Intelligent power distribution unit and method of assembling the same

Abstract

This invention relates to the field of power distribution and power consumption equipment technology, and in particular to an intelligent power distribution unit and its assembly method. The intelligent power distribution unit includes a housing, a terminal block, a power switch, a data center, and multiple output units. Each output unit includes a socket unit, a power input board, a metering board, a connection board, and multiple circuit breakers. The socket unit is mounted on the housing. The power input board, metering board, and connection board are arranged sequentially from bottom to top. The power input board is electrically connected to the connection board, the socket body is electrically connected to the connection board, the metering board is electrically connected to the connection board and the power input board, and the terminal block is electrically connected to the data center and the power input board. The circuit breakers are connected in series with the socket body. This invention not only supports high-precision metering and independent branch control in terms of function, but also achieves separation of strong and weak currents, optimized thermal management, and rapid maintenance in its physical architecture through a partitioned design and orderly stacked layout. It is small in size and convenient for installation in high-density cabinet environments.

Description

Technical Field

[0001] This invention relates to the field of power distribution and power consumption equipment technology, and in particular to an intelligent power distribution unit and its assembly method. Background Technology

[0002] With the rapid development of technologies such as cloud computing, artificial intelligence, and edge computing, data centers and communication equipment rooms are evolving towards higher power density, higher availability, and more refined operation and maintenance. As a critical end-point power distribution device, intelligent power distribution units not only need to provide reliable power output, but also need to have capabilities such as branch-level power metering, remote control, fault isolation, and status monitoring to support energy efficiency management and predictive maintenance.

[0003] While most smart PDUs on the market integrate metering and communication functions, they face multiple challenges in high-density deployment scenarios. On one hand, traditional designs often highly integrate power input, energy metering, signal processing, and output interfaces onto a single printed circuit board. This integration is acceptable in low-channel or low-power applications, but in high-density environments with multiple outputs, high current, and compact installations, it easily leads to interference between high-voltage and low-voltage signals, affecting metering accuracy and system stability. Simultaneously, issues such as concentrated heat, congested wiring, and insufficient safety clearance significantly increase electrical risks and limit the development of products towards higher channel densities. Furthermore, existing smart PDUs lack systematic optimization in their internal structural layout, resulting in complex assembly, inefficient heat dissipation paths, and severely impacting maintenance efficiency.

[0004] In particular, in high-density cabinet environments, the space in the PDU housing is extremely limited. How to reasonably arrange core functional modules such as power input boards, metering boards, and connection boards within a small volume, so that they meet electrical safety specifications and have good heat conduction paths and modular assembly characteristics, has become a key bottleneck restricting the improvement of product performance. Summary of the Invention

[0005] This invention aims to at least solve the technical problems existing in the prior art. To this end, this invention proposes an intelligent power distribution unit and its assembly method, which not only supports high-precision metering and independent branch control in terms of function, but also achieves separation of strong and weak currents, optimized thermal management, and rapid maintenance in terms of physical architecture through board design and orderly stacked layout. It is small in size and convenient for installation in high-density rack environments.

[0006] According to some embodiments of the first aspect of the present invention, an intelligent power distribution unit includes a housing, a terminal block, a power switch, a data center, and multiple output units. The terminal block is disposed at the end of the housing. The power switch and the data center are both connected to the housing. Each output unit includes a socket unit, a power input board, a metering board, a connecting board, and multiple circuit breakers. The socket unit is provided with multiple socket bodies and is disposed on the housing. The power input board, the metering board, and the connecting board are arranged sequentially from bottom to top. The power input board is electrically connected to the connecting board. The socket bodies are electrically connected to the connecting board. The metering board is electrically connected to the connecting board and the power input board. The terminal block is electrically connected to the data center and the power input board. Each circuit breaker is connected in series with one of the socket bodies. The power switch is connected in series with the data center. The metering board is electrically connected to the data center.

