UPS Power Module Layout for Live Removal and Flexible Wiring

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Solution Overview

Problem

Conventional power modules cannot remove the UPS while live, leading to poor maintainability and inflexible wiring due to integrated UPS and busbar structures.

Innovation Solution

The power module design includes an input busbar, output busbar, internal protection unit, and UPS, where the UPS is disposed independently from the busbars, allowing electrical connections through protection units, enabling isolation and removal while live.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the UPS is integrated with the busbar structure, then the device complexity is reduced, but the ease of repair deteriorates because the UPS cannot be removed while the power module is live

Engineering Contradiction:

Improvestructure integrationVSAvoidUPS removal capability

Core Design Contradiction:

Device complexityVSEase of repair

Solution Approach 1:

The patent divides the power module into separate functional components: the busbar structure and the UPS are physically separated rather than integrated. The UPS is positioned in a dedicated space with independent mounting, allowing it to be removed and replaced without affecting the busbar or requiring power shutdown. This segmentation enables independent maintenance while maintaining overall system compactness.

Inventive Principle:

Principle #1Segmentation

2Device complexity

If the UPS and busbar are integrated, then the device complexity is reduced, but the adaptability deteriorates due to inflexible wiring configurations

Engineering Contradiction:

Improvestructure integrationVSAvoidwiring flexibility

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

By separating the UPS from the busbar structure, the patent enables independent positioning and connection configurations. The UPS can be connected to the busbar through flexible cable arrangements rather than rigid integrated connections, allowing adaptability in wiring layouts and easier reconfiguration for different installation scenarios.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces spatial separation between the UPS and busbar, utilizing three-dimensional space within the power module enclosure. The UPS is mounted in a dedicated space that allows for flexible cable routing in multiple directions, rather than being constrained to a fixed two-dimensional integrated layout.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS12592580B2Power module and power distribution system

Publication Date: 2026.03.31 EMERSON NETWORK POWER CO LTD

AI summary

Provided are a power module and a power distribution system. The power module includes an input busbar, an output busbar, an internal protection unit and a UPS. The input busbar is electrically connected to an AC input terminal of the UPS through the internal protection unit. The output busbar is electrically connected to an AC output terminal of the UPS through the internal protection unit. The battery input terminal is electrically connected to a DC input terminal of the UPS through the internal protection unit, or is electrically connected to the DC input terminal of the UPS and an external protection unit disposed outside the power module. The input busbar and the output busbar are disposed outside the UPS without passing through the inside of the UPS. The AC input terminal, the AC output terminal and the DC input terminal are all electrically connected to the protection unit.