Methods and systems for a power supply housing

Details Methods and systems for a power supply housing Methods and systems for a power supply housing

1999-02-25

2001-09-25

Paumen, Gary (Department: 2833)

Electrical connectors

With insulation other than conductor sheath

Plural-contact coupling part

C439S076100

Reexamination Certificate

active

06293828

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates generally to power supplies, and more particularly to power supply housings.
DESCRIPTION OF THE RELATED ART
Mission critical systems, where even a temporary system shutdown is highly undesirable, play an increasingly important role in many essential industries. For example, mission critical systems are often used in the telecommunications industry, in hospitals, and in banking. To avoid system shutdowns, mission critical systems require highly reliable, redundant subsystems, such as redundant power supplies. In addition, many applications, such as telecommunication transmitters, require large amounts of power which may be provided by multiple power supplies.
The need for redundant power supplies capable of supplying large amounts of power has resulted in a corresponding increase in the use of hot-swap power supply technology. A hot-swappable power supply provides the ability to remove and replace the power supply from a power supply rack without turning off power to the rack. Thus, for example, in a power supply rack containing multiple or redundant removable power supply modules, should one module fail, the failed module can be replaced without interrupting the operation of other power supply modules. These racks of multiple power supplies may be used in high-power applications wherein the power supply outputs are ganged together. For example, the telecom industry has applications requiring up to 20,000 watts or more. This power may be provided by one or more racks, each containing multiple hot swappable power supplies ganged together.
However, the use of hot swappable power supplies poses many problems. For example, the removal of a power supply from a rack while power is still applied to the rack may result in arcing between the power supply connector pins and the corresponding rack connector sockets. Such arcing can severely injure an operator and may damage the power supply and the rack.
Furthermore, during a “hot” insertion, the power supply input and output signals may be connected to the corresponding rack signals in an unsafe order. For example, power supply input power pins may contact corresponding rack power pins before the power supply ground pin comes in contact with a corresponding rack ground pin. This can result in a potentially dangerous “floating” condition, where the power supply is operational, but not grounded.
In addition, conventional hot-swappable power supply connectors are particularly susceptible to damage resulting from the frequent handling of the removable supplies. For example, power supply connectors are often damaged as a result of service personnel resting the supply on its connectors while placing the supply on the ground.
Furthermore, the sliding action itself during removal of the power supply from the rack often causes abrasion and gouges on the bottom of the power supply or damages to the rack. Conventional attempts to solve this problem typically utilize plastic guides, or the like, mounted in the rack to guide the power supply as it is being pulled in or out. However, these guides are relatively expensive, and often become damaged themselves during the removal or insertion process.
SUMMARY OF THE INVENTION
The present invention is generally related to a robust, safe, and sturdy power supply systems, which may include one or more power supplies and a corresponding rack. In one embodiment, the power supply is a hot swappable supply with a suitable housing. That is, a power supply and associated housing which can be removed from or inserted into the rack while power to the rack connectors is still on.
In one embodiment, the power supply has an overall rectangular shape. In order to ensure that the power supply is properly oriented while being inserted into a rack, a keying system is provided on a first side, such as the rear of the power supply housing. In one embodiment, the keying is provided by one or more pins, posts, or the like, projecting from a connector-side of the power supply. For example, one or more key pins, which can also act as guide pins or posts, may extend rearward from one or more rear connectors. In one embodiment, these key pins or posts fit into corresponding receptacles on the rack side connectors. Thus, if the user attempts to insert the power supply upside down or sideways, the key pins will strike into a portion of the rack chassis before the power supply connectors and corresponding rack connectors can come into direct contact. Furthermore, in one embodiment, the keys are located so that if the power supply is inserted in an incorrect orientation, the keys will not strike the rack connectors. Thus, connector damage resulting from the improper insertion of the power supply into the rack is greatly reduced.
In addition, in one embodiment, standoff posts or the like are provided extending rearward from the supply. The standoffs advantageously extend past the connector pins or other sets of signal, power or key pins, so that if the power supply is rested on the ground, connector-side down, the power supply will rest on the standoffs, rather than the connector pins. Thus, the standoffs protect the connectors and connector pins from the type of damage that often results when a conventional power supply is rested on its connectors.
In one embodiment, the connectors on the rear of the power supply include at least an AC input connector, a DC output connector, and a control signal connector. In one embodiment, the AC connector is configured to receive single-phase AC power. In another embodiment, the AC connector is configured to receive three-phase AC power. In one embodiment, at least two AC connector pins are relatively staggered, thereby ensuring the safety of the system when the power supply is removed or inserted into the rack.
Thus, for example, in the case of a power supply which has a connector configured to receive single phase AC power, a common pin, a first polarity line pin, a second polarity line pin, and a precharge pin are provided. In one embodiment, the common pin extends the furthest out, thereby ensuring that when the power supply is inserted into the rack, the first connection made will couple the power supply common pin to a rack common point. In another embodiment, a first polarity pin and a precharge pin are shorter in length than the common pin. Thus, when the power supply is inserted into the rack, after the common connection is made, the first polarity line pin and the precharge pin will be connected to corresponding rack connections. This staggered arrangement ensures that a power supply internal EMI filter is charged before the second polarity line is connected. Thus, inrush current, which could cause arcing and pin damage, is thereby reduced. In addition, the second polarity pin is advantageously shorter than the first polarity pin. Thus, the complete AC connection will only be made after the common, the first polarity, and the precharge connections are made. In one embodiment, the control signal connector may have pins similarly staggered to ensure the safe turn-on and turn-off of the power supply.
In another embodiment, the power supply includes a handle extending from the front of the power supply. The handle allows a user to easily grasp the power supply during removal or insertion of the power supply, as well as when carrying the power supply. In one embodiment, the handle is shaped to accommodate a user's fingers. The handle may have a slot through which fingers can protrude slightly to enhance the grasping action.
In another embodiment, a latch is provided to latch the power supply into a correspond slot on the rack. In one embodiment, the latch is accessible from the front side of the power supply. In another embodiment, the latch includes a finger portion. In one embodiment, the finger portion is configured to be kicked out of the way if it is extended while the supply is being inserted into a rack. Thus, damage to the latch is prevented.
In addition, in the one embodiment, user accessible test points are provided. In one e

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