Abstract:
A memory system includes c-shell units, PCBs, and a controller logic. The c-shell units are positioned side-by-side adjacent each other. Each c-shell unit has at least two sled-less memory bays and the sled-less memory bays are positioned vertically relative to each other. Each of the sled-less memory bays receives a memory device. A PCB is vertically mounted to a corresponding c-shell unit. The control logic controls access to and from the memory devices so that it manages storing data to the memory devices and retrieving data from the memory devices. Each PCB comprises traces to route signals between the control logic and the memory devices.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of Invention 
     The current invention relates generally to apparatus, systems and methods for electronically storing data. More particularly, the apparatus, systems and methods relate to storing data in memory bays. Specifically, the apparatus, systems and methods provide for storing data in memory bays that are accessed from the sides of a rack mountable chassis that only requires air cooling at a room temperature of about 70 degree Fahrenheit. 
     2. Description of Related Art 
     Current Commercial Off the Shelf (COTS) storage solutions are insufficient to meet the low Size Weight and Power (SWaP) requirements imposed by the growing data storage requirements in the commercial government and military sectors. Conventional Network Accessible Storage (NAS) systems and Storage Area Network (SAN) systems are designed for use in a large support infrastructure environment making them unsuitable for smaller support infrastructure scenarios such as those in government and military environments. Conventional NAS and SAN systems of a high data capacity (over 100 terabytes) are on average six rack units in height (10.5 inches) and have a weight of approximately eighty pounds. The cost of traditional NAS storage purchased from commercial vendors is high, the industry average being about one thousand dollars per terabyte. A need exists for a better digital data storage solution. 
     SUMMARY 
     One aspect of an embodiment of the invention includes a memory system. The memory system includes c-shell units, printed circuit boards (PCBs), and a controller logic. The c-shell units are positioned side-by-side adjacent each other. Each c-shell unit has at least two sled-less memory bays and the sled-less memory bays are positioned vertically relative to each other. Each of the sled-less memory bays receives a memory device. A PCB is vertically mounted to a corresponding c-shell unit. The control logic controls access to and from the memory devices so that it manages storing data to the memory devices and retrieving data from the memory devices. Each PCB comprises traces to route signals between the control logic and the memory devices. 
     In one aspect another embodiment may provide a TeraStar memory system. This memory system includes a housing that houses memory bays and memory devices. The housing has a front side, a back side, a left side, a right side, a bottom side and a top side. Two or more horizontal memory bays are horizontal and adjacent each other on the left side of the memory system. Memory devices are inserted into the horizontal memory bays on the left side. The memory devices can also be removed from horizontal memory bays on the left side. Two or more horizontal memory bays that are horizontal and adjacent each other are located on the right side of the memory system. Memory devices are inserted into the horizontal memory bays on the right side. The memory devices can also be removed from the horizontal memory bays on the right side. 
     Another aspect of the invention is a method of adding and removing memory from a memory system. The memory system is rack mountable with a front side, a back side, a left side, a right side, a top side and a bottom side with the memory system rack mountable between its left and right sides. The method begins by installing a first memory device into a first memory bay located on the left side of the memory system. The memory device and memory bay are similar to the memory devices and memory bays discussed below. A second memory device is installed into a second memory bay that is located on the left side of the memory system and where the second memory bay is horizontally adjacent the first memory bay. A third memory device is then removed from a third memory bay located on the left side of the memory system. The third memory bay is horizontally adjacent the first memory bay. A fourth memory device is installed into a fourth memory bay located on the right side of the memory system. A fifth memory device is removed from a fifth memory bay located on the right side of the memory system where the fifth memory bay is vertically adjacent the fourth memory bay. 
    
    
     
       BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
       One or more preferred embodiments that illustrate the best mode(s) are set forth in the drawings and in the following description. The appended claims particularly and distinctly point out and set forth the invention. 
       The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate various example methods, and other example embodiments of various aspects of the invention. It will be appreciated that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. One of ordinary skill in the art will appreciate that in some examples one element may be designed as multiple elements or that multiple elements may be designed as one element. In some examples, an element shown as an internal component of another element may be implemented as an external component and vice versa. Furthermore, elements may not be drawn to scale. 
