EPOWER power management system includes six systems including generator set test system, high-power load cabinet, ATS switching cabinet, power distribution cabinet, generator parallel cabinet and photovoltaic energy storage cabinet. With its excellent comprehensive performance, it has made great contributions to the field of power security. As the core of the intelligent power solution, the power management system has built a full-chain technology system covering power detection, load simulation, intelligent switching, precise distribution and green energy storage through the deep collaboration of the six core modules of generator set test system, high-power load cabinet, ATS switching cabinet, power distribution cabinet, parallel cabinet and photovoltaic energy storage cabinet. The following is an in-depth analysis from the professional and technical dimensions:

1. Generator set test system:

The intelligent center for full-dimensional performance verification is like a strict "power referee". It uses precision sensors and intelligent algorithms to conduct all-round detection of key indicators such as output power, voltage stability, and frequency fluctuations of the generator set, accurately locate potential problems, and ensure that the unit is always in the best condition.

(I) Core technology architecture

The system integrates a high-precision sensor matrix (voltage/current transformers, temperature sensors, vibration sensors) and an industrial-grade data acquisition module, and uses an AI-based fault diagnosis algorithm to achieve real-time monitoring of all parameters of the generator set. Core testing indicators include:

Electrical performance: output voltage waveform distortion rate (≤5%), frequency stability (±0.5% rated frequency), voltage regulation rate (≤±0.5%)

Mechanical performance: bearing temperature (warning threshold 120℃), vibration amplitude (ISO 1940 G2.5 level)

Emission indicators: NOx concentration (adapting to the post-treatment system of the National VI emission standard)

(II) Dynamic testing technology

Using a programmable AC load module, it supports linear/step loading tests of 0-100% rated load, simulating the following typical working conditions:

.Cold start characteristic test: start time ≤15s at -20℃, voltage build-up time ≤3s

.Overload capacity test: 110% load continuous operation 1 hour, 150% load running for 1 minute without abnormality

.Temperature rise test: stator winding temperature rise ≤120K (B-class insulation), bearing temperature rise ≤80K

(III) Data closed-loop management

Through the OPC UA protocol and the host computer management system, a unit health report containing 300+ parameters is generated, and the LSTM neural network is used to predict the life of components to achieve preventive maintenance (MTBF increased by 30%). It is typically used for performance calibration before the factory test of the generator set and operation and maintenance, ensuring that the unit load capacity error is ≤2%.

2. High-power load cabinet:

As an industrial-grade verification platform for extreme working condition simulation, the high-power load cabinet is widely used in the data center field as a "touchstone of electricity". It can simulate the ultra-high load power consumption scenario of massive servers running at the same time, allowing the generator set to be tested under this extreme working condition, tempering the excellent power supply ability and ensuring that the power supply of the data center is foolproof.

(I) Load simulation technology

Adopting the modular design of pure resistive/inductive/capacitive load units, the maximum load capacity of a single cabinet can reach 5000kVA, with the following technical characteristics:

 Load accuracy: power factor 0.8-1.0 adjustable, load step accuracy ≤0.1% rated power

 Dynamic response: 10%-90% load step, voltage recovery time ≤0.5s (with magnetic saturation reactor)

 Thermal management system: forced air cooling + liquid cooling dual circuit, air inlet temperature controlled at 25±2℃, air outlet temperature rise ≤40℃

(II) Data center dedicated test solution

For the "N+1" redundant power supply architecture of the data center, the load cabinet supports:

. Harmonic injection test: simulate 1-50 harmonics (THD≤8%) to verify the filtering capacity of the generator set

. Instantaneous pulse load: 200% rated current for 100ms impact test to assess the generator rotor damping characteristics

. Parallel current sharing test: when multiple units are connected in parallel, the active/reactive distribution error is ≤5% (with digital power controller)

(III) Safety protection mechanism

Configure fast fuse (breaking capacity 100kA), overtemperature protection (automatic unloading when the fan fails), and arc monitoring system (response time ≤10ms) to ensure that the test process is safe and controllable. In a cloud computing center project, a 72-hour continuous full-load test was conducted to verify the continuous operation capability of the unit in a 40℃ environment, ensuring that the PUE value of the data center is ≤1.5.

3. ATS switch cabinet:

A millisecond-level seamless switching power protection system; the ATS switch cabinet can be called a "power bodyguard". When the city power fails suddenly, it can complete the switch in an instant and seamlessly connect to the backup generator to ensure uninterrupted power supply, building a solid safety line for key places such as hospitals and data centers.

(I) Core control technology

Adopt three-position (mains 1 / mains 2 / power generation) intelligent switching switch, integrated:

Synchronous detection module: automatic synchronization when voltage difference ≤10%, frequency difference ≤0.5Hz, phase difference ≤15°

Fast switching algorithm: switching time from mains power failure to generator power supply ≤80ms (typical value 50ms)

Dual power interlock: mechanical interlock + electrical interlock dual protection to prevent power backflow

(II) Industry customized solutions

.Medical scenario: configure battery backup power supply (maintain 4 hours of power supply for control circuit), support "zero interruption" switching, meet the requirements of IT isolation power system in operating room

.Data center: adopt dual bus ATS Architecture, supports online maintenance (MTTR≤15 minutes), and cooperates with BMS battery management system to achieve cold switching redundancy

.Industrial application: With motor soft start function (reduces starting current by 30%-50%), suitable for impact loads such as air compressors and water pumps

(III) Reliability design

The cabinet protection level is IP54, with silver-plated contacts (contact resistance ≤50μΩ) inside, mechanical life ≥100,000 times, and passed 100 continuous switching fault-free tests to ensure stable operation in -40℃~+70℃ environment, in line with IEC 60947-6-1 standard.

