A rail bus power supply system with distributed adaptive thermal management function

Abstract

This application discloses a track bus power supply system with distributed adaptive heat dissipation management function, including a track bus body, which includes an outer shell profile and T-shaped conductors housed inside the outer shell profile. The T-shaped conductors have a T-shaped cross-section, and the lateral protrusions of the T-shaped conductors form a surface contact fit with the grooves on the inner wall of the outer shell profile, forming a longitudinal geometric air duct between adjacent T-shaped conductors. It also includes a pluggable controlled flow field heat dissipation device, which is detachably plugged into the middle side wall of the track bus body, and an end active heat exchange sealing structure, which is set at the end of the track bus body. This invention solves the problems of heat island effect and heat dissipation bottleneck under high power density, the contradiction between high protection level and dynamic heat dissipation upgrade, the difficulty of power supply at the end of the power distribution system and the hidden dangers of secondary wiring, and the mechanical locking reliability problem under strong electromagnetic vibration environment, and realizes the establishment of an effective forced convection air duct in the closed cavity.

Description

Technical Field

[0001] This application relates to the field of power distribution equipment technology, and more specifically to a rail bus power supply system with distributed adaptive heat dissipation management function. Background Technology

[0002] Currently, mainstream data center rail busbar technologies both domestically and internationally fall into two main categories: the first is the natural convection type, which relies on increasing the cross-sectional area of ​​the copper busbars (copper foil stacking) and the outer casing heat sink for cooling, representing passive heat dissipation; the second is the external auxiliary type, which involves installing independent fans or air conditioning ducts outside the busbar, or implementing overall hot and cold aisle isolation at the data center level. In terms of protection logic, fixed end caps are commonly used, forming a closed space after installation, and upgrades or maintenance typically require power outages.

[0003] However, with the continuous increase in data center computing density, the power of a single rack has gradually increased from the traditional 10kW-15kW to 35kW or even higher, leading to a significant increase in the current carrying capacity and heat dissipation requirements of the rail bus system. The aforementioned conventional technical solutions have the following core drawbacks: First, the physical limitations of bulky designs lead to a significant conflict between cost and weight. To handle currents of 1200A or higher, traditional solutions reduce temperature rise by continuously increasing the thickness of the copper busbars. This results in extremely heavy busbars, increasing the structural load-bearing costs of the building, and the high price of copper leads to exorbitant system costs. More importantly, simply increasing the cross-sectional area is almost ineffective in addressing the heat accumulated in the internal cavities of the busbars (heat island effect). When the system actually requires high current, manufacturers try to forcefully reduce temperature rise by increasing the cross-sectional area of ​​the copper busbars, but this measure results in extremely high costs, a significant waste of electrolytic copper resources that directly drives up project costs, and the increased size and weight of the busbars, added to the load-bearing pressure on the data center server room.

[0004] Secondly, there is an inherent contradiction between heat dissipation performance and protection rating (IP). Some designs incorporate vents for heat dissipation, but this lowers the protection rating to below IP2X, making it susceptible to dust or metal shavings that could cause short circuits. Traditional high protection (IP4X / IP5X) implies complete enclosure, which means heat cannot escape. Conventional technologies cannot achieve efficient active heat exchange while maintaining high protection. Furthermore, passive cooling methods, such as adding heat sink fins or enlarging the casing, involve designing dense heat sinks on the aluminum alloy casing surface or simply increasing the casing size to increase the contact area with air. However, in actual use, it has been found that the conductor's heat dissipation efficiency exhibits a stepped decrease. After the conductor heats up, it must first be conducted to the casing through air gaps, and then from the casing to the air in the server room. Since air is a poor conductor of heat, this conduction chain is extremely inefficient.

[0005] Third, system silos lead to maintenance blind spots and power supply difficulties. Traditional busbars, junction boxes, and cooling fans are purchased and installed independently. Cooling fans typically require additional low-voltage power cabling, increasing low-voltage interference and fire hazards in the data center. Simultaneously, the busbar's operating status (temperature rise, load) cannot be directly fed back at the physical end, requiring complex monitoring software with delayed response. Forcibly adding brackets to the outside of the busbar trunking and installing commercially available industrial axial fans blowing directly onto the busbar system casing only cools the surface; the copper core inside the busbar remains at a high temperature. Furthermore, external fans require additional low-voltage cables from the data center's distribution box or finding sockets, resulting in messy wiring and increased potential points of failure.

[0006] Fourth, the lack of a flexible architecture that can be scaled up on demand, coupled with insufficient reliability of mechanical locking under strong electromagnetic vibration environments, makes data center loads increase year by year. The heat dissipation capacity of traditional busbars is fixed on the day of installation. If computing power increases later, it is necessary to shut down the power, remove the end caps, and replace them with larger-scale heat dissipation equipment, which is unacceptable for data centers that require 99.999% reliability. At the same time, the electrodynamic stress generated by high current can cause slight vibrations in the plug-in device, making it easy for traditional friction clamps to loosen, leading to increased contact resistance and even arcing. Existing technologies generally lack self-locking mechanisms with dynamic vibration compensation capabilities. Summary of the Invention

[0007] To overcome the above-mentioned shortcomings, the purpose of this application is to provide a track bus power supply system with distributed adaptive heat dissipation management function, which solves the technical problems of heat accumulation at the end of the track bus, contradiction between protection and heat dissipation, invisible status, inconvenient installation and power supply, and insufficient mechanical locking reliability under strong electromagnetic vibration environment in the prior art.

