A power module of intelligent power distribution cabinet matched with UPS
By designing intelligent power distribution cabinets and UPS power modules, synchronous parallel power supply and zero-delay switching of dual power sources are achieved, solving the problems of power outages and equipment damage in existing technologies and improving power supply stability and energy efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- SHANDONG NEW CONTINENT ELECTRIC POWER CO LTD
- Filing Date
- 2026-03-04
- Publication Date
- 2026-05-29
AI Technical Summary
Existing UPS systems and distribution cabinets cannot achieve unified power supply management, resulting in problems such as power outages, inrush currents, circulating currents damaging equipment, and load balancing control. They cannot meet the zero-delay uninterrupted power supply requirements of precision loads.
Design a power module that works with an intelligent power distribution cabinet and a UPS. The module enables dual-path parallel power supply through a connection module, uses a load balancing module for dynamic control, and combines power regulation and communication terminals to achieve synchronous parallel operation and zero-delay switching of the two power sources. It also features hardware interlocking protection.
It enables seamless switching between intelligent power distribution cabinets and UPS, load balancing control, improves power supply stability and energy efficiency, avoids power outages and equipment damage, and is compatible with existing equipment without modification.
Smart Images
Figure CN122119085A_ABST
Abstract
Description
Technical Field
[0001] This invention specifically relates to a power module that works in conjunction with an intelligent power distribution cabinet and a UPS, belonging to the field of intelligent power module technology. Background Technology
[0002] With the rapid development of electronic equipment and information technology, the demand for uninterruptible power supplies (UPS) is increasing across various industries. UPS systems play a crucial role in ensuring continuous power supply to computers, communication equipment, and other critical equipment, especially in data centers, medical facilities, and industrial control systems. Modern UPS systems not only need to provide stable power output but also possess intelligent management capabilities to adapt to dynamically changing load demands and environmental conditions. For example, Chinese Patent Publication No. CN118971325B discloses a UPS power supply and its intelligent power supply method. The UPS module is responsible for power management and switching to ensure uninterrupted power supply, while temperature and current sensors in the sensor module monitor ambient temperature and power consumption data of each load in real time. These data are transmitted to the intelligent control system for real-time analysis and adjustment of power supply strategies. Existing UPS systems require separate access to the mains power supply line, independent of the power supply link of the distribution cabinet, making unified management of upstream power supply impossible. Conventional UPS systems use hardware interlocking to switch power supplies with the mains power, resulting in millisecond-level power interruptions during the switching process. This cannot meet the zero-latency uninterrupted power supply requirements of precision loads and sensitive electronic equipment, nor can it achieve parallel energy-saving operation of dual power supplies. In addition, existing technologies cannot achieve coordinated operation between the distribution cabinet and UPS. When switching between the two, inrush currents and circulating currents are easily generated, damaging the power supply equipment. Furthermore, the overall power module cannot be load balanced, and problems such as distribution cabinet overload, unreasonable UPS charging and discharging, and low energy efficiency under light load cannot be autonomously controlled. Summary of the Invention
[0003] To address the aforementioned issues, this invention proposes a power module that integrates an intelligent power distribution cabinet with a UPS, enabling parallel power supply from both the intelligent power distribution cabinet and the UPS, allowing for seamless switching with zero delay in the event of a mains power failure. The load balancing submodule performs dynamic balancing control of the system, improving energy efficiency and power supply stability.
[0004] The intelligent power distribution cabinet and UPS power module of the present invention includes an intelligent power distribution cabinet and a UPS, and further includes a connection module. The connection module includes a housing, and a connection body is installed inside the housing. The connection body includes: The main control unit for overall machine control has a built-in load balancing module. Power input and output terminals, which are respectively connected to a set of output terminals of the intelligent power distribution cabinet, the input and output terminals of the UPS, and the load connection terminals; The communication terminal has an input side that connects to the communication interface of the intelligent power distribution cabinet and the communication interface of the UPS via data cables; the output side of the communication terminal is connected to the main control unit via a communication protocol conversion unit. A power regulation module, wherein the power input and output terminals are connected to the power regulation module; The acquisition module includes a power acquisition module, a switch status acquisition module, and a temperature and insulation acquisition module; the power acquisition module is connected to the power regulation module. The power acquisition module is connected to the output synchronization and coordination module and the main control unit.