         FIG. 1  illustrates an environment in which the preferred embodiment of a TeraStar memory system may operate. 
         FIG. 2  illustrates a perspective view of the preferred embodiment of the TeraStar memory system. 
         FIG. 3  illustrates a front view of the front panel of the preferred embodiment of the TeraStar memory system. 
         FIG. 4  illustrates a top view of the preferred embodiment of the TeraStar memory system with its top cover removed. 
         FIG. 5  illustrates a perspective view of a c-shell of the preferred embodiment of the TeraStar memory system. 
         FIG. 6  illustrates an example view of a printed circuit board (PCB) used with a c-shell of the preferred embodiment of the TeraStar memory system. 
         FIG. 7  illustrates a perspective view showing how memory devices are loaded into and taken out of the rights side of the preferred embodiment of the TeraStar memory system. 
         FIG. 8  illustrates a perspective view of memory devices loaded into a c-shell of the preferred embodiment of the TeraStar memory system. 
         FIG. 9  illustrates an embodiment of a method for loading and removing memory from the preferred embodiment of the TeraStar memory system. 
     
    
    
     Similar numbers refer to similar parts throughout the drawings. 
     DETAILED DESCRIPTION 
       FIGS. 1-8  illustrate the preferred embodiment of a memory system  1  that can store at least 128 terabytes of data. This memory system  1  is also known as a Terabyte Storage Transfer Archive Repository (TeraStar). TeraStar (memory system  1 ) is a great improvement over prior art system. For example, this memory system  1  fits into a small three rack unit (RU) in height (5.25 inches) chassis that is capable of hosting 32 removable/hot swap drives of serial advanced technology attachment (SATA) (versions I, II, III), serial attached SCSI (SAS) (versions 3, 6) and/or other Solid State Disk (SSD) versions in either a 3.5 inch and/or a 2.5 inch form factor. The capacity of this system  1  is a direct result of the internal disk orientation which is a unique side accessible design as discussed below. The memory system  1  also provides for the addition of 2×3.5 inch non-removable drives and 2×2.5 inch non-removable drives. This novel memory system  1  provides flexibility to utilize either Redundant Array of Independent Disks (RAID) configurations or Just a Bunch of Disks (JBOD) configurations or both simultaneously. Currently the COTS industry average storage capacity for a 3 RU data storage solution has a maximum disk capacity of sixteen removable disks. As of Jul. 10, 2013, high end NAS/SAN COTS vendors have an average cost to the customer of $1000.00+ per terabyte (TB). In contrast, the TeraStar memory system  1  on average costs about $200.00 per TB as of Jul. 10, 2013. The TeraStar memory system  1  also uses a highly efficient power utilization model reducing the need for the average 1200 W power supply which is a standard minimum for NAS/SAN COTS systems of similar size or capacity. 
     Prior art memory systems chassis in general utilize cold rolled steel. This results in an average weight per three rack units (RU) chassis of 80 pounds (system board and core components installed) per chassis. By taking advantage of high strength (5000 series) aluminum in the design and manufacturing of the TeraStar memory system  1 , the overall weight of the chassis is reduced to 28 pounds with the system board and core components installed. This makes for a much more consumer manageable system as well as increasing the overall capacity per server rack by reducing the total weight per rack to within standard defined manufacturer weight limits. 
       FIG. 1  illustrates one example environment where the TeraStar memory system  1  can operate. The TeraStar memory system  1  is connected to a network interface unit  100  that is connected to a local network  102 . The network interface unit  100  and the local network  102  can be any type of network interface or network us understood by one of ordinary skill in this art. The network interface unit  100  formats data exchanged between the TeraStar memory system  1  and the local network  102  so that it is a format expected by these two devices  1 ,  102 . A computer  104  is connected to the local network  102 . The computer  104  or any device that wants to write to memory or read from memory stored in the TeraStar memory system  1  can then access the memory stored in the TeraStar memory system  1  via the local network  102  and the network interface unit. 
