Abstract:
An interconnect for engaging a rectifier module with a rectifier cabinet has a first portion which includes AC output contacts, DC input contacts, a cabinet data signal connector and sidewalls which define an enclosed space of the rectifier cabinet. A second portion of the interconnect includes DC output contacts, AC input contacts, a module pin data signal connector and a housing which encloses a rectifier unit. A guide member is mounted to one of the first and second portions of the interconnect. A guide member hole is included with the other of the first and second portions of the interconnect for engaging with the guide member to align the first portion of the interconnect with the second portion of the interconnect. A pair of guide pins are mounted to one of the data signal connectors for engaging within sockets of the other of the data signals connectors for aligning the data signal connectors. One of the data signal connectors is moveably attached to a respective one of the rectifier module housing and the rectifier cabinet for moving to matingly engage with the other of the data signal connectors. Inserting the rectifier module within the rectifier cabinet engages the housing of the rectifier module with the sidewalls of cabinet, which aligns the guide member for engagement within a guide member hole to align the DC input and output connectors, the AC input and output connectors and the data signal connectors.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is related to U.S. patent application Serial No. 09/179,785, entitled, “REMOVABLE FAN FOR RACK MOUNTED RECTIFIERS” filed Oct. 27, 1998 now U.S. Pat. No. 6,075,698. 
    
    
     TECHNICAL FIELD OF THE INVENTION 
     The present invention relates in general to rack mounted rectifiers, and in particular to an interconnection system for rack mounted rectifiers. 
     BACKGROUND OF THE INVENTION 
     Prior art rack mounted rectifiers have been provided for mounting in rectifier cabinets. Such rectifiers have AC inputs and DC outputs. Rectifier cabinets have found extensive use in the rapidly expanding telecommunications industry, providing power for telephone switch gear and the like. Rectifier cabinets have been provided of modular design, in which rectifier modules were removably mounted within the cabinets. Typically, the rectifier modules may be “hot swapped;” that is, a portion of the rectifiers may be removed from the rectifier cabinets without having to shut down the entire cabinet such that power may be maintained by the equipment powered by the rectifier cabinet being serviced. 
     The mounting of rectifier modules within rectifier cabinets requires the proper alignment of various AC input and DC output contacts, and various signal connectors to enable operation of the rectifier modules. Once the modules are aligned and properly inserted into the racks of the rectifier cabinets, they are secured in place by a latch such that they cannot be removed from the cabinets while the latch is secured. Additional space is taken up by the latching mechanism and alignment members which are utilized for installing prior art rectifier modules into prior art rectifier cabinets. The industry for power equipment has generated predetermined modular unit sizes for determining the space utilized for modular rectifier components. The usage of additional space for alignment members and latching mechanisms prevents the size of rectifier cabinets from being reduced to more compact sizes. 
     SUMMARY OF THE INVENTION 
     The present invention disclosed and claimed herein comprises and interconnect for engaging a rectifier module with a rectifier cabinet. A first portion of the interconnect includes AC output contacts, DC input contacts, a cabinet data signal connector and sidewalls which define an enclosed space of the rectifier cabinet. A second portion of the interconnect includes DC output contacts, AC input contacts, a module pin data signal connector and a housing which encloses a rectifier unit. A guide member is mounted to one of the first and second portions of the interconnect. A guide pin member hole is included with the other of the first and second portions of the interconnect for engaging with the guide pin member to align the first portion of the interconnect with the second portion of the interconnect for proper mating of the input and output contacts and the data signal connectors. A pair of data signal connector guide pin members are mounted to one of the data signal connectors for engaging within guide pin sockets of the other of the data signals connectors for aligning the data signal connectors for a mating engagement therebetween. One of the data signal connectors is moveably attached to a respective one of the rectifier module housing and the rectifier cabinet for moving to matingly engage with the other of the data signal connectors, which is rigidly attached to the respective one of the module or cabinet. Inserting the rectifier module within the partially enclosed space of the rectifier cabinet engages the housing with the sidewalls of the partially enclosed spaced, which aligns the guide member for engagement within a guide member hole to align the DC input and output connectors, the AC input and output connectors, and the data signal connectors in mating engagements. 
