Nested Bus Bar Assembly for Power Distribution Racks
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Solution Overview
Problem
Existing power distribution racks face complexity and increased costs due to the need for multiple layers of insulation and mechanical joints to isolate AC and DC connections, leading to increased electromagnetic interference and transmission losses.
Innovation Solution
A central bus bar assembly with nested inner and outer bus bars directly coupled to AC and DC connectors of electronics modules, eliminating the need for backplanes and horizontal bus bars, and allowing for simplified cabling and reduced mechanical joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple horizontal bus bars are used to connect AC and DC connectors on each shelf, then electrical connections are established, but device complexity increases and production costs increase
Solution Approach 1:
The patent extracts and eliminates the horizontal bus bars from the system by directly connecting AC and DC connectors to the vertical bus bar. This removal of unnecessary intermediate components simplifies the cabling architecture and reduces production costs while maintaining electrical connectivity.
Solution Approach 2:
The patent transitions from a two-dimensional horizontal bus bar connection approach to a three-dimensional vertical bus bar connection approach. By connecting connectors directly to the vertical bus bar at different heights, the system eliminates the need for horizontal bus bars and complex cross-wiring while maintaining all necessary electrical connections.
2Object-affected harmful factors
If AC and DC connections are isolated with multiple layers of insulation, then electromagnetic interference is reduced, but production costs increase
Solution Approach 1:
The patent uses vertical separation in the third dimension to isolate AC and DC connections, eliminating the need for multiple layers of insulation. By positioning AC and DC connectors at different vertical levels and connecting them directly to the vertical bus bar, electromagnetic interference is minimized through spatial separation rather than insulating layers.
3Loss of energy
If multiple mechanical joints are used in horizontal bus bars, then electrical connections are established, but transmission power losses increase
Solution Approach 1:
The patent removes the horizontal bus bars and their associated mechanical joints from the system. By directly connecting AC and DC connectors to the vertical bus bar, the number of mechanical joints is minimized, reducing contact resistance and transmission power losses.
Solution Approach 2:
The vertical bus bar is pre-positioned and configured before module installation, allowing direct connections to be made without requiring additional mechanical joints during assembly. This preliminary configuration minimizes the number of joints and associated power losses.
4Ease of repair
If horizontal bus bars are used to connect adjacent modules, then power distribution is achieved, but maintenance costs increase
Solution Approach 1:
The patent eliminates horizontal bus bars and their mechanical joints by implementing direct vertical connections to the bus bar. This reduction in mechanical joints decreases maintenance requirements and costs, as there are fewer connection points that can fail or require inspection.
Data Source
AI summary
A power distribution rack includes a chassis that defines a first slot and a second slot adjacent the first slot. The power distribution rack also includes a plurality of electronics modules including a first module coupled within the first slot and a second module coupled within the second slot. A central bus bar assembly is coupled to the chassis and includes an outer bus bar including a first flange, a second flange, and a first bus plate extending therebetween. The first and second flanges and the first bus plate define a first channel. The bus bar assembly further includes an inner bus bar coupled within the first channel. The inner bus bar includes a third flange, a fourth flange, and a second bus plate extending therebetween. The first and third flanges are coupled to the first module and the second and fourth flanges are coupled to the second module.