POWER DISTRIBUTION UNIT WITH A MODULAR CONSTRUCTION

Abstract

A modular power distribution unit includes a power rail, a power input module, a control module, and a power output module. The power input module includes at least one power inlet which is connectable to a power source. The control module includes a microcontroller and at least one external communication interface to transfer data to and preferably also to receive data from external devices. The power output module includes at least one power socket and either a metering device for metering at least one power parameter or at least one switch configured to selectively interrupt the transmission of power between at least two contact elements of the power output module and the at least one power socket. The control module and the power output module each include at least one optical communication unit which sends and/or receives data from at least one neighboring module via optical signals.

Claims

1. A power distribution unit having a modular construction comprising: a power rail with a housing having an interior cavity, at least one first connection element and a power bus having at least two conducting elements, and a plurality of modules formed and sized to be inserted into said interior cavity, each of said modules comprising: at least one second connection element configured to cooperate with the at least one first connection element in order to releasably connect each module with the housing, and a at least two contact elements configured to be connected to or brought into contact with said at least two conducting elements upon insertion of one of the modules into said interior cavity, said plurality of modules including: a) a power input module comprising at least one power inlet, said power inlet being connectable to a power source, said power input module further including circuitry configured to relay power from the power inlet to the at least two contact elements of the power input module; b) at least one control module including a microcontroller and at least one external communication interface to transfer data to external devices; c) at least one power output module comprising at least one power socket electrically connected to the at least two contact elements, and a metering device for metering at least one power parameter of the power and/or at least one switch configured to selectively interrupt the power transmitted from said at least two contact elements to said at least one power socket, wherein said at least one control module and said at least one power output module each comprise at least one optical communication unit configured to send and/or receive data via optical signals.

2. The power distribution unit according to claim 1, wherein: said housing is a longitudinal housing, said at least two conducting elements span along a longitudinal axis of the interior cavity and the modules are arranged next to each other along the longitudinal axis of the interior cavity.

3. The power distribution unit according to claim 1, wherein said at least one power output module comprises: a first and a second optical communication unit, and a controller configured to relay data received from a first neighbouring module via the first optical communication unit to a second neighbouring module via the second optical communication unit or vice versa.

4. The power distribution unit according to claim 1, wherein said optical signals are infrared signals.

5. The power distribution unit according to claim 3, wherein: said first optical communication unit includes a photodetector, said second optical communication unit comprises a light emitting diode, and said at least one power output module includes means for requiring insertion of the at least one power output module into the internal cavity in a single orientation.

6. The power distribution unit according to claim 3, wherein said first optical communication unit and said second communication unit each comprise a photodetector and a light emitting diode.

7. The power distribution unit according to claim 1, wherein said power bus comprises: six conducting elements defining a neutral and an earth conductor, three conductors for three live phases, and a conductor for auxiliary power.

8. The power distribution unit according to claim 7, wherein the at least one control module comprises a power supply unit to provide auxiliary power to the auxiliary power conductor.

9. The power distribution unit according to claim 1, wherein said at least two conductors are in the form of at least two longitudinal bars that are made of a conducting material and are arranged parallel to each.

10. A power output module for a power distribution unit having a modular construction, comprising: at least one power socket electrically connected to at least two contact elements, and a metering device for metering at least one power parameter of the power transmitted from said at least two contact elements to said at least one power socket, wherein said power output module comprises at least one optical communication unit configured to send and/or receive data via optical signals.

11. A method for transmitting data from at least one power output module to at least one control module of a power distribution unit having a modular construction, comprising: transmitting the data via optical signals sent by at least one optical communication unit of the at least one power output module and received by at least one optical communication unit of the control unit.

12. The power distribution unit according to claim 4, wherein: said first optical communication unit includes a photodetector, said second optical communication unit comprises a light emitting diode, and at least one power output module includes means for requiring insertion of the at least one power output module into the internal cavity in a single orientation.

13. The power distribution unit according to claim 4, wherein said first optical communication unit and said second communication unit each comprise a photodetector and a light emitting diode.

14. The power distribution unit according to claim 1, wherein the microcontroller and the at least one external communication interface of the at least one control module are further configured to receive data from external devices.

15. The power distribution unit according to claim 2, wherein said at least one power output module comprises: a first and a second optical communication unit, and a controller configured to relay data received from a first neighbouring module via the first optical communication unit to a second neighbouring module via the second optical communication unit or vice versa, and wherein said optical signals are infrared signals.

