Worksite power distribution box

• US 10,727,653 B2
• Filed: 11/08/2018
• Issued: 07/28/2020
• Est. Priority Date: 02/22/2013
• Status: Active Grant

• Current Assignee: Milwaukee Electric Tool Corporation (Techtronic Industries Company Limited)
• Original Assignee: Milwaukee Electric Tool Corporation (Techtronic Industries Company Limited)
• Inventors: Burch, Wade F.
• Primary Examiner(s): Tan, Richard
• Application Number:
  US16/184,675
• Publication Number:
  US 20190081462A1
• Time in Patent Office: 628 Days
• Field of Search: 307131
• CPC Class Codes: H02B 1/52 Mobile units, e.g. for work sites
• CPC Class Codes: H02B 11/26 Arrangements of fuses, resistors, voltage arresters or the like
• CPC Class Codes: H02B 7/06 Distribution substations, e.g. for urban network H02B7/01 takes precedence

Abstract

A power distribution box apparatus and method for implementing a priority disconnect scheme and a network communication bridge at a worksite, where the power distribution box distributes temporary power. The power distribution box includes a housing portion and a base portion elevating the housing portion off of the ground or another surface. The power distribution box includes a communication module having a network connecting module operable to connect to an external communication network (e.g., the Internet), and a wireless network module operable to wirelessly communicate with an external device (e.g., a smart phone) to, thereby, connect the external device to the external communication network. The power distribution box may also include a priority disconnect module to selectively disconnect AC output receptacles in response to over-current situations based on a priority level associated with each receptacle.

Claims

1. A power distribution box with priority disconnection, the power distribution box comprising:

a power input that receives alternating current (AC) power from an external power source;

a housing;

a plurality of alternating current (AC) output receptacles supported by the housing and electrically coupled to the power input, wherein the AC power is distributed to the plurality of AC output receptacles;

a plurality of manual priority level selectors supported by the housing, wherein each of the plurality of manual priority level selectors is configurable among a plurality of priority levels and is set to a priority level for disconnecting a respective AC output receptacle;

a plurality of always-on mode selectors supported by the housing, each of the plurality of always-on mode selectors associated with a different one of the plurality of AC output receptacles, wherein each of the associated different one of the plurality of AC output receptacles is individually settable to one of an always-on mode and a priority disconnect mode by a respective always-on mode selector of the plurality of always-on mode selectors;

a manual reset selector supported by the housing; and

an electronic controller configured to;

detect a sum current level for the plurality of AC output receptacles,

determine that the sum current level exceeds a priority disconnect threshold,

in response to determining that the sum current level exceeds the priority disconnect threshold, selectively disconnect a first AC output receptacle of the plurality of AC output receptacles from the power input based on the priority level set for the first AC output receptacle, and

in response to receiving input at the manual reset selector, selectively reconnect the first AC output receptacle to the power input.

2. The power distribution box of claim 1, wherein the electronic controller is further configured to:

detect individual current levels for each of the plurality of AC output receptacles;

determine whether the individual current levels exceed an individual current threshold; and

selectively disconnect from the power input each of the plurality of AC output receptacles with individual current levels that exceed the individual current threshold.

3. The power distribution box of claim 1 further comprising:

a main breaker, wherein the main breaker opens when current conducted via the main breaker exceeds a main breaker threshold, the main breaker positioned between the power input and the plurality of AC output receptacles and the main breaker threshold being higher than the priority disconnect threshold.

4. The power distribution box of claim 3 further comprising:

a sub-breaker positioned between the main breaker and a second AC output receptacle of the plurality of AC output receptacles, wherein the sub-breaker opens when current conducted via the sub-breaker exceeds a sub-breaker threshold, the sub-breaker threshold being less than the main breaker threshold.

5. The power distribution box of claim 1, wherein selectively disconnecting the first AC output receptacle from the power input based on the priority level of the first AC output receptacle of the plurality of AC output receptacles includes determining that the first AC output receptacle has a lowest priority level of the plurality of AC output receptacles.

6. The power distribution box of claim 1, wherein selectively disconnecting the first AC output receptacle from the power input based on the priority level of the first AC output receptacle of the plurality of AC output receptacles includes determining that the first AC output receptacle and a second AC output receptacle of the plurality of AC output receptacles have equal priority levels, wherein the first AC output receptacle is selectively disconnected based on the first AC output receptacle conducting more current than the second AC output receptacle.

7. The power distribution box of claim 1, wherein selectively disconnecting the first AC output receptacle from the power input based on the priority level of the first AC output receptacle of the plurality of AC output receptacles is further based on the first AC output receptacle having a lowest priority level of a subset of the plurality of AC output receptacles that are set in the priority disconnect mode.

