WO2019178080A1 - Compact modular bus system for power and data management and distribution - Google Patents

Abstract

A modular bus system includes an extruded backbone, power busbars, and one or more power and data (P/D) modules. The backbone forms a base of the bus system, and has an extrusion profile defining elongated, axially-extending channels, ribs, and walls. Each busbar is disposed between a respective pair of the ribs. The busbars conduct main power from an external power supply. The P/D module, multiple ones of which may be arranged end-to-end, receives low-voltage power and data from respective cables. The P/D module is electrically connectable to an external device to supply the power and/or the data to the external device as needed, and includes a module cover assembly. When installed, the cover assembly mechanically engages the backbone walls, and the P/D module is simultaneously connected to power and data. In the uninstalled position, the P/D module is disconnected from power and data.

Description

COMPACT MODULAR BUS SYSTEM FOR

POWER AND DATA MANAGEMENT AND DISTRIBUTION

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of United States Provisional

Application Serial No. 62/641,457, which was filed on March 12, 2018, and which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

[0002] The present disclosure relates to a compact, modular bus system for managing and distributing power and data.

BACKGROUND

[0003] Power busbar systems generally include a main power bus in the form of side-by-side neutral, polyphase, and ground conductors. Power bus systems also include associated structure for connecting electrical power to the conductors, as well as multiple structural elements, colloquially referred to as“power taps”, that enable physical access to main power, e.g., 120/208V polyphase voltage from the electrical grid or other available main power supply. Main power may be fed into the bus system through conduits or one of the various modules, through a cable, conduit fitting, and/or a high-current connector. The power taps may be hardwired to external electrical loads through intervening circuit breakers in order to limit the maximum current draw of the connected loads.

[0004] Power busbar systems may be configured in various ways. For example, a permanent-tap busbar system typically uses bolts or clamps to connect the power taps to the main busbars. A“pluggable” busbar system employs U-shaped busbars with spring mechanisms to help maintain electrical contact with the busbars, with tab-style tap contacts configured to push into the U-shaped busbars wherever power is locally required. Alternatively, rectangular busbars may use U-shaped tap contacts with spring mechanisms that press over flat busbars to make the required electrical contact. Direct pressure-type busbar systems with rectangular or round busbars may also be used. In such systems, the individual power tap contacts may be biased using spring mechanisms or other suitable structure to maintain contact pressure with the busbars.

[0005] In each of the above example systems, the electrical contacts and conductors tend to be relatively large and structurally complex. Physical mechanisms are typically used to connect conductive wires to the various power taps, and to maintain contact pressure between tap and contact using a relatively complicated assortment of springs, screw terminals, set screws, machined features, and other similar features. The busbars are fixed in place and insulated from other metal components as well as from each other, with adequate spacing between busbars maintained to meet safety requirements. Mounting approaches must also

accommodate thermal expansion and contraction while maintaining sufficient electrical contact pressure with the busbars. This is often accomplished using non conducting standoffs, bolts, and insulating barriers. As a result, available power bus systems may be less than optimal.

SUMMARY

[0006] An improved modular bus system is disclosed herein that is intended to improve upon the state of the art in terms of power and data management flexibility, as well as in terms of overall packaging space. The bus system is configured for power and data distribution and management, and is usable in conjunction with external electrical loads, e.g., lamps, speakers, audio/visual displays, special effects devices, etc. Such devices may be used, by way of example, in support of musical, athletic, or theatrical performances in which lighting, acoustic, and other stage effects may be desirable.

[0007] An elongated extruded backbone provides a generally flat/planar base as a stable foundation on which the present bus system is constructed. The extruded backbone has an extrusion profile defining integrally -formed longitudinally-extending T-channels, box channels, ribs, and walls. The extruded backbone described herein securely engages and/or supports one or more application-specific power and data (“P/D”) modules, each of which is connected along a length of the backbone, with adjacent P/D modules situated end-to-end. The extrusion profile of the backbone facilitates the disclosed modular functionality, minimizes the need for machining, and enables efficient routing of low-voltage power and data to the individual P/D modules. Low-voltage power may be provided via an AC-DC converter and/or a small power supply located within the bus system in different embodiments.

