Modularly-expandable mini-rack server system

• US 9,693,464 B2
• Filed: 12/23/2013
• Issued: 06/27/2017
• Est. Priority Date: 12/23/2013
• Status: Active Grant

• Current Assignee: Dell Products LP (Dell Technologies Inc.)
• Original Assignee: Dell Products LP (Dell Technologies Inc.)
• Inventors: Vivio, Joseph Andrew, Bailey, Edmond
• Primary Examiner(s): Rojas, Bernard
• Application Number:
  US14/139,839
• Publication Number:
  US 20150181750A1
• Time in Patent Office: 1,282 Days
• Field of Search: 36167946-67948
• CPC Class Codes: H05K 3/306 Lead-in-hole components, e.g. affixing or retention before soldering, spacing means H05K3/32 takes precedence
• CPC Class Codes: H05K 7/1492 having electrical distribution arrangements, e.g. power supply or data communications
• CPC Class Codes: H05K 7/1498 Resource management, Optimisation arrangements, e.g. configuration, identification, tracking, physical location thermal management H05K7/20836
• CPC Class Codes: H05K 7/20736 within cabinets for removing heat from server blades
• CPC Class Codes: H05K 7/20836 Thermal management, e.g. server temperature control
• CPC Class Codes: Y10T 29/49126 Assembling bases

Abstract

A rack apparatus includes a frame having (i) a power and cooling area and (ii) a block chassis forming one or more information technology (IT) bays that enable insertion of IT components. A plurality of IT components are contained within a component cabinet inserted in the block chassis. When operational, enable the rack apparatus to function as one of an information handling system (IHS) and an extension of a modular, scalable/expandable rack-based IHS. A busbar physically located at a back of the block chassis within the power and cooling area and enables direct coupling to one of another busbar and a power source to supply power to the plurality of IT components from a power interface board. A block controller is contained in the block chassis and communicatively coupled to the other IT components. The block controller performs all localized, block level control for the rack apparatus.

Claims

1. A rack apparatus, comprising:

a frame comprising (i) a power and cooling area and (ii) a block chassis forming one or more;

a plurality of Information Technology (IT) components contained within a component cabinet inserted in the block chassis and which, when operational, enable the rack apparatus to function independently as an information handling system (IHS);

a first busbar physically located at a back of the block chassis within the power and cooling area and which enables direct coupling to at least one of a second busbar and a power source to supply power to the plurality of IT components;

a power interface board contained in the block chassis and coupled to the first busbar to supply power to the IT components contained in the component cabinet;

a block controller contained in the block chassis and communicatively coupled to the plurality of IT components and which performs all block level control for the rack apparatus; and

one or more physical supports at a bottom surface of the frame that enable the rack apparatus to be physically placed on top of a modular, expandable IT rack.

2. The rack apparatus of claim 1, wherein one or more of the plurality of IT components have electrical power conductors that physically abut to one of the busbar and the power interface board to receive electrical power.

3. The rack apparatus of claim 1, further comprising:

a fan bay located within the power and cooling area;

one or more fan modules inserted within the fan bay; and

one or more cables that connect the one or more fan modules to the block controller to enable the block controller to independently operate each of the one or more fan modules.

4. The rack apparatus of claim 1, wherein the block controller includes an Ethernet jack that enables the block controller to be communicatively connected to a rack management controller (RMC) of a rack assembly via an Ethernet cable to enable the RMC to provide system level control for the rack apparatus via communication with the block controller when the rack apparatus is integrated as a part of the rack assembly, wherein the rack apparatus operates as an extension of a modular, expandable rack-based IHS.

5. The rack apparatus of claim 1, wherein:

when the rack apparatus is included within a rack assembly, the plurality of IT components comprises at least one of storage device nodes and computing device nodes; and

when the rack apparatus is a stand-alone system, the plurality of IT components comprise at least one computing device node.

6. The rack apparatus of claim 1, further comprising:

a power bay chassis;

an infrastructure manager (IM) contained in the power bay chassis and communicatively coupled to the block controller to perform rack management and enable cooling of the plurality of IT components; and

a rack management controller (RMC) contained in the power bay chassis and which is communicatively coupled to the block controller to perform control of the modular, expandable IT rack, when connected thereto;

one or more power supply units (PSUs) contained in the power bay chassis to provide electrical power; and

a power bay power module contained in the power bay chassis and electrically coupled to the busbar and the one or more PSUs to receive the electrical power.

