Multi-position input cord assembly for a power distribution unit

Apparatuses and devices are provided that allow for a power input cord to be placed in two or more different orientations relative to a power distribution unit. A power distribution unit may be provided with one or more input cord assemblies that allow an input cord to be swiveled such that the cord exits an outside plane of the power distribution unit at a different angle. Such an assembly allows a power distribution unit to be placed in an equipment rack and coupled with an input power source in a flexible and convenient manner. Clearances and dimensions of equipment racks may be modified to provide enhanced space usage, efficiency, and/or density in a facility.

FIELD

The present disclosure is directed to power distribution units and, more specifically, to a power distribution unit having a multi-position power input.

BACKGROUND

A conventional Power Distribution Unit (PDU) is an assembly of electrical outlets (also called receptacles) that receive electrical power from a source and distribute the electrical power to one or more separate electronic appliances. Each such unit has a power input that receives power from a power source, and power outlets cords that may be used to provide power to electronic appliances. PDUs are used in many applications and settings such as, for example, in or on electronic equipment racks. One or more PDUs are commonly located in an equipment rack (or other cabinet), and may be installed together with other devices connected to the PDU such as environmental monitors, temperature and humidity sensors, fuse modules, or communications modules that may be external to or contained within the PDU housing. A PDU that is mountable in an equipment rack or cabinet may sometimes be referred to as a Cabinet PDU, or “CDU” for short.

A common use of PDUs is supplying operating power for electrical equipment in computing facilities, such as data centers or server farms. Such computing facilities may include electronic equipment racks that comprise rectangular or box-shaped housings sometimes referred to as a cabinet or a rack and associated components for mounting equipment, associated communications cables, and associated power distribution cables. Electronic equipment may be mounted in such racks so that the various electronic devices are aligned vertically one on top of the other in the rack. One or more PDUs may be used to provide power to the electronic equipment. Multiple racks may be oriented side-by-side, with each containing numerous electronic components and having substantial quantities of associated component wiring located both within and outside of the area occupied by the racks. Such racks commonly support equipment that is used in a computing network for an enterprise, referred to as an enterprise network.

As mentioned, many equipment racks may be located in a data center or server farm, each rack having one or more associated PDUs. Various different equipment racks may have different configurations, including different locations of sources of input power. One or more such data centers may serve as data communication hubs for an enterprise. As will be readily recognized, space within equipment racks is valuable with maximization of computing resources for any given volume being desirable.

SUMMARY

Apparatuses and devices are provided that allow for a power input cord to be placed in two or more different orientations relative to a power distribution unit. A power distribution unit may be provided with one or more input cord assemblies that allow an input cord to be swiveled such that the cord exits an outside plane of the power distribution unit at an angle, relative to a longitudinal axis of the power distribution unit. Such an assembly allows a power distribution unit to be placed in an equipment rack and coupled with an input power source in a flexible and convenient manner. Clearances and dimensions of equipment racks may be modified to provide enhanced space usage, efficiency, and/or density in a facility.

DETAILED DESCRIPTION

Thus, various embodiments may omit, substitute, or add various procedures or components as appropriate. For instance, aspects and elements described with respect to certain embodiments may be combined in various other embodiments. It should also be appreciated that the following systems, devices, and components may individually or collectively be components of a larger system, wherein other procedures may take precedence over or otherwise modify their application.

The following patents and patent applications are incorporated herein by reference in their entirety: U.S. Pat. No. 7,043,543, entitled “Vertical-Mount Electrical Power Distribution Plugstrip,” issued on May 9, 2006; U.S. Pat. No. 7,990,689, entitled “Power Distribution Unit And Methods Of Making And Use Including Modular Construction And Assemblies,” issued on Aug. 2, 2011; U.S. patent application Ser. No. 12/344,419, entitled “Power Distribution, Management, and Monitoring Systems,” and filed on Dec. 26, 2008; and U.S. patent application Ser. No. 12/717,879, entitled “Monitoring Power-Related Parameters in a Power Distribution Unit,” and filed on Mar. 4, 2010.

