Rack power distribution via modular, expandable bus bar for modular and scalable/expandable information handling system

A rack-based information handling system (IHS) includes a rack having a modular structure that supports insertion from a front of the rack of different numbers and sizes of information technology (IT) gear to create one or more IT nodes. Power bay chassis is received in the rack with a power distribution unit directed towards a rear of the rack. A modular busbar assembly is attached to the rear of the rack. A first vertical busbar segment is in direct electrical connection with the power distribution unit and spans one or more nodes to provide hot pluggable electrical power to an aft-directed connection of an IT node inserted into the rack. A second busbar segment can be attached to the first vertical busbar to electrically communicate with the power distribution unit and span an additional node adjacent to the one or more nodes to provide electrical power to the adjacent node.

BACKGROUND

1. Technical Field

The present disclosure generally relates to an information handling system and in particular to a modular busbar for a modular, scalable, and expandable rack-based information handling system and design.

2. Description of the Related Art

Large scale information handling systems, as utilized within data centers, are often designed in a rack configuration, having one or more servers and/or banks of storage physically located within a single rack chassis. The number of servers and thus the computing power that can be placed in these rack chassis can vary. However, each of the individual units that are inserted into the rack require a supply of power, whether AC or DC supply. In conventional rack systems, each unit is provided power via a separate power cable that is run at either the back or the front of the rack into the power receptacle of the unit being powered. This conventional methodology of supplying power results in a large number of power cables and does not accommodate scalability within a modular design of a rack-based IHS.

BRIEF SUMMARY

Disclosed are a rack-based information handling system (IHS) and a method for providing modularly expandable power supply to a modular, scalable and expandable, rack-based IHS. The racked-based IHS includes a rack having a modular structure that supports insertion from a front of the rack chassis of different numbers and sizes of information technology (IT) gear to create one or more IT nodes. A power bay chassis that is received in the rack has a power distribution unit directed toward a rear of the rack. A modular busbar assembly is attached to the rear of the rack. The modular busbar assembly includes a first vertical busbar segment in direct electrical connection with the power distribution unit and spans one or more nodes to provide hot pluggable electrical power to an aft-directed connection of an IT node inserted into the rack. In one embodiment, the modular busbar assembly can include at least one second busbar segment attached to the first vertical busbar to electrically connect with the power distribution unit. The at least one second busbar segment spans vertically across a rear sectional of one or more additional nodes that are adjacent to the one or more nodes, and the at least one second busbar segment provides electrical power to these additional nodes.

According to at least one aspect of the present disclosure, a method is provided for assembling a rack-based IHS. The method includes assembling a rack having a modular structure that supports insertion from a front of the rack of different numbers and sizes of IT gear to create one or more IT nodes. The method includes inserting a power bay chassis in the rack to present a power distribution unit directed toward a rear of the rack. The method includes attaching a modular busbar assembly to the rear of the rack by: attaching a first vertical busbar segment in direct electrical connection with the power distribution unit to span one or more nodes for providing hot pluggable electrical power to an aft-directed connection of an IT node inserted into the rack. In one embodiment, the method further includes attaching a second busbar segment to the first vertical busbar for indirect electrical connection with the power distribution unit and to span an additional node adjacent to the one or more nodes for providing electrical power.

According to at least one aspect of the present disclosure, a rack-based IHS includes a rack assembly having a modular structure that supports insertion from a front of the rack of different numbers and sizes of IT gear to create one or more IT nodes. A power bay chassis is inserted into the rack assembly and comprises a power distribution unit directed toward a rear of the rack. A first modular busbar assembly is attached to the rear of the rack and includes a power busbar assembly and a ground busbar assembly. Each of the power and ground busbar assemblies in turn include one or more block busbars lengthwise attached to span a corresponding one or more IT nodes inserted into the rack assembly into electrical. A connecting busbar is attached between the power distribution unit and the one or more block busbars to provide electrical power to the one or more IT nodes.

