Modular Plug-In Power Distribution Modules for Scalable Data Center Configurations
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Solution Overview
Problem
Existing power distribution systems in data centers are inflexible and require skilled personnel for circuit breaker installation or removal, leading to undesirable power outages and inefficiencies due to the need for pre-determined cable lengths and fixed capacity configurations that do not account for dynamic electrical loads.
Innovation Solution
A modular, scalable power distribution system with plug-in modules that include a housing, electrical isolation and overcurrent protection, and pre-terminated power cables, allowing safe installation and removal without disrupting other circuits, and a bus bar assembly that can accommodate various plug-in modules for flexible configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional power distribution systems use fixed panel boards with pre-installed circuit breakers, then power distribution is stable and reliable, but the system lacks flexibility and requires skilled personnel for installation/removal causing power outages
Solution Approach 1:
The power distribution system is divided into modular plug-in modules, each containing a circuit breaker, power cable, and housing. These modules can be independently installed or removed from the power distribution unit without affecting other modules, enabling flexible reconfiguration while maintaining continuous power supply to operational circuits.
Solution Approach 2:
The system transitions from a static fixed panel board configuration to a dynamic modular system where plug-in modules can be easily added, removed, or repositioned. This dynamic capability allows the system to adapt to changing power distribution needs without requiring complete system shutdown or skilled electrical work.
2Ease of operation
If pre-fabricated plug-in power cables are used to minimize power interruptions, then installation is safer without de-energizing the entire unit, but cable lengths must be pre-determined and the system is not scalable
Solution Approach 1:
The plug-in module design creates a universal interface that can accommodate various circuit breaker types, cable lengths, and configurations within a standardized housing. This universal design allows the same module type to serve multiple functions and be scaled to meet different power distribution requirements without requiring custom pre-fabricated cables for each specific application.
Solution Approach 2:
The circuit breaker and power cable are pre-assembled into an integrated plug-in module during manufacturing, with the circuit breaker already mounted and cables pre-terminated. This preliminary assembly ensures safe installation without requiring hot work, while the modular design maintains scalability by allowing different module configurations to be selected based on specific power distribution needs.
3Ease of manufacture
If preconfigured power distribution units with fixed capacity are used, then installation is simplified, but the system cannot accommodate dynamic electrical loads and results in excess capacity
Solution Approach 1:
The power distribution unit is segmented into multiple independent plug-in modules, each capable of being individually configured for different current ratings and circuit requirements. This segmentation allows the system to be easily manufactured with standardized modules while providing the flexibility to accommodate dynamic electrical loads by adding or removing modules as needed, eliminating the need for oversized preconfigured units.
4Adaptability or versatility
If circuit breakers are installed or removed from traditional panel boards, then power distribution can be reconfigured, but skilled personnel are required and power outages occur
Solution Approach 1:
Each circuit breaker is packaged with its dedicated power cable and housing as a self-contained plug-in module. This segmentation allows non-skilled personnel to safely install or remove entire modules without exposing themselves to energized conductors or requiring complex wiring knowledge, while still enabling easy reconfiguration of the power distribution system by plugging modules into different positions.
Solution Approach 2:
The plug-in module housing and connector serve as an intermediary between the circuit breaker and the power distribution unit's bus bars. This intermediary design provides a safe, pre-assembled interface that eliminates the need for skilled electrical work during installation or removal, while maintaining full reconfigurability of the power distribution system through simple module placement.
Data Source
AI summary
According to one aspect of the invention, a plug-in module is provided for installation in a power distribution assembly. In one embodiment, the plug-in module includes a housing, an electrical isolation and overcurrent protection device located in the housing and a current sensing device located in the housing and adapted to sense a current carried by the electrical isolation and overcurrent protection device. The plug-in module may further include a power cable including a first end that is pre-terminated at the plug-in module to connect the power cable to the electrical isolation and overcurrent protection device, and electrical contacts adapted to removably couple the plug-in module to a plurality of stationary electrical conductors of the power distribution assembly. According to one embodiment, the electrical isolation and overcurrent protection device includes a circuit breaker.