Systems and devices are described in which a power input cord, for a power distribution unit (PDU), can be placed in two or more different orientations relative to the PDU housing. A PDU may be provided with one or more input cord assemblies that allow an input cord to be swiveled, such that the cord may exit an outside plane of the PDU at different angles. Such an assembly allows a PDU to be placed in an equipment rack and coupled with an input power source in a flexible and convenient manner. With use of the disclosed assembly, clearances and dimensions of equipment racks may be modified to provide enhanced space usage, efficiency, and/or density in a facility. Such an input cord assembly may also allow for more efficient packaging of PDUs for shipment.

FIG. 1is an illustration of a PDU65that includes a swivel input cord assembly100, Intelligent Power Modules (“IPMs”)201, a communications module66that provides communications functions, an environmental monitor port68, and an input power cord70with associated plug72. The PDU65, according to this embodiment, includes a housing that is vertically mountable in an equipment rack, although it will be understood that other form factors may be used, such as a horizontally mountable housing. The IPMs201each include eight outlets202,204,206,209,211,212,214, and216that supply power to assets that may be mounted into an equipment rack. Such equipment racks are well known, and often include several individual assets that are used in operation of a data center. As is well known, numerous equipment racks may be included in a data center, and in various embodiments each asset in each equipment rack may be monitored for power usage through one or more associated IPMs201. The visual display23(shown displaying the numeral “57”) is disposed in the PDU65(although in other embodiments the display might be external to the PDU65), may display multiple items of information and/or may include multiple separate displays.

The input cord assembly100, according to various embodiments, includes a swivel assembly that allows the input power cord70to exit a plane of the PDU housing at one of multiple different angles. Such an assembly100allows the input power cord70to be situated or positioned to reduce bends in the power cord70, or to allow bends to be made more easily when connecting the input power cord70to a power source. As will be appreciated, equipment racks may have input power provided to the racks in various different locations and orientations. Depending upon where the power source is located in a particular rack, the input power cord70may need to extend, for example, from either a front face of the PDU housing or from an end of the PDU housing. Thus, PDU configurations may be specifically selected based on the location in an equipment rack for the power source. If such a PDU is later desired to be placed in a different rack, it may not be usable, or may require modification, if the different rack has input power provided at a different location or with a different configuration. PDUs provided with an input cord assembly100may allow for the input cord70to be moved relative to the PDU housing, thus allowing such a PDU to be used in a number of different applications as compared to a PDU which does not have such an input cord assembly100. Furthermore, such a feature may allow for fewer part numbers and fewer required option selections for suppliers and buyers of PDUs. Additionally, such an input cord assembly100may allow the input power cord70to be more conveniently placed in a shipping box for shipment of the PDU, and may allow for a reduced sized shipping box and/or reduced shipping materials when shipping such a PDU. As will be recognized, a reduced size and/or weight box may also result in reduced costs for shipping.

With continued reference toFIG. 1, some other elements of the PDU65are described. In one embodiment, the IPM201includes eight outlets (202-216), each of NEMA 5-20R type, contained in a housing. It will be understood that this embodiment, and other embodiments described herein as having NEMA 5-20R type outlets, are exemplary only and that any of various other types of outlets can alternatively be used. For example, the “outlets” can be other NEMA types (e.g., NEMA 5-15R, NEMA 6-20R, NEMA 6-30R or NEMA 6-50R) or any of various IEC types (e.g., IEC C13 or IEC C19). It also will be understood that all “outlets” in a particular power outlet module or IPM201, or other module-outlets described herein, need not be identical or oriented uniformly along the PDU. It also will be understood that the “outlets” are not limited to three-prong receptacles; alternatively, one or more of the “outlets” can be configured to receive more or less than three-prong mating male connectors. It also will be understood that the “outlets” are not limited to having female prong receptacles. In any “outlet,” one or more of the “prong receptacles” can be male instead of or in combination with female connection elements, according to alternative embodiments. In general, as used herein, female and male “prong receptacles” are termed “power-connection elements”. Furthermore, the principles described herein also are applicable to devices that may be hard-wired into an outlet module. While the outlet module201of this embodiment includes eight outlets, it will be understood that this is but one example and that an outlet module may include a different number of outlets.

