor 71 and an operation unit 72 that can perform various operations by pressing, and the operation base 7 is fixed to the housing body 2 on the rear surface side. In this state, the display monitor 71 and the operation unit 72 are exposed to the outside from the window 31 of the front cover 3.

  As shown in FIG. 4, the wiring cover 4 is formed by a side plate portion 41 and a bottom plate portion 42 having a L-shaped cross section, and is an engaging claw that protrudes upward from the upper edge of the side plate portion 41. 43, and two engagement pieces 44, 44 projecting upward from the edge position of the bottom plate portion 42.

On the other hand, the wiring connection portion 5 is a space partitioned by joining a top plate portion 22a extending horizontally from the lower end of the right side plate 22 and partition plates 24a and 24b rising upward from the right end of the bottom plate 24. A terminal block 81 (see FIG. 2) and connectors are installed on the surface side, and various wirings (DC wiring, AC wiring, etc.) are drawn into the wiring connection portion 5 to connect the terminal block 81 and connectors. Is possible. In addition, an engagement slit (not shown) that can be engaged with the engagement claw 43 of the wiring cover 4 is formed at a predetermined position on the right plate 22 side of the top plate portion 22a, while the lower end of the partition plate 24a is formed. At the side position, two engagement pieces 51 (see FIG. 4) that can be engaged with the engagement pieces 44, 44 of the wiring cover 4 are formed so as to protrude toward the inside of the space of the wiring connection portion 5. Yes.
The wiring cover 4 is detachable by engaging / disengaging the engaging claws 43 and the engaging slits, and the engaging pieces 44 and the engaging pieces 51.

  Next, the housing 2 will be specifically described with reference to FIGS. The housing 2 is formed by assembling the first housing member 2a and the second housing member 2b. The first casing member 2a is integrally provided with a top plate 21, a right side plate 22 and a left side plate 23, and the second casing member 2b is integrally provided with a bottom plate 24 and partition plates 24a and 24b. . Then, after the first housing member 2a and the second housing member 2b are assembled, the back plate 25 is attached from the back by, for example, screw fastening means and opened to the front surface. A body 2 is formed. Assembly of the first housing member 2a and the second housing member 2b is performed as follows. That is, the rising piece 24 c rising upward from the left end of the bottom plate 24 is spot-welded in a state where it covers the outer side of the joining piece 23 a at the lower end of the left plate 23, and the partition plate 24 b on the right end side of the bottom plate 24 extends from the right plate 22. The first casing member 2a and the second casing member 2b are assembled together as a result of being screwed with the top plate portion 22a covered from above. Reference numeral 26 in FIG. 4 denotes a support rod that also serves as a reinforcement. The upper and lower ends of the support rod 26 are screwed to the first housing member 2a side and the second housing member 2b side, and the power conversion unit E Used for fixing etc.

  In the first housing member 2 a, flange portions 211, 221, and 231 are formed so as to protrude inward from the edge located on the front opening side of the housing 2. That is, a flange portion 211 that protrudes inward (downward) from the edge on the front opening side of the top plate 21 is integrally formed, and from the edge on the front opening side of the right side plate 22 to the inner side (left side) of the casing. A protruding flange portion 221 is integrally formed, and a flange portion 231 that protrudes inward (rightward) from the edge of the left side plate 23 on the front opening side is formed integrally. Then, flange portions 211, 231 and 211 at the left and right corner portions (the left corner portion of the top plate 21 and the left side plate 23 and the right corner portion of the top plate 21 and the right side plate 22) of the first housing member 2a. , 221 are fitted in a staircase shape in a contact state or a contactable state so as to face each other in a predetermined direction (see FIGS. 3 and 5).

  That is, in the right corner, the end face 222 (the corner on the protruding end side) of the end portion (upper end portion) of the flange portion 221 has an end surface 222 parallel to the surface of the right plate 22 and the surface of the top plate 21. An L-shaped concave step portion 224 constituted by a parallel end surface 223 is formed, and the tip end corner portion (the corner portion on the protruding end side) of the end portion (right end portion) of the flange portion 211 with respect to the concave step portion 224. ) Are engaged with each other, and the end faces of each other are brought into contact with each other in a contact state or in a contactable state with a minute interval. In this case, the interval between the end faces is set to be 0 mm at the minimum and about 1.0 mm at the maximum, and usually the target value is about 0.2 mm. Further, at the left corner portion, the end of the flange portion 231 (upper end) is formed with an end surface 232 parallel to the surface of the left side plate 23 and an end surface 233 parallel to the surface of the top plate 21 on the protruding end side. An L-shaped concave step portion 234 is formed, and the corner portion 213 on the protruding end side of the end portion (left end portion) of the flange portion 211 is fitted to the concave step portion 234, and the same as described above. The end faces of each other are abutted against each other in a contact state or in a contactable state with a minute interval.

