Patent Description:
Certain embodiments relate to the field of assembly of server systems, specifically utilizing mechanized robotic systems for assembling server systems.

As data-center server design has increasing back-plane connector density (with more and more back-plane connectors involved) the problem of reliably engaging and disengaging back-plane connectors has grown significantly. Complex modules with thousands of pins require exceptional force (several hundreds of pounds of force) to engage all of the connectors at least substantially simultaneously and/or to disengage all of the connectors at least substantially simultaneously. Due to the at least substantially rigid nature of the server devices (e.g., blades, and/or the like), the backplane connectors are required to be connected at least substantially simultaneously, with high level of precision due to the fragile nature of the conductive aspects within each of the plurality of backplane connectors. Human-applied force alone is no longer a practical option to supply the level of force required to connect the plurality of backplane connectors of many server devices.

Another approach is to supply force for back-plane connector engagement / disengagement via a lever-arm design. These lever arms may decrease the amount of force that a human is required to apply due to the mechanical advantage provided by the lever arm. The mechanical advantage of the lever arm is the ratio of output force to input force, so a lever arm can decrease the force requirement from human hands by incorporating a longer lever arm. Thus, as the force requirement of back-plane connector engagement / disengagement continues to increase, increasingly long lever arms are required to maintain a reasonable human force input requirement for engagement/disengagement of backplane connectors. However, long length lever arms are highly impractical, as their bulk and size may limit the ability to efficiently utilize space around and/or within server cabinets.

Furthermore, using human-applied force via lever arms to engage a long row of back-plane connectors generally results in imperfect synchronization between left and right-side lever arms, which results in imperfect force and alignment to engage backplane connectors. The motion/force supplied from a human's left and right hands are naturally not synchronized, not aligned and not consistent. Differences in motion/force applied via left and right-side lever arms results in skewing of the server blade during installation, causing the server blade back plane connector pins to be skewed relative to corresponding connectors during engagement. This increases the chances of bending pins during installation, and just one bent pin can render an entire system including the server blade not functional fundamentally. Such inconsistencies between left and right side levers becomes more unpredictable when the lever arms are operated by different people, since the force patterns of human left and right hands are essentially different from one person to another.

Due at least in part to the requirement of highly precise alignment and high levels of force when engaging and disengaging backplane connectors of modern server devices, a need exists for mechanisms facilitating installation and disengagement of servers with corresponding backplane connectors while minimizing the likelihood of damage to connector pins and sockets of the backplane connectors.

<CIT> and <CIT> disclose an electronic device that is immersed in a coolant filled in a cooling apparatus, and directly cooled. The electronic device includes a storage substrate, and a plurality of flash storage units which are mounted on the storage substrate. The flash storage units are arranged on a surface parallel to at least one surface of each of the storage substrates so as to be adjacent one another in a width or a length direction, or in both the width and the length directions of the flash storage unit. The storage substrates are arranged on at least one surface of the base board. The backplane includes a plurality of connectors for electric connection of the respective storage substrates, and is mounted orthogonally onto the one surface of the base board. The flash storage unit may be an M. <NUM> SSD or an mSATA SSD.

<CIT> discloses a method of docking an electronic circuit board. The method includes securing the electronic circuit board to a mounting plate that is mechanically linked to a rigid guide plate, wherein the electronic circuit board has a first connector. The rigid guide plate is inserted in a linear insertion direction between guides that are positioned adjacent a second connector configured to receive the first connector. The rigid guide plate insertion stops in a position where the first connector of the electronic circuit board is aligned with the second connector. Actuating a positioning handle that is accessible from a trailing edge of the guide plate causes rotation of a rotatable plate relative to the guide plate. Accordingly, rotation of the rotatable plate causes linear movement of the mounting plate in a second linear direction that is substantially perpendicular to the insertion direction, wherein the linear movement of the mounting plate causes the first connector of the electronic circuit board to be received into the second connector.

<CIT> discloses an apparatus may include drive chassis, at least one horizontal drive drawer extending from a first side of the drive chassis to a second side of the drive chassis and/or at least one computer drive disposed on the horizontal drive drawer. Additionally, a computer server system and a method for providing the apparatus are disclosed.

According to a first aspect of the invention, there is provided a linear motion actuation system for moving a server blade within a server rack according to claim <NUM>.

According to a second aspect of the invention, there is provided a method for moving a server blade within a server rack according to claim <NUM>.

Further features according to embodiments of the invention are defined in the dependent claims.

The present disclosure more fully describes various embodiments with reference to the accompanying drawings. It should be understood that some, but not all embodiments are shown and described herein. Indeed, the embodiments may take many different forms, and accordingly this disclosure should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

Various embodiments are directed to an electromechanical tool embodied as a linear motion actuation system configured for moving server blades relative to server racks, for example during server installation and/or removal processes. As server blades require engagement of an ever-increasing number of back-plane connector pins between a back-surface of the server blade and a connection plate associated with the server rack (e.g., a bus), the amount of force required to simultaneously engage/disengage server blades from back-plane connectors is constantly increasing. In order to provide sufficiently high engagement/disengagement forces to a server blade during installation or removal processes, while maintaining sufficiently high degrees of precision in moving the server blade into/out of engagement with corresponding back plane connectors, the linear motion actuation system of various embodiments is configured to provide a high degree of installation/removal forces while maintaining high degrees of precision in moving the server blade in an at least substantially linear direction relative to the server rack, without skewing the server blade within the server rack, so as to ensure highly precise engagement between the back-plane connectors and corresponding pins of a server blade.

