Modular data center support rack system and installation method

A modular data center support rack system and installation method whereby system includes a plurality of modular support racks formed from bracket-like rack members that support data center electrical power components, and a transportable fixture that detachably holds the rack members into an assembly position. The transportable fixture remains detachably connected to the assembled modular support rack during the transportation thereof to an installation location to reinforce the modular support rack. Each modular support rack includes an arrangement of data center electrical power supply components that are registrable with and connectable the data center electrical power supply components on another of the modular support racks. In the installation method, the modular support racks are serially interconnected into an appropriate electrical supply configuration for a row of servers located beneath the row of modular support racks.

FIELD

This invention generally relates to overhead-mounted data center rack systems for supporting the cables, bus bars, and switches necessary to power the servers and other digital equipment in a data center. It is specifically directed toward a support rack system formed from individual modular racks assembled onto a transportable fixtures in a factory that reinforce the modular racks during transportation to a data center.

BACKGROUND

Systems for supporting the electrical components necessary to power the large amounts of computer equipment in data centers are known in the prior art. Such prior art systems typically include rows of support brackets mounted either on the ceilings or support walls of the data center above the rows of server racks and other data-processing equipment. The support brackets may have multiple pairs of horizontally-oriented support arms that support bus bars, manual switch boxes, and cable trays holding multiple electrical power and communication cables. Such electrical power support systems are usually installed by first mounting the support brackets on the ceilings or support walls over the server racks and other data-processing equipment. Next, the brackets are unitized into long, shelf-like structures by the installation of cable trays and support rails between the support arms of adjacent brackets. Bus bars are connected between adjacent brackets, and switch boxes and other components are then lifted up and secured across the unitized support brackets. Finally, power and communication cables are lifted up, dropped into the cable trays, pulled along the cable trays to properly position them, and connected to the server racks and other data-processing equipment located underneath.

SUMMARY

While such prior art electrical power supply support systems fulfill their intended purpose, they are time-consuming and difficult to construct, for two reasons. First, in order to clear the top ends of the stacks of computers and other equipment that form the servers, the support brackets, support rails, cable trays, bus bars, switch boxes and cables must all be lifted and installed between about 12 and 24 feet above floor level. Such construction necessitates the use of scaffolds and ladders to provide access for construction workers to assemble the support brackets into unitized, shelf-like structures. Additionally, lifting equipment such as forklifts and pulleys must be used to lift the relatively heavy components of the system in order to position them for installation. For example, the combined weight of the data communication cables and copper-laden power cables alone can amount to as much as 134 lbs. per linear foot, even not considering the additional weight of the bus bars and switch boxes. This is not only work-intensive, but dangerous as well in view of the hazards that any dropped components would present to construction workers below. Second, the limited space available for constructing such prior art support systems further adds to the time and effort necessary to install them. Much of the floor space in data center buildings is taken up by large, floor-mounted ventilator plenums that are necessary to remove the heat generated by the large number of stacked computer servers. Consequently, the aisle ways between the opposing walls of adjacent ventilator plenums that accommodate two opposing rows of servers are only about 10 feet wide. Since the support arms of the support brackets typically extend about two and a half feet from walls where the support brackets are mounted, only about 5 feet of aisle way space is available to complete a second power supply support system over a second row of servers after a first power supply support system has been installed. The relatively confined space that the construction workers have to assemble a second row power component support system makes the assembly process longer and more awkward than it otherwise would be, and increases the probability of injuries due to dropped components and falls.

Accordingly there is a need for an improved power component support system that is faster and easier to construct. Ideally, such a system would obviate the need for construction at elevated heights within narrow, space-constraining aisle ways. Also, such a system should substantially reduce the safety hazards associated with dropped components and falls.

To these ends, the data center system of the invention comprises a plurality of modular support racks that support data center electrical power components, and a transportable fixture that facilitates assembly and transportation of the completed modular support racks and that mechanically reinforces the resulting, component-laden racks during transportation and installation. Each modular support rack comprises two or more vertically-oriented rack members having two or more pairs of horizontally-oriented support arms. The rack members are detachably connected to the transportable fixture into proper alignment, and then assembled together into shelf-like structures via tying members. Next, cable trays and power components such as bus bars and switch boxes are assembled onto the rack members. All of these assembly steps are conducted remotely from the data center in a factory designed to facilitate such assembly. The resulting combination of completed modular rack and fixture then transported to and lifted into an installation position on a data center support wall as a unitized whole. During this time, the fixture advantageously reinforces the component-laden modular support rack as it experience the jostling and other temporary stresses associated with transportation and installation. The fixture further helps to prevent any accidental falling-off of power components from the modular rack. After the modular rack has been installed in the data center, the transportable fixture is removed and recycled back to the factory for use in assembling another modular support rack.

