Rack PDU Modular Construction for Fast Custom Configuration
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Solution Overview
Problem
The existing power distribution unit (PDU) manufacturing process is costly and time-consuming due to the need for customized designs that require significant engineering efforts and limited configuration options, leading to high costs and long turnaround times for customized PDUs that do not meet the diverse utility power specifications and IT hardware requirements of various data centers.
Innovation Solution
A method of constructing rack PDUs using standardized receptacles, printed circuit boards, carrier frames, monitoring frames, and a common frame, with the exception of a customized cover, allowing for over 6,000 configuration variants through machine soldering of circuitry outside the common frame, reducing production and delivery times, and lowering material and labor costs by up to 30% and 40%, respectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If customized power distribution units are designed to meet different utility power specifications and IT hardware requirements, then adaptability to diverse data center needs is improved, but manufacturing cost and turnaround time increase significantly
Solution Approach 1:
The PDU is divided into modular components: standardized cover assembly, standardized chassis assembly, and interchangeable power distribution modules. Each module can be independently manufactured and assembled, enabling customization without requiring complete redesign of the entire unit. This segmentation allows different module combinations to meet diverse utility power specifications while maintaining manufacturing efficiency.
Solution Approach 2:
The standardized chassis assembly and cover assembly are designed to accommodate multiple types of power distribution modules with different electrical configurations. A single universal chassis platform supports various utility power inputs (single-phase, three-phase, different voltages) through interchangeable modules, eliminating the need to manufacture entirely different PDU designs for each specification.
2Adaptability or versatility
If customized power distribution units are designed to meet different utility power specifications and IT hardware requirements, then adaptability to diverse data center needs is improved, but manufacturing cost and turnaround time increase significantly
Solution Approach 1:
The standardized cover assembly and chassis assembly are pre-manufactured with standardized mounting interfaces and electrical configurations. These standardized components are prepared in advance and can be quickly combined with different power distribution modules to create customized PDUs, significantly reducing the design and manufacturing lead time compared to creating entirely custom designs for each specification.
Solution Approach 2:
By segmenting the PDU into pre-manufacturable standardized modules, the system enables rapid assembly of customized configurations. Different power distribution modules can be swapped into the standardized chassis without requiring redesign or retooling, allowing quick response to diverse data center requirements while maintaining fast turnaround times.
3Productivity
If standardized components are used for construction, then manufacturing cost and production time are reduced, but configuration flexibility may be limited
Solution Approach 1:
The power distribution system is segmented into standardized structural components (cover, chassis) and interchangeable functional modules. Each module represents a discrete configuration option, and by combining different modules with the standardized components, the system achieves both manufacturing efficiency and extensive configuration flexibility, enabling over 6,000 variants through modular combination.
Solution Approach 2:
The modular architecture allows the system to dynamically adapt to different configuration requirements by simply changing which power distribution modules are assembled with the standardized components. This dynamic reconfigurability through module selection maintains high productivity while providing extensive adaptability for diverse data center applications.
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 approach enables the rapid production of reliable, cost-effective PDUs with extensive configuration options, significantly reducing material and labor costs while accelerating production and delivery times, addressing the limitations of current PDU manufacturing methods.
Implementation Method 1
The attached printed circuit boards are solder-connected to adjacent PCBs to reduce connection failure between the adjacent PCBs
Data Source
AI summary
The present disclosure provides a method of standardizing the construction of a power distribution device that includes power conveying wires, a plurality of receptacles, a power conveying flexible bus assembly, a plurality of power connection boards, a plurality of circuit breakers, a standardized receptacle module carrier, and a customized cover. The standardized receptacles and the receptacle printed circuit boards are configured into modules arranged and aligned about the standardized receptacle module carrier. The standardized receptacle module carrier is attached to the standardized common chassis. A customized cover is attached to the standardized common chassis.