Abstract:
An enhanced computer assembly and related method is provided that enables easy shipment and installation of such computing systems. In one embodiment a split top hat design is provided that can be removed. The removable split hat comprises a receiving member and an inner member that are secured to the frame in a manner that can be easily removed. In an alternate embodiment, a collapsible top hat is provided which adjusts the height of the assembly from a first to a second position. The collapsible feature has an upper portion that is connected to a plurality of pivoted side members that are capable of collapsing onto themselves.

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     This invention relates to the packaging of computing systems and more particularly to packaging of computing systems utilizing tall and/or heavy frames. 
     DESCRIPTION OF BACKGROUND 
     The industry trend has been to continuously increase the number of electronic components inside computing systems. As the number of components increase, there has been an effort to keep the footprints of these systems at a minimum. Unfortunately, however, in recent years the needs of the newer and more sophisticated environments have forced the fabrication of taller frames and housing footprints which are also much heavier than their predecessors. 
     The increased height and weight of these newer footprints have added to the already existing challenges in transportation and installation of large computing environments. Tall frames, are difficult to transport via an airplane or even using ground transportation. Once at a customer site, heavy frames may exceed elevator lifting limit and other factors may cause additional challenges. Lack of human resources, inadequate elevators, short ceilings and door frames, can all cause temporary challenges in subsequent installation of these systems. 
     In many instances, there has been no other option present than to breakdown and reassemble the frame to enable proper transportation and installation of it. An example of this breakdown and reassembly process is shown in the prior art pictorial depiction illustrated by  FIG. 1 . Although a more detailed discussion of this figure will be presented later, it is not difficult to see that a complete breakdown and reassembly process as depicted in  FIG. 1  is costly and time consuming. Furthermore, alongside the added installation time and the expense associated with such a process, a complete breakdown and reassembly process often provides an added potential for installation errors/problems which in turn affects overall service costs, and cause customer satisfaction and warranty issues. 
     Consequently, it is desirable to implement a method and system that can lower the challenges caused in the shipment and installation of such tall, heavy systems. 
     SUMMARY OF THE INVENTION 
     The shortcomings of the prior art are overcome and additional advantages are provided through the provision of an enhanced computer assembly and related method that enables easy shipment and installation of such computing systems. In one embodiment a split top hat design is provided that can be removed. The removable split hat comprises a receiving member and an inner member that are secured to the frame in a manner that can be easily removed. In an alternate embodiment, a collapsible top hat is provided which adjusts the height of the assembly from a first to a second position. The collapsible feature has an upper portion that is connected to a plurality of pivoted side members that are capable of collapsing onto themselves. 
     Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with advantages and features, refer to the description and to the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which: 
         FIG. 1  is a pictorial illustration of a conventional prior art breakdown and reassembly process used for shipping and installation of a tall and/or heavy frame; 
         FIG. 2  is a graphical illustration of a frame weight and size thresholds distribution; 
         FIG. 3  is an illustration of an exemplary frame and its important components as used by the embodiments of the present invention; 
         FIG. 4  is an illustration of one embodiment of the present invention using a split top-hat design; and 
         FIG. 5  is an illustration of an alternate embodiment of the present invention using a collapsible top-hat design. 
     
    
    
