WO2017207046A1

WO2017207046A1 - Support structure and system

Info

Publication number: WO2017207046A1
Application number: PCT/EP2016/062369
Authority: WO
Inventors: Irene GARDONI; Marcus LINDBLOM
Original assignee: Abb Schweiz Ag
Priority date: 2016-06-01
Filing date: 2016-06-01
Publication date: 2017-12-07
Also published as: CN109315078B; CN109315078A; DE112016006925T5

Abstract

Support structure (12) for supporting a stack (14) of electrical components, the support structure (12) comprising a first wall structure (22a); a second wall structure (22b) opposite to the first wall structure(22a) substantially in a horizontal first direction (16); and a cross member (32) connected between the first wall structure (22a) and the second wall structure (22b) to add strength to the support structure (12); wherein the cross member (32) provides a support surface (34) for the stack (14) of electrical components.

Description

SUPPORT STRUCTURE AND SYSTEM

Technical Field

The present disclosure generally relates to support structures for supporting electrical components. In particular, a support structure for supporting a stack of electrical components comprising a cross member and a system comprising the support structure and a stack of electrical components are provided.

Background Various types of support structures, such as cabinets, for supporting electrical components are known. One known type of support structure is a cabinet comprising a metal housing that provides the complete load carrying structure for the components to be supported. The housing is thus used as a main load carrying outer structure to provide the necessary structural strength.

In some prior art cabinets, a stack of electrical components is mounted on supports designed to withstand both the weight of the stack itself and the clamping force which may be necessary to make the electrical components (e.g. IGCT semiconductors, IGCT = Integrated Gate Commutated Thyristors) work properly.

CA 2920526 Ai discloses a power cabinet for medium-high voltage inverters. The cabinet comprises a cabinet shell and a support for mounting power modules. The support comprises at least one pair of upright beams and slide rails arranged on the paired upright beams. At least one column of space for accommodating the power modules is formed by the at least one pair of upright beams, and the slide rails are used for supporting the power modules. Summary

One object of the present disclosure is to provide a strong support structure for supporting a stack of electrical components having a reduced weight and requiring few components. A further object of the present disclosure is to provide a support structure having a simple design and enabling a simple assembly.

According to one aspect, there is provided a support structure for supporting a stack of electrical components, the support structure comprising a first wall structure; a second wall structure opposite to the first wall structure substantially in a horizontal first direction; and a cross member connected between the first wall structure and the second wall structure to add strength to the support structure; wherein the cross member provides a support surface for the stack of electrical components.

The support structure alone, i.e. without the cross member, may be dimensioned too weak to support the stack of electrical components.

However, by connecting the cross member between the first and second wall structures to add strength to the support structure, the support structure as a whole, i.e. a combination comprising the first wall structure, the second wall structure and the cross member, can be made sufficiently strong to support a clamped stack of electrical components. The term "sufficiently strong" as used herein may refer either to a break limit of the support structure when supporting the clamped stack or to a limit including both the break limit and a safety factor, e.g. 1.5 or 2 times the break limit. The cross member may thus constitute an integrated part of the support structure to contribute to the stiffness and strength of the support structure while at the same time providing a support surface for the stack of electrical components.

The support structure, which may be constituted by a cabinet or power module frame, may comprise one or more clamping mechanisms for holding the electrical components in line to form the stack and for applying a clamping force to the stack. By interconnecting the first wall structure and the second wall structure with the cross member, the cross member both serves as a structural element for the support structure and provides a load support surface for bearing the load from the stack, both the weight of the stack and the clamping force applied to the stack. By arranging the cross member transverse to the first and second wall structures, the cross member reduces sway and/or shear forces of the support structure in the first direction and helps the support structure to withstand compression forces and tension forces in the first direction.

Additionally, by arranging the first and second wall structures such that their normals are substantially parallel with the first direction, the first and second wall structures add rigidity to the support structure in a horizontal second direction, perpendicular to the first direction. In other words, the first and second wall structures reduce sway and/or shear forces of the support structure in the second direction. The support surface provided by the cross member may be substantially flat and may be oriented substantially horizontally. The support surface may have a substantially rectangular shape extending fully between the first and second wall structures in the first direction. Moreover, the support surface may have a length in the second direction that constitutes 10 to 50%, such as 15 to 40%, such as 20 to 30%, of the length of the first and second wall structures in the second direction.

