START TEST ELECTRONIC DEVICE AND SYSTEM AND METHOD OF USE THEREOF

• US 20100271006A1
• Filed: 04/28/2010
• Published: 10/28/2010
• Est. Priority Date: 04/28/2009
• Status: Active Grant

• Current Assignee: Darby Group Companies Incorporated
• Original Assignee: Darby Group Companies Incorporated
• Inventors: FORTNER, DOUGLAS C.
• Granted Patent: US 8,675,321 B2
• Time in Patent Office: Days
• US Class Current: 324/126
• CPC Class Codes: G01R 19/1659 to indicate that the value is within or outside a predetermined range of values (window) G01R19/16514, G01R19/16519, G01R19/16528 and G01R19/16533 take precedence
• CPC Class Codes: G01R 31/34 Testing dynamo-electric machines

Abstract

The present invention is a method and system for monitoring the continuous flow of power delivered by multiple DC Direct current operated starter motors used to start engine driven electrical generators. The method and system comprise the closing of a starter battery system and an associated starter control switch, causing the starter battery system to discharge through a shunt whereby current is fed into a starter motor. The shunt is optionally provided as a precision resistor with a pre-calibrated voltage drop in millivolts DC proportional to a current passing through it. The shunt directs current to a meter relay, which is calibrated by establishing two set points, or desired trigger ranges, for the meter relay. If the current falls outside a range established by the two set points, then a meter relay alarm output is activated; and, if the current remains within the range, then the meter relay alarm output is not activated. The meter relay alarm output is, optionally, a dry contact which activates a signal device.

Claims

1. A method for monitoring the continuous flow of power delivered by multiple DC direct current starter motors comprising the steps of:

(a) closing a starter battery system and an associated starter control switch causing said starter battery system to discharge through a shunt whereby current is fed into a starter motor;

(b) calibrating a meter relay;

(c) establishing two set points for said meter relay; and

,

(i) if said current falls outside a range established by said two set points, then activating a meter relay alarm output; and

,

(ii) if said current remains within said range, then said meter relay alarm output is not activated.

2. The monitoring method of claim 1, wherein said shunt is a precision resistor with a pre-calibrated voltage drop in millivolts DC proportional to a current passing through it.

3. The monitoring method of claim 2, wherein said shunt is rated up to, and including, 2000 amperes DC at 100 millivolts.

4. The monitoring method of claim 2, wherein at 1000 amperes DC passing through said shunt, said shunt will cause a voltage drop across said shunt of approximately 50 millivolts.

5. The monitoring method of claim 4, wherein said voltage drop across said shunt relative to amperes DC passing through said shunt establishes a proportion, and wherein said proportion is maintained for any amperage at 2000 amperes DC or below.

6. The monitoring method of claim 1, wherein said meter relay alarm output is a dry contact which activates a signal device.

7. The monitoring method of claim 6, wherein said signal device is selected from the group comprising:

(a) a bell;

(b) a set of one or more lighting devices;

(c) a digital signal in a communication protocol for interfacing with a monitoring system; and

(d) an Ethernet connection for transmitting said signal via a wireless communication system.

8. The monitoring method of claim 1, said method further comprising the step of interoperably connecting a circuit module, to said starter motor, for applying a test voltage for determining the possibility of said starter motor'"'"'s failure due to deterioration of the electrical insulation of said starter motor'"'"'s windings.

9. The connecting step of claim 8, wherein said connecting step further comprises the steps of:

(a) applying a DC test voltage within the range of 50-500 VDC to said starter motor windings;

(b) measuring the ohmic resistance of said starter motor windings to determine a measured value;

(c) comparing said measured resistance value with a profile value to determine a compared value; and

(i) if said measured value is proximate to said profile value, then determining that failure of said starter motor due to said insulation is not imminent; and

(ii) if said measured value is low relative to said profile value, then determining that failure of said starter motor due to said insulation is imminent.

10. A system for monitoring the continuous flow of power delivered by multiple starter motors comprising:

(a) a starter battery system having a starter battery control switch;

(b) a shunt through which said starter battery system is discharged;

(c) a voltage monitor and signal conditioner;

(d) a starter motor into which a current is fed by said discharge;

(e) a meter relay, and wherein said meter relay further comprises two set points; and

,

(f) a meter relay alarm output, wherein

(i) if said current falls outside a range established by said two set points, then activating said meter relay alarm output; and

,

(ii) if said current remains within said range, then said meter relay alarm output is not activated.

11. The monitoring system of claim 10 wherein said shunt is a precision resistor with a pre-calibrated voltage drop in millivolts DC proportional to a current passing through it.

12. The monitoring system of claim 10, wherein said shunt is rated for up to, and including, 2000 amperes DC at 100 millivolts.

13. The monitoring system of claim 10, wherein at 1000 amperes DC passing through said shunt, said shunt will cause a voltage drop across said shunt of approximately 50 millivolts.

14. The monitoring system of claim 13, wherein said voltage drop across said shunt relative to amperes DC passing through said shunt establishes a proportion, and wherein said proportion is maintained for any amperage at 2000 amperes DC or below.

15. The monitoring system of claim 10, wherein said meter relay alarm output is a dry contact which activates a signal device.

16. The monitoring system of claim of claim 15, wherein said signal device is selected from the group comprising:

(g) a bell;

(h) a set of one or more lighting devices;

(i) a digital signal in a communication protocol for interfacing with a monitoring system; and

(j) an Ethernet connection for transmitting said signal via a wireless communication system.

