A method and system for integrated integration and control of direct current power supply for data center

Abstract

The application relates to the technical field of data center power supply, in particular to a direct current power supply integrated and controlled method and system for a data center, which comprises the following steps: a medium-voltage power distribution step, in which a medium-voltage power distribution module is connected to a medium-voltage alternating current power supply for switch control and lightning protection; a transformer step, in which a non-phase-shifting isolation transformer module is used to reduce the voltage of the medium-voltage alternating current power supply and output low-voltage alternating current to a high-frequency PFC rectifier module; a high-frequency rectification step, in which the high-frequency PFC rectifier module receives the low-voltage alternating current, rectifies and corrects the power factor, and then outputs stable direct current voltage to a direct current bus; a direct current output step, in which the direct current voltage of the direct current bus is distributed and output to a data center load; and a cooperative control step, in which a control module is used to monitor working parameters in real time, perform parallel cooperative control on the high-frequency PFC rectifier module, and execute fault processing when a fault is detected. The application has the effects of improving the efficiency of a direct current power supply device of a data center and improving the capacity adaptability.

Description

Technical Field

[0001] This invention relates to the field of data center power supply technology, and specifically to an integrated method and system for DC power supply and control in data centers. Background Technology

[0002] With the rapid development of artificial intelligence, cloud computing, and big data technologies, the power of single data center racks has reached hundreds of kilowatts or even megawatts. The limitations of traditional AC power supply systems in terms of efficiency, space utilization, and power density are becoming increasingly apparent, making high-voltage DC power supply a core direction for data center energy architecture innovation. Among these, 800V or ±400V high-voltage DC power supply has become a new choice in the data center power supply field due to its advantages such as low transmission loss, low copper consumption, and high system efficiency.

[0003] Currently, there are three main technical routes for high-voltage DC power supply in data centers. The first route uses conventional power frequency transformers to convert 10kV AC to 380V AC, which is then connected to a rectifier via low-voltage distribution cables for two-stage AC-DC and DC-DC conversion before outputting DC power. This route has many power conversion stages, low system integration, dispersed functional modules, a large footprint, long on-site construction periods, and significant low-voltage AC current and line losses. The second route uses the Panama Canal power architecture with phase-shifting transformers. Although prefabrication is achieved through the integrated design of the transformer and rectifier modules, the phase-shifting transformer has high process complexity, large copper consumption, and high manufacturing costs. Furthermore, the low-voltage current harmonics are significant, affecting the overall system efficiency. The third route uses solid-state transformer power supply architectures. While these have advantages such as small size and high conversion efficiency, the core power devices rely on wide-bandgap semiconductors, resulting in high costs. Reliability still requires long-term verification, and the lack of unified industry standards makes large-scale application in the data center field difficult.

[0004] Regarding the aforementioned technologies, existing DC power supply devices for data centers either suffer from low efficiency, insufficient integration, and long construction cycles, or have drawbacks such as excessive cost, complex device processes, insufficient reliability, and poor capacity adaptability. They are unable to simultaneously meet the power supply requirements of data centers for high efficiency, low cost, high integration, high reliability, and flexible adaptability. Therefore, there is an urgent need to develop a new DC power supply technology solution for data centers that combines high efficiency, low cost, prefabricated integration, high reliability, and flexible capacity adaptability. Summary of the Invention

[0005] To address the technical problems of low efficiency, high cost, and poor capacity adaptability of existing DC power supply devices for data centers, this application provides an integrated and controlled method for DC power supply in data centers.

[0006] Firstly, this application provides an integrated method for DC power supply and control in data centers: An integrated DC power supply and control method for data centers includes: In the medium-voltage power distribution step, the medium-voltage AC power supply is connected through the medium-voltage power distribution module in the prefabricated integrated cabinet, and the medium-voltage AC power supply is switched and protected against lightning. The transformer step-down step involves using a non-phase-shifting isolation transformer module in the prefabricated integrated cabinet to step down the medium-voltage AC power supply, and then outputting the stepped-down low-voltage AC power to the high-frequency PFC rectifier module, while simultaneously achieving electrical isolation. In the high-frequency rectification step, the low-voltage AC power is received by the high-frequency PFC rectifier module in the prefabricated integrated cabinet. The low-voltage AC power is directly rectified and the power factor is corrected before a stable DC voltage is output to the DC bus. The high-frequency PFC rectifier module directly completes the AC to DC conversion without going through an intermediate DC / DC conversion stage. In the DC output step, the DC voltage of the DC bus is distributed and output to the data center load through the DC output module in the prefabricated integrated cabinet; The collaborative control step involves real-time monitoring of the operating parameters of the medium-voltage power distribution module, the non-phase-shifting isolation transformer module, the high-frequency PFC rectifier module, and the DC output module through the control module in the prefabricated integrated cabinet. This enables multi-module parallel collaborative control of the high-frequency PFC rectifier module and the execution of fault handling operations when a fault is detected.

[0007] By adopting the above technical solutions, the steps of medium-voltage power distribution, transformer step-down, high-frequency rectification, DC output and collaborative control work together to achieve integrated deployment with prefabricated integrated cabinets. Non-phase-shifting isolation transformers are used to complete voltage reduction and electrical isolation. The intermediate DC / DC conversion stage is eliminated by high-frequency PFC rectifier modules, which helps to improve the conversion efficiency of DC power supply in data centers, enhance system integration, shorten the on-site construction cycle and improve the capacity adaptability of the power supply system.

[0008] Optionally, in the high-frequency rectification step, the high-frequency PFC rectification module includes multiple parallel three-phase high-frequency PFC rectification units, and the coordinated control step further includes parallel current sharing control: The output current of each of the three-phase high-frequency PFC rectifier units is collected in real time. Based on the deviation between each output current and the average current, the switching duty cycle of each of the three-phase high-frequency PFC rectifier units is dynamically adjusted so that the output current deviation of each of the three-phase high-frequency PFC rectifier units is kept within a preset deviation threshold.

[0009] By adopting the above technical solution, the output current of each three-phase high-frequency PFC rectifier unit is collected in real time and the switching duty cycle is dynamically adjusted. This helps to realize the parallel current sharing operation of multiple rectifier units, control the output current deviation of each unit within a reasonable range, improve the stability of the parallel operation of multiple modules, and ensure the stability of the DC bus voltage output.

[0010] Optionally, it also includes adaptive charge / discharge control steps for the energy storage battery: The energy storage battery pack is connected to the DC bus via a bidirectional DC / DC module to monitor the voltage fluctuation of the DC bus in real time. When the DC bus voltage is detected to drop to a preset first voltage threshold, the bidirectional DC / DC module is controlled to discharge the energy storage battery pack and boost the voltage to the DC bus voltage to provide supplementary power to the load. When the DC bus voltage is detected to rise to a preset second voltage threshold, the bidirectional DC / DC module is controlled to step down the excess power in the DC bus and charge the energy storage battery pack, thereby maintaining the DC bus voltage within a preset stable range.

[0011] By adopting the above technical solution, the energy storage battery pack is connected through a bidirectional DC / DC module and the DC bus voltage is monitored in real time. The charging and discharging actions are adaptively controlled according to the voltage threshold, which helps to stabilize the DC bus voltage level, replenish the load with power in a timely manner or absorb excess power, and improve the continuity and voltage stability of the power supply to the data center.

