HK1162770A - Electrical power distribution system - Google Patents

Abstract

An electrical power distribution system that can provide power to load equipment at any point along its length includes two main components: a power track housing assembly with current carrying conductors that can be mounted to the wall, ceiling or under the floor, and a plug-in power tap. The power track housing assembly includes a housing, insulators, and two or multiple conductors. In order to increase the housing assembly length, the housing assembly is preferably arranged such that multiple housing assemblies can be spliced together using cam operated splicing assemblies that form straight,.90 degree. and/or.T. splices to configure the system to match the equipment arrangement, and that allow all conductors in respective housing assemblies to be connected to each other simultaneously. The plug-in power taps also employ a system such as a shaft-cam mechanism that allows the assemblies to be electrically connected to all phase conductors within the power track housing assembly simultaneously. In addition, the power taps may include circuit breakers or other protective devices, and/or other sub-modules.

Description

Power distribution system

Require priority

The present application claims priority from U.S. utility model application No. 12/617,289 entitled "power distribution system" filed on 12.11/2009.

Technical Field

The present invention relates to a system for distributing power from a junction box to electrical devices through a bus duct or track in which a distribution sub-assembly or power tap can be removably connected without shutting down the power supply. The bus duct or track includes a plurality of conductors to provide a dc power supply, either single phase or multi-phase ac power, via a plurality of track members or cabinet assemblies connected by unique cam operated engagement means and the power tap is also connected to the track members or cabinet assemblies via contact extending means or devices. Here, in connection with an expansion device, such as a cam, once installed in the power track housing assembly, no rotation of the power tap mechanical structure is required to ensure electrical connection of the track conductors.

Background

The stringent requirements for mission critical data hubs require solutions that can quickly interrupt the connection to equipment or quickly connect equipment without interrupting the power supply. In addition, all such power distribution systems for mission critical data centers and other web sites that require continuous power distribution to multiple devices must be able to provide both local and remote monitoring of power supply parameters.

The "continuous bus power distribution system" (CBusPDS) of the present invention provides additional underground or overhead cables to surface mounted Power Distribution Units (PDUs) that are conventionally used in key data centers and similar web sites for power distribution. In contrast, the CBusPDS of the present invention can be installed overhead or mounted to a wall surface, and also, if desired, under a raised floor, so that the power supply to the equipment or equipment rack can be maintained. The aerial or wall mounted CBusPDS configuration allows a user or installer to quickly insert or reposition a plug-in power tap in the event of a power interruption to add or replace equipment, and to quickly remove the power tap as needed for repair or replacement.

Power distribution systems in the form of bus ducts or tracks are well known. For example, tracks are often used to distribute power to lighting devices in so-called "track lighting systems". Other examples include those disclosed in us patent 5,336,097; 5,449,056, respectively; 6,039,584, respectively; 6,105,741, respectively; 6,296,498, respectively; 6,521,837, respectively; 6,517,363, respectively; 6,805,226, respectively; 7,374,444, respectively; 7,468,488, respectively; and 7,470,861 and in U.S. patent application No. 2008/0302553. These patents or patent applications represent patents or patent publications that are part of a power distribution system directly related to bus ducts or tracks. However, due to the lack of adequate protection and monitoring features, most prior rail or busway systems are not suitable for mission critical applications, with the result that mission critical data center and other similar website operators continue to rely primarily on underground lines and distribution subsystems capable of providing the necessary monitoring.

Disclosure of Invention

Accordingly, it is an object of the present invention to provide a power distribution system for web sites and equipment requiring a continuous supply of power, the power distribution system being adapted to provide protective and/or monitoring functionality for mission critical applications (although the power distribution system of the present invention can also be used in non-mission critical applications with or without the addition of all of the protective and/or monitoring features described above).

It is a further object of the present invention to provide a power distribution system that can be mounted overhead or wall-mounted, and that can be floor-mounted, and that can be conveniently operated by a plug-in power tap.

In accordance with the preferred embodiment of the present invention, the power distribution system takes the form of a "continuous bus power distribution system" or CBusPDS, capable of providing power to load devices at any point along its length, and includes two main components: a power track housing assembly having current carrying conductors, the assembly being mountable on a wall, ceiling, or floor, and a plug-in power tap, the plug-in power tap being mountable at any location along the length of the power track housing assembly.

The power track enclosure assembly in the preferred embodiment includes an enclosure, an insulator, and two or more conductors having different current carrying capabilities. To increase the length of the chassis assembly, the chassis assembly is optimally designed so that a plurality of chassis assemblies can be joined together by the joint assembly. The engagement assembly includes a cam, wedge, or other similar device capable of causing contact in the engagement assembly to engage the bus bar in the housing assembly. The engagement members form a straight line, "90 degrees", "T", "X", or other engagement to configure CBusPDS to match the device arrangement. The simultaneous joining device also allows all conductors in each chassis assembly to be automatically connected simultaneously.

The power to the power track housing assembly in the preferred embodiment is provided by a power terminal assembly. The terminal assembly is engageable with the power track housing assembly for connecting the power distribution system to a power source. The termination assembly may also include a circuit breaker or other protective device, and/or other sub-modules such as, but not limited to, power and temperature monitoring lines, a dc power source, a transformer, a voltage inverter/converter, or a frequency converter. CBusPDS can either be powered by the power terminal assembly from the terminal or can be powered centrally by the power terminal assembly through a "T" connection.

