U.S. patent application number 17/512350 was filed with the patent office on 2022-05-26 for redundant bus circuit breaker adapter assembly and power distribution system.
This patent application is currently assigned to C&C Power, Inc.. The applicant listed for this patent is C&C Power, Inc.. Invention is credited to William Fechalos, Kevin Long.
Application Number | 20220164264 17/512350 |
Document ID | / |
Family ID | 1000005974439 |
Filed Date | 2022-05-26 |
United States Patent
Application |
20220164264 |
Kind Code |
A1 |
Fechalos; William ; et
al. |
May 26, 2022 |
REDUNDANT BUS CIRCUIT BREAKER ADAPTER ASSEMBLY AND POWER
DISTRIBUTION SYSTEM
Abstract
An apparatus, system and method of efficiently configuring a
power distribution system includes the provision of a dual-bus
power distribution assembly, each bus of which may be connected to
power sources and where the circuit breakers are adapted such that
power from either of the two buses can be routed to an electrical
load to provide redundant or non-redundant power, as required. Each
circuit breaker position is capable of being configured to connect
between either of the two buses and an individual load equipment
supply bus. The circuit breaker may be a plug-in type where one of
the terminals is adapted by a part that may be installed in one of
two orientations. In the first orientation a first bus is connected
to the individual load equipment supply bus and in the second
orientation the second bus is connected to the individual load
equipment supply bus.
Inventors: |
Fechalos; William; (Carol
Stream, IL) ; Long; Kevin; (Carol Stream,
IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
C&C Power, Inc. |
Carol Stream |
IL |
US |
|
|
Assignee: |
C&C Power, Inc.
Carol Stream
IL
|
Family ID: |
1000005974439 |
Appl. No.: |
17/512350 |
Filed: |
October 27, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
63118165 |
Nov 25, 2020 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G06F 1/189 20130101;
H02J 9/061 20130101; G06F 11/2015 20130101 |
International
Class: |
G06F 11/20 20060101
G06F011/20; H02J 9/06 20060101 H02J009/06; G06F 1/18 20060101
G06F001/18 |
Claims
1. An apparatus comprising: a front panel having an aperture sized
and dimensioned to accept a circuit breaker, the circuit breaker
having a first terminal and a second terminal spaced apart by a
first distance; a first common power bus; and a second common power
bus, wherein the first common power bus and the second common power
bus have plurality of first and second sleeve sockets,
respectively, each of the first sleeve sockets and the second
sleeve sockets disposed along a length along thereof and spaced
apart by a distance equal to a centerline spacing between adjacent
circuit breakers; a pair of sleeve sockets comprising a adjacent
first sleeve socket and the second sleeve socket of the plurality
of first and second sleeve sockets, spaced apart by a second
distance; a plurality of third sleeve sockets, each third sleeve
socket associated with the pair of sleeve sockets and having a
conductive connection to an output terminal; and wherein the
circuit breaker is adaptable by a conductive bracket part to mate
with the third sleeve socket and a selectable one of the first or
the second sleeve sockets of the pair of sleeve sockets.
2. The apparatus of claim 1, further comprising at least one
adapted circuit breaker inserted through the front panel and
configured to be pluggably mate with the third sleeve socket and
one of the pair of first and second sleeve sockets.
3. The apparatus of claim 2 wherein the circuit breaker is adapted
to include a bullet extension of the first terminal.
4. The apparatus of claim 1, wherein the circuit breaker is adapted
to include the conductive bracket part including a bullet
extension, selectively positionable with respect to the second
terminal of the circuit breaker in one of two alternate positions,
so that the adapted circuit breaker pluggably mates with one of the
first sleeve socket or the second sleeve socket and with the third
sleeve socket to complete an electric circuit.
5. The apparatus of claim 4, wherein the conductive bracket part
comprises a first portion having a through hole sized and
dimensioned to conform to a diameter of the second terminal and a
second portion having a stud for mounting the bullet extension.
6. The apparatus of claim 5 wherein the conductive bracket part is
secured to the second terminal in one of the alternate mating
positions by a nut threaded onto the second terminal.
7. A circuit breaker adapter part, comprising: a conductive
structure, being a section of a channel having a length less than
or equal to a width of a circuit breaker and a first arm and a
second arm disposed orthogonal to a connecting piece; and a bullet
extension fastened to an outside face of the arm of the channel,
wherein the second arm of the channel has a through- hole sized and
dimensioned to accept a stud terminal of a circuit breaker, a
centerline of the through-hole being parallel to a centerline of
the bullet extension, wherein the circuit breaker adapter part is
sized and dimensioned such that distance between the centerline of
the through-hole and the centerline of the bullet extension is half
of to distance between a first sleeve socket and a second sleeve
socket of an apparatus to which the bullet extension is configured
to be pluggably mated when mounted to the stud terminal of the
circuit breaker.
