Prefabricated AC Power Module for Hot-Swap UPS Maintenance
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Solution Overview
Problem
Conventional power distribution solutions involve independent components that are not interconnected, leading to a large footprint, long deployment times, and difficult maintenance, especially in critical scenarios like banks and data centers where power outages can be catastrophic.
Innovation Solution
A prefabricated alternating-current integrated power module that integrates multiple devices, including a modular low-voltage input and bus coupling device, low-voltage compensation device, maintenance bypass device, uninterruptable power supply power module device, and uninterruptable power supply feed device, allowing for expansion and quick deployment without powering off the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple power distribution devices are placed independently in separate cabinets, then each device can be maintained independently, but the system occupies a large footprint and requires long cable connections
Solution Approach 1:
The patent combines multiple independent power distribution devices (medium-voltage switch device, transformer device, low-voltage distribution device, and UPS device) into a single integrated power module. This merging eliminates the need for separate cabinets and reduces the overall system footprint while maintaining functional independence through modular design. The devices are physically integrated and electrically connected via internal busbars rather than external cables.
Solution Approach 2:
The patent implements a nested structure where different functional devices are housed within a shared cabinet framework. The medium-voltage switch device, transformer device, low-voltage distribution device, and UPS device are all contained within the same cabinet space, with each device maintaining its own functional boundaries while sharing common structural and electrical infrastructure.
2Ease of manufacture
If devices are connected via cables between separate cabinets, then installation is simple, but the cable length increases delivery time and complicates maintenance
Solution Approach 1:
By integrating multiple devices into a single prefabricated module, the patent eliminates the need for long cable connections between separate cabinets. The internal electrical connections are pre-established during manufacturing, reducing on-site installation time and eliminating the time-consuming process of laying and connecting lengthy external cables.
Solution Approach 2:
The power distribution module is prefabricated in advance with all electrical connections, busbars, and components pre-installed and tested at the factory. This preliminary action transfers complex assembly work from the installation site to the manufacturing facility, significantly reducing on-site delivery and installation time while maintaining installation simplicity through modular plug-and-play deployment.
3Stability of the object's composition
If power distribution devices are independent and not interconnected, then each device operates independently, but maintenance and repair require system shutdown
Solution Approach 1:
The patent divides the integrated power module into distinct functional segments (medium-voltage switch device, transformer device, low-voltage distribution device, UPS device), each with independent access points and maintenance pathways. This segmentation allows technicians to access and repair specific devices without shutting down the entire system, as other segments can continue operating independently within the same cabinet.
Solution Approach 2:
The shared cabinet structure provides universal access points and common infrastructure (busbars, grounding systems, cooling) that serve all devices simultaneously. This multi-functional design enables maintenance operations on any single device while the cabinet framework and other devices remain operational, combining the benefits of integration with operational independence.
4Adaptability or versatility
If devices are physically separated, then each device has its own cabinet space, but expansion requires additional cabinets and time
Solution Approach 1:
The modular device architecture within the integrated cabinet allows for easy expansion by adding or removing individual functional segments (e.g., adding another transformer device or UPS module). This segmentation enables rapid system expansion without requiring additional cabinets, as new modules can be integrated into the existing cabinet framework and electrical infrastructure.
Solution Approach 2:
The shared cabinet and busbar system provides universal mounting and electrical connection infrastructure that can accommodate multiple device types and configurations. This multi-functional platform allows the system to expand from a single device to multiple devices within the same cabinet space, accelerating deployment productivity while maintaining adaptability to different power distribution requirements.
Data Source
AI summary
Disclosed is a prefabricated alternating-current integrated power module, including a modular low-voltage input and bus coupling device, a low-voltage compensation device, a maintenance bypass device, an uninterruptable power supply power module device and an uninterruptable power supply feed device, which are detachably connected along a horizontal direction. All the devices and connection components among the devices of the prefabricated alternating-current integrated power module are prefabricated in the factory, greatly reducing the footprint, and achieving rapid delivery and deployment at the customer's site. With the prefabricated alternating-current integrated power module, the uninterruptable power supply power module device can be repaired or replaced without powering off the system. Further, capacity expansion and quick deployment can be performed without powering off the system, eliminating the impact of power outage operation.