Like the housing assembly connectors mentioned above, the plug-in power tap in the preferred embodiment includes a shaft cam (or similar contact extending means or device). The plug-in power tap allows the coupling assembly to make electrical connections to all of the phase conductors in the CBusPDS power track housing assembly. Additionally, the power tap may include a circuit breaker or other protective device, and/or other sub-modules, such as, but not limited to, a power and temperature monitoring line, a dc power source, a transformer, a voltage converter or power converter, or a frequency converter.

Since the contact extension axis cam system is used to connect the power tap to the power track housing assembly in the preferred embodiment, the preferred power track housing assembly has the great advantage that once the plug-in power tap is installed in the housing assembly for electrical connection as with other products, it no longer requires the plug-in power tap mechanism to be rotated, and thus the chance of improper installation or excessive loss of power during repeated connection and removal is reduced.

In addition to the power supply conductors, the power track housing assembly in the preferred embodiment can optionally be designed to allow a "bare" fiber optic bundle to be incorporated into the housing assembly to pick up IR or other optical frequency signals from the power tap electronics in the plug-in housing assembly to enable network communications through the track housing power terminal assembly and/or one or more other wired or wireless network-connected communications units connected to or included in one or more housing assemblies.

Finally, in addition to the plug-in power taps of the preferred embodiment, those skilled in the art will appreciate that other types of plug-in pull-down/cancellation devices can be incorporated into the present track housing assembly, and that the housing assembly and plug-in power taps of the illustrated assembly need not be used together. For example, to improve the mechanical stability and structure of the CBusPDS, a plug-in pull-down/cancellation device can be added to the CBusPDS to enable it to withstand the mechanical forces associated with extreme overcurrent and short circuit conditions. On the other hand, the shaft cam system can protect the plug-in power tap, but cannot be used to protect the tap or power terminal subassembly. The present disclosure includes other variations on the preferred embodiments described above and illustrated above.

Drawings

Figure 1 is an isometric view of a power track housing assembly designed according to a preferred embodiment.

Figure 1A is a cross-sectional end view of the power track housing assembly of figure 1.

Figure 2 is an isometric view of a power rail engagement assembly designed according to the preferred embodiment.

Fig. 2A is an isometric view of a power track engagement assembly embedded in the power track housing assembly of fig. 1.

Figure 2B is an exploded isometric view of the power track housing assembly of figures 2 and 2A. The figure is a schematic block diagram showing the basic elements of a power supply in which the principles of the preferred embodiment of the present invention may be applied.

Figure 3 is an end view of the power track housing assembly of figure 1 and its internal mechanical support device.

Figure 3A is an isometric view of the power track housing assembly and internal mechanical support device shown in figure 3 joined together.

Figure 4 is an isometric view of a plug-in power tap designed according to the preferred embodiment.

Fig. 4A is a cross-sectional end view of the plug-in power tap shown in fig. 4.

Fig. 4B is an enlarged isometric view of the connection portion of the inserted power tap of fig. 4.

Fig. 4C is a side view of the grounding spring of the plug-in power tap of fig. 4.

Fig. 4D is an isometric view showing the mounting of the plug-in power tap of fig. 4 to the power track housing assembly shown in fig. 1.

Fig. 4E is a top view of the plug-in power tap shown in fig. 4, showing how the spring clip is extended by the cam.

Fig. 4F is a rear view of the power distribution and tower subassembly of the plug-in power tap shown in fig. 4.

Fig. 4G is an isometric view of a variation of the plug-in power tap shown in fig. 4, including not only a plurality of protective devices, but also a plurality of receptacles.

Fig. 4H is an isometric view from the rear of the plug-in power tap shown in fig. 4G.

Fig. 4I is an isometric view from the bottom of the plug-in power tap shown in fig. 4G.

FIGS. 5, 5A, and 5B are illustrations of "T", "X", and 90 degree engagement assemblies designed according to the preferred embodiment of this invention.

Figure 6 is an isometric view showing a track cabinet power terminal subassembly and its mating interface assembly designed according to the preferred embodiment of this invention.

Fig. 7 is an isometric view of one of the possible applications of CBusPDS consisting of the subassembly of parts shown in fig. 1-6.

DETAILED DESCRIPTION OF EMBODIMENT (S) OF INVENTION

Figures 1 and 1A show a power track enclosure assembly with isolated high current conductors or buses 3, in accordance with a preferred embodiment of the present invention. The power track housing assembly of fig. 1 is made up of four main components: a housing or enclosure 1; an insulator 2; a high current conductor or bus 3; the telecommunications assembly includes signal connectors 4 and cables 7 the cabinet or enclosure 1 may include grooved lines 6 extending along the top and sides of the cabinet assembly for mounting or securing EMI shielding. The EMI shield may be fabricated in the form of a flat plate (not shown) from a magnetically conductive material, such as molybdenum metal, or it may be a mounting plate (not shown) fabricated from a magnetically conductive material for mounting the circuitry to a wall or ceiling.

