Low-Profile Busbar System for High-Current Power Shelves
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Solution Overview
Problem
Low-profile power distribution systems face challenges in cooling high-power server equipment due to restricted airflow channels, which are further compromised by electrical components and cables, making it difficult to effectively manage heat dissipation in compact configurations like 1 U rack units.
Innovation Solution
The arrangement of bus bars one behind the other in a low-profile power shelf design allows for reduced height occupancy, enabling more than 50% of the shelf height to be used for airflow and additional components, with round pins providing electrical connections to power supplies while maintaining sufficient cross-sectional area for high current conduction without excessive losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If bus bars are arranged one on top of the other in conventional configurations, then electrical connectivity is maintained, but the height profile increases and airflow channels are restricted
Solution Approach 1:
The bus bars are arranged in a side-by-side configuration within the same horizontal plane rather than stacking them vertically, transitioning from a vertical arrangement to a horizontal one. This dimensional change reduces the height profile while maintaining electrical connectivity through laterally positioned connection elements.
Solution Approach 2:
Connection elements are integrated within apertures of the bus bar structure, with insulating materials nested around the connection elements. This nesting approach consolidates multiple components (bus bars, connection elements, insulation) into a compact arrangement that minimizes height while maintaining functionality.
2Ease of operation
If electrical components and cables are disposed alongside bus bars, then connectivity is achieved, but airflow channels are further restricted
Solution Approach 1:
Connection elements are extracted from traditional cable arrangements and integrated directly into the bus bar structure through apertures. This extraction simplifies the arrangement by eliminating separate cable routing alongside bus bars, reducing clutter and improving airflow paths while maintaining electrical connectivity.
3Reliability
If conventional heat sinks with forced-air mechanisms are used, then cooling capability is improved, but height profile becomes incompatible with low-profile shelves
Solution Approach 1:
The bus bar arrangement itself serves as a cooling structure by incorporating airflow channels within its structure. The design allows cooling air to pass through the bus bar assembly, eliminating the need for separate conventional heat sinks with forced-air mechanisms, thereby achieving cooling functionality within the low-profile constraint.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances cooling efficiency by allowing ample airflow through the shelf, reducing heat generation in high-power components and enabling increased power outputs in compact 1 U shelves without overheating, while maintaining structural integrity and electrical connectivity.
Implementation Method 1
The associated electrical components are typically cooled by air moving in parallel airflow channels, through convection or otherwise forced-air mechanisms (e.g., fans or blowers).
Implementation Method 2
A copper bus bar conducting 1500 A of current without generating excessive losses should not be loaded with more than 3 A per mm2 cross section.
Data Source
AI summary
A power distribution system includes a server rack comprising a vertically stacked plurality of power shelf assemblies. Each assembly has first and second opposing sides defining vertical planes, and third and fourth opposing sides extending between the first and second sides. For each assembly, a first bus bar extends along a horizontal plane between the third and fourth sides, a second bus bar extends along the horizontal plane between the first bus bar and the first side of the assembly, a first set of power supply pins extends along the horizontal plane from the first bus bar toward the second side of the assembly, and a second set of power supply pins extends along the horizontal plane from the second bus bar toward the second side of the assembly, wherein the second set of power supply pins further protrude through respective apertures in the first bus bar.