Load bank alternating current regulating control

• US 6,538,345 B1
• Filed: 10/24/2000
• Issued: 03/25/2003
• Est. Priority Date: 10/24/2000
• Status: Expired due to Term

• Current Assignee: Trumpet Holdings, Inc. (Standard Motor Products Incorporated)
• Original Assignee: Trombetta, LLC
• Inventors: Maller, Dennis A.
• Primary Examiner(s): Sircus, Brian
• Assistant Examiner(s): POLK, SHARON A
• Application Number:
  US09/696,655
• Time in Patent Office: 882 Days
• Field of Search: 307/64, 307/85, 307/86, 361/159
• US Class Current: 307/86
• CPC Class Codes: H02J 9/061 for DC powered loads
• CPC Class Codes: H02J 9/068 Electronic means for switching from one power supply to another power supply, e.g. to avoid parallel connection

Abstract

An electrical control module, including a control circuit, and voltage rectifier for controlling a solenoid. The control circuit is adapted for use in a transfer switch receiving power from two power sources and sending power to a single load, such as a commercial building or hospital. The control circuit and solenoid are designed to work over a broad range of voltages to quickly and efficiently transfer power from the first power source to the second. The circuit is particularly well suited for use in a closed transition transfer switch where the second source is connected before the first source is disconnected.

Claims

1. A solenoid control system for solenoid operated transfer switches used for switching an electrical load from a first electrical power source to a second electrical power source, the system comprising:

a transfer switch switchably connected between the first power source and the load and the second power source and the load;

a rectifier, the rectifier being connected to at least one of said power sources;

at least one solenoid, the solenoid being mechanically coupled to said transfer switch;

at least one solenoid control circuit, wherein the solenoid control circuit comprises a CMOS timer integrated circuit for controlling the solenoid, the control circuit connected to said rectifier and said solenoid; and

a controller, the controller being connected to said solenoid control circuit whereby the controller sends a signal to the solenoid control circuit thereby causing the solenoid to move the transfer switch from one of said power sources to the other.

2. The system of claim 1 wherein the transfer switch is a closed transition switch.

3. The system of claim 1 wherein the transfer switch is an open transition switch.

4. The system of claim 1 wherein the at least one solenoid is a dual action solenoid.

5. The system of claim 1 wherein the solenoid control circuit further comprises a second CMOS timer integrated circuits for controlling the solenoid.

6. The system of claim 5 wherein the solenoid control circuit further comprises transient voltage suppression means for protecting said circuit from an over voltage condition.

7. The circuit of claim 6 wherein the transient voltage suppression means comprise at least one transient absorption zener diode.

9. The system of claim 1 wherein the rectifier is a full wave bridge rectifier.

10. The system of claim 1 wherein a stored energy source is connected to said controller.

8. A solenoid control system for solenoid operated transfer switches used for switching an electrical load from a first electrical power source to a second electrical power source, the system comprising:

a transfer switch switchably connected between the first power source and the load and the second power source and the load;

a rectifier, the rectifier being connected to at least one of said power sources;

at least one solenoid, the solenoid being mechanically coupled to said transfer switch;

at least one solenoid control circuit, wherein the solenoid control circuit comprises low voltage protection means associated with said circuit for extending the time period a predetermined current is sent to each solenoid when an inadequate input voltage is received from said rectifier, the control circuit connected to said rectifier and said solenoid; and

a controller, the controller being connected to said solenoid control circuit whereby the controller sends a signal to the solenoid control circuit thereby causing the solenoid to move the transfer switch from one of said power sources to the other.

11. A solenoid control circuit connected to first and second voltage sources, connected to an external signal mechanism and connected to a solenoid having at least one coil, said circuit comprising:

a control means for receiving and validating a control signal from said external signal mechanism;

a solenoid current regulator circuit including a current monitoring circuit coupled to said control means, capable of receiving said control signal, and coupled to a micro-controller means;

a power switching means, said power switching means connected to and receiving power from one of said voltage sources;

said micro-controller means connected to and providing timing control to said power switching means;

said power switching means being connected to said solenoid coil; and

said current signal allowing a solenoid current to decay for a predetermined period of time after a predetermined current level is established in the solenoid coil.