[0005] The power input and output terminals include mains terminals, distribution cabinet docking terminals, UPS docking terminals, and load terminals; the communication terminals include distribution cabinet communication terminals and UPS communication terminals. The power regulation module consists of multiple physically separated and electrically isolated power buses, which include: The mains input bus has one end rigidly connected to the mains terminal and the other end connected to the fourth contactor via a bypass fuse. The mains input bus provides both internal power supply and bypass power supply for the connection module (to temporarily supply power to the load during the maintenance of the connection module). The distribution cabinet access bus is connected at one end to the distribution cabinet docking terminal and at the other end to the first contactor and the second contactor. The distribution cabinet access bus receives power output from a branch of the intelligent distribution cabinet in one direction and is divided into two independent branches internally. Branch one is rigidly connected to the load bus via the first contactor, and branch two is connected to the UPS transfer bus via the second contactor, thereby supplying power to the UPS transfer bus. The UPS transfer bus has one end connected to the input terminal of the UPS docking terminal and the other end connected to the output terminal of the second contactor. The UPS transfer bus is rigidly connected to the input side of the UPS docking terminal and transmits power from the intelligent power distribution cabinet to the UPS in one direction, providing the UPS with rectification and charging power. It has no direct electrical connection with other buses. UPS inverter bus; one end of the UPS inverter bus is connected to the output terminal of the UPS docking terminal, and the other end is connected to a third contactor; the UPS inverter bus is externally connected to the inverter output side of the UPS docking terminal, receiving UPS inverter power in one direction; internally, it is connected to the load bus via the third contactor. The load bus is connected to the output terminals of the first, third, and fourth contactors. The load bus is connected to the load terminals. The first, third, and fourth contactors are equipped with hardware mechanical interlocking or electrical interlocking. The load bus is rigidly connected to the load terminals externally and internally gathers three inputs from the first, third, and fourth contactors. The first and third contactors can close synchronously when synchronization is achieved, and are forcibly interlocked when synchronization fails, allowing only one path to be effectively connected at any given time. When the power module needs to be maintained or repaired, the mains power is directly connected to the load bus via the fourth contactor. When the fourth contactor is engaged, all contacts from the first to the third are forcibly locked by hardware, forming an independent internal direct path. By integrating two interconnected modules, without modifying the intelligent power distribution cabinet and UPS, or adding external wiring terminals, it achieves power supply control between the intelligent power distribution cabinet and UPS, synchronous parallel dual-output, zero-delay seamless switching, and intelligent load balancing. There are no new, split, or redundant terminals; a total of six external interfaces are provided: the AC power terminal only provides independent AC power to the independent switch isolation power supply and maintenance bypass within the module, without outputting power externally; the power distribution cabinet connection terminal unidirectionally receives output from a specific power distribution branch of the power distribution cabinet; the UPS connection terminal is bidirectional, capable of sending power from the power distribution cabinet to the UPS, receiving the UPS inverter power after processing, and the load terminal serves as the sole interface for load power supply; the main control unit... The power module is responsible for overall control, load balancing calculation, and command distribution. The power acquisition module is connected point-to-point to the mains input bus, distribution cabinet access bus, UPS transfer bus, UPS inverter bus, and load bus via shielded differential wiring harnesses. It collects voltage, current, active power, phase, and harmonic data of each bus in real time and transmits the collected signals unidirectionally to the main control unit and output synchronization module. The switch status acquisition module is connected to the auxiliary contacts of the first to fourth contactors via auxiliary contact wiring harnesses. It collects the on / off status of the contactors in real time and transmits the signals to the main control unit and the collaborative safety interlocking unit. The temperature and insulation acquisition module is attached to the surface of each bus and collects the bus temperature rise and insulation parameters. The signals are transmitted unidirectionally to the main control unit.
[0006] The power module works as follows: 1. Mains Power Normal Synchronous Parallel Energy Saving Mode: The intelligent distribution cabinet independently connects to the mains power and outputs stable industrial frequency power, which is input to the distribution cabinet's connection bus via the distribution cabinet's docking terminals; the first and second contactors engage synchronously, one path of power is transmitted to the load bus via the first contactor, and the other path is connected to the UPS transfer bus via the second contactor to provide power to the load and provide mains power input to the UPS, allowing the UPS to complete rectification and battery charging; the output synchronization and coordination module starts, using the mains power from the distribution cabinet's connection bus as the reference source, and uses a digital phase-locked loop algorithm to achieve phase and frequency closed-loop tracking of the UPS inverter output, through incremental... The PID algorithm achieves synchronous voltage amplitude regulation, controlling the phase difference between the two power supplies within 0.1° and the amplitude deviation within ±1%. The circulating current detection and suppression unit monitors the parallel circulating current in real time and controls the circulating current within 2% of the rated current through negative feedback regulation. After the synchronous verification is passed, the third contactor engages synchronously, and the output of the intelligent distribution cabinet and the output of the UPS inverter supply power to the load synchronously and in parallel. The load balancing module adjusts the power distribution in real time, so that the UPS operates in the optimal load range of 60%-70%, while controlling the UPS charging power to avoid overloading the intelligent distribution cabinet and achieve energy-saving operation of the power module.
[0007] 2. Zero-delay seamless switching mode for mains power failure: When the mains power is interrupted and the intelligent distribution cabinet stops outputting, the output synchronization module instantly detects the loss of the reference source and immediately switches the UPS from synchronous tracking mode to independent voltage regulation inverter mode; when the bus connected to the distribution cabinet loses power, the first and second contactors automatically disconnect, while the third contactor remains closed, and the load is powered by the UPS inverter throughout the process; the entire process is without contactor action delay, voltage drop, or power interruption, and the load is completely unaware of it, achieving zero-delay seamless switching; after the switching is completed, the load balancing module starts UPS load rate optimization, tieredly cuts off non-core loads, and extends backup time.