As a non-limiting example, an example server blade may include pins to engage <NUM> back-plane connectors associated with a blade slot of a server rack, with each connector embodied as a <NUM>-pin by <NUM>-pin signal connector array (plus an additional non-signal connector array). Accordingly, in such an embodiment, a total of <NUM> pins must be connected at least substantially simultaneously, and with a high degree of precision to avoid damage to any of the pins/connectors when installing the server blade. If each pin/connector is assumed to require at least approximately <NUM> lbf to engage the pin into a corresponding connector, the overall server blade requires at least approximately <NUM> lbf to simultaneously engage all of the <NUM> pins into corresponding connectors. Including frictional forces arising during the linear movement of a server blade relative to a server rack, an example server blade may require a total of at least approximately <NUM> lbf to install the server blade within a server rack. This level of force is drastically higher than an average human is expected to be able to apply, particularly in the space-limited environment often associated with installing a server blade within a server rack.

<FIG> illustrates an example server cabinet <NUM> within which a plurality of server racks <NUM> are installed. The server cabinet <NUM> may define a housing defining an access opening, for example, spanning at least substantially an entire side (e.g., a front side) of the server cabinet <NUM>. Although not shown, the server cabinet <NUM> may comprise a plurality of server rack mounting configurations for securely and at least substantially rigidly securing each of a plurality of server racks <NUM> therein. In the illustrated embodiment of <FIG>, for example, the server cabinet <NUM> may be configured to securely support three server racks <NUM> therein.

With reference to <FIG>, which illustrate various components of a server rack <NUM> according to certain example configurations, the server rack <NUM> may define a rack housing <NUM> defining a plurality of blade slots <NUM> therein (e.g., four blade slots as shown in the illustrated embodiment). Each blade slot <NUM> may be configured to support a single server blade therein. Each blade slot may be defined within the housing, and may have an open front end, slot dividers configured for supporting a server blade <NUM> therein. Moreover, the rack housing <NUM> may be associated with a back plane <NUM> having a plurality of connector arrays <NUM> thereon. The back plane <NUM> may comprise one or more connector arrays <NUM> corresponding to each blade slot <NUM>, wherein each connector array <NUM> is configured to provide electrical and signal connectivity to a corresponding server blade <NUM> installed in the blade slot <NUM>. Moreover, the connector arrays <NUM> of certain embodiments comprise alignment features (e.g., alignment pins) to ensure that the connectors are being appropriately engaged by the pin arrays of a server blade <NUM>. In certain embodiments, the back plane <NUM> may be embodied as or may comprise a circuit board (e.g., a printed circuit board) operating as a bus providing connectivity between server blades <NUM> installed within the server rack <NUM> and/or with additional server blades <NUM> installed in other server racks (e.g., within the same server cabinet <NUM> and/or additional server cabinets).

As also shown in the example embodiment of <FIG>, the rack housing <NUM> may define installation flanges <NUM> at least substantially aligned with a front surface of the rack housing <NUM> and positioned on opposing sides of the rack housing <NUM>. The installation flanges <NUM> may each be at least substantially perpendicular to the blade slots <NUM> (e.g., if the blade slots <NUM> are at least substantially horizontal, and configured to support server blades <NUM> installed in horizontal orientations, then the installation flanges <NUM> may extend at least substantially vertically, along opposite sides of the open front end of the rack housing <NUM>), such that the installation flanges <NUM> extend adjacent each of the blade slots <NUM> of the rack housing <NUM>.

Moreover, as shown, the installation flanges <NUM> comprise bracket mounting fastener portions (such as the T-head pins <NUM> in the illustrated embodiments) configured to engage corresponding bracket mounting fastener portions of a bracket <NUM> of a linear motion actuation system <NUM> as discussed herein. It should be understood that any of a variety of fasteners may be utilized for securing a bracket <NUM> relative to the installation flanges <NUM> of the server rack <NUM> (e.g., screws, bolts, pins, keyhole-and-T-head pins, and/or the like), and accordingly the bracket mounting fastener portions may be configured in accordance with a desired fastener configuration for use.

As illustrated in <FIG> specifically, the various illustrated components, including the rack housing <NUM>, the back plane <NUM>, and the server blade <NUM> are installed relative to one another (e.g., to form the installed configuration shown in <FIG>).