According to at least one aspect of the present disclosure, a method is provided for assembling a modular busbar assembly for a rack-based IHS; assembling a rack assembly having a modular structure that supports insertion from a front of the rack of different numbers and sizes of IT gear to create one or more IT nodes; providing a power bay chassis that is received in the rack assembly and comprises a power distribution unit directed toward a rear of the rack; and attaching a first modular busbar assembly to the rear of the rack, the first modular busbar assembly comprising a power busbar assembly and a ground busbar assembly. Each of the power and ground busbar assemblies include one or more block busbars lengthwise attached to span a corresponding one or more IT nodes inserted into the rack assembly into electrical connection with the first modular busbar assembly; and a connecting busbar attached between the power distribution unit and the one or more block busbars to provide electrical power to the one or more IT nodes.

The above presents a general summary of several aspects of the disclosure in order to provide a basic understanding of at least some aspects of the disclosure. The above summary contains simplifications, generalizations and omissions of detail and is not intended as a comprehensive description of the claimed subject matter but, rather, is intended to provide a brief overview of some of the functionality associated therewith. The summary is not intended to delineate the scope of the claims, and the summary merely presents some concepts of the disclosure in a general form as a prelude to the more detailed description that follows. Other systems, methods, functionality, features and advantages of the claimed subject matter will be or will become apparent to one with skill in the art upon examination of the following figures and detailed written description.

DETAILED DESCRIPTION

The present innovation provides a modular busbar created with segments that can be added or removed along the rear of a modular rack of an Information Handling System (IHS). Each segment of the busbar may be assembled as necessary to support the required Information Technology (IT) equipment positioned next to the busbar segment within the rack configuration. In one implementation, the rack is divided into blocks and a separate busbar sectional/segment is provided for each block being powered. One design provides a main segment of specific length that connects to a power bay of the rack, and with options to add additional segments for IT equipment added to the top and bottom of the rack extending beyond the main busbar. A horizontal busbar assembly is provided at the back of each block chassis or sled with a pin or sleeve to couple to the vertical busbar as the chassis or block is slid into place from the front of the rack. This innovation may support hot pluggable connections to power the IT components within the block without having to go to the back side of the rack and connect power cables.

FIG. 1illustrates a two-dimensional block diagram representation of an example rack-based information handling system (IHS)100, within which one or more of the described features of the various embodiments of the disclosure can be implemented to support hot swapping of storage devices for a modular, scalable/expandable IHS. As a two-dimensional image, certain of the presented components are shown in different orientations relative to each other for simplicity in describing the connectively of the components. For purposes of this disclosure, an information handling system, such as IHS100, may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, or other purposes. For example, an information handling system may be a handheld device, personal computer, a server, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. The information handling system may include random access memory (RAM), one or more processing resources such as a central processing unit (CPU) or hardware or software control logic, ROM, and/or other types of nonvolatile memory. Additional components of the information handling system may include one or more disk drives, one or more network ports for communicating with external devices as well as various input and output (I/O) devices, such as a keyboard, a mouse, and a video display. The information handling system may also include one or more buses operable to transmit communications between the various hardware components.

As presented inFIG. 1, IHS100includes a rack102, which can comprise one or more panels of sheet metal or other material interconnected to form a three dimensional volume generally referred to in the industry as a rack. Unique aspects of the rack102, which add to the modularity and expandability of IHS100, are further illustrated and described in one or more of the three-dimensional figures presented herein. As is further presented by these three-dimensional figures, certain components indicated herein are located internal to the rack102while other components can be located external to rack102. These various components are communicatively connected to one or more components via power and communication cables, which are generally represented by the connecting lines ofFIG. 1.

IHS100comprises a hierarchical arrangement of multiple management modules, along with power and cooling components, and functional processing components or IT components within end nodes. At the rack level, IHS100includes a management controller (MC)106communicatively connected to infrastructure manager/module (IM)108. MC106can also be referred to as a Rack Management Controller (RMC). MC106includes a microcontroller110(also generally referred to as a processor) which is coupled via an internal bus112to memory114, I/O interface controller116, removable storage device (RSD) interface118and storage120. Memory114can be flash or other form of memory. Illustrated within memory114is rack-level power management and control (RPMC or PMC) firmware122, which is inclusive of the firmware that controls the operation of MC106in communicating with and managing the down-stream components (i.e., blocks124and computing nodes104, etc.) of IHS100. I/O interface116provides connection points and hardware and firmware components that allow for user interfacing with the MC106via one or more connected I/O devices, such as a keyboard, a mouse, and a monitor. I/O interface116enables a user to enter commands via, for example, a command line interface (CLI), and to view status information of IHS100.