[0008] The application-specific P/D modules are configured to be easily plugged into, locked onto, and removed from the extruded backbone. Data and electrical power are thereby simultaneously connected to the P/D modules when the P/D modules are mounted onto the extruded backbone. In different example

embodiments, a given P/D module may include one or more power taps, such as but not limited to simple power and/or data outlets, branch circuit breakers, etc., and possibly more complex active modules. The P/D modules(s) ultimately manage and process power according to received data, or provide other application-specific functions such as audio, video, amplification, and data and signal processing.

[0009] In a non-limiting example embodiment, the modular bus system is used with an external power supply, e.g., a wall outlet or grid power, and with an external control console, and includes the extruded backbone, a plurality of insulated power busbars, and at least one P/D module. The backbone forms a foundation or base of the modular bus system, and has an extrusion profile defining elongated, axially- extending channels, ribs, and walls. The power busbars are supported by the extruded backbone and disposed between a respective pair of the ribs. Such busbars are collectively configured to conduct main power from an external power supply along a length of the modular bus system. The P/D modules are configured to receive low- voltage power and data from respective low-voltage and power cables. Each P/D module is electrically connectable to an external device to selectively supply the external device with the main power, the low-voltage power, and the data.

[0010] A module cover assembly of each respective P/D module has an installed position and an uninstalled position relative to the extruded backbone. In the installed position, axial or longitudinally-extending edges of the modular cover assembly mechanically engage a respective one of the walls of the extruded backbone, e.g., via wall slots, and the P/D module is simultaneously connected to the busbars, the low- voltage power, and the data. In the uninstalled position, the modular cover assembly is mechanically disengaged from the walls, and the P/D module is simultaneously disconnected from the main power, the low-voltage power, and the data. [0011] The above summary is not intended to represent every embodiment or aspect of the present disclosure. Rather, the foregoing summary exemplifies certain novel aspects and features as set forth herein. The above noted and other features and advantages of the present disclosure will be readily apparent from the following detailed description of representative embodiments and modes for carrying out the present disclosure when taken in connection with the accompanying drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 is a schematic perspective view illustration of a compact modular bus system for managing power and data as disclosed herein.

[0013] FIG. 2 is schematic perspective view illustration of a power and data (P/D) module that is usable with the modular bus system shown in FIG. 1.

[0014] FIG. 3 is an exploded perspective view illustration of an embodiment of the P/D module of FIG. 2.

[0015] FIG. 4 is a perspective view illustration of an extruded backbone of the modular bus system shown in FIG. 1.

[0016] FIG. 5 is an exploded perspective view illustration of a spring latch assembly and a busbar connection block for the modular bus system of FIG. 1.

[0017] FIGS. 6-9 are perspective view illustrations of a multi-functional key (MFK) of the modular bus system shown in FIG. 1.

[0018] The present disclosure is susceptible to modifications and alternative forms, with representative embodiments shown by way of example in the drawings and described in detail below. Inventive aspects of this disclosure are not limited to the particular forms disclosed. Rather, the present disclosure is intended to cover modifications, equivalents, combinations, and alternatives falling within the scope of the disclosure as defined by the appended claims.

DETAILED DESCRIPTION

[0019] Referring to the drawings, wherein like reference numbers refer to like components, a modular bus system 100 is shown schematically in FIG. 1. The bus system 100 envisioned herein is used for power and data distribution and management, e.g., in support of stage effects of the type described above. The bus system 100 is embodied as an elongated tunnel-like structure having a lengthwise or longitudinal axis (LL) along which one or more application-specific power and data (P/D) modules are connected. As used herein, the terms“longitudinal”,

“longitudinally-extending”,“axial”, and“axially-extending” each refer to a direction that is along or parallel to the lengthwise/longitudinal axis (LL) of the modular bus system. Likewise, the terms“transverse”,“lateral”, and“laterally-extending” refer to directions that are perpendicular to the longitudinal axis, and thus he along a lateral/transverse axis (TT).