[0008] To achieve the above objectives, this application adopts the following technical solution: This application provides a track bus power supply system with distributed adaptive thermal management function, including: The track busbar body includes an outer shell profile and a T-shaped conductor housed inside the outer shell profile. The T-shaped conductor has a T-shaped cross-section, and the lateral protrusion of the T-shaped conductor forms a surface contact fit with the groove of the inner wall of the outer shell profile. A longitudinal geometric air duct is formed between adjacent T-shaped conductors. A pluggable controlled flow field heat dissipation device is detachably plugged into the middle side wall of the rail bus body. The pluggable controlled flow field heat dissipation device includes a housing and a fan located inside the housing. A plug connector for plugging into the rail bus body is provided on one side of the front of the housing. An active heat exchange sealing structure is provided at the end of the track bus body. The active heat exchange sealing structure includes an end cover, a sealing plate, and a fan module. The end cover is fixedly provided at the end of the track bus body and has heat dissipation mesh holes. The sealing plate is fixedly provided on the part of the end cover with heat dissipation mesh holes and located on the surface of the end cover opposite to the track bus body. The fan module is detachably installed on the surface of the end cover opposite to the track bus body through an elastic fastening mechanism.

[0009] Furthermore, a low-thermal-resistance solid heat conduction path is formed between the lateral protrusion of the T-shaped conductor and the groove of the inner wall of the outer shell profile. The abdominal space array between the T-shaped conductors forms a through-type longitudinal geometric air duct inside the outer shell profile. The longitudinal geometric air duct extends parallel to the axial direction of the track bus body. The T-shaped conductor also serves as a current-carrying element and a heat dissipation air duct wall, realizing the synergistic heat exchange of solid heat conduction and airflow convection.

[0010] Furthermore, in the pluggable controlled flow field heat dissipation device, a mesh cover for covering the fan is provided above and below the fan and on the upper and lower surfaces of the housing. A pair of brackets are fixedly connected to the side of the mesh cover away from the fan. A first sensor is provided on the other side of the front of the housing. Sealing strips are provided on both sides of the front of the housing. A fastener is provided in the middle of the two sides of the housing corresponding to the sealing strip. An indicator light and a controller are respectively provided on the fastener and the front of the housing.

[0011] Furthermore, the connector structure includes a connector body, with multiple elastic contacts located in the middle of the front side of the connector body. The elastic contacts are made of beryllium bronze or phosphor bronze and have a U-shaped or V-shaped cross-section. Multiple through holes are evenly distributed on the surface of the connector body. The connector passes through a pre-set window in the outer shell profile and utilizes the cavity in the belly of the T-shaped conductor to achieve automatic alignment and power extraction, directly obtaining power energy from inside the busbar to drive the fan and monitoring unit. The elastic contacts have an adaptive clamping function to ensure constant contact pressure and contact resistance of no more than 0.5mΩ under high current conditions.

[0012] Furthermore, the latching component is a swing hook driven by an internal torsion spring sleeve shaft of the housing. One end of the latching component is provided with a hook-shaped protrusion, which is used to form a physical complementary engagement with the locking groove preset on the bus system housing. The torsion spring sleeve shaft provides a constant preload to counteract the electric stress vibration generated by the large current, realizing a self-locking mechanism with dynamic vibration compensation capability, and ensuring the electrical connection stability of the system throughout its entire life cycle.

[0013] Furthermore, in the pluggable controlled flow field heat dissipation device, the air outlet direction of the fan is aligned with the longitudinal air duct formed by the T-shaped conductor inside the main body of the rail busbar. The airflow is forced into the busbar cavity and flows along the low-resistance longitudinal geometric air duct, actively carrying away the heat accumulated in the core part of the copper busbar.

[0014] Furthermore, in the aforementioned active heat exchange sealing structure, the end cap is a pre-installed terminal component. The end cap is fixedly installed on the end plate portion of the track busbar by bolts. The heat dissipation mesh holes on the end cap adopt a grid structure. The heat dissipation mesh holes are opened on the surface of the end cap facing the track busbar. An installation groove is opened on the surface of the end cap away from the track busbar where it overlaps with the heat dissipation mesh holes. The sealing plate is embedded in the installation groove. The sealing plate and the end cap adopt an integrated embedded installation structure.

[0015] Furthermore, in the terminal active heat exchange sealing structure, the fan module includes a housing and a fan housed in the housing. The elastic fastening mechanism includes a plug block disposed on the housing and a plug interface disposed on the end cover corresponding to the plug block. The plug block has elastic protrusions on both sides of its edge. The plug block is inserted into the plug interface and forms an elastic fastening connection through the elastic protrusions. The housing is provided with a locking block extending toward the end cover. The end of the locking block is provided with a locking hook. The end cover is provided with a locking hole corresponding to the locking block. When the end cover is fixedly installed with the housing, the locking block is inserted into the locking hole and the locking hook passes through the end cover and hooks onto the surface of the end cover. A sealing strip is provided at the connection between the end cover and the housing.

[0016] Furthermore, a heat dissipation panel is provided on the surface of the housing opposite to the end cover. The heat dissipation panel is circular. A longitudinal air duct is formed inside the housing. A fan is installed in the longitudinal air duct. When the fan is working, it forms forced convection at the end of the busbar trunking, and the heat inside the busbar is discharged from the mesh of the heat dissipation panel through the longitudinal air duct.

[0017] Furthermore, a sensor is installed inside the housing, and an indicator light and a controller are installed on the surface of the housing opposite to the end cover. Electrical contacts are reserved on the end cover, and a power input interface is correspondingly provided on the fan module. When the fan module is snapped onto the end cover, the power input interface contacts the electrical contacts and completes the electrical connection, thereby realizing the fan module's wire-free power supply.

[0018] Beneficial effects This application provides a track bus power supply system with distributed adaptive heat dissipation management function, which has the following advantages compared with the prior art: This technology significantly overcomes the heat dissipation bottleneck of high-power current carrying capacity by constructing a dual solid-flow field heat exchange system. The tight fit between the T-shaped conductor and the outer casing establishes a low-thermal-resistance solid-state heat conduction path; the combination of the active heat dissipation module and the vertical airflow channel achieves forced convection heat transfer. By replacing bulky stacking with an irregular cross-section and employing T-shaped conductors, it utilizes solid thermal bridges to dissipate heat while artificially creating air channels, using geometric structure to improve heat dissipation efficiency and significantly reducing copper usage. With the same copper busbar cross-sectional area, this technology can reduce the full-load temperature rise of the busbar by 20K–30K, supporting high-density computing power requirements from the traditional 10kW–15kW to over 35kW.

