Modular Load Bank Trays for High-Voltage Power Dissipation
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Solution Overview
Problem
Existing load banks are large, heavy, and difficult to manufacture, ship, store, troubleshoot, and maintain, especially at high voltages, and face challenges with space efficiency and heat management.
Innovation Solution
A modular load bank apparatus comprising multiple load bank modules with trays of resistive components that dissipate power efficiently in a compact footprint, using coiled wire and efficient cooling systems, allowing direct high-voltage operation without transformers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional load bank design is used, then power dissipation capability is achieved, but device size and weight become excessively large
Solution Approach 1:
The load bank is divided into multiple modular units, each containing stacked trays with resistive components. This segmentation allows the system to achieve high power dissipation through modular aggregation rather than requiring a single large structure, thereby reducing overall device weight while maintaining power capability.
Solution Approach 2:
The design transitions from horizontal expansion to vertical stacking of trays within modular units. By utilizing the vertical dimension, the system achieves high power dissipation in a compact footprint, significantly reducing the device's horizontal footprint and associated weight requirements.
2Power
If traditional load bank design is used, then power dissipation capability is achieved, but device footprint area becomes excessively large
Solution Approach 1:
The load bank utilizes vertical stacking of trays within modular units, transforming the design from horizontal spread to vertical consolidation. This dimensional change enables high power dissipation capability while minimizing the horizontal footprint area to approximately 12.3 meters by 2.5 meters.
Solution Approach 2:
Multiple trays are nested vertically within each modular unit, with resistive components arranged in stacked configurations. This nesting approach maximizes power density within the vertical space, thereby reducing the required horizontal footprint area.
3Power
If high voltage operation is implemented, then power dissipation efficiency is improved, but manufacturing and maintenance difficulty increases
Solution Approach 1:
The high voltage load bank is segmented into standardized modular units with identical electrical configurations. Each module can be manufactured independently using standardized procedures, and maintenance can be performed on individual modules without shutting down the entire system, thereby improving both manufacturing ease and maintenance accessibility.
Solution Approach 2:
The system achieves high voltage operation (up to 35,000 volts) through standardized electrical parameters and configurations within each modular unit. By maintaining consistent electrical parameters across modules, the design simplifies manufacturing processes and maintenance procedures despite the high voltage requirements.
4Area of stationary object
If compact design is implemented, then space efficiency is improved, but heat management difficulty increases
Solution Approach 1:
The compact modular design segments the heat-generating resistive components into discrete trays within each module. This segmentation allows for distributed heat management, where each tray and module can be independently cooled, preventing heat accumulation despite the compact overall footprint.
Solution Approach 2:
The modular tray structure acts as an intermediary between the heat-generating resistive components and the cooling system. This intermediate structure facilitates efficient heat transfer from the resistive elements to cooling surfaces, enabling effective thermal management within the compact design.
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 design enables efficient power dissipation and heat management, reducing weight and space requirements, facilitating easier handling and maintenance, and supporting high-voltage operations.
Implementation Method 1
trays including resistive components to dissipate the power received from the power source at a voltage level of the power source
Data Source
AI summary
An apparatus can a load bank module configured to electrically couple with at least one other load bank module. The load bank module and the at least one other load bank module can be further configured to electrically couple to a power source to dissipate power received from the power source. The load bank module can include trays including resistive components to dissipate the power received from the power source at a voltage level of the power source. A resistive component of the resistive components can include a coil, the coil can extending between a first end of the resistive component and a second end of the resistive component opposite the first end of the resistive component to form three or more turns of the coil.