[0007] According to some embodiments of the first aspect of the present invention, an intelligent power distribution unit is provided with three first connectors at the bottom of the power input board for connecting three-phase AC power, the terminal block is electrically connected to the first connectors, three first connectors are provided at the top of the power input board, and three second connectors are provided at the bottom of the metering board, with the first connectors and the second connectors mating one-to-one.

[0008] According to some embodiments of the first aspect of the present invention, an intelligent power distribution unit is provided with a plurality of second connectors at the bottom of the power input board, a conductive post is provided on the power input board, a plurality of clearance holes are provided on the metering board, the conductive post passes through the clearance holes and is connected to the connector, a third connector is provided on the connector, the socket body is electrically connected to the connector, the terminal block is electrically connected to the second connectors to input current, and the terminal block is connected to the third connector to connect the neutral wire.

[0009] According to some embodiments of the first aspect of the present invention, an intelligent power distribution unit includes a terminal block comprising a frame and a plurality of terminal blocks. The frame has a plurality of channels, and the terminal blocks are disposed in the channels. An input connector is disposed on the left side of each terminal block, and a first connection hole is provided on the left side of the input connector. A first locking screw is screwed onto the top of the input connector, and the bottom of the first locking screw extends into the first connection hole. A plurality of output connectors are disposed on the right side of the terminal block, and the plurality of output connectors are connected sequentially from bottom to top. A plurality of second connection holes are provided on the right side of each output connector, and a second locking screw is screwed onto the top of each output connector, the bottom of the second locking screw extending into the second connection hole.

[0010] According to some embodiments of the first aspect of the present invention, an intelligent power distribution unit is provided with four terminals and four channels, corresponding to three-phase input and a neutral wire connection. Three first terminals are connected to the terminals for the three-phase input, and the terminal for the neutral wire is connected to the third terminal. The second terminals are all connected to the terminals for the three-phase input.

[0011] According to some embodiments of the first aspect of the present invention, an intelligent power distribution unit has an upper output connector at the bottom connected to the top right end of a lower output connector, the top of the output connector having a clearance space, and a second locking screw located within the clearance space.

[0012] According to some embodiments of the first aspect of the present invention, an intelligent power distribution unit is provided with three output connectors, each of which has two second connection holes on its right side.

[0013] According to some embodiments of the first aspect of the present invention, an intelligent power distribution unit is provided with a third connector on the top of the power input board and a fourth connector on the bottom of the metering board, wherein the third connector and the fourth connector are mated to enable the metering board to perform metering sampling.

[0014] According to some embodiments of the first aspect of the present invention, an intelligent power distribution unit is provided, wherein the data center includes a main control board and a display, the display is disposed on the top of the main control board, the top of the main control board is provided with a plurality of RJ45 interfaces, and the bottom of the main control board is provided with four fourth connectors for connecting three-phase AC power and connecting a neutral wire.

[0015] An assembly method for an intelligent power distribution unit according to some embodiments of a second aspect of the present invention is used to assemble an intelligent power distribution unit according to some embodiments of a first aspect. The assembly method includes the following steps: The power input board, metering board, and connecting board are coaxially connected by multiple conductive posts, which pass through clearance holes on the connecting board and metering board and are fixed to the power input board, forming a rigid circuit board assembly stacked from bottom to top. The socket body is installed on the connecting board, and the electrical connection between each circuit breaker and the corresponding socket body is completed, forming a complete socket unit. The socket unit and multiple circuit breakers are placed into the housing and fixed to the housing. The above steps are repeated to complete the side-by-side installation of multiple output unit modules in the housing. The terminal block is fixed to the end of the housing, and the data center and power switch are fixed in designated positions inside the housing. Wiring is then performed.

