认识19英寸机箱与机柜

　　Get to know 19 inch chassis and cabinets

　　一、什么是19英寸机箱？19英寸机箱是一种专门设计用来安装在19英寸机柜中的设备。机柜主要分为两种：Cabinet（机柜）：四周有外壳和顶盖，提供较好的保护。Rack（机架）：没有外壳，结构更简单。19英寸机箱通常设计成长方体，并遵循统一的高度标准，这样不同厂家生产的机箱都能安装到符合规格的机柜中。

　　1、 What is a 19 inch chassis? A 19 inch chassis is a device specifically designed to be installed in a 19 inch cabinet. Cabinets are mainly divided into two types: Cabinet: surrounded by a shell and a top cover, providing better protection. Rack: Without a casing, the structure is simpler. A 19 inch chassis is usually designed as a long cube and follows a uniform height standard, so that chassis produced by different manufacturers can be installed in cabinets that meet specifications.

　　二、19英寸机箱和机柜的由来这种规格初源于美国军方的电子设备标准，目的是统一设备尺寸，方便快速安装、更换和维护。后来，这项技术被民用行业广泛采用，尤其是工业控制和网络设备领域。三、19英寸机箱的种类19英寸机箱主要分为两大类：1. 办公室用产品服务器（Server）电信设备（Telcom）网络设备（Internet/Intranet）其他计算机周边产品2. 工业用产品工业计算机（IPC）控制面板（Control Panel）其他机器辅助设备四、机柜的规格机柜的尺寸遵循国际标准（如IEC-60297和EIA-310），主要包括三个方面：1. 高度（单位：U）1U = 1.75英寸（约44.45毫米）机柜的高度用“U”表示，例如35U的机柜可以安装总高度为35U的机箱。2. 宽度标准宽度为19英寸（约482.6毫米），但机柜的实际内部宽度通常为450毫米左右，以便安装机箱。常见的机柜宽度为600毫米。3. 深度深度没有严格限制，常见的有600毫米、700毫米和800毫米。机箱的深度一般建议小于450毫米，以便留出空间散热和布线。19英寸机箱的深度制造：工艺与方法详解步：设计与规划——制造的蓝图在任何制造开始之前，精密的设计是成功的基石。三维结构设计：使用CAD软件进行3D建模，确定机箱的长、宽、高、U数，并精确规划主板安装孔、扩展卡槽、通风孔、接口开口等所有细节。此时必须充分考虑EIA-310-D或IEC-60297等标准中对安装孔距、面板尺寸的严格要求。板材展开设计：将3D模型“展开”成2D平面图，为后续的激光切割做准备。需要精确计算折弯处的拉伸和补偿，确保折弯后尺寸准确。工艺规划：确定每个零件的加工顺序，例如先冲孔后折弯，还是先折弯后攻丝。

　　2、 The origin of 19 inch chassis and cabinets originated from the electronic equipment standards of the US military, with the aim of unifying equipment dimensions, facilitating quick installation, replacement, and maintenance. Later, this technology was widely adopted by the civilian industry, especially in the fields of industrial control and network equipment. 3、 There are two main types of 19 inch chassis: 1 Office products: Server, Telcom, Internet/Intranet, and other computer peripheral products. Industrial products: IPC, Control Panel, and other machine auxiliary equipment. Cabinet specifications: The size of the cabinet follows international standards (such as IEC-60297 and EIA-310), mainly including three aspects: 1 Height (unit: U) 1U=1.75 inches (approximately 44.45 millimeters) The height of a cabinet is represented by "U", for example, a 35U cabinet can accommodate a chassis with a total height of 35U. 2. The standard width is 19 inches (approximately 482.6 millimeters), but the actual internal width of the cabinet is usually around 450 millimeters for installing the chassis. The common cabinet width is 600 millimeters. 3. There is no strict limit on depth, and common ones are 600 millimeters, 700 millimeters, and 800 millimeters. The depth of the chassis is generally recommended to be less than 450 millimeters to leave space for heat dissipation and wiring. Deep Manufacturing of 19 inch Chassis: Process and Method Explanation Step 1: Design and Planning - The Blueprint for Manufacturing Before any manufacturing begins, precise design is the cornerstone of success. 3D structural design: Use CAD software for 3D modeling, determine the length, width, height, and number of U of the chassis, and accurately plan all details such as motherboard mounting holes, expansion card slots, ventilation holes, interface openings, etc. At this point, it is necessary to fully consider the strict requirements for installation hole spacing and panel size in standards such as EIA-310-D or IEC-60297. Plate unfolding design: Unfold the 3D model into a 2D plan view to prepare for subsequent laser cutting. Accurate calculation of stretch and compensation at the bend is required to ensure accurate dimensions after bending. Process planning: Determine the processing sequence of each part, such as punching first and then bending, or bending first and then tapping.