[0020] The modular bus system 100 may be rectangular in its top/plan view and side/end profiles as shown in FIG. 1. For instance, the modular bus system 100 may have a height (H) and a width (W) that are each between about 4-6 inches, with an overall length (L) varying with the application. By using the modular construction described herein, the bus system 100 may be constructed to an overall length (L) of 4- 6 inches (one P/D module 50) up to about ten feet or more in some embodiments.

[0021] In general, the modular bus system 100 of FIG. 1 is specially configured to receive, distribute, and manage the real-time flow of digital data and electrical power when energizing one more externally-connected loads, e.g., the example external devices 200 and 210 as shown schematically in FIG. 1. The external devices 200 and 210, which are not shown to scale and may vary with the application in size, shape, and configuration, may be optionally embodied as lighting fixtures. Modem lighting devices, as well as acoustic and other devices, are closely controlled and synchronized to create a particular effect, and thus the external devices 200 and 210 may require electrical power (VAC) and digital data, e.g., digital multiplex (DMX) data.

[0022] As will be appreciated, DMX is a standard in which multiple channels, e.g., 512 separate channels in a DMX-512 configuration, are assigned to control attributes of the external devices 200 and 210, such as red/green/blue (RGB) color combinations, strobe effects, intensity, and dynamic control actions such as panning and tilting. Thus, the modular bus system 200 is ultimately connected to an external control console 350, which like the external devices 200 and 210 is not shown to scale. The control console 350 transmits electrical pulses to the modular bus system 100 and, via the distribution and connections enabled by the modular bus system 100, to the external devices 200 and 210 and possibly other connected devices. Other external devices may be envisioned, such as but not limited to audio speakers, video and/or still image screens, waterfalls, lasers, strobes, pyrotechnics, flash pots, etc. As the variety and number of external devices may be expected to vary substantially based on the application, the present bus system 100 may be equipped with any number of power and/or data taps, plugs, outlets, branch circuits breakers, and the like, some of which are depicted in FIG. 1, to facilitate routing of power from an external power supply 300 and digital data through the bus system 100 to the external devices 200 and 210.

[0023] In the illustrated embodiment of FIG. 1, each P/D module 50 includes a removable modular cover assembly 52. The modular cover assembly 52 has an installed position (FIG. 2) in which the modular cover assembly 52 securely engages an extruded backbone 10 to simultaneously connect the P/D module 50 to main power, low-voltage power (e.g., 5V power), and digital data. Likewise, the modular cover assembly 52, when removed or placed in an uninstalled position, easily disengages from the backbone 10 to simultaneously disconnect the P/D module 50 from the main power, the low-voltage power, and the digital data. The modular cover assembly 52 and the remainder of the P/D modules 50 support and contain a module- specific assortment of electrical and/or data connectors, e.g., single XLR or double XLR audio cable connectors, twist-lock, duplex, or power input/output connectors, RJ-type connectors, etc., with some portions of the modular housing assembly 52 possibly including blank panels where power and data access is not needed. End plates 19 may be positioned at the distal ends of the bus system 100 to complete the construction.

[0024] Referring briefly to FIG. 2, an example construction of a particular P/D module 50 is shown in which the above-noted modular cover assembly 52 includes orthogonally-arranged upper and side panels 52U and 52S, respectively, forming a generally L-shaped cover portion as shown. One or more electrical connectors 55, such as the illustrated example 5-wire, 20A, 20/208V polyphase plug connector, may extend through the upper panel 52U to enable connection of desired power and/or data at easily accessible locations. While the side panel 52S may be embodied as a blank panel as shown at various locations in FIG. 1, at least one P/D module 52 within the bus system 100 may include a circuit breaker assembly 75 as shown in FIG. 2, with the circuit breaker assembly 75 ultimately configured to quickly interrupt a main power feed from the power supply 300 into the bus system 100 when tripped, as will be appreciated by those of ordinary skill in the art.