[0012] Optionally, in the transformer step-down step, the low-voltage side of the non-phase-shifting isolation transformer module uses a single-winding structure to supply power to a single high-frequency PFC rectifier module, or uses a multi-winding structure to supply power to multiple high-frequency PFC rectifier modules respectively.

[0013] By adopting the above technical solutions, the low-voltage side of the non-phase-shifting isolation transformer can use a single-winding or multi-winding structure to adapt to different power supply configurations. This helps to flexibly match single or multiple high-frequency PFC rectifier modules, simplify the line configuration of small-capacity systems, reduce the difficulty of parallel control of large-capacity systems, and improve the system's adaptability to different capacity scenarios.

[0014] Optionally, in the transformer step-down step, the primary side of the non-phase-shifting isolation transformer module is adapted to 10kV, 11kV, 13.8kV, 20kV, 33kV, and 35kV medium-voltage power grids; the output voltage of the low-voltage side of the transformer is matched according to the overvoltage fault ride-through level of the power grid: in the case of fault ride-through ≤120%, the low-voltage side output is 408V or 471VAC; in the case of fault ride-through ≥130%, the low-voltage side output is 377V or 435VAC, and the output DC bus voltage is kept constant by relying on high-frequency PFC rectification closed-loop voltage regulation.

[0015] By adopting the above technical solution, the non-phase-shifting isolation transformer differentiates the rated voltage of the primary winding according to the medium voltage level of the grid connection, adapting to the medium voltage power supply standards of different regions worldwide: for grid voltage = 10kV, a 10kV-class power frequency transformer is selected; for grid voltage = 33kV or 35kV, a 33kV / 35kV large-capacity power frequency transformer is selected; the AC output voltage of the low-voltage winding is configured according to the overvoltage ride-through level of the data center power supply system in different regions, which can minimize the effective value of the low-voltage side AC current, optimize transformer winding losses and PFC rectifier switching losses, and maximize the overall system efficiency; optionally, at least one of the following steps is also included: The midpoint balancing step generates a DC midpoint between the positive and negative poles of the DC bus through the midpoint balancing module, and outputs a three-wire DC power supply with positive DC voltage, negative DC voltage and zero voltage. In the backup power switching procedure, when an abnormality is detected in the main input power supply, the load power supply is switched from the main input power supply to the backup power supply through the static switching module, or the energy storage battery pack is controlled to discharge through the bidirectional DC / DC module, and the stored energy is delivered to the load through the DC bus.

[0016] By adopting the above technical solutions, the addition of a midpoint balancing step can output three-wire DC power to meet diverse load requirements, and the backup power switching step can quickly switch the power supply path when the main power supply is abnormal. This helps to expand the types of power supply output of the system and improve the uninterruption of power supply and the breadth of load adaptability of the data center.

[0017] Optionally, in the coordinated control step, the control module also performs insulation monitoring and protection control. The insulation monitoring module detects the insulation resistance of the DC bus to ground in real time, and issues an alarm signal when the insulation resistance is less than a preset alarm value. At the same time, the fuse of the protection module is used to cut off the extreme fault current, and the mechanical DC circuit breaker is used to achieve rapid tripping of overload and short circuit faults.

[0018] By adopting the above technical solution, the control module synchronously performs insulation monitoring and multiple protection controls, promptly detects insulation abnormalities and issues alarm signals, and uses fuses and mechanical DC circuit breakers to handle fault currents in a coordinated manner, which helps to improve the safety of system operation, quickly cut off faults and prevent the scope of accidents from expanding.

[0019] Secondly, this application provides an integrated DC power supply and control system for data centers, employing the following technical solution: An integrated DC power supply and control system for data centers includes: Prefabricated integrated cabinet; the prefabricated integrated cabinet integrates a medium-voltage power distribution module for connecting to a medium-voltage AC power supply and for switching control and lightning protection of the medium-voltage AC power supply; The non-phase-shifting isolation transformer module is integrated into the prefabricated integrated cabinet and is electrically connected to the medium-voltage power distribution module. It is used to step down the medium-voltage AC power supply and achieve electrical isolation. The high-frequency PFC rectifier module is integrated into the prefabricated integrated cabinet and electrically connected to the low-voltage side of the non-phase-shifting isolation transformer module. It is used to directly rectify and power factor correct the stepped-down low-voltage AC power and output a stable DC voltage to the DC bus. The high-frequency PFC rectifier module does not include an intermediate DC / DC conversion stage. A DC output module, integrated within the prefabricated integrated cabinet, is electrically connected to the DC bus and is used to distribute and output the DC voltage from the DC bus to the data center load. The control module, integrated within the prefabricated integrated cabinet, is electrically connected to the medium-voltage power distribution module, the non-phase-shifting isolation transformer module, the high-frequency PFC rectifier module, and the DC output module, respectively. It is used to monitor the operating parameters of each module in real time, perform multi-module parallel collaborative control of the high-frequency PFC rectifier module, and execute fault handling operations when a fault is detected.

[0020] By adopting the above technical solution, medium-voltage power distribution, non-phase-shifting isolation transformer, high-frequency PFC rectification, DC output and control module are integrated into a prefabricated cabinet. Each module works together to complete the entire DC power supply process. The high-frequency PFC rectification module eliminates the intermediate DC / DC conversion stage, which helps to improve the system's power conversion efficiency, reduce the cost of device manufacturing and on-site construction, and meet the high-efficiency and stable DC power supply requirements of data centers.

[0021] Optionally, the high-frequency PFC rectifier module includes multiple parallel three-phase high-frequency PFC rectifier units. The control module is also used to collect the output current of each of the three-phase high-frequency PFC rectifier units in real time, and dynamically adjust the switching duty cycle of each of the three-phase high-frequency PFC rectifier units according to the deviation value between each output current and the average current, so as to realize parallel current sharing control.

[0022] By adopting the above technical solution, the control module can collect the output current of each three-phase high-frequency PFC rectifier unit in real time and dynamically adjust the switching duty cycle, which helps to achieve balanced output of multiple rectifier units, improve the stability of system operation in large-capacity power supply scenarios, and ensure the consistency of DC power supply output.

[0023] Optionally, it also includes a bidirectional DC / DC module, one end of which is connected to the energy storage battery pack, and the other end is electrically connected to the DC bus. The control module is also used to monitor the voltage fluctuation of the DC bus in real time. When the DC bus voltage is detected to drop to a preset first voltage threshold, the bidirectional DC / DC module is controlled to discharge the energy storage battery pack and boost the voltage to the DC bus voltage. When the DC bus voltage is detected to rise to a preset second voltage threshold, the bidirectional DC / DC module is controlled to step down the excess power in the DC bus and charge the energy storage battery pack.

[0024] By adopting the above technical solution, adding a bidirectional DC / DC module to connect the energy storage battery pack and having the control module adaptively regulate the charging and discharging process, it helps to smooth DC bus voltage fluctuations, provide emergency power supply to the load when the mains power is interrupted, and enhance the fault tolerance and continuous operation capability of the system power supply.

[0025] Optionally, it may also include at least one of the following optional modules: An insulation monitoring module is electrically connected to the DC bus and is used to monitor the insulation resistance of the DC bus to ground in real time. The protection module includes a fuse and a mechanical DC circuit breaker. The fuse is used to interrupt extreme fault currents, and the mechanical DC circuit breaker is used to achieve rapid tripping of overload and short-circuit faults. The midpoint balancing module is connected between the positive and negative terminals of the DC bus to generate a DC midpoint, forming a three-wire output of positive DC voltage, negative DC voltage, and zero voltage.