The first and second wall structures may constitute side walls of the support structure. The wall structures may extend substantially in a vertical direction. Each of the first wall structure and the second wall structure may have a flat appearance. A flat appearance is intended to include slightly concave or convex cylindrical or spherical shapes, and combinations thereof.

One or both of the first wall structure and the second wall structure may be constituted by or comprise sheet metal. Alternatively, or in addition, the first and second wall structures may comprise various combinations of beams and/or profiles. Each of the first wall structure and the second wall structure may be oriented substantially parallel. For example, the first and second wall structures may be oriented in parallel vertical planes.

The cross member may be directly connected to the first wall structure and/or the second wall structure. Alternatively, one or more intermediate component may be provided between the cross member and the first wall structure and/or the second wall structure while the cross member is still connected between the first and second wall structure, i.e. the cross member may be indirectly connected to the first and second wall structures. As used herein, a horizontal direction is a direction substantially parallel with a ground surface on which the support structure is placed and a vertical direction is a direction substantially perpendicular to the horizontal direction. A substantially perpendicular/parallel relationship as used herein includes a perfectly perpendicular/parallel relationship as well as deviations from a perfectly perpendicular/parallel relationship with up to 5%, such as up to 2%. Similarly, a substantially corresponding distance as used herein includes a perfectly corresponding distance as well as deviations from a perfectly corresponding distance with up to 5%, such as up to 2%.

The cross member may have an elongated appearance extending

substantially in the first direction. The cross member may alternatively be referred to as an elongated support member, a profile structure, a transverse, lateral or connecting beam, a brace member, a reinforcing member, a transverse structural element or a connecting profile.

The cross member may comprise a sheet of metal that provides the support surface. A suitable sheet metal material according to the present disclosure may be steel or aluminium. The cross member may thus form a metal sheet construction of the support structure.

The cross member may comprise a sheet having a substantially U-shaped (or C-shaped) cross section as seen in the first direction. The cross member may comprise a sheet having two side portions substantially facing in the horizontal second direction, perpendicular to the first direction, and an intermediate portion between the two side portions. Each of the intermediate portion and the two side portions may have a substantially flat appearance. The intermediate portion may have a substantially vertical normal and may constitute the support surface for the stack. However, a further structure arranged on the intermediate portion could alternatively provide the support surface for the stack. Throughout the present disclosure, the side portions may alternatively be referred to as side web portions, legs or flanges and the intermediate portion may alternatively be referred to as an intermediate web portion or a central portion.

The cross member may further comprise at least one reinforcing element. Each of the at least one reinforcing element may provide a horizontal upper surface and two vertical side surfaces. A side surface as referred to herein is a surface having a normal substantially parallel with the second direction. The reinforcing elements may thus function as reinforcing inserts and be received within the upper U-shaped sheet such that each horizontal upper surface of the reinforcing elements mates with the underside of the intermediate portion of the upper sheet and each vertical side surface of the reinforcing elements mate with a respective inner surface of the side portions of the upper sheet. Furthermore, the horizontal upper surface of the reinforcing element may be fixedly attached to the underside of the intermediate portion of the upper sheet and/or each vertical side surface of the reinforcing element may be fixedly attached to a respective inner surface of the side portions of the upper sheet. The at least one reinforcing element may be arranged to lock the two side portions against relative movements in the second direction. The at least one reinforcing element thus enables a reduced thickness of the upper sheet.

The cross member may comprise two distal reinforcing elements. The two distal reinforcing elements may comprise substantially vertical end surfaces. Each end surface of the distal reinforcing elements may mate with a corresponding attachment surface provided on the first and second wall structures. The end surfaces of the distal reinforcing elements may be substantially aligned with a respective end of the upper sheet (e.g. a plane where the edges of the intermediate portion and the side portions lie) as seen in the first direction. Alternatively, the distal two distal reinforcing elements may slightly protrude out from the upper sheet such that the end surfaces of the distal reinforcing elements are outside of the ends of the upper sheet as seen in the first direction.