Additionally, the housing 1 in the power track housing assembly may be provided with sub-cavities 9, and/or compartments, channels, grooves, recesses, etc. to accommodate insulation and/or signal carrying members. When the signal connectors 4 are signal connected by cables 7 extending along the signal package compartments, the signal packages may be in a single compartment extending along the length of the chassis and covered by an optional channel cover 8 for safety or EMI shielding reasons. The connector 4 and cable 7 can carry electronic signals or be used for fiber optic communication as desired.

In addition to or instead of the EMI shield, the cabinet 1 itself may be fabricated or extruded from a material that constitutes a reasonable current or magnetic flux conductor. The current conductor will be a shield against electric field disturbances, and if the material of the housing is a magnetic conductor, this current conductor will be a shield against magnetic fields.

The housing 1 in fig. 1 has a complex cross-section of extruded material. However, those skilled in the art will appreciate that this cross-section may be a simple rectangular cross-section with conductors mounted by brackets or any other configuration as long as a continuous opening is provided in the bottom of the cabinet to allow insertion of a plug-in power tap as shown in fig. 4 and 4A-4I. Although four high current conductors or busbars 3 are shown in fig. 1 and 1A, those skilled in the art will appreciate that the present invention is not limited to four busbars arrangements and is not limited to the particular shape, size and configuration of the conductors shown.

In addition, these conductors may be used for single phase power, two pole power, neutral two pole power, or neutral or non-neutral three phase power with ground or dc power. Still further, in the case of a grounded conductive enclosure, the design of the insulator 2 can be varied to accommodate different conductors, so long as the thickness of the insulator provides sufficient distance between the conductor 3 and the enclosure 1 to avoid arcing.

In the illustrated embodiment, it is preferred to use a single insulator rather than a continuous insulator because a single insulator can prevent arcing between conductors, although other alternatives to a continuous insulator would not depart from the scope of the present invention. If an arc forms, it will exist between the conductor and the grounded enclosure, and typically the conductor-to-enclosure voltage is lower than the conductor-to-conductor voltage.

Fig. 2, 2A, and 2c illustrate a coupling assembly 11 for connecting power track housing assemblies in accordance with a preferred embodiment of the present invention. The illustrated junction assembly is adapted to connect to a housing assembly having four high current conductors or bus bars as shown in fig. 1 and 1A, but similarly, this junction assembly is adapted to connect to a housing assembly having a different number and arrangement of conductors or bus bars as discussed above.

As shown in FIG. 2A, one end of the housing 12 in the splice assembly 11 is configured to be inserted into one end of a first power rail housing assembly 1 and the opposite end of the splice assembly is configured to be inserted into one end of a second power rail housing assembly (not shown) to extend CBusPDS to a desired length by coupling the housing assemblies together. Each set of engagement assemblies comprises a number of resilient current-carrying fingers equal to the number of conductors 3 in the power track housing assembly to be connected. When the splice assembly is inserted into the housing 1 of a power track housing assembly, as shown in fig. 2A, then the current carrying fingers 13 shown in fig. 2 and 2B will be extended by a contact extension device or apparatus (e.g., cam 14, described in more detail below) to engage the conductors 3 to conduct power in the respective conductors 3 in the connected housing assemblies. Although the cam is illustrated herein as a contact spreading device or apparatus, it will be appreciated that other apparatus capable of moving a conductor, such as a wedge insertion apparatus, may be used in place of the cam shown.

Current carrying fingers 13 are located in recesses on both sides of the splice case 12, and in order to electrically isolate each current carrying finger 13, the splice case 12 is made of an electrically insulating material and is shaped to fit into the housing 1 of the respective power track assembly. The shape of the chassis 12 depends on the shape of the power track chassis assembly into which the splice assembly 11 is to be inserted and the shape and configuration of the current carrying fingers 13. The shape and configuration of the current carrying fingers will in turn depend on the configuration of the conductors 3 in the power track housing assembly. As shown in fig. 2c, additional insulating material 16 may be added to increase the distance between the current carrying fingers in order to provide additional arc protection. In addition, as shown in fig. 2c, current carrying fingers 13 may be in the form of conductive strips that may be embedded in the added insulator 16 and/or the mating shell 12 by a mounting bracket 17.

In order to ensure a good electrical connection between the current-carrying fingers 13 in the splice assembly and the conductors 3 in the power track housing assembly, the cam 14 in the preferred embodiment is designed in a shape such that the current-carrying fingers 13 extend at right angles to the insertion direction and away from the splice assembly housing 12, the purpose of which is to allow safe engagement of the conductors 3 in the track housing assembly after the splice assembly has been inserted into the track housing assembly. By the current carrying fingers 13 engaging the conductors 3 after insertion, unnecessary losses in the current carrying fingers and conductors are avoided and insertion of the splice assembly into the power track housing assembly is facilitated. In addition to ensuring a good electrical connection, the subsequent engagement of the current-carrying fingers 13 with the conductors 3 also helps retain the splice components in the respective housing assemblies, although such retention may not be necessary because the respective housing assemblies being connected will be mounted to a common surface with the splice components crossing therebetween.

While one skilled in the art will appreciate that other means of rotating the cam may be used, such as an integral knob, a screwdriver slot, etc., as shown in FIG. 2B, the cam 14 may further include an insert 18 to assist in rotating the cam after the splice assembly is inserted into the power track housing assembly. The exact cross-sectional shape and size of cam 14 will depend on the pressure that current carrying fingers 13 will be subjected to and should be readily ascertainable by one skilled in the art.

