Modular UPS systems and methods using modular interconnect assemblies

• US 20070217178A1
• Filed: 03/17/2006
• Published: 09/20/2007
• Est. Priority Date: 03/17/2006
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Eaton Corp. (Wisconsin) (Eaton Corporation PLC.)
• Inventors: Johnson, Robert, Jonsson, Lennart
• Granted Patent: US 7,760,516 B2
• Time in Patent Office: Days
• US Class Current: 361/826
• CPC Class Codes: H05K 7/1457 Power distribution arrangements

Abstract

A modular uninterruptible power supply (UPS) system includes a plurality of UPS system component modules, each configured to be arranged in at least one equipment rack, each of the UPS system component modules having at least one flexible power cable extending therefrom and having a pluggable first connector at an end thereof. The system also includes a modular power interconnect assembly configured to be attached to at least one equipment rack, the modular power interconnect assembly including a housing, a plurality of bus bars positioned within the housing, and a plurality of second connectors positioned at a face of the housing, electrically connected to the plurality of bus bars and configured to pluggably mate with the first connectors to provide electrical interconnection among the plurality of UPS system component modules.

Claims

1. A modular uninterruptible power supply (UPS) system, comprising:

a plurality of UPS system component modules, each configured to be arranged in at least one equipment rack, each of the UPS system component modules having at least one flexible power cable extending therefrom and having a pluggable first connector at an end thereof; and

a modular power interconnect assembly configured to be attached to at least one equipment rack, the modular power interconnect assembly including a housing, a plurality of bus bars positioned within the housing, and a plurality of second connectors positioned at a face of the housing, electrically connected to the plurality of bus bars and configured to pluggably mate with the first connectors to provide electrical interconnection among the plurality of UPS system component modules.

2. The UPS system of claim 1, further comprising at least one equipment rack, wherein the plurality of UPS system component modules are arranged in the at least one equipment rack, wherein the modular power interconnect assembly is attached to the at least one equipment rack, and wherein respective ones of the first connectors are pluggably mated with respective ones of the second connectors such that the power interconnect assembly provides electrical interconnection among the plurality of UPS system component modules.

3. The UPS system of claim 2:

wherein the UPS system component modules are arranged in a row or column;

wherein the power interconnect assembly housing comprises an elongate housing;

wherein the plurality of bus bars comprises elongate bus bars arranged substantially in parallel and extending along a length of the elongate housing;

wherein the plurality of second connectors are spaced along the length of the housing; and

wherein the power interconnect assembly extends along the row or column of UPS system component modules.

4. The UPS system of claim 3, wherein the UPS system component modules are positioned in a vertical column in a single equipment rack and wherein the power interconnect assembly is mounted vertically in and/or on the single equipment rack.

5. The UPS system of claim 3, wherein the UPS system component modules are positioned in a horizontal row of equipment racks and wherein the power interconnect assembly is mounted horizontally in and/or on the row of equipment racks.

6. The UPS system of claim 2:

wherein the plurality of UPS system component modules comprises a plurality of UPS modules; and

wherein the power interconnect assembly provides input and/or output paralleling of the UPS modules.

7. The UPS system of claim 2:

wherein the plurality of UPS system component modules comprises a plurality of UPS modules;

wherein the power cables comprise power output cables coupled to power outputs of the UPS modules;

wherein the power interconnect assembly provides output paralleling of the UPS modules; and

wherein the UPS modules further comprise power outlets electrically coupled to the power outputs and configured to be electrically coupled to external loads.

8. An electronic system comprising the UPS system of claim 7 and at least one load in the at least one equipment rack, wherein the at least one load is configured to operate redundantly from power supplies at first and second power inputs thereof, and

wherein respective power outlets of respective first and second ones of the UPS modules are electrically coupled to respective ones of the first and second power inputs of the at least one load.

9. The electronic system of claim 8:

wherein the at least one equipment rack comprises a plurality of equipment racks;

wherein the at least one load comprises a plurality of loads, respective ones of which are positioned in respective ones of the plurality of equipment racks;

wherein respective ones of the plurality of UPS modules are positioned in respective ones of the plurality of equipment racks;

wherein the power interconnect assembly is configured to provide output paralleling of the plurality of UPS modules; and

wherein the outlets of the UPS modules are electrically coupled to the first power inputs of the loads, and wherein the second power inputs of the loads are electrically coupled to an alternative power source.