     Referring to  FIG. 2 , the TeraStar memory system  1  includes a chassis/housing  3 . The housing  3  is generally rectangular in shape and includes a top side  5 A, a front side  5 B, a right side  5 C, a back side  5 D a left side  5 E and a bottom side  5 F. The housing  3  includes left and right doors  7 A-B each connected to the housing  3  with elongated hinges  9  similar to piano type of hinges. As illustrated in  FIG. 2  the hinges  9  allow the door  7 A to open in an upward direction as shown by arrow A1. Door  7 A opens in a similar way. Each door  7 A-B has a thumb-screw  11  that allows the doors  7 A-B to be locked in a closed position by the thumb-screw  11  or to be quickly released by removing the thumb-screw  11 . The thumb-screws  11  are located in a recessed portion  12  of the doors  7 A-B. Once the thumb-screws are unfastened, the doors  7 A-B can easily be opened by placing fingers in the recessed area  12  and pulling the door upward. 
     The housing  3  further includes an access panel  13  that is releasably held in place by several screws  15 . The access panel  13  provides access to a memory controller logic  17  located at the rear end of the housing near the back wall  5 D. Additional screws  19  hold c-shells, fans and other component that are discussed further below to the chassis/housing  3 . The front wall  5 B further includes side tabs  21  on its left and right sides. Bolts can be passed through openings  23  on the side tabs to easily mount the TeraStar memory system  1  in an equipment rack. 
       FIG. 3  illustrates the preferred embodiment of the TeraStar memory system  1  front panel  23  that forms the front wall  5 B. The front panel  23  includes a display  25  that can be a liquid crystal display (LCD) or another type of display as understood by one of ordinary skill in this art. The front panel  23  includes one or more labels  27  that can be used to display information about the TeraStar memory system  1  or other information. The front panel  23  has a lower central recessed area  29 . This recessed area  29  provides an ideal location for one to place their fingers when lifting the TeraStar memory system  1 . Bolts  31  in the recessed area  29  aid in connecting the front panel  23  to the chassis/housing  3 . 
     The front panel  23  contains distinctive openings. The openings include left and right arrays of square openings  33  arranged in rectangular patterns consisting of rows and columns of openings  33 . Additionally, two different sizes of round openings  35  are spread from left to right across the front panel as illustrated. 
       FIG. 4  illustrates a top view of the memory system  1  with its top wall  5 A removed. The top portions of eight c-shell units  37 A-H can be seen. As discussed below each c-shell unit can house four memory units such as disk drives, hard drives or another type of memory. Four c-shell units  37 A-D are aligned adjacent each other on the left side  39  of the memory system  1  and four c-shell units  37 E-H are similarly aligned adjacent each other on the right  40  side of the memory system  1 . Rear flanges  42  of each c-shell unit  37 A-H are attached to the top wall  5 A with screws  73 . Additionally, the corners of the upper left flanges  43  and upper right flanges  44  are attached to the top wall  5 A with screws  73 . As seen through openings  66  ( FIG. 5 ) in upper left flanges  43  and upper right flanges  44  screws  47  are also used to secure a bottom shelf  49  of the c-shells  37 A-H to bottom side  5 F of the housing  3 . 
     Fan cooling units  51  are located between the front panel  23  and c-shell  35 A and c-shell  37 E to provide active cooling of the c-shells  37 A-H. Fan cooling units  52  are located between c-shell  35 C and c-shell  37 B and between c-shell  35 G and c-shell  37 F. Additional fan cooling units  53  are located between c-shell  37 D and a control logic  17  as well as between c-shell  37 H and the control logic  17 . 
     “Processor” and “Logic”, as used herein, include but are not limited to hardware, firmware, software and/or combinations of each to perform a function(s) or an action(s), and/or to cause a function or action from another logic, method, and/or system. For example, based on a desired application or need, logic and/or processor may include a software controlled microprocessor, discrete logic, an application specific integrated circuit (ASIC), a programmed logic device, a memory device containing instructions, or the like. Logic and/or processor may include one or more gates, combinations of gates, or other circuit components. Logic and/or a processor may also be fully embodied as software. Where multiple logics and/or processors are described, it may be possible to incorporate the multiple logics and/or processors into one physical logic (or processors). Similarly, where a single logic and/or processor is described, it may be possible to distribute that single logic and/or processor between multiple physical logics and/or processors. 