　　第二步：钣金加工——从板材到零件这是机箱制造的核心环节，主要包括下料、冲压/钻孔和折弯。下料激光切割：这是目前主流、精密的方法。高功率激光束按照CAD图纸的路径对金属板材（通常是冷轧钢SPCC或铝合金）进行切割。优点在于切割精度高、切口光滑、灵活性强，可以轻松切割出各种复杂的通风网孔和IO接口形状。数控冲床：适用于大批量、标准化孔位的加工，效率高。但对于复杂图形的灵活性不如激光切割。现代制造中常采用激光切割与数控冲床结合的复合机，一次性完成大部分加工。成型折弯：使用数控折弯机对切割好的板材进行弯曲。操作员根据设计图纸编程，机器通过上模和下模的配合，对板材施加压力，形成精确角度的弯折。折弯的顺序和精度直接决定了机箱结构的准确性和强度。冲压：用于制作一些特定形状，如加强筋（增加板材刚性）、机箱的安装耳朵、快速拆装弹片等。螺纹加工对于需要螺丝固定的位置（如安装主板、电源），需要进行螺纹加工。攻丝：在预先钻好的孔内加工出内螺纹。压铆：预先将专用的螺母（如压铆螺母）或螺柱通过压力机牢固地压入板材中，形成强度高、不易滑牙的螺纹孔。这是高质量机箱的常见工艺。

　　Step 2: Sheet metal processing - from sheet metal to parts, this is the core process of chassis manufacturing, mainly including cutting, stamping/drilling, and bending. Laser cutting for cutting: This is currently the most mainstream and precise method. High power laser beams cut metal sheets (usually cold-rolled steel SPCC or aluminum alloys) according to the path of CAD drawings. The advantages are high cutting accuracy, smooth incision, and strong flexibility, which can easily cut various complex ventilation mesh holes and IO interface shapes. CNC punching machine: suitable for processing large quantities and standardized hole positions, with high efficiency. But its flexibility for complex shapes is not as good as laser cutting. In modern manufacturing, a composite machine combining laser cutting and CNC punching is often used to complete most of the processing in one go. Forming bending: Use a CNC bending machine to bend the cut sheet metal. The operator programs according to the design drawings, and the machine applies pressure to the sheet metal through the coordination of the upper and lower molds, forming precise angle bending. The order and accuracy of bending directly determine the accuracy and strength of the chassis structure. Stamping: used to make specific shapes, such as reinforcing ribs (to increase the rigidity of the board), installation ears for chassis, quick disassembly and assembly of spring clips, etc. Threading processing is required for positions that require screw fixation, such as installing motherboards or power supplies. Tapping: Machining internal threads into pre drilled holes. Riveting: Pre press a specialized nut (such as a rivet nut) or bolt firmly into the plate using a press, forming a high-strength, non slip threaded hole. This is a common process for high-quality chassis.

　　第三步：焊接与组装——将零件整合为一体对于结构复杂的机箱，部分部件需要通过焊接来连接。二氧化碳保护焊或氩弧焊：用于机箱主体框架的焊接，能提供较高的连接强度。点焊：适用于薄板之间的连接，热变形小。注意：焊接后通常需要进行校形处理，以焊接带来的应力变形，并打磨焊点，使其平整美观。

　　Step 3: Welding and Assembly - Integrate the parts into one. For complex chassis structures, some components need to be connected by welding. Carbon dioxide shielded welding or argon arc welding: used for welding the main frame of the chassis, which can provide high connection strength. Spot welding: suitable for connecting thin plates with minimal thermal deformation. Attention: After welding, it is usually necessary to perform shape correction treatment to eliminate stress deformation caused by welding, and polish the welding points to make them flat and beautiful.