     In another aspect of the present invention, the guide pin members are mounted to the data signal connectors which are mounted to the cabinet, and the guide pin holes are mounted to the data signal connectors which are mounted to the housings of the rectifier modules. 
     In another aspect of the present invention, one of the sidewalls of the partially enclosed spaces of the rectifier cabinet has a slot disposed in the forward portion for receiving a latch member which is movably mounted to the housing of the rectifier module. The latch member is sized such that it will fit flush with an opposite side of the sidewall having the slot that on which the respective rectifier module is disposed. The latch member is moveable for extending and retracting in lineal directions. 
     In another aspect of the present invention, the one of the sidewalls having the slot formed therein is defined by a singular sheet of metal. The forward end of the singular sheet of metal is folded over into a doubled layer at the forward portion thereof in which the slot is disposed for receiving the latch member of the rectifier module. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying Drawings in which: 
     FIG. 1 illustrates a front, perspective view of a rectifier cabinet made according to the present invention; 
     FIG. 2 illustrates a frontal, perspective view of one of the rectifier modules; 
     FIG. 3 illustrates a frontal perspective view of the fan module; 
     FIG. 4 illustrates a partial cut-away view of the fan module, showing the lower portion of the back plate; 
     FIG. 5 illustrates a frontal elevation view of a back plate and a side plate of the mounting bracket for the fan module; 
     FIG. 6 illustrates a right side elevational view of the fan module; 
     FIG. 7 illustrates a partial, side elevational view of the housing of the rectifier module; 
     FIG. 8 illustrates a partial, perspective view of the rearward end of the rectifier module; 
     FIG. 9 illustrates a frontal perspective view of a mating plate of one of the rectifier panels; 
     FIG. 10 illustrates partial, side elevational view depicting the mounting of the data signal connector to the rectifier cabinet; 
     FIG. 11 illustrates a perspective view of a panel housing of one of the rectifier panels; and 
     FIG. 12 illustrates a rear elevation view of the panel housing of the one of the rectifier panels. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to FIG. 1, there is illustrated a front, elevational view of a rectifier cabinet  12 . The rectifier cabinet  12  includes a plurality of rectifier panels  14  and rectifier panels  16 , within which rectifier modules  18  are mounted. Preferably, each of the rectifier panels  14  will receive four of the rectifier modules  18 , and each of the rectifier panels  16  will receive five of the rectifier modules  18 . Cabinet gauges  20  are provided for monitoring the voltage and the current output of the rectifier cabinet  12 . A plurality of power circuit breakers  22  are provided at the top of the rectifier cabinet  12 . 
     Referring now to FIG. 2, there is illustrated a frontal, perspective view of one of the rectifier modules  18 . The rectifier module  18  includes a housing  24 , which encloses a rectifier unit  25 . The housing  24  has a front plate  26  which is preferably perforated by a plurality of honeycomb-shaped perforations  28  that provide air flow ports for cooling the interior of the module  18 . A plurality of LEDs are disposed on the left side of the front plate  26  of the rectifier module  18  and provide output signal indicators  30 . A main power switch  32  is disposed on the lower left of the front plate  26 . A handle  33  is provided by a round rod which is U-shaped and mounted to extend forward of the front plate  26 . A latch  36  includes a knob  38  and a latch plate  40 , which provides a latch member. The knob  38  is fastened to the latch plate  40  by a threaded bolt which slides within the vertical slot  42 . The knob  38  is rotated clockwise to grip the front plate  26  between the latch plate  40  and the knob  38 . The knob  38  is rotated counterclockwise such that the knob  38  and latch plate  40  will slide within the vertical slot  42  of the front plate  26 . The knob  38  and the latch plate  40  may be pulled upwards until the bottom of the latch plate  40  is flush with the bottom of the front plate  26  and the bottom of the housing  24 , which is herein defined as the unlatched position for the latch  36 . 
