Integrated modular busway rack power distribution system

Abstract

The present invention relates to integrated modular busway rack power distribution systems. Systems configured to distribute power within a rack are disclosed. The system can include a rack junction box configured to receive power. The system can include a power rail coupled to the rack junction box and configured to receive power from the rack junction box. The system can include one or more power couplers coupled to the power rail and configured to receive power from the power rail and distribute power to a plurality of rack unit loads.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 738,360, filed December 23, 2024, and U.S. Provisional Patent Application Serial No. 63 / 746,704, filed January 17, 2025, pursuant to 35 USC § 119(e), both of which are incorporated herein by reference in their entirety. Technical Field

[0003] This disclosure relates generally to power for rack-mounted equipment, and more particularly to modular power distribution for rack-mounted equipment. Background Technology

[0004] As high-performance computing (HPC) and artificial intelligence (AI) push data center operations to their environmental and utilization limits, the need for improved power distribution systems is increasing. Conventional high-capacity power distribution systems typically use three-phase compatible components for floor-mounted and rack-mounted power distribution units (PDUs) to support the high power demands of computer servers used for processing HPC / AI workloads, or power supply units (PSUs) coupled to them. However, the zero-U space or negative-U space in the back and sides of server racks is often spatially limited and cannot accommodate a variety of competing components. For example, zero-U space can be used to accommodate two or more conventional rack PDUs (rPDUs); power cables for servers; and server cabling for information technology (IT), while also allowing sufficient and clear airflow paths to exhaust server heat.

[0005] Additionally, recent high-density (HD) server loads requiring direct liquid cooling (LC) have increased congestion in zero-U spaces with liquid cooling distribution manifolds, which include associated liquid distribution pipes / hooks and connectors. For example, a liquid cooling distribution manifold may include a supply manifold and a return manifold. HD servers generate air-side heat (5% to 20%), resulting in relatively high temperatures at the back of the rack. Increased ambient air temperatures in data centers (e.g., changes made to support sustainability goals) further contribute to heat buildup at the back of the rack. rPDUs are typically ambient temperature-limited (e.g., limited to 60°C (140°F)), and even when operating within these limits, the increased temperatures at the back of the rack over time due to thermal stress branch overcurrent protection devices (OCPDs), electronics, and power connections can reduce the operational reliability of rPDUs.

[0006] Integrating all these technologies together can create limited space at the back of the server rack, potentially leading to compromised computing reliability or performance, as well as thermal stress rPDUs due to reduced server heat dissipation efficiency. Furthermore, access to physical components such as cables and cooling manifolds is hindered due to the difficulty of working in a congested space. For example, installing initial servers, adding additional servers, and repairing servers can be hampered by congestion.

[0007] Therefore, a system is needed that can alleviate these space fit and thermal challenges and improve interoperability with other devices in the server rack. Summary of the Invention

[0008] According to one or more illustrative embodiments of this disclosure, a system configured to distribute power within a rack is disclosed.

[0009] According to one or more illustrative embodiments of this disclosure, a system configured to distribute power within a rack is disclosed. In one illustrative embodiment, the system includes a rack junction box configured to receive power. In another illustrative embodiment, a power rail is coupled to the rack junction box and configured to receive power from the rack junction box. In yet another illustrative embodiment, one or more power couplers are coupled to the power rail and configured to receive power from the power rail and distribute power to a plurality of rack unit loads.

[0010] In other respects, at least a portion of the system may be configured to be located within the zero-U space of the rack, wherein the zero-U space of the rack is defined as the volume within the rack at each side and rear of the rack, which is not configured to accommodate multiple rack unit loads.

[0011] In other aspects, the power rail may include a housing. In still other aspects, the power rail may include at least three busbars, which are at least partially enclosed by the housing and configured to receive and electrically coupler tabs to one or more power couplers.

[0012] In other respects, at least three busbars may include at least seven busbars.

[0013] In other respects, at least three busbars may include at least eleven busbars.

[0014] In other respects, in the rack-mounted configuration, at least three busbars of the power rails can be configured to be longitudinally arranged in the vertical direction within the zero-U space of the rack.

[0015] In other respects, in the rack-mounted configuration, at least three busbars of the power rails can be configured to be longitudinally arranged in the horizontal direction within the zero-U space of the rack.

[0016] In other respects, the rack junction box and power rails can be configured for six-phase power. In other respects, one or more power couplers can be configured to receive six-phase power from the power rails and distribute at least one of three-phase or single-phase power to multiple rack unit loads.

[0017] In other respects, the rack junction box and power rails can be configured for three-phase power. In other respects, one or more power couplers can be configured to receive three-phase power from the power rails and distribute at least one of the three-phase power or single-phase power to multiple rack unit loads.

[0018] In other respects, each of the one or more power couplers may include coupler tabs aligned in a row and configured to receive power from power rails.

[0019] In other respects, each of the one or more power couplers may include mounting features configured to selectively mechanically couple each power coupler to a power rail and mechanically decouple each power coupler from the power rail.

[0020] In other respects, each of the one or more power couplers may include a tab coupling mechanism configured to selectively operate independently of mounting features, wherein the tab coupling mechanism is configured to selectively extend coupler tabs to and retract coupler tabs from the power rail, thereby electrically coupling the coupler tabs to and electrically decoupling the coupler tabs from the power rail.

[0021] In other respects, each of the one or more power couplers may be bidirectionally oriented and configured to be coupled to a power rail in a first orientation and a second orientation, the second orientation being rotated 180 degrees about an axis relative to the first orientation, wherein each power coupler is configured to be coupled to the power rail along the axis.

[0022] In other respects, a rack junction box may include a housing. In other respects, a rack junction box may include at least one circuit breaker.

[0023] In other respects, the rack junction box can be configured to receive power from at least one busbar.

[0024] In other respects, the rack junction box can be configured to receive power from at least two busbars simultaneously.

[0025] In other respects, the power rail can be configured to receive two or more types of power couplers of different sizes along a finite number of possible locations along the power rail.