     The data of all four memory bays of each c-shell are collected on a single connector and transported to the control logic  17  on a single cable  59 . In summary, there are eight cables  59 , one to transport all four memory bay signals of each c-shell to the control logic  17 . These cables  59  are routed in a central trough running between the two banks of c-shells. The preferred embodiment of the TeraStar system  1  includes a pair of 1-gigabit input/output I/O lines  61  connected between connectors on the back wall  5 D and the control logic  15  as well as a pair of 10-gigabit input/output I/O lines  61  connected between connectors on the back wall  5 D and the control logic  17 . 
       FIG. 5  illustrates a single c-shell  37 . Each c-shell  37  has a left wall  64 A, a back wall  64 B and a right wall  64 C. These walls can be formed out of a single piece of high strength aluminum and then bent into the shape of  FIG. 5 . The upper left flange  43  extends inward from the left wall  64 A and the upper right flange  44  extends inward from the right wall  64 C. The rear flange  42  extends outward from the back wall  64 B. The left wall  64 A further includes a lower left flange  65 A that extends inward and the right wall  64 C includes a lower right flange  65 B that also extends inward toward the lower left flange  65 A. Holes  66  are located in the left flange  43  and the right flange  44  to allow a screwdriver to pass through to allow screws  47  to be tightened into through the lower left flange  65 A and the lower right flange  65 B and into the chassis  3 . 
     In addition to the bottom shelf  49 , the c-shell unit  37  has three other shelves  67 A-C. Each of these shelves  67 A-C has a tab  69  near each of its four corners. These tabs  69  are adapted to pass through complementary rectangular shaped openings  71  in the left wall  64 A and the right wall  64 C. Shelves  67 A-C contain openings  66  similar to the right flange  42  and the left flange  43  to allow a screwdriver to pass through to allow screws  47  to be tightened into the chassis  3 . Openings formed between the walls  64 A-C and the shelves  67 A-C are memory bays  110  into which a 2.5 inch, a 3.5 inch or another size of memory can be inserted as discussed in more detail later. 
     The c-shell  37  also contains a variety of other holes/openings. For example, thread holes  73  provide a way to attach a top wall of the housing  3  to the top of the c-shells  37  and/or to provide a way mount to a printed circuit board (PCB) vertically to the back wall  64 B. Other holes  75  provide openings to used bolts to connect adjacent c-shells together and/or to further mount the c-shells  37  to the bottom of the housing  3 . Of course some of these holes may not be used and can instead allow more cooling air to circulate through the c-shells while they are in operation. 
     One of the novel features of this c-shell  37  is that it is readily cooled by flowing air from its left side  64 A to its right side  64 C. Large openings  77 A-D in the left side  64 A and the right side  64 C provide open areas to allow air blow by fans to flow through. As illustrated, in the preferred embodiment, these openings  77 A-D generally extends from the front end  79  of the c-shell to the back wall  64 B. Openings in the back wall  64  allow connectors on a PCB (discussed below) or other components on the PCB to extend partially into the c-shell  37 . 
       FIG. 6  illustrates the preferred embodiment of a PCB  83  that is mounted to the back wall of a c-shell  37 . As discussed in more detail below, these memory backplanes (PCB  83 ) provide four serial attached SCSI (SAS) disk connections in a stacked vertical configuration unlike prior art disk drive backplanes are typically designed for Serial ATA (SATA) or SAS disks in a horizontal configuration. By utilizing a vertical orientation in the memory backplanes, the TeraStar memory system  1  reduces the overall PCB  83  trace length between the disk interface cable and the SAS disk drive ports. This results in a more efficient design which allows the use of primarily passive components on the PCB  83  which in turn reduces the power requirements for the overall TeraStar memory system  1 . 
