Modular UPS Lever Mechanism for Single-Operator Handling
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Solution Overview
Problem
Modular UPS systems face challenges in handling and installation due to the weight and insertion/extraction forces required for large power modules, making it difficult for a single operator to manage, especially with modules exceeding 250 kW, which can weigh over 350 kg and require forces exceeding 500 N.
Innovation Solution
A modular UPS system with a separable uninterruptible power supply module featuring movable and fixed electrical contacts, where the movable contacts can be operated by a lever to control insertion and removal forces, allowing for independent connection and disconnection, facilitating safer and more manageable handling by a single operator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the power rating of UPS modules is increased to provide larger UPS power capabilities, then the power capability is improved, but the weight and insertion/extraction forces increase making handling difficult
Solution Approach 1:
The electrical connection system is segmented into multiple independent contacts (first power contacts, second power contacts, protective earthing contacts) that can engage separately. This allows the heavy module to be connected through distributed contact points rather than a single high-force connection, reducing the force burden on any single operator action.
Solution Approach 2:
A lever mechanism is introduced as an intermediary device to amplify the operator's input force and control the engagement of electrical contacts. The lever provides mechanical advantage, enabling a single operator to manage the high insertion/extraction forces required for high-power modules without direct manual handling of the heavy module itself.
2Power
If the power rating of UPS modules is increased to provide larger UPS power capabilities, then the power capability is improved, but the weight increases making installation challenging
Solution Approach 1:
The electrical connection system is segmented into multiple independent contacts (first power contacts, second power contacts, protective earthing contacts) that can engage separately. This allows the heavy module to be connected through distributed contact points rather than a single high-force connection, reducing the force burden on any single operator action.
Solution Approach 2:
A lever mechanism is introduced as an intermediary device to amplify the operator's input force and control the engagement of electrical contacts. The lever provides mechanical advantage, enabling a single operator to manage the high insertion/extraction forces required for high-power modules without direct manual handling of the heavy module itself.
3Reliability
If the insertion force is increased to ensure secure electrical connection, then the connection reliability is improved, but the ease of operation deteriorates
Solution Approach 1:
The electrical connection system is segmented into multiple independent contacts (first power contacts, second power contacts, protective earthing contacts) that can engage separately. This allows the heavy module to be connected through distributed contact points rather than a single high-force connection, reducing the force burden on any single operator action.
Solution Approach 2:
A lever mechanism is introduced as an intermediary device to amplify the operator's input force and control the engagement of electrical contacts. The lever provides mechanical advantage, enabling a single operator to manage the high insertion/extraction forces required for high-power modules without direct manual handling of the heavy module itself.
Data Source
Figure 1~2
Figure 3~4B
Figure 5A~7B
AI summary
It is provided a modular uninterruptible power supply system including a separable uninterruptible power supply module and a system frame. It is further provided a method of operating a modular uninterruptible power supply system.