[0026] According to one or more illustrative embodiments of this disclosure, a power rail is disclosed. In one illustrative embodiment, the power rail includes a housing. In another illustrative embodiment, the power rail includes at least three busbars, which are at least partially enclosed by the housing and configured to receive and electrically coupler tabs to one or more power couplers. In yet another illustrative embodiment, the power rail is configured to receive two or more types of power couplers of different sizes at a finite number of possible locations along the power rail.

[0027] In other respects, at least three busbars may include at least seven busbars.

[0028] In other respects, at least three busbars may include at least eleven busbars.

[0029] The content of this invention is provided only as an introduction to the subject matter fully described in the detailed embodiments and accompanying drawings. This content should not be considered a description of essential features, nor should it be used to define the scope of the claims. Furthermore, it should be understood that both the foregoing content and the following detailed embodiments are exemplary and illustrative only, and do not necessarily limit the claimed subject matter. Attached Figure Description

[0030] The following detailed description is provided with reference to the accompanying drawings. The use of the same reference numerals in different instances of the specification and drawings may indicate similar or identical items. Various embodiments or examples (“Examples”) of this disclosure are disclosed in the following detailed description and drawings. The drawings are not necessarily drawn to scale. Generally, unless otherwise specified in the claims, the operations of the disclosed processes can be performed in any order.

[0031] Figure 1A This is a perspective view of a system configured to distribute power within a rack, according to one or more embodiments of this disclosure.

[0032] Figure 1B This is a perspective view of a system comprising multiple rack unit loads according to one or more embodiments of the present disclosure.

[0033] Figure 1C This is a perspective view of a system including alternative locations and orientations of a rack junction box and power rails according to one or more embodiments of this disclosure.

[0034] Figure 2A This is an enlarged perspective view of the lower part of a system according to one or more embodiments of the present disclosure.

[0035] Figure 2B This is an enlarged perspective view of the upper part of a system according to one or more embodiments of the present disclosure.

[0036] Figure 3A This is a rear view of a system according to one or more embodiments of the present disclosure.

[0037] Figure 3B This is a rear view of a system having multiple rack unit loads according to one or more embodiments of the present disclosure.

[0038] Figure 4A This is a perspective front view of a system of OCPDs with rack junction boxes according to one or more embodiments of the present disclosure.

[0039] Figure 4B This is an enlarged front perspective view of the upper part of a system according to one or more embodiments of the present disclosure.

[0040] Figure 5A This is a top view of the rack-defined zero-U space according to one or more embodiments of the present disclosure.

[0041] Figure 5B This is a top view of a system within a zero-U space according to one or more embodiments of the present disclosure.

[0042] Figure 6A This is a side view of the power rail of a system according to one or more embodiments of the present disclosure.

[0043] Figure 6B This is a cross-sectional end view of a power rail including a busbar according to one or more embodiments of this disclosure.

[0044] Figure 7A This is a perspective view of a power coupler of a system including a first power interface according to one or more embodiments of this disclosure.

[0045] Figure 7B This is a perspective view of a power coupler of a system including a second power interface for a non-removable wired adapter, according to one or more embodiments of this disclosure.

[0046] Figure 8A This is a top view of a power coupler of a system including a second power interface for a non-removable wired adapter, according to one or more embodiments of this disclosure.

[0047] Figure 8B This is a perspective view of a power coupler of a system including a second power interface according to one or more embodiments of this disclosure.

[0048] Figure 8CThis is a view of a power coupler for a system including a second power interface for a non-removable wired adapter, according to one or more embodiments of this disclosure.

[0049] Figure 9A This is a view of the power whip connector of a power coupler according to one or more embodiments of the present disclosure.

[0050] Figure 9B This is a wiring diagram of the power whip connector of a power coupler according to one or more embodiments of the present disclosure.

[0051] Figure 10 This includes diagrams and corresponding tables of busbars for power guideways according to one or more embodiments of this disclosure, which show alternative methods for supplying six-phase power from busbar trunking connection elements to the busbars. Detailed Implementation

[0052] The disclosed subject matter will now be described in detail with reference to the accompanying drawings.

[0053] Broadly speaking, embodiments of the concepts disclosed herein relate to a modular busbar rack power distribution unit (rPDU) system for distributing power within a rack. In at least some embodiments, the system includes three modular components: a power rail, power couplers coupled to the power rail, and a rack junction box for consolidating power to the power rail. The power rail may be compatible with both three-phase and / or full six-phase technologies. In some embodiments, the symmetry of the bus voltage phase pattern of the power rail may allow for both left-side and right-side orientations of the power couplers. In some embodiments, due to space constraints, it should be understood that precise pattern symmetry of the power rail may be impractical. The power rail can be configured to accommodate two or more types of power couplers of different sizes along a finite number of possible locations along the power rail.

[0054] In at least some embodiments, the system is configured to utilize one or more modular bus rack PDUs (rPDUs) for final-stage branch circuit shunting to provide multiphase power distribution to equipment power supply units (e.g., rack unit loads). The system may utilize three-phase to six-phase transformers or provide three-phase and / or full six-phase power near the power source or the first-stage sub-feed circuit tap point. For example, the system may include or be coupled to floor PDUs near the electrical energy source throughout the computing system (e.g., a server room).

[0055] At least some of the implementations described herein relate to power distribution systems that implement High Power Output (HPO) technology in modular bus rack PDUs, providing enhanced performance characteristics compared to conventional lower power systems. A six-phase system combines two three-phase distribution paths into a single integrated system, requiring less physical space than two separate three-phase systems. For the same total power delivery, a six-phase system can use phase buses rated at half the current carrying capacity of a three-phase system because power is distributed across six phases instead of three, allowing each phase conductor to carry approximately half the current. For the same conductor and insulation volume, six-phase can provide 73% higher power density than three-phase by increasing the phase voltage to greater than 300 V. Furthermore, six-phase can provide up to 25% insulation spacing reduction at phase voltages less than 300 V, enabling more compact distribution and equipment enclosure designs. Overhead busbars can be configured to be compatible with both three-phase and six-phase power distribution configurations.

[0056] In at least some embodiments, the system utilizes the negative U-space or free U-space of the rack. The system can support direct attachment of vertical busbars to overhead busbars, and their terminals can be separated to slide outwards from the rear for easier maintenance and repair.