In addition to this, the junction assembly may include a subassembly 17 for current monitoring or protection. The subassembly includes structural and/or electrical components (not shown), and connectors (not shown) may be used to connect fiber optic strands and/or cables between the power track chassis assembly portions. Power connections can also be provided at each end of the finger assembly to enable measurement of voltage drops, to enable temperature sensors to be attached directly to the current carrying fingers 3, to enable voltage drop measurement connections, and to enable temperature sensors to be connected to integrated voltage and/or temperature monitoring lines contained in the electronic components and to be provided in communication with a network, remote display or aggregate display. Alternatively, an IR or other type of remote temperature sensor can be embedded to monitor the temperature of the current carrying fingers and communicate directly with the electronic components in the network or subassembly 19.

Fig. 3 and 3A are internal mechanical support devices 23 for inserting the power track housing assembly at a desired location in accordance with the preferred embodiment of the present invention. The support device 23 is installed in order to prevent deformation of the conductors, which deformation is usually caused by the impulse generated by the high current in the event of a short circuit, the support device 23 usually being installed in the field or in the production site. As shown, the mechanical support device 23 includes vertical posts 24 and laterally extending arms 25 that engage the conductor 3 to prevent them from deforming inwardly. Although the scope of the present invention includes a variety of different shapes and configurations of the support device, including providing a design that enables the cam 3 to rotate and engage the conductor 3 after insertion into the housing assembly, the support device can be slide-fit into the housing assembly by being inserted into the open end of the portion in front of the terminal or engaged into another housing assembly and held by the bottom plate 22. Since the purpose of the support device is to engage the conductors 3 to avoid deformation, the support device should be made of a non-conductive material.

Figures 4 and 4A to 4I show plug-in power taps with optional power switching and/or monitoring circuitry in the sub-assembly, according to the preferred embodiment of the invention. As with the coupling assemblies shown in fig. 2, 2A, and 2c, the electrical connection herein uses spring clips 36 that are extended by contacting an extension device or apparatus (e.g., shaft-cam assembly 47 described below) to make contact with the conductors 3 in the power track housing assembly, thereby facilitating insertion of a plug-in power tap into the power track housing assembly while reducing wear and ensuring a good electrical connection.

Those skilled in the art will appreciate that the number and arrangement of the current conducting spring clips 36 should correspond to the number and arrangement of the conductors 3 in the power track housing assembly, and as noted above, the number and arrangement of the conductors 3 may vary. Such a design enables the plug-in power tap to be mounted anywhere along the length of the power track housing assembly. Furthermore, as shown in fig. 4, each spring clip unit corresponding to a busbar or conductor 3 may be made up of four unassociated spring clips, may contain less or more than four spring clips or conductive elements, or may be made up of only a single conductive element.

After the plug-in power tap is inserted into the power track housing assembly, the shaft-cam assembly 47 containing the single cam 43 will rotate to extend the spring clip 36, as shown in fig. 4E, and into contact with the power track housing assembly conductors. This allows the plug-in power tap in the illustrated embodiment to be placed and securely connected at any location along the length of the power track housing assembly.

As shown in fig. 4 and 4A to 4G, without being limited to the above examples, the preferred plug-in power tap can be composed of three sub-assemblies: a tower subassembly 38; a dispensing subassembly 40; and an electronic subassembly 42 (the scope of the present invention also includes integrating the subassembly into a single assembly or two subassemblies). As illustrated, the tower subassembly 38 is substantially flat in shape for insertion into the power track enclosure assembly, the tower subassembly 38 including a plurality of current conducting fingers 36 mounted in front of and behind the tower, and the distribution subassembly 40 is a parallel tube or box-like closure, including a power receptacle 50, and abutting the parallel tube or box-like electronic subassembly 42, as best illustrated in fig. 4. As best illustrated in fig. 4F and 4H, the turret subassembly 38 is mounted on the dispensing subassembly 40 such that an opening in the upper portion of the dispensing subassembly provides access to the dispensing subassembly 40 for the cam shaft 41, and the user can operate the shaft cam in the dispensing subassembly 40 to rotate the shaft. Of course, the shape of the various subassemblies is not limited to the illustrative shape, but the tower subassembly 38 must be configured to fit within the power track chassis assembly.

As shown in FIG. 4A, upon insertion of the plug-in power tap into the power track housing assembly, the plurality of cams or eccentrics 43 of the cam assembly 47 are fixed to the cam shaft 41 and are configured to press and thereby extend the respective fingers 36 on each side of the turret sub-assembly 38 as the cam shaft 41 rotates. In the illustrated configuration, after the plug-in power tap has been installed into the power track housing assembly, the installer may use a tool, such as a wrench, to rotate the cam shaft and establish an electrical connection between the spring clip 36 and the conductor 3. Alternatively, it is within the scope of the present invention to provide a handle or knob, or other mechanical device, to facilitate rotation of the shaft 41. As shown in fig. 4, a mounting bracket 44 can be used to secure the insertion of a plug-in power tap into the power track housing assembly before the shaft 41 is rotated, although this bracket may be omitted or replaced by other means for securing insertion. Fig. 4G through 4I illustrate an alternative mounting bracket 44A.