7. The rack apparatus of claim 6, further comprising:

a set of mount ear assemblies attached to a top portion of the block chassis; and

a set of power bay brackets attached to lateral sides of the power bay chassis in a vertical position corresponding to each position of the set of mount ear assemblies and aligned for vertical engagement, wherein the power bay chassis is slid into a stacked position with the block chassis.

8. The rack apparatus of claim 6, wherein the frame further comprises a second block chassis attached to the block chassis and forming one or more other IT bays that enable insertion of other IT components, the rack apparatus further comprising:

a second plurality of IT components contained within a second component cabinet inserted in the second block chassis;

another busbar segment within the power and cooling area that enables direct coupling to one of the busbar and the power source to supply power to the second plurality of IT components and which is physically located at a back of the second block chassis; and

a second power interface board contained in the second block chassis and coupled to the other busbar to supply power to the second plurality of IT components contained in the second component cabinet, wherein one or more of the second plurality of IT components have power connectors/conductors that are physically abutting to one of the other busbar segment and the second power interface board to receive electrical power.

9. The rack apparatus of claim 8, wherein the block chassis comprises one or more female key hole fastener components that are downwardly-presented and the second block chassis comprises one or more corresponding, male key hole fastener components that are upwardly presented, wherein the one or more downwardly-presented female key hole fastener components are aligned with and the one or more corresponding male key hole fastener components.

10. An information handling system (IHS), comprising:

a frame comprising (i) a power and cooling area and (ii) a block chassis forming one or more information technology (IT) bays;

a plurality of IT components contained within a component cabinet inserted in the block chassis and which, when operational, enable the IHS to function as an extension of a modular, expandable rack-based IHS;

a first busbar physically located at a back of the block chassis within the power and cooling area, and which is directly coupled to one of a second busbar and a power source to supply power to the plurality of IT components;

a power interface board contained in the block chassis and coupled to the first busbar to supply power to the plurality of IT components contained in the component cabinet;

a block controller contained in the block chassis and communicatively coupled to the plurality of IT components and which performs all block level control for the IHS; and

one or more physical supports at a bottom surface of the frame that enable the IHS to be physically placed on top of the modular, expandable IT rack.

11. The IHS of claim 10, wherein one or more of the plurality of IT components have electrical power conductors that physically abut to one of the busbar and the power interface board to receive electrical power.

12. The IHS of claim 10, further comprising:

a fan bay located within the power and cooling area;

one or more fan modules inserted within the fan bay; and

one or more cables that connect the one or more fan modules to the block controller to enable the block controller to independently operate each of the one or more fan modules.

13. The IHS of claim 10, wherein the block controller includes an Ethernet jack that enables the block controller to be communicatively connected to a rack management controller (RMC) of a rack assembly via an Ethernet cable to enable the RMC to provide system level control for the IHS via communication with the block controller when the IHS is integrated as a part of the rack assembly.

14. The IHS of claim 10, wherein:

the plurality of IT components comprises at least one of storage device nodes and computing device nodes; and

when the IHS is a stand-alone system, the plurality of IT components comprise at least one computing device node.

15. The IHS of claim 10, further comprising:

a power bay chassis;

an infrastructure manager (IM) contained in the power bay chassis and communicatively coupled to the block controller to perform rack management and cooling of the plurality of IT components;

a rack management controller (RMC) contained in the power bay chassis and which is communicatively coupled to the block controller to perform control of the modular, expandable IT rack;

one or more power supply units (PSUs) contained in the power bay chassis to provide electrical power; and

a power bay power module contained in the power bay chassis and electrically coupled to the one or more PSUs to receive the electrical power and electrically coupled to the busbar.

16. The IHS of claim 15, further comprising:

a set of mount ear assemblies attached to a top portion of the block chassis; and

a set of power bay brackets attached to lateral sides of the power bay chassis corresponding to the set of mount ear assemblies and aligned for vertical sliding engagement, wherein the power bay chassis is in a stacked position with the block chassis.