     The housing  24  of the rectifier module  18  has an opening  44 . Two notches  46  (one shown) are provided at the top and bottom, respectively, of the opening  44 . A strap  48  is defined by recesses formed into the side surface of the module  18 , rearward of the front plate  26  of the housing  24 . Notches  50  and  52  are defined on the rearward side of the opening  44  by the recesses formed into the surface of the module  18 . The opening  44  is sized for receiving a removable fan module  54 . The fan module  54  is removably mounted to the rectifier module  18  such that a failed fan module  54  may be replaced without requiring replacement of the entire rectifier module  18 . Four pairs of indentations  55  (two shown) are formed into the top and bottom outer surfaces of the housing  24  to provide inwardly extending protuberances which provide guides for receiving a portion of the fan module  54 . 
     Referring now to FIG. 3, there is illustrated a frontal, perspective view of the fan module  54 . The fan module  54  includes a side plate  56 , which is received between the pairs of indentations  55  to align the fan module  54  during insertion into the socket  44 . The side plate  56  includes tab  58 , tab  60  and tab  62 . The fan module  54  includes the holes  64  which are formed into the side plate  56 . Two fan units  66  and  68  are mounted to the fan module  54 , each including fan blades and an electric fan motor. A sidewall  70  extends around three sides of the fans  66  and  68 . A back plate  72  is provided with two holes which are preferably sized full bore with respect to the fans  66  and  68 . 
     Referring now to FIG. 4, there is illustrated a partial cut-away view of the fan module  54 , showing the lower portion of the back plate  72  in more detail. The back plate  72  has an electrical connector  74  mounted thereto. The connector  74  has power contacts  76 . A guide pin  78  is integrally formed as a singular member with the back plate  72 , and for mating with a guide hole  80  mounted to the housing  24  of the rectifier module  18 . An electrical connector  82  is also mounted within the housing  24  of the rectifier module  18 , and has contacts for engaging the contacts  76  of the connector  74  to electrically connect the fan module  54  to the rectifier module  18 . 
     Referring now to FIG. 5, there is illustrated a frontal elevation view of a back plate  72  and a side plate  56 . The guide pin  78  is shown as extending from the side of the back plate  78 , being formed from an edge of the back plate  72 . Preferably, the guide pin  78  and the back plate  72  are machined from a single, flat sheet of aluminum. Two apertures  86  are cut into the back plate  72  for aligning and registering with the fans  66  and  68  (shown in FIG.  3 ). 
     Referring now to FIG. 6, there is illustrated a side elevational view of the fan module  54 . The tabs  58  and  60  are shown having two captured screws  84 . The tab  64  is bent over a right angle for engaging within the strap  48  of the front plate  26  (shown in FIG.  2 ). The tabs  58  and  60  will fit within the notches  50  and  52  formed into the housing  24 , with the outward sides of the tabs  58 ,  60  and the face plate  56  fitting flush with the side of housing  24 . 
     Referring now to FIG. 7, there is illustrated a partial side elevational view of the housing  24  of the rectifier module  18 . The notches  46  are depicted on the top and bottom of the opening  44 . The opening  44  provides a socket for receiving the fan module  54 . The strap  48  is shown for receiving the tab  62  of the fan module  54 . Also depicted is the connector  82  having the guide hole  40  for receiving the guide pin  78  of the back plate  72 , which provides a mounting bracket of the fan module  54 . The protuberances provided by the indents  55  provide pairs of guide tabs for receiving the edges of the top and bottom of the back plate  72 , for aligning the connector  74  and the guide pin  78  for being received in respective ones of the connector  82  and the guide hole  80 . 
     Referring now to FIG. 8, there is illustrated a partial perspective view of the rearward end of the rectifier module  18 . The rectifier module  18  includes a back plate  102  having a plurality of vent holes  104  formed therethrough. Mounting screws  106  are provided for mounting the back plate  102  to the housing  24 . An input power connector  108 , having AC contacts  110 , is mounted to the rectifier module  18  for connecting AC power to the rectifier module  18 . A data signal connector  112  and output power DC contacts  114  and  116  are also mounted to the rectifier module  18 . The data signal connector  112  is preferably an RS  232  connector. The output power DC contacts  114  and  116  are preferably provided by standard spade-type contacts for mating with clip-type contacts which are mounted to bus bars. A module guide member hole  118  is formed into the back plate  102 . Data signal connector guide pin sockets  120  are formed on each end of the data signal connector  112 . Preferably, the input power connector  108 , the signal connector  112  and the output power DC contacts  114  and  116  are rigidly mounted to the back plate  102  and the housing  24  of the rectifier module  18 , such that they will not move for registering with mating connectors of one of the rectifier panels  16  and  18 . 