[0025] The above-noted extruded backbone 10, which forms a base or foundation of the modular bus system 100, defines an extrusion profile that is integral to the overall modular structure and functionality of the bus system 100. Referring briefly to FIG. 4, the extruded backbone 10 may be constructed from aluminum or another application-suitable material. A width (W) of the backbone 10 corresponds to the width (W) of the bus system 100 shown in FIG. 1, while a length (Lio) of the backbone 10 may be equal to or less than the overall length (L) of the bus system 100. That is, the backbone 10 may be extruded to overall length (L), or several shorter backbones 10 may be linked together end-to-end, e.g., by inserting a splice bar (not shown) into axial T-channels 150 disposed along the backbone 10 and extending along the length (Lio). In some embodiments, the length of the extruded backbone 10 isg equal to a combined length of P/D modules 50.

[0026] The extrusion profile of the backbone 10 is ultimately configured to engage, support, and retain corresponding structure of the P/D modules 50, an example of which is shown in FIG. 3. For instance, adjacent to comers 10C of the backbone 10 are the above-noted axial T-channels 150, along with a similar pair of axial T-channels 110 oriented 90-degrees with respect to the T-channels 150. Other extruded profile features include outer backbone walls 140 each defining an axial retention groove 142, with the backbone walls 140 extending along the length (Lio) of backbone 10. A ramp and ledge feature 142 is present on wall 140 opposite groove 142, for engagement with a J-shaped end 139A of a spring latch 38 shown in FIG. 5 and set forth below. Axial box channels 160 may also be located immediately adjacent to the backbone walls 140 as shown.

[0027] Additionally, the extrusion profile of the extruded backbone 10 may define a flat landing area 105 flanked by axial landing walls 135 A and 135B. Another box channel 130 may be defined by and between axial landing wall 135A and an axial wall 136. An elongated slot 120 extends along the respective lengths of the landing wall 135A and the axial wall 136, with a nut 65 being slidably disposed within the box channel 130. A fastener 66 (see FIG. 6) may be inserted into the slot 120 along a vertical axis ZZ of the nut 65, and then threaded into the nut 65 to securely fasten a multi-functional key 20, to the backbone 10. For clarity, the multi-functional key 20 is referred to hereinafter by the abbreviation“MFK” so as to differentiate general locating or keying actions described herein from the physical key structure of the MFK 20.

[0028] The extruded backbone 10 also supports multiple insulated, elongated power busbars 12 which, as best shown in FIG. 3, are spaced a short distance (WBB) apart from each other. The distance (WBB) may be being about lcm in some embodiments, which due to the construction of the modular bus system 100 is substantially less than would ordinarily be found in a conventional power bus. Such minimal spacing is enabled in part by a set of dielectric fins 13, with the busbars 12 interposed between the dielectric fins 13. The dielectric fins 13 may themselves be configured as an insulative extrusion of an application-suitable dielectric material holding the busbars 12 in place on the extruded backbone 10, and also aligning busbar power connector blocks 40 (see FIGS. 3 and 5) with the busbars 12. To facilitate installation of the busbars 12 into the P/D modules 50, the extrusion profile of the backbone 10 may include a plurality of parallel, axially-extending molded ribs 180 and, like the other noted features of the extrusion profile, axial in orientation. The ribs 180 are located between the axial landing wall 135B and the closest of the backbone walls 140 as shown. Thus, the dielectric fins 13, when engaged with the busbar power connector blocks 40 as explained below, assist in pressing the busbars 12 against the backbone 10.