[0019] This solution resolves the inherent conflict between high protection levels and dynamic heat dissipation upgrades. Through end-cap-first design, the busbar's terminals remain under IP4X protection throughout initial installation and subsequent operation. Even during heat dissipation module upgrades, internal live conductors are not exposed, completely eliminating the risk of accidental electric shock for maintenance personnel. The tool-free quick-plug design allows for the dynamic online addition of fan modules based on rack load, without power outages or removal of existing end caps. Two-stage deployment enables non-destructive thermal upgrades, allowing maintenance personnel to dynamically enhance heat dissipation capabilities based on rack power consumption, similar to plugging and unplugging a USB drive, without power interruption or disassembly.

[0020] Eliminating external secondary cabling enables a plug-and-play, self-sufficient energy architecture. Replacing external cabling with self-powered logic, both the junction box and heat dissipation modules draw power directly from self-aligning contacts. This self-aligning power structure eliminates the complexity of secondary cabling, allowing for simultaneous physical fixing and electrical connection of the heat dissipation module during installation. It completely eliminates the secondary low-voltage cabling required by traditional external heat dissipation equipment, avoiding line interference and fire hazards in 1200A strong electromagnetic environments, and improving the system's electromechanical integration. Maintenance personnel can replace modules with one hand, significantly reducing the difficulty of operations in confined spaces (such as the top of a server room).

[0021] A reliable mechanical locking system with electro-stress compensation capability is achieved. The preload provided by the elastic locking mechanism ensures that the plug-in box and fan module will not loosen or generate electric arcs when subjected to electromagnetic vibrations caused by a 1200A short-circuit current. A swing-type hook mechanism driven by a torsion spring was developed, whose hook geometry and the head step of the T-shaped conductor form a physically complementary deadlock. The constant preload generated by the hook can counteract the electro-stress vibrations caused by the 1200A high current, ensuring that the physical position of the plug-in device does not shift and the contact pressure does not decrease throughout its entire life cycle, thus solving the technical problem of increased electrical contact resistance under high-current vibration environments.

[0022] A closed-loop digital intelligent monitoring system is achieved. Multi-color indicator lights and sensors integrated into the blocking terminals and plug-in modules transform complex busbar temperature rise states into intuitive visual signals (green for normal / yellow for warning / red for alarm), significantly shortening fault response time, reducing inspection manpower costs, and enabling proactive early warning and one-glance maintenance of the power distribution system. Temperature data and operating status are transmitted to external monitoring equipment or a host computer system via the plug-in interface, enabling remote monitoring and intelligent management.

[0023] The controlled flow field addresses the localized heat island problem. By utilizing the synergy of distributed heat dissipation devices and end-point sealing, active forced convection is established within the busbar, completely breaking the physical stalemate of static air inside traditional busbars. The fan exhaust direction is precisely aligned with the longitudinal airflow channel formed by the T-shaped conductor array inside the busbar, allowing the airflow to directly scour the core of the copper busbar. This achieves an effective forced convection channel within the enclosed cavity. The airflow is forcibly pushed into the busbar cavity, flowing along a low-resistance longitudinal geometric channel, actively carrying away the heat accumulated in the core of the copper busbar. Attached Figure Description

[0024] The accompanying drawings are provided to illustrate the technical solutions of this disclosure and form part of the specification. They are used together with the embodiments of this disclosure to explain the technical solutions of this disclosure and do not constitute a limitation on the technical solutions of this disclosure. The shapes and sizes of the components in the drawings do not reflect actual proportions and are only intended to illustrate the content of this application.

[0025] Figure 1 This is a schematic diagram showing the overall structure of a track bus power supply system with distributed adaptive heat dissipation management function provided in an embodiment of the present invention.

[0026] Figure 2 This is a schematic diagram of the overall structure of a track bus power supply system with distributed adaptive heat dissipation management function provided in an embodiment of the present invention.

[0027] Figure 3 Exploded view of an active heat exchange sealing structure at the end of an embodiment of the present invention. Figure 1 .

[0028] Figure 4 Exploded view of an active heat exchange sealing structure at the end of an embodiment of the present invention. Figure 2 .

[0029] Figure 5 This is a schematic diagram of the overall structure of a pluggable controlled flow field heat dissipation device provided in an embodiment of the present invention.

[0030] Figure 6 This is a schematic diagram of the internal structure of a pluggable controlled flow field heat dissipation device according to an embodiment of the present invention.

[0031] Figure 7This is a schematic diagram of a connector structure provided in an embodiment of the present invention.

[0032] Figure 8 This is a schematic diagram of a buckle locking mechanism provided in an embodiment of the present invention.

[0033] In the above attached figures, Overall bus power supply system: 200-Rail busbar body; 201-Shell profile; 202-T-type conductor; 203-Longitudinal geometric air duct; 204-Air inlet; 205-Slide rail air vane; 300-End active heat exchange sealing structure; 400-Plug-in controlled flow field heat dissipation device; Terminal active heat exchange sealing structure: 1-End cover; 11-Heat dissipation mesh; 12-Mounting groove; 2-Sealing plate; 3-Fan module; 31-Casing; 32-Fan; 4-Sealing strip; 5-Heat dissipation panel; 6-Indicator light; 7-Controller; 8-Plug-in block; 81-Elastic protrusion; 82-Plug-in interface; 9-Locking block; 91-Locking hook; 10-Locking hole; 101-Temperature sensor; 100-Bus system; Plug-in controlled flow field heat dissipation device: 1-box; 2-fan; 3-mesh cover; 4-bracket; 5-screw; 6-plug connector; 601-plug-in body; 602-elastic contact foot; 603-through hole; 7-indicator light; 8-controller; 9-torsion spring sleeve shaft; 10-fastener; 11-sealing strip; 12-sensor. Detailed Implementation

[0034] The above-described solution will be further illustrated below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of this application. The implementation conditions used in the embodiments may be further adjusted according to the conditions of specific manufacturers, and the implementation conditions not specified are generally those in routine experiments.