[0016] According to some embodiments of the present invention, an intelligent power distribution unit and its assembly method have at least the following beneficial effects: This invention separates power input, power metering, and connection to the socket body into independent power input, metering, and connection boards, employing a bottom-up, layered layout. This effectively isolates high-current, high-voltage circuits from high-sensitivity, low-voltage signal circuits, significantly reducing electromagnetic interference and improving the accuracy of power metering and communication stability. Within a limited housing space, a vertically layered modular structure design rationally arranges the functional circuit boards, avoiding the wiring congestion and insufficient safety spacing issues caused by traditional single-board integration. It supports the integration of more output branches, meeting the dual requirements of PDU miniaturization and high channel count for high-density racks such as data centers. The separate board layout also minimizes the impact of heat generation. The physical separation of the temperature-sensitive elements on the metering board and the components creates a more rational heat flow path, which is conducive to directional heat conduction and dissipation, reduces local temperature rise, and improves the long-term reliability and electrical safety of the equipment. Each functional board is independently set up and arranged in an orderly manner, making the production and assembly process modular and standardized. When a fault occurs in a certain output branch, the corresponding module can be disassembled or replaced in a targeted manner without the need for overall rework, which greatly improves maintenance efficiency and reduces downtime. By connecting the circuit breaker and the socket body in series one by one, and combining the electrical connection between the metering board and the data center, independent overload protection, power consumption collection and remote monitoring of each output can be realized, providing a hardware foundation for refined energy efficiency management and fault location.

[0017] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0018] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a schematic diagram of the structure of an embodiment of the present invention.

[0019] Figure 2 This is a schematic diagram of the structure of the present invention with part of the shell hidden.

[0020] Figure 3 This is a schematic diagram of the socket unit according to an embodiment of the present invention. Figure 1 .

[0021] Figure 4 This is a schematic diagram of the socket unit according to an embodiment of the present invention. Figure 2 .

[0022] Figure 5 This is a schematic diagram of the terminal block structure according to an embodiment of the present invention.

[0023] Figure 6 This is a cross-sectional view of the terminal block according to an embodiment of the present invention.

[0024] Figure 7 This is a schematic diagram of the data center structure according to an embodiment of the present invention.

[0025] Figure 8 This is a wiring diagram for an embodiment of the present invention.

[0026] Reference numerals: 1. Housing; 2. Terminal block; 3. Power switch; 4. Data center; 5. Output unit; 6. Socket unit; 7. Power input board; 8. Metering board; 9. Connecting plate; 10. Circuit breaker; 11. Socket body; 12. First connector; 13. First connector; 14. Second connector; 15. Second connector; 16. Conductive post; 17. Clearance hole; 18. Third connector; 19. Conductive wire; 20. Frame; 21. Terminal block; 22. Channel; 23. Input connector; 24. First connection hole; 25. First locking screw; 26. Output connector; 27. Second connection hole; 28. Second locking screw; 29. ​​Third connector; 30. Fourth connector; 31. Clearance space; 32. Main control board; 33. Display; 34. RJ45 interface; 35. Fourth connector. Detailed Implementation

[0027] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0028] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, left, right, front, and back, are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the module or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0029] In the description of this invention, the use of "first" and "second" is for the purpose of distinguishing technical features only, and should not be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated or the order of the technical features indicated.

[0030] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0031] like Figures 1-8 As shown, this embodiment of the invention provides an intelligent power distribution unit.

[0032] An intelligent power distribution unit includes a housing 1, a terminal block 2, a power switch 3, a data center 4, and multiple output units 5. The terminal block 2 is disposed at the end of the housing 1. The power switch 3 and the data center 4 are both connected to the housing 1. Each output unit 5 includes a socket unit 6, a power input board 7, a metering board 8, a connecting board 9, and multiple circuit breakers 10. The socket unit 6 is provided with multiple socket bodies 11 and is disposed on the housing 1. The power input board 7, the metering board 8, and the connecting board 9 are arranged sequentially from bottom to top. The power input board 7 is electrically connected to the connecting board 9. The socket body 11 is electrically connected to the connecting board 9. The metering board 8 is electrically connected to the connecting board 9 and the power input board 7. The terminal block 2 is electrically connected to the data center 4 and the power input board 7. The circuit breakers 10 are connected in series with the socket body 11. The power switch 3 is connected in series with the data center 4. The metering board 8 is electrically connected to the data center 4.