16. The power distribution unit according to claim 15, wherein said power bus comprises: six conducting elements defining a neutral and an earth conductor, three conductors for three live phases, and a conductor for auxiliary power, and wherein the at least one control module comprises a power supply unit to provide auxiliary power to the auxiliary power conductor.

17. The power distribution unit according to claim 16, wherein said at least two conductors are in the form of at least two longitudinal bars that are made of a conducting material and are arranged parallel to each.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0092] The drawings used to explain the embodiments show:

[0093] FIG. 1 an isometric view of an exemplary embodiment of a power distribution unit according to the present invention;

[0094] FIG. 2 a detailed view of the control module of the power distribution unit according to FIG. 1;

[0095] FIGS. 3a, 3b show a top view of the power distribution unit of FIG. 1;

[0096] FIG. 4 a cross-sectional view through one of the power output modules and a side view of the power rail;

[0097] FIG. 5 the power output module of FIG. 4 inserted into the interior cavity of the power rail;

[0098] FIG. 6 a schematic representation of a data transfer between the control module and another module.

[0099] In the figures, the same components are given the same reference symbols.

PREFERRED EMBODIMENTS

[0100] FIG. 1 shows an isometric view of an exemplary embodiment of a power distribution unit 1 according to the present invention. The power distribution unit 1 comprises a power rail 2 with a longitudinal housing 3. The longitudinal housing 3 has a cross section resembling the letter “U” and comprises two longitudinal side walls 18.1, 18.2 as well as a longitudinal base wall 26 which define an interior cavity 4. Said interior cavity 4 is open on a first side which lies opposite the longitudinal base wall 26. The longitudinal housing 3 spans along a longitudinal axis A, wherein in the shown embodiment the ends of the longitudinal housing 3 are closed by means of two end caps 5.1, 5.2 This means that the interior cavity 4 is bordered on five sides by said longitudinal side walls 18.1, 18.2, said end caps 5.1, 5.2 as well as by said longitudinal base wall 26. The two longitudinal side walls 18.1, 18.2 each comprise a first connection element 6 which is in the form of a channel in the embodiment shown.

[0101] The power rail 2 includes a power bus 7 with conducting elements 8. As will be explained in more detail further below, the power bus 7 of the embodiment as shown comprises six conducting elements 8. Said conducting elements 8 are in the form of longitudinal bars of a conducting material which are arranged parallel to each other along the longitudinal axis A.

[0102] Further, the power distribution unit 1 comprises a power input module 9 comprising a power inlet 14 which may be connected with a cable (not shown). The power input module 9 may be inserted into the interior cavity 4 of the power rail 2. The power input module 9 comprises second connection elements (not shown) which cooperate with the first connection elements 6 of the longitudinal housing 3 in order to releasable lock said power input module 9 within said interior cavity 4. Further, the power input module 9 comprises contact elements 13 which are brought into contact with the conducting elements 8 of the power bus 7 when the power input module 9 is inserted into the interior cavity 4. The power input module 9 may be connected to a power source by means of the cable which may be connected to the power inlet 14. The electrical power is relied to the power bus 7 by means of the contact elements 13 which are in contact with the conducting elements 8 of the power bus 7. The electrical power may thereby be modified by the power input module 9, for example a voltage of the electrical power may be reduced by a transformer (not shown) arranged within said power input module 9. The power input module 9 includes appropriate circuitry (not shown) in order to rely the power from said power inlet 14 to said contact elements 13.

[0103] The power distribution unit 1 further comprises a control module 10 which may be inserted into the interior cavity 4 of the power rail 2. Similar to the power input module 9, the control module 10 comprises second connection elements (not shown) which cooperate with the first connection elements 6 of the longitudinal housing 3 in order to releasable lock said control module 10 within said interior cavity 4. Further, the control module 10 comprises contact elements 13 which are brought into contact with the conducting elements 8 of the power bus 7 when the control module 10 is inserted into the interior cavity 4. By this contact the control module 10 may be supplied with the required electrical power. The control module 10 comprises a microcontroller (not shown) which allows to process, prepare and use data. Further, the control module comprises an external communication interface 15 in order to be able to transfer data to an external device (not shown). In the embodiment shown, the external communication interface 15 includes one plug of the RJ-45 type in order to e.g. connect the control module 10 to an Ethernet network. Additionally, the external communication interface includes two plugs of the USB type.