[0008] 3. Synchronous fault fallback mode: If the phase or amplitude of the dual power supply exceeds the standard or the circulating current exceeds the limit, the synchronization verification and fault interlocking unit will immediately trigger the hardware interlock, terminate the synchronization adjustment, forcibly disconnect the third contactor, restore the hardware interlocking mechanism between the first and third contactors, and switch to the traditional single power supply mode to ensure the safe operation of the system.
[0009] 4. Maintenance Bypass Mode: After the maintenance bypass is triggered, the fourth contactor engages, and all contactors from the first to the third are hardware locked. The mains power is directly supplied to the load through the mains power input bus. The power distribution cabinet and UPS can be powered off for maintenance without interrupting the power supply to the load.
[0010] Furthermore, the output synchronization and coordination module includes a coordination controller, which is connected to a synchronization verification and fault interlocking unit, a dual-channel synchronous high-speed sampling unit, a digital phase-locked loop control unit, an amplitude closed-loop adjustment unit, and a circulating current detection and suppression unit. The coordination controller and the main control unit can use a unified controller. The acquisition terminals of the dual-channel synchronous high-speed sampling unit are connected to the distribution cabinet access bus and the UPS inverter bus, respectively. The dual-channel synchronous high-speed sampling unit synchronously acquires the electrical parameters of the distribution cabinet access bus and the UPS inverter bus. Using the electrical parameters of the distribution cabinet access bus as a reference source, the digital phase-locked loop control and amplitude closed-loop control are completed through the digital phase-locked loop control unit and the amplitude closed-loop adjustment unit to achieve closed-loop synchronization of the frequency, phase, and amplitude of the dual power supplies of the distribution cabinet access bus and the UPS inverter bus. The main control unit is in synchronous output mode.
[0011] Data Acquisition: The dual-channel synchronous high-speed sampling unit is directly connected to the power distribution cabinet access bus and the UPS inverter bus via a dedicated shielded cable harness, enabling high-speed synchronous acquisition of dual-channel electrical parameters from the same source. Control Connection: The digital phase-locked loop control unit and amplitude closed-loop adjustment unit interact bidirectionally with the main control unit via an internal high-speed CAN bus; the synchronization verification and fault interlocking unit is directly connected to the interlocking circuit of the collaborative safety interlocking unit through hardware dry contacts, that is, the coil drive circuit of the first to fourth contactors is connected in series in hardware, which can independently cut off the contactor drive power supply and is not affected by the control of the main control unit; in the event of a synchronization fault, hardware-level forced protection can be triggered, and the output interlock power supply mode can be entered. Command issuance connection: The main control unit converts data through the communication protocol conversion unit and issues synchronous adjustment commands for phase, frequency, and amplitude to the UPS through the UPS communication terminals.
[0012] Furthermore, when the input or output of the output synchronization and coordination module is abnormal, the main control unit switches from the synchronous coordination output mode to the output interlock power supply mode. The output interlock power supply mode is an interlocked power supply mode in which the main control unit controls one of the first contactor and the third contactor to be turned on while the other is turned off.
[0013] Furthermore, the connection body also includes an independent switch isolation power supply. The input end of the independent switch isolation power supply is rigidly connected to the mains input bus. The output side of the independent switch power supply provides isolated uninterrupted power supply for all control, acquisition, synchronization and coordination and communication within the connection body. The independent switch isolation power supply is completely electrically isolated from the power regulation module.
[0014] Furthermore, the load balancing module acquires the collected power data, processes the power data and determines thresholds, and outputs control data. This control data is forwarded to the intelligent distribution cabinet and UPS via communication terminals to complete heavy load suppression, UPS charging current limiting, light load energy efficiency optimization, and backup load rate regulation. The load balancing module is integrated within the main control unit and uses a 100ms scheduling cycle to execute closed-loop balancing control, specifically as follows: Data preprocessing: Real-time power data is acquired and a moving average filtering algorithm is used to remove noise and abnormal data to ensure the reliability of the data source; Dynamic threshold calibration: Based on the rated parameters of the intelligent power distribution cabinet and UPS, calculate dynamic thresholds such as heavy load warning, overload protection, and optimal load capacity in real time to adapt to different equipment specifications; Overload suppression and control: When the output of the distribution cabinet exceeds the threshold, an instruction is issued to cut off non-core loads, while reducing the UPS charging power and releasing the upstream power supply capacity. Charging power balancing: The incremental PID algorithm is used to dynamically adjust the UPS charging power to avoid excessive use of the power distribution cabinet capacity by the charging power. Light load energy efficiency optimization: Under light load conditions, the redundant branches of the control cabinet are disconnected or the UPS is controlled to enter energy-saving standby mode to reduce system losses; Closed-loop verification: The execution effect is verified in real time after the command is issued. In case of an anomaly, a resend and alarm mechanism is activated to ensure balanced and effective execution.
