UPS Power Recirculation for High-Power Load Testing

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Solution Overview

Problem

Conventional methods for testing uninterruptible power supplies (UPS) require significant amounts of external power, often from fuel-consuming generators, leading to high fuel costs and environmental impact.

Innovation Solution

A system and method where the output of a first UPS is connected to the input of a second UPS, allowing power to be recirculated and maintained at a desired level, with makeup power drawn from an external source as needed to compensate for losses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If conventional testing methods using external power sources are used, then sufficient power can be provided for high power load testing, but fuel consumption and environmental impact increase significantly

Engineering Contradiction:

Improvepower delivery capabilityVSAvoidfuel consumption

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The patent combines the UPS under test with an existing UPS system in the facility to form a closed-loop testing configuration. The tested UPS outputs power that is fed into the existing UPS, which then feeds back to the tested UPS input, creating a self-sustaining power loop that eliminates the need for external generator power sources.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The testing system uses the facility's existing UPS infrastructure to provide the power needed for testing. Rather than relying on external fuel-consuming generators, the system serves itself by utilizing already-available power conversion equipment within the facility to provide the necessary load and power conversion functions.

Inventive Principle:

Principle #25Self-service

2Power

If conventional testing methods using generators are used, then high power testing can be performed, but operational costs increase due to fuel consumption

Engineering Contradiction:

Improvetesting power levelVSAvoidoperational energy cost

Core Design Contradiction:

PowerVSUse of energy by moving object

Solution Approach 1:

The patent merges the testing function with the facility's existing UPS infrastructure. By connecting the tested UPS to the existing UPS system, the facility's own power conversion equipment is utilized to provide the necessary power levels for testing, eliminating the need to operate fuel-consuming generators during testing operations.

Inventive Principle:

Principle #5Merging (Combining)

3Loss of energy

If a closed-loop UPS testing configuration is implemented, then external power sources are reduced, but system complexity increases

Engineering Contradiction:

Improveexternal power dependencyVSAvoidtesting system configuration

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The existing UPS system in the facility serves multiple functions: it continues to provide its normal power conversion services to facility equipment while simultaneously serving as the load and power source for the UPS testing operation. This multi-functionality reduces the need for dedicated testing equipment and simplifies the overall system configuration.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20250199085A1Uninterruptible power supply for performing high power load testing

Publication Date: 2025.06.19 SCHNEIDER ELECTRIC IT CORP

AI summary

A non-transitory computer readable media has instruction encoded thereon which, when executed by a control system of an uninterruptible power supply (UPS) test system, cause the UPS test system to deliver power from an output of a first UPS system to an inlet of a second UPS system, receive power from an outlet of the second UPS system at an inlet of the first UPS system, and maintain a magnitude of the power delivered from the output of the first UPS system to the inlet of a second UPS system at a desired level.