[0035] Unless otherwise defined, the technical or scientific terms used in the embodiments of this disclosure shall have the ordinary meaning understood by one of ordinary skill in the art to which this application pertains. The terms "first," "second," and similar terms used in the embodiments of this disclosure do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the element or object listed following the word and its equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. In this document, "electrical connection" includes the situation where constituent elements are connected together by an element having some electrical function. There is no particular limitation on the "electrically functioning element," as long as it enables the transmission and reception of electrical signals between the connected constituent elements. An "electrically functioning element" can be, for example, an electrode or wiring, a switching element such as a transistor, or other functional elements such as a resistor, inductor, or capacitor. "Up," "down," "left," and "right" are only used to indicate relative positional relationships. When the absolute position of the object being described changes, the relative positional relationship may also change accordingly.

[0036] In this application, the terms "upper," "lower," "inner," "middle," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing this application and its embodiments, and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation.

[0037] Example like Figure 1-2 As shown, an embodiment of the present invention provides a track bus power supply system with distributed adaptive heat dissipation management function. The system includes a track bus body 200, an end active heat exchange sealing structure 300, and at least one pluggable controlled flow field heat dissipation device 400.

[0038] The track bus body 200 includes an outer shell profile 201 and an array of T-shaped conductors housed within the outer shell profile 201. The outer shell profile 201 is made of high-strength aluminum alloy through extrusion molding, possessing excellent mechanical strength and heat dissipation performance. The T-shaped conductors 202 adopt a T-shaped cross-section design with specific protrusions, breaking through the traditional rectangular flat-arrange design. The T-shaped conductors 202 form a surface contact fit with the grooves on the inner wall of the outer shell profile 201 through their lateral protrusions, establishing a low thermal resistance solid heat conduction path (solid thermal bridge), initially transferring the conductor heat to the outer shell profile 201. Simultaneously, utilizing the abdominal space array between adjacent T-shaped conductors 202, a through-type longitudinal geometric air duct 203 is formed inside the outer shell profile 201. The side wall of the track busbar body 200 is provided with a filtered air inlet 204. The air inlet 204 is installed on the side wall profile of the track busbar body 200 via a slide rail sealing plate 205. The longitudinal geometric air duct 203 extends parallel to the axial direction of the track busbar body 200, changing the physical stagnation of air inside the traditional busbar. The T-shaped conductor 202 serves as both a current-carrying component and a heat dissipation air duct wall. By exchanging geometric structure for heat dissipation efficiency, the amount of copper used is significantly reduced, decreasing copper consumption by approximately 30% for the same current-carrying capacity.

[0039] During the low-load phase, the system relies on natural convection cooling through the longitudinal cavity between the T-shaped conductors 202. At this time, the end caps of the active heat exchange sealing structure at the end provide IP4X-level physical protection to ensure that no foreign objects enter the busbar. When the system detects an increase in branch current or a temperature rise exceeding a preset threshold, it enters the active cooling phase.

[0040] like Figure 3-4 As shown, the end active heat exchange sealing structure is set at the end of the track bus body 200, including end cover 1, sealing plate 2, fan module 3, sealing strip 4, temperature sensor 101, heat dissipation panel 5, indicator light 6 and controller 7.

[0041] End cap 1 is fixedly installed at the end of the track busbar body 200. End cap 1 is a pre-installed terminal assembly, and is fixedly installed to the end plate portion of the track busbar by bolts. Heat dissipation mesh 11 is provided on the end cap 1, located on the surface of the end cap 1 facing the track busbar. The heat dissipation mesh 11 on the end cap 1 adopts a grid structure, and the pore size of the grid is precisely calculated to ensure airflow while meeting the IP4X protection level requirement, i.e., preventing tools or metal wires with a diameter of 1.0 mm from entering the busbar groove.

[0042] An installation groove 12 is provided on the surface of the end cover 1 facing away from the busbar, where it overlaps with the heat dissipation mesh 11. A sealing plate 2 is embedded in the installation groove 12. The sealing plate 2 is used to seal the mesh when the fan module is not installed, preventing dust and foreign objects from entering the busbar trough. The end cover 1 and the sealing plate 2 adopt an integrated installation structure, meaning the sealing plate 2 does not protrude from the surface of the end cover 1 and uses an embedded installation structure. This facilitates installation and improves the overall structural integrity, making subsequent installation between the end cover 1 and the fan module easier.

[0043] The fan module 3 is detachably mounted on the surface of the end cover 1 facing away from the track busbar via an elastic fastening mechanism. The fan module 3 includes a housing 31 and a fan 32 housed within the housing 31. The elastic fastening mechanism includes a plug block 8 on the housing 31 and a plug interface 82 on the end cover 1 corresponding to the plug block 8. Elastic protrusions 81 are provided on both sides of the plug block 8, and the plug block 8 is inserted into the plug interface 82 to form an elastic fastening connection through the elastic protrusions 81. The end cover 1 has corresponding force-bearing points that cooperate with the elastic protrusions 81, and the fan module 3 is automatically spring-locked onto the end cover 1 by the elastic fastening mechanism. The pre-tightening force provided by the elastic fastening mechanism ensures that the plug box and the fan module 3 will not loosen or generate electric arcs when encountering electromagnetic vibrations caused by short-circuit currents. Meanwhile, maintenance personnel only need to snap the wind turbine module directly onto the end cover 1, and the elastic protrusion 81 will automatically spring back and lock. The whole process does not require the use of screwdrivers or wrenches, achieving rapid installation.