The housing for an outlet module may be any suitable housing for such a device, as is known to one of skill in the art, and may be assembled with other modules in a PDU. Such a housing generally includes a front portion, e.g., a front wall, and a rear portion, e.g., a rear wall, the front portion is substantially planar, and the rear portion is substantially planar and parallel to the front portion. The housing also includes longitudinally extending side portions, e.g., side walls, and one or more transverse end portions, e.g., end walls. The front portion, rear portion, side portions, and end portion(s) are generally orthogonal to each other in a generally rectangular or box-type configuration. The housing can be made of any suitable, typically rigid, material, including, for example, a rigid polymeric (“plastic”) material. In at least certain embodiments, the front and rear portions are made from an electrically insulating material, whereas in other embodiments conducting materials are used for safe ground bonding. The side portions and the end portion(s) may be integrally formed along with the front portion or the rear portion. Furthermore, while the outlet module described in this embodiment includes a housing, other embodiments may include an outlet module that does not include a housing. For example, an outlet module may include a number of outlets coupled together with no exterior housing, so the outlet module may be installed into another piece of equipment. Each outlet202-216is interconnected to a power source through any of a number of well-known connection schemes, such as spade connectors, lug connectors, plug connectors, screw connectors, or other suitable types of connectors. Furthermore, if desired, one or more of these electrical connectors can be located inside the housing or outside the power outlet module housing (when included).

Referring now toFIGS. 2-4, a PDU200having an input cord assembly of various embodiments is described. The PDU200comprises a PDU housing205and an input power cord210. These figures illustrate a side view of the PDU200, which may include a number of outlets on a front and/or rear face thereof.FIG. 2illustrates input power cord210extending away from the PDU housing205at about a 90 degree angle relative to the longitudinal axis of the PDU housing205.FIG. 3illustrates input power cord210extending away from the PDU housing205at about a 45 degree angle relative to the longitudinal axis of the PDU housing205. Finally,FIG. 4illustrates input power cord210extending away from the PDU housing205in a direction parallel to the longitudinal axis of the PDU housing205.

The embodiments illustrated inFIGS. 5-7show an input cord assembly implemented as an input cord module500. The input cord module500may include a swivel or pivot assembly that allows input cord505to be manipulated into several different positions. Input cord505may include a plug assembly510that may be plugged into a receptacle of a power source. It will be understood, however, that other configurations of input power cord505and plug510may be used, such as different plug configurations or hard wiring of conductors of the input cord505to an input power source. The input cord module500includes a module housing515which has an opening520through which the input power cord505extends. Power cord505is connected to a rotational member525, which may be rotated relative to the housing515. Conductors530extend from the housing515, and may be coupled with other components of a PDU. In the illustrations ofFIGS. 5-7the input cord module500includes module connectors535that may be coupled with complementary receiving members of other modules that are assembled to form a PDU. In some embodiments, conductors530are coupled with the input cord505and are provided with sufficient slack within the housing515to allow for rotation of the rotational member525through 90 degrees of travel. It will be understood, however, that larger or smaller ranges of rotation for the input cord505may be accommodated. The power input cord505and plug510may have numerous different configurations, as will be readily recognized by one of skill in the art. For example, the input cord505and plug510may provide a polyphase connection to a power source, such as a three-phase power source. In some embodiments, a PDU may have dual power inputs, with each of the power inputs provided with an input cord module500. The exit point of the power cord505from the rotating input cord module500may be oriented such that it minimizes the movement of the wires within the power distribution unit. This may be done by passing the input power cord through the rotational member525perpendicular to and laterally offset from a rotational axis of the rotational member525to reduce strain on the conductors caused by displacement of the input power cord from a first position to a second position. This is advantageous in that it allows the apparatus to be made smaller, and puts less strain on the point of connection where the wires attach to a power distribution unit. The module500may also serve as ‘strain relief’ for the power cord505, which is associated with safety requirements of a power distribution unit. The module500, according to some embodiments, may accommodate a range of power cord diameters, by using inserts within the rotational member525to effectively reduce the diameter of the connection. Using relatively small, low cost inserts to achieve the range of diameters provides the ability to provide a unique rotational apparatus for each input cord diameter.