As additionally illustrated in <FIG>, server blades <NUM> in accordance with certain embodiments are embodied as a housing having a front face <NUM> and an opposing rear surface. Although not shown, the rear surface defines a pin array comprising a plurality of connector pins each configured to engage a corresponding connector of the connector array <NUM> of the back plane <NUM>. The front face <NUM> may be at least substantially planar in certain embodiments, with one or more features, connectors, user interface elements, and/or the like provided thereon. It should be understood that the front face <NUM> of a server blade <NUM> may have any of a variety of configurations defining contours of the front face <NUM> of the server blade <NUM>, and the linear motion actuation system <NUM> as discussed herein may be configured to accommodate any of a variety of configurations of a front face <NUM> of a server blade <NUM>. In the illustrated embodiment, the front face <NUM> defines at least a plurality of planar portions and one or more fastener engagement features which may be utilized to secure the linear motion assembly <NUM> discussed herein relative to the server blade <NUM>. Specifically with respect to the illustrated embodiments, the fastener engagement features of the server blade <NUM> is embodied as T-head pins <NUM> configured to engage corresponding keyhole slots <NUM> of the linear motion assembly <NUM>. However, it should be understood that any of a variety of fasteners may be utilized for securing a linear motion assembly <NUM> relative to a server blade <NUM>, and accordingly the fastener engagement features of the server blade <NUM> may be configured to accommodate a desired fastener type. For example, the fastener engagement features of the server blade <NUM> may be embodied as male threaded pins to accommodate nut-style fasteners, female threaded pins to accommodate bolt-style fasteners, keyhole slots to accommodate T-head pin style fasteners of a linear motion assembly <NUM>, and/or the like.

As discussed herein, the linear motion actuation system <NUM> is configured to move a server blade <NUM> at least substantially linearly, with minimal skewing, relative to a server rack <NUM>, specifically, to move the server blade <NUM> within a blade slot <NUM> to engage/disengage pins of the server blade <NUM> with corresponding connector arrays <NUM> disposed on a back plane <NUM> during installation or removal processes. Because the travel path length required to install the server blade <NUM> within a blade slot <NUM> is minimal, with the installation force required only increasing during engagement of the pins of the server blade <NUM> with corresponding connector arrays <NUM>, the linear motion actuation system <NUM> may be configured specifically for a small linear motion travel path length (e.g., <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and/or the like), while the remaining linear motion path of the server blade <NUM> into/out of the blade slot <NUM> may be performed manually. However it should be understood that the amount of linear motion provided by the linear motion actuation system <NUM> may be adjusted to accommodate installation/removal requirements of specific server blades <NUM>. Moreover, it should be understood that while the illustrations and discussed configurations explicitly discuss installation server blades <NUM> in a horizontal orientation, analogous configurations of a linear motion actuation system <NUM> may be utilized for installing server blades <NUM> in any of a variety of orientations, such as vertical orientations.

<FIG> illustrate various components of the linear motion actuation system <NUM> according to certain embodiments. <FIG> specifically illustrates a complete linear motion actuation system <NUM>, <FIG> illustrates a linear motion assembly <NUM> of the linear motion actuation system <NUM> (and having linear motion actuators <NUM> secured thereon), and <FIG> illustrates a bracket of the linear motion actuation system <NUM> in accordance with one embodiment.

As illustrated in <FIG>, the linear motion actuation system <NUM> comprises a linear motion assembly <NUM>, at least one (e.g., two) linear motion actuators <NUM>, and a bracket <NUM>. In the illustrated embodiment, the linear motion assembly <NUM> is configured for movement (e.g., along a linear movement path) relative to the bracket <NUM>, via the at least one linear motion actuators <NUM>. For example, the linear motion assembly <NUM> may be configured to be secured relative to a server blade <NUM> (e.g., a front face <NUM> of the server blade) such that the linear motion assembly <NUM> moves with the server blade <NUM> relative to the server rack <NUM>, and the bracket <NUM> may be configured to be secured relative to the server rack <NUM> and to remain at least substantially stationary with the server rack <NUM>, while the linear motion actuator <NUM> utilizes the bracket <NUM> for leverage in applying a movement force to the linear motion assembly <NUM>, thereby moving the server blade <NUM> relative to the server rack <NUM>.

As illustrated specifically in <FIG>, the linear motion assembly <NUM> comprises a frame <NUM> defining a base portion and a face portion <NUM>. The frame <NUM> may comprise a rigid material (for example, a rigid material includes, but is not limited to, sheet metal, stainless steel, aluminum, as well titanium plate, fiberglass panels, or other materials). The face portion <NUM> of the illustrated embodiment is at least substantially planar, however it should be understood that the face portion <NUM> may have any of a variety of configurations, for example, to accommodate contours of features of a front face <NUM> of a server blade <NUM> to be installed/removed utilizing the linear motion assembly <NUM>. Additionally or alternatively, the face portion <NUM> may have an at least substantially universal configuration to accommodate contours and/or features of a plurality of front face <NUM> of a plurality of server blades <NUM>, and accordingly the face portion <NUM> of the frame <NUM> (and/or other portions of the frame <NUM>) may define/comprise various features, apertures, contours, and/or the like to accommodate configurations of a plurality of server blades <NUM>. Moreover, in the illustrated embodiment, the face portion <NUM> has a protective layer applied thereto, such as a protective, non-scratch plastic material configured to contact the front face <NUM> of the server blade <NUM> so as to avoid direct contact between metallic components of the linear motion actuation system <NUM> and the server blade <NUM>. However, it should be understood that certain embodiments may omit such a protective layer and/or the protective layer may have any of a variety of configurations (e.g., discrete protective spacers, a protective coating, and/or the like).

