Modular Power Control Enclosure Thermal Management

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Solution Overview

Problem

Current power control systems pose safety hazards due to exposed bus bars and inadequate heat dissipation, leading to increased risks of electrocution, shock, and component failure.

Innovation Solution

A modular power control system with a base enclosure and module enclosures that include fans and vent openings for airflow, along with guide channels for secure module placement, to create a safer environment by reducing heat and preventing unauthorized access.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If components are exposed inside the enclosure for easy access, then ease of operation is improved, but safety is worsened due to electrocution and shock hazards

Engineering Contradiction:
Improveaccess to componentsVSAvoidelectrocution and shock hazards
Core Design Contradiction:
Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The enclosure is divided into multiple compartments with isolated sections for different electrical components. Each compartment has its own access points, allowing technicians to access specific components without exposing themselves to the entire electrical system, thus maintaining ease of operation while improving safety.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Insulating barriers and protective coverings are introduced as intermediary elements between the electrical components and the technician. These intermediaries allow access to functional components while blocking direct contact with hazardous electrical elements, resolving the contradiction between accessibility and safety.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Temperature

If the enclosure door is left open to dissipate heat, then temperature is reduced, but safety is worsened by exposing non-trained personnel to electrical components

Engineering Contradiction:
Improveheat dissipationVSAvoidexposure to electrical components
Core Design Contradiction:
TemperatureVSObject-affected harmful factors

Solution Approach 1:

The enclosure door is segmented into removable panels or sections that can be opened selectively. Heat-generating components have dedicated ventilation openings in the door that remain open for thermal dissipation, while the main access ports remain closed and locked, preventing personnel exposure while maintaining effective heat management.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Ventilation channels are created through the door structure itself, providing a third-dimensional pathway for heat escape that does not require opening the door to the external environment. This allows thermal management through the door's thickness rather than through door opening.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

3Volume of stationary object

If large enclosures are used to house all components, then all components can be contained, but device complexity and wiring complexity increase creating a rats nest

Engineering Contradiction:
Improveenclosure sizeVSAvoidwiring complexity
Core Design Contradiction:
Volume of stationary objectVSDevice complexity

Solution Approach 1:

The system is divided into multiple smaller modular enclosures, each housing specific functional components. This segmentation reduces the internal volume of each enclosure, simplifying wiring within each module while maintaining the ability to house all necessary components across the distributed modular system.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Multiple enclosures are arranged in a distributed spatial configuration rather than consolidating all components in a single large volume. This dimensional distribution transforms the wiring problem from a complex three-dimensional rats nest into simpler, localized connections within each module plus standardized inter-module connections.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

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 enhances safety by minimizing electrical hazards and heat-related failures, while allowing for efficient power distribution and control across multiple phases, improving operational reliability and safety.

Implementation Method 1

The module enclosure includes a fan to direct air flow through the module enclosure cavity

Methodology Applied
Scientific EffectForced Convection: Forced Convection

Implementation Method 2

The module enclosure includes a vent opening in the module enclosure top

Methodology Applied
Scientific EffectConvection: Convection

Data Source

PatentUS9172220B1Configurable modular power control system
Publication Date: 2015.10.27 LEX PRODS
  • US9172220B1 patent drawing
  • US9172220B1 patent drawing
  • US9172220B1 patent drawing

AI summary

A modular power control system is provided and includes a base enclosure, wherein the base enclosure and a base enclosure door, wherein the base enclosure defines a base enclosure cavity and the base enclosure door defines a base enclosure door cavity. Additionally, a module enclosure is provided and includes a module enclosure top, a module enclosure bottom, and two module enclosure sides, wherein the module enclose defines a module enclosure cavity and a module enclosure internal support, wherein the module enclosure internal support includes a module enclosure internal support rear and two module enclosure internal support sides having a first module guide channel located on one of the two module enclosure internal support sides and a second module guide channel located on the other of the two module enclosure internal support side.