[0015] Furthermore, the outer casing is equipped with a grounding maintenance port and an internal maintenance button connected to the main control unit. During operation, pressing the internal maintenance button enters the maintenance bypass mode, and the mains power is directly supplied to the load through the mains power input bus. This allows for power-off maintenance of the distribution cabinet and UPS without interrupting the load power supply. During maintenance, the maintenance data of the power module can be obtained by connecting to the maintenance terminal through the local maintenance port.
[0016] Furthermore, the communication protocol conversion unit has a built-in multi-protocol parsing engine, compatible with Modbus RTU, Modbus TCP, SNMP, IEC61850, and various types of UPS proprietary protocols. The communication protocol conversion unit automatically identifies and converts heterogeneous data between the intelligent power distribution cabinet and the UPS, completing bidirectional data transmission between the main control unit and the intelligent power distribution cabinet and the UPS. The communication protocol conversion unit is rigidly connected to the communication terminals of the power distribution cabinet and the UPS externally, and internally it is only bidirectionally connected to the main control unit to complete heterogeneous protocol parsing and command translation, without any electrical connection to the power link.
[0017] Furthermore, the communication protocol conversion unit also includes a protocol update interface, which completes the update of the UPS private protocol; the UPS private protocol can be updated through the protocol update interface, thereby adapting to mainstream UPSs on the market.
[0018] Furthermore, a UPS type selection button is provided on the outer casing. When the UPS type selection button is pressed, the main control unit obtains the selection data, obtains the UPS type, and sends the selection data to the communication protocol conversion unit. After obtaining the selection data, the communication protocol conversion unit selects the UPS private protocol that is compatible with it.
[0019] Compared with the prior art, the intelligent power distribution cabinet and UPS power module of the present invention have the following advantages: 1. The connection module can integrate intelligent power distribution cabinet and UPS. The power distribution output branch of the intelligent power distribution cabinet is uniformly powered by the UPS. The UPS does not need a separate mains power line and only has six sets of external terminals. There is no extra wiring complexity during on-site construction, and it is compatible with existing standard equipment without modification.
[0020] 2. Enables simultaneous parallel output from both intelligent power distribution cabinet and UPS, eliminating the need for hardware interlocking during mains power failures, achieving zero-delay uninterrupted power supply without load awareness, and completely eliminating the power outage problem of traditional switching methods.
[0021] 3. Dual-path parallel operation can achieve reasonable distribution of load power, enabling the UPS to operate in the optimal load range, reducing system energy consumption, reducing battery charging and discharging frequency, and extending UPS lifespan.
[0022] 4. Excellent operational safety performance. It adopts a three-level operation mode, with the highest priority being the dual-path parallel synchronous load. When a synchronization failure occurs, the output interlock power supply mode provides a safety backup. The output interlock power supply mode provides hardware interlock protection. When the connected module fails, it can switch to bypass power supply. The system has high operational safety and ensures uninterrupted power supply. Attached Figure Description
[0023] Figure 1 This is a wiring diagram of the intelligent power distribution cabinet, UPS, and connection module of the present invention.
[0024] Figure 2 This is a schematic diagram of the overall structure of the power module of the intelligent power distribution cabinet and UPS of the present invention.
[0025] Figure 3 This is a schematic diagram of the overall structure of the output synchronization and coordination module of the present invention.
[0026] Figure 4 This is a schematic diagram of the mode selection process of the present invention.
[0027] Figure 5 This is a schematic diagram of the normal synchronous parallel energy-saving mode of the mains power supply according to the present invention.
[0028] Figure 6 This is a schematic diagram of the zero-delay seamless switching mode for mains power failures according to the present invention.
[0029] Figure 7 This is a schematic diagram of the synchronous fault fallback mode of the present invention.
[0030] Figure 8 This is a schematic diagram of the maintenance bypass mode of the present invention. Detailed Implementation
[0031] Example 1: like Figures 1 to 8 The power module shown, which works with the intelligent power distribution cabinet and UPS, includes the intelligent power distribution cabinet and the UPS, and also includes a connection module. The connection module includes a housing, and a connection body is installed inside the housing. The connection body includes: The main control unit for overall machine control has a built-in load balancing module. Power input and output terminals, which are respectively connected to a set of output terminals of the intelligent power distribution cabinet, the input and output terminals of the UPS, and the load connection terminals; The communication terminal has an input side that connects to the communication interface of the intelligent power distribution cabinet and the communication interface of the UPS via data cables; the output side of the communication terminal is connected to the main control unit via a communication protocol conversion unit. A power regulation module, wherein the power input and output terminals are connected to the power regulation module; The acquisition module includes a power acquisition module, a switch status acquisition module, and a temperature and insulation acquisition module; the power acquisition module is connected to the power regulation module. The power acquisition module is connected to the output synchronization and coordination module and the main control unit.