[0044] Meanwhile, a physical interference protection structure is designed between the fan module 3 and the end cover 1. This physical interference protection structure includes a locking block 9 extending from the housing 31 toward the end cover 1. The end of the locking block 9 is provided with a locking hook 91, and the end cover 1 has a locking hole 10 corresponding to the locking block 9. When the end cover 1 is fixedly installed with the housing 31, the locking block 9 is inserted into the locking hole 10, and the locking hook 91 passes through the end cover 1 and hooks onto the surface of the end cover 1. In the event that the fan is not properly inserted, the hook will not lock, thus preventing accidental operation.

[0045] A sealing strip 4 is provided at the connection between the end cover 1 and the housing 31 to improve the overall sealing performance of the structure. The sealing strip 4 is made of high-temperature resistant silicone rubber material, which can maintain good sealing performance in a temperature range of -40℃ to 150℃.

[0046] A heat dissipation panel 5 is provided on the surface of the housing 31 opposite to the end cover 1. The heat dissipation panel 5 is circular. A longitudinal air duct is formed inside the housing 31, and the fan 32 is installed in the longitudinal air duct. The fan 32 adopts a high-reliability DC brushless fan, which features low noise, long life and high efficiency. When the fan 32 is working, it creates forced convection at the end of the busbar, which exhausts the heat inside the busbar through the mesh of the heat dissipation panel 5 through the longitudinal air duct, breaking the stagnation of airflow at the end and achieving uniform heat dissipation throughout the busbar.

[0047] Electrical contacts are pre-installed on end cap 1, and these contacts are electrically connected to the live conductors inside the busbar trunking. A corresponding power input interface is provided on the fan module, which is electrically connected to the power module inside the fan module. When the fan module is snapped onto end cap 1, the power input interface contacts the electrical contacts and completes the electrical connection, enabling wired power supply to the fan module. This self-aligning power input structure eliminates the complexity of secondary wiring, allowing the heat dissipation module to be physically fixed and electrically connected simultaneously during installation, improving the system's modularity and reliability.

[0048] A temperature sensor 101 is installed on the fan module. In this embodiment, the temperature sensor 101 is located inside the end cover 1, near the busbar end connection, and is used to detect the temperature at the busbar end connection in real time. The temperature sensor 101 is a high-precision digital temperature sensor with a measurement accuracy of ±0.5℃ and a response time of less than 1 second. The temperature sensor 101 is electrically connected to the controller 7, and transmits the detected temperature signal to the controller 7. The controller 7 is located inside the fan module and is an embedded microcontroller with data acquisition, processing, and control output functions. The controller 7 is electrically connected to the indicator light 6, and the controller 7 controls the indicator light 6 to display different colors according to the temperature signal.

[0049] Indicator 6 is a multi-color LED indicator, located on the outer surface of the fan module for easy observation by maintenance personnel. Indicator 6 displays green, yellow, or red according to the instructions of controller 7, corresponding to normal operation, warning, and overheat alarm status at the bus terminal, respectively. Specifically, when the temperature detected by temperature sensor 101 is lower than a preset first threshold (e.g., 60℃), controller 7 controls indicator 6 to display green, indicating normal operation at the bus terminal; when the temperature detected by temperature sensor reaches or exceeds the first threshold but is lower than the second threshold (e.g., 80℃), controller 7 controls indicator 6 to display yellow, indicating the bus terminal is in a warning state, reminding maintenance personnel to pay attention; when the temperature detected by temperature sensor 101 reaches or exceeds the second threshold, controller 7 controls indicator 6 to display red, indicating the bus terminal is in an overheat alarm state, requiring immediate action. Simultaneously, controller 7 can also control the fan speed 32 based on the temperature signal, automatically increasing the fan speed to enhance heat dissipation when the temperature rises and automatically decreasing the fan speed to save energy and reduce noise when the temperature falls.

[0050] The wind turbine module is equipped with a connector located on its side. This connector is used to connect to external monitoring equipment or a host computer system. The connector uses a standard communication interface (such as RS485 or Ethernet), allowing data such as temperature data detected by temperature sensors, wind turbine operating status, and indicator light status to be transmitted to the external monitoring equipment or host computer system. This enables remote monitoring and data transmission of the busbar terminal's operating status. Maintenance personnel can view the real-time operating status of each busbar terminal from the monitoring center, promptly identify and handle anomalies, and achieve intelligent management of the power distribution system.

[0051] like Figure 5-8 As shown, it includes a pluggable controlled flow field heat dissipation device, which can be distributedly plugged into any plug-in position of the track bus body 200, including a housing 1, a fan 2, a mesh cover 3, a bracket 4, screws 5, a plug connector 6, an indicator light 7, a controller 8, a torsion spring sleeve shaft 9, a fastener 10, a sealing strip 11, and a sensor 12.

[0052] The enclosure 1 is a box-shaped structure with a square bottom but rounded corners. The enclosure 1 is made of aluminum alloy or flame-retardant ABS plastic, and the bottom surface of the enclosure 1 in contact with the bus system shell is coated with a thermally conductive silicone grease layer with a thermal conductivity of not less than 2.0 W / (m·K) to reduce contact thermal resistance and enhance solid thermal conductivity.

[0053] The interior of housing 1 houses a fan 2 for heat dissipation. Fan 2 has five identical impellers, each with a diameter ranging from 40-80mm. Fan 2 has a rated voltage of DC-12V or 24V, a rated power of 2-10W, an airflow range of 10-50CFM, and a static pressure range of 10-50Pa. Fan 2 is driven by a high-reliability DC brushless motor, characterized by low noise, long lifespan, and high efficiency.

[0054] A mesh cover 3 is installed above and below the fan 2 and on the upper and lower surfaces of the housing 1 to cover the fan 2. The mesh cover 3 is made of corrosion-resistant stainless steel, and the mesh size of the mesh cover 3 has been precisely calculated to ensure maximum airflow area while meeting safety protection requirements. A pair of brackets 4 are fixedly connected to the side of the mesh cover 3 away from the fan 2. The brackets 4 are fixedly connected to the housing 1 by screws 5 to enhance structural stability.