[0026] By adopting the above technical solutions and configuring optional modules for insulation monitoring, protection, and neutral point balancing, the system functions can be expanded according to actual needs. This helps to monitor the DC bus insulation status in real time, respond quickly to overload and short-circuit faults, output multiple types of DC voltages, and improve the system's operational safety and scenario adaptability.

[0027] In summary, this application includes at least one of the following beneficial technical effects: 1. The medium-voltage power distribution, transformer step-down, high-frequency rectification, DC output, and coordinated control steps work together to achieve integrated deployment in a prefabricated cabinet, enhancing system integration and shortening the on-site construction cycle. Compared to the gray and white area of ​​the equipment room in traditional HVDC power supply, the footprint is significantly reduced, and the construction cycle is shortened. The transformer and rectifier module are physically decoupled, allowing for independent shutdown and maintenance, making operation and maintenance more convenient than the SST integrated solid-state transformer. 2. A non-phase-shifting isolation transformer is used to achieve voltage reduction and electrical isolation. The high-frequency PFC rectifier module eliminates the rectifier harmonic loss on the low-voltage side and eliminates the intermediate DC / DC conversion stage of other solutions, which helps to improve the conversion efficiency of DC power supply in data centers.

[0028] 3. By connecting the energy storage battery pack through a bidirectional DC / DC module and monitoring the DC bus voltage in real time, the charging and discharging actions are adaptively controlled according to the voltage threshold, which helps to stabilize the DC bus voltage level, replenish the load with power in a timely manner or absorb excess power, and improve the continuity and voltage stability of the data center power supply. 4. The non-phase-shifting isolation transformer supports adaptation to multiple levels of medium-voltage power grids from 10kV to 35kV. The low-voltage side adopts a single-winding or multi-winding structure to adapt to different power supply configurations, which helps to flexibly match single or multiple high-frequency PFC rectifier modules, simplify the line configuration of small-capacity systems, reduce the parallel control difficulty of large-capacity systems, and improve the system's short-circuit withstand capability and its adaptability to different capacity scenarios.

[0029] 5. It is compatible with emergency power supply from diesel generator sets and the reuse of existing medium-voltage transformer rooms, making it more adaptable to different scenarios than Panama Power and SST systems.

[0030] 6. The dedicated non-phase-shifting transformer and high-frequency PFC rectifier power supply meet the overvoltage fault ride-through requirements of the power grid and optimize the overall efficiency of the power supply system. Attached Figure Description

[0031] Figure 1 This is a flowchart illustrating the DC power supply method for data centers according to the present invention.

[0032] Figure 2 This is a schematic diagram of the module architecture of the DC power supply system for the data center of the present invention.

[0033] Figure 3 This is a schematic diagram of the control logic for parallel current sharing control of the high-frequency PFC rectifier module of the present invention.

[0034] Figure 4 This is a logic diagram of the adaptive charge and discharge control of the energy storage battery according to the present invention.

[0035] Figure 5 This is a schematic diagram of the system configuration of Embodiment 1 of the present invention.

[0036] Figure 6 This is a schematic diagram of the system configuration of Embodiment 2 of the present invention. Detailed Implementation

[0037] To make the purpose, technical solution, and advantages of this application clearer, the following description is provided in conjunction with the appendix. Figures 1-6 The present application will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the application.

[0038] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The following embodiments are used to illustrate the present invention, but are not intended to limit the scope of protection of the present invention.

[0039] This invention addresses the technical problems of low efficiency, high cost, insufficient integration, and poor capacity adaptability of existing 800V high-voltage DC power supply devices for data centers. It provides a data center DC power supply technology solution that integrates all functional modules, including medium-voltage power distribution, non-phase-shifting isolation transformer step-down, high-frequency PFC direct-to-DC conversion, DC output, and collaborative control, into a prefabricated integrated cabinet.

[0040] This solution reduces manufacturing costs by replacing traditional phase-shifting transformers with non-phase-shifting isolation transformers. It directly converts low-voltage AC to DC using high-frequency PFC rectifier modules, eliminating intermediate DC / DC conversion stages to improve overall system efficiency. Prefabricated integrated cabinets enable factory prefabrication and rapid deployment. It also features diverse functions such as multi-module parallel redundancy, flexible capacity expansion, intelligent charging and discharging of energy storage batteries, insulation monitoring and protection, and bipolar DC output, comprehensively meeting the needs of data centers of different sizes for efficient, low-cost, and highly reliable power supply systems.

[0041] To facilitate understanding of the technical solution of this invention, some of the technical terms involved will be explained first. Medium-voltage AC power supply refers to AC power supply with a voltage level ranging from 10kV to 35kV, widely adaptable to the medium-voltage power supply standards of data centers in different regions worldwide. Non-phase-shifting isolation transformer refers to an isolation transformer that uses conventional power frequency transformer technology and does not contain phase-shifting windings; its low-voltage side can be configured with a single winding or multiple winding structure.

[0042] A high-frequency PFC rectifier module refers to a rectifier module that uses high-frequency switching devices and has power factor correction function, which can directly convert AC power to DC power. A prefabricated integrated cabinet refers to a power supply device carrier that integrates multiple functional modules into one or more standardized cabinets, and is transported to the site for installation after assembly and testing in the factory.

[0043] Reference Figure 2In a first aspect, embodiments of the present invention provide an integrated DC power supply and control system for data centers, comprising one or more prefabricated integrated cabinets, a medium-voltage power distribution module, a non-phase-shifting isolation transformer module, a high-frequency PFC rectifier module, a DC output module, and a control module integrated within the prefabricated integrated cabinets, as well as optional insulation monitoring modules, protection modules, midpoint balancing modules, bidirectional DC / DC modules, and static switching modules. The input terminal of the medium-voltage power distribution module is connected to a medium-voltage AC power source, and its output terminal is electrically connected to the primary side of the non-phase-shifting isolation transformer module. The secondary side (low-voltage side) of the non-phase-shifting isolation transformer module is electrically connected to the AC input terminal of the high-frequency PFC rectifier module, and the DC output terminal of the high-frequency PFC rectifier module is connected to the DC bus. The DC output module is connected between the DC bus and the data center load to realize the distribution and output of DC power. The control module is connected to the medium-voltage power distribution module, the non-phase-shifting isolation transformer module, the high-frequency PFC rectifier module, the DC output module, and each optional module via signal lines to realize real-time monitoring and coordinated control of the entire link's operating parameters.

[0044] The medium-voltage distribution module is used to connect to medium-voltage AC power sources ranging from 10kV to 35kV, and is equipped with a medium-voltage switch and lightning protection unit. The medium-voltage switch is used to control the connection and disconnection of the medium-voltage power supply, and can reliably cut off the power supply circuit during system maintenance or faults.

[0045] The lightning protection unit is used to suppress lightning overvoltage and switching overvoltage, ensuring the safety of the input equipment. The non-phase-shifting isolation transformer module adopts conventional power frequency isolation transformer technology, without phase-shifting windings. It is used to step down the medium-voltage AC power supply to a preset low-voltage AC voltage, while achieving safety isolation through electrical isolation between the primary and secondary windings. Compared to traditional phase-shifting transformers, non-phase-shifting isolation transformers have a simpler structure, mature technology, and use less copper, significantly reducing manufacturing costs.