17. The IHS of claim 15, wherein the frame further comprises a second block chassis attached to the block chassis and forming one or more other IT bays that enable insertion of other IT components, the IHS further comprising:

a second plurality of IT components contained within a second component cabinet inserted in the second block chassis;

the other busbar within the power and cooling area that enables direct coupling to one of the busbar and the power source to supply power to the second plurality of IT components and which is physically located at a back of the second block chassis; and

a second power interface board contained in the second block chassis and coupled to the other busbar to supply power to the second plurality of IT components contained in the second component cabinet, wherein one or more of the second plurality of IT components have power connectors/conductors that are physically abutting to one of the other busbar and the other power interface board to receive electrical power.

18. The IHS of claim 17, wherein the block chassis comprises one or more female key hole fastener components and the second block chassis comprises one or more corresponding, male key hole fastener components, wherein the one or more downwardly-presented female key hole fastener components are aligned with and downwardly presented to receive by horizontally-translating engagement the one or more corresponding male key hole fastener components that are upwardly presented.

19. A method for providing a rack assembly to function as a physically attachable extension of a modular, scalable/expandable rack-based IHS, the method comprising:

assembling a frame comprising a power and cooling area and a block chassis forming one or more information technology (IT) bays;

providing a plurality of IT components within a component cabinet inserted in the block chassis and which, when operational, enable the rack apparatus to function as one or more blocks of a plurality of blocks supported by the modular, scalable/expandable rack-based IHS;

attaching a first busbar within the power and cooling area, which is physically located at a back of the block chassis, wherein the first busbar enables direct coupling to one of a second busbar and a power source to supply power to the plurality of IT components;

coupling a power interface board, which is contained in the block chassis, to the first busbar to supply power to the plurality of IT components contained in the component cabinet, wherein one or more of the plurality IT components have power connectors/conductors that are physically abutting to one of the busbar and the power interface board to receive electrical power;

communicatively coupling a block controller, which is contained in the block chassis and which performs all block level control for the rack assembly, to the plurality of IT components; and

providing one or more physical supports to a bottom surface of the frame that enable the rack apparatus to be physically placed on top of a modular, expandable IT rack.

20. The method of claim 19, further comprising:

attaching a fan bay located within the power and cooling area;

inserting one or more fan modules within the fan bay; and

connecting one or more cables between the one or more fan modules and the block controller to enable the block controller to independently operate each of the one or more fan modules.

21. The method of claim 19, wherein:

when the rack apparatus is a stand-alone system, providing the plurality of IT components comprise providing at least one computing device node; and

when the rack apparatus is to be integrated as a part of modular, scalable/expandable rack;

providing the plurality of IT components comprise providing at least one of storage device nodes and computing device nodes; and

the method further comprises communicatively connecting an Ethernet cable between the block controller and a rack management controller (RMC) of the modular, scalable/expandable rack-based IHS to enable the RMC to provide control for the rack apparatus as a part of the rack-based IHS via communication with the block controller.

22. The method of claim 21, further comprising:

assembling the frame further comprising providing a power bay chassis;

communicatively coupling an infrastructure manager (IM), which is contained in the power bay chassis and which controls block cooling, to the block controller to perform rack management of the plurality of IT components;

providing a rack management controller (RMC) in the power bay chassis that is in communication with the block controller to perform system level control;

providing one or more power supply units (PSUs) in the power bay chassis to provide electrical power; and

electrically coupling a power bay power module, which is contained in the power bay chassis, to the one or more PSUs to receive the electrical power.

23. The method of claim 22, further comprising:

attaching a set of mount ear assemblies to a top portion of the block chassis; and

attaching a set of power bay brackets to lateral sides of the power bay chassis at locations corresponding to opposing locations of the set of mount ear assemblies and aligned for vertical engagement as the power bay chassis is placed upon the block chassis.

24. The method of claim 19, further comprising:

forming in the block chassis one or more downwardly-presented female key hole fastener components; and

forming in a second block chassis one or more corresponding, upwardly presented male key hole fastener components, wherein the one or more downwardly-presented female key hole fastener components are aligned to receive the one or more corresponding, upwardly presented male key hole fastener components.