The transportable fixture may include a base, and a frame mounted on the base. The base preferably includes a portion such as a recess that receives, for example, the fork of a forklift that transports the fixture along with an assembled modular support rack. The frame mounted on the base detachably connects to the at least two rack members into a position for assembly of the modular support rack. The frame of the transportable fixture includes connecting members that are alignable with and detachably connectable to the at least two horizontally-oriented support arms of each of the rack members. These connecting members may include elongated, tubular members that are slidable over and fixable to the horizontally-oriented support arms in telescopic fashion to provide a quick and mechanically strong interconnection. These connecting members extend orthogonally from vertical support posts such that the frame of the fixture vertically interconnects the distal ends of the horizontal support arms of the rack members, which not only mechanically reinforces the arm members but also provides a barrier that prevents any of the power components from falling off of the modular rack during transportation and installation.

Each of the plurality of modular support racks includes an arrangement of data center electrical power supply components that are mechanically and electrically registrable with and connectable to another arrangement of data center electrical power supply components on another of the support racks. This allows the electrical supply components of a row of the modular support racks to be serially interconnected into an appropriate electrical supply configuration for the row of servers located beneath the row of modular support racks.

In the method of the invention, each of the modular data racks is first assembled in one of the transportable fixtures. This is accomplished by slidably connecting the horizontal supports of the rack members into the tubular connecting members of the fixture. Next, the rack members are interconnected by the horizontal tying members. Horizontal support rails for the manual switch boxes and cable support trays are next bolted or otherwise secured across the horizontal support arms of the rack members. The modular support rack is then substantially completed by the installation of a pre-selected configuration of bus bars, switch boxes, and other components on the support arms and horizontal support rails.

Next, each of the modular support racks along with its interconnected fixture is transported to an installation location, such as a support wall within a data center. The modular support racks are serially mounted about 12 feet above floor level in a pre-selected order that allows their electrical supply components to be serially interconnected into an appropriate electrical supply configuration for the row of servers to be installed beneath. All during the transportation and installation of the modular support rack, (and the accompanying jolts, jostling, and vibrations) the interconnected fixture provides mechanical reinforcement to the support arms of the rack members, which may be carrying a combined load of 1,000 lbs. in bus bars and switch boxes and conduits.

After each of the modular support racks is secured into position on the support wall of the data center, its respective fixture is disconnected, removed, and recycled for use on another modular support rack. Power and communication cables are lifted and laid into the cable trays, and the bus bars and switch boxes of adjacent modular racks are interconnected to provide an appropriate electrical supply configuration for the row of servers located beneath the row of modular support racks.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference toFIG. 1, the modular data center support rack system1generally includes multiple modular support racks3, and one or more transportable fixtures5that are used to both assemble, transport, and install the support racks3.

In this embodiment of the invention, each support rack3includes three vertically-oriented rack members9a,9b, and9c. Preferably, each rack member9a-cis formed from Unistrut® tubular steel for its relatively high strength and low weight. Each of the rack members9a-cincludes a mounting slot11along one of its sides for receiving fasteners, as will be explained in more detail hereinafter. A pair of mounting plates12and13are welded near the top and middle of each of the rack members9a-cas shown. Each of the rack members9a-cfurther includes a plurality of horizontally-extending support arms14a-e. The support arms14a-eare preferably all the same length and are parallel to one another. Like the rack members9a-cfrom which they extend, each of these support arms14a-eis formed from Unistrut® tubular steel and has a mounting slot15on its upper side for receiving fasteners. A U-shaped base connector is welded on the proximal end of each of the support arms14a-eas shown. Each support rack3further includes a pair of horizontally-oriented tying members20a,20bthat interconnect the rack members9a-c. The tying members20a,20bare bolted onto the rack members9a-cvia the mounting plates12and13present on each of the rack members.