Fourth, power distribution cabinet:

A full-scenario solution for intelligent power distribution. The power distribution cabinet is like a "power housekeeper". It distributes the power output of the generator reasonably, and accurately controls the current and voltage according to the power demand of different areas and equipment to ensure the stable and orderly operation of each power unit and avoid risks such as overload and short circuit.

(I) Electrical design technology

It adopts modular structure design and supports rated current of 100A-6300A. The core technologies include:

Bus system: The cross-sectional area of the copper bar is designed according to 1.2 times the rated current, the surface is tinned (temperature rise ≤60K), and the short-circuit withstand capacity is 50kA/1s

Protection device: Equipped with molded case circuit breaker (breaking capacity 50kA), residual current action protector (30mA/0.1s response), surge protector (In=50kA)

Intelligent monitoring: integrated power meter (accuracy 0.5S level), supports Modbus RTU/RS485 communication, and real-time monitoring of three-phase voltage/current, active/reactive power, and power quality parameters

(II) Industry adaptation solutions

.Industrial power distribution: Configure motor control module (support star-delta/soft start), with overload inverse time protection, and adapt to production line frequency conversion equipment

.Commercial buildings: Use prepaid power management system, support 4G wireless remote transmission, realize sub-item metering (accuracy ≤1%) and load balancing

.New energy scenarios: reserve photovoltaic/energy storage interface, support bidirectional power flow, and configure anti-reverse flow protection device (action threshold ≤5% rated power)

(III) Energy efficiency optimization technology

Dynamically adjust transformer taps (voltage regulation accuracy ±2.5%) through intelligent algorithms, combined with real-time monitoring of load rate (economic operation range 40%-70%), to achieve a comprehensive energy efficiency improvement of 5%-8%. In a certain industrial park project, the line loss was reduced by 12% through harmonic control (THD≤10%) and reactive power compensation (power factor≥0.95).

V. Parallel system:

There are three types: manual, automatic and fully automatic.

The fully automatic parallel cabinet adopts parallel control modules such as Deepsea and Zhongzhi, and imported programmable controller PLC, which can control generator sets equipped with various types of speed regulators, and can ensure that the load distribution difference of the unit is not more than 5%, automatic load distribution, automatic scheduling controlled by programmable controller, automatic input when load changes, decoupling and emergency automatic start input, etc.

Sixth, Photovoltaic Energy Storage Cabinet:

As the core carrier of green energy management, photovoltaic energy storage cabinets keep up with the green trend, absorbing solar energy during the day to convert it into electrical energy storage, and releasing it at night or during peak power consumption, which can not only save energy and reduce emissions, but also "cut peaks and fill valleys" to optimize power allocation. These five major sectors work closely together to provide stable, efficient and intelligent power management solutions for multiple fields such as industry, commerce, and people's livelihood.

(I) Energy storage technology configuration

Using lithium iron phosphate battery pack (energy density ≥140Wh/kg), integrated:

BMS battery management system: realize battery balancing (single cell voltage difference ≤5mV), overcharge/over-discharge protection (response time ≤20ms), thermal runaway warning (temperature gradient ≥5℃/min trigger)

Bidirectional converter: efficiency ≥98% (rated power), support PQ/Vf control mode, grid-connected current THD ≤3% (full load)

Energy management system: based on MPPT algorithm (efficiency ≥99.5%), combined with meteorological forecast data, optimize charging and discharging strategy (peak-valley electricity price difference utilization efficiency increased by 40%)

(II) System coordination technology

. Photovoltaic storage and diesel complementarity: When the photovoltaic power is insufficient, the generator set is automatically started (response time ≤ 30s), and the power of multiple power sources is evenly distributed through droop control

. Peak shaving and valley filling: Release the stored energy (discharge depth ≤ 80%) during the peak power consumption period (10:00-16:00), charge during the valley period (23:00-7:00), and reduce the demand electricity charge by more than 30%

. Emergency standby: Support black start function (energy storage capacity meets 30 minutes of emergency power supply), cooperate with ATS to achieve seamless switching between off-grid/grid mode

(III) Environmental adaptability design

The cabinet adopts C4-H anti-corrosion coating (salt spray test ≥ 1000 hours), built-in constant temperature air conditioner (temperature control accuracy ±2℃), supports - 25℃ ~ + 55℃ environment operation, protection level IP65, suitable for complex scenarios such as plateaus (altitude ≤4000m) and coastal areas. In a border outpost project, through the configuration of 10kWh energy storage, the photovoltaic self-sufficiency rate was achieved ≥85%, and annual CO₂ emissions were reduced by 12 tons.

System synergy and technical advantages:

The five modules are deeply integrated with the PLC control system through industrial Ethernet (transmission rate 1Gbps) to achieve:

A. Test - load - switching - power distribution - energy storage full process automation, data collection cycle ≤50ms;

B. Fault diagnosis closed loop: generator test data is synchronized to the load cabinet in real time, and abnormal parameters trigger automatic shutdown

C. Energy optimization strategy: photovoltaic energy storage cabinet data is connected to the distribution cabinet to dynamically adjust the load distribution priority

EPOWER power management system has become the core technology of industrial-grade power security and green energy transformation with 99.99% power supply reliability (MTBF≥80000 hours), 20% energy saving rate, and full life cycle digital management.Technical support, continue to empower data centers, smart grids, new energy and other strategic areas.