[0104] The control module 10 also comprises a display 19, such as for example a TFT or LCD display in order to display data such as the actual power consumption. The display 19 may feature touchscreen capabilities, such that a user may perform certain inputs by means of the display 19.

[0105] The embodiment of the inventive power distribution unit 1 as shown further comprises two power output modules 11.1, 11.2. Each of the two power output modules 11.1, 11.2 includes a plurality of power sockets 16. The power sockets 16 allow to plug in power cables of electric devices (not shown), especially of server units. The power output modules 11.1, 11.2 may be inserted into the interior cavity 4 of the power rail 2. Similar to the power input module 9, the power output modules 11.1, 11.2 comprise second connection elements (not shown) which cooperate with the first connection elements 6 of the longitudinal housing 3 in order to releasable lock the power output modules 11.1, 11.2 within said interior cavity 4. Further, the power output modules 11.1, 11.2 comprise contact elements 13 which are brought into contact with the conducting elements 8 of the power bus 7 when the respective power output module 11.1, 11.2 is inserted into the interior cavity 4.

[0106] A second power output module 11.2 of the two power output modules 11.1, 11.2 is shown to comprise a protective power breaker 20. Each of the power sockets 16 of both power output modules 11.1, 11.2 are electrically connected to the contact elements 13 in order to rely electric power from said power rail 7 to said power sockets 16. Each of the power output modules 11.1, 11.2 further includes a metering device (not shown) which allows to measure a parameter of the power relied to each of said power sockets 16. For example, the metering device may measure the wattage.

[0107] The power input module 9, the control module 10 as well as both power output modules 11.1, 11.2 are sized and dimensioned such that they may be inserted into the interior cavity one next to each other along the longitudinal axis A.

[0108] Further, each of the power input module 9, the control module 10 as well as both power output modules 11.1, 11.2 include four optical communication units 17.1-17.4 (of which only the first optical communication unit 17.1 and the second optical communication unit 17.2 of the second power output module 11.2 are shown for perspective reasons in FIG. 1). The optical communication units 17.1-17.4 allow to transmit data via an optical signal between the modules, as is explained in further detail in connection with FIG. 6.

[0109] FIG. 2 shows a detailed view of the control module 10 of the power distribution unit 1 according to FIG. 1. The control module 10 comprises a housing 21 of the general rectangular shape. Said housing comprises a circumferential wall with a first side 27.1, a second side 27.2, a third side 27.3 and a fourth side 27.4. The first side 27.1 and the second side 27.2 are configured such as to partially cooperate with the longitudinal side walls of the housing 3 of the power rail 2. On the underside, the contact elements 13, which are in the form of blades in the embodiment as shown, are more clearly visible.

[0110] On the third side 27.3 of the housing 21 the first optical unit 17.1 and the second optical unit 17.2 are located. On the fourth side 27.4, which lies opposite to the third side 27.3 the third optical unit 17.3 and the fourth optical unit 17.4 are located. It is to be noted that the third side 27.3 and the fourth side 27.4 of each of the modules 9, 10, 11.1, 11.2 of the power distribution unit 1 are configured in the same way such that the first optical communication unit 17.1 of a first module lies in a direct line-of-sight to the third optical communication unit 17.3 of a second module and that the second optical communication unit 17.2 of the first module lies in a direct line-of-sight to the fourth optical communication unit 17.4 of the second module. Further, this configuration allows to arrange a plurality of modules next to each other wherein the third side 27.3 of a module faces the fourth side 27.4 of a neighbouring module.

[0111] On a top side, the control module 10 comprises the display 19, the external communication interface 15 as well as two buttons 28.1, 28.2 used to input commands into the control unit 10 by a user.

[0112] FIGS. 3a and 3b show a top view of the power distribution unit 1 of FIG. 1. FIG. 3a shows the power distribution unit 1 with all modules 9, 10, 11.1, 11.2 inserted into the cavity 4 while

[0113] FIG. 3b shows the power distribution unit 1 without the second power output module 11.2. Removal of the second power output module 11.2 reveals the power bus 7 located within the interior cavity 4. As may be well seen on this figure, the power bus 7 comprises six conducting elements 8 in the form of longitudinal bars of a conducting material which are arranged parallel to each other and which extend along the longitudinal axis A.

[0114] As is further seen on these figures, the first power output module 11.1 comprises seven power sockets 16.1-16.7 of two different socket configurations. The second power output module 11.2 comprises six power sockets 16.8-16.13 of two different socket configurations.

