Sliding Power Converter Rack With Flexible Cables and Quiet Cooling
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Solution Overview
Problem
Existing power converter racks face inefficiencies in cooling and power connection, with prior art solutions being expensive, heavy, and noisy, and requiring difficult maintenance access due to obstructed airflow and fixed power connections.
Innovation Solution
A power converter rack design using flexible power cables and axial fans for easy installation and removal of modules with front access, combined with a perforated exhaust for efficient cooling and reduced noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a busbar plugin system is used for power connection, then quick and easy converter connection is achieved, but the rack becomes extensively expensive, heavy, and time consuming to install
Solution Approach 1:
The patent extracts the complex busbar plugin system from the rack and replaces it with simple flexible power cables with connectors. The power connection function is separated from the rack structure, allowing the rack to be simpler while maintaining ease of converter connection and removal through front access.
Solution Approach 2:
The patent changes the power connection parameter from rigid busbars to flexible cables, fundamentally altering how power is delivered. This parameter change enables front-accessible connection points while dramatically reducing rack complexity, weight, and installation time.
2Temperature
If centrifugal cooling fans are positioned at the roof top, then hot air can exit the rack, but the plugin busbar system obstructs hot air flow creating higher flow resistance and less efficient cooling
Solution Approach 1:
The patent removes the obstructing busbar system from the airflow path. By replacing the busbars with flexible cables routed differently, the airflow path from converters to roof fans is cleared, eliminating the obstruction that caused high flow resistance and energy loss.
Solution Approach 2:
The patent relocates power cable routing to a different spatial dimension that does not interfere with the vertical airflow path. Cables are routed along the sides or bottom of the rack, allowing hot air to flow vertically upward to the roof fans without obstruction.
3Ease of operation
If centrifugal fans are used to overcome higher pressure drop, then air can exit from the sides, but more noise is generated due to change of air flow direction
Solution Approach 1:
The patent removes the source of the problem - the busbar system that created high pressure drop. By eliminating this obstruction, the need for high-power centrifugal fans is removed, and quieter axial fans can be used instead, significantly reducing noise levels.
Solution Approach 2:
The patent changes the fan type parameter from centrifugal to axial, which fundamentally alters the airflow characteristics. Axial fans move air in a straight line with minimal direction change, reducing turbulence and noise while maintaining effective cooling.
4Reliability
If fixed power connections are used, then safety is improved with back side connections, but serviceability is reduced as intervention is only possible through front access
Solution Approach 1:
The patent segments the power connection system into separate, modular components - flexible cables with connectors that can be independently accessed. This segmentation allows the connection point to be positioned at the front for serviceability while the cable provides the secure back-side anchored connection for safety.
Solution Approach 2:
The patent introduces flexibility and mobility to the power connection system through flexible cables, transforming it from a static fixed connection to a dynamic system that can accommodate both secure installation and easy access for maintenance through front opening.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces cooling costs by 30% and noise levels from 76dB to 65dB, allowing more modules per rack while maintaining efficient airflow and easy maintenance.
Implementation Method 1
at least one fan configured for being carried on another one of the plurality of sliding elements for being slid into and out of the rack
Implementation Method 2
each power converter module of the plurality of power converter modules comprising a flexible power cable connecting the respective power converter module with the rack
Data Source
Figure 1
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AI summary
The invention relates to a power converter rack (1) comprising a plurality of sliding elements (4) arranged one above another inside the rack (1), a plurality of power converter modules (3) configured for each being carried on a respective sliding element (4) of the plurality of sliding elements (4) for being slid into and out of the rack (1) and each power converter module (3) of the plurality of power converter modules (3) comprising a flexible power cable (6) connecting the respective power converter module (3) with the rack (1), and at least one fan (10) configured for being carried on another one of the plurality of sliding elements (4) for being slid into and out of the rack (1).