[0057] In some implementations, the system may include additional types of couplers, such as network interface card (NIC) couplers, sensor couplers, and other couplers that may be developed or added to the system later. These couplers can be configured to provide additional functionality to the system, such as communication capabilities, system performance monitoring, or other features.

[0058] The typical rPDU construction for HPC / AI may contradict Six Sigma lean manufacturing principles. Efficiently constructing these rPDUs above 200 kVA may be impractical; they exhibit relatively high defects-per-chance (DPO) due to the number of wires, fasteners, sensors, connectors, and modules; they suffer from unpredictable thermal performance due to inconsistent wiring and density, Joule heating generation, and variations in proximity to Joule heat; and / or they may include centralized, multi-channel electronic modules that are not easily scalable, lack redundancy, and are poorly fault-tolerant.

[0059] In contrast, at least some embodiments of this disclosure offer improved DPO due to fewer components compared to conventional rPDU designs. Thermal performance can be more predictable and uniform as components such as power rails and rack junction boxes eliminate the need for unpredictable cable densities in custom setups. Furthermore, the use of decentralized, distributed intelligence provides adaptive scalability and greater fault tolerance.

[0060] Reference Figures 1A to 10The present disclosure illustrates system 100. For the purposes of this disclosure, the terms “system 100”, “modular system 100”, “rack power distribution unit system 100”, “modular bus rack power distribution unit (rPDU) system”, and variations thereof may be considered equivalent unless otherwise stated herein.

[0061] Figure 1A A perspective view of a system 100 configured to distribute power within a rack 110 (e.g., a server cabinet) according to one or more embodiments of the present disclosure is shown. Figure 1B A plurality of rack unit loads 112 installed in system 100 according to one or more embodiments of the present disclosure are shown.

[0062] System 100 may include a rack junction box 102. The rack junction box 102 may be configured to receive power. For example, the rack junction box 102 may receive power via a busbar connection element 108, such as a cable, conduit, etc. For example, cables directly or indirectly coupled to an overhead busbar (not shown) may be used.

[0063] System 100 may include a power rail 104. The power rail 104 may be coupled to a rack junction box 102 and may be configured to receive power from the rack junction box 102.

[0064] System 100 may include one or more power couplers 106. One or more power couplers 106 may be coupled to power rails 104 and receive power from power rails 104 and distribute power to rack unit loads 112. For example, power couplers 106 may include or be configured to couple to power whip connectors configured to distribute power to rack unit loads 112.

[0065] In implementations, the rack junction box 102 and one or more power rails 104 can be located in any orientation both inside and outside the rack 110. For example, the rack junction box 102 can be configured to be vertically mounted on one side of the rack 110 with vertical power rails 104 as shown, or it can be configured to be positioned outside the rack at a first location along a first axis of the rack 110 or at a second location along a second axis of the rack 110 perpendicular to the first axis.

[0066] Figure 1C A perspective view of a system 100 including an alternative location and orientation of a rack junction box 102 and a power rail 104, according to one or more embodiments of the present disclosure, is shown.

[0067] In some implementations, rack junction box 102 can be configured for horizontal mounting. Rack junction box 102 can be installed in any suitable location, such as the top of rack 110, the bottom of rack, etc., as shown. For example, rack junction box 102 can be used at the top of a 24-inch (600 mm) rack without side zero-U space.

[0068] In some implementations, one or more power rails 104 may be configured to be mounted in a horizontal orientation. For example, as shown, two or more horizontal power rails 104 may be arranged adjacent to the horizontal rack junction box 102.

[0069] Figure 2A An enlarged perspective view of the lower part of a system 100 according to one or more embodiments of the present disclosure is shown, and Figure 2B An enlarged perspective view of the upper part of system 100 is shown.

[0070] A power whip connector 202 is shown connected to a rack unit load 112. The power whip connector 202 may be flexible (e.g., cable) and may include a single connector or be divided into two or more connectors for transmitting power.

[0071] Figure 3A and Figure 3B Rear views of a system 100 with and without the power whip connector 202 and rack unit load 112, according to one or more embodiments of this disclosure, are shown respectively. A protective cover 302 may be coupled to the power rail 104 and is used to block unused power coupler locations to prevent the ingress of foreign debris.

[0072] The power rail 104 can be configured to couple to any number of power couplers 106. It is contemplated herein, unless otherwise stated, that the busbar configuration of the channels of the power rail 104 allows for more than one location and / or more than one size of power couplers 106. For example, the same power rail 104 can be configured to receive two or more types of power couplers 106 of different sizes. In this way, the entire power rail 104 can include one type of power coupler 106 and then reuse it for power couplers 106 of twice the size, such that only half the number of the larger power couplers 106 are mounted on the power rail 104. Other illustrative examples include any type and size of power couplers 106 of various sizes used in any random order along a limited number of vertical locations due to the flexibility provided by the power rail 104. For example, a single-phase power coupler can be half the size (e.g., height) of a three-phase power coupler 106. Note that the phrase “height” is used here for brevity and is defined as the overall dimension of the power coupler 106 measured along the length of the power rail 104, and it limits the number of power couplers 106 that can be mounted on the power rail 104.

[0073] In one embodiment, the power rail 104 can be configured to couple to ten or more power couplers 106. In another embodiment, the power rail 104 can be configured to couple to 20 or more power couplers 106. For example, as shown, 23 power couplers 106 can be mounted on a single power rail 104.

[0074] Figure 4A and Figure 4B A front view of a system 100 showing an OCPD 406 with a junction box 102, according to one or more embodiments of the present disclosure, is shown.

[0075] The rack junction box 102 includes a housing 402 for accommodating one or more components.

[0076] Figure 4A and Figure 4B Rack junction box 102 is depicted in a specific configuration and location: rack junction box 102 is located on one side of rack 110, behind power rail 104. However, it is contemplated herein that rack junction box 102 can be arranged in any configuration and include any electrical components suitable for supplying power to power rail 104.

[0077] For example, as shown, rack junction box 102 may include at least one OCPD 406 coupled to a power supply and configured to protect system 100 during an electrical fault. As another example, rack junction box 102 may include a leak detection sensor configured to shut off power based on leak detection. As yet another example, rack junction box 102 may include a smart sensor configured to monitor power consumption.