8. The power distribution box of claim 1 further comprising:

a communication module that is communicatively coupled to an external communication network, wherein an external device is communicatively coupled to the external communication network via the communication module.

9. A power distribution box with priority disconnection, the power distribution box comprising:

a power distribution box (PDB) housing;

a power input supported by the PDB housing that receives power from an external power source;

a plurality of output receptacles including at least a first output receptacle and a second output receptacle that are supported by the PDB housing and electrically coupled to the power input, wherein power received at the power input is distributed to the plurality of output receptacles;

a manual priority level selector supported by the PDB housing, wherein the manual priority level selector is associated with the first output receptacle of the plurality of output receptacles and the first output receptacle is configurable among a plurality of priority levels based on a setting of the manual priority level selector;

an always-on mode selector supported by the PDB housing, the always-on mode selector associated with the first output receptacle of the plurality of output receptacles, wherein the always-on mode selector is manually settable to configure the first output receptacle to switch between an always-on mode and a priority select mode, and the always-on mode enables a connection from the power input to the first output receptacle;

a second always-on mode selector supported by the PDB housing, the second always-on mode selector associated with the second output receptacle of the plurality of output receptacles, wherein the second always-on mode selector is manually settable to configure the second output receptacle to switch between the always-on mode and the priority select mode, and the always- on mode for the second output receptacle enables a connection from the power input to the second output receptacle;

a manual reset selector supported by the PDB housing; and

an electronic controller configured to;

detect a current level;

determine that the current level exceeds a current threshold;

in response to exceeding the current threshold, determine whether to disconnect the first output receptacle of the plurality of output receptacles from the power input based on the setting of the manual priority level selector; and

in response to receiving input at the manual reset selector, connect the first output receptacle to the power input when the first output receptacle is disconnected.

10. The power distribution box of claim 9, wherein the first output receptacle is an alternating current (AC) output receptacle.

11. The power distribution box of claim 9, wherein the first output receptacle is a direct current (DC) output receptacle.

12. The power distribution box claim 9 further comprising:

a disconnect switch associated with the first output receptacle and controlled by the electronic controller for disconnecting and connecting the first output receptacle to the power input; and

an indicator light supported by the PDB housing that indicates whether the first output receptacle is disconnected or connected to the power input by the disconnect switch.

13. The power distribution box claim 9, wherein determining whether to disconnect the first output receptacle of the plurality of output receptacles from the power input based the setting of the manual priority level selector further includes determining whether to disconnect the first output receptacle from the power input based on the setting of the manual priority level selector and a setting of the always-on mode selector.

14. A method for priority disconnection in a power distribution box, the method comprising:

receiving power from an external source at a power input of the power distribution box (PDB) and distributing the power to a plurality of output receptacles supported by a housing of the PDB, wherein the plurality of output receptacles include a first output receptacle and a second output receptacle;

detecting a current level by an electronic controller of the PDB;

determining, by the electronic controller, that the current level exceeds a current threshold;

in response to exceeding the current threshold, determining, by the electronic controller, whether to disconnect the first output receptacle of the plurality of output receptacles from the power input based on a setting of a manual priority level selector supported by the FOB housing, wherein the first output receptacle is configurable among a plurality of priority levels based on a setting of the manual priority level selector;

enabling, when the first output receptacle is in an always-on mode, a connection from the power input to the first output receptacle of the plurality of output receptacles, wherein a first always-on mode selector supported by the PDB housing is manually settable to configure the first output receptacle of the plurality of output receptacles to switch between the always-on mode and a priority select mode;

enabling, when the second output receptacle is in the always-on mode, a connection from the power input to the second output receptacle of the plurality of output receptacles, wherein a second always-on mode selector supported by the PDB housing is manually settable to configure the second output receptacle of the plurality of output receptacles to switch between the always-on mode and the priority select mode; and

in response to receiving input at a manual reset selector supported by the PDB housing, connecting, by the electronic controller, the first output receptacle to the power input when the first output receptacle is disconnected.

15. The method of claim 14, wherein the first output receptacle is an AC output receptacle.

16. The method of claim 14, wherein the first output receptacle is a direct current (DC) output receptacle.

17. The method of claim 14 further comprising:

disconnecting or connecting, by a disconnect switch controlled by the electronic controller, the first output receptacle to the power input; and

indicating, by an indicator light supported by the PDB housing, whether the first output receptacle is disconnected or connected to the power input by the disconnect switch.

18. The method of claim 17 further comprising:

wherein determining whether to disconnect the first output receptacle of the plurality of output receptacles from the power input based the setting of the manual priority level selector further includes determining whether to disconnect the first output receptacle from the power input based on the setting of the manual priority level selector and a setting of the always-on mode selector.