Single-Piece PDU Frame With Cable Trough for Compact Safe Assembly
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Solution Overview
Problem
Existing power distribution units (PDUs) face challenges with large input cables occupying significant space, hazardous live parts, and complex assembly, especially in tight installations and seismic conditions, requiring a design that reduces system costs and simplifies installation.
Innovation Solution
A single piece frame with an integrated cable trough and optional welded base, featuring a removable lifting handle, which separates high and low voltage cables and enhances structural strength, simplifying assembly and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional multi-component frame assemblies are used, then structural strength can be achieved, but assembly complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple frame components (side frames, cross members, cable troughs, lifting handles, and base assemblies) into a single integrated frame assembly made from one continuous sheet of metal. This merging eliminates the need for separate manufacturing and assembly of individual components, reducing assembly complexity while maintaining structural strength through the integrated design.
Solution Approach 2:
The single piece frame serves multiple functions simultaneously: it provides structural support, houses and protects cables through integrated troughs, includes lifting handles for installation, and incorporates a base for positioning. This multi-functionality consolidates what would traditionally require multiple separate components into one universal structure.
2Area of stationary object
If high voltage cables and components are housed together with low voltage components, then space is utilized efficiently, but safety hazards increase due to exposed live parts
Solution Approach 1:
The patent segments the frame into distinct functional zones: a cable receiving area with integrated troughs for high voltage cables, a separate equipment mounting area for low voltage components, and protected busbar locations. This segmentation physically separates hazardous high voltage elements from low voltage components while maintaining efficient space utilization through the integrated single-piece structure.
Solution Approach 2:
The integrated cable troughs act as intermediary protective structures that channel and isolate high voltage cables, preventing direct exposure of live parts. The single-piece construction provides inherent shielding and routing paths that mediate between the high voltage and low voltage zones, reducing safety hazards while preserving compact design.
3Ease of operation
If cable troughs and routing structures are added to organize cables, then cable management improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The cable troughs are merged directly into the frame structure itself, formed from the same continuous sheet of metal as the rest of the frame. This integration eliminates the need for separate cable management components, maintaining ease of cable organization while avoiding additional device complexity and manufacturing steps.
Solution Approach 2:
The frame structure simultaneously serves as both the structural support and the cable routing system. The integrated troughs are multi-functional elements that provide structural integrity while also organizing and protecting cables, eliminating the need for dedicated cable management components.
Data Source
AI summary
An equipment cabinet frame is provided comprising first and second wrappers. The first wrapper extends from a rear edge at a rear side of the cabinet, is bent to form a first rear corner, extends across a first lateral side of the cabinet, and is bent to form a first front corner. The second wrapper extends from a rear edge at the rear side of the cabinet, is bent to form a second rear corner, extends across a second lateral side of the cabinet, and is bent to form a second front corner. A portion of the first wrapper extending from the front first corner to a first front edge is bent into a trough comprising a three-sided channel having an open side facing a front of the equipment cabinet. A top panel is mounted to top edges of the first and second wrappers. A bottom panel, and/or a bottom welded frame may be mounted to bottom edges of the first and second wrappers.