[0078] In at least some embodiments, rack junction box 102 incorporates remote power panel (RPP) or junction box (TOB) whips to terminate to power rail 104 relatively efficiently.

[0079] The rack junction box 102 can be configured for one or more features, such as combinations of two or more features as described in this disclosure. In some embodiments, the rack junction box 102 is configured to support electrical connections to up to two independent busbars. In some embodiments, the rack junction box 102 is directly coupled to one or more overhead busbars. In some embodiments, the rack junction box 102 is configured to utilize zero-U space 502 for space optimization. In some embodiments, the rack junction box 102 is configured to utilize at least one circuit breaker, such as a molded case circuit breaker (MCCB), adjacent to the front side of the rack 110 for easier access and maintenance. In some embodiments, the rack junction box 102 is configured to utilize at least one of a 3-pole or 4-pole molded case circuit breaker (MCCB) for overcurrent protection. Additionally, the rack junction box 102 may include perforated ventilation along the top and bottom surfaces of its housing 402 to improve vertical convection airflow. Therefore, the molded case circuit breaker (MCCB) and internal terminal elements can preferably be positioned lower along the front (e.g., in the lower half), for example, near the inlet for colder air.

[0080] The inner surface of the rack junction box 102 may be painted black to better absorb infrared (IR) radiation from the heat-generating components, while the outer surface may be painted a relatively lighter color than the interior and / or galvanized to obtain better infrared (IR) reflectivity.

[0081] Components of the rack junction box 102 (e.g., internal electrical active components, passive radiating components) may be coupled to heat dissipation elements joined using thermal interface materials or similar devices to better dissipate heat to the surrounding air.

[0082] Rack junction box 102 can be configured to receive power using any power coupling element known in the field of power distribution. Rack junction box 102 may include a power input interface 404 for receiving power. For example, power input interface 404 may include an opening in housing 402, a cable / wire, electrical connector / plug, etc. The opening in power input interface 404 allows cable entry and also provides strain relief for the cable.

[0083] Rack junction box 102 can be configured to receive power from at least one busbar. Rack junction box 102 can also be configured to receive power from at least two busbars simultaneously. For example, rack junction box 102 can distribute power from two busbars to power rails 104 to obtain more power. For example, the busbars 604 of each power rail 104 can branch along their length to define two or more sets (e.g., four or more sets) of busbars 604, wherein each corresponding set of busbars 604 is configured to receive power from a corresponding busbar. Connections to the busbars can be coupled directly or indirectly, such as using a TOB.

[0084] Figure 5A A top view of a zero-U space 502 defined by a rack 110 according to one or more embodiments of the present disclosure is shown. Figure 5B This illustrates how a zero-U space 502 and a system 100 can be installed inside a zero-U space 502 according to one or more embodiments of the present disclosure.

[0085] In one implementation, at least a portion of system 100 is configured to reside within the zero-U space 502 of rack 110. For example, the entire system 100 may be contained within the zero-U space 502, except for connections to overhead busbars. However, note that this is an example configuration, and other configurations may include one or more portions of system 100 extending into non-zero-U space regions.

[0086] The zero-U space 502 of rack 110 can be defined as the volume within rack 110 on each side and rear of rack 110 that is not configured to accommodate multiple rack unit loads 112. As another example, the zero-U space 502 of rack 110 can be defined as unallocated space within rack 110 that is not otherwise configured for rack unit loads 112. In this implementation, the use of the zero-U space 502 in conjunction with the modular busbar design system 100 facilitates a more efficient and less cluttered power delivery method than conventional rack PDUs (rPDUs).

[0087] Figure 6A A side view of the power rail 104 of a system 100 according to one or more embodiments of the present disclosure is shown.

[0088] In at least some embodiments, the power rail 104 is configured to provide up to 720 kVA of three-phase 346 / 600V power distribution or six-phase 480 / 480V, 50 / 60 Hz power distribution; up to 250 amperes (A / Φ) per phase. The power rail 104 may be configured to include: a single set of six-phase buses or dual three-phase buses for flexible branch circuit shunting; adjacent vertical or horizontal linear array orientations; an aluminum chassis housing 602 with heat dissipation elements or an integral liquid cooling plate; side bus contacts that allow the bus 604 to be enclosed; a width of 125 mm or less and configured to be compatible with the installation of adjacent liquid-cooled manifolds; and / or a protective cover 302 for blocking unused passage portions (e.g., Figure 3B (As shown).

[0089] In one embodiment, the power rail 104 includes a housing 602. The housing 602 may be configured to at least partially enclose the busbar (e.g., a conductive channel).

[0090] The power rail 104 may include a power receiving element 606. For example, the power receiving element 606 may include one or more end portions of the busbar of the power rail 104 configured to be electrically coupled to one or more end portions of the rack junction box 102 and to receive power. For example, the power receiving element 606 may protrude outward beyond the housing 602.

[0091] The power rail 104 may include a power rail mounting surface 608. For example, the power rail mounting surface 608 may include any mounting surface known in the mechanical field for mounting components to a frame, such as a button (as shown), hook, tab, etc., configured to be removably coupled to a receiving feature. For example, the receiving feature may include a gap (e.g., a hole) defined by the frame or bracket of the rack 110.

[0092] Figure 6B A cross-sectional end view of an electric rail 104 including a busbar 604 is shown according to one or more embodiments of the present disclosure.

[0093] The rack junction box 102 and power rail 104 can be configured for six-phase power, three-phase power, or both. In some embodiments, the power coupler 106 can be configured to receive power from the power rail 104 configured for three-phase and / or six-phase power distribution and, based on a specific configuration, convert the power to deliver three-phase or single-phase power output.

[0094] For example, the rack junction box 102 and the power rail 104 can be compatible with six-phase power. One or more power couplers 106 can be configured to receive six-phase power from the power rail 104 and distribute at least one of three-phase or single-phase power to the multiple rack unit loads 112.