[0046] The high-frequency PFC rectifier module uses multiple three-phase high-frequency PFC rectifier units connected in parallel to directly rectify and correct the power factor of the stepped-down low-voltage AC power, outputting a stable DC voltage to the DC bus. This module does not include an additional DC / DC conversion stage, directly achieving a single-stage conversion from low-voltage AC to 800V high-voltage DC, eliminating the power loss introduced by the DC / DC conversion stage.

[0047] The DC output module is equipped with a DC bus and a DC circuit breaker to distribute the DC voltage from the DC bus to multiple output branches, supplying power to loads such as IT server racks in the data center. It also includes a reserved DC / DC conversion interface for adapting to charge / discharge conversion modules for energy storage battery packs with different voltage levels.

[0048] The control module uses a high-performance microprocessor, such as an MCU or DSP, and has multi-channel analog signal acquisition, digital input / output, and communication interface functions. It is used to monitor the voltage, current, temperature, and other operating parameters of each module in real time, and to perform multi-module parallel collaborative control of the high-frequency PFC rectifier module to achieve balanced distribution and redundancy switching of output power. It also has fault detection, alarm, and emergency handling functions.

[0049] Reference Figure 1 Secondly, embodiments of the present invention provide an integrated DC power supply and control method for data centers, comprising the following steps: In the medium-voltage power distribution step S1, the medium-voltage AC power supply is connected through the medium-voltage power distribution module in the prefabricated integrated cabinet, and the medium-voltage AC power supply is switched and protected against lightning. In transformer step S2, the medium-voltage AC power supply is stepped down through a non-phase-shifting isolation transformer module, and the stepped-down low-voltage AC power is output to the high-frequency PFC rectifier module, while achieving electrical isolation. In the high-frequency rectification step S3, the low-voltage AC power is directly rectified and power factor corrected by the high-frequency PFC rectifier module, and a stable DC voltage is output to the DC bus without going through the intermediate DC / DC conversion stage. In DC output step S4, the DC voltage of the DC bus is distributed and output to the data center load through the DC output module. In the collaborative control step S5, the operating parameters of each module are monitored in real time by the control module, and the high-frequency PFC rectifier module is controlled in parallel by multiple modules. When a fault is detected, a fault handling operation is performed.

[0050] The above steps have a clear logical progression and temporal dependency. The medium-voltage power distribution step S1, as the starting point of the entire power supply process, is responsible for safely introducing medium-voltage grid power into the device; the transformer step-down step S2 reduces the medium-voltage power to a low voltage level suitable for the rectifier module input and achieves electrical isolation; the high-frequency rectification step S3 directly converts the low-voltage AC power into DC power, which is the core link of the entire conversion chain; the DC output step S4 delivers the converted DC power to the load end; and the coordinated control step S5 runs through the entire process, ensuring the coordinated operation of each link and system safety.

[0051] The method provided in this application significantly reduces equipment costs by replacing phase-shifting transformers with non-phase-shifting isolation transformers, achieving both voltage transformation and electrical isolation functions. By integrating full-chain functional modules within a prefabricated integrated cabinet, factory prefabrication and overall transportation and installation are achieved, avoiding the on-site construction and wiring work required for the dispersed placement of multiple devices in traditional solutions.

[0052] By directly converting low-voltage AC to 800V DC using a high-frequency PFC rectifier module in a single stage, eliminating the intermediate DC / DC conversion stage and thus removing the power loss introduced by this stage, the overall system efficiency can be effectively improved. Simultaneously, the parallel connection of multiple high-frequency PFC rectifier modules provides redundancy, ensuring that the failure of a single module does not affect the overall system operation. The real-time monitoring and coordinated control functions of the control module further guarantee the system's high reliability. These technical features work synergistically to form a complete technical solution that balances high efficiency, low cost, high integration, and high reliability, fundamentally resolving the multiple technical contradictions inherent in existing data center DC power supply devices.

[0053] Specifically, in step S1, the medium-voltage power distribution step, a medium-voltage AC power supply is connected via a medium-voltage power distribution module. The medium-voltage power distribution module is the first interface between the power supply device and the external power grid, and its core function is to safely and reliably introduce 10kV to 35kV medium-voltage power. The reason for adopting a wide range of different voltage inputs (10kV to 35kV) is that the medium-voltage power supply standards accessed by data centers in different regions of the world vary. Selecting different voltage input designs for the medium-voltage matching module and transformer allows this device to directly adapt to the medium-voltage power grid environment of different data centers globally, without the need for additional voltage adaptation transformers.

[0054] The medium-voltage switch inside the medium-voltage power distribution module is used to connect the power supply circuit during normal operation and reliably disconnect the high-voltage power input during equipment maintenance or fault conditions. The lightning protection unit uses surge protection devices installed on the power input side to suppress lightning-induced overvoltages and grid operation overvoltages from entering the device, protecting the insulation safety of the downstream transformer and rectifier equipment.

[0055] In one optional implementation, the medium-voltage switch can be a vacuum circuit breaker or an SF6 circuit breaker, which features strong arc extinguishing capability and long electrical life. The lightning protection unit can adopt a multi-level SPD coordination method to achieve comprehensive protection from direct lightning strike protection to switching overvoltage suppression.

[0056] In another optional implementation, the medium-voltage power distribution module can also integrate a smart meter unit to monitor parameters such as voltage, current, and power factor of the input power in real time, providing data support for the control module.

[0057] In practice, by directly connecting the medium-voltage power distribution module to the medium-voltage power grid, the input of the entire power supply device is raised to the medium-voltage level. This allows the device to directly complete the complete conversion process from medium voltage to the DC voltage required by the load within the data center, avoiding the multi-stage architecture of the traditional solution where the voltage is first stepped down to low voltage by an external transformer before being introduced into the rectifier equipment.

[0058] Compared to traditional AC power supply solutions, which require deploying a 10kV / 0.4kV step-down transformer outside the data center and then introducing power into the UPS and rectifier equipment inside the data center via low-voltage cables, this solution increases the independent footprint of the transformer, requires numerous low-voltage distribution cabinets, and involves complex cable connections. This solution integrates medium-voltage power distribution directly into a prefabricated cabinet, enabling direct access to medium-voltage power. This eliminates the need for an external step-down transformer and corresponding civil engineering work, reducing the footprint by more than 50% and shortening the construction period by more than 60%.

[0059] For step S2, the medium-voltage AC power supply is stepped down using a non-phase-shifting isolation transformer module. The non-phase-shifting isolation transformer employs conventional power frequency transformer technology, its core characteristic being the absence of a phase-shifting winding structure. The reason for using a non-phase-shifting isolation transformer instead of the phase-shifting transformer in the traditional Panama power architecture is that the Panama power architecture uses a phase-shifting transformer to achieve multi-pulse rectification and reduce harmonics, and also to achieve deep coupling between the transformer and the rectifier to reduce the footprint.

[0060] However, the manufacturing process of phase-shifting transformers is complex, requiring precise control of the number of turns and phase relationship of each winding, significantly increasing copper usage and manufacturing costs. This solution replaces the traditional combination of a phase-shifting transformer and an uncontrolled rectifier bridge with a high-frequency PFC rectifier module. Utilizing the power factor correction function of the high-frequency PFC rectifier module itself, it achieves high power factor and low harmonic input, thus allowing the transformer side to use a conventional non-phase-shifting structure, eliminating the need for phase-shifting windings.