I/O interface116also enables the setting of operating parameters for IHS100, among other supported user inputs. RSD interface118enables insertion or connection of a RSD126, such as a storage device (SD) card containing pre-programmable operating firmware for IHS100. In at least one embodiment, a RSD126stores a copy of the operating parameters of IHS100and the RSD126can be utilized to reboot the IHS100to its operating state following a system failure or maintenance shutdown. Storage120can be any form of persistent storage and can include different types of data and operating parameters (settings)132utilized for functional operation of IHS100. Among the stored content within storage120may also be algorithms128for fan and/or power and/or control. For example, the algorithms128can facilitate hot swapping of blocks124or nodes104. In one or more embodiments, IHS100can optionally include at least one other MC, illustrated as secondary MC130, to provide a redundant configuration of MCs106/130which are both simultaneously active and functioning. With these embodiments, the redundant configuration enables IHS100to continue operating following a failure of either of the MCs106/130or in the event one of the MCs106/130has to be taken offline for maintenance.

Infrastructure manager108includes cooling subsystem interface134, Ethernet switch136, power distribution interface138and network interface140. Network interface140enables IHS100and specifically the components within IHS100to connect to communicate with or via an external network142.

In addition to the above described MC106and IM108, IHS100further comprises a fan and cooling subsystem143, power subsystem144, and a plurality of processing blocks124, individually labeled as blocks A-D124a-124d. In one implementation, each block124has an associated block controller (BC)146. Each block124may be enclosed within a block chassis148that is inserted to the rack102with connectors and conductors aligned for automatic engagement.

Cooling subsystem143includes a plurality of fan modules, or merely “fans”, of which a first fan152aand a second fan152bare shown. These fans152a,152bare located within a respective fan bay module154and can be different sizes and provide different numbers of fans152per fan bay module154. Also included within cooling subsystem143is a plurality of temperature sensors150, which are further shown distributed within or associated with specific blocks124. Cooling subsystem143of IHS100further includes some design features of the rack102, such as perforations for air flow and other design features not expanded upon within the present description. Each fan bay module154a-154bis located behind (or in the air flow path of) a specific block124and the fan152a-152bis communicatively coupled to and controlled by the block controller146associated with that block124. Within each block124is at least one, and likely a plurality, of functional/processing nodes (computing nodes104). As one aspect of the disclosure, the number of computing nodes104that can be placed within each block and/or supported by a single block controller146can vary up to a maximum number (e.g., 16) based on the block dimension relative to the size and configuration of each computing nodes104. Also, as shown with blocks B124band C124c, a single block controller146bcan be assigned to control multiple blocks124b-124c, when the number of computing nodes104within an individual block does not exceed the pre-established block controller (BC) threshold. In at least one implementation, the BC threshold can be set to 16 nodes. Each computing node104controlled by a respective block controller146is communicatively coupled to block controller146via one or more cables.

Ethernet switch136enables MC106to communicate with block controllers146via a network of Ethernet cables156. Specifically, according to at least one embodiment, MC106provides certain control and/or management signals to BCs146via one or more select wires within the Ethernet cables156, which select wires are additional wires within the Ethernet cable156that are not utilized for general system and network communication.

Power subsystem144generally includes a plurality of power supply units (PSUs)158, one or more power distribution units (PDUs)160, and a modular busbar assembly162. Power subsystem144also includes a source of external AC source164connected to an internal AC power166. Each of the individual computing nodes104and other components within the IHS100that require power are either directly coupled to modular busbar assembly162or coupled via power cables to PDUs160to obtain power. As one aspect of power distribution within IHS100, MC106can monitor power consumption across the IHS100as well as the amount of available power provided by the functional PSUs158and trigger changes in power consumption at the block level and ultimately at the (processing) node level based on changes in the amount of available power and other factors. Control of the power subsystem144can, in one embodiment, be provided by a separate power controller168, separate from MC106. As further illustrated, one additional aspect of the power subsystem144for the IHS100is the inclusion of AC switch box170. AC switch box170is communicatively coupled to both IM108and power subsystem144. AC switch box170includes a plurality of AC inputs172and a plurality of AC outlets174that are utilized to supply power to the PSUs158, and other functional components of the IHS100that require AC power.

