Power Module Open Architecture for Compact Stacking
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Solution Overview
Problem
Conventional power modules occupy excessive space due to redundant casing space and unused slots, leading to inefficiencies in cabinet utilization and increased manufacturing costs.
Innovation Solution
A power module with an open architecture featuring a frame, insulative plate, and cover, where transformers are arranged with high-voltage and low-voltage sets on separate surfaces of the plate, and fans are integrated to enhance heat dissipation, allowing for compact stacking and assembly without additional slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple power modules with individual casings are used, then the load requirement can be met, but the cabinet space is excessively occupied due to redundant casing space and unused slots
Solution Approach 1:
Multiple transformers are merged into a single shared casing structure with a common frame, insulative plate, and cover. This consolidation eliminates redundant casing components and reduces the total volume occupied in the cabinet while maintaining the required power transformation capacity through multiple transformer units arranged within the shared structure.
Solution Approach 2:
The shared casing structure serves multiple functions simultaneously: it provides mechanical support for multiple transformers, offers electrical insulation through the common insulative plate and cover, enables heat dissipation through integrated fans, and allows modular assembly. This multi-functionality reduces the need for separate protective structures for each transformer.
2Reliability
If transformers are arranged with high-voltage and low-voltage sets on separate surfaces, then electrical insulation is improved, but the structural complexity increases
Solution Approach 1:
The insulative plate creates a three-dimensional separation where high-voltage transformer sets are arranged on one surface and low-voltage transformer sets are arranged on the opposite surface. This spatial separation in the vertical dimension provides effective electrical insulation while maintaining a compact overall structure, avoiding the need for complex lateral insulation arrangements.
Solution Approach 2:
The internal structure is segmented into distinct high-voltage and low-voltage zones separated by the insulative plate. This segmentation allows independent arrangement and insulation of high-voltage components on one side and low-voltage components on the other, simplifying the insulation design while maintaining electrical safety.
3Ease of manufacture
If an open architecture frame structure is used, then manufacturing cost is reduced and assembly is simplified, but heat dissipation efficiency may be compromised
Solution Approach 1:
The open frame structure allows the transformers to utilize the surrounding environment for heat dissipation without requiring fully enclosed casings. The structure serves itself by using the frame and insulative components as both structural supports and heat dissipation pathways, eliminating the need for additional heavy-duty cooling infrastructure.
Solution Approach 2:
Fans are integrated into the frame structure to create forced air convection currents that flow through and around the transformers. This pneumatic cooling system efficiently removes heat from the transformers while maintaining the open architecture, as the air flow paths are established through the frame structure itself rather than requiring enclosed channels.
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
This configuration reduces overall casing occupancy, allows for arbitrary module arrangement, decreases manufacturing costs, and improves heat dissipation efficiency, resulting in a more compact and cost-effective power module design.
Implementation Method 1
a fan is respectively arranged in the frame corresponding to each transformer. Each fan is disposed on an edge of the corresponding insulative plate and crosses the two surfaces of the insulative plate.
Implementation Method 2
An elastic supporter is arranged in the housing, and the elastic supporter passes through the housing to abut against the insulative cover.
Data Source
AI summary
A rack device having a cabinet and power modules stacked in the cabinet is provided. The power module has a frame, an insulative plate, an insulative cover and transformers. The insulative plate is arranged in the frame. The insulative cover is arranged in the frame and disposed spacedly from and parallel with the insulative plate. Each transformer arranged in the frame has a high-voltage set and a low-voltage set electrically connected with each other. The low-voltage sets are arranged on one surface of the insulative plate and do not protrude from the frame, and the high-voltage sets are arranged on another surface of the insulative plate and between the insulative plate and the insulative cover. The frame of each power module is connected with the frame of adjacent power module, and the frame of at least one of the power modules is connected to the cabinet.