POWER MODULE CONNECTION ASSEMBLIES AND UNIVERSAL POWER SUPPLIES AND METHODS INCLUDING THE SAME

Abstract

Power module connection assemblies include a longitudinally extending channel member and cam member. The longitudinally extending channel member includes a first end of a connector member in a sidewall thereof having a face exposed to an interior channel of the channel member. The connector member has an electrical connection section on a second end of the connector member, the second end being displaced from the first end. The longitudinally extending cam member is configured to be positioned in the channel of the channel member. The cam member is rotatably movable within the channel from a first position, wherein a mating connector bar may be received in the channel of the channel member proximate the first end of the connector member, to a second position to press the mating connector bar and the first end of the connector member together.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a channel member according to some embodiments of the present invention.

FIG. 2 is a perspective view of an end portion of the channel member of FIG. 1 with mating connector bars received within the channel member.

FIG. 3 is a perspective view of a connector member for use in the channel member of FIG. 1 according to some embodiments of the present invention.

FIG. 4 is a perspective view of a cam member according to some embodiments of the present invention.

FIG. 5 is a perspective view of an end portion of the cam member of FIG. 4.

FIG. 6 is a perspective view of a power module connection assembly according to some embodiments of the present invention.

FIG. 7 is a partially exploded bottom perspective of a cam member in a frame of a power module according to some embodiments of the present invention.

FIG. 8 is a perspective view of an end portion of a cam member mounted in a frame of a power module according to some embodiments of the present invention.

FIG. 9 is a perspective view of a uninterruptible power supply according to some embodiments of the present invention.

FIG. 10 is a perspective view illustrating a lock out feature according to some embodiments of the present invention.

FIG. 11 is a perspective view illustrating a power module connection assembly with bus bars received therein according to some embodiments of the present invention.

FIG. 12 is a perspective view illustrating a cam member according to other embodiments of the present invention.

FIG. 13 is an end view of a cam member according to some embodiments of the present invention.

FIGS. 14 and 15 are cross-sectional views of a power module connection assembly according to some embodiments of the present invention with the cam member in a first and a second position, respectively.

FIG. 16A is a perspective view of a uninterruptible power supply according to some embodiments of the present invention.

FIG. 16B is a perspective view illustrating a power module and power module connection assembly of the uninterruptible power supply of FIG. 16A according to some embodiments of the present invention.

FIG. 17 is a perspective view of a power cabinet frame and inductor array according to some embodiments of the present invention.

FIG. 18 is a flow chart illustrating a method configuring a uninterruptible power supply according to some embodiments of the present invention.

FIG. 19 is a perspective view of a channel member according to other embodiments of the present invention.

Claims

1. A power module connection assembly, comprising: a longitudinally extending channel member including a first end of a connector member in a sidewall thereof having a face exposed to an interior channel of the channel member, the connector member having an electrical connection section on a second end of the connector member, the second end being displaced from the first end;a longitudinally extending cam member configured to be positioned in the channel of the channel member, the cam member being rotatably movable within the channel from a first position wherein a mating connector bar may be received in the channel of the channel member proximate the first end of the connector member to a second position to press the mating connector bar and the first end of the connector member together.

2. The assembly of claim 1, wherein, in the second position, the cam member deflects one of the mating connector bar and the first end of the connector member towards the other of the first end of the connector member and the mating connector bar.

3. The assembly of claim 1, further comprising a power module and wherein the cam member is rotatably connected to the power module or the channel member is coupled to the power module and wherein the power module is configured to be received in a power cabinet including the other of the cam member or the channel member with the cam member in the channel when the cam member is in the first position.

4. The assembly of claim 1, further comprising a power module and a power cabinet and wherein the cam member is rotatably connected to the power module and the channel member is configured to be coupled to the power cabinet and wherein the power module is configured to be received in the power cabinet with the cam member in the channel when the cam member is in the first position.

5. The assembly of claim 3, wherein the power module is configured to be longitudinally slidably receivable in the power cabinet.

6. The assembly of claim 3, wherein the first end of the connector member has first portion extending at an angle from second portion to define a contact region therebetween and wherein the first end of connector member is positioned in channel member so that the contact region contacts the mating connector bar and the first and second portion do not contact the mating connector bar in the second position.

7. The assembly of claim 3, wherein the channel member further comprises a longitudinal position reference portion and the cam member includes a mating portion and wherein the longitudinal position reference portion and the mating portion limit rotation of the cam member from the first position to the second position when the cam member is not in a longitudinal position in the channel member defined by the longitudinal reference portion.

8. The assembly of claim 7, wherein the longitudinal reference portion comprises a slot in the channel member and wherein the mating portion comprises a tab extending from the cam member into the slot when the cam member is in the longitudinal position in the channel member defined by the longitudinal reference portion.

9. The assembly of claim 7, wherein the longitudinal reference portion and the mating portion are further configured to limit longitudinal movement of the cam member in the channel when the cam member is not in the first position.

10. The assembly of claim 3, further comprising a travel limiter on the cam member configured to limit rotational movement of the cam member beyond the second position.

11. The assembly of claim 10, wherein the cam member is rotationally mounted in a frame and wherein the travel limiter comprises an extension member extending from an end of the cam member that is received in a corresponding opening in the frame, the opening having a first end corresponding to the first position and a second end corresponding to the second position.