8. The circuit breaker adapter part of claim 7 wherein the
conductive structure is fabricated from copper, brass, or
aluminum
9. A kit, comprising: a conductive structure, being a section of a
conductive channel having a length less than or equal to a width of
a circuit breaker and a first arm and a second arm; and a bullet
extension fastened to an outside face of the arm of the conductive
channel, wherein the second arm of the conductive channel has a
through-hole sized and dimensioned to accept a stud terminal of a
circuit breaker, a centerline of the through-hole being parallel to
a centerline of the bullet extension, wherein a adapter is sized
and dimensioned such that distance between the centerline of the
through-hole and the centerline of the bullet extension is half of
the distance between first sleeve socket centerline and a second
sleeve socket centerline of an apparatus to which the bullet
extension is configured to be pluggably mated when mounted to the
stud terminal of a circuit breaker; a nut sized and dimensioned to
thread on to the stud terminal to fasten the conductive channel to
the circuit breaker; and a circuit breaker having the stud
terminal.
10. A method of supplying power to a plurality of loads,
comprising: a front panel having an aperture sized and dimensioned
to accept a circuit breaker, the circuit breaker having a first
terminal and a second terminal spaced apart by a first distance; a
first common bus; and a second common bus, wherein the first common
bus and the second common bus have plurality of first and second
sleeve sockets, respectively, each of the first sleeve sockets and
the second sleeve sockets disposed horizontally along a length of a
corresponding bus and spaced apart by a distance equal to a
centerline spacing between adjacent circuit breakers; a pair of
sleeve sockets comprising a first sleeve socket and a second sleeve
socket of the plurality of first and second sleeve sockets, the
first sleeve socket and the second sleeve sleeve socket of the pair
of sleeve sockets spaced apart by a second distance; a plurality of
third sleeve sockets, each third sleeve socket associated with the
pair of sleeve sockets and having a conductive connection to an
output terminal; and a common return terminal, wherein the circuit
breaker is adaptable to mate with the third sleeve socket and a
selectable one of the first or the second sleeve socket of an
associated pair of sleeve sockets; the method further comprising;
providing the circuit breaker; providing a circuit breaker adapter
part; securing the circuit breaker adapter part to the circuit
breaker in a one of two selectable orientations; and mating the
adapted circuit breaker part with the third sleeve socket and one
of the first or second sleeve sockets corresponding to the selected
one of two selectable orientations.
11. A conductive adapter part, comprising: a first metallic plate
adapted to bear on a surface; a second metallic plate spaced apart
by a first distance from the first metallic plate by a web and
facing the first metallic plate; wherein that first metallic plate
has a first through-hole sized and dimensioned to accept a stud
terminal of a circuit breaker, the first through-hole having a
first centerline; and the second metallic plate having a
through-hole or a stud having a second centerline; the distance
between the first metallic plate and the second metallic plate
being at least equal to a thickness of a nut to engage the stud
terminal, a width of the adapter part being less than or equal to a
width of the circuit breaker; and, when the part is rotated about
the stud terminal from a first position to a second position, a
second distance between the centerline of the bullet when in the
first position is changed by a second distance equal, the second
distance being equal to the spacing of the centerline of the the
two adjacent sleeve sockets to which the circuit breaker is
intended to mate.
12. The adapter part of claim 11, further comprising: the stud
terminal having a same thread pattern as a bullet extension; and
the bullet extension, configured to mate with the sleeve socket and
threaded onto the stud terminal.
13. The adapter part of claim 11, further comprising: a stud
terminal having a same thread pattern as a bullet extension; and
the bullet extension, configured to mate with a sleeve socket,
threaded onto the stud terminal, wherein the through-hole having
the second centerline is a threaded through-hole.
14. The adapter part of claim 11, further comprising: a bolt having
a same thread pattern as a bullet extension; and the bullet
extension, configured to mate with a sleeve socket, threaded onto
the bolt, wherein the through-hole having the second centerline is
sized and dimensioned to accept the bolt and the bolt is captivated
to the second plate by the bullet extension.
15. The adapter part of claim 11, wherein the first metal plate is
a planar surface configured to bear against a conductive flat
portion of the circuit breaker.
16. The adapter part of claim 11, wherein the first metallic plate
is a planar surface having a recessed portion surrounding the
through-hole and configured to bear against a flat portion of the
circuit breaker to locate an orientation of the adapter part.
17. A system for distributing electrical power, comprising: a
dual-bus configuration where each bus is connectable to a separate
source of electrical power; wherein the apparatus has a panel
capable accepting a plurality of circuit breakers of differing
operating characteristics; a separate output bus connectable to
each electrical load; a plurality of plug-in circuit breakers,
wherein each of the plug-in circuit breakers is adapted and
configurable to connect between either bus of the dual-bus
configuration and any separate output bus.