     DESCRIPTION OF THE INVENTION 
       FIG. 2  provides an graphical illustration of an exemplary frame  200  and pinpoints particular challenges as the weight and the footprint of the frame  200  is increased. As shown in the illustration of  FIG. 2 , a graphical distribution of weight and size thresholds of the frame is provided. The vertical y-axis, provides the height of the frame as it grows while the x, or the horizontal axis reflects the weight of the frame. 
     Referring back to  FIG. 2 , as illustrated, in instances where frame is under 160 cm or 63 inches, the conditions are optimized for transportation and installation of the frame. For ease of reference, this particular frame footprint is illustrated by reference numerals  210  and even though the frames in general are all referenced by numerals  200 , because of its particular footprint, the frame at this footprint will be herein also referenced as frame  210 . 
     In this height frame, the weight of the frame is estimated to be somewhere around 1100 lbs or 500 kg, although there may be some variations due to the components the frame will be housing. At this height and weight, the frame can easily fit the tightest transportation facilities, such as the belly of most aircrafts. Having a size that fits the belly or any aircraft, not only means that any plane at any time can be used, but it also ensures that the frame can easily fit other forms of transportation such as trucks and cargo trains. Furthermore, at this height and weight installation is also simple as the frame can fit standard doors and elevator doors. The weight also allows the frame to be transported up most elevators and be stored at any environment without much difficulty. 
     As the footprint of the frame increases, the challenges also increase. The new footprint is delineated by heavier lines and referenced by numerals  220 . As before, for ease of reference, since the particular frame footprint is referenced as  220 , (even though the frame is still represented by numerals  200 ), because of the particular footprint, the frame at this footprint will be herein also referenced as frame  220 . 
     As illustrated, at this footprint frame  220  has a height of around 78 inches or 198 cm. The weight of the frame, at this height is estimated to be around 2500 lbs or 1136 kg. The absolute height for most narrow bodied aircrafts, are somewhere between 80 to 82 inches, leaving some but very little clearance. 
     As can be deduced, even at this height, frame  220  is difficult to maneuver. A 2 inch clearance, hardly allows the frame to be moved into and out of the container. This makes tilting and shifting the frame difficult. In addition, if the frame is to be carried on some sort of carrier with wheels to and from the aircraft, the additional height of the wheel may just be sufficient to make the task a challenging one. For a heavy computer most likely the computer is packaged on a pallet and in some instances, the available clearance, for a safer handling will be taken by the height of the pallet. Nonetheless, it is likely that the increased clearance is not available in most such aircrafts thus causing problems. By comparison, the same kind of challenges are also present when using ground transportation or when trying to transport the frame  220  into buildings and up some elevators. In addition, the added weight of the frame makes installation a multi person task and the environment where the frame is being stored needs to also be able to support multiple such frames. 
     With the next incremental footprint, the challenges increase even more. As illustrated in  FIG. 1 , the new footprint is delineated by heavier lines and referenced by numerals  230 . As before, for ease of reference, since the particular frame footprint is referenced as  230 , (even though the frame is still represented by numerals  200 ), because of the particular footprint, the frame at this footprint will be herein also referenced as frame  230 . 
     Frame  230  has a height of 89 inches or around 208 cms. At this height, the frame (plus the height of the pallet or the container) can only be placed on the upper deck of most wider bodied aircrafts and intermodal containers but narrow bodied aircrafts no longer support this height. This of course narrows the shipping option and takes away from shipping and installation flexibility. Some door frames may also cause a problem when the frame  230  is being transported for final installation. The weight considerations at this weight are similar with that discussed in conjunction with frame  220  and no significant additional challenges are added at this point. However, as was discussed before, the weight is sufficiently heavy to make the installation and servicing of the frame a multi-person task. 
     When again the footprint of the frame increases, the challenges this time become much more difficult to resolve. The new footprint is delineated by heavier lines and referenced by numerals  240 . As before, for ease of reference, since the particular frame footprint is referenced as  240 , even though the frame is still represented by numerals  200 , because of the particular footprint, the frame at this footprint will be herein also referenced as frame  240 . 
     The new frame  240  now possesses a height of 118 inches or 300 cm. The weight of the frame is now estimated to be far exceeding 2500 lbs. At this height, the frame provides the least amount of flexibility for shipping. Frame  240  only can be shipped by using the upper decks of larger bodied airplanes. Any 8 foot ceiling or door frame, as used in many standard buildings but not warehouses, will also pose a problem. The greatly increased weight also provides a problem with transporting the frame up elevators. The new weight greatly exceeds most regular elevator weight limits. Therefore, at this weight and height, most such frames were broken down and reassembled as discussed before.  FIG. 1 , provides a pictorial example of such conventional prior art processes. 
       FIG. 1  is a progression of pictures referenced by numerals  110  through  160 . In the first process step,  110 , the bolts, cables and other components are first disconnected and shipping bars are then connected as depicted in  120 . To reduce the weight and height of the frame, different components are then removed as shown in the depictions of process steps  130  though  150 . Process step  160  illustrates the frame as completely disassembled for shipping and installation. Note that after the frame is shipped and arrives at its final destination, the process steps have to be repeated in reverse to reinstall the frame back to its original condition. As discussed earlier, not only this process is time and labor intensive, it adds cost and can lead to potential problems and errors (i.e destruction of parts and software) both at the disassembly and reassembly level. 