     Referring now to FIG. 9, there is illustrated a partial perspective view of a mating plate  122  of one of the rectifier panels  16 . The mating plate  122  is provided for mating with components of the back plate  102  of the rectifier module  18 . The mating plate  122  includes a plurality of vents holes  124 . A power connector  128  is mounted to the mating plate  122  and has a plurality of AC contacts  130  for mating with the AC contacts  110  of the input power connector  108  of the rectifier module  18 . A data signal connector  132  is mounted to the mating plate  122  for mating with the signal connector  112 . A plurality of power DC contacts  134  and  136  are preferably provided by clip-type contacts which will engage the output power DC contacts  114  and  116  of the module  18 . A guide member  138  extends in a horizontal direction from the mating plate  122  for engaging within the module guide member hole  118 . The guide member  138  is provided by a tapered guide pin. An alternate guide member mounting hole  140  is provided such that the guide member  138  may be mounted therein when the mating plate  122  is connected by power contacts  134  and  136  to a bus of a different output voltage than that which the mating plate  122 , as shown, is configured for mating with. The data signal connector  132  has two spaced apart guide pins  142  located on opposite sides of the data signal connector  132 . The connector guide pins  142  are tapered guide pins which extend horizontally from the data signal connector  132  for mating with the guide pin sockets  120  of the data signal connector  112  of the rectifier module  18 . 
     The gather ability of the mating components extending from the back plate  102  of the rectifier module  12  and the mating plate  122  of the rectifier panel  16  is provided such that a slight misalignment will not interfere with respective ones of the connectors and contacts lining up during installation. The sidewalls of the housing  24  align the guide member  138  of the mating plate  122  for fitting within the guide member hole  118  of the module  18  to provide a gross alignment for aligning the DC spade contacts  114  and  116  with the DC clip contacts  134  and  136 . A fine alignment for aligning the data signal connector  112  with the data signal connector  132  is provided by the connector guide pins  142  fitting within the signal connector guide pin sockets  120 . The data signal connector  132  is mounted to the mating plate  122  such that it is movable to float slightly to align with the data signal connector  112  of the module  18  according to registration of the connector guide pins  142  within the signal connector guide pin holes  120 . The guide pins  142  mount the data signal connector  132  to a plate  143 , which connects to the mounting plate  122  such that plate  143  is movable over a limited range of motion relative to the mounting plate  122 . The power connector  128  is moveable for a limited range of motion for aligning the AC contacts  130  with the AC contacts  110  of the input power connector  108  for supplying AC power to the rectifier module  18 . 
     Referring now to FIG. 10, there is illustrated a partial, sectional side elevational view of the plate  122  of the rectifier panel  144 , which depict s the mounting of the data signal connector  132  thereto. The guide pins  142  are rigidly mounted to the connector  132 . The connector  132  is rigidly mounted to a plate  143 . The plate  143  is mounted to the mating plate  122  of the panel housing  144  by fasteners  145 . The fasteners  154  allow the mounting plate  143  to move relative to the mating plate  122  such that there is a slight amount of movement to allow play for the data signal connector  132  to mate with the data signal connector  112  of the rectifier module  18 . The fasteners  125  may slip relative to the mating plate  122  in the mounting plate  143  for a limited distance. 
