DC Power Distribution Unit Eliminates Double Conversion Losses

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Solution Overview

Problem

Data centers face design challenges due to high-density hard drives with increased track per inch (TPI) numbers, leading to issues like vibrational energy, acoustic noise, and reduced HDD throughput, exacerbated by double power conversion from DC to AC and back to DC in existing power distribution systems, which occupy valuable space and increase costs.

Innovation Solution

Implementing a direct current (DC) uninterruptible power supply (UPS) and DC power distribution unit (PDU) that converts AC power to multiple DC outputs with varying voltage levels for ITE components, eliminating the need for AC to DC and DC to AC conversion, using DC mating connectors for efficient power distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If double power conversion from DC to AC and back to DC is used in existing power distribution systems, then power supply compatibility is improved, but power conversion losses increase and space is consumed

Engineering Contradiction:

Improvepower supply compatibilityVSAvoidpower conversion losses

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent extracts and eliminates the redundant AC-to-DC conversion stage from the power distribution system. By implementing a DC-native power distribution architecture where the UPS outputs DC directly and PDUs receive DC input, the system removes the unnecessary double conversion process, thereby reducing power losses while maintaining compatibility through standardized DC interfaces and voltage regulation mechanisms

Inventive Principle:

Principle #2Taking out (Extraction)

2Adaptability or versatility

If double power conversion components are installed in existing systems, then power distribution flexibility is improved, but device complexity and space occupation increase

Engineering Contradiction:

Improvepower distribution flexibilityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent removes redundant AC-to-DC conversion components from the power distribution path. By adopting a DC-native architecture where the UPS directly outputs DC and PDUs are designed for DC input, the system simplifies the overall device complexity while maintaining distribution flexibility through modular DC-powered units and standardized DC connectors

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the power conversion functions into a single stage at the UPS, eliminating the need for separate AC-to-DC converters in each PDU or rack. This consolidation reduces system complexity by integrating conversion capabilities centrally while distributing DC power efficiently throughout the facility

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If redundant power conversion components are used, then power supply reliability is improved, but space for power distribution equipment increases

Engineering Contradiction:

Improvepower supply reliabilityVSAvoidspace for power distribution equipment

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent extracts and eliminates redundant AC-to-DC conversion equipment from the power distribution infrastructure. By implementing a DC-native architecture, the system removes unnecessary converters and associated cooling, wiring, and mounting space, thereby reducing the physical footprint of power distribution equipment while maintaining reliability through a simplified, fewer-failure-points architecture

Inventive Principle:

Principle #2Taking out (Extraction)

4Adaptability or versatility

If AC to DC and DC to AC conversion is implemented, then power distribution adaptability is improved, but power conversion losses and costs increase

Engineering Contradiction:

Improvepower distribution adaptabilityVSAvoidpower conversion losses

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent extracts the redundant conversion stages from the power distribution path. By implementing a DC-native architecture where power is converted once from AC to DC at the UPS and then distributed as DC throughout the facility, the system eliminates repeated power conversions and associated losses while maintaining adaptability through DC-to-DC conversion capabilities at individual loads

Inventive Principle:

Principle #2Taking out (Extraction)

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

This solution reduces power conversion losses, saves space and costs, minimizes vibrational and acoustic noise, improves HDD stability and throughput, and allows for increased drive density by eliminating redundant power conversion components and reducing the size of power distribution equipment.

Implementation Method 1

The DC PDU converts the first DC power output into multiple different second DC power outputs. Each different second DC power output has a different DC voltage level for supplying power to different components

Methodology Applied

Scientific EffectPower conversion:

Data Source

PatentUS10847994B2Data center power distribution system

Publication Date: 2020.11.24 SEAGATE TECH LLC

AI summary

A system includes a direct current uninterruptible power supply (DC UPS) that receives an alternating current (AC) power input and provides a first DC power output. The system also includes a power distribution unit (PDU). The PDU receives the first DC power output from the DC UPS. The PDU converts the first DC power output into a second DC power output that supplies power to at least one component of information technology equipment (ITE) via a DC mating connector.