[0029] FIG. 3 provides an exploded-view diagram of an example P/D module 50 having the extruded backbone 10 of FIG. 4. The modular cover assembly 52 is shown with the upper panel 52U defining two example electrical ports 21 and 23 and the side panel 52S being blank, without limiting the panels 52U and 52S to such a

configuration. The upper panel 52U defines an elongated/axial lip 53. A removable door 26 is constructed of sheet metal or other suitable materials and may be equipped with a pair of clamps 26C. Each clamp 26 in turn has a clamp end 27 configured, e.g., in shape and spring force, to engage the elongated lip 53 and thereby partially define a cable duct 30 running alongside the P/D module 50 as shown. The cable duct 30 may be further defined by a vertically-oriented panel 25 whenever then the door 26 is securely clamped to the elongated lip 53 using the clamp ends 27. Device-specific data, audio-visual, ethemet, fiberoptic, and/or other cables (not shown) that may traverse the length (L) of the bus system 100 of FIG. 1 are thereby neatly stowed in the cable duct 30 behind the door 26.

[0030] The panel 25 serves as a module divider situated within a main cavity 24 of the modular cover assembly 52. A free edge 25E of the panel 25, itself axially- or longitudinally-extending, is ultimately inserted into an indexing clamp 25B defined by the MFKs 20, with such MFKs 20 described in further detail below with particular reference to FIGS. 6-9. Within the P/D module 50, an insulated module floor 29 may be orthogonally arranged with respect to the vertically-oriented panel 25 such that busbars 12 are separated from the main cavity 24 by the intervening module floor 29. The main cavity 24 may be bounded at either end by the end plates 41. Optionally, an outer cover plate 19 may be positioned at each distal end of the bus system 100 of FIG. 1 to enclose and protect the collective set of P/D modules 50.

[0031] Each P/D module 50 may include a pair of the above-noted MFKs 20, with the MFKs 20 securely fastened to the extruded backbone 10. Each MFK 20 provides locking or latching structure suitable for securing the P/D modules 50 to the extruded backbone 10, i.e., via threading of a fastener 66 in the direction of arrow B in FIG. 6 through a center hole 165 of a corresponding nut 65, as well as other functions.

[0032] Referring briefly to FIG. 6, each MFK 20 may be a unitary or integrally- formed piece, e.g., of injection-molded or 3D-printed plastic. The MFK 20 in the illustrated embodiment defines axial walls 20A that flank and thus straddle the box channel 130 of FIG. 4, and thereby engage mating structure of the extruded backbone 10. The MFK 20 also includes or integrally defines an indexing clamp 20B configured to grasp and receive therein the free edge 25E of the vertically-oriented panel 25, with the free edge 25E gently inserted into an interference-fit gap (GG) defined by the indexing clamp 20B when transitioning the modular cover assembly 52 to an installed position. Together, the axial walls 20A and a spring-latch connector 20C provide indexing or locating functions to properly secure and align the MFK 20 within the P/D module 20. The MFKs 20 are therefore configured to enable the module cover assembly 52 to be installed with simultaneous connection of power and data as noted above.

[0033] The MFK 20 further includes or integrally-defmes the above-noted spring- latch connector 20C and a ramp and ledge feature 20D. A terminal end 62 of a length of data cable 60 is moved toward the spring-latch connector 20C as represented by arrow A. The terminal end 62 may be variously embodied as a DMX-512, Ethernet, Remote Device Management (RDM), or RS-485 data bus connector and/or a module- specific connection from the cable duct 30 shown in FIG. 3. In such embodiments, DMX data and low-voltage power may be connected via the terminal end 62, or Ethernet data plus low-voltage power, i.e., power-over-Ethemet (POE). The spring- latch connector 20C is configured to receive and engage the terminal end 62, with multiple views of such an engaged position shown in FIGS. 7-9. The spring-latch connector 20C, combined with the other features of the MFK 20, vertically-orients the terminal end 62 in a fixed position that aligns with port 21 or 23 defined by the upper panel of FIG. 3. That is, port 21 or 23 and thus any connector coupled thereto, when the modular cover assembly 52 is installed, is located directly opposite the retained vertically-oriented terminal end 62. In this manner, simple installation of the module cover assembly 52 serves to connect data to the terminal end 62 via port 21 and/or 23.