18. The system of claim 17, where a first bus of the dual-bus
apparatus is connectable to a first power source and a second bus
of the dual-bus apparatus is connectable to a second power
source.
19. The system of claim 17 wherein both buses of the dual-bus
apparatus are connected to a common power source.
20. The system of claim 17, at least one bus of the dual-bus
configuration is connected to a power suitable to be connected to
an output load.
Description
[0001] This application claims the benefit of priority to U.S.
provisional application Ser. No. 63/118,165 "REDUNDANT BUS CIRCUIT
BREAKER ADAPTER ASSEMBLY AND POWER DISTRIBUTION SYSTEM", filed on
Nov. 25, 2020, which is incorporated herein by reference in its
entirety.
TECHNICAL FIELD
[0002] This application may be relevant to the control and
distribution of electrical power.
BACKGROUND
[0003] Direct current (DC) power is needed for many types of
telephone communication equipment, for control equipment used at
electric utility substations, for computer data centers, and power
plants, and other similar uses. The DC power may be supplied, for
example, by a DC power source which may convert AC power from an
external AC power source, such as the local power grid, or a
generator and prime mover to DC power. DC Power may be obtained
directly from solar cells, fuel cells or other sources that are
known in the art or may be developed. In other circumstances the DC
power source, may include a storage battery system to provide
un-interruptible power during an outage of the input power source.
In some instances, the individual equipment or cabinets of
equipment may be supplied directly from a DC power source.
[0004] The DC power source may have sufficient capacity to supply a
plurality of electrical and electronic devices such as computers,
switch arrays, telecommunications equipment or the like, where each
one of the devices consumes less than the maximum capacity of the
DC power source. It may be desirable to control the provision of
the power to each individual device or to groups of devices, so as
to facilitate the removal and replacement of a device for, for
example, servicing, to disable and re-power for rebooting a
computer, or the like. Each connection of a load to a power supply
bus may be protected by a circuit breaker (CBs), fuse or similarly
functioning component in case of a fault resulting in an excess
current demand.
[0005] For flexibility in configuring local DC power distribution,
a power supply may be connected to a bus from which the power is
distributed to a plurality of individual DC loads through
individual circuit breakers (CD), switches, or the like. Each load
may have a different nominal power requirement and the CB used to
connect the load to the bus may be appropriately sized and the
arrangement configured so that the total power requirements of the
loads connected to the bus is within the capacity of the power
supply. In the usual course of events, equipment failures may occur
and circuit breakers may be tripped, or the bus-connected power
supply may fail.
[0006] Existing DC power distribution assemblies may provide for a
plurality of suitably rated circuit breakers connecting between a
power bus and individual outputs of the power distribution assembly
which may then route the power over suitably sized conductive
cables to the using equipment. Where a redundant power source is
required for some or all of the equipment, the distribution
assembly may be configured with a second power bus with circuit
breakers sized for the designated loads and connected thereto by
separate cables.
[0007] Often such power distribution assemblies are generic in
nature, providing for a fixed maximum number of circuit breakers
for a bus. In some installations, not all of the positions may be
need to be populated with circuit breakers for a particular
installation. The number and location of using equipment's
requiring redundant DC power may vary with each rack or system
design. This may lead to inefficient use of the circuit breaker
numerical capacity and complicate the layout of the connecting
cables to as to provide a second bus for the redundancy
requirement.
SUMMARY
[0008] Disclosed herein is an apparatus and adapter part that
provides for a dual bus or redundant configuration of a power
distribution panel, where a circuit breaker installed in the power
distribution panel can be configured so that the circuit breaker is
inserted in the circuit of the first bus or the second bus,
depending on the configuration of a metallic adapter part. This
simplifies the configuration of a power distribution system where
at least two power sources are connected to one or more electrical
loads having different load protection ratings, and the routing of
power cables between the apparatus and the loads.
[0009] The apparatus may comprise a front panel having an aperture
sized and dimensioned to accept a circuit breaker, the circuit
breaker having a first terminal and a second terminal spaced apart
by a first distance; a first common power bus; and a second common
power bus, and each bus may be connected to a separate power
supply. Each of the first common power bus and the second common
power bus has a plurality of sleeve sockets mounted thereto, the
spacing between adjacent sleeve sockets on each power bus being
compatible with the spacing of the circuit breakers insertable
through the front panel. The sleeve sockets mounted on the first
common power bus and the second common power bus are mounted so as
to be separated by a predetermined distance from each other.
Further, a plurality of sleeve sockets are mounted to individual
buses that connect to output terminal of the apparatus so as to
provide a power circuit to individual loads. The location of the
output bus sleeve sockets is determined so that each output sleeve
socket is configurably associated with a sleeve socket on the first
common bus and a sleeve socket on the second power bus.