[0061] This alternative eliminates the need for phase-shifting transformers at the system architecture level, reducing transformer manufacturing costs by more than 30%. The non-phase-shifting isolation transformer module, while achieving voltage transformation, provides safety isolation through electrical isolation between the primary and secondary windings, isolating the medium-voltage side from the low-voltage side and ensuring the safety of low-voltage side equipment and personnel.

[0062] In one alternative implementation, the low-voltage side of the non-phase-shifting isolation transformer employs a single-winding structure. This single-winding structure is suitable for systems with capacities of 1.25MW and below. The transformer's low-voltage side has only one output winding, and the output voltage is directly connected to one or more parallel high-frequency PFC rectifier modules.

[0063] In another optional implementation, for systems with a capacity of 2.5MW and above, the high-voltage side of the non-phase-shifting isolation transformer is a complete single winding, while the low-voltage side is split into multiple independently windings with complete electrical isolation and weak magnetic coupling (mainly double-split, with a few triple / quadruple splits). Each low-voltage winding has completely symmetrical capacity and voltage, with no electrical connection, only magnetic coupling through the iron core. Each winding is connected to a corresponding set of high-frequency PFC rectifier modules. The dual-winding or even multi-winding structure physically groups and isolates the rectifier modules, reducing the number of parallel rectifier modules in each group, thereby reducing the difficulty of controlling the circulating current in multi-module parallel connections. It also helps limit low-voltage short-circuit current, isolate faults, and provide power supply redundancy, improving system reliability. Furthermore, the multi-winding structure reduces the busbar length and circulating current path between the various rectifier modules, reducing the amount of copper busbars and cables used, further saving cost and space.

[0064] In practice, by adopting a single-winding or multi-winding structure to flexibly adapt to different capacity requirements, this solution covers different scenarios from small data centers of 1.2MW to large AI data centers of 2.5MW and above under a unified system architecture.

[0065] Compared to existing solutions that require redesigning the transformer structure and rectifier module configuration for different capacities, this solution, by changing the transformer winding method, can achieve capacity expansion simply by replacing the transformer with a different output winding structure without changing the design of other modules. It has a high degree of modularity and reduces R&D and production costs.

[0066] For step S3, the high-frequency rectification step, the low-voltage AC power after step-down is directly rectified and power factor corrected by the high-frequency PFC rectifier module, and then a stable DC voltage is output to the DC bus. The core technical feature of this step is that the high-frequency PFC rectifier module directly completes the single-stage conversion of the low-voltage AC power to a stable 800V DC power, without any intermediate DC / DC conversion stage.

[0067] The reason for adopting a high-frequency PFC rectification direct-to-DC design is that, in traditional power supply schemes, low-voltage AC power, after uncontrolled rectification or thyristor rectification, results in an unstable DC voltage, such as a rated voltage of approximately 540V with a voltage fluctuation of ±10%. This requires a first-stage DC / DC converter for boosting and regulation, ultimately outputting a stable 800V DC power. In this two-stage conversion architecture, each stage introduces approximately 1% to 2% power loss, and the combined system efficiency after both stages is typically below 96%.

[0068] By using a high-frequency PFC rectifier module to directly output 800V DC, only one stage of conversion is needed to complete the entire conversion from AC to stable DC, eliminating the power loss in the DC / DC conversion stage. The single-stage efficiency can reach 99%, and the overall system efficiency can reach 98%, with an efficiency improvement of about 2% to 3%.

[0069] In one optional implementation, the high-frequency PFC rectifier module employs multiple three-phase high-frequency PFC rectifier units connected in parallel, with each unit using a six-switch two-level rectifier topology. The six-switch two-level rectifier bridge consists of six switching transistors, such as IGBTs or SiC MOSFETs, forming a three-phase full-bridge structure. It achieves power factor correction of the input current and stable control of the output voltage through PWM modulation, offering advantages such as fewer components, simple and reliable structure, and a wide AC input voltage range.

[0070] In another alternative implementation, a T-type three-level rectifier topology can be used. The T-type three-level topology uses four switching transistors and two clamping diodes on each phase arm, enabling it to output a three-level voltage waveform. It offers advantages such as low switching stress, low output harmonics, and high efficiency. When the system has high voltage quality requirements or needs to reduce EMI interference, the T-type three-level topology is preferred.

[0071] Corresponding to different choices of high-frequency PFC rectifier topologies, the rated voltage of the secondary side of the non-phase-shifting transformer was optimized. To meet the requirements of 800V DC power supply, the boost rectifier limited the maximum input voltage, with an effective input line voltage of 490V corresponding to the minimum common-mode voltage and an input voltage of 565V corresponding to the maximum DC voltage utilization. Choosing a higher input voltage helps reduce input current, thereby reducing losses in the transformer's low-voltage winding and the PFC rectifier converter. Simultaneously, the data center power supply load needs to meet the grid's high-voltage and low-voltage fault ride-through specifications. Designed with high-voltage ride-through within 120% and minimum common-mode voltage requirements, the rated voltage of the transformer's low-voltage winding was set at 408V.

[0072] In one alternative implementation, the high-frequency rectification step further includes parallel current sharing control. When the high-frequency PFC rectifier module comprises multiple parallel three-phase high-frequency PFC rectifier units, the output current of each unit needs to be kept balanced to avoid overloading of individual units.

[0073] The collaborative control process involves real-time acquisition of the output current of each three-phase high-frequency PFC rectifier unit, calculation of the average current value of all units, and comparison of the output current of each unit with the average current to obtain the current deviation value. Based on this deviation value, the switching duty cycle of the corresponding unit is dynamically adjusted. For units with output current higher than the average value, the duty cycle is appropriately reduced to decrease the output current; for units with output current lower than the average value, the duty cycle is appropriately increased to increase the output current, thereby keeping the output current deviation of each unit within a preset deviation threshold.

[0074] This current sharing control scheme is particularly important in architectures that omit the DC / DC converter stage. Due to the lack of current sharing capability in the subsequent DC / DC stage, current sharing must be completed within the PFC rectification stage, which places higher demands on the response speed and accuracy of the control algorithm. By integrating the current sharing control into the drive control loop of the PFC rectification module, closed-loop regulation of the current of the parallel modules is achieved.

[0075] In practical implementation, this solution integrates the traditional two-stage conversion into a single-stage conversion through a high-frequency PFC rectification direct-to-DC design. Compared with the existing two-stage conversion architecture, this solution not only eliminates the DC / DC converter and its corresponding power devices, magnetic components, capacitors, drive circuits, and heat dissipation systems, reducing BOM costs and system size, but also improves system reliability and reduces a potential point of failure by eliminating a power conversion stage.

[0076] Meanwhile, the efficiency improvement brought about by the first-level transformation is of great significance: for a 10MW-level data center, every 1% improvement in system efficiency can save hundreds of thousands of kilowatt-hours of electricity consumption per year, corresponding to a significant reduction in operating costs and carbon emissions.

[0077] For step S4, the DC output step, the DC voltage from the DC bus is distributed and output to the data center load via the DC output module. The DC output module is connected between the DC bus and the load, and internally contains a DC busbar and a DC circuit breaker. The DC busbar uses low-impedance copper or aluminum busbars to introduce DC power from the DC busbar into the output module and distribute it through multiple paths.