[0095] In another embodiment, the rack junction box 102 and the power rail 104 are configured for three-phase power. One or more power couplers 106 may be configured to receive three-phase power from the power rail 104 and distribute at least one of the three-phase power or single-phase power to the plurality of rack unit loads 112.

[0096] The power rail 104 may include any number of busbars 604. In at least some embodiments, each busbar 604 is configured as an electrical conductor for a line connection, neutral connection, or protective grounding connection, according to electrical safety standards. For example, the power rail 104 may include at least five busbars 604. As another example, the power rail 104 may include at least seven busbars 604. As another example, the power rail 104 may include at least nine busbars 604. As another example, the power rail 104 may include at least eleven busbars 604.

[0097] The power rail 104 may include multiple independent groups of three-phase power buses (e.g., bus 604) extending along the entire length of the power rail 104. Each group of bus 604 along its entire length may be individually defined such that two groups of side-by-side bus 604 extend along the entire length of the power rail 104. Alternatively and / or additionally, the bus 604 may be longitudinally separated to define separate groups of electrically independent bus 604 with adjacent ends. For example, each group may span half the length of the power rail 104. In this way, the bus 604 of the power rail 104 may be implemented as two adjacent half-length power rail arrangements defining four groups of independent three-phase bus 604. For example, Figure 1A The gap 114 can define the electrical separation between the first power rail device above the gap 114 and the second power rail device below the gap 114.

[0098] Note that for the sake of brevity, the discussion of the bus in this document may use the term and number “bus 604”, but unless otherwise stated, such discussion and limitations (e.g., longitudinal extension, mid-course adjacency) may be extended to other bus elements, such as center bus 616, communication bus 614, etc.

[0099] In some implementations, the power rail 104 flexibly supports various power distribution modes using only a single configuration of bus 604. For example, the power rail 104 may include two groups of four buses 604. This configuration enables the distribution of three-phase or six-phase power, configured as Y-connected (star) or delta-connected. For example, when the power rail 104 is configured for a delta-connected three-phase power system, one bus 604 in each of the two groups may remain unfilled or unused because the neutral bus is not used in the delta configuration. In implementations, the power rail 104 includes a secondary bus 616 for protective earth (PE). The secondary bus 616 can meet the relevant safety requirements associated with PE. In some examples, one or more secondary buses 616, such as two or more, or three or more secondary buses 616, may be used for PE. For example, the secondary bus 616 may be centrally located between two groups of four or more buses 604.

[0100] In some embodiments, the power rail 104 includes two or more additional buses 614 configured to transmit communication signals between the power coupler 106 and a host device (e.g., a network interface card). The additional buses 614 may be relatively small and centrally located.

[0101] In embodiments where multiple power rails 104 are mounted within a single rack 110, a communication bus 614 can be configured to be electrically connected or daisy-chained among all power rails 104 to facilitate communication between the power coupler 106 and other couplers spanning all power rails 104. For example, four or more power rails 104 can be configured within the rack 110, with two power rails 104 on each side of the rack 110. Each side of the power rails 104 can be powered by a single corresponding rack junction box 102. Power rails 104 on the same side of the rack 110 may include a communication bus 614 configured to be adjacent along their fully contiguous length, thereby allowing communication signals to be transmitted along the entire length of the power rail 104.

[0102] In this implementation, bridging elements (e.g., small cable bridges) may be provided and configured to connect a communication bus 614 between power rails 104 on opposite sides of rack 110. For example, the cable bridge may include a connector (e.g., an RJ-11 connector with a grounded shield) located at the bottom of the power rail 104 and may be configured to electrically connect the communication bus 614 while maintaining electrical isolation and meeting safety standards. This configuration allows communication signals to be transmitted between couplers on all power rails 104 within rack 110.

[0103] In one implementation, a single network interface card (NIC) coupler can be configured to communicate with all power couplers 106 and other couplers within rack 110 via a communication bus 614. The NIC coupler can be configured to provide communication and control within system 100. Therefore, communication bus 614 can be configured to provide a communication path bridging all power rails 104, thereby ensuring that the NIC coupler can communicate with couplers on all power rails 104.

[0104] Bus 604 can be configured to receive and couple (e.g., electrically couple) to the coupler tabs of power coupler 106 (e.g., see [link]). Figure 7A (Coupled insert 704 in the middle).

[0105] Each busbar 604 may include a corresponding conductive recess 610 (e.g., a gap, a groove). For example, the cross-sectional shape of the busbar 604 may include two conductive gap surfaces defining the conductive recess 610 along the length of the busbar 604. The busbar 604 may be any conductive material. For example, the busbar 604 may include copper. As another example, the busbar 604 may include aluminum.

[0106] Busbar 604 may include a uniform cross-sectional shape along the entire length or nearly the entire length (e.g., 90% or more) of the power rail 104. In this way, due to the uniform shape of busbar 604, a plurality of power couplers 106 can be configured to couple to a plurality of locations along busbar 604.

[0107] like Figures 1A to 5B As shown, when busbar 604 is in a mounting configuration within rack 110, busbar 604 can be configured to be longitudinally positioned vertically within the zero-U space 502 of rack 110. For example, power rail 104 can be vertically mounted on one or both sides of the zero-U space 502, and / or vertically mounted at the back or front of rack 110. The vertical direction can be defined as the direction in which rack unit loads 112 are stacked along and perpendicular to the ground surface when rack 110 is installed. However, it is contemplated that power rail 104 can be mounted in any suitable orientation and location. For example, as... Figure 1C As shown, the busbar 604 of the power rail 104 can be configured to be longitudinally arranged in the horizontal direction within the zero-U space 502 of the rack 110. For example, the power rail 104 can be horizontally mounted along the side or back of the rack 110.

[0108] Figures 7A to 7B A view of a power coupler 106 of a system 100 including various power interfaces 712, 714 according to one or more embodiments of this disclosure is shown. However, it is contemplated that any power interface 710 known in the rPDU field can be used.

[0109] In an implementation, each power coupler 106 includes a housing 702, such as a casing.

