Modular data center support rack system and installation method
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Solution Overview
Problem
Existing data center power component support systems are time-consuming and hazardous to install due to the need for elevated construction and assembly in narrow, space-constrained areas, posing risks of dropped components and falls.
Innovation Solution
A modular support rack system with a transportable fixture that allows assembly and reinforcement of components in a factory, facilitating unitized installation and reducing the need for elevated construction, using telescopic connections and a forklift-compatible base to secure and stabilize the racks during transport and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If support brackets and components are installed at elevated heights (12-24 feet) in narrow aisle ways, then the power supply support system can be positioned correctly over server racks, but construction workers face safety hazards from dropped components and falls, and installation becomes time-consuming and difficult
Solution Approach 1:
The support brackets are pre-assembled into complete unitized structures at ground level before installation. All components including cable trays, support rails, bus bars, and switch boxes are pre-positioned and secured to the brackets during factory assembly, eliminating the need for workers to assemble these components at elevated heights during on-site installation.
Solution Approach 2:
Multiple support brackets are unitized into a single integrated structure by pre-installing cable trays, support rails, and other components across adjacent brackets. This creates a unified assembly that functions as one complete unit, reducing the number of separate installation operations required and minimizing worker exposure to hazards.
2Ease of manufacture
If heavy components (cables, bus bars, switch boxes) are lifted and positioned at elevated heights, then the power support system can be assembled, but the risk of dropped components increases and additional lifting equipment is required
Solution Approach 1:
All heavy components including cable trays, support rails, bus bars, and switch boxes are pre-installed and secured to the support brackets during factory assembly. This preliminary assembly at ground level eliminates the need for workers to manually lift and position these heavy components at elevated heights during on-site installation, thereby eliminating the risk of dropped components.
Solution Approach 2:
A lifting interface is provided on the unitized support structure that enables mechanical lifting equipment to safely raise the entire pre-assembled unit. This intermediary mechanism allows the complete structure with all heavy components already attached to be lifted as one unit, preventing component separation and drops during the lifting process.
3Strength
If support brackets extend two and a half feet from walls, then they can provide adequate support arms for components, but only about 5 feet of aisle way space remains for assembling a second power supply support system
Solution Approach 1:
Complete unitized support structures are fully assembled at ground level in controlled factory conditions where ample space is available. This preliminary assembly eliminates the need for workers to perform complex assembly operations in the confined aisle way space at the installation site, as all components are already pre-positioned and secured during manufacturing.
Solution Approach 2:
The power support system is divided into discrete modular unitized structures that can be independently assembled and handled. Each unitized structure serves as a complete functional module that can be installed as a single unit, simplifying the on-site installation process and reducing the complexity of working in confined spaces.
4Productivity
If individual support brackets are assembled into unitized shelf-like structures at elevated heights, then the power support system can be constructed, but scaffolds and ladders are required and the process becomes work-intensive
Solution Approach 1:
Individual support brackets are pre-assembled into complete unitized shelf-like structures at ground level during factory manufacturing. All connection points, cable trays, and support rails are pre-installed and secured during this preliminary assembly, eliminating the need for workers to perform these assembly operations at elevated heights using scaffolds and ladders during on-site installation.
Solution Approach 2:
Multiple support brackets are merged into a single unitized structure during factory assembly, creating a unified assembly that functions as one complete unit. This merging of components into a single installable unit dramatically reduces the number of separate assembly operations required on-site and eliminates the need for complex scaffolding arrangements.
Data Source
AI summary
A modular data center support rack system and installation method whereby system includes a plurality of modular support racks formed from bracket-like rack members that support data center electrical power components, and a transportable fixture that detachably holds the rack members into an assembly position. The transportable fixture remains detachably connected to the assembled modular support rack during the transportation thereof to an installation location to reinforce the modular support rack. Each modular support rack includes an arrangement of data center electrical power supply components that are registrable with and connectable the data center electrical power supply components on another of the modular support racks. In the installation method, the modular support racks are serially interconnected into an appropriate electrical supply configuration for a row of servers located beneath the row of modular support racks.