12. The circuit of claim 11 further including at least two zener diodes for protecting said power switching means from excessively high voltages in said circuit.

13. The circuit of claim 11 wherein the power switching means comprise at least one CMOS type 555 type general purpose timer.

14. The circuit of claim 11 further comprising transient voltage suppressing means coupled to said solenoid control circuit for protecting said circuit from an over voltage condition.

15. The circuit of claim 14 wherein the transient voltage suppressing means is a transient absorption zener diode.

16. The circuit of claim 11 further including voltage comparator means for monitoring at least one of said voltage sources, said voltage comparator means connected to at least one of said voltage sources and capable of extending the predetermined time current is applied to said solenoid.

17. The circuit of claim 11 further including two solenoids, each solenoid having at least one solenoid coil, said circuit being connected to each said solenoid.

18. The circuit of claim 11 wherein said current monitoring circuit comprises a current sense resistor array coupled to said circuit, a voltage comparator coupled to said resistor array, and a voltage reference mechanism for holding an input of the comparator at a substantially predetermined voltage level.

19. The circuit of claim 18 wherein the array comprises a series of metal oxide resistors.

20. The circuit of claim 18 wherein the array comprises a series of axial lead wire wound reisitors.

21. The circuit of claim 11 further including low voltage protection means associated with said power switching means for disabling said power switching means when inadequate input voltage is supplied to said circuit.

22. The circuit of claim 11 further including a shunt regulating means coupled to one of said voltage sources for maintaining a predetermined voltage level at a circuit voltage input.

23. The circuit of claim 11 further including a rectifier, said rectifier being connected to said first and said second power sources and providing a rectified voltage to operate said micro-controller and said solenoid.

24. The circuit of claim 23 wherein the rectifier further includes transient voltage suppression means whereby said micro-controller is protected from transient energy originating from said first and said second power sources.

25. The circuit of claim 23 further including at least one varistor connected to said rectifier and at least one transorb connected to said power switching means.

26. The circuit of claim 23 wherein the rectified voltage coupled to said micro-controller is coupled to a series of voltage dropping resistors.

27. The circuit of claim 11 wherein the solenoid current regulator comprises a current sense resistor coupled to a voltage regulator coupled to a voltage comparator coupled to a monostable multivibrator coupled to a gate driver coupled to a power switching semiconductor.

28. The circuit of claim 27 wherein the monostable multivibrator and gate driver comprises at least one 555 timer integrated circuits.

29. The circuit of claim 27 wherein the monostable multivibrator and gate drive comprise a 556 timer integrated circuit.

30. A circuit for controlling a current applied to a solenoid having an external signal source and a voltage source, the circuit comprising:

a signal receiving means for receiving a signal from the external signal source;

a power switching means, said power switching means being connected in series with said voltage source and said solenoid;

a current regulating solenoid driver circuit, said driver circuit capable of monitoring the signal from said signal receiving means and sending an output to said power switching means thereby allowing the current to flow through said solenoid until it reaches a predetermined level thereby causing the switching means to turn off for a predetermined period of time after which the switching means is again turned on.

31. The circuit of claim 30 wherein the current regulating driver circuit is capable of supplying a predetermined mono-stable signal to said power switching means.

32. The circuit of claim 31 further including a voltage comparitor means coupled to said circuit and capable of extending the predetermined time period if the voltage source falls below a predetermined voltage level.

33. The circuit of claim 30 wherein the power switching means is a insulated gate bipolar transistor.

34. The circuit of claim 30 capable of receiving an input voltage in the range of 146 to 476 volts.

35. The circuit of claim 30 wherein the power supplied to the solenoid is in excess of one thousand watts.

36. The circuit of claim 30 further including low voltage protection means associated with said power switching means for disabling said switching means when inadequate input voltage is supplied to said circuit.

37. The circuit of claim 30 further including a timing means whereby the current regulating circuit regulates the current for a predetermined period of time.