For safety reasons, as shown in fig. 4D, a grounding finger spring 35 is used to establish a ground connection between the power track housing assembly and the plug-in power tap before the current conducting finger 36 makes contact with a possible high voltage power track housing assembly conductor 4.

Also, as shown in fig. 4G to 4I, a safety locking device in the form of a slidable locking member 49 may be introduced to prevent rotation of the cam shaft 41 to retract or extend the fingers 36, unless the slidable locking member 49 is moved to an "open" or unlocked position, the slidable locking member 49 having an extension that snaps the locking cam 51 onto the cam shaft 41. This slidable locking member 49 can extend to the exterior of the dispensing subassembly 40 in order to be operable from the exterior of the subassembly, as shown in fig. 4E and 4G. Other ways of ensuring that the plug-in power tap is prevented from accidentally falling out of the power track housing assembly include, but are not limited to: coupled to the slider and arranged to cover the tongue of the mounting fastener that mates with the mounting bracket 44 so that the mounting fastener cannot be rotated without "opening" the protective device.

As shown in fig. 4 and 4E through 4G, the removable cover 43 on the dispensing subassembly and/or electronics subassembly 40 can be made of any material, including IR, RF, or optically transparent materials. The use of IR transparent materials will allow the user to easily detect IR temperatures. In another aspect, wireless transmission can be achieved through the cover using an RF transparent material, however, the use of an optically transparent cover allows the fiber optic receiver to be placed against or near the cover so that optically transmitted data can be picked up. In either case, a bundle of bare optical fibers may be embedded in the power track housing assembly of FIG. 1 for receiving optical or IR transmission data from the plug-in power tap assembly when an optical or IR transmitter is introduced into the plug-in power tap assembly for transmitting/receiving supervisory line processed data in the electronic sub-assembly. Multiple transmitters/receivers may be installed for redundancy, or coding or multiplexing purposes.

As shown in fig. 4, an optional antenna 57 may be mounted to the electronics subassembly 42 for wireless RF data communication. If the antenna is mounted on top of the electronics sub-assembly 42 as shown in fig. 4, signals are easily transmitted/received in the power track chassis assembly cavity, and thus signals from outside interference or radar interference are shielded. Multiple antennas may be installed for redundancy, or coding or multiplexing purposes.

As shown in fig. 4 and 4D through 4I, the dispensing subassembly 40 of the plug-in electrical tap assembly may include a circuit breaker 52, a receptacle 50, a fused disconnect and/or other current or power activated protective equipment. The number and arrangement of these protective devices depends on the number and arrangement of conductors 3 in the power track chassis assembly. The protective devices may be connected to a connector or port, or to the cable 44, which cable 44 exits through a grommet 50 for connection to one or more loads.

Additionally, as shown in FIG. 4B, the tower subassembly 40 may also include power sensors and contact or non-contact temperature sensors 58 and 59 that can send signals from the outside or to the internal electronics. A built-in power sensor may be placed or attached to the conductor to detect the voltage level of the conductor and/or the plug-in power tap. All data can be displayed on a display mounted on the electronic subassembly 42 or can be transmitted to a remote location by wired or wireless means.

Electronic circuitry or components that can be included in the electronic subassembly 42 include, but are not limited to, the following examples:

-means for monitoring and collecting data including voltage, temperature, individual distribution assembly current, individual or all power supply parameters and/or simplex, duplex or multiplex communication data.

-a power conversion module, such as: an ac to dc converter, a dc power supply, a frequency converter, an energy storage component, a transfer switch, a line conditioner, or other power conversion circuit/component.

The dc logic power for the electronic assembly may be provided from the power track housing assembly conductor 3 or may be an external power source obtained through the signal cable 46. The wired, wireless, or fiber optic communication terminals may be included in the electronics sub-assembly 42 as a stand-alone plug-in, or in the electronics and/or distribution sub-assembly of any plug-in power tap.

As described above with respect to fig. 1 and 1A, connectors 4 are mounted on the power track chassis 1 at intervals. As a result, the connectors and associated conductors can form a communications network to which plug-in power taps can be attached via corresponding connectors and signal cables 45 and 46. As shown in fig. 1 and 1A, a second set of connectors and cables may be placed into the second subcavity 8 for encoding and multiplexing purposes. As shown in fig. 4G, an optical or IR transmitter/receiver 52 may be mounted at the bottom of the plug-in power tap device for the purpose of transmitting data to and from a floor-mounted cabinet.

After the plug-in power taps are inserted into the power track housing assembly, the openings between the plug-in power taps can be covered with a snap-in cover 38. The covers are slidably received over each other so that any size opening between the plug-in power taps can be covered. The material from which the cover is made may be an optically conductive material and/or a magnetic field conductive material for the purpose of RF protection or EMI protection.

Figures 5, 5A, and 5B illustrate various variations of the power track housing assembly of figures 1 and 1A. Together with the substantially linear components illustrated in fig. 1 and 1A, these variations form "T", "X", and 90 degree components, enabling an installer to generate unique CBusPDS configurations to match the layout arrangement of the power plant. The internal arrangement of these components is the same except for the different shapes of the components shown in fig. 5, 5A and 5B. Each of the modules is connected to the other module by the coupling module shown in fig. 2, 2A and 2B, each of which is also capable of receiving a plug-in power tap as shown in fig. 4, 4A to 4G, and 5.