12. The assembly of claim 3, further comprising a drive member on an end of the cam member configured to receive a tool and transmit a torsional force from the tool to the cam member to rotate the cam member between the first position and the second position.

13. The assembly of claim 12 wherein the cam member is a molded member and wherein the tool is integrally molded with the cam member.

14. The assembly of claim 3, further comprising a switch coupled to prevent energizing of the power module when the cam member is not in the second position.

15. The assembly of claim 3 wherein the cam member and the channel member are longitudinally self-aligning when the cam member is inserted in the channel member.

16. The assembly of claim 15 wherein the cam member and/or the channel member are connected to the power module or power cabinet, respectively, so as to allow angular movement about a longitudinal axis of the cam member and/or channel member to longitudinally self-align the cam member and the channel member when the cam member is inserted in the channel member.

17. The assembly of claim 3, wherein the channel member includes a plurality of longitudinally spaced connector members in respective sidewalls thereof and wherein a plurality of mating connector bars may be received in the channel of the channel member proximate corresponding ones of the plurality of connector members and pressed together therewith responsive to rotation of the cam member from the first position to the second position.

18. The assembly of claim 17 wherein ones of the connector members are arranged in a paired arrangement on opposite sidewalls of the channel member at respective longitudinal positions so that transverse forces on the cam member pressing the connector members and mating connector bars together are substantially offsetting.

19. The assembly of claim 3, wherein, in the second position, the cam member deflects one of the mating connector bar and the first end of the connector member towards the other of the first end of the connector member and the mating connector bar and wherein sidewalls of the channel have a spring characteristic selected to provide a desired force responsive to deflection of the one of the mating connector bar and the first end of the connector member in the second position.

20. The assembly of claim 19, wherein the spring characteristic is provided by a material and a sidewall thickness of the channel member and a height of a contact region of the connector member where the connector member contacts the mating connector bar relative to a bottom surface of the channel member.

21. The assembly of claim 3, wherein, in the second position, the cam member deflects one of the mating connector bar and the first end of the connector member towards the other of the first end of the connector member and the mating connector bar and wherein the cam member has a spring characteristic selected to provide a desired force responsive to deflection of the one of the mating connector bar and the first end of the connector member in the second position.

22. The assembly of claim 21, wherein the spring characteristic is provided by a spring member mounted in the cam member.

23. A uninterruptible power supply, comprising: a power cabinet;a power module removably coupled to the power cabinet; anda power module connection assembly that couples the power module to the power cabinet, the power module connection assembly, comprising:a longitudinally extending channel member coupled to one of the power cabinet or the power module, the channel member including a first end of each of a plurality of connector members at longitudinally spaced positions in a sidewall thereof, each of the first ends having a face exposed to an interior channel of the channel member, the connector members having an electrical connection section on a second end of the connector members, the second end being displaced from the first end;a longitudinally extending cam member coupled to the other of the power cabinet or the power module, the cam member being configured to be positioned in the channel of the channel member, the cam member being rotatably movable within the channel from a first position wherein a plurality of mating connector bars may be received in the channel of the channel member proximate the first ends of the connector members to a second position to press the mating connector bars and the first ends of the connector members together.

24. The uninterruptible power supply of claim 23, wherein the channel member is coupled to the power cabinet and wherein the power cabinet includes a plurality of inductors electrically coupled to the electrical connection sections on the second ends of ones of the connector members and wherein the power module includes a printed circuit board and the mating connector bars comprise bus bars extending from the printed circuit board and/or crimped lugs on ends of wires extending from the printed circuit board.

25. The uninterruptible power supply of claim 23, wherein the channel member extends from a front face to a rear face of the power cabinet and wherein cam member is longitudinally slidably receivable in the channel member to receive the power module in the power cabinet.

26. The uninterruptible power supply of claim 25, wherein the power cabinet is configured to receive a plurality of power modules, each having an associated power module connection assembly for slidably receiving the respective power module in the power cabinet.

27. The uninterruptible power supply of claim 23, further comprising a plurality of inductors, electrically coupled to the electrical connection sections of the second ends of ones of the connector members, positioned below the power module connection assembly and the power module and a cooling fan positioned below the inductors that provides cooling for the inductors and for the power module connection assembly.

28. The uninterruptible power supply of claim 23, wherein the cam member includes a lockout feature extending therefrom that impedes closure of a front panel of the power cabinet when the cam member is not in the second position.

29. A method configuring a uninterruptible power supply, comprising: providing a power cabinet including components of the uninterruptible power supply and including one of a longitudinally extending channel member or a longitudinally extending cam member therein, the longitudinally extending channel member including a first end of each of a plurality of connector members at longitudinally spaced positions in a sidewall thereof, each of the first ends having a face exposed to an interior channel of the channel member, the connector members having an electrical connection section on a second end of the connector members, the second end being displaced from the first end, and the longitudinally extending cam member being configured to be positioned in the channel of the channel member, the cam member being rotatably movable within the channel;providing a power module including the other of the longitudinally extending channel member or the longitudinally extending cam member therein;installing the power module in the power cabinet with the cam member in the channel in a first rotational position with a plurality of mating connector bars extending from the one of the power module and the power cabinet having the cam member coupled thereto received in the channel of the channel member proximate the first ends of the connector members; androtating the cam member to a second rotational position to press the mating connector bars and the first ends of the connector members together.