[0010] This triad of sleeve sockets is used to permit selection of
connecting the first common power bus or the second power bus to
supply the individual output bus, depending on the configuration of
the circuit breaker adapter part. A conventional plug-in circuit
breaker is adapted, using a metallic bracket so that, depending on
the orientation of the bracket as affixed to the circuit breaker,
one of the first or the second power buses is connected to the
individual output power bus.
[0011] The circuit breaker may have stud terminals to which bullet
extensions are mounted so as to provide the plug-in capability. One
of the bullet extensions may be retained, although it may have a
further axial extension so as to mate with the associated sleeve.
The other of the stud terminals may be fitted with an adapter
bracket part. This adapter bracket may be a U-channel J-channel or
the like where a through-hole is provided on one of the faces
thereof so that the bracket may be bolted to the stud terminal.
Offset from the through-hole, and on the opposite external face of
the bracket, a bullet extension may be mounted. The adapter bracket
may be fixed in one of two positions by rotating the bracket prior
to fastening the bracket to the circuit breaker stud. In a first
position, the circuit breaker may connect to one of the common
busses and to the individual output bus; in the other of the two
positions, the circuit breaker may connect to the other of the two
common busses and to the individual output bus.
[0012] In this manner, a particular installation may be designed
where the location of circuit breakers in the apparatus serving
specific loads may be selected, so that the appropriate bus is
selected. The circuit breakers may have differing operating
characteristics depending on the load requirements, and each output
bus is independent. This means that the connection from the output
bus to the load may be physically routed in an efficient manner
depending of the location of the load with respect to the
apparatus, and the circuit breakers serving a load may be located
in a more logical manner.
[0013] A combination of redundant power supply to a load, using the
capabilities of the two buses and non-redundant power to other
loads, using a selectable one of the two busses may be
configured.
[0014] As examples, a single large power supply may be connected so
as to supply all of the loads in a non-redundant configuration, or
a separate power supply may connect to each of the common buses so
as to provide a redundant configuration.
[0015] A power distribution system may be configured efficiently by
combining appropriate power supplies, the dual-bus apparatus
described herein and conventional circuit breakers as modified
using the adapter part. Since the full number of circuit breaker
positions may be populated, regardless of the number of circuits
fed from each of the common buses, the space needed for the circuit
breakers can be reduced as compared with present systems which
pre-allocate the connection of the first common bus to the
individual output buses and the connection of the second common bus
to the individual output buses.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a portion of exemplary single-line electrical
schematic of the redundant bus circuit breaker power distribution
system showing connections made between either of two input buses
and an output bus;
[0017] FIG. 2 is a perspective view of an embodiment of the system,
in an enclosure suitable for mounting in an electrical rack, with
the cover removed and with insulating and other passive supporting
structures not shown for clarity;
[0018] FIG. 3 shows a rear perspective image of a typical
electrical circuit breaker and an adapter part configured to be
attached to one of the output terminals of the circuit breaker and
positioned to mate with a selected one of the input buses;
[0019] FIG. 4A shows a side view of the circuit breaker with the
adapter part attached in a superior (uppermost) position to a
bottom terminal of the circuit breaker and positioned in relation
to the corresponding sockets of the output bus with the relative
vertical spacing to permit the adapted circuit breaker to pluggably
mate therewith;
[0020] FIG. 4B shows a side view of the components of FIG. 4A mated
with each other so that one terminal of the circuit breaker engages
with the output bus and the other circuit breaker terminal engages
with a selected input bus;
[0021] FIG. 4C shows a side view of the components of FIG. 4A with
the adapter part attached in an inferior (lowermost) position to
the bottom terminal of the circuit breaker and to mate to the other
of the two input buses.
[0022] FIG. 5 is a perspective view of the components of FIG. 4A in
an unmated state;
[0023] FIG. 6 is a perspective view of a plurality of circuit
breakers mated with selected ones of the two input busses; the
output bus structure is not shown for clarity;
[0024] FIG. 7 shows a perspective image corresponding to the
arrangement of FIG. 6 and having a plurality of adjacent adapted
circuit breakers; individual circuit breakers are selectively
associated with one or the other of the input buses;
[0025] FIG. 7 is a perspective view of the conductive elements of
the system, including the plurality of output buses engaged with
the individual circuit breakers and the output bus connection to
the rear output terminals;
[0026] FIG. 8A is an exploded perspective view of the adapter part,
positioned for assembly to the lower terminal of the circuit
breaker and oriented in the superior (uppermost) position;
[0027] FIG. 8B shows a side view of the components of FIG. 8A in an
assembled state; and
[0028] FIG. 8C is an expanded view of the adapter part of FIG. 8B
showing a configuration of the mounting surface intended to
facilitate the location of the adapter part in a superior (shown)
or inferior position with respect to the circuit breaker.