[0110] Each power coupler 106 may include a row of coupler tabs 704 aligned together. Coupler tabs 704 may be configured to receive power from the power rail 104. For example, each coupler tab 704, 705, 706 may be aligned with a corresponding busbar 604 of the power rail 104 and configured to selectively couple with it. For example, coupler tabs 704 may be configured to slide into a corresponding conductive recess 610 (e.g., a slot) of the busbar 604.

[0111] Note that for the sake of brevity, the discussion of inserts in this document may use the terms and numbers such as "insert 704", but such discussion and limitations (e.g., how they are coupled, their shape) may extend to other inserts 705, 706, unless otherwise stated.

[0112] In this implementation, each coupler (including power coupler 106, NIC coupler, sensor coupler, and any other coupler) may include and be operated by its own internal AC / DC offline switching power supply, which is configured to convert AC power received from power rail 104 into appropriate DC power. By including an internal power supply, the communication bus electrical interface of each coupler can be configured to be electrically isolated, thereby improving the reliability of the communication system within rack 110.

[0113] In implementations, the tabs 704, 705, and 706 are configured to electrically couple and decouple in a specific order based on any method (e.g., the length of each tab extending from the housing 702). For example, tab 705 (e.g., the PE coupler tab) may be longer than tab 704 to ensure that it can be matched first and disconnected last in a specific sequence. This provides safety by establishing a PE connection before the line connection when the tabs are coupled and decoupled in reverse order. In some implementations, the two smaller tabs 706 are low-voltage and used for data communication. Coupler tab 704 may include a phase coupler tab 704 (e.g., a line conductor tab 704) configured for power distribution and / or a neutral coupler tab 704 configured to return the current path. For a power coupler 106 configured for single-phase power distribution, the PE coupler tab 705 may be longer than both the phase coupler tabs 704 and the neutral coupler tab 704. For a power coupler 106 configured for three-phase power distribution, the lengths of coupler contacts 704 and 705 can be: PE coupler contact 705 is longer than neutral coupler contact 704, and neutral coupler contact 704 is longer than phase coupler contact 704.

[0114] In an implementation, the power coupler 106 can be configured for sequential two-step engagement of coupler tabs 704, 705, and 706 using mounting features 708, 709 and tab coupling mechanism 716. Each power coupler 106 may include mounting features 708, 709, such as a first mounting feature 708 and / or a second mounting feature 709. The first mounting feature 708 can be used to key each power coupler 106 to ensure correct position and orientation. The first mounting feature 708 may correspond to... Figure 6A The first receiving feature 618 (e.g., a notch) is configured to be in conjunction with... Figure 6A The first receiving feature 618 is aligned with and coupled to the power rail 104. For example, the first mounting feature 708 may include a key (e.g., a protrusion). The second mounting feature 709 may be configured to selectively and mechanically couple the power coupler 106 to the power rail 104 and decouple the power coupler 106 from the power rail 104. For example, the second mounting feature 709 may include a tab or the like, configured to slide into a second receiving feature (e.g., a recess) of the power rail 104, and thus provide structural support during installation to hold the power coupler 106 in place. An example of the second receiving feature is... Figure 6A One or more second receiving features 612 (e.g., recesses, holes) shown and defined by the housing 602.

[0115] Each power coupler 106 may include a tab coupling mechanism 716, which may be configured to operate selectively independent of one or more mounting features 708, 709. The tab coupling mechanism 716 may be configured to selectively extend coupler tabs 704, 705, 706 to and retract coupler tabs 704, 705, 706 from the power rail 104, thereby electrically coupling the coupler tabs to and decoupling them from the power rail 104. For example, the tab coupling mechanism 716 may include a sliding feature 720 configured to extend and retract coupler tabs 704, 705, 706 relative to the housing 702. For example, the sliding feature 720 may be configured to slide within a slot 718 defined by the housing 702. When in the extended position, the insert coupling mechanism 716 can be configured to prevent the power coupler 106 from being decoupled / removed from the power rail 104. In the retracted position, the power coupler 106 can be decoupled from the power rail 104.

[0116] In some embodiments, the power coupler 106 may be bidirectionally oriented. For example, it is conceivable that a particular six-phase compatible configuration of the power rail 104 of this disclosure can achieve bidirectional orientation of the power coupler 106 due to the electrical symmetry of the particular arrangement of the bus 604. For example, a center or near-center bus 616 may be used for protective grounding, and other buses 604 on either side of the center bus 616 may be symmetrically spaced from the center bus 616. For example, the power coupler 106 may be configured to be placed in both a first orientation and a second orientation, the second orientation being rotated 180 degrees relative to the first orientation about an axis, wherein the power coupler 106 is configured to be coupled to the power rail 104 along this axis.

[0117] In at least some embodiments, the power coupler 106 may include one or more power interfaces 710. For example, the power interface 710 may be configured as an IEC-compliant, custom-designed, zone-grade switch and / or metering socket. The power interface 710 may be configured to single-phase to three-phase 240 V or 277 V, and to distribute up to 16 amps to 40 amps. The power interface 710 may be configured to connect to a non-removable wired adapter power whip connector 202 to achieve Open Compute Project (OCP) compliant power rack compatibility. Alternatively, the power interface 710 may be configured to connect to a detachable wired adapter power whip configured to distribute power to the rack unit load 112.

[0118] Alternatively, the power interface 710 can be configured to connect to an auxiliary, detachable device that does not necessarily distribute power to the rack unit load 112. For example, the auxiliary device may include a network interface card, an environmental sensor aggregator, etc. In this way, various functions and sensors can be added to the power rail 104. In at least some embodiments, the power coupler 106 can be configured in a hot-swappable configuration by including overcurrent protection devices (not shown) (e.g., hot-swappable circuit breakers, fuses for overcurrent and short-circuit fault protection and improved selective coordination (e.g., 100 kAIC fuses), etc.). In at least some embodiments, the power coupler 106 can be configured for: distributed intelligence to achieve adaptive scalability and greater fault tolerance; compliance with IEC 62053-21 0.5% energy metering and optional residual current monitoring (RCM); and / or installation at finite / discrete adjustable rack unit (U) locations (e.g., a set of discrete vertical locations) to achieve the shortest cable span to the power rail 104.

[0119] like Figure 7AAs shown, the power interface 710 may include two or more first power interfaces 712 (e.g., a socket configured to receive a three-prong plug).

