Modular Power Cell Air Cooling and Self-Sealing Connections
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Solution Overview
Problem
Existing power delivery systems for medium-voltage applications face challenges in reducing size, increasing reliability, and maintaining operation under fault conditions, particularly in efficiently managing heat and cooling within modular power cells.
Innovation Solution
A power delivery system with removable power cells featuring a water-cooled heat sink, air intake, and air plenum, where air is cooled by a heat exchanger and recirculated, and a water delivery manifold with self-sealing connections, allowing for efficient heat management and reduced ionization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air is circulated through power cells to cool components, then heat removal is improved, but air ionization and arcing faults increase
Solution Approach 1:
A recirculating air cooling system with a heat exchanger is introduced as an intermediary mechanism. The system cools the air externally before recirculating it back to the power cells, thereby removing heat without causing ionization and arcing faults that occur with direct air cooling methods.
2Reliability
If power cells are designed as removable modular units, then system reliability and fault tolerance are improved, but device complexity increases
Solution Approach 1:
The power delivery system is divided into separate, removable power cell modules that can be independently replaced. Each module contains complete functional components, allowing faulty cells to be quickly swapped out without affecting the entire system, thereby improving reliability through modular architecture.
Solution Approach 2:
The system incorporates dynamic self-sealing connections that automatically seal when power cells are removed or disconnected. This dynamic sealing mechanism simplifies the modular design by eliminating complex manual sealing procedures while maintaining system integrity during module replacement.
3Volume of stationary object
If system size is reduced for compactness, then space efficiency is improved, but heat management becomes more difficult
Solution Approach 1:
The recirculating air cooling system with heat exchanger is integrated within the compact housing structure. The heat exchanger is positioned to receive air from the air plenum and cool it before recirculation, nesting the cooling function within the existing system volume rather than adding external cooling infrastructure.
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 system effectively reduces air ionization and arcing faults, increases reliability, and allows for modular replacement of power cells, enhancing the operational efficiency and longevity of medium-voltage power delivery systems.
Implementation Method 1
The heat exchanger may be positioned to receive the air from the air plenum, cool the air, and recirculate the cooled air to the cells via each cell's air intake
Implementation Method 2
Each power cell includes a water cooled heat sink
Data Source
AI summary
A method of operating a power delivery system that has at least one power cell includes directing air into the power cells to cool them, receiving the air from the cells, directing the air to a cooling system, and recirculating the cooled air to the power cells. Each cell may include an air intake, an air output, a water-cooled heat sink, and optionally a plurality of capacitor connectors and/or a circuit board. The air may be directed through the air intake to the air output so that air passes over the capacitor connectors and/or the circuit board before passing over the heat sink.