[0055] A connector 6 for insertion into a busbar system slot is provided on one side of the front of the enclosure 1. The connector 6 includes a connector body 601, and multiple elastic contacts 602 are provided in the middle of the front side of the connector body 601. The elastic contacts 602 are made of beryllium bronze or phosphor bronze, which has excellent elasticity and conductivity. The cross-section of the elastic contacts 602 is U-shaped or V-shaped, and it has an adaptive clamping function. Multiple through holes 603 are evenly distributed on the surface of the connector body 601 to reduce weight and assist in heat dissipation.

[0056] Sensor 12 is located on the other side of the front of enclosure 1. Sensor 12 is a temperature / wind speed sensor. The temperature sensor is attached to the bottom surface of enclosure 1 to monitor the temperature of the bus system casing in real time; while the wind speed sensor is located on the fan outlet side to monitor the wind speed on the fan outlet side.

[0057] Unlike the right-angled sides of the connector 6 and sensor 12, the front of the enclosure 1 has sealing strips 11 on both sides. The sealing strips 11 are made of either silicone rubber or ethylene propylene diene monomer (EPDM) rubber, and have a D-shaped cross-section with a compression deformation rate controlled within the range of 20%-30%. They are used to establish a reliable sealing fit between the enclosure 1 and the busbar system shell to prevent dust and moisture from entering.

[0058] A latching element 10 is located in the middle of the two sides of the housing 1 corresponding to the sealing strip 11. The latching element 10 is a swing hook driven by the internal torsion spring sleeve shaft 9 of the housing 1. One end of the latching element 10 has a hook-shaped protrusion for physical complementary engagement with the pre-set locking groove on the busbar system housing. The torsion spring sleeve shaft 9 provides a constant preload force, which can counteract the electro-mechanical stress vibration generated by the 1200A high current, realizing a self-locking mechanism for dynamic vibration compensation. When the heat dissipation device is installed in place, the latching element 10 automatically hooks into the locking groove and makes a clicking sound to indicate that the locking is complete; when disassembly is required, the operator can press the unlocking end of the latching element 10 by hand to disengage the hook from the locking groove and pull it out.

[0059] The fastener 10 and the front of the housing 1 are respectively equipped with an indicator light 7 and a controller 8. The indicator light 7 is a three-color LED indicator used to display the working status of the heat dissipation device, including green for normal operation, yellow for over-temperature warning, and red for fan failure or maintenance. The controller 8 is an embedded microcontroller (MCU) used to receive real-time signal feedback from the sensor 12 to control the operating status of the fan 2. Based on the feedback signal from the temperature sensor, the controller 8 automatically adjusts the fan speed of the fan 2 using a PID algorithm: when the bus temperature rises, the fan speed of the fan 2 increases, and the airflow increases; when the temperature drops to a set threshold, the fan 2 slows down to reduce energy consumption and noise.

[0060] The working process of the track bus power supply system with distributed adaptive heat dissipation management function of the present invention is as follows: (I) Physical Architecture and Initial Security Deployment Phase The system first establishes a basic power distribution channel through T-shaped conductors 202 with T-shaped cross-sections. The T-shaped conductors 202 form surface contact with the grooves on the inner wall of the outer shell profile 201 through their lateral protrusions, establishing a low thermal resistance solid heat conduction path to initially conduct heat to the outer shell profile 201. The internal space between adjacent T-shaped conductors 202 forms a longitudinal geometric air duct 203.

[0061] During the initial system installation phase, the end cap 1 of the active heat exchange sealing structure is first fixed to the end of the busbar profile using bolts. The heat dissipation mesh 11 on the end cap 1 is sealed by the sealing plate 2, and the sealing strip 4 between the sealing plate 2 and the end cap 1 ensures the sealing protection of the end. At this time, the busbar end is under IP4X protection, and the internal live conductors are not exposed, so there is no need to worry about electric shock to maintenance personnel. The temperature sensor 101 inside the end cap 1 monitors the temperature at the connection point of the busbar end in real time. During the low-load phase, the system relies on the longitudinal cavity between the T-shaped conductors 202 for natural convection heat dissipation, and the end cap 1 provides IP4X physical protection to ensure that no foreign objects enter the busbar.

[0062] (II) Wireless self-powering and active flow field activation stage When the system detects an increase in branch current or a temperature rise exceeding a preset threshold, it enters the active heat dissipation phase. For end-point heat dissipation: When the load on the data center cabinet increases and the busbar temperature rises too high, maintenance personnel can add fan modules 3 online in real time. The specific operation is as follows: push the fan module 3 into place along the guide rail of the end cover 1. The power interface on the fan module 3 contacts the electrical contacts on the end cover 1, and the elastic locking mechanism automatically springs back and locks it onto the end cover 1, completing the physical fixation and electrical connection of the fan module 3. After the fan module 3 is installed, the fan 32 starts working, creating forced convection at the end of the busbar, dissipating the heat inside the busbar through the heat dissipation mesh 11 and the heat dissipation panel 5, breaking the stagnant airflow at the end and achieving uniform heat dissipation throughout the busbar.

[0063] For distributed heat dissipation: Maintenance personnel directly attach the active heat dissipation module (plug-in controlled flow field heat dissipation device) to the side wall of the busbar trunking using the snap-fit ​​component 10. Specifically, the operator holds the heat dissipation device and pushes the plug-in 6 on the front of the enclosure 1 into the pre-set interface inside the busbar system casing. During insertion, the elastic contact 602 at the front of the plug-in body 601 adaptively clamps the T-shaped copper busbar inside the busbar, achieving electrical connection. When the plug-in 6 is fully inserted, the swing hook snap-fit ​​components 10 on both sides of the enclosure 1, driven by the torsion spring-sleeved shaft 9, automatically hook into the locking groove on the busbar system casing, emitting a click sound to indicate that locking is complete. At this time, the sealing strip 11 is tightly attached to the busbar system casing.

