UPS Frequency Sensor Load Control

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Solution Overview

Problem

Data centers face challenges in managing power loads during outages, as existing systems rely on programmable logic controllers (PLCs) and ladder logic to prevent generator overload, which adds complexity and cost, and introduces additional failure points.

Innovation Solution

Implementing a UPS system that uses frequency sensors to determine when to draw power from a generator based on specific frequency thresholds, allowing load addition and drop without overloading the generator, thereby eliminating the need for additional PLC controllers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If PLC and ladder logic are used to control load addition to generator, then generator overload is prevented, but system complexity and cost increase

Engineering Contradiction:

Improvegenerator overload preventionVSAvoidcontrol system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The UPS system automatically monitors generator frequency and self-regulates its power draw based on frequency thresholds, eliminating the need for external PLC controllers. The system serves itself by using inherent frequency variations as control signals to prevent generator overload without additional control hardware

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system uses generator frequency as a feedback signal to control UPS power draw. When frequency drops below thresholds, UPS automatically reduces or stops drawing power, creating a closed-loop control system that prevents generator overload using the generator's own operational parameters

Inventive Principle:

Principle #23Feedback

2Reliability

If PLC and ladder logic are used to control load addition to generator, then generator overload is prevented, but operational cost increases

Engineering Contradiction:

Improvegenerator overload preventionVSAvoidoperational cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The system replaces expensive PLC controllers and ladder logic programming with simple, built-in frequency threshold monitoring capabilities that are already present in modern UPS systems. This eliminates the need for additional costly control hardware and reduces operational expenses

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The UPS system performs multiple functions: it provides uninterrupted power supply, monitors generator frequency, and automatically regulates its own power draw to prevent generator overload. This multi-functionality eliminates the need for separate PLC control systems, reducing both capital and operational costs

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If PLC and ladder logic are used for load add determination, then power distribution is controlled, but additional failure points are introduced

Engineering Contradiction:

Improvepower distribution controlVSAvoidsystem failure points

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system extracts the control function from external PLC hardware and embeds it within the UPS system itself. By removing the separate PLC control layer and using only the frequency sensor and threshold comparison logic already present in the UPS, the system eliminates additional failure points while maintaining power distribution control

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The control functions for power distribution and frequency monitoring are merged into a single integrated system within the UPS. This consolidation eliminates the need for separate PLC controllers and reduces the number of potential failure points in the overall system architecture

Inventive Principle:

Principle #5Merging (Combining)

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 reduces the number of components required for power management, enhances reliability by avoiding additional control systems, and lowers operational expenses by enabling self-regulation of power distribution based on frequency priority thresholds.

Implementation Method 1

Each UPS of the plurality of UPSs comprises a corresponding frequency sensor configured to generate an indication of a frequency of the AC power at the supply bus

Methodology Applied

Scientific EffectFrequency detection:

Data Source

PatentUS10826293B1Power supply load control using frequency

Publication Date: 2020.11.03 EQUINIX INC

AI summary

A power supply system includes a plurality of UPSs configured to provide output power to one or more loads using AC power drawn from a supply bus and energy stored at respective energy modules of the plurality of UPSs. Each UPS of the plurality of UPSs comprises a corresponding frequency sensor configured to generate an indication of a frequency of the AC power at the supply bus. The plurality of UPSs comprises a first UPS configured to draw the AC power from the supply bus when the indication of the frequency output by the corresponding frequency sensor for the first UPS satisfies a first frequency priority threshold and a second UPS configured to draw the AC power from the supply bus when the indication of the frequency output by the corresponding frequency sensor for the second UPS satisfies a second frequency priority threshold.