     Referring now to FIG. 11, there is illustrated a perspective view of a panel housing  144  of one of the rectifier panels  16 . The panel housing  144  includes five partially enclosed spaces which define five rectifier module bays  146  for receiving respective ones of the rectifier modules  18 . The forward ends of the bays  146  are open. The rectifier module bays  146  are separated by partition plates  148  which mounted directly between a bottom plate  150  and a top plate  152  of the panel housing  144 . Preferably, the partition plates  148  are provided by singular sheets of metal. Each of the rectifier bays  146  includes a latch slot  154  which extends through the bottom plate  150  for receiving a latch plate  140  (shown in FIG.  1 ). The forward end of the bottom plate  150  is folded-over, such that it has a double-walled thickness at the latch slot  154 . The bottom of the latch plate  140  (shown in FIG. 1) will fit flush with the lower-most side of the bottom plate  150  to latch one of the modules  18  (shown in FIG. 1) into a respective one to the rectifier module bays  146 . The housing  24  will fit within one of the rectifier module bays  146  with a slight clearance. Each of the rectifier modules bays  146  has one of the mating plates  122  disposed for matingly engaging with a back plate  102  of one of the rectifier modules  18 . The panel housing  144  further includes a mounting bracket  156  for mounting the panel housing  144  within the rectifier cabinet  12 . A plurality of cable ports are provided through a rearward flange of the panel housing  144 . 
     Referring now to FIG. 12, there is illustrated a rear elevation view of the panel housing  144  of the one of the rectifier panels  16 . The panel housing  144  includes an open, low voltage, rectified output compartment  162  and an enclosed AC power compartment  164 . A barrier  166  and a barrier  168  extend on the sides of the low voltage compartment  162 . A cover plate  170  is provided to cover the AC power compartment  164 . The cover plate  170  fits flush with a back plate  172  of the panel housing  144 . A mounting plate  174 , which defines each of the mating plates  122  (shown in FIG.  9 ), extends beneath the AC power compartment  164 . An AC vertical mounting plate  176  extends parallel to the mounting plate  174 , and spaced apart therefrom such that bus bars  180  and  182  may be accessed with sufficient clearance for mounting the clip type DC contacts  134  and  136  thereto (shown in FIG.  9 ). A plurality of cables pass through the ports  158  and mount to intermediate portions of the buses  180  and  182  by being bolted thereto. The cables have connectors  188  for fastening the cables  186  to the respective one of the buses  180  and  182  with bolts. 
     A partition  190  extends between the buses  180  and  182  at an angle to the horizontal. The partition extends outward for several inches, such that a screw driver or other tool being used to connect components to the buses  180  and  182 , and various other components of the panel  16 , cannot bridge across and short the two buses  180  and  182 . The partition  190  is canted to extend at an angle to the horizontal such that there will be clearance for passing cabling connectors  188  through the each of ports  158 , and to allow the cabling connectors  188  to be connected to the upper bus  180 , adjacent to the ports  158 . The cabling connectors  188  require sufficient clearance for passing through the ports  158  on the bottom of the partition  190 , and also require sufficient clearance for being secured above the partition to the bus  180 . It should be noted that mounting the connectors  188  to intermediate positions of respective ones of the buses  180  and  182  provides that bus bars of a smaller size current capacity rating than that required for carrying the full current load of the panel  16  may be used, since the current flows to the center and not to one side of the bus bars  180  and  182 . Thus, bus bars of a lower rated capacity and smaller physical size may be utilized to provide units which are of compact size. 
     In operation, one of the modules  18  may be removed from the cabinet  12  when a failure occurs. The switch  32  on the face plate is turned off. The latch knob  38  is rotated counterclockwise to release the knob  38  and the latch plate  40  from gripping the front plate  26  of the housing  24  therebetween. The latch plate  40  and the knob  38  are moved upwards such that the latch plate  40  will be cleared from the slot  154  and the module  18  may then be slid out of the forward end of one of the rectifier module bays  146  of one of the panel housings  144 . If only the fan module  18  is to be replaced, the module  18  need only be moved forward a few inches until the tabs  58  and  60  clear the partition plates  148 , such that the fasteners  84  may be released from engaging the housing  24  of the rectifier  18 . The handle  33  may be gripped to pull the module  18  out of the forward end of one of the rectifier module bays  146 . Moving the module  18  a few inches forward within the rectifier module bay  146  will electrically disconnect the module  18  from the panel housing  144 , removing the connector  108  from the connector  128 , removing the signal connector  112  from the signal connector  132 , and removing the power output contacts  114  and  116  from respective ones of the contacts  134  and  136 , which are connected to respective ones of the buses  184  and  186 . Power will then be removed from the selected module  18 . 