DESCRIPTION
[0029] In a non-limiting example, a dual-bus power distribution
assembly (DBA) may be configured to mount in a 19 inch or 23 inch
equipment rack or similar and occupy 2U of vertical rack space. A
19 panel configuration may provide, for example, 14 single-pole
circuit breaker positions and a 23 inch panel may provide 20
single-pole circuit breaker positions, and may have space for a
status or control display. The assemblies may be configured with a
first DC bus 20 and a second independent DC bus 30. A circuit
breaker 50 in any location on the panel may be assigned may be
assigned to either the bus 20 or the 30 bus by the user. Each bus
may be connected to a separate DC power supply of suitable
capacity. This flexibility allows multiple configurations, such as
all of the breakers to be on a single bus or a dual-bus
configuration with circuit breakers connected to the either bus
depending on the load power and redundancy requirements. The total
capacity of the DBA may be doubled, for example, by connecting both
of the independent buses to a non-redundant power supply source
having twice the capacity of a single bus rating.
[0030] For the particular embodiment being described, the maximum
current on any one breaker position may be 100A with a maximum
single-bus current of 250A. The second bus may have a same rating.
Circuit breakers of an appropriate rating between about 0.1 and
100A may be selected as required. The assembly can operate in
either 24 or 48 VDC systems. The equipment (load) side of the
breakers are terminated, for example, on a terminal block on the
rear of the assembly, each terminal capable of supporting 100A.
Bolted or other suitable electrical jointing techniques may be
used. A Load Return connection may be located on the rear panel of
the assembly.
[0031] Equipment may be designed with similar functionality for
higher voltages and currents providing the physical dimensions,
conductor spacing, insulation techniques and the like are
consistent with safety standards and electrical codes.
[0032] The dual-bus assembly (DBA) disclosed herein permits the
circuit breakers for either of the two buses supplying redundant
power to a load to be located next to each other, simplifying the
cable routing between the assembly and the load. Moreover, where a
circuit breaker services a non-redundant load, the power cable may
be routed from the assembly to the load in an efficient manner and
the appropriate position for the circuit breaker selected
subsequently. This simplifies and neatens cabling of the power
distribution system.
[0033] FIG. 1 is a single-line electrical diagram of a portion of
the DBA illustrating the connection of several circuit breakers
(CB) 50, disposed between a selected one of a first input power
bus, 20, or a second input power bus, 30 and an output bus 40
connecting to a output terminal 150 to which the electrical load
350a-d is attached by a distribution cable. As connected, a
continuous conductive path is created from the power supply through
the selected bus (20 or 30), the circuit breaker 10 and the output
bus 40 to the output terminal 150. The circuit breaker 50 in each
occupied panel position is selected based on technical
characteristics related to protection of the load and the power
supply connected to the associated bus. The sum of the current
ratings of the circuit breakers connected to each one of the buses
is limited to the rating of input bus or the external power supply
connected to the input bus, whichever is the smaller value.
Similarly, the maximum current rating of any circuit breaker may be
limited to the current rating of the individual output bus
connecting to the load.
[0034] It would be appreciated by persons of skill in the art that
selection of circuit breaker types may depend on the load transient
start up or overload characteristics as well as the characteristics
of the power supplies. Circuit breakers may be designed to be
pluggably mated with a distribution assembly or to be attached to
distribution cables by bolts, clamps, screw terminals or the like.
The detailed specifications of a circuit breaker may in include
surge current characteristics, overload tolerance, activation time
or the like. A DBA may accept circuit breakers having a compatible
form factor but diverse operating characteristics. A suitable
circuit breaker for the example described in detail herein may be a
Heinemann hydraulic magnetic circuit breaker as described in Eaton
Corporation catalog for "AR and AP Series" circuit breakers,
CA130002EN, July 2016, available on-line or from Eaton Industries
Manufacturing GmbH, 7 Route de la Longeraie, 1110 Morges,
Switzerland.
[0035] Such circuit breakers may be configured with a variety of
input/output connection types which may include screw terminals,
posts, threaded studs or the like and are available from Heinemann
Canada Ltd., Montreal, Canada. A circuit breaker having threaded
stud connections may be fitted with bullet extensions so as to
pluggably mate with sleeve sockets to connect to the input and
output buses where the locations of the sleeve sockets are
positioned to be compatible with the spacing between the two bullet
extensions.
[0036] An example of suitable bullet extension would be a M3 or
6-32 stud which would mate, for example with an Eaton K03860LL
sleeve socket (FIG. 4A, 270). As seen in FIG. 3, the one of the
studs 220 may be terminated at the breaker with a bracket 250, and
a bullet extension 230 may be threaded onto the other stud 220. For
purposes of this embodiment, a lower one of the two bullet
extensions 230 may be removed from the corresponding stud and
threaded onto a stud on a dual-bus adapter part 250, which will be
described herein.