Each of the two distal reinforcing elements may constitute a mount for attaching the cross member to the first wall structure and the second wall structure, respectively. For example, one or several attachment holes may be provided in the end surfaces of the distal reinforcing elements for securing the cross member to the first and second wall structures by means of fastening elements (e.g. screws). One or both of the distal reinforcing elements may comprise two sets of opposing and substantially vertical walls to form a continuous frame. The vertical walls of the distal reinforcing elements may be secured against relative movement.

The cross member may comprise at least one central reinforcing element. A central position as used herein may be any position between two distal reinforcing elements as seen in the first direction. The cross member may for example comprise two central reinforcing elements. The at least one central reinforcing element may be spaced from the two distal reinforcing elements in the first direction. Each central reinforcing element may comprise two vertical side walls to mate with the insides of the side portions of the upper sheet. In other words, these two side walls may have a normal substantially parallel with the second direction. The two central reinforcing elements may be substantially centered along the cross member as seen in the first direction. Each central reinforcing element may further comprise one vertical wall having a normal substantially parallel with the first direction. These vertical walls of two central reinforcing elements may be mated and fixedly

connected, for example by means of fastening elements. Each reinforcing element (i.e. both the at least one central reinforcing element and the two distal reinforcing elements) may be fixedly attached to the upper sheet. For example, attachment holes may be provided in the respective horizontal upper surfaces of the reinforcing elements and in the intermediate portion of the upper sheet for fixedly locking these parts by means of fastening elements.

The at least one reinforcing element may be made of folded sheet metal. For example, the two distal reinforcing elements may each be formed by cutting slits in, and folding, a flat continuous sheet of metal to form a hollow box shape (without a bottom surface) having a top surface to mate with and/or be fixed to an underside of the intermediate portion of the upper sheet, one set of vertical walls having a normal substantially in the first direction (e.g. one of these walls may be constituted by the end surface of the distal reinforcing element) and one set of vertical walls to mate with and/or be fixed to the insides of the two side portions of the upper sheet. Also the at least one central reinforcing element may be formed by folding a flat sheet of metal to form a horizontal upper surface to mate with and/or be fixed to the underside of the intermediate portion of the upper sheet, two vertical side surfaces to mate and/or be fixed to with the insides of respective side portions of the upper sheet and a vertical surface having a normal substantially parallel with the first direction to mate with and/or be fixed to a corresponding surface of a further central reinforcing element or a vertical surface of a distal reinforcing element.

The cross member may be substantially centered along the lengths of the first wall structure and the second wall structure substantially in the horizontal second direction (depth direction), perpendicular to the first direction. For example, the cross member may be positioned at 30 to 70%, such as 40 to 60%, such as 50%, of the distance between two vertical edges (e.g. a front edge and a rear edge) of the first and second wall structures.

The support structure may further comprise a base structure and a top structure, opposite to the base structure substantially in a vertical third direction, wherein the cross member is distanced from the base structure in the third direction. The first wall structure, the second wall structure, the base structure and the top structure may thus together form a cube shape or a rectangular cuboid shape of the support structure or cabinet. Alternative designs of the support structure, such as a cylindrical design where the base structure and the top structure form the bottom and top, respectively, of the cylinder, are however possible. The base structure and the top structure may have a structural design corresponding to the first and second wall structures. For example, one or both of the base structure and the top structure may be constituted by or comprise sheet metal.

According to a further aspect, there is provided a system comprising a support structure according to the present disclosure and a stack of electrical components, wherein the stack is supported by the support surface of the cross member. The support structure of the system may comprise one or more clamping mechanisms for holding the electrical components in line to form the stack and for applying a clamping force to the stack. The electrical components may be semiconductors, such as IGCT semiconductors.

Brief Description of the Drawings

Further details, advantages and aspects of the present disclosure will become apparent from the following embodiments taken in conjunction with the drawings, wherein:

Fig. 1: schematically represents a perspective top/front view of a system comprising a support structure and a cross member;

Fig. 2: schematically represents a perspective top/front view of the cross member;

Fig. 3: schematically represents an exploded perspective top/front view of the cross member; and

Fig. 4: schematically represents a perspective bottom/front view of the cross member.