Moreover, as shown in the illustrated embodiment of <FIG>, the face portion <NUM> of the frame <NUM> defines one or more fastener engagement features, such as the keyhole slots <NUM> of the illustrated embodiment. As noted above in reference to the configuration of the server blade <NUM>, the fastener engagement features of the linear motion assembly <NUM> may be embodied as any of a variety of fastener engagement feature types to accommodate a desired fastener configuration (e.g., to accommodate bolts, nuts, screws, and/or the like). Specifically, the keyhole slots <NUM> illustrated in <FIG> may be configured to engage corresponding T-head pins <NUM> on a front face <NUM> of a server blade <NUM>, such as shown in the close-up view of a portion of a front face <NUM> of a server blade <NUM> as shown in <FIG>.

As additionally illustrated in <FIG>, the frame <NUM> may comprise one or more additional surface portions, such as side-surfaces configured to provide additional rigidity to the frame <NUM>, for example, to support the weight of the linear motion actuators <NUM>, to support forces generated by the linear motion actuators <NUM>, and/or the like.

Moreover, one or more linear motion actuators <NUM> may be secured (e.g., rigidly secured) relative to the frame <NUM>. In the illustrated embodiments, two linear motion actuators <NUM> are secured relative to the frame <NUM>, however it should be understood that more or fewer linear motion actuators <NUM> may be utilized in certain embodiments. The linear motion actuators <NUM> may be embodied as linear-motion motors (e.g., capable of high torque outputs and/or slow travel speeds), although any of a variety of linear motion actuators <NUM> may be utilized, such as solenoids, and/or the like. As just one non-limiting example, the linear motion actuators <NUM> may be embodied as high-torque, low-speed linear motion motors (e.g., screw-drive motors) capable of outputting a linear motion force of at least approximately <NUM> lbf and capable of a travel speed of <NUM>/second. The linear motion actuators <NUM> may be indexed based on displacement, such that the linear motion actuators <NUM> are configured to maintain an at least substantially constant movement speed even when faced with varying loading (e.g., via appropriate feedback loop circuitry, which may be embodied at least in part within a controller <NUM> as discussed in greater detail herein).

In the invention and as reflected in the illustrated embodiments a housing <NUM> is rigidly secured relative to the frame <NUM> of the linear motion assembly <NUM> (e.g., via one or more fasteners). Such rigid securing of the housing <NUM> of the linear motion actuators <NUM> relative to the frame <NUM> causes the housing <NUM> to move together with the frame <NUM> and the remainder of the linear motion assembly <NUM>, along with the server blade <NUM>. The linear motion actuators <NUM> each additionally comprise one or more movement saddles <NUM> configured for linear motion relative to the housing <NUM>. The movement saddles <NUM> of certain example embodiments may be controlled by <NUM>-bit serial encoder technology having a resolution of <NUM>,<NUM> count/rev to maintain precise linear travel accuracy, (e.g., within a positional tolerance of <NUM>). At the same time, robot saddle's smooth speed control may minimize potential movement wobble that may otherwise contribute to skewing of the server blade <NUM> during movement.

Moreover, the one or more movement saddles <NUM> are configured to be movably secured relative to a bracket <NUM> (discussed in greater detail herein), for example, via one or more fasteners (e.g., screws, pins, pin-and-cotter-pin combinations, bolts, nuts, and/or the like). In the illustrated embodiment for example, the movement saddles <NUM> each define a plurality of positioning pins and/or one or more female screw holes (e.g., a single female screw hole) configured to accept screws extending through corresponding through-holes of a bracket <NUM>, to secure the bracket relative to the movement saddles <NUM>. However, it should be understood that other configurations may be provided in certain embodiments, such as utilizing one or more screws (e.g., and a single corresponding screw hole of a movement saddle <NUM>) or other mechanisms for securing the movement saddle <NUM> to bracket <NUM>.

As just one example, the movement saddles <NUM> may comprise angular-to-linear movement features, for example, moveably secured with a rotational screw of the linear motion actuators <NUM>. Accordingly, upon rotation of the included screw of the linear motion actuator <NUM>, the movement saddles <NUM> move at least substantially linearly relative to the housing <NUM> of the linear motion actuators <NUM>. In certain embodiments, the included movement screw may be rotated by an included angular motor (e.g., a brushed motor, a brushless motor, and/or the like) upon receipt of appropriate power signals, for example, from an included controller <NUM> as discussed in greater detail herein. It should be understood that any of a variety of linear motion actuators <NUM> may be utilized for moving the included movement saddles <NUM>. The movement saddles <NUM> may also be powered by any of a variety of linear motion actuators. As additional non-limiting examples, other linear motion actuators may be embodied as linear motors, hydraulic cylinders, pneumatic cylinders, and/or the like.

As mentioned, the illustrated embodiment comprises two linear motion actuators <NUM> spaced apart from one another and positioned proximate opposing lateral ends of the frame <NUM> (and the linear motion assembly <NUM>), such that the linear motion actuators <NUM> are each positioned closer to a respective edge of the frame than the center of the frame <NUM>. Accordingly, the linear motion actuators <NUM> are configured to apply force relative to corresponding lateral edges of a server blade <NUM>, so as to minimize the likelihood of the server blade <NUM> skewing relative to the blade slot <NUM> during installation and/or removal. However, it should be understood that the linear motion actuators <NUM> may be positioned in other configurations, such as proximate a center of a frame <NUM> (or a single linear motion actuator <NUM> may be positioned proximate a center of a frame <NUM>, and may include or omit various gearing to apply forces to opposing edges of the frame <NUM> and server blade <NUM>).