With reference toFIG. 1andFIGS. 2B-2C, a switch box support assembly21is further provided in each support rack3. In this embodiment, the switch box support assembly21is formed from three vertical support posts22a-caffixed across the second and third support arms14b,14cof each of the vertically-oriented rack members9a-c. The upper and lower ends of each of the support posts22a-ceach include a mounting flange23(of which only the lowermost flange23is visible) which are respectively bolted onto the support arms14band14c. The switch box support assembly21further includes a horizontally-oriented support plate24welded across all three support posts22a-cvia welds25, and a horizontally-oriented support rail26formed from the same Unistrut® tubular steel material that the rack members9a-care formed from. The support rail26is affixed in place via mounting brackets27bolted onto the support arm14cof the side rack members9aand9c. The mounting brackets27each have a socket28that receives an end of the rail member26.

With reference now toFIGS. 5A and 5B, each of the support racks3preferably includes cable trays29a-cwhich are bolted or otherwise affixed across the support arms14e,14d, and14c, respectively. Finally, each of the support racks3includes electrical power components which may take the form of manual switch boxes33mounted on the switch box support assembly21, bus bars35mounted across the support arms14a and14b, and power and communication cables37(shown inFIG. 7) which are laid into the cable trays29a-cafter the support racks3have been installed on a support wall of a data center.

Turning now to the transportable fixtures5of the system, and with reference toFIG. 1andFIGS. 2B-2D, each fixture5includes a base41, and a frame50attached to and extending upwardly from the base41.

The base41of each fixture5is formed from a rectangular platform43of C-channel steel material welded together at the corners. A pair of tubular fork-receiving members45a,45bterminating in open ends46a,46bare welded across the rectangular platform43in parallel as shown. The fork-receiving members45a,45bare spaced apart the same distance as the forks of a forklift so as to slidably receive the same. The fork-receiving members45a,45bare further spaced equidistantly from a center of mass of the rectangular frame so as to balance the load exerted on the forks of a forklift. A lengthwise reinforcing member47is welded at either end to the inside ends of the platform43and serves to reinforce both the platform43and the fork-receiving members45a,45b. Finally, three cross-struts48a-care welded cross-wise on the rectangular platform43. These cross-struts48a-cfurther reinforce the platform43. Additionally, each of these cross-struts has a “U” shaped cross section complimentary in shape to the bottom-most support arms14eof each of the rack members9a-cso as to slidably receive and support the same during the assembly of the support racks3.

The frame50of each fixture5is formed from three vertical posts52a-c. Each of the posts52a-cis preferably formed from tubular steel material having a rectangular cross section. The bottom end of each of the posts52a-cis bolted or otherwise rigidly affixed to the platform43. Each of the posts52a-cincludes three horizontal connecting arms or members54a-cwhich are likewise preferably formed from a tubular steel material having a rectangular cross section. As shown inFIG. 2B, the proximal end57of each of the connecting members54a-cis welded to its respective post52a-c. As indicated inFIGS. 2A, 2B, and 2C, the open, distal end59of each of the connecting members54a-cis capable of receiving the distal ends of the support arms14a-c. As is specifically shown inFIG. 2D, the inner perimeter60of the connecting members54a-cis complimentary in shape to the outer perimeter61of the support arms14a-csuch that the support arms14a-ccan telescopically slide into the connecting members54a-c. The combination of a clamping bolt62and T-nut64detachably fastens the support arms14a-cof a support rack3to the connecting members54a-cof its respective fixture5during the assembly and installation of the support rack3, as is explained in more detail hereinafter.

In addition to the previously-described modular support rack system1, the invention also includes an assembly and installation method for such a system. In the first step of the method, assembly of a modular support rack3is commenced by attaching three rack members9a-cto the fixture5. This is accomplished by aligning the distal ends of the top three support arms14a-cwith the open distal ends59of the connecting members54a-cof the fixture5, and the bottommost support arms14eof the rack members9a-cwith the U-shaped grooves49present in the cross-struts48a-cpresent on the base41of the fixture5. Next, the support arms14a-cand14eare slid into the connecting members54a-cand grooves49of the cross-struts48a-cin telescopic fashion into the position illustrated inFIG. 2A. The clamping bolt62of each of the connecting members54a-cis then tightened to bring the T nut into the position illustrated inFIG. 2D, thereby squeezing the top sides of the support arms14a-cinto frictional engagement with the top sides of the connecting members54a-c. It should be noted that this step not only detachably connects the rack members9a-cto the fixture5, but also properly spaces and orients the rack members9a-cso that the connecting interfaces (such as bolt holes) between the rack members9a-cand the remaining components of the support rack3are pre-aligned for easy assembly.