  The manufacturing method of the first casing member 2a described above will be described with reference to FIG. 6. The first casing member 2a is a strip-shaped plate material of a predetermined size (for example, a plate thickness of 1 mm) that is unfolded in the first step. Various shaped parts are formed by using, for example, press cutting or the like to form a primary processed product 200, and then the flange portions 231, 211, and 221 are bent by press bending or the like in the second step. The next processed product 201 is then bent at predetermined bending positions m1, m2, and m3 in the third step to obtain the final first housing member 2a. The cross-sectional shapes of the flange portions 231, 211, and 221 in the second step are the same, and the step portion 210 that is slightly displaced inward from the plate portions that become the top plate 21, the left side plate 23, and the right side plate 22 is stepped. Above, it is set as the shape which bent the flange parts 231, 211, 221 from the position extended in parallel with the top plate 21, the left side plate 23, and the right side plate 22 only by the predetermined dimension. The step portion 210 is provided so that the front cover 3 can be mounted flush with the top plate 21, the left side plate 23, and the right side plate 22 when the periphery of the front cover 3 is fitted. It is. Accordingly, the formation of the stepped portion 210 is not essential for performing the characteristic functions of the present invention described later. Even if the left and right side plates 23, 22 open in the left-right direction due to bending in the third step (springback; see the one-dot chain line in FIG. 5), the second housing By attaching the member 2b, the left and right side plates 23 and 22 can be restrained from being opened, and the housing 2 having an accurate shape and size can be reliably maintained.

  In the case of the power conditioner using the casing 2 described above, even if a drop or the like occurs and a collision force or the like acts on the corner portion, the recessed step portions 234 of the flange portions 231 and 221 at the left and right corner portions. By fitting the 224 with the corner portions 213 and 212 of the flange portion 211, the occurrence of deformation can be suppressed as much as possible and the deformation can be made difficult. For example, even if an operator slides one hand while transporting the power conditioner while the front cover 3 is facing upward and falls down from the side plate 22 or 23, a collision force acts (for example, FIG. 5). The collision force is transmitted and supported when the end surface 222 of the concave step portion 224 or the end surface 232 of the concave step portion 234 abuts against the corner portion 212 or 213 of the flange portion 211. The shapes of the corners of the side plates 22 and 23 and the top plate 21 are maintained, and the occurrence of deformation can be suppressed as much as possible. On the other hand, when the falling direction falls from the top plate 21 side and a collision force acts (see, for example, the arrow X in FIG. 5), the collision force is the end surface 223 of the concave step portion 224 or the concave step portion. As a result of the end surface 233 of the 234 being transmitted and supported by contacting the corner portion 212 or 213 of the flange portion 211, the shapes of the corner portions of the top plate 21 and the side plates 22 and 23 are maintained, and deformation occurs. Can be suppressed as much as possible.

<Other embodiments>
In addition, this invention is not limited to the said embodiment, Other various embodiment is included. That is, as a combination of the concave step portion and the corner portion in the corner portion, in the embodiment, the concave step portions 224 and 234 are formed on the flange portions 221 and 231 side of the side plates 22 and 23, and the corner portions 212 and 213 are formed. Is formed on the flange portion 211 side of the top plate 21, but this combination may be formed on opposite sides as illustrated in FIG. Moreover, in the said embodiment, although the example in which the one recessed step part 224,234 and the one corner | angular part 212,213 were mutually fitted was shown, it illustrates not only in this but in FIG.7 (b). As described above, two or more corner portions (convex step portions) may be fitted to two or more concave step portions. Furthermore, in the said embodiment, although the reinforcement structure by the combination of the above-mentioned concave step part and a corner | angular part was applied to the corner part by the side of the 1st housing member 2a, this reinforcement structure is the 2nd housing member 2b side. It can also be applied to the corners. When the back plate is not attached, the reinforcing structure can be applied not only to the front opening side of the housing 2 but also to the back side.

2 Housing 2a First housing member 2b Second housing member 3 Front cover (front cover)
21 Top plate 22 Right side plate 23 Left side plate 24 Bottom plate 211, 221, 231 Flange part 212, 213 Corner part 224, 234 Concave step part E Power conversion part

Claims (3)

A top plate, left and right side plates, and a bottom plate; a housing having a substantially rectangular overall shape in front view; and a power converter for converting power between the power generator and the power system. A power conditioner arranged in the body,
The top plate or the bottom plate, and the left and right side plates are formed with flange portions protruding inward from the respective end edges, and are formed by the top plate or the bottom plate and the left and right side plates. A concave step portion is formed on one of the front end corner portion of the flange portion of the top plate or the bottom plate and the front end corner portion of the flange portion of the side plate, and a corner portion is formed on the other side. The corner portion is formed by fitting the corner portion into a contact state or a contactable state with the concave stepped portion and butting each other.
A power conditioner characterized by that. The power conditioner according to claim 1,
The first housing member and the second housing member are assembled together to form a housing,
The first casing member integrally includes a part or all of the top plate and the left and right side plates, and a part or all of the left and right side plates are bent from both sides of the top plate. And
The second casing member includes the bottom plate, and both ends thereof are attached to the first casing member in a state in which a part or all of the lower end sides of the left and right side plates are constrained not to open in the left-right direction. It is a power conditioner. A power conditioner according to claim 1 or claim 2,
The concave step portion is a power conditioner that includes an end surface parallel to the top plate or the bottom plate and an end surface parallel to the side plate.

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