FIG. 8illustrates an input cord module800, according to another embodiment. As illustrated, the input cord module800includes a locking mechanism805and a pull member810. The pull member810may be configured to feed through the locking mechanism805to engage apertures in rotational member525. By engaging the apertures, the pull member810latches or locks rotational member525in a position to secure input cord505at specific angles relative to the housing. In such a manner, the input power cord505may be held relatively securely in a predetermined position. Pull member810provides the ability to change input power cord positions in a PDU without requiring tools.

With reference toFIG. 9, an input cord module900of still other embodiments is described. The input cord module900includes a locking mechanism805and the pull member or pin810that may engage with holes or cavities in the swivel lower housing925to secure input cord505at specific angles relative to a PDU housing. In such a manner, the input power cord505may be held relatively securely in a predetermined position. According to some embodiments, the swivel lower housing925has holes to allow for five locked positions of the input cord505, each position being approximately 22.5 degrees from adjacent positions. In the illustration ofFIG. 9, the input cord module also includes a main enclosure member905, a dust shield910, an enclosure cover915, a swivel upper housing920, the swivel lower housing925, and an enclosure plate930. Each of these items is assembled to form input cord module900, which can be an assembly of discrete components. In this embodiment, dust shield910serves to prevent foreign objects and/or internal components from passing between the module900and an adjacent portion of the PDU, which could result in safety or functionality concerns. Such a shield910allows the module900to be relatively compact while also serving to prevent passage of loose or molten materials from the PDU, for example, in the event of a catastrophic failure. Enclosure cover915serves as a housing, or a portion of a housing for the module900. Swivel upper and lower housings920and925may be secured together through hex screws935, for example, to compress the power cord505between the assembled swivel upper and lower housings920and925. Enclosure plate930may be assembled with the main enclosure member905, as illustrated. Similarly as discussed above, the module900may be coupled with a PDU housing, or with other modules that may be assembled to form a PDU.

According to some embodiments, the present disclosure also provides a method for assembling a power distribution unit. The method may be performed during initial assembly of a power distribution unit, such as the power distribution unit ofFIG. 1, or may be a final portion of an assembly process, in which an input may be assembled with a PDU based on a particular customer's needs related to input power cord size, plug type, etc. In such embodiments, a housing may be provided that has an opening there through. A rotational member, such as rotational member525, may be rotatably secured within the housing. A power cord may then be secured within the housing and coupled with the rotational member. When secured within the housing, the power input cord may extend through the opening, and the rotational member may be rotated into multiple different orientations relative to a longitudinal axis of the housing and thereby allow the power input cord to exit the housing at different angles. In some embodiments, a locking mechanism may also be coupled with the housing and with the rotational member. Such a locking mechanism may secure the rotational member at one of two or more different orientations within the housing, and may include, for example, a latch that may be secured with the rotational member. A barrier may also be secured at a first end of the housing adjacent to other portions of a power distribution unit, and may act to prevent passage of objects or materials through the first end. Furthermore, in some embodiments, one or more shims may be inserted into the rotational member to reduce an effective width of the rotational member to accommodate a range of power cord diameters.

FIG. 10illustrates an input cord module1000that includes a cord position locking mechanism, in accordance with another embodiment. The input cord module1000can be coupled to an end of a PDU, e.g., PDU65or PDU200, to electrically couple the PDU to a power source of, for example, a server farm. The input cord module1000enables a user to be able to manipulate, position, or pivot an input power cord into any one of a number of locked positions, with respect to a longitudinal axis of the PDU. In other words, the input power cord enables a user to change the angle of incidence of the input power cord, with respect to the longitudinal axis of the PDU. To enable repositioning of the input power cord, the input cord module1000includes the input power cord505, the plug or plug assembly510, and a body1005.

The body1005may include any one of a number of locking mechanisms to enable the input power cord505to be slidably, pivotably, and/or rotatably repositioned, with respect to the body1005. To accomplish this, the body1005may include an opening1010that exposes at least part of a cylinder1015. The cylinder1015may be clamped around or otherwise mated to the input power cord505. When unlocked or released, the cylinder1015may rotate within the opening1010, allowing the input power cord505to pivot through positions within the opening1010. Additional details regarding how an embodiment of the locking mechanism may be implemented are provided below in connection withFIG. 13.

