Modular Data Center with Rolling Carriage Assemblies
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Solution Overview
Problem
Conventional data center construction methods are costly and time-consuming, especially when expanding or building in remote locations, due to the 'stick build' approach, which requires numerous workers, materials, and is prone to delays from weather and logistical issues.
Innovation Solution
A modular, prefabricated data center system using unit structures with carriage assemblies and elevated support rails allows for rapid assembly by rolling the units into position, reducing the need for on-site construction and enabling efficient expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional 'stick build' construction methods are used, then data centers can be constructed at selected sites, but construction time and cost increase significantly
Solution Approach 1:
The data center is divided into multiple modular unit structures that can be manufactured separately and then assembled together. Each module contains complete functional components (server racks, cooling units, electrical systems), allowing parallel manufacturing and rapid on-site assembly, thus reducing construction time while maintaining ease of construction.
Solution Approach 2:
Unit structures are pre-assembled with all necessary components (server racks, cooling equipment, electrical systems) before being transported to the construction site. This preliminary preparation eliminates the need for time-consuming on-site installation of individual components, significantly reducing construction time while keeping the overall construction process manageable.
2Ease of manufacture
If conventional 'stick build' construction methods are used, then data centers can be constructed at selected sites, but construction cost increases significantly
Solution Approach 1:
By segmenting the data center into standardized modular units, the patent enables efficient manufacturing processes and economies of scale. Modules can be produced in factories with controlled conditions, reducing material waste and labor costs compared to traditional on-site construction, thereby lowering overall construction costs while maintaining ease of construction.
Solution Approach 2:
The modular unit structures are designed to be universal and interchangeable, with standardized interfaces and configurations. This universality allows the same module design to be replicated across multiple units, reducing design and manufacturing costs through standardization, while simplifying the construction process.
3Productivity
If modular unit structures are used with carriage assemblies, then assembly time is reduced, but device complexity increases
Solution Approach 1:
The patent introduces movable carriage assemblies that enable dynamic repositioning of heavy unit structures along elevated rails. This dynamic positioning system allows modules to be rolled into place rather than requiring complex lifting and positioning equipment, increasing assembly speed while the modular design keeps the overall system complexity manageable through standardization.
Solution Approach 2:
The carriage assemblies act as intermediary devices between the transported unit structures and the final installation position. These carriages simplify the transfer process by providing a straightforward rolling mechanism along rails, increasing assembly speed without requiring complex heavy-lifting equipment, thus managing system complexity effectively.
Data Source
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Figure 2a~2b
AI summary
A modular data center system is disclosed for constructing a modular data center building. A plurality of structural support columns are used to support a plurality of unit structures above a floor surface at a desired height relative to the floor surface. A pair of elongated support rails are also included which are coupled perpendicularly to the plurality of structural support columns, at approximately the desired height, to form two parallel, horizontally spaced apart tracks. Each of the unit structures includes a plurality of carriage assemblies, with each of the carriage assemblies including a wheel. The wheels allow the unit structures to be rolled horizontally into a desired position on the pair of elongated support rails when constructing the modular data center building to expedite its assembly.