[0120] like Figure 7B As shown, the power interface 710 may include a second power interface 714, such as a non-removable wired adapter. For example, the second power interface 714 may include a circular recess for receiving a circular cable such as a whip. However, in some embodiments, the whip or the like is configured to be detachable.

[0121] In one implementation, the power interface 710 may be configured to receive a cable (e.g., a power whip connector 202) that passes through the power interface 710 and terminates at the coupler tab 704. For example, the cable may be configured to terminate directly using the coupler tab 704 or indirectly using a circuit board (not shown).

[0122] Figure 8A A top view of a power coupler 106 of a system 100 including a second power interface for a non-removable wired adapter, according to one or more embodiments of the present disclosure, is shown, wherein the coupler tab 704 is retracted. Figure 8B A perspective view of a power coupler 106 of a system 100 including a second power interface 714, according to one or more embodiments of the present disclosure, is shown. Figure 8C A view of a power coupler 106 of a system 100 including a second power interface 714 for a power whip connector 202, according to one or more embodiments of the present disclosure, is shown.

[0123] As shown, power coupler 106 is configured as a monitored three-phase power coupler 106. For example, power coupler 106 may include one or more additional elements (e.g., additional tabs 706) configured to transmit low-voltage data communication signals to monitor power distribution. Power coupler 106 may include a secondary tab 705 configured for protective earth (PE). Tab 704 (e.g., a primary tab) may be configured for line connection and neutral connection. Tab 704 may be configured to... Figure 6B The bus 604 shown is aligned with and coupled to it. A secondary tab 705 can be configured to be aligned with and coupled to the secondary bus 616. An additional tab 706 can be configured to be aligned with and coupled to an additional bus 614.

[0124] In embodiments configured for a single-phase socket type (e.g., power interface 712), the power coupler 106 may include at least one set of tabs 704 configured for the line (e.g., power) and neutral, and tabs 705 configured for protective earth (PE). Alternatively, for such a single-phase power interface 712, the power coupler 106 may include a set of three tabs configured for the line, line, and PE. The set of three tabs is configured to physically and electrically couple the single-phase power interface 712 to a set of three corresponding busbars. Furthermore, in some examples, the power coupler 106 includes additional sets, such that there are two different sets of three tabs, each configured to couple to a corresponding set of three busbars.

[0125] In some embodiments configured for a three-phase socket and / or a wired power interface 710, the power coupler 106 includes a set of four or more prongs. This set of four or more prongs can physically and electrically couple the three-phase socket and / or power interface 710 to a set of four or more corresponding busbars. In one example, there are exactly four prongs and corresponding busbars. For example, four prongs can be configured for line, line, line, and PE. In another example, there are exactly five prongs and corresponding busbars. For example, five prongs (e.g., four prongs 704 and PE prong 705) can be configured for line, line, line, neutral, and PE.

[0126] Figure 9A This is a view of the power whip connector 202 of a power coupler 106 according to one or more embodiments of this disclosure. For example, the power whip connector 202 may be coupled to the power interface 710 of the power coupler 106, such as... Figure 2A As shown in the image.

[0127] Each power whip connector 202 can be configured to receive power via a power receiving connector 902 (e.g., a detachable wired adapter connector, a non-detachable wired adapter connector, etc.). For example, the power receiving connector 902 may include one or more input conductive terminals 920 (e.g., terminals such as pins, socket terminals; solder wires, etc.). For example, the power receiving connector 902 may include five or more input conductive terminals 920. In one example, as shown, the power receiving connector 902 includes exactly five input conductive terminals 920.

[0128] As described above, the power whip connector 202 can be detachable or non-detachable as shown. For example, in a non-detachable configuration, the power whip connector 202 cannot be removed, and the power whip connector conductors (e.g., cables, a set of wires, etc.) indirectly pass through and terminate within the power coupler 106. For example, the power whip connector conductors can be configured to terminate (e.g., couple to) a printed circuit board (not shown) or coupler tab 704 within the power coupler 106.

[0129] Each power whip connector 202 can be configured to deliver power through one or more connectors 906. For example, the power whip connector 202 may include a splitter 904 configured to branch power to two or more connectors 906. Each connector 906 may include one or more electrical contact elements 908 (e.g., terminals such as pins, sockets, etc.) configured to distribute power. For example, as shown, a connector 906 may include seven or more electrical contact elements 908.

[0130] Figure 9B This is a wiring diagram of an electric whip connector 202 according to one or more embodiments of the present disclosure.

[0131] Connector 906 can be wired in any way suitable for transmitting power.

[0132] For example, connector 906 may include branching, such that a single neutral input conductive terminal 920 of power receiving connector 902 is branched multiple times, and a neutral element 912 is provided at connector 906, which corresponds to each respective line element 910, 914, 918.

[0133] In one embodiment, each connector 906 includes a line element 910 L1, a neutral element 912 N1, a line element 914 L2, a PE element 916, a neutral element 912 N2, a line element 918 L3, and a neutral element 912 N3.

[0134] Figure 10 This document contains diagrams and corresponding tables illustrating busbar 604 of power guide rail 104 according to one or more embodiments of this disclosure, showing alternative methods for supplying six-phase power from busbar connection element 108 (e.g., overhead busbar whip) to busbar 604. Examples of busbar connection element 108 are provided in... Figure 1A As shown, and may include any busbar connection element 108 known in the field of busbar trunking, such as cables, conduits, etc., and may be directly connected to the busbar trunking or indirectly connected. This mapping can be used to illustrate... Figure 1A How the busbar connection element 108 can be electrically mapped to the corresponding numbering sequence (i.e., "busbar number") of the busbar 604 of the power rail 104.

[0135] Table 1002 shows two separate mappings 1004 and 1006. The first mapping 1004 shows a mapping between two busbar connection elements 108A and 108B configured to each connect to a three-phase busbar and receive three-phase power. For example, the two busbar connection elements 108A and 108B can be used to branch power twice from the same three-phase overhead busbar. The second mapping 1006 utilizes a single busbar connection element 108C configured to connect to a single six-phase busbar.