Figure 6 illustrates an example of a track housing power terminal assembly in accordance with a preferred embodiment of the present invention. Although the subassemblies may be integrated into a single subassembly, this assembly optionally includes two integrated subassemblies: an input power subassembly 68 and an electronics subassembly 67.

The input power subassembly includes a compartment 71 for receiving a circuit breaker or other protective equipment. Although more or less conductors have been discussed in the above description of the power track housing assembly, the subassembly is shown as containing 4 conductors. The input power subassembly may also house current, voltage, temperature and/or power sensors.

Like the plug-in power tap, the terminal device may include an optional antenna 70 for wireless communication, optional IR, optical or other transmitter/receiver for communication, optional connectors for wired communication, and/or visual indicators so that the user can determine whether the circuit breaker or fused disconnect or other device is in an "on" or "off" state. A flange 76 and exit window 77 may be provided for cabling or connection to protective equipment. When an antenna 79 is used to transmit the collected data, a light or IR transmitter/receiver may be provided to the bottom of the plug-in power tap device for transmitting data to and from the main cabinet mounted on the ground. To reduce interference, the data has been compressed and burst transmitted. Multiple antennas may be installed for redundancy, or coding or multiplexing purposes. If a fiber optic bundle 69 is used, the fiber optic bundle 69 and connector can be inserted into the junction box of the track housing power terminal assembly for connection to an external module, or can be inserted into the internal electronics section 67. The dc logic power supply for the electronic assembly may be the power supplied by the input power supply section conductors or may be an external power supply obtained through one of the signal cables.

The material of the sub-assembly housing of the terminal assembly shown in fig. 6 may be metallic, or may be an IR or optically transparent material, or any other material. The termination equipment may also include flanges 76 for securing cables and/or other equipment, cable exit windows 77, and other structures or features that are typically retained in the junction box. A separate cover (not shown) may be removably connected to the input power supply subassembly 68 through mounting holes 75, or the module may contain a door that provides access to the protective equipment and contained electronic components. Preferably, a connection portion 78 having a similar configuration as the power track housing assembly extends from the input power subassembly such that the power track housing assembly can be connected to the terminal device by a suitable engagement assembly, such as the engagement assembly 11 shown in fig. 2, 2A and 2B.

Finally, FIG. 7 illustrates one possible example of the application of CBusPDS to a typical data center with floor mounted equipment, in accordance with the preferred embodiment. As shown in FIG. 7, a power track housing assembly portion 98 of CBusPDS, which includes joints 93, is mounted to the ceiling via the rods 83, while another power track housing assembly portion 91 is mounted to a wall, although any wall, ceiling, and/or floor mounting combination may be used. The two rail housing power terminal assemblies engage into a "90 degree" section 90. Alternatively, these components may be joined together by connecting two track housing power terminal components with conductors to the two housing components.

As in the typical example, the load devices are unevenly spaced on the ground. The mounting location of the load device is then unimportant due to the nature that the plug-in power tap assembly can be mounted anywhere along the length of the power track housing assembly.

Fig. 7 illustrates four of the following configurations of a plug-in electrical tap assembly, which are possible in accordance with the principles of the present invention:

in a first configuration, the load cabinet 86 is powered by using a plurality of power cable transmission lines 84 that are plugged into the sockets of corresponding plug-in power taps 101, such as the sockets shown in fig. 4G to 4I, corresponding to fig. 1 and 1A, that have been plugged into the power tap housing assembly 98.

In the second configuration, the load cabinet 87 is powered by using a power transmission line fixedly mounted in the plug-in power tap assembly 102, a signal cable transmission line is used to perform communications or other small signal functions, the power and signal transmission lines being referenced 83 in fig. 7.

In a third configuration, the load cabinet 88 is powered by using a plurality of power transmission lines 85 supplying three-phase power and is fixedly mounted in the plug-in power tap assembly 3.

Finally, in the fourth illustrated configuration, the load cabinet 89 is supplied with dc power by using a two-conductor power transmission line cable 99 fixedly mounted in the plug-in power tap assembly 80, the dc power being generated by a rectifier mounted on an electronics subassembly in the plug-in power tap assembly, and a communication link 94, such as by IR communication, is provided between the plug-in power tap assembly and the load cabinet.

In all of the illustrated configurations, the plug-in power tap assembly may have a local display mounted on the respective electronic subassembly, which may include overcurrent protection and power parameter monitoring equipment.

CBusPDS in this application receives power from a floor mounted cabinet 96 through, for example, a conductive tube 103 and a rail housing power terminal assembly 97. The track housing power terminal assembly, which may include local displays of overcurrent protection devices and/or power supply parameters and all CBusPDS data, may transmit the data to the cabinet 96 via the RF link 82. In addition, a wall-mounted display may be included to display all network data.

Although the preferred embodiments of the present invention and variations thereof have been described in detail, numerous variations and modifications of the preferred embodiments can be effected without departing from the spirit of the invention. Accordingly, the invention is not limited by the foregoing description or drawings, but instead the scope of the invention should be determined solely by the appended claims.