Detailed Description

In the following, a support structure for supporting a stack of electrical components comprising a cross member and a system comprising the support structure and a stack of electrical components will be described. The same reference numerals will be used to denote the same or similar structural features.

Fig. 1 schematically represents a perspective top/front view of a system 10 comprising a support structure 12 and a stack 14 of electrical components. The electrical components are here semiconductors but may be constituted by alternative electrical components. The support structure 12 is here exemplified as a cabinet. A coordinate system is illustrated in Fig. 1 and comprises a horizontal first direction 16, a horizontal second direction 18, perpendicular to the first direction 16, and a vertical third direction 20, perpendicular to both the first direction 16 and the second direction 18.

The support structure 12 comprises a first wall structure 22a and a second wall structure 22b. The two wall structures 22a, 22b have a flat appearance and are vertically oriented as side walls. More specifically, the two wall structures 22a, 22b are parallel and spaced from each other (e.g. opposing each other) in the first direction 16. Each of the first and second wall structures 22a, 22b is mainly composed of a sheet metal. The orientation and shape of the first and second wall structures 22a, 22b add rigidity to the support structure 12 against shear forces substantially in a plane parallel with the second direction 18 and the third direction 20 (i.e. front/back sway of the support structure 12). The support structure 12 further comprises a base structure 24 and a top structure 26. The base structure 24 and the top structure 26 are horizontally oriented, i.e. have the third direction 20 as a normal. In other words, the top structure 26 is spaced from the base structure 24 in the third direction 20. The support structure 12 thus has a substantially vertically extending rectangular cuboid shape in this implementation. Also the base structure 24 and the top structure 26 are mainly composed of a sheet metal.

The base structure 24 the top structure 26 and the two wall structures 22a, 22b define a front opening 28 and a rear opening 30 of the support structure 12 in the second direction 18. Thus, the front opening 28 and the rear opening 30 are at least partly enclosed by the first wall structure 22a and the second wall structure 22b.

The support structure 12 further comprises a cross member 32. The cross member 32 has an elongated appearance and is connected with a respective end to the first wall structure 22a and the second wall structure 22b. The cross member 32 extends substantially in the horizontal first direction 16.

The cross member 32 comprises a substantially flat and substantially horizontal support surface 34 on which the stack 14 of electrical components is supported. The support surface 34 has a rectangular shape where the length in the first direction 16 is longer than the length in the second direction 18. The support surface 34 extends fully between the first and second wall structures 22a, 22b in the first direction 16. The length of the support surface 34 in the second direction 18 is approximately 25% of the depth of the support structure 12, i.e. the length of the first and second wall structures 22a, 22b in the second direction 18.

The cross member 32 carries the gravity load of the stack 14 as well as any clamping force applied to the stack 14 by means of one or more clamping mechanisms (not shown) substantially in a downward direction (i.e. in a direction opposite to the third direction 20) and/or a reaction force from a clamping force applied to the stack 14 in the third direction 20. Furthermore, since the cross member 32 is arranged substantially

perpendicular to the first and second wall structures 22a, 22b, the cross member 32 adds rigidity to the support structure 12, in particular rigidity against shear forces substantially in a plane parallel with the first direction 16 and the third direction 20 (i.e. lateral or sideway sway of the support structure 12). The cross member 32 also provides strength to the support structure 12 against compression forces and tension forces in the first direction 16 (or in a direction opposite to the first direction 16). The cross member 32 thereby adds strength to the support structure 12. The cross member 32 is centered along the lengths of the first and second wall structures 22a, 22b in the horizontal second direction 18. Moreover, the cross member 32 is distanced from the base structure 24 in the vertical third direction 20. In the implementation of Fig. 1, the distance between the base structure 24 and the cross member 32 in the vertical third direction 20 is approximately 20% of the distance between the base structure 24 and the top structure 26 in the vertical third direction 20.