[0037] In the present example, a circuit breaker may be
individually configured so as to connect to either one of two input
busses so as to provide for redundant power inputs to a specific
load, or to select the bus to supply a non-redundant load. An
adapter part used to select the configuration is sized and
dimensioned so as to permit the installation of the circuit breaker
through the front panel of the DBA in an aperture that may be the
same dimensions as would accept an unmodified circuit breaker. By
enlarging the aperture, a configuration, permitting selection
between any of three input buses may be feasible.
[0038] The location of the output bus 40 with respect to the input
buses 20, 30 is not intended to be constrained by this example and
is a matter of design choice. The circuit breaker 50 would be
adapted accordingly.
[0039] In FIG. 1, CB1, CB2 and CB4 are shown connected to input bus
20 and CB3 is connected to input bus 30. This may represent a
configuration where loads 350a and 350b are redundant power inputs
to a single electrical load, where the load is capable of accepting
redundant power input from two sources. The configuration may
represent a load 350c, connected to bus 20 in a non-redundant
fashion and load 350d connected to bus 30 in a non-redundant
fashion. The configurations are established by the power cables
connected to the output terminals 150 of the DBA for each
particular equipment installation.
[0040] FIG. 2 is a partial perspective view of the DBA 100 where,
in addition to the components shown in the electrical diagram of
FIG. 1, a housing 110 (with the cover removed) the rear output
terminal block 150, and a front panel 165, which may provide for an
opening into which the individual circuit breakers may be inserted,
and for any optional status display 160.
[0041] Generally the figures do not show any of the insulating
structures or the structures for securing the various components to
the chassis of the DBA as they are selected during the engineering
design process so as to provide for separation of the two buses
electrically from each other and from the remainder of the
components, as well as with respect to the individual output buses
40. The buses may be copper aluminum of bar, flexible conductive
strap, cables or the like, that are jointed or connected using
techniques that are known in the art.
[0042] An example of a connector 120, 130 affixed to an end of a
cable from the external power supply (not shown) to the buses 20,
30 uses a lug with two through holes that is bolted to an end of
the associated bus. Other types of connectors may be used,
providing they meet the electrical and mechanical design
requirements. Similarly, the output terminal block 150 has a
plurality of connection points, each connection point corresponding
to the output of a single circuit breaker. Various styles of
connection are known to those skilled in the art and would be
selected based on power, voltage and mechanical considerations as
would be appropriate in the circumstances. The conductive materials
of the bus may typically copper, brass or aluminum.
[0043] Before describing the structure of the arrangement of the
interior components in further detail, the adaptation of a
conventional circuit breaker 50 to function as a component in the
redundant bus configuration is described. FIG. 3 is a perspective
image view focused on the rear of the circuit breaker. Here, the
circuit breaker 50 is configured as having an input terminal 220
and an output terminal, each comprising a threaded stud 220. This
may be seen clearly at the lower (input) terminal, however a bullet
extension 230 has been threaded onto the upper stud 220. The
dual-bus-adapter part 250 which is intended to be attached to the
lower threaded stud 220 is shown in an unattached configuration.
The dual bus adapter part 250 is sized and dimensioned so that an
aperture in the front panel of the DBA 100 may permit the
dual-bus-adapter part 250 to be positioned such that the lower stud
220 extends through the aperture 220 (see FIG. 8A so that a nut 225
may be threaded onto the stud 220 and tightened so as to captivate
the dual bus adapter part 250 to the circuit breaker stud 220 in
either of two positions. The aperture in the front panel may
provide sufficient clearance for the adapter part 250 to pass
through the aperture in the front panel without an interference
fit.
[0044] Further, the dual-bus-adapter part 250 has a bullet
extension 230 (which may have been removed from the corresponding
circuit breaker stud), which is threaded onto a stud or bolt so as
to extend the adapter part 250. The stud may be threaded into a
aperture in the dual-bus-adapter part 250, or be a bolt passing
through an aperture 222 which is captivated to the part 250 by
screwing on the bullet extension 230, or the like.
[0045] The orientation of the part 250 may be selected between
either a position where the bullet extension 230 is oriented
horizontally in a superior position or in an inferior position, the
positions differing by 180 degrees. The difference in the vertical
dimension of the bullet extension 230 when oriented in the two
positions is equal to the difference in vertical dimension of a
corresponding socket connector associated with each of the two
input buses of the DBA.
[0046] FIG. 4A is a detail drawing of the circuit breaker 50 with
the dual-bus-adapter part 250 installed on the stud 220 and secured
by a nut 225 so that the bullet extension is oriented in the
superior horizontal position as viewed from a side of the circuit
breaker 50. Also shown are the portions of the bus
electro-mechanical structures with which it is intended to
pluggably mate.