[0033] This invention separates the functions of power input, power metering, and connection to the socket body 11 onto independent power input boards 7, metering boards 8, and connection boards 9, employing a bottom-to-top stacked layout. This effectively isolates high-current, high-voltage circuits from high-sensitivity, low-voltage signal circuits, significantly reducing electromagnetic interference and improving the accuracy of power metering and communication stability. Within the limited space of the housing 1, a vertically layered modular structure design is used to rationally arrange the functional circuit boards, avoiding the wiring congestion and insufficient safety spacing problems caused by traditional single-board integration. This supports the integration of more output branches, meeting the dual requirements of PDU miniaturization and high channel count for high-density cabinets such as data centers. The separate board layout also minimizes the impact on heat-generating components. Physically separated from the temperature-sensitive element on the metering board 8, a more rational heat flow path is formed, which is conducive to directional heat conduction and dissipation, reduces local temperature rise, and improves the long-term reliability and electrical safety of the equipment. Each functional board is independently set up and arranged in an orderly manner, making the production and assembly process modular and standardized. When a certain output branch fails, the corresponding module can be disassembled or replaced in a targeted manner without overall rework, which greatly improves maintenance efficiency and reduces downtime. By connecting the circuit breaker 10 and the socket body 11 in series one by one, and combining the electrical connection between the metering board 8 and the data center 4, independent overload protection, power consumption collection and remote monitoring of each output are realized, providing a hardware foundation for refined energy efficiency management and fault location.

[0034] This embodiment describes an intelligent power distribution unit. The power input board 7 has three first connectors 12 at its bottom for connecting three-phase AC power. The terminal block 2 is electrically connected to the first connectors 12. The power input board 7 has three first connectors 13 at its top, and the metering board 8 has three second connectors 14 at its bottom. The first connectors 13 and second connectors 14 are connected one-to-one. Specifically, the three first connectors 12 at the bottom of the power input board 7 are used to connect three-phase AC power L1, L2, and L3, and the three first connectors 13 at the top connect one-to-one with the three second connectors 14 at the bottom of the metering board 8, forming a three-phase current transmission. This avoids the parasitic inductance and contact resistance caused by long wires or copper busbars used in traditional solutions, ensuring stable input of large currents while providing the metering board 8 with original, unattenuated phase current signals. Furthermore, the three-phase current paths are completely symmetrical, which helps to achieve three-phase load balance monitoring and imbalance alarms, providing a data foundation for data center energy efficiency optimization.

[0035] In this embodiment, an intelligent power distribution unit is provided. The bottom of the power input board 7 has multiple second connecting seats 15. Conductive posts 16 are provided on the power input board 7. The metering board 8 has multiple clearance holes 17. The conductive posts 16 pass through the clearance holes 17 and are connected to the connecting board 9. The connecting board 9 has a third connecting seat 18. The socket body 11 is electrically connected to the connecting board 9. The terminal block 2 is electrically connected to the second connecting seats 15 to input current, and the terminal block 2 is connected to the third connecting seat 18 to connect to the neutral wire. Specifically, a conductive post 16 is installed on the power input board 7, which passes through the clearance hole 17 on the metering board 8 and connects to the connecting plate 9, forming a direct main path for the phase line. The neutral line is connected separately to the third connecting seat 18 of the connecting plate 9 through the terminal block 2, forming a dual-path power supply architecture with physical separation of the phase and neutral lines. The conductive post 16 is made of hexagonal copper. Through the above design, the high-current phase line does not flow through the metering board 8, thus completely avoiding the temperature drift error caused by the heating of the metering board 8 due to high current. The conductive post 16 is made of hexagonal copper, which has low contact resistance and minimal voltage drop. The clearance hole 17 is precisely matched to the outer diameter of the conductive post 16, with an insulation gap greater than 2mm, which also prevents shaking. This structure achieves compatibility between high-precision metering and high-power output while ensuring electrical safety.