[0078] DC circuit breakers are installed on each output branch to control the on / off state and provide overload and short-circuit protection. The DC output module also has a reserved DC / DC conversion interface for connecting an external DC / DC conversion module. This allows the system to be adapted to charge / discharge conversion modules for energy storage battery packs with different DC voltage levels, ranging from 200V to 1500V, enabling flexible compatibility with energy storage devices from different manufacturers and specifications.

[0079] In practical implementation, this solution demonstrates excellent flexibility in energy storage device adaptation through its modular design with reserved DC / DC conversion interfaces. Existing solutions often have built-in energy storage interfaces with fixed voltage levels, which may require replacing the entire power supply system when data centers replace or upgrade energy storage devices. This solution, through its standardized interface design, eliminates the voltage range limitations of the power supply's built-in chargers when selecting energy storage devices, thus reducing the cost of upgrading and transforming data center energy storage systems.

[0080] For step S5, the collaborative control step, the control module monitors the operating parameters of each module in real time, performs multi-module parallel collaborative control of the high-frequency PFC rectifier module, and executes fault handling operations when a fault is detected. The control module acquires data in real time, such as the input voltage and current of the medium-voltage distribution module, the temperature and operating status of the non-phase-shifting isolation transformer module, the input and output parameters and temperature of each unit of the high-frequency PFC rectifier module, and the branch current of the DC output module, through sensors and signal acquisition circuits.

[0081] Based on this data, the control module adjusts the operating status of the high-frequency PFC rectifier module in real time, such as adjusting the PWM drive parameters of each unit to achieve current sharing control, adjusting the output voltage reference value to achieve voltage stability, and automatically disconnecting the faulty unit and transferring the load to the redundant unit when a unit fails.

[0082] The control module also performs insulation monitoring and protection control. The insulation monitoring module is electrically connected to the DC bus and uses an unbalanced bridge method or a low-frequency pulse injection method to detect the DC bus insulation resistance to ground in real time. When the insulation resistance drops below a preset alarm value, the control module issues an alarm signal, prompting maintenance personnel to check for potential insulation problems and prevent leakage accidents.

[0083] The protection module includes fuses and mechanical DC circuit breakers, which work together: the fuses act as backup protection, quickly interrupting extreme fault currents; the mechanical DC circuit breakers are used for rapid tripping under normal overload and short-circuit faults. The fuses have current-limiting characteristics, capable of rapidly melting under extreme short-circuit currents to limit fault energy; the mechanical circuit breakers provide resettable overcurrent protection under overload and general short-circuit faults. Together, they form dual protection, ensuring safe and reliable disconnection of the system under various fault scenarios.

[0084] In an optional implementation, the method further includes an adaptive charge / discharge control step for the energy storage battery. This step connects the energy storage battery pack to a DC bus via a bidirectional DC / DC module, and the control module monitors the voltage fluctuations of the DC bus in real time. When the DC bus voltage drops to a preset first voltage threshold, indicating an increase in load or insufficient input power, the control module sends a discharge command to the bidirectional DC / DC module to boost the energy from the energy storage battery pack to the DC bus voltage, replenishing the load and maintaining a stable bus voltage.

[0085] When the DC bus voltage rises to the preset second voltage threshold, it indicates that the load has decreased or the input power is excessive. The control module sends a charging command to reduce the voltage of the excess power on the DC bus and charge the energy storage battery pack, storing the excess power in the battery pack.

[0086] Through this adaptive charge and discharge control, the energy storage battery pack is upgraded from a traditional emergency backup power supply to an intelligent energy storage buffer unit that participates in the active regulation of DC bus voltage. This effectively smooths load power fluctuations and reduces the impact of sudden load changes on the high-frequency PFC rectifier module. Simultaneously, when the mains power input is abnormally interrupted, the energy storage battery pack quickly switches to discharge mode through the bidirectional DC / DC module, providing uninterrupted power to critical loads until the backup generator starts or the mains power is restored.

[0087] In practical implementation, this solution achieves real-time buffering compensation and energy feedback recovery during load power fluctuations through the active voltage regulation mechanism of the energy storage battery's adaptive charge and discharge control. Compared with traditional solutions where the energy storage battery is only used as an emergency backup power source and is idle or in a float charging state during normal operation, this solution makes full use of the energy storage battery's fast response characteristics, using it as a voltage regulation buffer unit for the flexible DC power supply system.

[0088] For example, when AI training tasks are launched in batches within a data center, the instantaneous power demand may surge by tens of kilowatts. The response speed of the high-frequency PFC rectifier module is limited by the time constant of the input-side transformer and filter, which may cause a brief drop in the DC bus voltage. At this time, the energy storage battery pack can respond within milliseconds through the bidirectional DC / DC module, replenishing the bus with power and suppressing the voltage drop. After the rectifier module adjusts to a new steady-state operating point, the energy storage battery pack can then smoothly exit or enter charging mode. This function is particularly valuable in data centers equipped with high-power AI chips.

[0089] In an optional implementation, the method further includes a midpoint balancing step. A midpoint balancing module is connected across the positive and negative terminals of the DC bus to generate a DC midpoint. This midpoint forms a +400V and a -400V DC output with the positive and negative terminals of the DC bus, respectively, thereby outputting a three-wire DC power supply with positive DC voltage, negative DC voltage, and zero voltage.

[0090] The midpoint balancing module comprises one or more switching arms and a common capacitor arm. The midpoint of each switching arm is connected to the midpoint of the capacitor arm via an inductor, which is the output DC midpoint. This module actively adjusts the voltage balance between the positive and negative buses and the midpoint by controlling the duty cycle of the switching transistors in the switching arms, ensuring that the +400V and -400V voltages remain stable even under unbalanced loads.

[0091] In an optional implementation, the method further includes a backup power switching step. The backup power module includes a diesel generator interface and is configured with a dual-path AC automatic transfer switch. When an abnormality is detected in the main input power supply, the static switching module switches the load power supply from the main input power supply to the backup power supply, or controls the energy storage battery pack to discharge via a bidirectional DC / DC module, delivering the stored energy to the load via the DC bus.

[0092] In practical applications, this solution covers a variety of typical operating conditions. When the data center is in normal operation, the medium-voltage AC power supply is connected through the medium-voltage power distribution module, stepped down to 408VAC through a non-phase-shifting isolation transformer, the high-frequency PFC rectifier module converts 408VAC to 800VDC and delivers it to the DC bus, the DC output module distributes 800VDC to each load branch, and the control module monitors and provides feedback to adjust the operating parameters of each module in real time.

[0093] When the load is stable, the energy storage battery pack is in standby mode or trickle charging. When the load suddenly increases, the DC bus voltage drops. After the control module detects that the voltage has dropped to the first voltage threshold, it controls the bidirectional DC / DC module to discharge the energy storage battery pack to replenish the energy, while simultaneously adjusting the high-frequency PFC rectifier module to increase the output power.

[0094] When the load decreases, the voltage rises, and the control module controls charging to absorb excess energy. When the power grid fails, the diesel generator starts and switches to backup power via ATS, while the energy storage battery pack immediately discharges to ensure uninterrupted power supply.

[0095] When adapting to bipolar DC loads, the midpoint balancing module generates a ±400V bipolar output. When multiple rectifier modules are running in parallel, the control module performs real-time current sharing control to ensure balanced output current across all modules.

[0096] The solution in step S1 also includes the following implementation steps, and the technical process of the present invention will be described in detail with reference to specific embodiments.

