Load Bank Assembly With Automated Damper Cooling
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Solution Overview
Problem
Existing load bank systems face inefficiencies in testing power infrastructure and HVAC systems due to heat recirculation issues, manual configuration errors, and labor-intensive testing processes, particularly when switching between primary and redundant power sources.
Innovation Solution
A versatile load bank assembly that can be configured in wye and delta configurations using relays and a multi-pole relay system for testing various power sources, combined with an automated cooling system featuring a damper and blower to prevent heat recirculation and reduce manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If makeshift baffles are used to block heat recirculation, then heat recirculation is reduced, but manual error and safety threats increase
Solution Approach 1:
The patent replaces manual mechanical baffles with an automated damper system controlled by a controller. The damper is automatically positioned based on load bank operational status, eliminating manual intervention and its associated errors while maintaining heat recirculation prevention.
Solution Approach 2:
The load bank assembly performs self-monitoring and self-regulation of heat recirculation prevention. The controller automatically detects load bank operational status and adjusts the damper position accordingly, enabling the system to manage its own thermal environment without external intervention.
2Adaptability or versatility
If multiple load banks are installed for comprehensive testing, then testing coverage is improved, but heat recirculation problems worsen
Solution Approach 1:
The patent divides the data center testing environment into independent load bank assemblies, each with its own damper and cooling system. This segmentation allows each unit to independently manage its heat recirculation, enabling multiple load banks to operate simultaneously without collective heat recirculation problems.
Solution Approach 2:
The damper is pre-positioned in the closed position to prevent heat recirculation before testing begins. This preliminary action ensures that when multiple load banks operate simultaneously, heat recirculation is already blocked, maintaining testing integrity from the start.
3Device complexity
If manual configuration is used for load bank setup, then device complexity is reduced, but productivity decreases
Solution Approach 1:
The patent replaces manual configuration operations with automated electronic control. The controller automatically configures the damper and relay settings based on pre-programmed parameters, eliminating time-consuming manual setup while maintaining system simplicity through standardized interfaces.
Solution Approach 2:
The load bank assembly is designed with universal, pre-configurable settings that can accommodate different testing scenarios without requiring complex manual reconfiguration. The automated controller handles various test configurations, making the system adaptable to different testing needs while maintaining ease of use.
4Use of energy by moving object
If load banks are turned off when not in use, then energy consumption is reduced, but heat recirculation control becomes problematic
Solution Approach 1:
The controller continuously monitors load bank operational status and provides feedback to automatically adjust the damper position. When a load bank is turned off, the controller detects this status change and automatically closes the damper to prevent heat recirculation, eliminating the need for manual intervention.
Solution Approach 2:
The system automatically manages heat recirculation prevention based on its own operational status. Each load bank assembly self-regulates its thermal environment by having the controller monitor its operational state and adjust the damper accordingly, ensuring heat recirculation is prevented whether the load bank is on or off.
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
Enables faster, more accurate testing of power sources with reduced labor and improved safety by allowing simultaneous testing of primary and redundant power sources, and automated cooling that prevents heat recirculation, thereby enhancing test integrity and reducing operational costs.
Implementation Method 1
A blower is arranged in the housing adjacent the cold air inlet for circulating cold air through the load resistor assembly to cool the load resistor assembly via heat exchange
Implementation Method 2
circulating cold air through the load resistor assembly to cool the load resistor assembly via heat exchange which results in hot air
Data Source
AI summary
A load bank for testing power sources includes a load resistor assembly having a plurality of resistors which can be switched between wye and delta configurations for testing a variety of voltages and power sources requiring various load applications. First and second power connections are connected with primary and redundant power sources and a relay alternately connects the first and second power connections with the load resistor assembly for alternately testing the primary and redundant power sources while maintaining the sources electrically isolated. A damper is arranged adjacent the load resistor assembly and is operable between an open position which permits cold air to be delivered to the load resistor assembly to cool the assembly when the load bank is operating and a closed position which prevents hot air from being recirculated when the load bank is not operating.