In one embodiment, the rack-based IHS100includes the rack102having a modular structure that supports insertion from a front of the rack of different numbers and sizes of IT gear to create one or more IT nodes104. A power bay chassis176is received in the rack102and includes a PDU160, which is directed toward a rear of the rack102. A modular busbar assembly162is attached to the rear of the rack and includes a first vertical busbar segment178that is in direct electrical connection with the PDU160and spans one or more nodes104to provide electrical power. For example, first vertical busbar segment178spans block B124band block C124c. A second vertical busbar segment180is attachable to the first vertical busbar segment178to electrically connect with the PDU160. Second vertical busbar segment180spans at least one additional node104adjacent to the one or more nodes104to provide electrical power. For example, the second vertical busbar segment180may be above the first vertical busbar segment178to provide power to block A124a. Alternatively, another second vertical busbar segment180may be below the first vertical busbar segment178to provide power to block D124d.

In one or more embodiments, the PDU160of the power bay chassis176includes a positive distribution conductor182aand a negative distribution conductor182b. In correspondence, the first vertical busbar segment178includes a first positive vertical busbar conductor184ain direct electrical connection with the positive distribution conductor182aand a first negative vertical busbar conductor184bin direct electrical connection with the negative distribution conductor182b. Similarly, the second vertical busbar segment180includes a second positive vertical busbar conductor186ain direct electrical connection with the first positive vertical busbar conductor184aand a second negative busbar conductor186bin direct electrical connection with the first negative vertical busbar conductor184b. In an exemplary embodiment, one of the first and second vertical busbar segments178,180include one or more holes188and another of the first and second vertical busbar segments178,180includes corresponding one or more pins190that are to be inserted into the one or more holes to form an electrically conductive attachment.

In one embodiment, the block chassis148includes an aft-facing busbar connector192aligned to contact, physically attach, and electrically communicate with one of the first and second vertical busbar segments178,180when the block chassis148is horizontally inserted into the rack102from the front. For example, the aft-facing busbar connector192may include a horizontal busbar assembly194as an attachment component with aft-facing pins190that are received within holes188formed in the first and/or second vertical busbar segments178,180. Each horizontal busbar assembly194may include a positive horizontal conductor196aand a negative horizontal conductor196b. The horizontal busbar assembly194may electrically communicate with each full width block (i.e., a block containing full-width IT components) or each of more than one partial-width or fractional-width configuration, such as one-third width blocks (containing three side-by-side one-third width IT components) and half-width blocks (containing two side-by-side half width IT components).

In one embodiment, the rack102includes a first frame assembly198having a first number of IT nodes104in a standard zone200of the rack102spanned by the first vertical busbar segment178. For example, the first vertical busbar segment178may supply block B124band block C124cthat are in the standard zone200of the first frame assembly198. A second frame assembly202is mountable on the first frame assembly198and has a second number of IT nodes104in an expansion zone204spanned at least in part by the second vertical busbar segment180. For example, the second vertical busbar segment180may supply block A124athat is in the expansion zone204of the second frame assembly202. Block D124dmay be in another expansion zone204that is supplied by another second vertical busbar segment180. The second frame assembly202may provide an expansion to the first frame assembly198or provide a method of reducing the overall height of the rack102during deployment.

In one embodiment, the power bay chassis176is installed within a switch zone206of the rack102of the first frame assembly198that is below the standard zone200. Alternatively, the power bay chassis176may be in the second frame assembly202. The power bay chassis176may enclose one or more AC switches, such as the AC switch box170having AC inputs172and AC outlets174that are connected to the external AC source164. The power bay chassis176may further contain PSUs158that are electrically connected to the AC switch box170to receive internal AC power166. The PDU160is electrically connected to the one or more PSUs158to receive direct current (DC) electrical power.