[0036] The intelligent power distribution unit described in this embodiment includes a terminal block 2 comprising a frame 20 and multiple terminal blocks 21. The frame 20 has multiple channels 22, and each terminal block 21 is disposed within one of the channels 22. An input connector 23 is disposed on the left side of each terminal block 21, and a first connection hole 24 is provided on the left side of the input connector 23. A first locking screw 25 is screwed onto the top of the input connector 23, with the bottom of the first locking screw 25 extending into the first connection hole 24. Multiple output connectors 26 are disposed on the right side of the terminal block 21, connected sequentially from bottom to top. Several second connection holes 27 are provided on the right side of each output connector 26, and a second locking screw 28 is screwed onto the top of each output connector 26, with the bottom of the second locking screw 28 extending into the second connection hole 27. Specifically, after the external power cord or internal lead is inserted into the connector, tightening the locking screw can firmly press the wire. This structure effectively overcomes the problems of traditional spring terminals being prone to loosening, oxidation, and arcing under long-term vibration and thermal expansion and contraction.

[0037] It is understood that the ground wire in this invention does not need to pass through the terminal block 2. After each component that needs to be grounded is connected to the ground wire, the ground wire can simply pass through the housing 1. In the grounding process of the socket body 11, a ground wire 19 is provided on the connecting plate 9, and the grounding terminals of the socket body 11 are all connected to the ground wire 19. The ground wire 19 can simply be connected to the ground wire.

[0038] In this embodiment, an intelligent power distribution unit is provided with four terminal blocks 21 and four channels 22, corresponding to three-phase input and neutral wire connection. Three first connecting blocks 12 are connected to the three-phase input terminal blocks 21, and the terminal block 21 connecting the neutral wire is connected to the third connecting block 18. The second connecting blocks 15 are all connected to the three-phase input terminal blocks 21. Specifically, the number of terminal blocks 21 and channels 22 is set to four, corresponding to the three-phase input (L1, L2, L3) and neutral wire respectively. The three phase wire terminal blocks 21 are connected to the first connecting blocks 12 and the second connecting blocks 15 of the power input board 7, respectively, to realize the power supply of the metering board 8 and the main input. The neutral wire terminal block 21 is connected to the third connecting block 18 of the connecting board 9. The phase wire and neutral wire are separated and wired inside the terminal block 2, reducing cross wiring inside the housing 1 and improving insulation performance and maintenance identification.

[0039] This embodiment describes an intelligent power distribution unit where a third connector 29 is located on the top of the power input board 7, and a fourth connector 30 is located on the bottom of the metering board 8. The third connector 29 and the fourth connector 30 are connected to enable the metering board 8 to perform metering sampling. Specifically, the third connector 29 is added to the top of the power input board 7, and the fourth connector 30 is correspondingly located on the bottom of the metering board 8. The connection between the two is dedicated to high-fidelity current signal transmission. This connector transmits only a weak sampling current, simplifying the PCB layout and preventing damage to the sampling circuit due to overcurrent in the main circuit, thereby improving the immunity and lifespan of the metering module.

[0040] The intelligent power distribution unit described in this embodiment connects the bottom of the upper output connector 26 to the top right end of the lower output connector 26. A clearance space 31 is provided at the top of the output connector 26, and the second locking screw 28 is located within this clearance space 31. Specifically, multiple output connectors 26 are stacked in a stepped manner, with the bottom of the upper output connector 26 overlapping the top right end of the lower output connector 26, and a clearance space 31 reserved at the top to accommodate the second locking screw 28. This structure cleverly utilizes vertical space, integrating multiple output terminals within a limited height, while ensuring sufficient operating space for each screw head, facilitating tightening or loosening with a standard screwdriver, thus improving the product's ergonomics and on-site installation efficiency.

[0041] The intelligent power distribution unit described in this embodiment has three output connectors 26, each with two second connection holes 27 on its right side. Specifically, each output connector 26 has two second connection holes 27 on its right side, allowing two internal wires to be connected in parallel from a single physical terminal, for example, to different circuit breakers 10 or metering channels. This significantly increases the number of output interfaces without increasing the width or height of the terminal block 2, making it particularly suitable for scenarios requiring multiple in-phase outputs. It also allows users to flexibly choose wiring methods, enhancing product adaptability.

