Modular Power Distribution System With Electronic Breakers
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Solution Overview
Problem
Existing power distribution panels are inflexible and costly to retool for different configurations, with limited component arrangements and difficult assembly due to pre-cut holes, and they often require extensive internal wiring and large OR-ing diodes that create space and reliability issues.
Innovation Solution
A modular power distribution system with a chassis and removable circuit modules, featuring a backplane for interconnection, electronic breakers, and localized OR-ing diodes, allowing for customizable configurations and reduced internal wiring, with control logic and microcontrollers for dynamic breaker control and diagnostics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-cut holes are used in housing structure for component insertion, then assembly is simplified, but flexibility and reconfigurability are lost
Solution Approach 1:
The circuit panel is divided into modular components that can be independently positioned and configured. Instead of a fixed housing with pre-cut holes, the system uses separate circuit elements that can be arranged flexibly within the housing, allowing reconfiguration without manufacturing new housing structures.
Solution Approach 2:
The circuit panel transitions from a static, fixed configuration to a dynamic, reconfigurable system. Circuit elements can be moved, added, or removed from the housing, enabling the panel to adapt to different electrical distribution requirements while maintaining ease of assembly through standardized interfaces.
2Adaptability or versatility
If different fixed circuit panels are manufactured with different hole patterns, then component arrangement flexibility is achieved, but retooling time and costs increase significantly
Solution Approach 1:
A single universal housing structure is designed to accommodate multiple circuit element configurations through standardized mounting interfaces. The same housing can be used for different circuit panel configurations by simply rearranging the circuit elements, eliminating the need for multiple specialized housing types and reducing retooling requirements.
3Reliability
If redundant power connections with OR-ing diodes and heat sinks are provided, then reliability is improved, but space within the panel increases significantly
Solution Approach 1:
The OR-ing diodes and heat sinks are integrated into the circuit elements themselves rather than being separate components. This nested arrangement allows the redundancy functionality to be embedded within the existing circuit element structure, maintaining reliability while minimizing additional space requirements in the panel.
Data Source
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AI summary
A modular power distribution system comprising a chassis; a backplane including a plurality of module connection locations; a plurality of modules mounted in the chassis, each module mounted to a module connection location and at least one of the plurality of modules including a circuit protection device operable at a plurality of selectable trip levels; a microprocessor controlling the circuit protection device; an OR-ing diode; and a power output connection location.