For purposes of the disclosure all general references to an information handling system shall refer to the rack-level IHS100, while references to actual computing nodes104within the IHS100shall be referenced as chassis level computing nodes104or IT components. It is further appreciated that within the rack-level IHS100can be implemented separate domains or systems that are independent of each other and can be assigned to different independent customers and/or users. However, this level of detail of the actual use of the computing nodes104within the general rack-level IHS100is not relevant to the descriptions provided herein and are specifically omitted. For clarity, a single rack-level IHS100is illustrated. However, an IHS may include multiple racks. For example, one rack may contain only storage sleds with other racks providing computing nodes. In an exemplary embodiment, components of the IHS100are organized into a hierarchy as described in TABLE A:

Further, those of ordinary skill in the art will appreciate that the hardware components and basic configuration depicted in the various figures and described herein may vary. For example, the illustrative components within IHS100are not intended to be exhaustive, but rather are representative to highlight components that can be utilized to implement various aspects of the present disclosure. For example, other devices/components/modules may be used in addition to or in place of the hardware and software modules depicted. The depicted examples do not convey or imply any architectural or other limitations with respect to the presently described embodiments and/or the general disclosure.

FIG. 2illustrates a front isometric view208of an example rack102that is ready to receive functional components within a first frame assembly198that includes an upper standard zone200aand a lower standard zone200bon either side of a switch zone206. The rack102also includes the second frame assembly202attached on top of the first frame assembly198and includes an expansion zone204. In an illustrative configuration, the second frame assembly202is divided vertically by a partition244into two half-width IT bays242a. The upper standard zone200aof the first frame assembly198may be configured as a 20 GU server zone divided horizontally into four tiers by shelves246. Each shelf246may be provide full-width IT bays242bor include partitions for partial-width bays. The switch zone206of the rack102includes a switch bay248(2 U), two power bays250(3 GU×2), and another switch bay248(2 U). The lower standard zone200bmay be configured as a 25 GU server zone divided into five tiers by shelves246into full-width IT bays242b.

FIG. 3illustrates the example rack102having functional components inserted therein to operate as a rack-based IHS100. In an illustrative configuration, the half-width IT bays242aof the expansion zone204of the second frame assembly202have received 1×5 GU blocks124. Similarly, the full-width IT bays242aof the upper standard zone204of the first frame assembly198contains 4×5 GU blocks124including storage sleds252. Then, the switch zone206includes power bay chasses176. The lower standard zone200bis configured as a 25 GU server zone that has received 5×5 GU blocks124.

FIG. 4illustrates a rear side view254of the rack102having a modular busbar assembly162as installed, as well as illustrating the modular busbar assembly162in an exploded view. The rack102also includes the second frame assembly202attached on top of the first frame assembly198. The example rack-based IHS100includes an upper and lower power bay chasses176with each having corresponding first vertical busbar segment178. In the illustrative configuration, the upper first vertical busbar segment178extends upwardly from the upper power bay chassis176and the lower first vertical busbar segment178extends downwardly from the lower power bay chassis176. The upper and lower first vertical busbar segment178further include respectively a first positive vertical busbar conductor184aand a first negative vertical busbar conductor184b. A middle vertical busbar segment256includes a positive middle conductor258aand a negative middle conductor258bthat tie the upper and lower vertical busbar segments178together. The upper vertical busbar segment178is connected to the second vertical busbar segment180and includes a second positive vertical busbar conductor186aand a second negative busbar conductor186b.

FIGS. 4-5illustrate fan bay receptacles260that are attached to the rack102to receive respective fan bay modules154(FIG. 1). Each fan bay receptacle260positions an inserted fan bay module154into contact with pairs of rear facing conductive components262vertically spaced on the first and second busbar segments178,180. Shrouds264are attachable to the rear of the rack102to block rear access to pairs of rear facing conductive components262that are not behind fan bay modules154.

FIG. 6illustrates the rear side view254of the power bay chassis176in the switch zone206of the rack102. The electrical attachment between the power bay chassis176and the upper and lower vertical busbar segments178are covered by shrouds264(FIG. 5).FIG. 7illustrates the shroud264removed to expose the PDU160of the power bay chassis176, including a positive distribution conductor182aand a negative distribution conductor182b. Aft-facing pins190are aligned to engage holes188(FIG. 4) in the middle vertical busbar segment256and one of the first and second vertical busbar segments178,180(FIG. 4).FIG. 8illustrates a front view of the power bay chassis176prior to receiving PSUs158(FIG. 1).