[0042] This embodiment describes an intelligent power distribution unit. The data center 4 includes a main control board 32 and a display 33. The display 33 is located on top of the main control board 32. The top of the main control board 32 has several RJ45 interfaces 34, and the bottom of the main control board 32 has four fourth connection sockets 35 for connecting three-phase AC power and the neutral wire. Specifically, the data center 4 integrates the main control board 32, the top display 33, and multiple RJ45 interfaces 34, and connects to three-phase power and the neutral wire through the four fourth connection sockets 35 at the bottom, providing an independent and isolated auxiliary power supply for the main control system. This design ensures that even if a branch circuit breaker 10 trips, the main control board 32 can continue to work, maintaining remote monitoring, log recording, and alarm uploading functions, avoiding "monitoring blind spots." The display 33 displays the current, voltage, power, and switch status of each branch in real time, facilitating local operation and maintenance. The overall structure is compact and the functions are complete.

[0043] The intelligent power distribution unit described in this embodiment uses a liquid magnetic circuit breaker 10. Specifically, the liquid magnetic circuit breaker structure combines the characteristics of thermal tripping and magnetic tripping, resulting in fast response, high precision, long lifespan, and is unaffected by ambient temperature. It can provide highly reliable independent protection for each socket branch, effectively preventing the spread of local faults and ensuring the overall electrical safety of the device.

[0044] The intelligent power distribution unit of this invention has six socket bodies 11 and six circuit breakers 10 in each output unit 5. In each output unit 5, the three-phase input power supplies L1, L2, and L3 each drive two independent output branches, so that the maximum load current of a single phase is distributed to two branches, effectively reducing the current stress of a single branch and improving system redundancy. For example, in a dual-power supply scenario for a server, the two power supplies can be connected to two socket bodies 11 of the same phase (such as A1 and A2), which ensures the consistency of power supply in the same phase and avoids overload of a single socket body 11. The metering board 8 integrates a 6-channel current sampling circuit, with each channel corresponding to one socket body 11. The current of each branch is collected in real time through 6 independent current sensors, and the voltage sampling uses the three-phase signals of L1 / L2 / L3 to N. The conductive posts 16 and connection structures on the power input board 7 are designed according to phase grouping: each phase L1, L2, and L3 is equipped with a dual-output interface, which is respectively connected to the two socket bodies 11 of that phase in the same output unit 5. This design ensures that the large current can be stably distributed and that the impedance of each branch is matched, avoiding load imbalance caused by uneven lines. Each phase wire terminal block 2 has a one-to-two output structure inside, which divides the single-phase input current into two paths, which are respectively supplied to the two branches of that phase in the same output unit 5. The neutral wire terminal block 21 provides a common circuit and is connected to the neutral wire terminals of all 6 socket bodies 11 through the connecting plate 9.

[0045] The intelligent power distribution unit of this invention adopts a three-phase input L1, L2, L3 power supply architecture, and its circuit current flow direction and signal acquisition path are as follows: An external three-phase AC power supply is connected to terminal block 2 of this PDU through the cabinet power distribution system. Terminal block 2 has four independent terminal blocks 21, corresponding to the three-phase live wires L1, L2, L3 and the neutral wire N, respectively. The three-phase live wires L1, L2, and L3 are output from terminal block 2 and then split into two paths: The first path is the main power path. The three-phase live wires L1, L2, and L3 are connected to the circuit breaker 10 via the output connector 26 of the terminal block 2. Then, they are connected from the circuit breaker 10 to the second connector 15 at the bottom of the power input board 7. After entering from the second connector 15 of the power input board 7, the current passes vertically upward through the conductive post 16 and through the clearance hole 17 on the metering board 8 without making electrical contact with the metering board 8, directly reaching the connecting board 9. On the connecting board 9, the current is distributed to each socket body 11 via the internal connecting board 9, forming a load power supply circuit.