[0034] An example embodiment of a spring latch 28 shown in FIG. 3 is depicted in detail in FIG. 5 along with an end plate 41 and a busbar connection block 40, all of which may be used in the construction of the P/D modules 50 contemplated herein. Each end plate 41 defines a pair of edge flanges 141 extending a short distance along the length (Lio) of FIG. 4, i.e., a distance sufficient for forming mounting holes 141H. Similar mounting holes 41H are defined on a major surface of the end plate 41. Each P/D module 50 includes a pair of the spring latches 38, which in turn securely snap onto, engage, and lock the P/D module 50 into position along the extruded backbone 10

[0035] The spring latch 38 may be optionally embodied as an H-shaped spring assembly with a transverse member 72 forming a cross-bar between a parallel pair of vertical members 66. One of the vertical members 66 may include a spring member 67, e.g., a U-shaped axial projection of the transverse member 72, with J-shaped ends 139A and 139B of the vertical members 66 configured to respectively engage the extruded backbone 10 at a ramp and ledge feature 142A of FIG. 4 (i.e., feature 142A is engaged by the J-shaped end 139A) and a similar ramp and ledge feature 20D of the MFK 20 (i.e., feature 20D is engaged by the J-shaped end 139B), to securely hold the P/D module 50 in place. That is, the J-shaped ends 139A and 139B slide down and hook under the ramp and ledge features 142A and 20D. The presence of the ramp thus helps provide sufficient spring force for retaining the P/D module 50.

[0036] A fastening screw 39 may be passed through one of the flange holes 141H and tightened from outside of the P/D module 50 to gently urge the vertical members 66 laterally outward, i.e., away from the longitudinal axis (LL) of the modular bus system 100, with engagement of J-shaped ends 139A and 139B with the backbone 10 and MFK 20, respectively, ultimately retaining the P/D module 50 to the extruded backbone 10. The screw 39 in some embodiments may have a specially configured security head that can only be used in conjunction with a special tool (not shown) to help prevent tampering or unauthorized access to or removal of a given P/D module 50. Additional fasteners 68 may be used to properly align and attach the spring latches 38 to a corresponding one of the end plates 41.

[0037] Referring again to FIG. 3, the cable duct 30 noted above may be electrically and physically isolated from any power and data located within the larger main cavity 24. That is, data and low power cables (not shown) may be routed within the cable duct 30 alongside the door 26, and therefore can be easily added, removed, connected, and disconnected as needed even while the P/D modules 50 remain locked in place via the spring latches 38. Such structure still permits additional P/D modules 50 to be added/removed without disrupting the cable routing between other P/D modules 50 of the bus system 100.

[0038] Vertically-oriented cable tie-down brackets 14 may be used to help retain such cables (not shown) when the P/D modules 50 are removed and replaced, and can also hold connectors extending through front cutouts in the P/D modules 50 for connections to the outside world. The brackets 14 would be located in the cable duct 30 adjacent to the vertically-oriented panel 25 when the modular cover assembly 52 is in the installed position, e.g., FIG. 2. This capability facilitates removal and replacement of a given P/D module 50 without disturbing cabling situated within the cable duct 30. Extensive use of“registered jack” (RJ)-type modular connectors with unique mounting and alignment features in the MFKs 20 may also facilitate fast inter module connections in an inexpensive, reliable, and versatile manner. As will be appreciated, RJ-45 and other standard connector types are typically used with unshielded, twisted pair network cables, e.g., Ethernet.

[0039] As noted above with specific reference to FIG. 4, the extrusion profile of backbone 10 may include the flat landing 105, which in turn is flanked by axial landing walls 135 A and 135B. The flat landing area 105 may be configured to receive thereon a ribbon cable 16. Such a ribbon cable 16 may include multi-pin connectors 16C, e.g., 20-pin low-voltage connectors of the type well understood in the art. While shown outside of the P/D module 50 for added clarity, the multi-pin connector 16C would typically be located on a span of the ribbon cable 16 extending between the MFKs 20 of a given P/D module 50. The ribbon cable 16 may convey low-voltage power (generally 5V or less) and digital data, e.g., DMX data. The multi pin connectors 16C are located within each P/D module 50, such that low-voltage power and digital data may be easily tapped by inserting mating pins (not shown) of an interface board 45 into the multi-pin connector 16C.