<FIG> illustrates a bracket <NUM> of a linear motion actuation system <NUM> in accordance with one example embodiment. As discussed above, the bracket <NUM> is configured to be secured relative to a server rack <NUM> (e.g., relative to an installation flange <NUM> of the server rack <NUM>) to provide an anchor for the linear motion actuator <NUM> to provide leverage for providing a force to move the server blade <NUM> relative to the server rack <NUM>. Thus, during operation of the linear motion actuation system <NUM>, the bracket <NUM> remains at least substantially stationary, while the linear motion assembly <NUM> moves relative to the bracket <NUM> (e.g., based on a force generated by the one or more linear motion actuators between the bracket <NUM> and the linear motion assembly <NUM>) to move the server blade <NUM> relative to the server rack <NUM>.

With reference to <FIG>, the bracket <NUM> comprises bracket arms <NUM> each defining a first end and a second end. The first end of each bracket arm <NUM> has a mounting plate <NUM> secured thereto (e.g., separately attached to the bracket arm <NUM> via one or more fasteners, welds, and/or the like, or integrally formed with the bracket arm <NUM>). The mounting plates <NUM> are each configured to mount relative to a portion of the server rack <NUM>, such as the installation flanges <NUM> of the server rack <NUM>. For example, the mounting plates <NUM> of the bracket <NUM> may comprise one or more fastener engagement features, configured to engage fasteners to secure the mounting plates <NUM> relative to the server rack <NUM>. As illustrated in the embodiment of <FIG>, the fastener engagement features are embodied as keyhole slots <NUM> configured to slidably engage T-head pins <NUM> extending away from the surfaces of the installation flanges <NUM>. However, as discussed throughout the present discussion, any of a variety of fastener configurations may be utilized, and the fastener engagement portions of the mounting plates <NUM> may have corresponding configurations to accommodate a desired fastener configuration (e.g., through holes to accommodate bolts or screws, and/or the like).

As additionally illustrated in <FIG>, the bracket <NUM> additionally comprises a bracket body <NUM> extending between the bracket arms <NUM> and positioned proximate a second end of the bracket arms <NUM> (the second end being opposite the mounting plates <NUM> of the bracket arms <NUM>). It should be understood that the positioning of the body <NUM> may be adjusted, for example, to accommodate different contours of various server blades <NUM> and/or to adjust the anchor position for the linear motion actuators <NUM>. As indicated, the body may be secured relative to the bracket arms <NUM> (e.g., via one or more fasteners that may be positionally adjusted, for example, into a plurality of discrete mounting holes, so as to adjust the relative positioning of the body <NUM> relative to the bracket arms <NUM>). Moreover, the body may define one or more fastener engagement features configured to be secured relative to the movement saddles <NUM> of the linear motion actuators <NUM>, as discussed herein. As specifically illustrated in <FIG>, the fastener engagement features of the body <NUM> may be defined as throughholes <NUM> configured to accept a screw extending into a corresponding threaded hole within the movement saddle <NUM>. In certain embodiments, the fastener engagement features may encompass a single throughhole (to enable a screw to extend through the throughhole <NUM> to engage a corresponding single threaded hole of a movement saddle <NUM>, as shown in <FIG>) or a plurality of througholes (to engage a corresponding plurality of threaded holes of a corresponding movement saddle <NUM>). The bracket <NUM> may thus be rigidly secured relative to the movement saddles <NUM>, such that movement of the movement saddles <NUM> relative to the housing <NUM> of the one or more linear motion actuators <NUM> utilizes the bracket <NUM> as an anchor against which the linear motion actuators <NUM> push (or pull) to move the linear motion assembly <NUM> relative to the bracket <NUM> to move the server blade <NUM> relative to the server rack <NUM> (e.g., into the server rack <NUM> during installation or out of the server rack <NUM> during removal).

Each of the bracket arms <NUM>, mounting plates <NUM>, and the body <NUM> of the illustrated embodiment comprise a rigid material, such as a metal material (e.g. sheet metal, stainless steel, aluminum, titanium plate, and/or the like. ), as well as but not limited to non-metal materials (e.g. fiberglass panel, and/or the like) configured to withstand deformation forces at least as strong as may be applied by the one or more linear motion actuators <NUM>.

As discussed herein, the operation of the one or more linear motion actuators <NUM> may be controlled via a controller <NUM> in electronic connection with each of the one or more linear motion actuators <NUM>. In certain embodiments, the electronic connection between the one or more linear motion actuators <NUM> and the controller <NUM> may be configured for two-way communication, for example, for transmitting control signals from the controller <NUM> to the one or more linear motion actuators <NUM> and for receiving feedback signals from the one or more linear motion actuators <NUM> to the controller <NUM>, for example, to enable adjustment of one or more control signals provided to the one or more linear motion actuators <NUM>.

<FIG> illustrate an example embodiment of a controller <NUM> in accordance with one embodiment, and <FIG> schematically illustrates an electronic connection between the controller <NUM> and the one or more linear motion actuators <NUM> in accordance with one embodiment, via conductors <NUM>.