The body1005may also include one or more fingers or extending members1020, configured to operate a locking mechanism internal to the body1005. According to various implementations, applying effort to one or both of the extending members1020results in unlocking or releasing the cylinder1015. The body1005can be configured to release the cylinder1015in response to pressing at least one of the extending members1020or in response to lifting at least one of the extending members1020. For example, the body1005can be configured to release the cylinder1015in response to pivoting one end of the extending member1020away from a surface1025, in the direction of an arrow1030. The body1005can additionally or alternatively be configured to release the cylinder1015in response to sliding all or part of at least one of the extending members1020: towards the input power cable505, away from the input power cable505, towards the other extending member1020, and/or away from the other extending member1020.

The body1005may be partially contoured to the shape of the cylinder1015to seal the internal compartment of the body1005from the environment. For example, a part of the body1005that is adjacent to the input cord505may have a curved, bull-nosed, or arcuate end1035. The arcuate end1035may provide a seal from external moisture, liquid, and/or debris that can corrode, electrically short, or otherwise interfere with the operation of the PDU to which the input cord module1000is attached. The arcuate end1035may also provide a safety seal that prevents conductive objects or body parts from entering an internal compartment of the body1005to protect a user or installer or the PDU to which the input cord module1000is attached. Furthermore, the arcuate end1035may provide a seal that protects the environment from molten components, fire, and/or electrical arcing that can originate from inside the input cord module1000.

FIGS. 11 and 12illustrate additional views of the input cord module1000. FromFIGS. 11 and 12, it can be seen that the input cord module1000receives the input cord505from the arcuate end1035and provides conductors1040on another side for electrically coupling the PDU to the conductive prongs1045.

FIG. 13illustrates an exploded view of an input cord module1300, according to an embodiment. The input cord module1300represents one of various potential implementations of the input cord module1000. In addition to the previously disclosed components, the input cord module1300includes a housing1305, a cylinder1310(inclusive of1310a,1310b), and a lever1315.

The housing1305may include one or more sections for sealing and providing structural integrity to the body1005of the input cord module1300. The housing1305may manufactured from one or more polymers or plastics, other non-conductive materials, or one or more conductive materials, or a combination thereof (e.g., polymer-coated aluminum). The housing1305may be a single unit that or may comprise several plates or sections1305a,1305b,1305c,1305d(accumulatively1305). The housing1305may include the arcuate end1035to provide various sealing advantages, as described above.

The cylinder1310may be configured to be rotatably repositioned within the housing1305to support repositioning the input power cord505. The cylinder1310may include two sections, an upper cylinder section1310aand a lower cylinder section1310b. The upper cylinder section1310amay join with the lower cylinder section1310bto provide a clamping mechanism for securing the input power cord505and/or the conductors1040between the upper cylinder section1310aand the lower cylinder section1310b. For example, the upper cylinder section1310aand the lower cylinder section1310bmay apply pressure to the input power cord505and/or the conductors1040using a clamp gate1320that is trapped or secured within the cylinder1310. In a preferred embodiment, the clamp gate1320is used to secure the input power cord505.

The lower cylinder section1310bcan include several notches or crenels1325around a perimeter of the lower cylinder section1310bto provide a mechanism for securing the cylinder1310. The notches1325may be shaped, machined, manufactured or formed to receive one or more parts of the lever1315. The notches1325may engage with the lever1315while the extending members1020are in a first or neutral position, to prevent the cylinder1310from rotating. The notches1325may disengage from the lever1315while the extending member1020are in a second or activated position, to enable to the cylinder1310to rotate between multiple positions. The cylinder1310may include several notches1325, e.g.,100, to provide a large number of locking positions, or the cylinder1310may include a few notches, e.g.,8, to provide less locking positions, in accordance with various embodiments. WhileFIG. 13depicts the lower cylinder section1310bhaving the notches1325, alternative implementations of rotation resists or locking mechanisms may include holes, grooves, or a high friction surface around the cylinder1310. Although, in the illustrated embodiment, the lower cylinder section1310bincludes the notches1325, in alternative embodiments, the upper cylinder section1310a, the entire cylinder1310, and/or other parts of the cylinder1310can be manufactured to include the notches1325or other locking mechanisms.