Fig. 2 schematically represents a perspective top/front view of the cross member 32. The cross member 32 comprises a sheet 36 of metal bent to provide a U-shaped cross section as seen in the first direction 16. The sheet 36 comprises two substantially flat side portions 38 (only one is visible in Fig. 2) and a substantially flat intermediate portion 40 between the two side portions 38. In this implementation, the intermediate portion 40 provides the support surface 34 for the stack 14. Each of the two side portions 38 has a normal parallel with the horizontal second direction 18 and the intermediate portion 40 has a normal parallel with the vertical third direction 20.

The cross member 32 further comprises two distal reinforcing elements 42 and two central reinforcing elements (not visible in Fig. 2). The two distal reinforcing elements 42 are partly accommodated within the sheet 36 and the two central reinforcing elements are fully accommodated within the sheet 36, i.e. inside the outer dimensions of the sheet 36. Fig. 2 further shows that each distal reinforcing element 42 comprises a substantially vertical end surface 44. Each distal reinforcing element 42 protrudes slightly out from the upper sheet 36 such that the end surfaces 44 are positioned outside of the upper sheet 36 in the first direction 16. The end surfaces 44 are provided with attachment holes for securing the distal reinforcing elements 42, and thereby also the entire cross member 32, by means of fastening elements (not shown) to a respective wall structure 22a, 22b. The distal reinforcing elements 42 thus constitute mount for attaching the cross member 32 to the first and second wall structures 22a, 22b. Fig. 3 schematically represents an exploded perspective top/front view of the cross member 32. Fig. 3 shows that the cross member 32 is composed of the upper sheet 36, the two distal reinforcing elements 42 and the two central reinforcing elements 46. Each distal reinforcing element 42 comprises a substantially horizontal upper surface 48 and each central reinforcing elements 46 comprises a substantially horizontal upper surface 50. These surfaces 48, 50 are dimensioned and designed to be mated with the underside of the intermediate portion 40. These surfaces 48, 50 may also be fixedly secured to the underside of the intermediate portion 40, for example by means of fastening elements piercing through attachment holes in these surfaces 48, 50.

Each reinforcing element 42, 46 is made by cutting slits in and folding a single piece of sheet metal. The two distal reinforcing elements 42 are folded to a general box shape (without bottom) having two sets of opposing vertical walls 52, 54. Flanges of the vertical walls 52 are folded to mate with, and be fixedly attached to, insides of the vertical side walls 54. The two sets of vertical walls 52, 54 thereby form a continuous frame. The distal vertical wall 52 of each distal reinforcing element 42, i.e. the wall comprising the end surface 44, has a substantially triangular, downwardly pointing, extension provided with further attachment holes for attaching the cross member 32 to a respective wall structure 22a, 22b. The vertical side walls 54 of the distal reinforcing element 42 are designed to mate with, and be fixedly attached to (e.g. by means of fastening elements), a respective inner surface of the side portions 38 of the upper sheet 36. The distal reinforcing elements 42 thereby lock the side portions 38 of the upper sheet 36 against relative movements, in particular relative movements in the second direction 18.

The two central reinforcing elements 46 are centered along the length of the upper sheet 36 as seen in the first direction 16. In addition to the horizontal upper surface 50, each central reinforcing element 46 also comprises two vertical side walls 56. When the cross member 32 is assembled, the vertical side walls 56 of the central reinforcing element 46 are mated with, and fixed to (e.g. by means of fastening elements), the inner surfaces of the side portions 38 of the upper sheet 36. Also the central reinforcing elements 46 thereby lock the side portions 38 against relative movements, in particular relative movements in the second direction 18. The vertical side walls 54 of the two distal reinforcing elements 42 and the vertical side walls 56 of the central reinforcing elements 46 may in total occupy 30 to 70%, such as 40 to 60%, such as approximately 50%, of the length of the side portions 38 in the first direction 16. Fig. 4 schematically represents a perspective bottom/front view of the cross member 32 in an assembled state. As can be seen in Fig. 4, also the two central reinforcing elements 46 are made from a single piece of sheet metal by cutting slits and folding the sheet metal into the illustrated shape. Fig. 4 also shows that the vertical walls 52, 54 of the distal reinforcing elements 42 are partly composed of overlapping sheet metal.

