Fluid-Cooled Busbar Assembly for High-Amperage Track Busways
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Solution Overview
Problem
Existing liquid-cooled busbar assemblies for track busway systems lack flexibility and adaptability, limiting their scalability and maintenance, while air-cooled systems are insufficient for high amperage applications, leading to inefficient cooling and potential overheating.
Innovation Solution
A fluid cooling system with cooling jackets and separate cooling for section joints, allowing flexible placement of plug-in units and temperature regulation, using a closed-loop cooling fluid system with temperature sensors to maintain consistent operating temperatures and handle higher currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If air cooling systems are used for busbar assemblies, then the system structure is simple and easy to implement, but the cooling effectiveness is insufficient for high amperage applications
Solution Approach 1:
The patent applies hydraulic cooling by circulating liquid coolant through cooling channels formed within the busbar structure itself. The cooling channels are integrated into the busbar cross-section, allowing direct liquid-to-busbar heat transfer. This hydraulic approach provides superior cooling capacity compared to air cooling, enabling the system to handle high amperage loads while maintaining safe operating temperatures.
2Temperature
If direct liquid cooling is integrated into busbar components, then cooling effectiveness is improved, but the system flexibility and adaptability are reduced
Solution Approach 1:
The patent designs the busbar with integrated cooling channels that serve multiple functions: electrical current conduction and thermal management. The universal busbar design can be configured for different amperage requirements and cooling scenarios without requiring completely different structures. The cooling system is built into the busbar itself, making it adaptable to various applications while maintaining effective temperature control.
3Temperature
If the entire busbar is designed with integrated water-cooling system, then temperature control is maximized, but the manufacturing cost becomes prohibitively expensive
Solution Approach 1:
The patent implements cooling channels only in specific high-heat-generation zones of the busbar rather than uniformly throughout the entire structure. The cooling channels are strategically positioned where current density and heat generation are highest, providing targeted thermal management. This localized approach maintains effective temperature control in critical areas while reducing manufacturing complexity and cost compared to fully integrated cooling throughout the entire busbar.
4Temperature
If traditional liquid cooling pipes are integrated into busbar portions, then cooling is effective for that portion, but the system becomes inflexible regarding deployment location
Solution Approach 1:
The patent merges the cooling function directly into the busbar structure by forming cooling channels within the busbar material itself rather than attaching separate external pipes. This integration eliminates the need for separate piping components and their associated mounting requirements, allowing the busbar to be installed in various locations and configurations. The combined structure maintains effective cooling while providing the flexibility to be deployed wherever electrical power distribution is needed.
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
The fluid-cooled busbar assembly maintains consistent temperatures, handles up to 33-50% more current before overheating, and provides flexible, scalable power distribution for high-amperage applications.
Implementation Method 1
a first cooling jacket (140) in thermal contact with the busbars (16) of a section (10) of the track busway system; a second cooling jacket (140) in thermal contact with the joint pack (74) connecting the sections (10) of the track busway system
Implementation Method 2
fluid cooling system with cooling jackets and separate cooling for section joints, allowing flexible placement of plug-in units and temperature regulation
Data Source
AI summary
A fluid cooling system provides integrated fluid cooling to dissipate heat from a track busway system, particularly the busbars of a track busway system. The fluid cooling system for the track busway system includes one or more cooling jackets in thermal contact with the busbars of a section of the track busway system. A cooling fluid flows through the cooling jackets to remove or dissipate heat from the busbars of the track busway system through conductive heat transfer. In addition, section joints or busway joinders may receive separate fluid cooling from the fluid cooling system using a cooler positioned between the joint packs connecting the sections of the track busway system.