Modular Electrical System with Integral Air Duct Cooling
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Solution Overview
Problem
Traditional solar-battery systems face challenges with high shipping costs and handling difficulties due to voluminous and unwieldy cabinets, limited expansion capabilities, and inefficient thermal management, particularly with air duct cooling systems that require precise thermal contact between components and the air duct.
Innovation Solution
A modular electrical system comprising stackable modules with identical top and bottom connectors and a continuous air channel, allowing for flexible arrangement and improved air cooling without the need for customization, enabling efficient thermal management and easier expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cabinet-based systems are used to house solar-battery components, then all components can be contained in a single enclosure, but the cabinet becomes voluminous and unwieldy, increasing shipping costs and handling difficulties
Solution Approach 1:
The system is divided into multiple rack-mounted components (inverter, battery, charger, controller) that can be installed separately in standard 19-inch racks. This segmentation allows each component to be shipped individually in compact form and assembled at the installation site, reducing the volume of any single moving object while maintaining complete system functionality.
2Strength
If components are mounted in rack-type cabinets with vertical rails, then components can be securely mounted, but the rack structure requires significant vertical space and becomes difficult to handle when fully loaded
Solution Approach 1:
Instead of mounting all components in a single large rack, the system uses multiple smaller rack units that can be mounted individually. Each rack unit contains specific components (e.g., inverter rack, battery rack) and can be handled and installed separately, improving ease of operation while maintaining secure mounting through standard rack rails.
Solution Approach 2:
The system transitions from vertical rack mounting to horizontal cabinet-style mounting for battery components. Batteries are placed horizontally on shelves within cabinets, which reduces the vertical height requirement and makes the overall system more compact and easier to handle, while still providing secure mounting through cabinet shelving structures.
3Reliability
If an external air duct is used for cooling cabinet components, then the cabinet interior remains clean and free of moisture, but all components require precise thermal contact with the air duct, making installation difficult
Solution Approach 1:
Each rack-mounted component is equipped with its own integrated cooling system, including dedicated fans and heat sinks. This self-service approach allows each component to manage its own thermal requirements independently, eliminating the need for precise thermal contact with external air ducts while maintaining clean and dry cabinet interiors. The components are designed to be thermally self-sufficient.
4Weight of moving object
If the cabinet is shipped empty to save weight, then shipping costs are reduced, but components must be installed at the site, complicating the air duct cooling system setup
Solution Approach 1:
The system is shipped as separate, pre-configured rack units and cabinet components rather than as a fully assembled system. Each component (inverter rack, battery cabinet, air handling units) is independently packaged and can be installed separately. The modular design allows for straightforward assembly at the installation site without complex cooling system setup, as each unit comes with its own integrated cooling components already configured.
5Strength
If traditional rack-mounted systems are used, then components can be securely mounted, but expansion is limited by the fixed cabinet size
Solution Approach 1:
The system is designed with dynamic expandability through standardized rack mounts and cabinet configurations. Additional rack units and cabinet modules can be added to the existing system as needs grow. The modular architecture allows for incremental expansion while maintaining secure mounting through consistent rack rail interfaces and standardized mounting procedures.
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 modular system reduces shipping costs, simplifies installation, and enhances thermal management by allowing flexible module arrangement and air cooling, addressing the limitations of traditional cabinet-based systems while maintaining efficient thermal performance.
Implementation Method 1
air cooling without the need for customization, enabling efficient thermal management
Data Source
AI summary
A system of modules that hold components for operating an external energy source including solar cells and other energy sources is provided, where upon assembly of the modules an electrical cabinet with a module internal air channel for air duct cooling for the components is created. The resulting modular cabinet is only as large as required and is easily expandable. Modules are no larger than the components housed therein and the modules are easy to handle. Interior modules can be in any order reducing the chance of error during assembly and allowing modules in certain positions which may ease installation or operation. Components are thermally connected at the factory to a portion of the air duct in each module and none of the present challenges associated with thermal connection exist at the time of installation.