Integrated Power Rack Segmentation for DC Rail Length Reduction

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Solution Overview

Problem

Existing data processing centers face inefficiencies in power transmission and space utilization due to significant resistive power losses and reduced capacity for revenue-producing devices, as they require extensive low-voltage DC power distribution and sacrifice space for power conversion equipment in integrated power racks.

Innovation Solution

An integrated power rack design with a side power sub-compartment houses power equipment, such as AC/DC converters, vertically spaced throughout the rack, reducing the distance low-voltage DC power is transmitted and allowing additional revenue-producing devices by shifting power conversion from the base to the side, thereby minimizing resistive losses and optimizing space.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If power conversion equipment is housed at the base of the rack, then high-voltage AC power can be routed to each rack, but space for revenue producing devices is reduced and long DC rails are required

Engineering Contradiction:

Improveresistive power lossesVSAvoidspace for revenue producing devices

Core Design Contradiction:

Loss of energyVSQuantity of substance

Solution Approach 1:

The rack is divided into multiple vertical sections with power conversion equipment distributed throughout the height of the rack rather than concentrated at the base. This segmentation allows DC rails to be shorter in each section, reducing resistive power losses while preserving total space for revenue producing devices.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The power conversion equipment is redistributed along the vertical dimension of the rack rather than being confined to the horizontal base area. This dimensional redistribution enables simultaneous optimization of power efficiency and space utilization for revenue producing devices.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of manufacture

If power conversion equipment is housed at the base of the rack, then high-voltage AC power can be routed to each rack, but additional safety hazards are created

Engineering Contradiction:

Improvepower distribution simplicityVSAvoidsafety hazards from high-voltage AC

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The concentration of high-voltage AC power equipment at the base is segmented and distributed vertically throughout the rack. This reduces the density of hazardous equipment in any single location, minimizing safety hazards while maintaining simplified power distribution.

Inventive Principle:

Principle #1Segmentation

3Device complexity

If a main conversion hub is used to convert high-voltage AC to low-voltage DC, then centralized power management is achieved, but significant resistive power losses occur

Engineering Contradiction:

Improvepower distribution architectureVSAvoidresistive power losses

Core Design Contradiction:

Device complexityVSLoss of energy

Solution Approach 1:

The centralized main conversion hub is segmented into multiple distributed power conversion units throughout the rack. Each unit converts AC to DC locally, eliminating the need for long-distance low-voltage DC transmission and associated resistive losses while maintaining manageable system complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple intermediate power conversion units are introduced between the high-voltage AC source and the low-voltage DC devices. These intermediary conversion points enable progressive voltage transformation, reducing resistive losses compared to direct long-distance low-voltage transmission.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enhances power efficiency by shortening DC rail lengths, reducing capital costs, and enabling more revenue-producing devices to be housed, while segregating high-voltage AC from revenue-generating equipment, thus minimizing exposure and power losses.

Implementation Method 1

the AC/DC converter configured to convert the received high-voltage AC power to low-voltage DC power

Methodology Applied

Scientific EffectAC/DC conversion:

Implementation Method 2

significant resistive power losses caused by transmitting the low-voltage DC power over long distances throughout the data processing center

Methodology Applied

Scientific EffectResistive power losses: Electrical Resistance

Data Source

PatentUS9723742B2Integrated power racks and methods of assembling the same

Publication Date: 2017.08.01 ACLEAP POWER INC

AI summary

An integrated power rack for use in a data center is provided. The integrated power rack includes a top, a base, a first side and a second side extending between the base and the top, a back member extending between the top, the base, the first side, and the second side, a divider extending from the top to the base, the divider positioned between the first side and the second side, a revenue sub-compartment defined between the first side and the divider, the revenue sub-compartment configured to receive a plurality of revenue producing devices, and a power sub-compartment defined between the second side and the divider, the power sub-compartment housing power equipment that is configured to provide direct-current (DC) power to the revenue sub-compartment.