As illustrated in <FIG>, the controller <NUM> may comprise a controller housing <NUM> configured for supporting and protecting various electronic control modules therein. For example, the controller housing <NUM> may house a control module corresponding to each of the one or more linear motion actuators <NUM>, and a master control module configured for maintaining consistency of movement between the one or more linear motion actuators <NUM> (e.g., monitoring relative displacement of the linear motion actuators <NUM> to ensure the difference is position of each of the linear motion actuators <NUM> is within a maximum off-sync range) as discussed herein.

In various embodiments the controller <NUM> may have an onboard power supply and/or may receive electric power from an outside power source (e.g., a wall outlet, such as a 120V wall outlet, a 240V wall outlet, and/or the like). The onboard power supply may comprise a power converter, such as to convert received AC power from an outside power source to DC power to be utilized in control signals provided to the one or more linear motion actuators <NUM>. The onboard power supply may be configured to supply electrical power to the one or more onboard controllers, which may pass electrical control signals to the one or more linear motion actuators <NUM> in accordance with various embodiments.

Although not shown, the controller may additionally comprise one or more onboard cooling mechanisms (e.g., air-cooling systems, liquid cooling systems, and/or the like) including one or more housing fans and/or other cooling mechanisms.

The controller <NUM> may additionally comprise an onboard user interface <NUM> configured for displaying data indicative of the current operation of the one or more linear motion actuators <NUM>. The user interface <NUM> may comprise one or more user input elements (e.g., separate buttons or the user interface <NUM> may be configured as a touch-screen device configured to receive user input) so as to receive user input to initiate movement of the one or more linear motion actuators <NUM>.

As illustrated in <FIG>, the controller housing <NUM> may additionally comprise one or more features and/or components to facilitate movement of the controller <NUM>, such as wheels <NUM>, carry handles, and/or a pulling handle <NUM> (e.g., an extendable pulling handle <NUM> that may be adjustable in length to accommodate a user). Moreover, as shown in <FIG>, the controller housing <NUM> may additionally comprise one or more hanger elements <NUM> configured to support components of the linear motion actuation system <NUM> thereon (e.g., specifically, the linear motion assembly <NUM> and/or bracket <NUM> (and linear motion actuators <NUM>). Such a configuration facilitates movement of the entire controller <NUM> and remaining portions of the linear motion actuation system <NUM>, for example, between server cabinets <NUM> during an extended server blade <NUM> installation job.

<FIG> provide various illustrations and flowcharts indicating the installation and use of a linear motion actuation system <NUM> for moving a server blade <NUM> relative to a server rack <NUM>.

As illustrated in <FIG> and as reflected at Block <NUM> of <FIG>, a server blade <NUM> to be installed within a server rack <NUM> is positioned within a blade slot <NUM> within which the server blade <NUM> is to be installed. Initial placement may be performed by hand, with the server blade <NUM> being slid into the blade slot <NUM>, without engaging pins with connector arrays <NUM> of the back plane <NUM> at the back of the blade slot <NUM>.

With reference to <FIG> and Block <NUM> of <FIG>, the linear motion assembly <NUM> is secured relative to the front face <NUM> of the server blade <NUM>. As mentioned above, the linear motion assembly <NUM> comprises a frame <NUM> defining a face portion <NUM> having fastener engagement features defined therein for engaging the linear motion assembly <NUM> relative to the front face <NUM> of the server blade <NUM>. In the specific embodiments of the figures, the face portion <NUM> defines a plurality of keyhole slots <NUM> each configured to slidably engage a corresponding T-head pin <NUM> extending away from the front face <NUM> of the server blade <NUM>. The linear motion assembly <NUM> may be hung from the T-head pins <NUM> of the server blade <NUM>, without additional support or fasteners. These T-head pins <NUM> are configured to enable pushing forces to be applied against the front face <NUM> of the server blade <NUM> (e.g., by enabling the face portion <NUM> to directly apply a force to the front face <NUM> of the server blade <NUM>) and to enable pulling forces to be applied against the front face <NUM> of the server blade <NUM> (e.g., by enabling the face portion <NUM> to apply a pulling force to a back-side of each of the T-head pins <NUM>, which are securely connected with the server blade <NUM>). As mentioned herein, other fastener configurations may be utilized in other configurations enabling similar transmission of push and pull forces between the linear motion actuation system <NUM> and the server blade <NUM>.

With reference to <FIG> and <FIG> (which illustrates the bracket mounted relative to the server rack <NUM> without inclusion of the linear motion assembly <NUM> to more clearly illustrate the installation of the bracket <NUM>), and with reference to Block <NUM> of <FIG>, the bracket <NUM> may be secured relative to the server rack <NUM>, in alignment with the blade slot <NUM> into which the server blade <NUM> is being installed (or removed). The bracket <NUM> may be installed by securing the mounting plates <NUM> of the bracket <NUM> (via integrated fastener engagement features) to the server rack <NUM> (e.g., the installation flanges <NUM> of the server rack <NUM>). Specifically with reference to the illustrated embodiments, the mounting plates <NUM> each define a plurality of keyholes <NUM> each configured to slidably engage a corresponding T-head pin <NUM> extending away from the installation flange <NUM> of the server rack <NUM>. The bracket <NUM> may be hung from the T-head pins <NUM> of the server rack <NUM>, without additional support or fasteners. These T-head pins <NUM> are configured to enable pushing forces to be applied against the server rack <NUM> (e.g., by enabling the mounting plates <NUM> to directly apply a force to the installation flanges <NUM> of the server rack <NUM>) and to enable pulling forces to be applied against the server rack <NUM> (e.g., by enabling the mounting plates <NUM> to apply a pulling force to a back-side of each of the T-head pins <NUM>, which are securely connected with installation flanges <NUM>). As mentioned herein, other fastener configurations may be utilized in other configurations enabling similar transmission of push and pull forces between the bracket <NUM> and the server rack <NUM>.