[0064] Self-powered logic: The elastic contact 602 at the bottom of the heat dissipation module passes through the profile window and directly contacts the belly of the bus conductor to obtain power (DC-12V or 24V). This process requires no external secondary wiring and realizes plug-and-play power drive.

[0065] Controlled flow field construction: After fan 2 starts, the airflow generated is drawn in through the mesh cover 3 on the lower surface of housing 1 and discharged through the mesh cover 3 on the upper surface of housing 1. Because the airflow direction of fan 2 is precisely aligned with the longitudinal airflow channel formed by the T-shaped conductor array inside the busbar, the airflow is forcibly pushed into the busbar cavity, flowing along the low-resistance longitudinal geometric airflow channel, actively carrying away the heat accumulated in the core area of ​​the copper busbar, forming a controlled flow field. Combined with the negative pressure generated at the end of the busbar by the terminal fan module 3, the longitudinal channel formed by the T-shaped conductor array is used as an exhaust duct to forcibly extract the hot air accumulated deep within the busbar cavity, forming a controlled longitudinal flow field that runs through the entire busbar.

[0066] (III) Intelligent monitoring and locking coordination stage under dynamic load During high-power system operation (e.g., 1200A full load): Status Feedback: Controller 8 (or Controller 7) collects data from the temperature and wind speed sensors in real time. During normal operation, indicator light 7 (or indicator light 6) is green. When the bus temperature exceeds the set threshold, the controller switches the indicator light to a yellow warning state and runs the fan at full speed. When a fan malfunctions or the air duct is blocked, causing the wind speed to fall below the set lower limit, the indicator light switches to a red alarm state. The multi-color LED indicator on the panel provides feedback on the operating status (green for normal / yellow for warning / red for alarm), enabling quick and on-site fault diagnosis.

[0067] Vibration compensation locking: For the electric stress vibration generated by high current, the torsion spring sleeved with the shaft 9 and the buckle 10 driven by it provides dynamic pressure compensation, ensuring that the physical engagement between the heat dissipation device and the bus system shell remains stable under vibration environment, and preventing secondary heating caused by increased contact resistance.

[0068] Remote monitoring: Temperature data and operating status are transmitted to external monitoring equipment or host computer system through the interface. Maintenance personnel can view the operating status of each heat dissipation node in real time at the monitoring center, promptly detect and handle abnormal situations, and realize intelligent remote monitoring and management of the power distribution system.

[0069] (iv) Uninterrupted power supply maintenance and heat dissipation upgrade phase When increased cooling capacity or maintenance is required, maintenance personnel can operate without power interruption. For pluggable controlled flow field cooling devices, operators can manually press the unlocking end of the latch 10 to disengage the hook from the locking slot, allowing the cooling device to be pulled out for maintenance or replacement. For the terminal fan module 3, pressing the elastic protrusion 81 releases the latch, enabling quick module replacement. The entire process requires no screwdrivers or wrenches, and no external wiring, achieving plug-and-play hot-swappable maintenance. Through a two-tier deployment logic of adding the fan after the end cover is installed, online non-destructive thermal upgrades of the cooling module are achieved while ensuring the system remains under IP4X safety protection, meeting the flexible expansion requirements of computing load.

[0070] In practical applications, the rail bus power supply system with distributed adaptive heat dissipation management function of the present invention can be flexibly configured and dynamically expanded according to the actual load of the data center.

[0071] In the initial deployment phase (low-load scenario), only the end cover 1 and the sealing plate 2 are installed to form a basic protection system. The system relies on the solid heat conduction path of the T-shaped conductor 202 and the natural convection of the longitudinal geometric air duct 203 for passive heat dissipation, which can meet the heat dissipation requirements of the low power density cabinet in the initial stage. The end cover 1 provides an IP4X protection rating, and the temperature sensor 101 continuously monitors the terminal temperature status.

[0072] When the load increases to a moderate level (e.g., single-cabinet power increases to 20-25kW), maintenance personnel can plug in and install pluggable controlled flow field cooling devices at critical hotspot locations on the track busbar (e.g., the middle and end sections of the busbar). These cooling devices draw power directly from the belly of the T-shaped conductor via connector 6, allowing for the activation of fan 2 to create a localized forced convection airflow without external wiring. Controller 8 automatically adjusts the fan speed based on temperature sensor feedback, and indicator lights 7 display the operating status in real time, enabling on-demand cooling management.

[0073] In high-load scenarios (such as single-rack power reaching 35kW or higher, system current reaching 1200A), a fan module 3 is installed at the end position to work in conjunction with a distributed, pluggable, controlled flow field cooling device. The end fan module 3 generates a negative pressure suction effect at the end of the bus, which, together with the positive pressure push of the distributed cooling device, establishes a through-type controlled forced flow field along the entire bus. This bidirectional flow field architecture of end suction plus central push completely eliminates the airflow dead zone and heat island effect inside the bus, reducing the full-load temperature rise of the bus by 20K to 30K.

[0074] The entire upgrade process for heat dissipation capacity is carried out online, without power outages, disassembly of the original structure, or external wiring. Maintenance personnel can gradually enhance heat dissipation capacity in stages and steps, based on the annual increase in actual load, without power interruption, achieving true flexible expansion and investment protection.

[0075] The above embodiments are only for illustrating the technical concept and features of this application, and are intended to enable those skilled in the art to understand the content of this application and implement it accordingly. They should not be used to limit the scope of protection of this application. All equivalent changes or modifications made in accordance with the spirit and essence of this application should be included within the scope of protection of this application.

