Hot-Swappable Power Supply Modules with Shutter Mechanisms
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Solution Overview
Problem
Existing power supplies require shutdown to safely replace failed power electronic modules, leading to disruptive and costly interruptions in industrial applications.
Innovation Solution
A power supply design with compartments for each power electronic module, featuring grounded or insulated surfaces, stationary electrical connectors, and a shutter mechanism that allows 'hot-swapping' by disconnecting and reconnecting modules while the supply operates, enabling safe replacement without shutting down the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power supply is shut down to replace power electronic modules, then safety is improved, but productivity deteriorates due to system downtime
Solution Approach 1:
The power supply is divided into modular compartments, each housing a separate power electronic module. This segmentation allows individual modules to be replaced without affecting the entire system, enabling hot-swapping capability where modules can be exchanged while the power supply remains operational, thus maintaining productivity while improving safety
Solution Approach 2:
An intermediary mechanism (shutter or barrier) is introduced between the electrical connectors and the module being replaced. This intermediary allows the module to be physically removed or replaced while preventing direct contact with live electrical components, enabling safe hot-swapping operations without system shutdown
2Productivity
If the power supply remains operational during module replacement, then productivity is improved, but safety deteriorates due to risk of contact with live power connections
Solution Approach 1:
The shutter or barrier is positioned to block access to live electrical connectors before the module removal process begins. This preliminary protective action is already in place when the module needs to be replaced, allowing safe hot-swapping operations without requiring system shutdown, thus maintaining both productivity and safety
Solution Approach 2:
A movable shutter or insulating barrier acts as an intermediary element that can be positioned to block access to live electrical connectors. This intermediary provides physical protection against accidental contact with live power connections while allowing the module replacement process to proceed, enabling safe operational maintenance
Data Source
AI summary
A power supply having one or more power electronic modules that may be replaced without shutting down the power supply. Each power electronic module may be enclosed in a separate compartment of the power supply. Each compartment may have stationary electrical connectors configured to electrically connect to the power electronic module. A racking mechanism connected to a handle outside the compartment may move a power electronic module out of electrical contact with the stationary electrical connectors and/or into electrical contact with the stationary electrical connectors. Movement of a power electronic module within the compartment may occur without shutting down the power supply. Methods of replacing power electronic modules without shutting down the power supply are also provided, as are other aspects.