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Integrated Mechanical Design

Special Design for OperationMechanism

Apply the plug-aided and pull-aidedmethod in the design of hard disk modules, PCB plug-in units, memory modulesand other plug-in modules, compute motion displacement, and accurately ensurethe connector to be inserted and plugged safely. Experience accumulated from morethan 30 relevant cases has been collected for this design.

 



 

Strength/Rigidity/MechanicalLife Design and Simulation

High - strength stainless steel hinge design. The maximum load can withstand 100 kg of gravity. Suitable for indoor and outdoor cabinets, can afford air conditioning or heat exchange units.

Design of 25 kg heavy - duty module puller. The deadweight friction of the module is superimposed on the connector insertion force of the back plate 13, and the force to pull out the module to disengage the connector exceeds 50 kg. Therefore, in the calculation of the upper and lower ends of the module design of the two large puller, puller and base using zinc alloy casting molding.

High strength backplane design. Highly Configured Rack The front and back of the server are connected to the backplane or the module, and the insertion or removal force of the board or module is large. The rigidity of the backplane alone can greatly deform the insertion force of the board.


 

MovementMechanism Deign

It adoptstranslatingmechanism. In some special applications, module assembly adopts irregularassembly design to meet the requirements of large or overweight hardware. Afterbeing insertedintothe chassis,PCBthat installed on the same tray shall be translated to theleft for more than23mmthroughgear-rack mechanismand then buttjointed withthe mated PCB by connectors. The technicaldifficulties lie not only in arranging the whole translating mechanism, butalso in keeping the left and right PCB aligned precisely and matched reliably



 

Carbon fiber composite process

Brief introduction of carbon fiber composites
Carbon fiber composite is a new kind of fiber material with high carbon content and high modulus fiber with carbon content of more than 95%. Carbon fiber has many excellent properties, such as high axial strength and modulus, low density, no creep, high temperature resistance and good fatigue resistance in non oxidation environment. Carbon fiber also has good conductivity, thermal conductivity and electromagnetic shielding performance.

Carbon fiber composite products
1. carbon fiber composite products to break the traditional raw materials and process design limitations, using composite material has the advantages of light weight, high strength ratio, load ratio, corrosion resistance, impact resistance, strong environmental adaptability and high cost etc..

2. carbon fiber composites with sufficient strength and stiffness are the lightest materials for making car bodies. Now it is widely used in automobile field.

3. carbon fiber strength toughness of the composites are better than the traditional ordinary plastic, can use thin material to achieve high strength parts production, the weight and strength of the metal is much lighter than the same, so the use of carbon fiber technology in uav.


MechanicalReliabilityDesign

“Mechanical reliability mainlyconsiders about strength of mechanism and any failure led by fatigue, abrasionand fracture owing to the influence of loading; while mechanism reliabilitymainly considers about the faults caused by problems on kinematics during mechanismmotion instead of failure owing to strength problem. Redundancy design is meantto set spare mechanism or parts for finishing regulated functions, in order toprevent the whole machine or the system from losing the regular functions whenlocal mechanism has some unexpected faults. If the reliability specificationsof some mechanical assemblies are relatively higher beyond present technicallevel, such as adopting derating design, simplified design and other reliabledesign methods, or the cost for improving the reliability of spare parts ishigher than that for repeated configuration, redundancy design is able to be agood or relatively good design method, e.g. adopting mechanical system withdouble-pump or double-engine. What’s more, it shall be noted that the volume,weight and cost for the entire machine will increase by applying redundancydesign. Redundancy design will reduce the basic reliability of the mechanicalsystem while raising its task reliability; thus please be prudent when applyingredundancy design.”

DFX

Meaning of DFX

DFX is short for “Design for X”.X represents life cycle of the product or one of the links; or productcompetitiveness or factors determining the competitiveness of the product.

Design refers to not only theproduct design, but also design for product development process and the system.
DFA——Design for Assembly;
DFC——Design for Cost;
DFE——Design For Environment;
DFEA——Design For Engineering Analysis;
DFI——Design for Inspection;
DFM——Design for Manufacture;
DFR——Design For Reliability;
DFS——Design for Service/Maintain/Repair;


DFM –Design for Manufacture

Principles:

1.Simplify the shape of parts
2. Avoid adopting machining technology with high cost   
3. Select materials easy to be processed
4. Set relatively big tolerance
5. Adopt standard andoutsourcingparts
6. Reduce unnecessaryprecision requirements


DFA –Design for Assembly

Principles:

1. Reduce the number of parts

2. Adopt standard fasteners and otherstandard parts

3. Remain the directions of parts

4. Adopt modularized parts

5. Try to design parts that can bedirectly inserted

6. Try to reduce the necessity to makeadjustment


DFS–Design for Service

Principles:

1. Increase product reliability

2. Place theparts of high maintenance frequency or easy to be worn or disable in a placeeasily to be found or nearby

3. Avoid moving other parts when removingsome parts

4. Try to reduce the types of maintenancetools

5. Adopt modularized design and standardparts

6. Reserve enough maintenance space

Mechanical Reliability Design

EMC Design (electromagneticshielding design)

Chassis-level EMC design.Assemble the body and cover ofchassis with screws or rivets, and fill the gaps between the chassis body andPCBs with conductive fabric or reeds, which achieve the complete electricconnection among these parts. The chassis shell will form into a continuous andseamless conductor.

Module-level EMC design.Conductivefabric or shielding reeds shall be adhered or installed to one side of themodule, and electric-continuous contact shall be formed when the product isinserted into chassis and adjacent modules or inner wall of the chassis. In thefigure, shielding reeds are pasted on the upper part of the front panel.EMC standard class (for mechanical shell);EMC for machinery shells of different EMC standards (as for machineryshells) will increase in light of different costs.EMxxx210x——25% ——Small-boxproduct;EMxxx210x——25% —— Large andmiddle-sized plug-in box product;EMxxx654x——300%~500% ——RF product;Figure/EMCstandards for different grades (for the whole machine)




Safety Standard Design

Safety Standard Design aims at avoidhuman or property loss or harm caused by the following risks:

IP protection–dust-proof; inner side of air inlet of the server chassis shall adopt 50PPIdust mesh to keep dust out.
 

IP protection–water-proof; water-proof groove with water-proof/shielding rubber ring shall bedesigned on the flange surface of the chassis. Rubber ring can be compacted forwater-proof and electromagnetic shielding.

IPprotection – water-proof; water-proof groove with water-proof and shieldingrubber ring shall be designed on the flange surface of the chassis. Upper boxof the equipment shall be covered to make rubber rings between upper and lowerchassis compacted, and also ensure the waterproof and electromagnetic shieldingfunctions.  

一、Electric Shock

二、Energy Related Hazards

三、Fire Hazards

四、Heat Related Hazards

五、Mechanical Hazards

六、Radiation Hazards

七、Chemical Hazards



Package Design

Suitable packing scheme shall bedetermined by product characteristics. After investigating the overall processof packing and transportation, wooden box design for transportation of largeequipment shall give advices to the mechanical design engineers during theproduct development. The fast unlock mechanism available for over 100 times,and universal pallet compatible to all kinds of forklifts and any fork-intodirections are adopted in the design of wooden case.The package shall becapable of bearing weight of more than800kg;equipment inside the package shall be fixed by EPE material to resist shakingduring transportation.


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