[0046] The second path is the metering sampling path: the three-phase live wires L1, L2, and L3 are connected to the first connector 12 at the bottom of the power input board 7 via the output connector 26 of the terminal block 2, which is used to provide the original current signal for metering. Current sampling: the main power transmission three-phase live wires are led out as small signal currents on the power input board 7; this signal is transmitted through the third connector 29 at the top of the power input board 7 to the fourth connector 30 at the bottom of the metering board 8, so that the current sensor in the metering board 8, such as a Hall element or a precision sampling resistor, can perform real-time sampling. The metering board 8 obtains the voltage signals of each phase (L1 / L2 / L3 to N) through the connector 9, which are used to calculate parameters such as power and power factor. Finally, the metering board 8 transmits the collected branch electrical parameters to the main control board 32 of the data center 4 through the digital interface. After the main control board 32 summarizes the data, it drives the top display 33 to display the operating status in real time, and uploads it to the remote monitoring system through the RJ45 interface 34, supporting remote query, alarm and energy efficiency analysis.

[0047] The main control board 32 of the data center 4 obtains three-phase power and neutral wire directly from the terminal block 2 through four fourth connectors 35 at its bottom. The power is then converted into low-voltage DC such as 12V / 5V by the internal AC / DC power module to power the main control board 32, the display 33, the communication module, etc.

[0048] It is understood that this invention does not simply distribute circuit functions across different PCBs, but rather reconstructs the current topology to completely decouple the high-current main circuit and the high-sensitivity metering circuit in three dimensions: physical path, electrical network, and heat flow path. Specifically, the main power channel is directly connected through a rigid conductive post 16 conductor, without flowing through any signal board; metering sampling obtains the original signal through an independent low-noise channel; and the heat source and temperature-sensitive element are spatially separated.

[0049] With this structural design, the present invention achieves a high-density design, which can set up 3 to 4 output units 4, that is, it can meet 18-bit or 24-bit output, and under this condition, it simultaneously meets IEC safety regulations, ±0.8% metering accuracy and 36A continuous output capability.

[0050] A method for assembling an intelligent power distribution unit includes the following steps: S1. The power input board 7, metering board 8, and connecting board 9 are coaxially connected by multiple conductive posts 16, so that the conductive posts 16 pass through the clearance holes 17 on the connecting board 9 and metering board 8 in sequence and are fixed on the power input board 7, forming a rigid circuit board assembly stacked from bottom to top; the socket body 11 is installed on the connecting board 9, and the electrical connection between each circuit breaker 10 and the corresponding socket body 11 is completed, forming a complete socket unit 6.

[0051] S2. Place the socket unit 6 and multiple circuit breakers 10 into the housing 1 and fix them to the housing 1.

[0052] S3. Repeat steps S1 to S2 to complete the side-by-side installation of multiple output unit modules 5 within the housing 1. Note that the step numbers in the original description are repeated; here, we assume that the second S3 is a typo and should be an instruction to continue to the next step.

[0053] S4. Fix the terminal block 2 to the end of the housing 1, and fix the data center 4 and the power switch 3 in the designated positions inside the housing 1.

[0054] S5. Perform the wiring, the specific steps are as follows: S51. Connect the L1, L2, and L3 phase lines of the external three-phase four-wire power supply to the corresponding phase line terminals of the terminal block 2, and connect the output terminals of each phase line terminal to the first connection terminal 12 and the circuit breaker 10 of the power input board 7 in each output unit module through wires. The circuit breaker is then connected to the second connection terminal 15.

[0055] S52. Connect the neutral wire to the neutral wire terminal block of the terminal block 2, and lead out a wire to connect to the third terminal block 18 of the connection plate 9 in each output unit module.

[0056] S53. Connect the L1, L2, L3 phase lines and neutral line of the terminal block 2 to the data center 4, and connect the data output terminals of the metering board 8 in each output unit module to the main control board 32 through data lines.

[0057] It is understood that, in this embodiment, the power switch specifically selected is the IRM30ST model.

