Modular Power Distribution Chassis with Removable AC-DC Conversion Modules
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Solution Overview
Problem
Existing power and data distribution systems are limited by fixed AC power connections, requiring separate AC-DC converters, known as 'wall-warts', which are not easily integrated into modular raceways.
Innovation Solution
A modular power distribution system with an elongated chassis and removable power modules that include electrical circuitry for AC-DC conversion, allowing for flexible mounting and integration of power, data, and signal transmission, using line busses and connectors for secure and isolated power and data connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed AC power connections are used, then power distribution is simple, but flexibility and relocatability are limited
Solution Approach 1:
The power distribution system is divided into modular components: a fixed chassis containing AC power input and distribution busses, and removable modules containing DC conversion electronics and outlet ports. This segmentation allows the AC-DC conversion functionality to be relocated to different positions along the chassis by simply moving modules, providing flexibility without requiring changes to the fixed AC infrastructure.
Solution Approach 2:
The patent introduces an intermediary modular module that acts as a bridge between the fixed AC power distribution chassis and the need for relocatable DC power outlets. The module contains AC-DC conversion electronics and connects to the chassis via electrical contacts, serving as a movable intermediary that transfers power from fixed AC sources to flexible DC outlets.
2Adaptability or versatility
If separate AC-DC converters are used, then power conversion is achieved, but integration into modular raceways is difficult
Solution Approach 1:
The patent merges the AC-DC conversion electronics with the outlet housing into a single integrated module. This combination allows the conversion functionality to be seamlessly integrated into the modular raceway system, as the entire module can be easily mounted to the chassis without requiring separate mounting of converters and outlets.
Solution Approach 2:
The modular module is designed with universal functionality, serving multiple purposes: housing AC-DC conversion electronics, providing DC power outlets, and acting as the mounting interface to the chassis. This multi-functionality simplifies integration into the modular raceway system by eliminating the need for separate components.
3Adaptability or versatility
If modular modules are removable, then flexibility is improved, but secure connection and isolation are challenging
Solution Approach 1:
The connection system employs a dynamic locking mechanism with spring-loaded electrical contacts that automatically engage when a module is inserted into the chassis. The spring force ensures reliable electrical connection while allowing easy removal by overcoming the spring force, thus providing both reliability and relocatability.
Solution Approach 2:
The locking mechanism is designed to automatically engage and secure the module to the chassis upon insertion, providing beforehand cushioning against accidental disconnection. The spring-loaded contacts ensure firm electrical connection before any operation begins, preventing connection failures during use.
Data Source
AI summary
A power distribution system for providing power, data and/or signals including a chassis with an open channel formed on one side. At least one line buss is mounted on the inside of at least one sidewall and configured to be connected to a power source for providing AC power. A plurality of power modules are configured to removably mount to the chassis and receive power/data/signals from the chassis. Each module includes a housing with walls. A front wall includes openings with one outlet port accessible through the openings. Electrical circuitry in the housing coverts or transmits power, data or communication signals to the outlet port. One or more line connections protrude out from at least one of the walls and are located so as to come into contact with one of the associated busses in the chassis when the module is attached to the chassis.