[0115] Further, as may be derived from FIGS. 3a and 3b the modules 9, 10, 11.1, 11.2 span the entire width of the longitudinal housing 3, i.e. the entire dimension of the longitudinal housing 3 in a direction perpendicular to the longitudinal axis A. Thereby, the modules 9. 10, 11.1, 11.2 are arranged one next to each other along the longitudinal axis A.

[0116] FIG. 4 is a cross-sectional view through one of a power output module 11 and a side view of a power rail 2. On an underside of the power output module 11 six contact elements 13.1-13.6 are arranged. The contact elements 13.1-13.6 are in the form of blades which span in the direction of the longitudinal axis A when the module 11 is inserted into the interior cavity 4. The contact elements 13.1-13.6 extend into an interior space 25 within the housing 21 of the power output module 11. Conductive elements which are configured in the form of a printed board 24 and connection lugs 29.1-29.3 electrically connect the contact elements 13.1-13.6 with the power socket(s) 16. Alternatively, the conductive elements may further comprise a circuit breaker e.g. located between the contact elements 13.1-13.6 and the connection lugs 29.1-29.3.

[0117] Each power socket 16 includes socket openings 22.1, 22.2 into which lugs of a plug may be inserted. In the embodiment as shown in FIG. 1, each power socket 16 comprises three socket openings, of which two socket openings 22.1, 22.2 are seen on the cross-section according to FIG. 4. Within each socket opening 22.1, 22.2 a contact sleeve 23.1, 23.2 is arranged. The contact sleeves 23.1, 23.2 enable a reliable electric contact to pins of a plug inserted into the socket openings 22.1, 22.2.

[0118] The power rail 2 comprises the power bus 7 with six conducting elements 8.1-8.6 in the form of longitudinal bars of a conducting material which are arranged parallel to each other and which extend along the longitudinal axis A. Each longitudinal bar of conducting material comprises a groove extending the length thereof. The groove is dimensioned such that a contact element 13.1-13.6 of a module 9, 10, 11.1, 11.2 may be inserted therein such as to transfer power between said respective conducting element 8.1-8.6 and said contact element 13.1-13.6. The conducting elements 8.1-8.6 are spaced from each other in a direction perpendicular to the longitudinal axis A. The spacing of the conducting elements 8.1-8.6 is such that it corresponds to the spacing of the contact elements 13.1-13.6 of the modules 9, 10, 11.1, 11.2.

[0119] The conducting elements 8.1-8.6 are arranged within an insert 30 of isolating material, such that a protrusion of the isolating material is arranged between each of the neighbouring conducting elements 8.1-8.6. This allows for a proper separation of each of the conducting elements 8.1-8.6 from each other as well as a safe electric separation of the conducting elements 8.1-8.6 from the longitudinal housing 2.

[0120] FIG. 5 shows the power output module 11 of FIG. 4 inserted into the cavity 4 of the power rail 2. As may be seen, each contact element 13.1-13.6 snuggly fits into a groove of one of the conductive elements 8.1-8.6. Further, it is to be noted that the housing 21 of the power output module 11 is sized and dimensioned such that a part of it may be snuggly inserted into the interior cavity 4 of the longitudinal housing 3.

[0121] By means of the contact between the contact elements 13.1-13.6 and the conductive elements 8.1-8.6 an electric power may be transmitted from the power bus 7 to the power output module 11. Said electric power is then relied by means of the circuit board 24 and the connection lugs 29.1-29.3 to the power socket 16. Power transmission to the control module 10 is realized similarly by the contact of the contact elements 13.1-13.6 of the control module 10 with the conductive elements 8.1-8.6.

[0122] The conducting elements 8.1-8.6 of the power bus 7 are fed with the electrical power by means of the contact of the contact elements 13.1-13.6 of the power input module 9 with the conducting elements 8.1-8.6.

[0123] The power bus 7 as well as the modules 9, 10, 11.1, 11.2 according to the embodiment of the present invention shown comprise six conducting elements 8.1-8.6 respectively six contact elements 13.1-13.6. A first conducting element 8.1 and a corresponding first contact element 13.1 are configured as earth conductor, a second conducting element 8.2 and a corresponding second contact element 13.2 are configured as neutral conductor while a third to a fifth conducting elements 8.3-8.5 and respective contact elements 13.3-13.5 are configured as phase conductors. As such, the power distribution unit 1 as shown may be used in connection with electrical power having up to three phases L1 to L3. A sixth conducting element 8.6 and a respective sixth contact element 13.6 are carrying an auxiliary electrical power which may be used e.g. to power the metering devices of the power output devices 11.1, 11.2, the microcontroller of the control module 10 or any further electronic component integrated within one of the modules 9, 10, 11.1, 11.2.

