Integrated Power Supply Module with Backup Battery Management
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Solution Overview
Problem
Current power supply systems for DC loads, particularly in data centers, face challenges in reducing space consumption, installation time, and increasing safety while balancing backup battery needs, as they require numerous battery controllers that are costly and labor-intensive to install, and pose risks of battery accidents leading to chain reactions.
Innovation Solution
A power supply system module with an integrated backup battery device and battery management system, including sensors and a safety system, which monitors and controls battery status, current flow, and disconnects the battery if safety limits are exceeded, housed within a compact design with a cooling fan to prevent overheating and minimize damage from potential explosions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate battery controllers are installed for each battery group, then battery monitoring and safety control are improved, but device complexity and installation labor increase significantly
Solution Approach 1:
The patent combines multiple battery controllers into a single integrated controller that can manage multiple battery groups. This single controller includes multiple control channels, each capable of independently monitoring and controlling a separate battery group, thereby reducing the total number of controllers from multiple separate units to one unified device.
Solution Approach 2:
The integrated battery controller is designed with multi-functional capabilities to perform monitoring and safety control across multiple battery groups simultaneously. It includes multiple control channels that can independently manage different battery groups, making a single device universal enough to replace multiple specialized controllers.
2Reliability
If more backup batteries are installed to ensure uninterrupted power supply, then power supply reliability is improved, but space consumption and cost increase
Solution Approach 1:
The system dynamically switches between main power supply and backup battery based on real-time power availability. When AC power is present, the backup battery remains in standby mode with minimal space requirements. When AC power fails, the system automatically transitions to battery power, providing uninterrupted supply without requiring excessive battery capacity for continuous operation.
Solution Approach 2:
The backup battery is designed to provide power for a limited duration (e.g., 30-60 seconds) rather than extended periods. This partial action approach provides sufficient time for safe shutdown or generator startup without requiring large battery banks that would consume excessive space.
3Area of stationary object
If batteries are placed close together to save space, then area consumption is reduced, but safety risk increases due to potential chain reactions from battery accidents
Solution Approach 1:
The battery system is divided into multiple independent battery groups, each with its own isolation barriers. The housing includes separate compartments for different battery groups, preventing direct contact between them. This segmentation allows batteries to be arranged in a compact configuration while maintaining safety through physical separation into distinct zones.
Solution Approach 2:
Isolation barriers and protective structures are introduced as intermediary elements between adjacent battery groups. These barriers act as mediators that prevent the propagation of thermal runaway or other accidents from one battery group to another, enabling closer battery placement without increasing chain reaction risk.
4Reliability
If manual installation of multiple battery controllers is performed, then individual battery monitoring is achieved, but installation time and manual labor increase
Solution Approach 1:
Multiple battery controllers are merged into a single integrated unit that can monitor and control multiple battery groups simultaneously. This consolidation reduces the number of separate installation operations from multiple individual controller installations to one single integrated controller installation, significantly reducing installation time and manual labor.
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 solution reduces the number of components, saves space, decreases installation time, enhances safety by preventing chain reactions, and balances backup battery needs, ensuring reliable power supply for over 30 seconds with reduced manual labor and risk of accidents.
Implementation Method 1
The power supply system module further comprises a cooling fan for blowing air through the housing, where the backup battery is cooled by the cooling fan
Data Source
AI summary
A power supply system module that includes a first and second AC terminals, positive and negative DC terminals and a housing. An AC-DC converter is connected to the first and second AC terminals, and a DC-DC converter is connected between the AC-DC converter and an internal DC bus. A protection circuit is connected between the internal DC bus and the positive or negative DC terminal. A control device controls the AC-DC converter and/or the DC-DC converter. The AC-DC converter, the DC-DC converter and the control device are provided inside the housing. The power supply system module also includes a backup battery device that has a backup battery connected to the internal DC bus via a battery management system. The backup battery device is provided inside the housing.