[0047] The dual bus structure 20, 30 is arranged so that a sleeve
socket 270 on each bus is presented to the circuit breaker such
that the bullet extension 230 of the dual-bus-adapter part 250 may
mate with one of them, while the bullet extension 230 of the upper
stud terminal of the circuit breaker 50 mates with a sleeve socket
270 attached to the corresponding output bus 40. The panel (not
shown) may guide or position the circuit breaker 50 horizontally
when inserted in the panel so as to mate with 2 of the 3 sockets
that are fixedly mounted to the input and output buses.
[0048] FIG. 4B shows the circuit breaker 50 and dual-bus- adapter
part 250 mated with corresponding components of the DBA where the
dual-bus-adapter part 250 is positioned in the superior position so
that the bullet extension mates with the sleeve socket 270
associated with a first bus 20. FIG. 4C shows the circuit breaker
50 and dual-bus-adapter part 250 mated with corresponding
components of the DBA where the dual-bus-adapter part 250 is
positioned in the inferior position so that the bullet extension
mates with the sleeve socket 270 associated with a second bus 30.
In this manner any of the connections to an output terminal of the
output block 150 may be serviced with power from the desired bus by
configuring the circuit breaker 50 in the electrical path to
connect to either the first or second bus by rotating the dual bus
adapter part 250 by 180 degrees and fixing the part 250 in position
using the nut 225 on the stud 220.
[0049] FIG. 5 shows the unmated adapted circuit breaker assembly
from a front side perspective where a section including one circuit
breaker position is presented. The output bus 40 for a single load
leads from the front to the back of the DBA to route the power from
one of the input buses (in this case 20) to a terminal of the
output block 150 on the rear of the DBA 100. As the input to the
buses 20, 30 is positioned at a rear side of the DBA and the
individual circuit breakers are spaced apart in a direction
orthogonal thereto, as may be seen in FIG. 2, each of the redundant
buses 20, 30 makes a turn through a right angle (as well as
rotating from a vertical to a horizontal orientation) in this
embodiment so as to conform to the form factor of the enclosure of
the DBA. These bus extensions 20a, 30a may be affixed, for example,
by a nut and bolt to the continuous portion of each bus 20, 30. The
nut and bolt assembly may be a compatible metal such as brass or
steel in combination with a Bellville washer, or the like.
Consequently, only a small section of each of the continuous input
buses 20, 30 is seen in FIG. 5 where the circuit breaker 50 is
shown disengaged from the buses and in relative alignment with the
conductive portions of the buses prior to mating.
[0050] Jointing of bus elements and other conductive components may
be by bolting, riveting, welding, soldering, brazing, connectors,
or any such technique resulting in the appropriate mechanical and
electrical properties.
[0051] The sleeve sockets 270 are attached in an end of each bus
extension 20a, 30a so as to be spaced apart in a vertical direction
by a distance conforming to difference in vertical distance of the
centerline of the bullet extension 230 occasioned by the rotation
of the dual-bus-adapter part 250 from a superior to an inferior
position. The relative position of the pair of bus extensions may
be maintained by an insulating material (not shown).
[0052] A plurality of individual circuits are shown in FIG. 6 where
the adapted circuit breakers 50 are shown configured to be inserted
into either a first bus 20 or a second bus 30. The output bus 40
and sleeve socket assembly is not shown, for clarity.
[0053] FIG. 7 shows the principal electrical components of the DBA
in relation to each other where a plurality of adapted circuit
breakers 50 are inserted in the respective sleeve sockets 270. The
length of the extension of the buses 20, 30, 40 behind the front of
the DBA is for convenience in interfacing with the power supply
inputs and the load distribution cables at the rear of an equipment
rack. The depth of the DBA may be reduced for other types of
installations.
[0054] Other components such as current and voltage sensors, a
monitoring and communications processor and display, network
interface or safety fuses may be incorporated in the DBA in
accordance with specific design requirements. FIG. 8A is a detailed
drawing of the dual-bus-adapter part 250, including the bullet
extension 230 and an example of the fastening of the bullet
extension to the bracket. Overall, the dual-bus-adapter part 250
may be characterized as two plates (223 and 224) spaced apart so
that the surfaces oppose each other by a web 280. A through hole
222 in a first mounting plate 224 sized to accept the stud 220. The
second mounting plate 223 has a hole 226 that may be threaded to
accept a stud of similar characters to stud 220 so that the bullet
extension 230 may be threaded thereon. In some examples the hole
may be a though hole and threaded to accept the stud, or be
unthreaded so as to accept a bolt, which would be captivated to the
first mounting surface by the bullet extension 230.
[0055] The surface of the first plate 224 may be planar, or may be
adapted (as shown) to conform to a feature 221 of the terminal so
as to facilitate locating the dual-bus-adapter part 250 for
assembly. When assembled, the through hole 222 is fitted onto the
stud 220, and captivated thereto by a nut 225. A washer may be
provided as well.