Claims (20)

1. A power distribution system, comprising:

a power track housing assembly comprising:

a housing;

a plurality of conductors extending from a first end of the housing to a second end of the housing;

an opening at a bottom of the chassis assembly and extending continuously from a first end of the chassis to a second end of the chassis, the opening configured to receive a plug-in power tap anywhere along a length of the chassis assembly; and

additional end openings at the first and second ends of the chassis, the additional end openings configured to receive engagement assemblies for connecting a plurality of the chassis assemblies together;

a plug-in power tap, a portion of the plug-in power tap configured to be inserted into the power track housing assembly through the bottom opening, the plug-in power tap comprising:

a contact extension device; and

a plurality of elastic spring members, each of which is provided with a spring element,

wherein, upon insertion of said plug-in power tap into said housing, said contact extension device is positioned to engage and press at least one of said resilient spring members against each of said conductors to thereby establish electrical power connection between said resilient spring members and said conductors, said plug-in power tap further comprising at least one socket connected to at least one of said resilient spring members for supplying power to said device when said cam member is rotated to engage said resilient spring members and said device is connected to said socket.

2. The power distribution system of claim 1,

wherein the contact expansion apparatus comprises a cam mounted on a shaft, the cam being arranged to rotate upon insertion of the plug-in power tap into the power track housing assembly,

wherein resilient spring members are mounted on opposite sides of the cam such that rotation of the cam causes the resilient spring members on each side of the cam to engage one of the respective conductors,

wherein a plurality of said cams are mounted on said camshaft, one for each pair of resilient spring members and conductors,

wherein the number of conductors is four.

3. The power distribution system of claim 1, further comprising

An engagement assembly configured to be received in one of the end openings of the power track housing assembly to extend a length of the housing assembly by connecting the housing assembly with another of the power track housing assemblies, the engagement assembly including a plurality of conductors configured to engage the resilient spring member of the housing assembly,

wherein the splice assembly includes a contact spreading device configured to engage and push the resilient spring member after the splice assembly is inserted into the one of the end openings of the power track housing assembly such that the resilient spring member engages the plurality of conductors of the power track housing assembly,

wherein the contact expanding means is a cam means,

wherein the junction assembly further comprises at least one of a voltage and temperature monitoring component,

wherein the plug-in power tap comprises a circuit breaker or a fuse,

wherein the plug-in power tap comprises at least one of a DC power source, a transformer, a voltage inverter/converter, a transfer switch, and a variable frequency/frequency converter,

wherein the plug-in power tap includes a monitoring circuit including at least one of a power monitoring circuit and a temperature monitoring circuit.

4. The power distribution system of claim 1, further comprising

A cable carried by the power track housing assembly for transmitting electrical signals from the monitoring circuitry to a remote monitoring or display device,

wherein the cable is a fiber optic cable,

wherein at least one of the plug-in power tap and an engagement assembly for the power track housing assembly to another power track housing assembly includes a transceiver for communicating with a remote monitoring or display device,

wherein the transceiver is connected to an antenna extending from the plug-in power tap, the antenna being plugged into the power track housing assembly when the portion of the plug-in power tap is plugged into the power track housing assembly,

wherein the plug-in power tap further comprises a bracket for securing the plug-in power tap to the power track housing assembly upon insertion of the portion of the plug-in power tap into the power track housing assembly,

wherein the plug-in power tap further comprises a slidable locking member arranged to be movable to a locking position preventing the contact extending apparatus from moving to engage or disengage the at least one resilient spring member and to an unlocking position in which the cam is free to be manually moved to engage or disengage the at least one resilient spring member,

wherein the plug-in power tap comprises: a tower subassembly including a portion configured to be inserted into the power track chassis assembly, the portion including the contact extension apparatus and resilient spring member, a dispensing subassembly including the at least one receptacle, and an electronics subassembly including a monitoring circuit,

wherein the plug-in power tap includes at least one grounding feature extending from a top end of the plug-in power tap, and the grounding feature is configured to contact a grounded member of the power track housing assembly when the portion of the plug-in power tap is inserted into the power track housing assembly.

5. The power distribution system of claim 1, further comprising

An internal mechanical support device configured to be inserted into the power track housing assembly and to engage the conductors to prevent deformation of the conductors in the event of a short circuit,

wherein the chassis of the power track chassis assembly is made of an EMI protective material,

wherein the housing of the power track housing assembly is made of an electrically conductive material,

wherein the chassis of the power track chassis assembly includes an external slot for receiving an EMI shield,

wherein the housing of the power track housing assembly includes an internal slot for receiving an insulator surrounding the conductor.

6. The power distribution system of claim 1, further comprising

A terminal subassembly including a power terminal junction box for connecting the conductors to an input power source, the terminal subassembly configured to be connected to the power track housing assembly by having one end of an engagement assembly fit into one of the end openings of the power track housing assembly and a second end fit into a corresponding opening of the terminal subassembly,

wherein the terminal sub-assembly further comprises an electronic portion for a housing monitoring circuit, the housing monitoring circuit being connected to the monitoring circuit in the plug-in power tap by a cable or a wireless connection, and the housing monitoring circuit being further connected to a remote monitor or display by a cable, a wireless connection or a network,

wherein the power track housing assembly is linear,

wherein the power track housing assembly is "T" shaped,

wherein the power track housing assembly is "X" shaped.

