Modular Power Distribution Rack Assembly with Bus Bars
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Solution Overview
Problem
Conventional power distribution rack assemblies in aircraft systems are not optimized for minimal installation volume, leading to larger-than-necessary racks with unused or underutilized components, which results in increased size, weight, and cost, as well as reduced reliability and maintenance efficiency.
Innovation Solution
A modular power distribution rack assembly with a manifold and slots for receiving electronic cards, featuring a communication backplane and bus bars, where primary and secondary modules are configured to connect via bus bars and communication backplanes, allowing for selective powering of electrical loads and optimized component placement to reduce unnecessary components and installation volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If conventional power distribution rack assemblies are used, then power distribution functionality is provided, but the installation volume is larger than necessary and includes unused or underutilized components
Solution Approach 1:
The power distribution rack assembly is divided into modular components: a manifold with standardized slots, electronic cards with connectors, bus bars, and a communication backplane. This segmentation allows the system to be configured with only the necessary components for each specific application, eliminating unused components and reducing installation volume while maintaining adaptability through standardized interfaces.
Solution Approach 2:
The manifold with standardized slots, bus bars, and communication backplane provides a universal platform that can accommodate different electronic cards and configurations. This universal interface design enables the same rack structure to be adapted to various power distribution requirements without requiring unused components, resolving the contradiction between volume optimization and configurability.
2Volume of stationary object
If rack assemblies are not optimized for minimal installation volume, then manufacturing and assembly are simpler, but the rack size and weight increase
Solution Approach 1:
The assembly is segmented into standardized modules (manifold, electronic cards, bus bars, backplane) that can be manufactured independently and assembled through standardized interfaces. This segmentation enables minimal installation volume optimization without significantly increasing assembly complexity, as the modular design simplifies both manufacturing and assembly processes.
3Quantity of substance
If conventional power distribution rack assemblies are used, then power distribution is provided, but wiring complexity and weight increase
Solution Approach 1:
Power distribution and communication functions are merged into a single integrated manifold structure with standardized slots and backplane. This consolidation eliminates separate wiring harnesses for power and communication, significantly reducing wiring weight and complexity while maintaining full power distribution functionality.
Solution Approach 2:
The communication backplane and standardized connectors act as intermediaries between electronic cards and the manifold, providing structured connectivity that reduces wiring complexity. This intermediary structure enables systematic power and signal distribution with minimal wiring requirements.
Data Source
AI summary
An apparatus for distributing power from a power source to a set of power outputs using a power distribution rack includes a manifold having a set of bus bars in a wall and coupling a power source to a set of electronic cards, wherein the electronic cards route the power from the power source to the power outputs.