[0040] The busbars 12 shown schematically at the bottom of FIG. 3 form another integral component of the modular bus system 100. Such busbars 12 may be embodied as extruded copper or aluminum bars, which in some embodiments may be tin- or silver-plated. A set of such busbars 12, e.g., five parallel copper busbars 12, may be held in and/or interposed between the dielectric fins 13 to extend end-to-along the length (L) of the extruded backbone 10. The dielectric fins 13 are configured to insulate the busbars 12 from each other and from the surrounding enclosure, as well as from contact with a human operator, e.g., to prevent an operator’s fingers from inadvertently touching the busbars 12 when accessing the P/D module 50.

Additionally, the dielectric fins 13 may be part of an insulated extrusion that holds the busbars 12 in place on the backbone 10 while aligning the busbar connector blocks 40, e.g., by engaging mating vertical slots 40S thereof (see FIG. 5). That is, in the installed position of the modular cover assembly 52 of FIG. 1, the dielectric fins 13 are received within a respective one of the vertical slots 40S. The dielectric fins 13 may also be used to help align the busbars 12 and maintain sufficient electrical contact pressure with the busbars 12 when the modular cover assembly 52 is in an installed position. After insertion of each of the busbars 12 between adjacent ribs 180 of the backbone 10 shown in FIG. 4, the multi-contact busbar connection blocks 40 remain firmly seated against the busbars 12 without the need for continuing pressure on the modular cover assembly 52.

[0041] Referring again briefly to FIG. 5, the spring latches 38 also help maintain contact pressure between the electrical contacts 40C of the busbar connection blocks 40 and the individual busbars 12 of FIG. 3. As shown, the busbar connection blocks 40 may include mating halves 48 and 49 that together support and contain a plurality of main electrical cables 51, e.g., five such cables 51 in the example configuration, each of which is rated for the particular main power feed from the external power supply 300 of FIG. 1. Mounting holes 40H correspond in number to the number of holes 41H formed in the end plate 41 to which the busbar connection block 40 is securely mounted. Such an approach requires no machining or special features in the busbars 12. Instead, the busbar connection block 40 and the dielectric fins 13 alone maintain good electrical contact and isolation.

[0042] The busbar connection block 40, which is just one possible example configuration, may accept several commercially-available contact spring and insulator assemblies, such as but not limited to a POWERPOLE^®plug from ANDERSON POWER PRODUCTS, a POWERLOCK^® plug from TE CONNECTIVITY LTD, or similar. Alternatively, a multiple-contact housing may receive multiple busbar contacts 40C and spring latches 38, eliminating the need for individual contact insulators. Busbar contacts 40C may be crimped directly onto wire conductors located in the P/D module 50 as needed, thus requiring no additional connecting hardware such as screw terminals, lugs, etc. would otherwise add complexity, reduce reliability and generate heat.

[0043] While some of the best modes and other embodiments have been described in detail, various alternative designs and embodiments exist for practicing the present teachings defined in the appended claims. Those skilled in the art will recognize that modifications may be made to the disclosed embodiments without departing from the scope of the present disclosure. Moreover, the present concepts expressly include combinations and sub-combinations of the described elements and features. The detailed description and the drawings are supportive and descriptive of the present teachings, with the scope of the present teachings defined solely by the claims.