     In order to overcome these and many other such challenges, the workings of the present embodiment provides for a flexible alternative. Some concepts as will be presently disclosed and discussed will focus on reducing frame height to a manageable size to reduce costs and improve overall system shipment-ability and customer satisfaction. 
     In  FIG. 3 , three different exemplary base frames are provided as referenced by  310 ,  312  and  314 . Each of these frames are somewhat different to reflect that the workings of the present invention can be applied to a variety of different conditions. Some of these frames as illustrated may include BPA is Bulk Power Assembly, CEC Central Electronic Cage, Cargo is Input Output Assembly (I/O) MRU is Modular Refrigeration Unit. In short some of the base frames represented in  FIG. 3  are to provide different frame characteristics, including but not limited to those discussed in  FIG. 2 . The three frames are chosen to also imply height and weight differences to demonstrate that although the workings of the present invention is designed to aid shipment and installation of tall and/or heavy frames, but it can be applied to those that are lighter and/or shorter when desired. 
       FIGS. 4 and 5  provide two alternate embodiments of the present invention. The embodiment of  FIG. 4  provides for a split top hat design and the alternate embodiment of  FIG. 5  provides for a collapsible top-hat design. 
     It should be noted that the embodiments of  FIGS. 4 and 5  are only provided as way of example and to ease understanding and other embodiments are equally available under the workings of the present invention. Therefore, the examples provided in these figures shall not be considered to place any limitations on the concepts provided herein by the present invention. 
     In  FIG. 4 , a generic base frame  400  which can be representative of a variety of base frames, including but not limited to those discussed in  FIGS. 2 and 3  is provided. In other words, the split top hat design can be used with a variety of frame designs such as the examples shown in  FIGS. 2 and 3 . A two component (split) top hat design will then be assembled on the base frame as shown in the figure. The two split—top hat components of  FIG. 4  are shown individually and respectively referenced as  413  and  415 . The two portions  413  and  415  are designed to compliment each other and to fit securely. The frame  400  and the two components  413  and  415  are all also designed to fit securely with each other and the frame  400  as desired. 
     As illustrated, the split top hat includes a receiving member  413  having an upper portion and a plurality of sides. The receiving member  413  then is to receive an inner member  415 . In the illustrated embodiment, the receiving member  413  has no bottom so that it is placed over the inner member  415 , in a design that encompasses the inner member on three sides. In alternate embodiments, it is possible to have alternate designs where the receiving member has a bottom and the inner member slides into the receiving member. Other such alternate designs are also possible. 
     The receiving member  413  and inner member  415  are then secured to the base frame independently or to one another and then to the frame as a unit, using a variety of methods as known to those skilled in the art. 
     It should be noted that when desired, it is possible to have embodiments where the top hat can only be partially removed. In such an example, the receiving portion and the inner portion may be only secured to the frame independently such that only the receiving portion is removed selectively. In certain instances, removing the receiving member may be sufficient to cause adequate and desired height/weight reduction to enable easier installation and/or transport of the unit. However, once final installation is performed, it may be desirable to have the receiving member to ensure structural and electrical integrity. 
     The concept of having an easy to assemble and disassemble top hat promotes the reduction in weight of currently the heaviest element in the breakdown process which is the top hat itself. Referring back to  FIG. 3 , it is possible to use the top hat design with the frame  400  in a way such that by providing this option the number of personnel that requires the installation of the frame is reduced to a minimum. In this case, it is even possible to limit the number of Customer Engineers (CE) operation to one person, thereby saving costs. This is because in smaller units, a removable top hat allows the reduction of all single element weights below 39.6 lbs or so which is easily manageable by one person. 
     Referring back to  FIG. 3 , in a different arrangement when the frame and/or servers are larger and resemble that of frame  312  and  314 , the top hat design as provided by the embodiment of  FIG. 4  allows the bulk power enclosure(s) (hereinafter BPE) to remain fastened to the top-hat, thereby shortening disassembly/re-assembly time. In this case, again even though the number of CEs required to carryout the process may be more than one person, but it is nonetheless kept to a minimum. It is for example possible to only have (2) CEs carrying the procedure. This is because many of the requirements that were procedural necessities in the breakdown process employed by the prior art can be suspended. For example, if a traditional breakdown process is to be employed, only the removal of A-frame Internal Battery Feature(s) (IBF) or possibly the removal of backup cooling Air Moving Assembly (AMA) may be necessary. In doing so, the breakup of many larger servers can be reduced to a single CE operation. 
     The following table provides some examples of this reduction of process steps. In Table 1, some examples of the weight of conventional units are provided. In addition, one example of the approximate weight of some of the embodiments of the present invention is also provided. As can be seen by providing a split top hat design the weight is significantly reduced. 
     