FIG. 9illustrates the power bay chassis176with functional components installed. PSUs158have been inserted at the front of the power bay chassis176into electrical contact with a back plane902. A management controller (MC1)106and a secondary management controller (MC2)130are also inserted in the front of the power bay chassis176in electrical contact with a back plane902. An AC electrical cord904brings power from AC switch box170through one of two side cord channels attached to lateral sides of the power bay chassis176. A power bay power module (PBPM)906is in electrical contact with an interior side of the back plane902. The PBPM910includes a battery backup908. An IM108is also contained in the power bay chassis176. The PDU160including the positive and negative distribution conductors182a-182bare electrically connected to the back plane902and terminate in aft-facing pins190that engage the holes in the middle vertical busbar segment256(FIG. 4).

FIG. 10illustrates a rear side view1000of the block chassis148including an aft-facing busbar connector192, in particular a positive connector192aand a negative connector192b, aligned to contact, physically attach, and electrically communicate with one of the first and second vertical busbar segments178,180when the block chassis148is horizontally inserted into the rack102from the front (FIGS. 2-4). For example, the aft-facing busbar connector192may include a horizontal busbar assembly194as an attachment component for engaging the first and second vertical busbar segments178,180(FIG. 4). Each horizontal busbar assembly194may include a positive horizontal conductor196aand a negative horizontal conductor196b. The horizontal busbar assembly194may electrically communicate with each of more than one full width, partial-width or fractional-width configuration, such as one-third width blocks and half-width blocks.

FIGS. 11A-11Billustrate a method1100for providing power to block components within a modular, scalable and/or expandable rack-based IHS. With initial reference toFIG. 11A, the method1100includes assembling a rack having a modular structure that supports insertion from a front of the rack of different numbers and sizes of IT gear to create one or more IT nodes (block1102). In block1104, the method1100includes inserting a power bay chassis in a switch zone of the rack to present a PDU including a positive distribution conductor and a negative distribution conductor directed toward a rear of the rack. In one embodiment, the method1100includes electrically attaching an AC switch of the power bay chassis to an external AC source, electrically connecting one or more PSUs inserted in the power bay chassis to the AC switch to receive AC power, and electrically connecting the PDU to the one or more PSUs to receive DC electrical power (block1106).

In block1108, the method1100includes attaching a modular busbar assembly to the rear of the rack by attaching a first vertical busbar segment to span one or more nodes for providing electrical power in a standard zone of the rack. In an example embodiment, the method1100includes attaching, for direct electrical connection, a first positive vertical busbar conductor of the first vertical busbar segment to the positive distribution conductor and attaching a first negative busbar conductor of the first vertical busbar segment to the negative distribution conductor (block1110). The method1100includes attaching a second vertical busbar segment to the first vertical busbar for indirect electrical connection with the PDU (block1112). The second vertical busbar segment spans an additional node adjacent to the one or more nodes for providing hot pluggable electrical power to an aft-directed connection of an IT node inserted into an expansion zone of the rack. Continuing inFIG. 11B, the method1100includes attaching, for direct electrical connection, a first positive vertical busbar conductor of the first vertical busbar segment to the positive distribution conductor and attaching a first negative busbar conductor of the second vertical busbar segment to the negative distribution conductor (block1114). In one embodiment, the method1100includes attaching the second busbar segment by forming an electrical attachment between one or more holes in one of the first and second busbar segments and one or more pins on another of the first and second busbar segments (block1116).

In one embodiment, the method1100includes providing, on a block chassis, an aft-facing busbar connector including an attached component aligned to contact, physically engage, and electrically connect with one of the first and second busbar segments when the block chassis is horizontally inserted into the rack from the front (block1118). In block1120, for a block chassis of more than one partial-width configuration, the method1100includes providing a horizontal busbar assembly of the aft-facing busbar connector electrically connected to each of the more than one partial-width configuration.

In one embodiment, the method1100includes providing pairs of rear facing conductive components vertically spaced on the first and second busbar segments (block1122). In block1124, the method includes attaching one or more fan bay modules attachable to the rear of the rack to electrically engage respective pairs of rear facing conductive components. The method further includes attaching a shroud to the rear of the rack to block rear access to one pair of rear facing conductive components (block1126). Then method1100ends.