Claims

1. A modular bus system configured for use with an external power supply and an external control console, comprising: an extruded backbone forming a foundation or base of the modular bus system, wherein the extruded backbone has an extrusion profile defining a plurality of elongated, axially-extending channels, ribs, and walls;

a plurality of power busbars, each respective busbar of which is supported by the extruded backbone and disposed between a respective pair of the ribs, wherein the plurality of power busbars is configured to conduct main power from the external power supply along a length of the modular bus system; and

a power and data (P/D) module configured to receive low-voltage power and data from the external console, wherein the P/D module is electrically connectable to an external device to selectively supply the main power, the low-voltage power, and the data to the external device, the P/D module includes a removable module cover assembly having an installed position and an uninstalled position relative to the extruded backbone, and:

in the installed position, edges of the removable modular cover assembly mechanically engage a respective one of the walls of the extruded backbone, and the P/D module is simultaneously connected to the busbars, the low- voltage power, and the data, and

in the uninstalled position, the modular cover assembly is mechanically disengaged from the walls, and the P/D module is simultaneously disconnected from the main power, the low-voltage power, and the data.

2. The modular bus system of claim 1, wherein the removable module cover assembly includes an L-shaped cover portion and a removable door, the L- shaped cover portion defines an axial edge configured to engage a first one of the walls, and an axial lip configured to engage the removable door.

3. The modular bus system of claim 2, wherein the removable door includes a pair of spaced clamps configured to engage the axial lip.

4. The modular bus of claim 2, further comprising a vertically-oriented panel connected to the L-shaped cover within the P/D module, wherein a cable duct is defined alongside the P/D module by the removable door and the vertically-oriented panel.

5. The modular bus of claim 1, wherein the plurality of power busbars includes five parallel copper busbars interposed between five dielectric fins, such that the five parallel copper busbars are electrically insulated and isolated from each other and from contact with a human operator.

6. The modular bus of claim 1, wherein the axially-extending channels of the extruded backbone include, on each lateral side of the extruded backbone, an orthogonally-arranged pair of axially-extending T-channels.

7. The modular bus of claim 1, further comprising a pair of multi functional keys (MFKs) each configured to straddle a respective one of the axially- extending channels, position and secure the P/D module to the extruded backbone, and receive, retain, and vertically-orient a terminal end of a cable providing the data.

8. The modular bus of claim 7, wherein each of the MFKs is formed from a unitary plastic piece that is configured to engage the terminal end.

9. The modular bus of claim 8, wherein the P/D module contains a pair of vertically-oriented cable tie-down brackets adjacent to a respective one of the MFKs.

10. The modular bus system of claim 1, further comprising a pair of busbar connection blocks each fastened to different ends of the module cover assembly, and each of which is configured to make electrical contact with the busbars when the removable module cover assembly is in the installed position.

11. The modular bus system of claim 10, wherein each respective busbar connection block of the pair of busbar connection blocks defines a plurality of vertical slots, and the plurality of insulated power busbars includes vertical dielectric fins that, in the installed position of the removable modular cover assembly, are received within plurality of vertical slots.

12. The modular bus system of claim 1, further comprising a ribbon cable having a multi-pin connector providing the data and the low-voltage power, wherein the extrusion profile includes a flat landing area adjacent to the ribs, and wherein the ribbon cable is disposed on the flat landing.

13. The modular bus system of claim 12, wherein the P/D module includes a digital interface card that is connected to the ribbon cable via the multi-pin connector.

14. The modular bus system of claim 1, wherein the P/D module includes a pair of spring latches configured to snap onto, engage, and lock the P/D module to the extruded backbone.

15. The modular bus system of claim 14, wherein the spring latches are H- shaped springs with a transverse member forming a cross-bar between a pair of parallel vertical members, at least one of the vertical members defines a J-shaped end configured to engage a ramp and ledge feature of the extruded backbone, and the spring latches include a security fastener that, when tightened, moves the vertical members in a lateral direction to thereby lock the P/D module to the extruded backbone via the J-shaped end.

16. The modular bus system of claim 1, wherein the P/D module includes a plurality of P/D modules connected end-to-end, and wherein a length of the extruded backbone is equal to a combined length of the plurality of P/D modules.