With reference to <FIG> and Block <NUM> of <FIG>, the bracket <NUM> is secured relative to the movement saddles <NUM> of the one or more linear motion actuators <NUM>. Because the linear motion assembly <NUM> (having the one or more linear motion actuators <NUM> secured thereto) is secured relative to the server blade <NUM>, the throughholes <NUM> of the bracket <NUM> may be aligned with corresponding mounting holes (or other fastener components) of the movement saddles <NUM> by manually adjusting the positioning of the server blade <NUM> (and the linear motion assembly <NUM>) until alignment. If applicable (such as in the illustrated embodiments) fasteners (e.g., screws) may be used to secure the bracket <NUM> relative to the movement saddles <NUM>.

Once the bracket <NUM> is secured relative to the movement saddles <NUM>, the one or more linear motion actuators <NUM> may be utilized to move the server blade <NUM> relative to the server rack <NUM>. As indicated in Block <NUM> of <FIG>, the controller <NUM> may generate and transmit appropriate control signals to the one or more linear motion actuators <NUM> (e.g., in response to receipt of corresponding user input) to initiate movement of the server blade <NUM> relative to the server rack <NUM>, such as to move the server blade <NUM> into the server rack <NUM> during an installation procedure to engage pins with corresponding connector arrays <NUM> of the back plane <NUM>, or to move the server blade <NUM> out of the server rack <NUM> during a removal procedure to disengage pins from corresponding connector arrays of the back plane <NUM>.

Once the server blade <NUM> installed or removed from the server rack <NUM> (as desired), the linear motion actuation system <NUM> may be removed by reversing the installation procedure discussed above. First, the fasteners connecting the bracket <NUM> with the movement saddles <NUM> may be removed, thereby decoupling the bracket <NUM> from the movement saddles <NUM>. The bracket <NUM> may then be removed from the server rack <NUM> by decoupling the corresponding fasteners (e.g., by lifting the keyholes <NUM> and decoupling the keyholes <NUM> of the mounting plates <NUM> from the T-head pins <NUM> of the installation flanges <NUM>). The linear motion assembly <NUM> may then be removed from the server blade <NUM> by decoupling corresponding fasteners (e.g., by lifting the keyhole slots <NUM> and decoupling the keyhole slots <NUM> of the frame <NUM> from the T-head pins <NUM> of the front face <NUM> of the server blade <NUM>).

<FIG> illustrate example graphical user interfaces (GUIs) that may be displayed via the user interface <NUM> of the controller <NUM>. The controller <NUM> functionality may be limited based at least in part on the positioning of the one or more linear motion actuators <NUM>. For example, when the one or more linear motion actuators <NUM> are in an extended position (corresponding to pushing a server blade <NUM> into a server rack <NUM>), the controller <NUM> may only permit functionality to retract the one or more linear motion actuators <NUM> (corresponding to moving a server blade <NUM> out of a server rack <NUM>). Accordingly, the GUIs may correspond to the limited functionality permitted by the controller <NUM>. In the examples shown, <FIG> illustrates a GUI that may be displayed while the one or more linear motion actuators <NUM> are in a retracted position (corresponding to the server blade <NUM> being in an uninstalled position). The displayed GUI illustrates the "IN" functionality as a pressable button (e.g., a pressable GUI element on a touch-screen device), thereby enabling the controller <NUM> to receive user input requesting initiation of an installation functionality to extend the one or more linear motion actuators <NUM> to install a server blade <NUM> into a server rack <NUM>. The "OUT" user interface element is not indicated as a pressable button, and accordingly the GUI is not configured to accept user input to initiate a removal procedure in the configuration reflected in <FIG>. <FIG> illustrates a GUI that may be displayed while the one or more linear motion actuators <NUM> are in an extended position (corresponding to the server blade <NUM> being in an installed position). The displayed GUI illustrates the "OUT" functionality as a pressable button (e.g., a pressable GUI element on a touch-screen device), thereby enabling the controller <NUM> to receive user input requesting initiation of a removal functionality to retract the one or more linear motion actuators <NUM> to remove a server blade <NUM> from a server rack <NUM>. The "IN" user interface element is not indicated as a pressable button, and accordingly the GUI is not configured to accept user input to initiate an installation procedure in the configuration reflected in <FIG>. Moreover, in various embodiments, the controller <NUM> is configured to disable all user interface elements during execution of a desired command. For example, while the one or more linear motion actuators <NUM> are moving (e.g., in response to an "IN" command or an "OUT" command), the controller <NUM> may disable all other GUI elements. However, the controller <NUM> may additionally include one or more emergency stop switches <NUM> to depower the system at any time (even during movement of the one or more linear motion actuators <NUM>).