[0032] The power input and output terminals include mains terminals, distribution cabinet docking terminals, UPS docking terminals, and load terminals; the communication terminals include distribution cabinet communication terminals and UPS communication terminals. The power regulation module consists of multiple physically separated and electrically isolated power buses, which include: The mains input bus has one end rigidly connected to the mains terminal and the other end connected to the fourth contactor via a bypass fuse. The mains input bus provides both internal power supply and bypass power supply for the connection module (to temporarily supply power to the load during the maintenance of the connection module). The distribution cabinet access bus is connected at one end to the distribution cabinet docking terminal and at the other end to the first contactor and the second contactor. The distribution cabinet access bus receives power output from a branch of the intelligent distribution cabinet in one direction and is divided into two independent branches internally. Branch one is rigidly connected to the load bus via the first contactor, and branch two is connected to the UPS transfer bus via the second contactor, thereby supplying power to the UPS transfer bus. The UPS transfer bus has one end connected to the input terminal of the UPS docking terminal and the other end connected to the output terminal of the second contactor. The UPS transfer bus is rigidly connected to the input side of the UPS docking terminal and transmits power from the intelligent power distribution cabinet to the UPS in one direction, providing the UPS with rectification and charging power. It has no direct electrical connection with other buses. UPS inverter bus; one end of the UPS inverter bus is connected to the output terminal of the UPS docking terminal, and the other end is connected to a third contactor; the UPS inverter bus is externally connected to the inverter output side of the UPS docking terminal, receiving UPS inverter power in one direction; internally, it is connected to the load bus via the third contactor. The load bus is connected to the output terminals of the first, third, and fourth contactors. The load bus is connected to the load terminals. The first, third, and fourth contactors are equipped with hardware mechanical interlocking or electrical interlocking. The load bus is rigidly connected to the load terminals externally and internally gathers three inputs from the first, third, and fourth contactors. The first and third contactors can close synchronously when synchronization is achieved, and are forcibly interlocked when synchronization fails, allowing only one path to be effectively connected at any given time. When the power module needs to be maintained or repaired, the mains power is directly connected to the load bus via the fourth contactor. When the fourth contactor is engaged, all contacts from the first to the third are forcibly locked by hardware, forming an independent internal direct path. By integrating two interconnected modules, without modifying the intelligent power distribution cabinet and UPS, or adding external wiring terminals, it achieves power supply control between the intelligent power distribution cabinet and UPS, synchronous parallel dual-output, zero-delay seamless switching, and intelligent load balancing. There are no new, split, or redundant terminals; a total of six external interfaces are provided: the AC power terminal only provides independent AC power to the independent switch isolation power supply and maintenance bypass within the module, without outputting power externally; the power distribution cabinet connection terminal unidirectionally receives output from a specific power distribution branch of the power distribution cabinet; the UPS connection terminal is bidirectional, capable of sending power from the power distribution cabinet to the UPS, receiving the UPS inverter power after processing, and the load terminal serves as the sole interface for load power supply; the main control unit... The power module is responsible for overall control, load balancing calculation, and command distribution. The power acquisition module is connected point-to-point to the mains input bus, distribution cabinet access bus, UPS transfer bus, UPS inverter bus, and load bus via shielded differential wiring harnesses. It collects voltage, current, active power, phase, and harmonic data of each bus in real time and transmits the collected signals unidirectionally to the main control unit and output synchronization module. The switch status acquisition module is connected to the auxiliary contacts of the first to fourth contactors via auxiliary contact wiring harnesses. It collects the on / off status of the contactors in real time and transmits the signals to the main control unit and the collaborative safety interlocking unit. The temperature and insulation acquisition module is attached to the surface of each bus and collects the bus temperature rise and insulation parameters. The signals are transmitted unidirectionally to the main control unit.