10. The UPS system of claim 2:

wherein the plurality of UPS system component modules comprises a power distribution module and a UPS module;

wherein the power cables comprise a first power cable coupled to a power output of the UPS module and a second power cable coupled to a power input of the power distribution module; and

wherein the power interconnect assembly electrically interconnects the power output of the UPS module and the power input of the power distribution unit.

11. The UPS system of claim 10, wherein the plurality of UPS system component modules further comprises a transformer module, wherein the power cables further comprise a third power cable coupled to the transformer module and a fourth power cable coupled to the UPS module, and wherein the power interconnect assembly electrically interconnects the transformer module and the UPS module.

12. The UPS system of claim 1, wherein the UPS system component modules and/or the power interconnect assembly is configured to be attached to standardized rack mounting points.

13. The UPS system of claim 1, wherein the plurality of UPS system component modules comprises a UPS module, a battery module, a transformer module, a switch module, and/or a power distribution unit (PDU) module.

14. A method comprising:

arranging a plurality of UPS system component modules in at least one equipment rack, each of the UPS system component modules having at least one flexible power cable extending therefrom and having a pluggable first connector at an end thereof; and

mounting a modular power interconnect assembly in and/or on the at least one equipment rack, the power interconnect assembly comprising a housing, a plurality of bus bars positioned within the housing, and a plurality of second connectors positioned at a face of the housing, electrically connected to the plurality of bus bars and configured to pluggably mate with the first connectors.

15. The method of claim 14:

wherein arranging a plurality of UPS system component modules in the at least one equipment rack comprises arranging the UPS system component modules in a row or column;

wherein the power interconnect assembly housing comprises an elongate housing, wherein the plurality of bus bars comprises elongate bus bars arranged substantially in parallel and extending along a length of the elongate housing, and wherein the plurality of second connectors are spaced along the length of the housing; and

wherein mounting the modular power interconnect assembly in and/or on the at least one equipment rack comprises mounting the power interconnect assembly such that it extends along the row or column of UPS system component modules.

16. The method of claim 14, wherein arranging the UPS system component modules in a row or column comprises arranging the UPS system component modules in a vertical column in a single equipment rack and wherein mounting the power interconnect assembly such that it extends along the row or column of UPS system component modules comprises mounting the power interconnect assembly vertically in and/or on the single equipment rack.

17. The method of claim 14, wherein arranging a plurality of UPS system component modules in the at least one equipment rack comprises arranging the UPS system component modules in a horizontal row of equipment racks and wherein mounting the power interconnect assembly such that it extends along the row or column of UPS system component modules comprises mounting the power interconnect assembly horizontally in and/or on the row of equipment racks.

18. The method of claim 14, further comprising pluggably mating respective ones of the first connectors with respective ones of the second connectors such that the power interconnect assembly provides electrical interconnection among the plurality of UPS system component modules.

19. The method of claim 18:

wherein the plurality of UPS system component modules comprises a plurality of UPS modules; and

wherein pluggably mating respective ones of the first connectors with respective ones of the second connectors such that the power interconnect assembly provides electrical interconnection among the plurality of UPS system component modules comprises pluggably mating respective ones of the first connectors with respective ones of the second connectors such that the power interconnect assembly provides input and/or output paralleling of the UPS modules.

20. The method of claim 18:

wherein the plurality of UPS system component modules comprises a plurality of UPS modules;

wherein the power cables comprise power output cables coupled to power outputs of the UPS modules;

wherein the plurality of UPS modules further comprise power outlets electrically coupled to the power outputs;

wherein pluggably mating respective ones of the first connectors with respective ones of the second connectors such that the power interconnect assembly provides electrical interconnection among the plurality of UPS system component modules comprises pluggably mating respective ones of the first connectors with respective ones of the second connectors such that the power interconnect assembly provides output paralleling of the UPS modules; and

wherein the method further comprises electrically coupling external loads to the power outlets of the UPS modules.

21. The method of claim 18:

wherein the plurality of UPS system component modules comprises a power distribution module and a UPS module and the power cables comprise a first power cable coupled to a power output of the UPS module and a second power cable coupled to a power input of the power distribution module; and

wherein pluggably mating respective ones of the first connectors with respective ones of the second connectors such that the power interconnect assembly provides electrical interconnection among the plurality of UPS system component modules comprises pluggably mating respective ones of the first connectors with respective ones of the second connectors such that the power interconnect assembly provides electrical interconnection among the plurality of UPS system component modules to electrically interconnect the power output of the UPS module and the power input of the power distribution unit.

22. The method of claim 14, wherein the plurality of UPS system component modules comprises a UPS module, a battery module, a transformer module, a switch module, and/or a power distribution unit (PDU) module.