Each central reinforcing element 46 comprises a vertical wall 58 having a normal substantially parallel with the first direction 16. The vertical walls 58 are mated and fixedly attached to each other in order to provide additional rigidity to the upper sheet 36. The lengths of the vertical walls 58 and vertical side walls 56 of the central reinforcing elements 46 in the third direction 20 are smaller than (approximately 50% in this implementation) the length of the side portions 38 of the upper sheet 36 in the third direction 20.

Furthermore, the lengths of the inner vertical wall 52 and the vertical side walls 54 of the distal reinforcing element 42 in the third direction 20 are substantially equal to the length of the side portions 38 of the upper sheet 36 in the third direction 20.

By both adding strength to the support structure 12 (i.e. serving as a bearing member) and providing a support surface 34 to the stack 14 of electrical components, the cross member 32 according to the present disclosure is a multifunctional cross member 32. As a consequence, the number of components in the support structure 12 can be reduced and also the costs for the support structure 12 can be reduced. The strength added by the cross member 32 also contributes to the global stiffness and strength of the support structure 12 so that it can withstand dynamic forces generated for example by vibration during transport and seismic events. The cross member 32 as described herein also contributes to a lightweight, yet strong, support structure 12.

While the present disclosure has been described with reference to exemplary embodiments, it will be appreciated that the present invention is not limited to what has been described above. For example, it will be appreciated that the dimensions of the parts may be varied as needed. Accordingly, it is intended that the present invention may be limited only by the scope of the claims appended hereto.

Claims

Support structure (12) for supporting a stack (14) of electrical components, the support structure (12) comprising:

- a first wall structure (22a);

- a second wall structure (22b) opposite to the first wall structure (22a) substantially in a horizontal first direction (16); and

- a cross member (32) connected between the first wall structure (22a) and the second wall structure (22b) to add strength to the support structure (12);

wherein the cross member (32) provides a support surface (34) for the stack (14) of electrical components.

The support structure (12) according to claim 1, wherein the cross member (32) has an elongated appearance extending substantially in the first direction (16).

The support structure (12) according to claim 1 or 2, wherein the cross member (32) comprises a sheet (36) of metal that provides the support surface (34).

The support structure (12) according to any of the preceding claims, wherein the cross member (32) comprises a sheet (36) having a substantially U-shaped cross section as seen in the first direction (16).

The support structure (12) according to any of the preceding claims, wherein the cross member (32) comprises a sheet (36) having two side portions (38) substantially facing in a horizontal second direction (18), perpendicular to the first direction (16), and an intermediate portion (40) between the two side portions (38).

The support structure (12) according to claim 5, wherein the cross member (32) further comprises at least one reinforcing element (42, 46).

7· The support structure (12) according to claim 6, wherein the at least one reinforcing element (42, 46) is arranged to lock the two side portions (38) against relative movements in the second direction (18).

8. The support structure (12) according to claim 6 or 7, wherein the cross member (32) comprises two distal reinforcing elements (42).

9. The support structure (12) according to claim 8, wherein each of the two distal reinforcing elements (42) constitutes a mount for attaching the cross member (32) to the first wall structure (22a) and the second wall structure (22b), respectively.

10. The support structure (12) according to claim 8 or 9, wherein one or both of the distal reinforcing elements (42) comprise two sets of opposing and substantially vertical walls (52, 54) to form a continuous frame.

11. The support structure (12) according to any of claims 6 to 10, wherein the cross member (32) comprises at least one central reinforcing element (46).

12. The support structure (12) according to any of claims 6 to 11, wherein the at least one reinforcing element (42, 46) is made of folded sheet metal.

13. The support structure (12) according to any of the preceding claims, wherein the cross member (32) is substantially centered along the lengths of the first wall structure (22a) and the second wall structure (22b) substantially in a horizontal second direction (18), perpendicular to the first direction (16).

14. The support structure (12) according to any of the preceding claims, further comprising a base structure (24) and a top structure (26), opposite to the base structure (24) substantially in a vertical third direction (20), wherein the cross member (32) is distanced from the base structure (24) in the third direction (20). System (10) comprising a support structure (12) according to any of the preceding claims and a stack (14) of electrical components, wherein the stack (14) is supported by the support surface (34) of the cross member (32).