     This PCB  83  is novel in that it does not need to alter data signals transmitted to and received from each of the four memory bays before reaching the controller logic  17 . The power signal(s) are isolated on a right side of the PCB and may be conditioned with one or more capacitors  91  of various values. Additionally, there may be pull-up circuits to be sure that power is supplied at a specific value. Connectors for each media bay are mounted to the memory bay connector pads  85 A-D located toward the right side of the PCB  83 . Traces  87 A-D carrying generally non-power data signals leave these pads and run generally directly to c-shell consolidation connector pads  89  located near the upper left corner of the PCB  83 . For example, Traces  87 D-C are routed from a lower right/central location diagonally toward the upper left location of the c-shell consolidation connector pads  89 . Traces  87 A-B that are located generally to the right of the c-shell consolidation connector pads  89  travel generally horizontally toward the c-shell consolidation connector pads  89 . This routing reduces interference with power signals on the right side of the PCB  83  and reduces the length of travel of unaltered data signals between a memory bay and the controller logic  15 . A c-shell consolidation connector is mounted on the c-shell consolidation connector pads  89  pads and bundles all four sets of data signals from each of the four media bays installed in the TeraStar memory system  1  at this connector. In the preferred embodiment, this consolidation connector is an SFF-8087 connector but it can be another type of connector. These four sets of raw/unconditioned and unamplified data signals can then travel through a single cable from the c-shell connector at the c-shell connector Pads to the controller logic  17 . 
       FIG. 7  illustrates the TeraStar memory system  1  with its right door  7 B opened in the upward position. This example illustrates how memory devices  108  can be loaded into and removed from the four adjacent c-shells, for example in the direction of arrows A3. Here, 14 of the 16 memory bay contain a 3.5 inch memory device  108  that nearly fills each memory bay  110 . However, other sizes of memory can be used in the memory bay  110 . For example, SATA (I, II, III), SAS (3, 6) and Solid State Disk (SSD) versions in either a 3.5 inch and/or a 2.5 inch form factor or other types of memory devices can be used in any of the memory bays  110 . 
     It will be appreciated that the orientation of the memory devices  108  within the c-shells  37 A-H of the TeraStar memory system  1  is a unique design allowing for the use of 32 hot swappable memory devices when inserted into the main TeraStar chassis  3  at a total quantity of eight c-shell units  37 A-H (e.g., disk cages) per system. Through the use of non-magnetically conductive metal in the construction of these c-shell units  37 A-H, the memory devices can be placed in close proximity to one another eliminating magnetic interference from other memory devices in the c-shell units  37 A-H and the system  1  when placed in this orientation. Furthermore and as mentioned below, the c-shell units  37 A-H allow for positive airflow from one side of the c-shell units  37 A-H to another over the top of the inserted memory devices thus allowing for the memory device to be adequately cooled at room temperature when in operation. The use of high strength aluminum in the construction of the c-shell units  37 A-H allows for the c-shell units  37 A-H to act as a passive heat sink for the installed disks as well as providing structural reinforcement for the system in its assembled configuration. 
       FIG. 8  illustrates a detailed view of memory loaded into a c-shell  37 . In this example, one 2.5 inch form factor memory device  107  is load in the upper most memory bay  110  with three 3.5 inch form factor memory devices  108  loaded into the three other memory bays  110 . The TeraStar memory system  1  does not require traditional “sleds” that are needed by prior art systems to ensure proper insertion into the chassis disk drive bay and typically are attached to the disk drives via 4-6 screws installed through the disk sled into the disk drive itself. The use of these disk “sleds” consumes an excessive amount of man hours to install and remove these screws on a regular basis in many disk drives at once decreasing the use of the hot swap disk technology. Unlike COTS storage servers that use disk “sleds” which attach to the disk drive prior to insertion into a memory bay, the c-shells  37  of the TeraStar memory system  1  do not require memory devices to be attached to sleds. The TeraStar memory system  1  eliminates the need for this “sled” by using specific mechanical design specifications in the c-shells  37  conforming to COTS storage media measurements and the use of one overall side door panel on each side of the unit. This provides a cleaner, quicker and more flexible disk drive insertion and removal process. 
