Portable Power Supply Bus Bar Adapter Tool-less Connection
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Solution Overview
Problem
Existing solutions for powering rack-mountable equipment modules, such as those used in OCP racks, are inconvenient and pose safety risks due to the need for installation in a rack, potential damage from incorrect polarity connections, power loss through cables, and the requirement for tools to secure connections.
Innovation Solution
A portable power supply unit with a bus bar adapter and tool-less connection that allows for direct engagement with the equipment module's bus bar connector, eliminating the need for rack installation and using a DC power supply with an AC/DC converter to provide a secure and efficient power output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flying lead power cables with lugs, screws, and nuts are used to connect the product to the DC power supply, then the product can be powered outside the rack, but the connection requires tools and poses safety risks from incorrect polarity and exposed connections
Solution Approach 1:
The patent introduces a bus bar adapter as an intermediary component between the DC power supply and the equipment module. This adapter includes a bus bar connector that interfaces with the module's bus bar connector and a power cable connector that interfaces with the power supply, eliminating the need for exposed lug connections and tools while ensuring proper polarity alignment through a key-lock mechanism
Solution Approach 2:
The patent replaces the traditional mechanical connection system (lugs, screws, nuts requiring tools) with a blind-mate bus bar connector system that uses a key-lock polarity connection mechanism. This substitution eliminates the need for tools and provides inherent safety by preventing incorrect polarity connections through mechanical interlocking
2Ease of operation
If flying lead power cables are used to connect the product to the DC power supply, then the product can be powered outside the rack, but power loss occurs due to cable resistance
Solution Approach 1:
The bus bar adapter serves as an intermediary that provides a low-resistance electrical path between the power supply and the equipment module. By using bus bar connectors with large surface area and low resistance rather than thin power cables, the adapter minimizes power loss while maintaining connection flexibility
3Reliability
If the product is installed in the OCP rack, then the product can be powered by the central power distribution system, but the rack must be dedicated and available, which is impractical for field tests, beta tests, and development stages
Solution Approach 1:
The patent extracts the power connection functionality from the rack-mounted configuration by providing a portable bus bar adapter that can be used independently of the OCP rack. This allows the equipment module to be powered by a standalone DC power supply, enabling field tests, beta tests, and development work without requiring rack installation
Solution Approach 2:
The bus bar adapter provides universal power connection capability that works both within the OCP rack environment and outside it. The adapter can connect to the rack's power distribution system when installed in the rack, or connect to a portable DC power supply when used in field tests and development, making it adaptable to multiple testing and deployment scenarios
4Reliability
If the product is installed in the OCP rack, then the product can be powered, but it is inconvenient for manufacturers and customers to perform function checks before and after shipping by installing and uninstalling the product on the rack
Solution Approach 1:
The patent extracts the power connection capability from the rack-dependent configuration by providing a portable bus bar adapter that enables power connection without rack installation. This allows manufacturers and customers to perform function checks quickly by simply connecting the adapter to a portable DC power supply, eliminating the time-consuming installation and uninstallation process
Solution Approach 2:
The bus bar adapter enables preliminary power connection setup before shipping by allowing function checks to be performed with a portable DC power supply rather than requiring full rack installation. This preliminary testing capability saves time and allows validation of power functionality earlier in the process
Data Source
AI summary
A portable power unit is used for powering a rack-mountable equipment module, in which the equipment module includes an equipment chassis and a bus bar connector extending from the equipment chassis, and in which the bus bar connector is configured to engage a power distribution system of an equipment rack when the equipment module is mounted in the equipment rack. One aspect is directed to a portable power supply unit generally including a bus bar adapter electrically connected to a DC power supply, a mount for supporting the bus bar adapter, the mount having an end, and a tool-less connection electrically connected to the bus bar adapter and extending from the end of the mount, in which the tool-less connection is configured for engaging the bus bar connector of the equipment module.