Hinged Busbar Assembly for Powered Sliding Rack Units
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Solution Overview
Problem
Conventional cabling systems for powering sliding insertable/extractable units in rack-mounted hardware are cumbersome, limiting ease of insertion/extraction and airflow due to large wire gauge wires and physical size, and fail to maintain power when fully extended.
Innovation Solution
Transitioning power delivery to a hinged busbar assembly using variable-length busbar elements connected with high-current machined pins and electrical sockets at pivotal connections, allowing for a smaller footprint and improved airflow/cooling while maintaining power to the units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cabling assemblies are used to maintain power to sliding units, then power transmission is achieved, but the assembly becomes cumbersome and limits airflow due to large wire gauge wires and physical size
Solution Approach 1:
The busbar assembly is divided into multiple segments (first busbar portion, second busbar portion, and intermediate busbar portions) connected by pivotal connections. This segmentation allows the assembly to flex and adapt to the sliding motion while maintaining electrical connectivity, eliminating the need for cumbersome conventional cabling.
Solution Approach 2:
The patent replaces the conventional mechanical cabling system with a rigid busbar structure that uses pivotal connections (hinges) to accommodate motion. This substitution provides a more reliable electrical connection while reducing the physical bulk and improving airflow compared to flexible cable assemblies.
2Reliability
If conventional cabling assemblies are used to maintain power to sliding units, then power transmission is achieved, but the physical size is large and limits airflow
Solution Approach 1:
The busbar is segmented into multiple portions that can be arranged in a compact configuration. The intermediate busbar portions with pivotal connections allow the structure to fold or articulate, reducing the overall volume occupied while maintaining the electrical pathway for power transmission.
Solution Approach 2:
The pivotal connections introduce dynamic capability to the busbar assembly, allowing it to change its physical configuration as the sliding unit moves. This dynamic structure maintains electrical connectivity while adapting to space constraints and preserving airflow paths.
3Reliability
If standard interconnect assemblies with large AWG wires are used, then power delivery is maintained, but ease of insertion/extraction is limited
Solution Approach 1:
The busbar assembly is segmented with pivotal connections that act as flexible joints. This segmentation allows the rigid busbar structure to accommodate the sliding motion during insertion and extraction, maintaining reliable power delivery without the bulk of conventional cabling.
Solution Approach 2:
The pivotal connections change the physical parameters (position, orientation) of the busbar segments relative to each other during sliding motion. This parameter change allows the assembly to maintain electrical connectivity while facilitating easy insertion and extraction of the sliding unit.
4Reliability
If conventional cabling is used in sliding track systems, then power to extended units is maintained, but airflow is limited in both open and closed states
Solution Approach 1:
The segmented busbar structure with pivotal connections occupies less space than conventional cabling assemblies. This reduced physical footprint eliminates the airflow blockage caused by large cables while maintaining power delivery to the sliding unit in both extended and retracted positions.
Solution Approach 2:
Replacing the flexible cable system with a rigid but articulating busbar structure eliminates the voluminous cabling that restricts airflow. The pivotal connections provide the necessary flexibility without the bulk of conventional mechanical cabling systems.
Data Source
AI summary
A hinged busbar assembly includes a first mounting busbar configured to be electrically and mechanically connected to the first component at a fixed connection, a second mounting busbar configured to be electrically and mechanically connected to the second component at a fixed connection, and at least two extension busbars extending between the first and second mounting busbars. Adjacent extension busbars are electrically and mechanically connected to each other at a pivotal connection. One of the at least two extension busbars is electrically and mechanically connected to the first mounting busbar at a pivotal connection, and another one of the at least two extension busbars is electrically and mechanically connected to the second mounting busbar at a pivotal connection. Each pivotal connection includes at least one extension extending from each adjacent busbar and at least one electrical contact mounted in each extension, and a pin inserted through the electrical contacts.