[0097] Step S101: Medium-voltage power distribution connection. Power is connected from the 10kV to 35kV medium-voltage power grid via the medium-voltage power distribution module. The medium-voltage switch closes to connect the power supply circuit, and the lightning protection unit suppresses surge overvoltage in real time. The medium-voltage power distribution module delivers power to the primary side of the non-phase-shifting isolation transformer module.

[0098] Step S102, Transformer step-down and isolation. The non-phase-shifting isolation transformer module steps down the medium-voltage AC to 408V or 377V low-voltage AC, while simultaneously achieving electrical isolation between the primary and secondary sides. Depending on the system capacity requirements, the low-voltage side can be selected for single-winding output or multi-winding output.

[0099] Step S103, High-Frequency PFC Rectification. Multiple parallel three-phase high-frequency PFC rectifier units receive low-voltage AC power and rectify and correct the AC power with a six-switch two-level or T-type three-level topology, directly outputting a stable 800V DC voltage to the DC bus without intermediate DC / DC conversion. During parallel operation, the control module collects the output current of each unit in real time and achieves current sharing control by adjusting the duty cycle through deviation adjustment.

[0100] Step S104, DC output distribution. The DC output module distributes the 800V DC voltage to each load branch of the data center through the DC bus and DC circuit breaker to power the IT server racks.

[0101] Step S105: Coordinated Control and Fault Handling. The control module monitors the operating parameters of each module throughout the process, adjusts the operating status of the rectifier module in real time, and performs functions such as current sharing, voltage adjustment, insulation monitoring, and protection control. When a fault is detected, the faulty module is disconnected, redundant units are switched, or protection actions are triggered.

[0102] In the above method flow, control step S105 runs in parallel with steps S101 to S104 in real time. The current sharing control in step S103 and the fault handling in step S105 form a closed loop: the current sharing control prevents individual rectifier units from overloading due to excessive current, reducing the probability of fault occurrence; once a fault occurs, after the fault handling logic cuts off the faulty unit, the current sharing control readjusts the current distribution of the surviving units to ensure that the system continues to operate stably.

[0103] Corresponding to the above method, the present invention also provides a data center DC power supply system. The core functional modules of this system include: a medium-voltage power distribution module for accessing and protecting medium-voltage AC power; a non-phase-shifting isolation transformer module for voltage transformation and electrical isolation; a high-frequency PFC rectifier module for directly performing a single-stage conversion from low-voltage AC to 800V DC; a DC output module for distributing and outputting DC power; and a control module for end-to-end coordinated control and fault handling. All of these modules are integrated within a prefabricated integrated cabinet.

[0104] The system also includes extension modules corresponding to the technical features of the dependent claims: an insulation monitoring module for monitoring the insulation resistance of the DC bus, a protection module for the coordinated protection of fuses and circuit breakers, a midpoint balancing module for generating bipolar DC output, and a bidirectional DC / DC module for adaptive charge and discharge control of the energy storage battery and backup power switching.

[0105] The technical solution of the present invention will be further described in detail below through two specific embodiments.

[0106] Example 1: 1.2MW DC power supply unit for a data center. (Refer to...) Figure 5This embodiment provides a 1.2MW DC power supply unit suitable for small data centers. The prefabricated integrated cabinet adopts the specifications of a 20-foot shipping container, with external dimensions of 6.1m × 2.44m × 2.59m. It is made of cold-rolled steel plate and has dustproof, moisture-proof and heat dissipation functions. The interior is divided into a medium-voltage distribution compartment, a transformer compartment, a rectifier module and control system cabinet, an output cabinet, and an optional functional area. The high-voltage area and the low-voltage area are independently isolated to ensure operational safety.

[0107] The medium-voltage power distribution module is connected to a 10kV AC power supply, with an overvoltage ride capacity of 120%. It is equipped with a medium-voltage vacuum switch and lightning protection unit, with a rated current of 200A and overload and overvoltage protection functions. The non-phase-shifting isolation transformer adopts a single-winding structure, with a primary side input of 10.5kV, a frequency of 50Hz, all copper, H-class insulation, a 35kV withstand voltage, a lightning impulse withstand voltage of 75kV, a short-circuit impedance of 4%, a secondary output voltage of 408V, and a rated capacity of 1250kVA. The high-frequency PFC rectifier module uses 12 125kW six-switch three-phase rectifier bridge modules connected in parallel, with an input voltage of 408VAC, an output voltage of 800VDC, a power factor of not less than 0.99, a total harmonic distortion of not more than 3%, and a peak efficiency of not less than 99%. The DC output module is equipped with an 800V DC bus, two DC circuit breakers with a rated current of 1600A, and two reserved DC / DC conversion interfaces for adapting to the charging and discharging conversion of energy storage batteries. The control module uses an MCU processor. The system can be further configured with bidirectional DC / DC modules to connect to energy storage battery packs and perform midpoint balancing.

[0108] Example 2: 2.5MW DC power supply system for a data center. (Refer to...) Figure 6 This embodiment provides a 2.5MW capacity 1+1 dual-path DC power supply device suitable for large-scale AI data centers, with a high voltage ride-through rate of up to 130%. The prefabricated integrated cabinet adopts a multi-cabinet combination design, consisting of two 2.5MW cabinets, providing dual-path 800V DC power supply for the data center's 2.4MW computing load. The total dimensions of each 2.5MW cabinet combination are: 8.7 meters (length) × 1.3 meters (depth) × 2.0 meters (height), internally divided into a medium-voltage distribution cabinet, a dual-winding transformer cabinet, a rectifier area, an output area, a control area, and a backup power supply area. The medium-voltage distribution module is connected to the 35kV AC power grid and is equipped with a medium-voltage intelligent switch with a rated current of 63A and a multi-level lightning protection unit.

[0109] Each 2.5MW cabinet is equipped with one non-phase-shifting isolation transformer, using a YNd11-d11 double-winding structure, with an input rated voltage of 35kV and ±2×2.5% voltage regulation, an output rated voltage of 376V, and a rated capacity of 3.125kVA. The high-frequency PFC rectifier uses two sets of parallel modules, each corresponding to the double-winding output of each transformer. Each set consists of 12 125kW six-switch three-phase rectifier bridge modules connected in parallel, with an input voltage of 376VAC, an output voltage of 800V, a power factor of not less than 0.99, a total harmonic distortion of not more than 3%, and a peak efficiency of not less than 99%. The DC output module is equipped with an 800V DC bus and two DC circuit breakers with a rated current of 2000A. The control module uses dual MCU redundant control. The system also includes a backup power module, an insulation monitoring module, and a protection module.

[0110] As can be seen from the above embodiments, the technical solution of the present invention achieves an organic combination of high efficiency, low cost, high integration and high reliability through the combined application of core technologies such as prefabricated integrated design, non-phase-shifting isolation transformers instead of phase-shifting transformers, high-frequency PFC direct-to-DC conversion to eliminate the DC / DC conversion stage, multi-module parallel redundancy and intelligent collaborative control. It can flexibly cover different capacity requirements from 1.2MW small data centers to 2.5MW and above large AI data centers, providing the data center industry with a DC power supply solution that balances performance and economy.

[0111] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0112] The above are all preferred embodiments of this application and are not intended to limit the scope of protection of this application. Any feature disclosed in this specification (including the abstract and drawings) may be replaced by other equivalent or similar features unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is only one example of a series of equivalent or similar features.