[0033] The power module works as follows: 1. Mains Power Normal Synchronous Parallel Energy Saving Mode: The intelligent distribution cabinet independently connects to the mains power and outputs stable industrial frequency power, which is input to the distribution cabinet bus via the distribution cabinet docking terminals; the first and second contactors engage synchronously, one power path is transmitted to the load bus via the first contactor, and the other path is connected to the UPS transfer bus via the second contactor to provide power to the load and provide mains power input to the UPS, enabling the UPS to complete rectification and battery charging; the output synchronization and coordination module starts, using the mains power from the distribution cabinet bus as the reference source, and uses a digital phase-locked loop algorithm to achieve phase and frequency closed-loop tracking of the UPS inverter output, and uses an incremental PID algorithm to achieve synchronous voltage amplitude adjustment, controlling the phase difference between the two power supplies within 0.1° and the amplitude deviation within ±1%; the circulating current detection and suppression unit monitors the parallel circulating current in real time, and controls the circulating current within 2% of the rated current through negative feedback adjustment; after the synchronization verification is passed, the third contactor engages synchronously, and the intelligent distribution cabinet output and the UPS inverter output supply power to the load synchronously and in parallel; specifically: Using the data collected from the input distribution cabinet's busbar as the reference signal, the UPS inverter output serves as the tracking signal. Next, the difference between the real-time phase angle of the reference source and the real-time phase angle of the UPS inverter is calculated, and the digital phase detector outputs the phase error value. Then, the phase error value is filtered using a second-order digital low-pass filter to remove harmonics and noise. The filtered error signal drives frequency adjustment, resulting in the UPS inverter frequency adjustment amount. The output synchronization module performs closed-loop adjustment based on the target adjustment amount, ensuring a steady-state phase difference ≤ 0.1° and a frequency deviation ≤ 0.01Hz. Finally, the difference between the amplitude of the reference signal and the amplitude of the tracking signal is calculated to obtain the amplitude deviation, and incremental PID control is used to achieve closed-loop amplitude adjustment of the UPS output amplitude, ensuring a steady-state amplitude deviation ≤ ±1%. The circulating current is the differential current after the two parallel circuits are connected. The effective value of the circulating current is monitored and calculated in real time. When the effective value of the circulating current exceeds 5% of the rated current, the circulating current suppression unit is activated. By adjusting the phase and amplitude, the circulating current is forcibly reduced to within the safe threshold value. The output synchronization module performs synchronization verification with a period of 50ms. When any of the following conditions occurs for 3 consecutive verification cycles: phase difference > 0.1°, amplitude deviation > ±1%, or circulating current > 5%, synchronization is determined to be failed. The module immediately switches from synchronization tracking mode to independent voltage regulation inverter mode, terminates synchronization adjustment, and sends a stop tracking command to the UPS. A hard interlock signal is sent to the safety interlock unit to disconnect the third contactor and restore the original hardware interlock mode of the first and third contactors to ensure the overall safety of the power module.
[0034] The load balancing module adjusts the power distribution in real time, so that the UPS operates in the optimal load range of 60%-70%, avoiding overload of the intelligent power distribution cabinet and realizing energy-saving operation of the power module. At the same time, it manages the UPS charging power to avoid the UPS charging power occupying too much power distribution cabinet capacity, resulting in insufficient power supply to the load. It stabilizes the charging power at 40%~60% of the rated value, which ensures battery charging efficiency and reserves enough power to supply the load.
[0035] 2. Zero-delay seamless switching mode for mains power failure: When the mains power is interrupted and the intelligent distribution cabinet stops outputting, the output synchronization module instantly detects the loss of the reference source and immediately switches the UPS from synchronous tracking mode to independent voltage regulation inverter mode; when the bus connected to the distribution cabinet loses power, the first and second contactors automatically disconnect, while the third contactor remains closed, and the load is powered by the UPS inverter throughout the process; the entire process is without contactor action delay, voltage drop, or power interruption, and the load is completely unaware of it, achieving zero-delay seamless switching; after the switching is completed, the load balancing module starts UPS load rate optimization, tieredly cuts off non-core loads, and extends backup time.
[0036] 3. Synchronous fault fallback mode: If the phase or amplitude of the dual power supply exceeds the standard or the circulating current exceeds the limit, the synchronization verification and fault interlocking unit will immediately trigger the hardware interlock, terminate the synchronization adjustment, forcibly disconnect the third contactor, restore the hardware interlocking mechanism between the first and third contactors, and switch to the traditional single power supply mode to ensure the safe operation of the system.
[0037] 4. Maintenance Bypass Mode: After the maintenance bypass is triggered, the fourth contactor engages, and all contactors from the first to the third are hardware locked. The mains power is directly supplied to the load through the mains power input bus. The power distribution cabinet and UPS can be powered off for maintenance without interrupting the power supply to the load.
[0038] The output synchronization and coordination module includes a coordination controller, which is connected to a synchronization verification and fault interlocking unit, a dual-channel synchronous high-speed sampling unit, a digital phase-locked loop control unit, an amplitude closed-loop adjustment unit, and a circulating current detection and suppression unit. The acquisition terminals of the dual-channel synchronous high-speed sampling unit are connected to the distribution cabinet access bus and the UPS inverter bus, respectively. The dual-channel synchronous high-speed sampling unit synchronously acquires the electrical parameters of the distribution cabinet access bus and the UPS inverter bus. Using the electrical parameters of the distribution cabinet access bus as a reference source, the digital phase-locked loop control unit and the amplitude closed-loop adjustment unit complete the digital phase-locked loop and amplitude closed-loop control, and complete the closed-loop synchronization of the frequency, phase, and amplitude of the dual power supply of the distribution cabinet access bus and the UPS inverter bus. The main control unit is in synchronous output mode.