　　第四步：表面处理——防护与美观表面处理关重要，它能防止金属生锈、腐蚀，并赋予机箱终的外观。前处理：包括脱脂（去除油污）、酸洗（去除锈迹）和磷化（在金属表面形成一层磷酸盐保护膜，增强油漆附着力）。喷涂：粉末喷涂：这是机箱常用的表面处理方式。通过静电吸附将干燥的塑料粉末附着在工件表面，然后经过高温烘烤，粉末熔融固化形成一层坚固、耐用、美观的涂层。优点是无溶剂、、涂层厚、耐磨耐腐蚀。电泳：主要用于底漆，提供均匀的防锈保护。其他处理：丝网印刷：在机箱面板上印刷Logo、指示灯标识、接口名称等。阳极氧化：主要用于铝合金机箱，形成一层坚硬、耐磨、耐腐蚀的氧化层，并可染成各种颜色。

　　Step 4: Surface Treatment - Protective and Aesthetic Surface treatment is crucial as it can prevent metal rusting and corrosion, and give the chassis its final appearance. Pre treatment: including degreasing (removing oil stains), acid washing (removing rust), and phosphating (forming a layer of phosphate protective film on the metal surface to enhance paint adhesion). Spray coating: Powder coating: This is the most commonly used surface treatment method for chassis. Dry plastic powder is attached to the surface of the workpiece through electrostatic adsorption, and then baked at high temperature. The powder melts and solidifies to form a strong, durable, and aesthetically pleasing coating. The advantages are solvent-free, environmentally friendly, thick coating, and wear and corrosion resistance. Electrophoresis: mainly used for primer, providing uniform rust protection. Other processing: Screen printing: Printing logos, indicator lights, interface names, etc. on the chassis panel. Anodizing: mainly used for aluminum alloy chassis to form a hard, wear-resistant, and corrosion-resistant oxide layer, which can be dyed in various colors.

　　第五步：总装与检验——终的质量关卡总装：将经过表面处理的所有金属结构件、预先采购的标准件（如硬盘架、风扇、导轨、把手、脚垫）和绝缘件（如主板铜柱）按照工艺要求组装起来。电磁兼容性设计：高端机箱会在此环节安装EMI弹片。这些弹片通常由铍铜制成，具有良好的导电性和弹性，安装在机箱盖板与主体的接合处，用于屏蔽内部电子设备产生的高频电磁辐射，防止其泄漏干扰其他设备，也防止外部干扰进入。终检验：尺寸检验：使用卡尺、高度规等工具检验关键安装尺寸是否符合标准。外观检验：检查表面是否有划伤、色差、脏污等瑕疵。装配检验：模拟安装主板、扩展卡等，检查是否存在干涉，螺丝孔位是否对齐。接地电阻测试：检验机箱的接地是否良好，确保使用。

　　Step 5: Assembly and Inspection - Final Quality Level Assembly: Assemble all surface treated metal structural components, pre purchased standard components (such as hard drive racks, fans, rails, handles, floor mats), and insulation components (such as motherboard copper columns) according to process requirements. Electromagnetic compatibility design: High end chassis will install EMI shrapnel at this stage. These shrapnel are usually made of beryllium copper, which has good conductivity and elasticity. They are installed at the junction of the chassis cover and the main body to shield the high-frequency electromagnetic radiation generated by internal electronic devices, prevent leakage and interference with other devices, and also prevent external interference from entering. Final inspection: Dimensional inspection: Use tools such as calipers and height gauges to check whether the key installation dimensions meet the standards. Appearance inspection: Check the surface for scratches, color differences, dirt, and other defects. Assembly inspection: Simulate the installation of motherboards, expansion cards, etc., and check for interference and alignment of screw holes. Grounding resistance test: Check whether the grounding of the chassis is good to ensure safe use.

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