Next, as shown inFIG. 3, the tying members20a,20bare attached across the rack members9a-cby bolting the ends and the center of each of these components to the mounting plates12a-c. This step unitizes the rack members9a-cand defines the basic frame of the modular rack3. Next, as shown inFIG. 4, the switch box support assembly21is assembled across the unitized rack members9a-c. This is accomplished by first connecting the upper and lower mounting flanges23of the support posts22a-cto the support arms14band14c, respectively. Support plate24is then welded to the support posts22a-c, followed by the bolting of the support rail26into the position indicated inFIG. 4via the mounting brackets27as previously described. Next. As indicated inFIG. 5A, the cable shelves29a,29b, and29care bolted or otherwise affixed across the support arms14e,14d, and14c, respectively. These steps complete the frame of the modular rack3.

In the final steps of the assembly of each of the racks3, the electrical power and communication components are assembled onto the rack frame. As shown inFIG. 5A, these components include, for example, manual switch boxes33(which are installed onto the switch box support assembly21) and bus bars35, although any number of other types of electrical components are within the purview of this invention. It should be noted that the specific types of electrical components and their specific arrangement is preselected for each of the assembled modular support racks3so that when the plurality of modular support racks3are linearly arranged in a specific order, the electrical components of one modular support rack are mechanically and electrically registrable with and connectable to the data center electrical power supply components on adjacent modular support racks3.

The completion of the aforementioned assembly steps results in a combination support rack and fixture structure68in which the fixture5substantially reinforces the mechanical strength of the modular support rack3to which it is connected. This important, as the off-site assembly of the modular racks3requires that they be transported to their final destination and lifted into a specific installation location, all of which necessarily applies momentary stresses and loads onto the support arms14a-edue to the jostling and momentary shocks that inevitably accompany such movement. Additionally, the tubular fork-receiving members45a,45bof the base41of the fixture5provides a convenient and robust attachment point for the fork of a forklift, greatly facilitating the transporting, lifting, and installation of the modular data racks3onto the support wall of a data center.

FIGS. 5A-7illustrate the final steps of the method of the invention. Specifically,FIGS. 5A and 5Billustrate how a forklift70having a lifting assembly72slidably inserts the forks74a,74binto the openings46a,46bof the fork receiving members45a,45b, and lifts the completed combination support rack and fixture structure68. The forklift70then proceeds to move the combination structure68onto the bed of a transportation vehicle, such as a truck (not shown) which transports the combination structure68to a data center remotely located from the assembly site. As indicated inFIGS. 6 and 7, after the combination structure68is delivered to a data center80, the forklift70transports the combination structure68to its assigned installation location on one of the support walls82B of the data center. In this particular step, the forklift70is preferably a side loader forklift due to the space constraints imposed by the aisle ways84. As is best seen inFIG. 7, the combination structure68is then lifted into its installation location, and bolted or otherwise secured to the support wall82b. The arrangement of the electrical power components on the united structure68, and its specific location in the linear arrangement of the modular racks3, has been pre-selected so that the electrical power components on the right side87of the installed modular rack3are mechanically and electrically registrable with the electrical power components on the left side86of the combined structure68. As a result, the modular support racks3may be interconnected to form a power supply arrangement compatible with a row of servers and other data processing equipment90that will be installed beneath the linear arrangement of modular racks3.

After the combined structure68is mounted in it installation location on the support wall82b, the fixture5is detached from the installed modular rack3by loosening the clamping bolts62and slidably withdrawing the connecting members54a-cfrom the support arms14a-c. The fixture5is then recycled to assemble and install another modular support rack3.

Although the invention has been described in detail with particular reference to a preferred embodiment, it will be understood that variations and modifications can be effected within the spirit and scope of the invention. For example, the frame50of the transportable fixture5may assume a variety of alternative forms to fulfill its two-fold function of facilitating the assembly of the modular support rack3and reinforcing a completed rack3during transportation and assembly. In particular, the detachable connection between the fixture5and the modular rack3may be implemented via snap-fit, spring loaded detents, or via simple pipe-type couplings wherein an annular, rotatable threaded coupling is screwed over a threaded distal end of the horizontal support arms of the modular rack. Other modifications, variations, and additions to the invention will become apparent to persons of skill in the art, and all such modifications, variations, and additions are intended to be within the scope of this invention, which is limited only by the claims appended hereto and their various equivalents.