[0124] FIG. 6 is a schematic representation of a data transfer between the control module 10 and another module, specifically shown for example as a second power output module 11.2. At first, data is prepared by a control unit of the control module 10, wherein said data comprises an address of the power output module 11.1-11.4 said data is intended for. The data is then sent in a first step (represented by an arrow with the number 1. in a circle on the figure) through an optical signal generated by the first optical communication unit 17.1 of the control module 10, which is configured as sender and thus comprises a diode to emit the optical signal, e.g. in the infrared spectrum. This data is received by the third optical communication unit 17.3 of a first power output module 11.1 which is configured as a receiver and thus comprises a photodetector, e.g. in the form of a photodiode or phototransistor. The data is processed by a controller of the first power output module 11.1. As the data should be sent to the second power output module 11.2, the data comprises an address which does not correspond to the address of the first power output module 11.1. Hence, the controller of the first power output module 11.1 forwards the data to the next neighbouring power output module, which happens to be the second power output module 11.2 in the example shown. The data is send by means of an optical signal emitted from the first optical communication unit 17.1 of the first power output module 11.1. Said optical signal is received by the third optical communication unit 17.3 of the second power output module 11.2. This second step is represented by an arrow marked by the number 2. in a circle on FIG. 6. As the address included in the data corresponds to address of the second power output module 11.2, a controller of the second power output module 11.2 can determine that the data is intended for this module. The data is then further processed by the controller. The data may for example contain a command to send the actual wattage of a certain power socket 16 of said second power output module 11.2 back to the control module 10.

[0125] The transmission of data from the second power output module 11.2 to the control module 10 happens in a similar fashion as the data transfer from the control module 10 to the second power output module 11.2, albeit in reversed order. The data is prepared by the controller of the second power output module 11.2, wherein the data comprises an address identifying the control module 10 as recipient of the data. The data is sent as optical signal by means of a fourth optical communication unit 17.4 of the second power output module 11.2 which is configured as sender and thus comprises a diode to emit the optical signal. This data is received by the second optical communication unit 17.2 of the first power output module 11.1 which is configured as a receiver and thus comprises a photodetector, e.g. in the form of a photodiode or phototransistor. This third step is represented by an arrow marked by the number 3. in a circle on FIG. 6. The data is processed by the controller of the first power output module 11.1.

[0126] As the data is intended for the control module 10, the controller of the first power output module 11.1 forwards the data to the next neighbouring module, which happens to be the control module 10 in the example shown. The data is send by means of an optical signal emitted from the fourth optical communication unit 17.4 of the first power output module 11.1. Said optical signal is received by the second optical communication unit 17.2 of the control module. This fourth step is represented by an arrow marked by the number 4. in a circle on FIG. 6. As the address included in the data corresponds to address of the control module, the control unit of the control module 10 can determine that the data is intended for this module. The data is then further processed by the microcontroller.

[0127] In the same way, data may be sent from the control module 10 to the third power output module 11.3, the fourth power output module 11.4 or to the power input module 9 or vice versa.

[0128] The transmission of data via optical signal by means of the optical communication units 17.1-17.4 of each of the module 9, 10, 11.1-11.4 thus happens in the sense of a “daisy chain” where data is passed from one module 9, 10, 11.1-11.4 to a neighbouring module 9, 10, 11.1-11.4 until the data reaches the intended module 9, 10, 11.1-11.4.

[0129] In the example shown, the control module 10 is located about in the middle of all modules 9, 10, 11.1-11.4. Hence, the control module 10 may send or receive data from two different sides. In this case, the power distribution unit 1 comprises a first daisy chain I comprising the first power output module 11.1 and the second power output module 11.2 as well as a second daisy chain II comprising the third power output module 11.3, the fourth power output module 11.4 and the power input module 9.

[0130] The number of power output modules 11 may be varied depending on the specific needs. For example, a power distribution unit 1 according to the present invention may comprise more than four power output modules. Therefore the length of the “daisy chains” may also vary. In theory, there is no limit as to the number of power output modules present in any of the “daisy chains”. However, said number will be limited due to dimensional constraints, as the power distribution unit needs to keep a useful maximal size.