Apparatus and method for scalable power distribution

• US 7,606,014 B2
• Filed: 06/16/2006
• Issued: 10/20/2009
• Est. Priority Date: 06/16/2006
• Status: Active Grant

• Current Assignee: American Power Conversion Corporation (Schneider Electric SE)
• Original Assignee: American Power Conversion Corporation (Schneider Electric SE)
• Inventors: Colucci, David A., Ziegler, William, Hjort, Thomas E.
• Primary Examiner(s): Nguyen; Danny
• Application Number:
  US11/455,227
• Publication Number:
  US 20070291433A1
• Time in Patent Office: 1,222 Days
• Field of Search: 361 42- 50, 361/115, 361/93.1, 361/600, 361/622
• US Class Current: 361/93.1
• CPC Class Codes: H01R 13/6666 with built-in overvoltage protection
• CPC Class Codes: H01R 25/003 the coupling part being secured only to wires or cables
• CPC Class Codes: H02B 1/056 Mounting on plugboards
• CPC Class Codes: H02B 1/21 Bus-bar arrangements for rack-mounted devices with withdrawable units
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

According to one aspect of the invention, a plug-in module is provided for installation in a power distribution assembly. In one embodiment, the plug-in module includes a housing, an electrical isolation and overcurrent protection device located in the housing and a current sensing device located in the housing and adapted to sense a current carried by the electrical isolation and overcurrent protection device. The plug-in module may further include a power cable including a first end that is pre-terminated at the plug-in module to connect the power cable to the electrical isolation and overcurrent protection device, and electrical contacts adapted to removably couple the plug-in module to a plurality of stationary electrical conductors of the power distribution assembly. According to one embodiment, the electrical isolation and overcurrent protection device includes a circuit breaker.

Claims

1. A plug-in module for installing in a power distribution assembly, the plug-in module comprising:

a housing;

an electrical isolation and overcurrent protection device located in the housing;

a current sensing device located in the housing and adapted to sense a current carried by the electrical isolation and overcurrent protection device;

a power cable including a first end that is pre-terminated at the plug-in module to connect the power cable to the electrical isolation and overcurrent protection device; and

electrical contacts adapted to removably couple the plug-in module to a plurality of stationary electrical conductors of the power distribution assembly,

wherein the electrical isolation and overcurrent protection device includes a circuit breaker, and

wherein the plug-in module is constructed and arranged to be coupled to the plurality of stationary electrical conductors by manually sliding the plug-in module into the power distribution assembly.

2. The plug-in module of claim 1, further comprising a printed circuit board adapted to couple to the current sensing device.

3. The plug-in module of claim 1, further comprising a secondary contact in electrical communication with an output of the current sensing device, wherein the secondary contact is adapted to engage a contact of the power distribution assembly.

4. The plug-in module of claim 1, wherein the housing includes a side wall and a first extension extending substantially perpendicular from the side wall, and wherein a rejection element is attached to the first extension.

5. The plug-in module of claim 4, wherein the first extension includes an interlock adapted to open the circuit breaker before the electrical contacts are coupled to the plurality of stationary electrical conductors when the plug-in module is installed in the power distribution assembly.

6. The plug-in module of claim 1, further comprising a mechanical stress relief device for the power cable.

7. The plug-in module of claim 1, wherein the power cable is pre-terminated inside the housing.

8. The plug-in module of claim 7, wherein the circuit breaker has a current rating in a range of from less than 1 ampere to greater than 60 amperes.

9. The plug-in module of claim 1, wherein the circuit breaker is adapted for mounting on a DIN rail.

10. The plug-in module of claim 1, wherein the circuit breaker is a molded case circuit breaker adapted to be externally accessible.

11. The plug-in module of claim 1, wherein the stationary electrical conductors include bus bars located in the power distribution assembly.

12. The plug-in module of claim 1, further comprising electrical contacts adapted to removably connect an output of the current sensing device to wiring located in the power distribution assembly.

13. The plug-in module of claim 1, further comprising a printed circuit board located in the housing, wherein the current sensing device is coupled to the printed circuit board.

14. The plug-in module of claim 1, further comprising at least one control element.

15. The plug-in module of claim 14, wherein the control element is an indicating light.

16. The plug-in module of claim 1, further comprising a mechanically assisted engagement device configured to assist in coupling the plug-in module to the plurality of stationary electrical connectors.

17. The plug-in module of claim 16, wherein the mechanically assisted engagement device includes a lever.

18. The plug-in module of claim 17, wherein the mechanically assisted engagement device further includes a cam coupled to the lever.

19. The plug-in module of claim 1, wherein the electrical isolation and overcurrent protection device includes a plurality of circuit breakers.

20. The plug-in module of claim 19, wherein each of the plurality of circuit breakers is coupled to a different one of the plurality of stationary electrical connectors when the plug-in module is coupled to the plurality of stationary electrical conductors.

21. A plug-in module for installing in a power distribution assembly, the plug-in module comprising:

a housing;

an electrical isolation and overcurrent protection device located in the housing;

a current sensing device located in the housing and adapted to sense a current carried by the electrical isolation and overcurrent protection device;

a power cable including;

a first end configured to be coupled to the electrical isolation and overcurrent protection device; and

a second end coupled to the first end;

an electrical connector attached to the second end, the electrical connector configured to couple to an electrical load; and

electrical contacts adapted to removably couple the plug-in module to a plurality of stationary electrical conductors of the power distribution assembly,

wherein the plug-in module is constructed and arranged to be coupled to the plurality of stationary electrical conductors by manually sliding the plug-in module into the power distribution assembly.

22. The plug-in module of claim 21, wherein the electrical connector is a first electrical connector, and wherein the first electrical connector is configured to couple to a second electrical connector connected to the electrical load.

23. A plug-in module for installing in a power distribution assembly, the plug-in module comprising:

a housing;

an electrical isolation and overcurrent protection device located in the housing;

a current sensing device located in the housing and adapted to sense a current carried by the electrical isolation and overcurrent protection device;

a power cable including a first end that is pre-terminated at the plug-in module to connect the power cable to the electrical isolation and overcurrent protection device; and

electrical contacts adapted to removably couple the plug-in module to a plurality of stationary electrical conductors of the power distribution assembly,

wherein the electrical isolation and overcurrent protection device includes a circuit breaker, and

wherein the housing includes a side wall and a first extension extending substantially perpendicular from the side wall, and wherein a rejection element is attached to the first extension.