[0058] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. An intelligent power distribution unit, characterized in that: The device includes a housing, a terminal block, a power switch, a data center, and multiple output units. The terminal block is located at the end of the housing. The power switch and the data center are both connected to the housing. Each output unit includes a socket unit, a power input board, a metering board, a connecting board, and multiple circuit breakers. The socket unit has multiple socket bodies and is located on the housing. The power input board, the metering board, and the connecting board are arranged sequentially from bottom to top. The power input board is electrically connected to the connecting board, the socket bodies are electrically connected to the connecting board, the metering board is electrically connected to the connecting board and the power input board, the terminal block is electrically connected to the data center and the power input board, the circuit breakers are connected in series with each socket body, the power switch is connected in series with the data center, and the metering board is electrically connected to the data center.

2. The intelligent power distribution unit according to claim 1, characterized in that: The bottom of the power input board is provided with three first connectors for connecting three-phase AC power. The terminal block is electrically connected to the first connectors. The top of the power input board is provided with three first connectors. The bottom of the metering board is provided with three second connectors. The first connectors and the second connectors are mated one by one.

3. The intelligent power distribution unit according to claim 2, characterized in that: The bottom of the power input board is provided with multiple second connectors, the power input board is provided with conductive posts, the metering board is provided with multiple clearance holes, the conductive posts pass through the clearance holes and are connected to the connecting board, the connecting board is provided with a third connector, the socket body is electrically connected to the connecting board, the terminal block is electrically connected to the second connectors to input current, and the terminal block is connected to the third connector to connect the neutral wire.

4. The intelligent power distribution unit according to claim 3, characterized in that: The terminal block includes a frame and multiple terminal blocks. The frame has multiple channels, and the terminal blocks are arranged in the channels. An input connector is provided on the left side of the terminal block, and a first connection hole is provided on the left side of the input connector. A first locking screw is screwed to the top of the input connector, and the bottom of the first locking screw extends into the first connection hole. Multiple output connectors are provided on the right side of the terminal block, and the multiple output connectors are connected sequentially from bottom to top. Several second connection holes are provided on the right side of the output connectors, and a second locking screw is screwed to the top of the output connector, and the bottom of the second locking screw extends into the second connection hole.

5. The intelligent power distribution unit according to claim 4, characterized in that: There are four terminals and four channels, corresponding to three-phase input and neutral wire connection. The three first terminals are connected to the three-phase input terminals, the terminal connected to the neutral wire is connected to the third terminal, and the second terminals are all connected to the three-phase input terminals.

6. The intelligent power distribution unit according to claim 4, characterized in that: The bottom of the upper output connector is connected to the top right end of the lower output connector. The top of the output connector has a clearance space, and the second locking screw is located within the clearance space.

7. The intelligent power distribution unit according to claim 4, characterized in that: There are three output connectors, and each output connector has two second connection holes on its right side.

8. The intelligent power distribution unit according to claim 2, characterized in that: A third connector is provided on the top of the power input board, and a fourth connector is provided on the bottom of the metering board. The third connector and the fourth connector are mated together to enable the metering board to perform metering sampling.

9. The intelligent power distribution unit according to claim 1, characterized in that: The data center includes a main control board and a monitor. The monitor is located on the top of the main control board, which has several RJ45 interfaces on the top and four fourth connectors on the bottom for connecting three-phase AC power and a neutral wire.

10. A method for assembling an intelligent power distribution unit, characterized in that, The assembly method for assembling the intelligent power distribution unit according to any one of claims 1-9 includes the following steps: The power input board, metering board, and connecting board are coaxially connected by multiple conductive posts, which pass through clearance holes on the connecting board and metering board and are fixed to the power input board, forming a rigid circuit board assembly stacked from bottom to top. The socket body is installed on the connecting board, and the electrical connection between each circuit breaker and the corresponding socket body is completed, forming a complete socket unit. The socket unit and multiple circuit breakers are placed into the housing and fixed to the housing. The above steps are repeated to complete the side-by-side installation of multiple output unit modules in the housing. The terminal block is fixed to the end of the housing, and the data center and power switch are fixed in designated positions inside the housing. Wiring is then performed.

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