[0039] Data Acquisition: The dual-channel synchronous high-speed sampling unit is directly connected to the power distribution cabinet access bus and the UPS inverter bus via a dedicated shielded cable harness, enabling high-speed synchronous acquisition of dual-channel electrical parameters from the same source. Control Connection: The digital phase-locked loop control unit and amplitude closed-loop adjustment unit interact bidirectionally with the main control unit via an internal high-speed CAN bus; the synchronization verification and fault interlocking unit is directly connected to the interlocking circuit of the collaborative safety interlocking unit through hardware dry contacts, that is, the coil drive circuit of the first to fourth contactors is connected in series in hardware, which can independently cut off the contactor drive power supply and is not affected by the control of the main control unit; in the event of a synchronization fault, hardware-level forced protection can be triggered, and the output interlock power supply mode can be entered. Command issuance connection: The main control unit converts data through the communication protocol conversion unit and issues synchronous adjustment commands for phase, frequency, and amplitude to the UPS through the UPS communication terminals.
[0040] When the input or output of the output synchronization and coordination module is abnormal, the main control unit switches from the synchronous coordination output mode to the output interlock power supply mode. The output interlock power supply mode is an interlocked power supply mode in which the main control unit controls one of the first contactor and the third contactor to be turned on while the other is turned off.
[0041] The connection unit also includes an independent switch isolation power supply. The input end of the independent switch isolation power supply is rigidly connected to the mains input bus. The output side of the independent switch power supply provides isolated uninterrupted power supply for all control, acquisition, synchronization and coordination and communication within the connection unit. The independent switch isolation power supply is completely electrically isolated from the power regulation module.
[0042] The load balancing module acquires the collected power data, processes the data and determines thresholds, and outputs control data. This control data is forwarded to the intelligent distribution cabinet and UPS via communication terminals to perform heavy load suppression, UPS charging current limiting, light load energy efficiency optimization, and backup load rate regulation. The load balancing module is integrated within the main control unit and uses a 100ms scheduling cycle to execute closed-loop balancing control, specifically as follows: Data preprocessing: Real-time power data is acquired and a moving average filtering algorithm is used to remove noise and abnormal data to ensure the reliability of the data source; Dynamic threshold calibration: Based on the rated parameters of the intelligent power distribution cabinet and UPS, calculate dynamic thresholds such as heavy load warning, overload protection, and optimal load capacity in real time to adapt to different equipment specifications; Overload suppression and control: When the output of the distribution cabinet exceeds the threshold, an instruction is issued to cut off non-core loads, while reducing the UPS charging power and releasing the upstream power supply capacity. Charging power balancing: The incremental PID algorithm is used to dynamically adjust the UPS charging power to avoid excessive use of the power distribution cabinet capacity by the charging power. Light load energy efficiency optimization: Under light load conditions, the redundant branches of the control cabinet are disconnected or the UPS is controlled to enter energy-saving standby mode to reduce system losses; Closed-loop verification: The execution effect is verified in real time after the command is issued. In case of an anomaly, a resend and alarm mechanism is activated to ensure balanced and effective execution.
[0043] The outer casing is equipped with a grounding maintenance port and an internal maintenance button connected to the main control unit. During operation, pressing the internal maintenance button enters the maintenance bypass mode, and the mains power is directly supplied to the load through the mains power input bus. The power distribution cabinet and UPS can be powered off for maintenance without interrupting the power supply to the load. During maintenance, the maintenance data of the power module can be obtained by connecting to the maintenance terminal through the local maintenance port.
[0044] The communication protocol conversion unit has a built-in multi-protocol parsing engine, compatible with Modbus RTU, Modbus TCP, SNMP, IEC61850 and various types of UPS proprietary protocols. The communication protocol conversion unit automatically identifies and converts heterogeneous data between the intelligent power distribution cabinet and the UPS, and completes bidirectional data transmission between the main control unit and the intelligent power distribution cabinet and the UPS. The communication protocol conversion unit is rigidly connected to the communication terminals of the power distribution cabinet and the UPS externally, and internally it is only bidirectionally connected to the main control unit to complete heterogeneous protocol parsing and command translation, without any electrical connection to the power link.
[0045] The communication protocol conversion unit also includes a protocol update interface, which completes the update of the UPS private protocol. The UPS private protocol can be updated through the protocol update interface, thereby adapting to the mainstream UPS on the market.
[0046] The outer casing is equipped with a UPS type selection button. When the UPS type selection button is pressed, the main control unit obtains the selection data, determines the UPS type, and sends the selection data to the communication protocol conversion unit. After obtaining the selection data, the communication protocol conversion unit selects the UPS private protocol that is compatible with it.
[0047] The above embodiments are merely preferred embodiments of the present invention. Therefore, all equivalent changes or modifications made to the structure, features and principles described in the claims of the present invention are included within the scope of the present invention.