     If failure of the rectifier module  18  is due to a failure of the fan module  54 , the fan module  54  may be replaced while the rectifier module  18  is only partially removed from the cabinet  12 . The captive screws  84  are first released from securing the tabs  58  and  60  to the housing  24 , then the fan module  54  may be slid out of the side of the housing  24  and removed form the rectifier module  18 . Removal of the fan module from the rectifier module  18  disconnects the connector  74  from the connector  82 , removing power from the fan and preferably electrically disabling the rectifier module  24  so that it cannot be inserted into the panel housing  144  and be powered up without the fan module  54  being installed. A new module  54  is installed in to the blind hole  44  of the housing  24  of the rectifier module  18 . The fan module  54  is pushed inward with the upward and lower edges of the back plate  72  fitting between the four pairs of protuberances provided by the indentations  55 , until the guide pin  78  mates with a guide pin hole  82  of the rectifier module  18 . Then, the connector contacts  76  of the connector  74  are aligned for engaging with the contacts of the connector  82 . The connector  74  of the module  54  is mated with the connector  82  of the rectifier module  18 . The captive screws are then fastened to the housing  24 . The rectifier module  18  is not enabled and cannot be inserted into one of the bays  146  of the panel housing  144  until the fan module  54  is fully inserted into the opening  44  of the housing  24 . The captive screws  184  need to be fully engaged into the housing  144  with the rectifier module  18  such that they will clear the partition plates  148  and the rectifier module  18  may fit within one of the rectifier module bays  146 . 
     During insertion of the rectifier module  18  into the rectifier module bay  146 , the sidewalls of the housing  24  fit closely to respective ones of the partition plates  148 , the top plate  152  and the bottom plate  150  of the panel  144 , such that the guide pin member  148  fits within guide pin member hole  118 . The contacts  114  and  116  will then engage within the clip contacts  134  and  136  to provide further alignment, such that the guide pins  142  of the connector  132  register with and fit within the guide pin holes  120  of the connector  112 . The connector  132  will have a limited amount of play for aligning with the signal connector  112  which is rigidly secured to the back plate  102  of the rectifier module  18 . Then, the AC power connector  128  will have a limited amount of movement for aligning with the connector  108  of the module  18  to connect power to the module  18  after the signal connector  112  is connected to the signal connector  132 , and the output contacts  114  and  116  are connected to the contacts  134  and  136  of the panel housing  134 . These connections will automatically align such that the connectors  108  and  112 , and the contacts  114  and  116 , will automatically register and mate with respective ones of the connectors  128 ,  132  and the output contacts  134  and  136 . The contacts of the module  18  are self aligning with the components of the panel housing  144  of the rectifier module bay  146 . The components mounted to the back plate  102  are then matingly engaged with the components mounted to the back plate  122 , such that the rectifier module  18  may be operated. The switch  32  on the face plate of the module  18  is then turned back on. 
     The disclosed embodiment provides several advantages over prior rectifier cabinets. Rectifier modules are provided which are self aligning such that they will blind mate with the rectifier panels during installation into the rectifier cabinets. The sidewalls of the housing of the rectifier modules are sized such that they are close fitting with the walls of the bays of the rectifier panels to align a guide pin member for insertion into a guide pin member hole. This aligns the DC input and output contacts, which aligns the AC input and output contacts, and the data signal connector guide pins for insertion into guide pin sockets which aligns the data signal connectors. A flush type latch is provided which does not occupy excess space, such that a higher value of rectified output wattage per unit space is obtained to provide compactness. Rectifier modules are provided with replaceable fan units. The replaceable fan units are mounted to fan module which may be removed after the rectifier modules are moved but a few inches outward from their positions within the cabinets. Moving the rectifier modules outward a few inches to allow removal of the fan modules from the rectifier panels serves to disconnect power from the rectifier modules prior to access for removal of the fan modules such that the rectifier modules cannot be powered up and subsequently overheated. Removal of the fan modules from the rectifier modules disables the rectifiers modules from being powered up. The rectifier modules may be hot swapped and the fans replaced while the remainder of the rectifier modules remain in operation to provide rectified power output from the power rectifier cabinet. 
     Although the preferred embodiment has been described in detail, it should be understood that various changes, substitutions and alterations can be made therein without departing from the spirit and scope of the invention as defined by the appended claims.