[0136] Embodiments of this disclosure may utilize these mappings. For example, in one embodiment, system 100 may include a rack junction box 102 configured to receive power from two different busbar connection elements 108, each configured for three-phase power. The rack junction box 102 may be configured to map the connections of the two different busbar connection elements 108 to provide six-phase power to the power rail 104. In another embodiment, system 100 may include a rack junction box 102 configured to receive power from a single busbar connection element 108 configured for six-phase power. The rack junction box 102 may be configured to map the connections of the busbar connection elements 108 to provide six-phase power to the power rail 104.

[0137] In this way, system 100 can be configured to flexibly support various power distribution input modes. For example, as shown in Table 1002, two sets of three-phase power connections or a single set of six-phase power connections can be terminated at a single power rail 104.

[0138] In Table 1002, phases such as X, X0, X1, Y, Y0, Y1, Z, Z0, and Z1 are configured as line conductors for power distribution, while N, N0, and N1 are configured as neutral conductors for the return current path. Note that, for simplicity only, the mapping shown does not include the mapping of PE bus 616.

[0139] The topics described herein sometimes illustrate different components contained within or connected to different other components. It should be understood that the architectures depicted are merely exemplary, and many other architectures implementing the same functionality can actually be implemented. Conceptually, any arrangement of components implementing the same functionality is effectively “associated” to achieve the desired functionality. Therefore, any two components combined herein to achieve a particular function can be considered “associated” with each other to achieve the desired functionality, regardless of the architecture or intermediate components. Similarly, any two such associated components can also be considered “operationally connectable” or “operationally coupled” to each other to achieve the desired functionality, and any two components that can be suchly associated can also be considered “operationally coupled” to each other to achieve the desired functionality. Specific examples of operationally coupled components include, but are not limited to, physically matchable and / or physically interactable components and / or wirelessly interactable components and / or logically interactable and / or logically interactable components.

[0140] While specific aspects of the subject matter described herein have been shown and described, it will be apparent to those skilled in the art that changes and modifications can be made based on the teachings herein without departing from the subject matter and its broader aspects, and therefore, the appended claims cover all such changes and modifications within their scope, as well as the true spirit and scope of the subject matter described herein. Furthermore, it should be understood that the invention is defined by the appended claims.

Claims

1. A system configured to distribute power within a rack, the system comprising: A rack junction box configured to receive the power; A power rail, which is coupled to the rack junction box and configured to receive power from the rack junction box; as well as One or more power couplers are coupled to the power rail and configured to receive power from the power rail and distribute the power to a plurality of rack unit loads.

2. The system according to claim 1, wherein, At least a portion of the system is configured to be located within the zero-U space of the rack, wherein the zero-U space of the rack is defined as the volume within the rack at each side and rear of the rack, which is not configured to accommodate the plurality of rack unit loads.

3. The system according to claim 1, wherein, The power rail includes: The outer casing; and At least three busbars, which are at least partially enclosed by the housing and configured to receive and electrically couple to the coupler tabs of the one or more power couplers.

4. The system according to claim 3, wherein, The rack junction box is configured to be coupled to at least one of a remote power panel RPP whip or a junction box TOB whip for termination to the power rail.

5. The system according to claim 3, wherein, The rack junction box includes at least one circuit breaker.

6. The system according to claim 3, wherein, In the mounting configuration within the rack, the at least three busbars of the power rail are configured to be longitudinally arranged in the vertical direction within the zero-U space of the rack.

7. The system according to claim 3, wherein, In the mounting configuration within the rack, the at least three busbars of the power rail are configured to be longitudinally arranged in the horizontal direction within the zero-U space of the rack.

8. The system according to claim 3, wherein, The rack junction box and the power rail are configured for six-phase power, and wherein the one or more power couplers are configured to receive the six-phase power from the power rail and distribute at least one of three-phase power or single-phase power to the plurality of rack unit loads.

9. The system according to claim 3, wherein, The rack junction box and the power rail are configured for three-phase power, and wherein the one or more power couplers are configured to receive the three-phase power from the power rail and distribute at least one of the three-phase power or single-phase power to the plurality of rack unit loads.

10. The system according to claim 3, wherein, Each of the one or more power couplers includes: The coupler tabs are aligned in a row and configured to receive power from the power rail.

11. The system according to claim 10, wherein, Each of the one or more power couplers include: Installation features, wherein the installation features are configured to selectively mechanically couple each power coupler to the power rail and mechanically decouple each power coupler from the power rail.

12. The system according to claim 11, wherein, Each of the one or more power couplers includes: A tab coupling mechanism configured to selectively operate independently of the mounting features, wherein the tab coupling mechanism is configured to selectively extend the coupler tab to the power rail and retract the coupler tab from the power rail, thereby electrically coupling the coupler tab to the power rail and electrically decoupling the coupler tab from the power rail.

13. The system according to claim 10, wherein, Each of the one or more power couplers is bidirectionally oriented and configured to be coupled to the power rail in a first orientation and a second orientation, the second orientation being rotated 180 degrees about an axis relative to the first orientation, wherein each power coupler is configured to be coupled to the power rail along the axis.

14. The system according to claim 1, wherein, The rack junction box includes: The outer casing; and At least one circuit breaker.

15. The system according to claim 1, wherein, The rack junction box is configured to receive power from at least one busbar.

16. The system according to claim 1, wherein, The rack junction box is configured to receive power simultaneously from at least two busbars.

17. The system according to claim 1, wherein, The power rail is configured to receive two or more types of power couplers of different sizes at a finite number of possible locations along the power rail.

18. An electric guide rail, comprising: shell; as well as At least three busbars, which are at least partially enclosed by the housing and configured to receive and electrically couple to coupler tabs of one or more power couplers. The power rail is configured to receive two or more types of power couplers of different sizes at a finite number of possible locations along the power rail.

19. The power rail according to claim 18, wherein, Each power coupler includes coupler tabs of different lengths, which are configured to electrically couple and decouple in a specific sequence.

20. The power rail according to claim 18, wherein, Each power coupler includes a power interface configured for at least one of an IEC-compliant socket, a non-removable wired adapter, or a removable wired adapter.

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