[0056] A center line of the hole 222 and a centerline of the hole
226 are parallel to each other but displaced with respect to each
other. In this example the centerlines are displaced in a direction
transverse to the holes such that rotating the installation of the
dual-bus-adapter part 150 through 180 degrees from a superior
position (bullet at maximum vertical position) to an inferior
vertical position (bullet at a minimum vertical position) results
in a difference in height, D, between the two positions equal to a
distance determined between the sleeve sockets 270 of the bus 20
and the bus 30. The sleeve sockets 270 of the two buses need not be
disposed directly above each other, so long at the spacing between
the center lines of the holes results in a mating configuration,
when the part has been rotated from a first installation position
to a second installation position.
[0057] As the nut 225 is threaded over the stud 220 to install the
part, sufficient space between opposing surfaces of the first plate
223 and the second plate 224 is provided. The spacing may be
slightly greater than the thickness of the nut 225 (and any washer)
as the nut may be threaded onto the stud 222 during installation as
it passes through the hole 222.
[0058] The relative sizes of the plates 223 and 224 are shown as
examples only, as it is the relative positions of the holes 222 and
226 that determine the offset occasioned by installing the part 250
in one of the two orientations described. When installed,
preferably the width of the dual-bus adapter part is less than or
equal than that of the circuit breaker 50 so as to minimize the
required separation between adjacent circuit breakers. So, the
overall longitudinal cross section shape of the dual-bus adapter
part 250 may be a squared-off U or J shape.
[0059] Thus, the bullet extension 230 is positioned so that it may
be threaded onto a stud to form the connection to the bus, selected
by the rotational positioning of the adapter part when attached to
the circuit breaker. The axis of the hole for accommodating the
stud of the circuit breaker and the axis of the stud onto which the
bullet extender 230 is to be mounted are offset by the half of the
centerline distance between the sleeve sockets 270 of the buses 20,
30 to which the adapted circuit breaker 50 can mate.
[0060] The dimensions of the dual-bus-adapter part 250 may be sized
with respect to those of the circuit breaker 50 so that, when
installed on the circuit breaker, the dimension of the
dual-bus-adapter part 250 transverse to the studs is less than or
equal to the corresponding dimension of the circuit breaker 50, so
that the circuit breaker 50 with the dual-bus-adapter part 250 may
be inserted through the aperture in the front panel. In any
installation where not all of the circuit breaker positions are
needed, the gaps between the circuit breakers is covered as is a
normal practice.
[0061] A person of skill in the art will recognize that a circuit
breaker in any position in the row of circuit breakers inserted
through the front panel may be configured to form a
circuit-breaker-protected connection between either input bus 20,
30 and an individual output bus 40.
[0062] The number of loads connected to each bus may be flexibly
determined based on the current demand and circuit breaker sizing
for each load and the total capacity of each bus. Further, there is
additional flexibility in the positioning of the exterior
distribution wiring and the most convenient routing scheme hay be
employed with the circuit breaker position assignments selected to
correspond to the appropriate connection.
[0063] When describing a particular example, the example may
include a particular feature, structure, or characteristic, but
every example may not necessarily include the particular feature,
structure or characteristic. This should not be taken as a
suggestion or implication that the features, structure or
characteristics of two or more examples should not or could not be
combined, except when such a combination is explicitly excluded.
When a particular feature, structure, or characteristic is
described in connection with an example, a person skilled in the
art may give effect to such feature, structure or characteristic in
connection with other examples, whether or not explicitly
described.
[0064] A method of distribution of electrical power may include the
provision of a DBA and connecting an output bus to a corresponding
power input of a load. An adapted circuit breaker type and rating
is selected based on the power requirements of the connected load
and configured to connect between one of the two input buses and
the output bus. Plugging the circuit breaker into the corresponding
position of the front panel provides the connectivity between the
power supply and the electrical load. The selection of the bus to
be connected, in each instance, is determined by the particular
installation design and may be governed by the individual power
requirements of the loads, including redundancy requirements, and
the capacity of the power supplies connected to the input
buses.
[0065] A method of modifying a circuit breaker to be compatible
with a DBA includes providing an adapter bracket part, suitable for
mounting to one of the terminals of the circuit breaker so that the
spacing between the connection portion of the terminal is
positionable to mate with a selected input electrical bus; and,
attaching the modified adapter bracket part to the circuit breaker
in the selected orientation.
[0066] While the methods disclosed herein have been described and
shown with reference to particular steps performed in a particular
order, it will be understood that these steps may be combined,
sub-divided, or reordered to from an equivalent method without
departing from the teachings of the present invention. Accordingly,
unless specifically indicated herein, the order and grouping of
steps is not a limitation of the present invention.
[0067] It is therefore intended that the foregoing detailed
description be regarded as illustrative rather than limiting, and
that it be understood that it is the following claims, including
all equivalents, that are intended to define the spirit and scope
of this invention.
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