FIG. 12illustrates a rack-based IHS1200which includes a rack assembly1202having a sectional busbar assembly1204that is expandable, modular and scalable for each IT node1206inserted into the rack assembly1202. The rack assembly1202has a modular structure that supports insertion from a front of the rack assembly1202of different numbers and sizes of IT gear to create the one or more IT nodes1206. In addition, the sectional busbar assembly1204may provide electrical power to IT nodes1206inserted in a first frame assembly1208of the rack assembly1202. Alternatively or subsequently, the sectional busbar assembly1204may provide electrical power to IT nodes1206inserted into both the first frame assembly1208and a second frame assembly1210received on top thereof that serves for expansion.

A power bay chassis1212inserted into the rack assembly1202has a power distribution unit1214directed toward a rear of the rack assembly1202. A first modular busbar assembly1216, which in the “one stick” design ofFIG. 12is the same as the sectional busbar assembly1204, is attached to the rear1217of the rack assembly1202. The first modular busbar assembly1216includes a power busbar assembly1218aand a ground busbar assembly1218b. Each of the power and ground busbar assemblies1218a-bincludes one or more block busbars1220lengthwise attached to span a corresponding one or more IT nodes1206inserted into the rack assembly1202. The one or more IT nodes1206are inserted into electrical connection with the first modular busbar assembly1216. A PDU connecting busbar1222is attached between the power distribution unit1214and the one or more block busbars1220to provide electrical power to the one or more IT nodes1206. In one embodiment, the first modular busbar assembly1216includes one or more additional block busbars1220lengthwise attached to span a corresponding one or more additional IT nodes1206inserted into an expansion zone1224of the second frame assembly1210. A top-of-rack (TOR) connecting bar1226is attached between the one or more block busbars1220in the first frame assembly1208and the one or more additional block busbars1220to provide electrical power to the one or more additional IT nodes1206in the second frame assembly1210.

In one embodiment, a connection1228between a selected block busbar1220and one of a PDU connecting busbar1222and another block busbar1220includes an overlapping area of at least 20 cm2 (e.g., 40 mm wide by 53 mm high) with a respective thickness of each of the selected additional block busbar1220and the one of the PDU connecting busbar1222and another block busbar1220being at least 8 mm at the overlapping area.

FIG. 13illustrates a top block bus bar1230of the first modular busbar assembly1216attached to a top notched portion1232of each of block busbar1220(power and ground). Top block bus bar1230includes a standoff1234for electrically connecting to a fan board (not shown). In one or more embodiments, notched portions1232on both the top and bottom of the block busbars1220allow use of a thick conductive busbar material that is relatively inflexible but is assembled into a straight vertical plane. Since the two block busbars1220span the top-most IT node1206in the second frame assembly1210of the rack assembly1202, there is not another block busbar1220to utilize the top notched portion1232and to provide a standoff1234(i.e., attachment) for a fan board. Top block bus bars1230may also be used at the top of the first frame assembly1208in lieu of a connecting bar1226(FIG. 12) when the second frame assembly1210is not installed.FIG. 14illustrates a top block busbar1230that is not installed.

FIG. 15illustrates the TOR connecting bar1226attached between block bars1220of the first frame assembly1208and block bars1220of the second frame assembly1210. Over the top notched portion1232of the lower block busbars1220, the TOR connecting busbar1226also includes a standoff1234for electrically connecting to a fan board (not shown).FIG. 16illustrates a TOR connecting busbar1226that is not installed.

FIG. 17illustrates a central portion of the first frame assembly1208of the rack assembly1202. The power distribution unit1214of the power bay chassis1212is attached to PDU connecting bars1222. Connecting blocks1236have standoffs1234for mounting of a fan board1238and are sized to span and to be attached to adjacent notched portions1232of two block busbars1220. Nonconductive mounting fasteners1240pass through the block busbars1220and an insulative spacer1242for attachment to the rack assembly1202.FIG. 18illustrates a connecting block1236that is not installed.FIG. 19illustrates block busbars1220having top and bottom notch portions1232.FIG. 20illustrates PDU connecting bars1222that are not installed.

FIG. 21illustrates a side view2100in vertical cross section through a connecting block1236attached to a fan board1238. The connecting block1236is also physically and electrically connected to two block busbars1220, each in turn electrically connected from a front side to IT nodes1206. Nonconductive mounting fasteners1240pass through the block busbars1220and an insulative spacer1242for attachment to the rack assembly1202.