As illustrated in <FIG>, the controller <NUM> may be configured to store and/or output additional data regarding the functionality of the one or more linear motion actuators <NUM>, such as illustrating a position of each of the one or more linear motion actuators <NUM>, an indication of loading on each of the one or more linear motion actuators <NUM>, a movement speed of each of the one or more linear motion actuators <NUM>, an off-sync range measurement (indicative of a difference in linear positioning of the linear motion actuators <NUM>, for embodiments comprising at least two linear motion actuators, such that the controller <NUM> may ensure that the linear motion actuators <NUM> are moving at least substantially parallel and equal in distance and/or speed), and/or the like. In certain embodiments, the included linear motion actuators <NUM> may have a low positioning error tolerance (e.g., the precision of each linear motion actuator <NUM> may be within <NUM>), such that the linear motion actuators <NUM> minimize the skew movement of the server blade <NUM> during an installation or removal process into/from the server rack <NUM>. For example, in embodiments in which the one or more linear motion actuators <NUM> are embodied as two linear motion actuators <NUM> positioned <NUM> inches apart (corresponding to positions of the two linear motion actuators <NUM> on opposing ends of the frame <NUM> of the linear motion assembly <NUM>) and having a tolerance of <NUM> in linear motion positioning, a maximum skew angle of the server blade <NUM> during installation via the linear motion actuation system <NUM> may be <NUM> degrees.

Movement of the one or more linear motion actuators <NUM> in accordance with an "IN" functionality (e.g., an install functionality in which the one or more linear motion actuators <NUM> move to an extended position) or an "OUT" functionality (e.g., a removal functionality in which the one or more linear motion actuators <NUM> move to a retracted position) may comprise movement of the one or more linear motion actuators <NUM> may be a set distance (e.g., a set distance that may be manually set by user input in an applicable GUI). In certain embodiments, the "IN" and the "OUT" functionalities may be characterized by identical travel distances in opposite directions, such that sequential initiation of the "IN" and "OUT" functionalities (or vice versa) results in movement between a set "installed" position and a set "uninstalled" position for the linear motion actuators <NUM>.

The controller <NUM>, together with the one or more linear motion actuators <NUM>, may provide a plurality of safety functionalities in certain embodiments. For example, use of the linear motion actuation system <NUM> may be limited to registered users having log-in credentials (e.g., a user name and password that may be entered via a corresponding GUI of the controller) that may be required for obtaining access to the functionality of the linear motion actuation system <NUM>. Moreover, the controller <NUM>, together with the one or more linear motion actuators <NUM>, may monitor the amount of loading on the linear motion actuators <NUM> (e.g., via appropriate feedback loops), and to ensure that the loading does not exceed a determined maximum loading. Moreover, through similar feedback loops, the controller <NUM> and/or the one or more linear motion actuators <NUM> may be configured to maintain a desired constant movement speed, regardless of experienced loading, so as to ensure that the one server blade <NUM> is installed/removed at a carefully controlled rate by the linear motion actuation system. It should be understood that in certain embodiments, the set velocity of the linear motion actuation system <NUM> may be adjusted (e.g., via manual input provided to a corresponding GUI). Similarly, maximum off-sync measurements, maximum axial loading measurements, and/or the like may be adjusted via manual user input provided to a corresponding GUI. It should be understood that the off-sync measurements (as well as other potential positional measurements) may be determined by internal feedback provided by the linear motion actuators <NUM> and/or various external position sensors (e.g., optical position sensors) connected proximate the one or more linear motion actuators <NUM> according to certain embodiments.

In various embodiments, the controller <NUM> may be configured to execute a calibration process, during which the one or more linear motion actuators <NUM> are moved to a known home position to maintain desired consistency between movements of the linear motion actuators <NUM>.

Claim 1:
A linear motion actuation system (<NUM>) for moving a server blade (<NUM>) within a server rack (<NUM>), the system comprising:
a controller (<NUM>);
a linear motion assembly (<NUM>) comprising a frame (<NUM>) and configured for fastening relative to a server blade (<NUM>) and configured for linear motion with the server blade (<NUM>), the linear motion assembly (<NUM>) configured to accommodate at least a front portion (<NUM>) of the server blade (<NUM>) within at least a front face (<NUM>) of the frame (<NUM>);
a bracket (<NUM>) configured for fastening relative to the server rack (<NUM>); and
at least one linear motion actuator (<NUM>) comprising:
a first component (<NUM>) comprising a housing (<NUM>) rigidly secured with the frame (<NUM>) of the linear motion assembly (<NUM>); and
a second component (<NUM>) movably secured with the first component (<NUM>) and rigidly secured with the bracket (<NUM>), wherein the second component (<NUM>) is configured for at least linear movement relative to the first component (<NUM>);
wherein the at least one linear motion actuator is configured to, upon receipt of a signal from the controller (<NUM>), move the second component (<NUM>) in an at least linear direction relative to the first component (<NUM>) to move the housing (<NUM>) and the server blade (<NUM>) relative to the server rack (<NUM>) in the at least linear direction.