Modular Switchgear Assembly with Integrated AC/DC Converter Modules

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Solution Overview

Problem

Conventional data centre switchgear assemblies with stand-alone UPS modules require additional engineering, commissioning, and maintenance efforts, incur higher costs, and experience thermal losses due to extensive cabling and additional breakers, limiting customization and efficiency in power distribution.

Innovation Solution

A modular low voltage switchgear assembly with integrated AC/DC converter modules that allow for flexible and reliable power distribution, featuring a main breaker module, AC/DC converter units, and a floating ground system to provide uninterrupted AC and DC power, reducing the need for separate UPS modules and enhancing maintainability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If stand-alone UPS modules are used for uninterrupted power supply, then reliability is improved, but device complexity and cost increase

Engineering Contradiction:

Improveuninterrupted power supplyVSAvoidseparate UPS modules and cabling

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the converter unit and UPS module into a single integrated switchgear assembly. The converter unit (41) and UPS module (5) share common cabling connections to the DC power distribution bus bars (7), eliminating the need for separate cabling systems. This integration reduces device complexity while maintaining uninterrupted power supply capability, as the UPS module can immediately take over when the converter unit fails or during maintenance.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If extensive cabling and additional breakers are installed for stand-alone UPS modules, then reliability is improved, but thermal losses increase

Engineering Contradiction:

Improvepermanent energy supplyVSAvoidthermal losses

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The integrated design allows the converter unit and UPS module to share common cabling connections to the DC power distribution bus bars. This reduces the total length and cross-section of cabling required compared to separate systems, thereby reducing resistive thermal losses while maintaining the same reliability level for uninterrupted power supply.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If separate stand-alone converter units are used for power conversion, then adaptability is improved, but device complexity increases

Engineering Contradiction:

Improvecustomization for specific power requirementsVSAvoidengineering and commissioning effort

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The switchgear assembly is designed as a universal platform that can accommodate different converter unit types (AC/DC, AC/AC) and UPS module configurations within a single integrated structure. The modular design with standardized connections allows the same assembly framework to serve various power distribution scenarios, reducing engineering and commissioning effort while maintaining adaptability to specific power requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Adaptability or versatility

If multiple independent components are used for power conversion and UPS, then adaptability is improved, but ease of operation deteriorates

Engineering Contradiction:

Improveflexible power distributionVSAvoidmaintenance effort

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

By integrating the converter unit and UPS module into a single switchgear assembly with shared cabling and control systems, the patent simplifies maintenance operations. Technicians can service the entire power conversion and UPS system from a single location without needing to access separate components, thereby improving ease of operation while maintaining the flexible adaptability provided by modular components.

Inventive Principle:

Principle #5Merging (Combining)

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 flexibility, reliability, and maintainability while reducing investment and operational costs by integrating converter modules for efficient AC and DC power distribution, ensuring continuous power supply with reduced thermal losses and simplified maintenance.

Implementation Method 1

an AC/DC converter unit (41) having an input configured to be connectable to an AC power supply and having an output configured to supply a Direct Current (DC) power

Methodology Applied

Scientific EffectAC/DC conversion:

Data Source

PatentEP2887484B1Switchgear assembly for AC and DC power distribution

Publication Date: 2023.06.28 ABB AG(DE)

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AI summary

The invention relates to a converter module (4, 11) for use in a switchgear assembly (1) for power distribution, comprising: - one or more AC supply bus bars (42, 112) for providing AC power supply; - one or more AC or DC power distribution bus bars (48, 113) for distributing power to loads; and - one or more converter units (41, 111) for converting AC power from the AC supply bus bars (42, 112) to AC or DC power onto AC or DC power distribution bus bars (48, 113), respectively.