FIGS. 22-23illustrate an alternative sectional busbar assembly1204′ having a two stick design of a first modular busbar assembly1216and further including a second modular busbar assembly1246, which may be identical to the first modular busbar assembly1216. Both the first and second modular busbar assemblies1216,1246may be rigid and thick for carrying a large current load. Alternatively, each of the first and second modular busbar assemblies1216,1246may be thinner for carrying half of the power load but being flexible for attachment without notching. InFIG. 23, the power busbar assemblies1216a,1246aand the ground busbar assemblies (not shown) of the first and second modular busbar assemblies1216,1246respectively are electrically connected by front and back cross bars1248,1250that are fastened together through the power busbar assemblies1216a,1246a. In an exemplary embodiment, the first and second modular busbar assemblies1216,1246are formed to have a flexible busbar thickness of up to and including 4 mm.

FIG. 24illustrates a method2400for assembling a modular busbar assembly for a rack-based IHS. The method2400includes assembling a rack assembly having a modular structure that supports insertion from a front of the rack of different numbers and sizes of IT gear to create one or more IT nodes (block2402). In block2404, the method2400includes providing a power bay chassis that is received in the rack assembly and comprises a power distribution unit directed toward a rear of the rack assembly. In block2406, method2400includes attaching a first modular busbar assembly to the rear of the rack assembly, the first modular busbar assembly comprising a power busbar assembly and a ground busbar assembly. Each of the power and ground busbar assemblies include one or more block busbars lengthwise attached to span a corresponding one or more IT nodes inserted into the rack assembly. Each of the power and ground busbar assemblies also include a connecting busbar attached between the power distribution unit and the one or more block busbars to provide electrical power to the one or more IT nodes.

In one embodiment, the method2400further includes forming a connection between a selected block busbar and one of a connecting busbar and another block busbar comprising an overlapping area of at least 20 cm2 with a respective thickness of each of the selected block busbar and the one of the connecting busbar and another block busbar being at least 8 mm at the overlapping area (block2408).

In one embodiment, the method2400further comprises assembling the rack assembly by assembling a first frame assembly and a second frame assembly placed on top thereof to provide physical support to an expansion zone of one or more additional IT nodes (block2410). In block2412, the method2400further comprises assembling the first modular busbar assembly by attaching one or more additional block busbars lengthwise to span a corresponding one or more additional IT nodes inserted into the expansion zone of the second frame assembly. The method2400further includes attaching a top-of-rack connecting bar between the one or more block busbars and the one or more additional block busbars to provide electrical power to the one or more additional IT nodes (block2414). Method2400then ends.

FIG. 25illustrates a method2500for assembling a two stick busbar design rather than a one stick design for a more flexible busbar assembly that carry current levels of1200A. In block2502, the method2500includes assembling a second modular busbar assembly. The method2500further includes electrically connecting the power busbar assemblies and the ground busbar assemblies of the first and second modular busbar assemblies respectively (block2504). The first and second modular busbar assemblies each have a flexible thickness of up to and including 4 mm.

In the above described flow charts ofFIGS. 11A-11B, 24 and 25one or more of the methods may be embodied in an automated manufacturing system that perform a series of functional processes. In some implementations, certain steps of the methods are combined, performed simultaneously or in a different order, or perhaps omitted, without deviating from the scope of the disclosure. Thus, while the method blocks are described and illustrated in a particular sequence, use of a specific sequence of functional processes represented by the blocks is not meant to imply any limitations on the disclosure. Changes may be made with regards to the sequence of processes without departing from the scope of the present disclosure. Use of a particular sequence is therefore, not to be taken in a limiting sense, and the scope of the present disclosure is defined only by the appended claims.

One or more of the embodiments of the disclosure described can be implementable, at least in part, using a software-controlled programmable processing device, such as a microprocessor, digital signal processor or other processing device, data processing apparatus or system. Thus, it is appreciated that a computer program for configuring a programmable device, apparatus or system to implement the foregoing described methods is envisaged as an aspect of the present disclosure. The computer program may be embodied as source code or undergo compilation for implementation on a processing device, apparatus, or system. Suitably, the computer program is stored on a carrier device in machine or device readable form, for example in solid-state memory, magnetic memory such as disk or tape, optically or magneto-optically readable memory such as compact disk or digital versatile disk, flash memory, etc. The processing device, apparatus or system utilizes the program or a part thereof to configure the processing device, apparatus, or system for operation.