17. The monitoring system of claim 10, said system further comprising a circuit module, interoperably connected to said starter motor, for applying a test voltage for determining the possibility of said starter motor'"'"'s failure due to deterioration of the electrical insulation of said starter motor'"'"'s windings.

18. The monitoring system of claim 17, wherein said circuit module further comprises:

(a) application means for applying a DC test voltage within the range of 50-500 VDC to said starter motor windings;

(b) measuring means for measuring the ohmic resistance of said starter motor windings to determine a measured value;

(c) comparing means for comparing said measured resistance value with a profile value to determine a compared value; and

(i) if said measured value is proximate to said profile value, then determining that failure of said starter motor due to said insulation is not imminent; and

(ii) if said measured value is low relative to said profile value, then determining that failure of said starter motor due to said insulation is imminent.

19. A method for monitoring the continuous flow of power delivered by multiple DC direct current starter motors comprising the steps of:

(a) closing a starter battery system and an associated starter control switch causing said starter battery system to discharge through a shunt whereby current is fed into a starter motor;

(b) directing DC current flow through a Hall Effect having a wire cable throughput;

(c) inducing a current signal from said wire cable throughput wherein said current signal can be read by a control and alarm circuit;

(d) calibrating said control and alarm circuit;

(e) establishing two set points for said control and alarm circuit; and

,

(i) if said current falls outside a range established by said two set points, then activating a meter relay alarm output; and

,

(ii) if said current remains within said range, then said meter relay alarm output is not activated.

20. The monitoring method of claim 19, further comprising the step of establishing a hysteresis at said control and alarm circuit upon the starting of an engine wherein said control and alarm circuit will ignore for a period of time a high current surge as said starter motor begins to turn.

21. The monitoring method of claim 20, further comprising the steps of:

(a) self-calibrating by said control and alarm circuit wherein said control and alarm circuit takes a steady state current as said starter motor is turning over said engine and establishes said steady state current as a baseline current; and

(b) utilizing said set points to establish said range to be applied to said baseline current.

22. The monitoring method of claim 19, wherein said Hall Effect Device is a device which provides a signal output proportional to the current flow through a DC direct current feeder cable passed through its center.

23. The monitoring method of claim 22, wherein said Hall Effect Device is rated up to, and including, 2000 amperes DC and produces an output current proportional electrical signal.

24. The monitoring method of claim 22, wherein at 1000 amperes DC passing through said Hall Effect Device, said device will cause a produce an output electrical signal approximately half the amplitude of the signal it would produce if the feeder cable were carrying 2000 amperes DC.

25. The monitoring method of claim 24, wherein said Hall Effect Device produces an electrical signal output proportional to DC current, and wherein said proportion is maintained for any amperage at 2000 amperes DC or below.

26. The monitoring method of claim 19, wherein said current sensor alarm circuit output is a dry contact which activates a signal device.

27. The monitoring system of claim of claim 26, wherein said signal device is selected from the group comprising:

(a) a bell;

(b) a set of one or more lighting devices;

(c) a digital signal in a communication protocol for interfacing with a monitoring system; and

(d) an Ethernet connection for transmitting said signal via a wireless communication system.

28. A system for monitoring the continuous flow of power delivered by multiple DC direct current starter motors each comprising:

(a) a starter battery system having a starter battery control switch;

(b) a Hall Effect Device through which said starter battery system is discharged;

(c) a starter motor into which a current is fed by said discharge;

(d) a current alarm circuit further comprising;

(i) a control and alarm circuit, wherein said control and alarm circuit is capable of establishing a current baseline; and

(ii) self calibrating around said current baseline two set points (one high and one low); and

(e) a relay alarm output, wherein

(i) if said current falls outside a range established by said two set points on said current baseline, then activating said meter current alarm output; and

,

(ii) if said current remains within said range, then said current alarm relay output is not activated.

29. The monitoring system of claim 28, wherein said control and alarm circuit is capable of establishing a hysteresis upon the starting of an engine wherein said control and alarm circuit will ignore for a period of time a high current surge as said starter motor beings to turn to drive said engine.

30. The monitoring system of claim 29, wherein said control and alarm circuit is capable of taking a steady state current as said starter motor is turning over said engine and establishing said steady state current as a baseline current;

and, utilizing said set points to establish said range to be applied to said baseline current.

31. The monitoring system of claim 28 wherein said Hall Effect device is providing an electrical output signal proportional to a current passing through a DC direct current feeder cable passing through the opening in the Hall Effect Device.

32. The monitoring system of claim 31, wherein said Hall Effect Device is rated for up to, and including, 2000 amperes.

33. The monitoring system of claim 31, wherein at 1000 amperes DC passing through said Hall Effect Device, said device will cause an output signal proportional in amplitude and approximately half of the amplitude at 1000 A DC as is obtained at 2000 A DC current flow in the starter motor feeder cable passing through the opening in the Hall Effect Device.

34. The monitoring system of claim 33, wherein said Hall Effect Device output signal proportional to amperes DC passing through said device via the starter motor feeder cable, establishes a proportion, and wherein said proportion is maintained for any amperage at 2000 amperes DC or below.

35. The monitoring system of claim 28, wherein said current alarm circuit output alarm is a dry contact which activates a signal device.

36. The monitoring system of claim of claim 35, wherein said signal device is selected from the group comprising:

(iii) a bell;

(iv) a set of one or more lighting devices;

(v) a digital signal in a communication protocol for interfacing with a monitoring system; and

(vi) an Ethernet connection for transmitting said signal via a wireless communication system.