Claims

1. An integrated DC power supply and control method for data centers, characterized in that, Includes the following steps: In the medium-voltage power distribution step, the medium-voltage AC power supply is connected through the medium-voltage power distribution module in the prefabricated integrated cabinet, and the medium-voltage AC power supply is switched and protected against lightning. The transformer step-down step involves using a non-phase-shifting isolation transformer module in the prefabricated integrated cabinet to step down the medium-voltage AC power supply, and then outputting the stepped-down low-voltage AC power to the high-frequency PFC rectifier module, while simultaneously achieving electrical isolation. In the high-frequency rectification step, the low-voltage AC power is received by the high-frequency PFC rectifier module in the prefabricated integrated cabinet. The low-voltage AC power is directly rectified and the power factor is corrected before a stable DC voltage is output to the DC bus. The high-frequency PFC rectifier module directly completes the AC to DC conversion without going through an intermediate DC / DC conversion stage. In the DC output step, the DC voltage of the DC bus is distributed and output to the data center load through the DC output module in the prefabricated integrated cabinet; The collaborative control step involves real-time monitoring of the operating parameters of the medium-voltage power distribution module, the non-phase-shifting isolation transformer module, the high-frequency PFC rectifier module, and the DC output module through the control module in the prefabricated integrated cabinet. This enables multi-module parallel collaborative control of the high-frequency PFC rectifier module and the execution of fault handling operations when a fault is detected.

2. The integrated DC power supply and control method for data centers according to claim 1, characterized in that, In the high-frequency rectification step, the high-frequency PFC rectification module includes multiple parallel three-phase high-frequency PFC rectification units, and the coordinated control step further includes parallel current sharing control: The output current of each of the three-phase high-frequency PFC rectifier units is collected in real time. Based on the deviation between each output current and the average current, the switching duty cycle of each of the three-phase high-frequency PFC rectifier units is dynamically adjusted so that the output current deviation of each of the three-phase high-frequency PFC rectifier units is kept within a preset deviation threshold.

3. The integrated DC power supply and control method for data centers according to claim 1, characterized in that, It also includes adaptive charge and discharge control steps for energy storage batteries: The energy storage battery pack is connected to the DC bus via a bidirectional DC / DC module to monitor the voltage fluctuation of the DC bus in real time. When the DC bus voltage is detected to drop to a preset first voltage threshold, the bidirectional DC / DC module is controlled to discharge the energy storage battery pack and boost the voltage to the DC bus voltage to provide supplementary power to the load. When the DC bus voltage is detected to rise to a preset second voltage threshold, the bidirectional DC / DC module is controlled to step down the excess power in the DC bus and charge the energy storage battery pack, thereby maintaining the DC bus voltage within a preset stable range.

4. The integrated DC power supply and control method for data centers according to claim 1, characterized in that, In the transformer step-down step, the non-phase-shifting isolation transformer module is a dedicated isolation transformer for data centers. It has no phase-shifting winding and its low-voltage side uses a single winding structure to supply power to a single high-frequency PFC rectifier module, or uses a multi-winding structure to supply power to multiple high-frequency PFC rectifier modules respectively.

5. The integrated DC power supply and control method for data centers according to claim 1, characterized in that, In the transformer step-down step, the primary side of the non-phase-shifting isolation transformer module is adapted to conventional medium-voltage power grid levels of 10kV, 11kV, 13.8kV, 20kV, 33kV, and 35kV. The secondary side matches the rated AC output voltage of the low-voltage side of the transformer according to the overvoltage fault ride-through level of the primary power grid and the DC power supply voltage of the data center: in the scenario of fault ride-through ≤120%, the low-voltage side outputs 408V or 471VAC; in the scenario of fault ride-through ≥130%, the low-voltage side outputs 377V or 435V, and the output DC bus voltage is kept constant by relying on high-frequency PFC rectification closed-loop voltage regulation.

6. The integrated DC power supply and control method for data centers according to claim 1, characterized in that, It also includes at least one of the following steps: The midpoint balancing step generates a DC midpoint between the positive and negative poles of the DC bus through the midpoint balancing module, and outputs a three-wire DC power supply with positive DC voltage, negative DC voltage and zero voltage. In the backup power switching procedure, when an abnormality is detected in the main input power supply, the load power supply is switched from the main input power supply to the backup power supply through the static switching module, or the energy storage battery pack is controlled to discharge through the bidirectional DC / DC module, and the stored energy is delivered to the load through the DC bus.

7. The integrated DC power supply and control method for data centers according to claim 5, characterized in that, In the coordinated control steps, the control module also performs insulation monitoring and protection control. The insulation monitoring module detects the insulation resistance of the DC bus to ground in real time, and issues an alarm signal when the insulation resistance is less than a preset alarm value. At the same time, the fuse of the protection module is used to cut off the extreme fault current, and the mechanical DC circuit breaker is used to achieve rapid tripping of overload and short circuit faults.

8. An integrated DC power supply and control system for data centers, employing the method described in any one of claims 1-7, characterized in that, include: The prefabricated integrated cabinet integrates a medium-voltage power distribution module for connecting to a medium-voltage AC power supply and for switching control and lightning protection of the medium-voltage AC power supply. The non-phase-shifting isolation transformer module is integrated into the prefabricated integrated cabinet and is electrically connected to the medium-voltage power distribution module. It is used to step down the medium-voltage AC power supply and achieve electrical isolation. The high-frequency PFC rectifier module is integrated into the prefabricated integrated cabinet and electrically connected to the low-voltage side of the non-phase-shifting isolation transformer module. It is used to directly rectify and power factor correct the stepped-down low-voltage AC power and output a stable DC voltage to the DC bus. The high-frequency PFC rectifier module does not include an intermediate DC / DC conversion stage. A DC output module, integrated within the prefabricated integrated cabinet, is electrically connected to the DC bus and is used to distribute and output the DC voltage from the DC bus to the data center load. The control module, integrated within the prefabricated integrated cabinet, is electrically connected to the medium-voltage power distribution module, the non-phase-shifting isolation transformer module, the high-frequency PFC rectifier module, and the DC output module, respectively. It is used to monitor the operating parameters of each module in real time, perform multi-module parallel collaborative control of the high-frequency PFC rectifier module, and execute fault handling operations when a fault is detected.

9. The integrated DC power supply and control system for data centers according to claim 8, characterized in that, The high-frequency PFC rectifier module includes multiple parallel three-phase high-frequency PFC rectifier units. The control module is also used to collect the output current of each of the three-phase high-frequency PFC rectifier units in real time, and dynamically adjust the switching duty cycle of each of the three-phase high-frequency PFC rectifier units according to the deviation value between each output current and the average current, so as to realize parallel current sharing control.

10. The integrated DC power supply and control system for data centers according to claim 8, characterized in that, It also includes a bidirectional DC / DC module, one end of which is used to connect to the energy storage battery pack, and the other end is electrically connected to the DC bus. The control module is also used to monitor the voltage fluctuation of the DC bus in real time. When the DC bus voltage is detected to drop to a preset first voltage threshold, the bidirectional DC / DC module is controlled to discharge the energy storage battery pack and boost the voltage to the DC bus voltage. When the DC bus voltage is detected to rise to a preset second voltage threshold, the bidirectional DC / DC module is controlled to step down the excess power in the DC bus and charge the energy storage battery pack.

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