Claims

1. A track bus power supply system with distributed adaptive heat dissipation management function, characterized in that, include: The track busbar body includes an outer shell profile and a T-shaped conductor housed inside the outer shell profile. The T-shaped conductor has a T-shaped cross-section, and the lateral protrusion of the T-shaped conductor forms a surface contact fit with the groove of the inner wall of the outer shell profile. A longitudinal geometric air duct is formed between adjacent T-shaped conductors. A pluggable controlled flow field heat dissipation device is detachably plugged into the middle side wall of the rail bus body. The pluggable controlled flow field heat dissipation device includes a housing and a fan located inside the housing. A plug connector for plugging into the rail bus body is provided on one side of the front of the housing. An active heat exchange sealing structure is provided at the end of the track bus body. The active heat exchange sealing structure includes an end cover, a sealing plate, and a fan module. The end cover is fixedly provided at the end of the track bus body and has heat dissipation mesh holes. The sealing plate is fixedly provided on the part of the end cover with heat dissipation mesh holes and located on the surface of the end cover opposite to the track bus body. The fan module is detachably installed on the surface of the end cover opposite to the track bus body through an elastic fastening mechanism.

2. The track bus power supply system with distributed adaptive heat dissipation management function according to claim 1, characterized in that: The lateral protrusions of the T-shaped conductors form a low-thermal-resistance solid heat conduction path between the grooves on the inner wall of the outer shell profile. The abdominal space array between the T-shaped conductors forms a through-type longitudinal geometric air duct inside the outer shell profile. The longitudinal geometric air duct extends parallel to the axial direction of the track busbar body. The T-shaped conductors also serve as current-carrying elements and heat dissipation air duct walls, realizing the synergistic heat exchange of solid heat conduction and airflow convection.

3. The track bus power supply system with distributed adaptive heat dissipation management function according to claim 1, characterized in that: In the pluggable controlled flow field heat dissipation device, a mesh cover for covering the fan is provided above and below the fan and on the upper and lower surfaces of the housing. A pair of brackets are fixedly connected to the side of the mesh cover away from the fan. A sensor is provided on the other side of the front of the housing. Sealing strips are provided on both sides of the front of the housing. A fastener is provided in the middle of the two sides of the housing corresponding to the sealing strip. An indicator light and a controller are respectively provided on the fastener and the front of the housing.

4. The track bus power supply system with distributed adaptive heat dissipation management function according to claim 3, characterized in that: The connector structure includes a connector body, with multiple elastic contacts located in the middle of the front side of the connector body. The elastic contacts are made of beryllium bronze or phosphor bronze and have a U-shaped or V-shaped cross-section. Multiple through holes are evenly distributed on the surface of the connector body. The connector passes through a pre-set window in the outer shell profile and uses the cavity in the belly of the T-shaped conductor to achieve automatic alignment and power extraction, directly obtaining power energy from inside the busbar to drive the fan and monitoring unit. The elastic contacts have an adaptive clamping function to ensure constant contact pressure and contact resistance of no more than 0.5mΩ under high current conditions.

5. The track bus power supply system with distributed adaptive heat dissipation management function according to claim 3, characterized in that: The latching component is a swing hook driven by an internal torsion spring sleeve shaft of the housing. One end of the latching component has a hook-shaped protrusion, which is used to form a physical complementary engagement with the locking groove preset on the bus system housing. The torsion spring sleeve shaft provides a constant preload to counteract the electric stress vibration generated by the large current, realizing a self-locking mechanism with dynamic vibration compensation capability, and ensuring the electrical connection stability of the system throughout its entire life cycle.

6. The track bus power supply system with distributed adaptive heat dissipation management function according to claim 1, characterized in that: In the pluggable controlled flow field heat dissipation device, the air outlet direction of the fan is aligned with the longitudinal air duct formed by the T-shaped conductor inside the main body of the rail busbar. The airflow is forced into the busbar cavity and flows along the low-resistance longitudinal geometric air duct, actively carrying away the heat accumulated in the core part of the copper busbar.

7. The track bus power supply system with distributed adaptive heat dissipation management function according to claim 1, characterized in that: In the aforementioned active heat exchange sealing structure, the end cover is a pre-installed terminal component. The end cover is fixedly installed on the end plate portion of the track busbar by bolts. The heat dissipation mesh on the end cover adopts a grid structure. The heat dissipation mesh is opened on the surface of the end cover facing the track busbar. An installation groove is opened on the surface of the end cover away from the track busbar where it overlaps with the heat dissipation mesh. The sealing plate is embedded in the installation groove. The sealing plate and the end cover adopt an integrated embedded installation structure.

8. The track bus power supply system with distributed adaptive heat dissipation management function according to claim 1, characterized in that: In the terminal active heat exchange sealing structure, the fan module includes a housing and a fan housed in the housing. The elastic fastening mechanism includes a plug block disposed on the housing and a plug interface disposed on the end cover corresponding to the plug block. The plug block has elastic protrusions on both sides of its edge. The plug block is inserted into the plug interface and forms an elastic fastening connection through the elastic protrusions. The housing is provided with a locking block extending toward the end cover. The end of the locking block is provided with a locking hook. The end cover is provided with a locking hole corresponding to the locking block. When the end cover is fixedly installed with the housing, the locking block is inserted into the locking hole and the locking hook passes through the end cover and hooks onto the surface of the end cover. A sealing strip is provided at the connection between the end cover and the housing.

9. The track bus power supply system with distributed adaptive heat dissipation management function according to claim 8, characterized in that: A heat dissipation panel is provided on the surface of the housing opposite to the end cover. The heat dissipation panel is circular. A longitudinal air duct is formed inside the housing. A fan is installed in the longitudinal air duct. When the fan is working, it forms forced convection at the end of the busbar trunking, and the heat inside the busbar is discharged from the mesh of the heat dissipation panel through the longitudinal air duct.

10. The track bus power supply system with distributed adaptive heat dissipation management function according to claim 8, characterized in that: A sensor is installed inside the housing, and an indicator light and a controller are installed on the side of the housing facing away from the end cover. Electrical contacts are reserved on the end cover, and a power input interface is correspondingly provided on the fan module. When the fan module is snapped onto the end cover, the power input interface contacts the electrical contacts and completes the electrical connection, realizing the fan module's wire-free power supply.

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