       
         
               
             
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Top hat attributes: 
               
             
          
           
               
                   
                   
                 Split Top Hat such as 
               
               
                   
                   
                 proposed by 
               
               
                 Design attribute 
                 Conventional Hats 
                 embodiment of FIG. 4 
               
               
                   
               
               
                 Top Hat Weight 
                 70 lbs (unpopulated) 
                 38 lbs 
               
               
                 Other components such 
                 30 lbs 
                 30 lbs 
               
               
                 as BPE weight 
               
               
                 Weight of Top Hat plus 
                 130 lbs or more (single 
                 70 lbs 
               
               
                 BPE 
                 fields replaceable unit 
               
               
                   
                 or FRU not possible) 
               
               
                   
               
             
          
         
       
     
     In  FIG. 5 , an alternate embodiment is provided illustrating a collapsible top hat referenced as  500 . In this embodiment, the frame&#39;s height reduction is supported by employing a plurality of self-contained, collapsible side members referenced as  510 . The embodiment of  FIG. 5  provides for an illustration of the collapsible option. Moving from the left hand side to the right, a progression of illustrations can be observed showing the feature in its full height and collapsing it until it is almost flush with the height of the frame  550 . 
     A variety of different embodiments can be employed that allows for the collapsibility feature of the present invention as suggested by illustration of  FIG. 5 . In the embodiment, as shown in  FIG. 5 , a top member or an “upper portion”  520  of top hat  500  is connected to a plurality of collapsible side members  510  that are pivotable and can collapse upon themselves to extend (or retract) the top member. The side members extend between the top member  520  and base frame  550 . The top hat  500  as shown in this is used for housing electronic components. The base frame  550  has a height  502  and a length  504  and the collapsible top hat  500  is connected to an upper portion  552  of the frame. The top member  520  of the top hat has a length  506  extending in a direction of the length  504  of base frame  550  and the side members  510  have lengths  508  extending in the direction of length of the base frame  550 . The top member  520  and the side members  510  collectively provide surfaces of the top hat on which to mount at least a bulk power enclosure. Each the side member is pivotable from an upright first position supporting the top member above the base frame to a lowered second position in which the top member is adjacent the base frame. In this way, the side members can extend or retract the top member from a first position to a second position. 
     In the illustrated figure, the frame contents are removed from and a preferred embodiment is shown that allows a lever or screw actuated approach to be used to drive the pivoted side members to collapse onto themselves, thereby lowering/increasing the frames top height and/or moving the upper portion of the collapsible feature or collapsible member from a first to a second position (top to base). As shown, in an embodiment of the present invention, the top hat  500  has collapsible pivot points at the top member  520  of the top hat  500 . In a further embodiment the side members remain substantially rigid and unbent while extending or retracting. A variety of other options are also available and the designs of the sides may be selectively designed. For example, in one design, the sides may be secured to the bottom of the upper portion and have a criss-cross collapsible design, while in other alternate embodiments they may be secured to the sides of the upper portion and have additional extending members to aid them in extending and collapsing action. 
     In addition, the collapsible top hat may be secured to the frame in a number of manners known to those skilled in the art. The same is true about the securing of the sides to the upper portion  520 . Since a variety of designs may be possible, a variety of securing option for the securing of the sides are also therefore possible. 
     As before, the collapsible top hat design provided in conjunction with  FIG. 5  can be utilized with a variety of base frames, including but not limited to those discussed in conjunction with  FIGS. 2 and 3 , previously. 
     While the preferred embodiment to the invention has been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described.