Claims
1. A power module for use with an intelligent power distribution cabinet and a UPS, comprising an intelligent power distribution cabinet and a UPS, characterized in that: It also includes a mating module, which includes a housing, and a mating body is installed inside the housing. The mating body includes: The main control unit for overall machine control has a built-in load balancing module. Power input and output terminals, which are respectively connected to a set of output terminals of the intelligent power distribution cabinet, the input and output terminals of the UPS, and the load connection terminals; The communication terminal has an input side that connects to the communication interface of the intelligent power distribution cabinet and the communication interface of the UPS via data cables; the output side of the communication terminal is connected to the main control unit via a communication protocol conversion unit. A power regulation module, wherein the power input and output terminals are connected to the power regulation module; The acquisition module includes a power acquisition module, a switch status acquisition module, and a temperature and insulation acquisition module; the power acquisition module is connected to the power regulation module. The power acquisition module is connected to the output synchronization and coordination module and the main control unit.
2. The power module for intelligent power distribution cabinet and UPS as described in claim 1, characterized in that: The power input and output terminals include mains terminals, distribution cabinet docking terminals, UPS docking terminals, and load terminals; the communication terminals include distribution cabinet communication terminals and UPS communication terminals. The power regulation module consists of multiple physically separated and electrically isolated power buses, which include: A mains input busbar, one end of which is rigidly connected to the mains terminal, and the other end of which is connected to the fourth contactor via a bypass fuse; The distribution cabinet is connected to the busbar, one end of which is connected to the distribution cabinet docking terminal, and the other end of which is connected to the first contactor and the second contactor. The UPS transfer bus is connected at one end to the input terminal of the UPS docking terminal and at the other end to the output terminal of the second contactor. UPS inverter bus; one end of the UPS inverter bus is connected to the output terminal of the UPS docking terminal, and the other end is connected to a third contactor; The load bus is connected to the output terminals of the first, third, and fourth contactors; the load bus is connected to the load terminals.
3. The power module for intelligent power distribution cabinet and UPS as described in claim 2, characterized in that: The output synchronization and coordination module includes a coordination controller, which is connected to a synchronization verification and fault interlocking unit, a dual-channel synchronous high-speed sampling unit, a digital phase-locked loop control unit, an amplitude closed-loop adjustment unit, and a circulating current detection and suppression unit. The acquisition terminals of the dual-channel synchronous high-speed sampling unit are connected to the distribution cabinet access bus and the UPS inverter bus, respectively. The dual-channel synchronous high-speed sampling unit synchronously acquires the electrical parameters of the distribution cabinet access bus and the UPS inverter bus. Using the electrical parameters of the distribution cabinet access bus as a reference source, the digital phase-locked loop control unit and the amplitude closed-loop adjustment unit complete the digital phase-locked loop and amplitude closed-loop control, and complete the closed-loop synchronization of the frequency, phase, and amplitude of the dual power supply of the distribution cabinet access bus and the UPS inverter bus. The main control unit is in synchronous output mode.
4. The power module for intelligent power distribution cabinet and UPS as described in claim 3, characterized in that: When the input or output of the output synchronization module is abnormal, the main control unit switches from the synchronous coordination output mode to the output interlock power supply mode. The output interlock power supply mode is an interlocked power supply mode in which the main control unit controls one of the first contactor and the third contactor to be turned on while the other is turned off.
5. The power module for intelligent power distribution cabinet and UPS as described in claim 2, characterized in that: The connection unit also includes an independent switch isolation power supply. The input end of the independent switch isolation power supply is rigidly connected to the mains input bus. The output side of the independent switch power supply provides isolated uninterrupted power supply for all control, acquisition, synchronization and coordination and communication within the connection unit. The independent switch isolation power supply is completely electrically isolated from the power regulation module.
6. The power module for intelligent power distribution cabinet and UPS as described in claim 1, characterized in that: The load balancing module acquires the collected power data, processes the power data and determines thresholds, and outputs control data. The control data is forwarded to the intelligent power distribution cabinet and UPS through the communication terminal to complete heavy load suppression, UPS charging current limiting, light load energy efficiency optimization and backup load rate regulation.
7. The power module for intelligent power distribution cabinet and UPS as described in claim 1, characterized in that: The outer casing is equipped with a grounding maintenance port and an internal maintenance button that are connected to the main control unit.
8. The power module for intelligent power distribution cabinet and UPS as described in claim 1, characterized in that: The communication protocol conversion unit has a built-in multi-protocol parsing engine, which is compatible with SNMP, Modbus RTU, Modbus TCP, IEC61850 and various types of UPS private protocols. The communication protocol conversion unit automatically identifies and converts heterogeneous data between the intelligent power distribution cabinet and the UPS, and completes bidirectional data transmission between the main control unit and the intelligent power distribution cabinet and the UPS.
9. The power module for intelligent power distribution cabinet and UPS as described in claim 8, characterized in that: The communication protocol conversion unit also includes a protocol update interface, which performs UPS private protocol updates.
10. The power module for intelligent power distribution cabinet and UPS as described in claim 8, characterized in that: The outer casing is equipped with a UPS type selection button.