     The elimination of the use of sleds also provides more free space to allow the TeraStar memory system  1  to be air cooled at a room temperature of about 70 degrees Fahrenheit (F) only using fans. Because sleds are not used, there is a gap of T1 ( FIG. 8 ) between the top of a 3.5 inch form factor memory  108  and the floor above that memory. This small gap of about ⅛ of an inch allows air to flow in the direction of arrows A2 from the left side  64 A of the c-shell  37  of  FIG. 8  to the right side  64 C of the c-shell. The openings  77 A-D also greatly aid in this airflow and cooling of memory devices  107 ,  108  in the c-shell. A gap of T2 between memory devices  108  and the left wall  64 A (and similarly with the right wall  64 C) also aids in cooling the memory devices  108 . In an alternative configuration, there may be a gap between the bottom of a memory device and the bottom shelves or aid in further cooling and this gap may be created with small pads located on the bottom of some of the memory devices. 
     Note that either a 2.5 inch form factor memory device  207  or a 3.5 inch form factor memory device  108  can be hot-plugged into one of the same connector  85 A-D located on the PCB  83  that is vertically attached to the back wall  64 B of the c-shell  37  while the TeraStar memory system is in operation. These connectors  85 A-D are located near the lower right portion of each memory bay  110  so that different types of memories will fit into the memory bays  110  and be physically supported by a corresponding memory bay  110  shelf  64 A-D. For example and as mentioned above, SATA (I, II, III), SAS (3, 6), SSD versions in either a 3.5 inch and/or a 2.5 inch form factor or other types of memory devices can be used with the same connector. In the preferred embodiment, the connector is an SFF-8482 connector that is supports SATA as well as SAS and other types of memory devices. Having described the components of the TeraStar memory system  1 , its use and operation will now be described. To prepare the system  1  for operation its side doors  7 A-B are rotated upward in the direction of arrow A1 ( FIG. 1 ) and any combination of memory devices  107  with a 2.5 inch form factor and/or memory devices  108  with a 2.5 inch form factor are loaded into the 32 memory bays  110 . After that the TeraStar memory system  1  is started and begins to operate at room temperature of about 70 degrees Fahrenheit. It is air cooled by its internal fans without having any additional cooling requirements. This allows the system  1  to solely be air cooled but not reaching an operating temperature of about 85 degree Fahrenheit. Once up and running the TeraStar memory system  1  can be accessed by any computing device on the local network  102  of  FIG. 1 . For example, commands from the computer  104  can store data in the TeraStar memory system  1  and request data from the TeraStar memory system  1 . 
     Example methods may be better appreciated with reference to flow diagrams. While for purposes of simplicity of explanation, the illustrated methodologies are shown and described as a series of blocks, it is to be appreciated that the methodologies are not limited by the order of the blocks, as some blocks can occur in different orders and/or concurrently with other blocks from that shown and described. Moreover, less than all the illustrated blocks may be required to implement an example methodology. Blocks may be combined or separated into multiple components. Furthermore, additional and/or alternative methodologies can employ additional, not illustrated blocks. 
       FIG. 9  illustrates a method  900  of adding and removing memory from a memory system. The memory system is rack mountable with a front side a back side, a left side, a right side, a top side and a bottom side with the memory system rack mountable between is left and right sides. The method  900  begins by installing a first memory device into a first memory bay located on the left side of the memory system, at  902 . The memory device and memory bay are similar to the memory devices and memory bays discussed above. A second memory device is installed into a second memory bay, at  904 , that is located on the left side of the memory system and where the second memory bay is horizontally adjacent the first memory bay. A third memory device is then removed from a third memory bay located on the left side of the memory system, at  906 . The third memory bay is horizontally adjacent the first memory. A fourth memory device is installed into a fourth memory bay located on the right side of the memory system, at  908 . A fifth memory device is removed from a fifth memory bay located on the right side of the memory system, at  910 , where the fifth memory bay is vertically adjacent the fourth memory bay. 
     In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. Therefore, the invention is not limited to the specific details, the representative embodiments, and illustrative examples shown and described. Thus, this application is intended to embrace alterations, modifications, and variations that fall within the scope of the appended claims. 
     Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described. References to “the preferred embodiment”, “an embodiment”, “one example”, “an example”, and so on, indicate that the embodiment(s) or example(s) so described may include a particular feature, structure, characteristic, property, element, or limitation, but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element or limitation. Furthermore, repeated use of the phrase “in the preferred embodiment” does not necessarily refer to the same embodiment, though it may.