The lever1315can be manipulated by a user to engage or disengage with the cylinder1310. The lever1315can include the fingers or extending members1020and hooks or tongues1330. The extending members1020can provide a low-profile mechanism for applying effort to the lever1315or for otherwise operating the lever1315. When a user operates (e.g., pulls, lifts, depresses) one side of the extending members1020, the lever1315may pivot about an axle1335to disengage or engage the tongues1330with the notches1325. The axle1335may be supported by one or more sections of the housing1305(e.g.,1305b,1305c) to enable the lever1315to engageably pivot to and from the cylinder1310. In addition to the extending members1020and the tongues1330, the lever1315may also include a lever arm1340that couple the extending members1020to the tongues1330. The lever arm1340may also include an aperture or partial opening that allows the conductors1040or the input power cord505to pass through the lever1315. While two extending members1020and two tongues1330are illustrated, more or less than the number shown may also be used, according to alternate implementations.

A few embodiments of locking mechanisms have been described above, but additional embodiments may also be used to selectively secure and release the cylinder1015or1310. For example, as alternatives to the pull-pin or pull member mechanism ofFIG. 8and the level mechanism ofFIGS. 10-13, the input cord modules1000,1300could employ other cylinder locking/release mechanisms, such as sliders, push buttons, push levers, squeeze mechanisms, a magnetic key or device, an electromagnet, an electromagnetic mechanism, knobs, or the like. As will be discussed below and shown inFIG. 14, any one or more of these operating mechanisms can also be used to cause the input power cords to swivel around a longitudinal axis of a PDU rather than pivot away from the longitudinal axis of the PDU.

FIG. 14illustrates an input cord module1400that enables the input power cord505to both pivot and swivel, with respect to a longitudinal axis of a PDU. The input cord module1400may include a swivel joint1405that enables the input power cord505to swivel or axially rotate about the longitudinal axis1410of the PDU to which the input cord module1400may be attached. The swivel joint1405may include one or more lubricated rubber bushings, bearings, ball-socket combinations, and cylinders to enable a cord section1415of the input cord module1400to axially rotate independent from PDU section1420of the input cord module1400.

The swivel joint1405can be configured to freely rotate, or the swivel joint1405can be selectively secured from rotating. For example, a release mechanism1425may be a lever or may be part of a lever that is configured to unlock or release the swivel joint1405to enable the input cord505to axially rotate. Other release mechanisms may also be used, such as slides, buttons, squeeze mechanisms, and magnetic keys. In some implementations, operation of the release mechanism1425enables the input power cord505to both axially rotate around the longitudinal axis1410in addition to pivoting within an opening1430(e.g., along the general direction of the arrows1435). Pivoting the input power cord505with respect to the longitudinal axis1410of the PDU may allow a user to change the angle of incidence of the input cord from zero degrees to, for example, 90 degrees, or anywhere in between.

Embodiments described herein provide several benefits relative to PDUs having a single fixed position for an input power cord. For example, embodiments of the disclosure may simplify manufacturing and purchasing because angle of incidence of the power cord can be adjusted according to a customer's needs. This feature simplifies manufacturing and purchasing because customizing incident angle of a power cord can require order-specific parts and can require the client to determine the egress angle prior to submitting an order for the PDU. Thus, through the disclosed embodiments, assembly time and cost may be reduced, and reliability may be increased. Furthermore, embodiments may be used to produce a product that may require a smaller packaging footprint than products without such a feature. PDUs having multi-position input cords may also be more versatile and usable in a wider range of applications as compared to PDUs having a single fixed position for an input power cord.

It should be noted that the systems and devices discussed above are intended merely to be examples. It must be stressed that various embodiments may omit, substitute, or add various procedures or components as appropriate. For instance, it should be appreciated that, in alternative embodiments, features described with respect to certain embodiments may be combined in various other embodiments. Different aspects and elements of the embodiments may be combined in a similar manner. Also, it should be emphasized that technology evolves and, thus, many of the elements are exemplary in nature and should not be interpreted to limit the scope of the invention.

Specific details are given in the description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, well-known circuits, structures, and techniques have been shown without unnecessary detail in order to avoid obscuring the embodiments.