7. A power track enclosure assembly for an electrical distribution system, comprising:

a housing;

a plurality of conductors extending from a first end of the housing to a second end of the housing;

an opening at a bottom of the chassis assembly and extending continuously from a first end of the chassis to a second end of the chassis, the opening configured to receive a plug-in power tap anywhere along a length of the chassis assembly; and

additional end openings at the first and second ends of the chassis, the additional end openings configured to receive engagement assemblies for connecting a plurality of the chassis assemblies together;

wherein the power track housing assembly is adapted to receive a portion of a plug-in power tap through the bottom opening, the plug-in power tap including a contact spreading device and a plurality of resilient spring members, the contact spreading device being positioned to engage and press at least one of the resilient spring members against a respective one of the conductors upon insertion of the plug-in power tap into the housing, thereby establishing an electrical connection between the resilient spring member and the conductor, and

wherein the power track housing assembly further comprises a compartment for carrying at least one data bus establishing communication between the monitoring circuitry in the plug-in power tap and a remote monitor or display.

8. The power track housing assembly of claim 7,

wherein the cable is a fiber optic cable,

wherein the chassis of the power track chassis assembly is made of an EMI protective material,

wherein the housing of the power track housing assembly is made of an electrically conductive material,

wherein the chassis of the power track chassis assembly includes an external slot for receiving an EMI shield,

wherein the housing of the power track housing assembly includes an internal slot for receiving an insulator surrounding the conductor,

wherein the housing of the power track housing assembly is adapted to receive an antenna extending from the plug-in power tap, the antenna being connected with monitoring circuitry in the plug-in power tap and being protected by the housing upon partial insertion of the plug-in power tap into the housing, wherein the power track housing assembly is "L" shaped.

9. The power track housing assembly of claim 7, wherein the power track housing assembly is "X" shaped.

10. A plug-in power tap for a power distribution system, the power distribution system comprising a power track housing assembly having a housing; a plurality of conductors extending from a first end of the housing to a second end of the housing; an opening at a bottom of the case assembly and extending continuously from a first end of the case to a second end of the case, the opening configured to receive the plug-in power tap anywhere along a length of the case assembly, the plug-in power tap comprising:

a contact extension device; and

a plurality of elastic spring members, each of which is provided with a spring element,

wherein, upon insertion of said plug-in power tap into said housing, said contact extension device is positioned to engage and press at least one of said resilient spring members against each of said conductors to thereby establish electrical power connection between said resilient spring members and said conductors, said plug-in power tap further comprising at least one socket connected to at least one of said resilient spring members for supplying power to said device when said cam member is rotated to engage said resilient spring members and said device is connected to said socket.

11. The plug-in power tap of claim 10, wherein the contact extending device is a cam and the cam is mounted on a cam shaft, the cam shaft being arranged to rotate upon insertion of the plug-in power tap into the power track housing assembly.

12. The plug-in power tap of claim 10, wherein the plug-in power tap comprises a circuit breaker.

13. The plug-in power tap of claim 10, wherein the plug-in power tap includes a monitoring circuit, the monitoring circuit including at least one of a power monitoring circuit and a temperature monitoring circuit.

14. The plug-in power tap of claim 10, wherein the plug-in power tap comprises a transceiver for communicating with a remote monitoring or display device.

15. The plug-in power tap of claim 14, wherein the transceiver is connected to an antenna extending from the plug-in power tap, the antenna being plugged into the power track housing assembly when the portion of the plug-in power tap is plugged into the power track housing assembly.

16. The plug-in power tap of claim 10, wherein the plug-in power tap further comprises a bracket for securing the plug-in power tap to the power track housing assembly upon insertion of the portion of the plug-in power tap into the power track housing assembly.

17. A plug-in power tap as claimed in claim 10, wherein the plug-in power tap further comprises a slidable locking member arranged to be movable to a locking position preventing the contact extending apparatus from moving to engage or disengage the at least one resilient spring member and to an unlocking position in which the cam is free to be manually moved to engage or disengage the at least one resilient spring member.

18. The plug-in power tap of claim 10, wherein the plug-in power tap comprises: a tower subassembly including a portion configured to be inserted into the power track chassis assembly, the portion including the cam and resilient spring member, a dispensing subassembly including the at least one receptacle, and an electronics subassembly including a monitoring circuit.

19. The plug-in power tap of claim 10, wherein the plug-in power tap includes at least one grounding feature extending from a top end of the plug-in power tap, and the grounding feature is configured to contact a grounded member of the power track housing assembly when the portion of the plug-in power tap is inserted into the power track housing assembly.

20. A junction assembly for an electrical distribution system, the electrical distribution system comprising a power track enclosure assembly having an enclosure; a plurality of conductors extending from a first end of the housing to a second end of the housing; an opening at a bottom of the housing assembly and extending continuously from a first end of the housing to a second end of the housing, the opening configured to receive the plug-in power tap anywhere along a length of the housing assembly; and an open-ended end for receiving the engagement assembly, the engagement assembly comprising:

a plurality of resilient spring members;

a support device for supporting the plurality of resilient spring members; and

a contact spreading device configured to engage and push the resilient spring member after the splice assembly is inserted into the one of the end openings of the power track housing assembly such that the resilient spring member engages the plurality of conductors of the power track housing assembly,

wherein the engagement assembly is configured to be received in one of the end openings of the power track housing assembly to extend the length of the housing assembly by connecting the housing assembly with the other power track housing assembly.