System and method for circuit protector monitoring and management

• US 7,612,654 B2
• Filed: 09/09/2005
• Issued: 11/03/2009
• Est. Priority Date: 09/10/2004
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Darr, Matthew R., Douglass, Robert Stephen, Bender, Joan Leslie Winnett, Henricks, Michael Craig, Bender, Robert Lawrence, Speno, Timothy Hamilton
• Primary Examiner(s): Trieu; Van T.
• Application Number:
  US11/223,702
• Publication Number:
  US 20060077609A1
• Time in Patent Office: 1,516 Days
• Field of Search: 340/288, 340/292, 340/635, 340/649, 340/650, 340/662, 340/663, 340/664, 340/668, 340/539.1, 340/638, 361/72, 700/292, 700/293, 337/206
• US Class Current: 340/292
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders
• CPC Class Codes: H01H 2085/0266 Structural association with a measurement device, e.g. a shunt
• CPC Class Codes: H02H 3/00 Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems H02H7/00; systems for change-over to standby supply H02J9/00 ; integrated protection for motors H02H7/0822
• CPC Class Codes: H02H 3/042 combined with means for locating the fault locating faults in cables G01R31/08
• CPC Class Codes: H02H 7/261 involving signal transmission between at least two stations transmission of signals in general H02H1/0061
• CPC Class Codes: H02J 13/00001 characterised by the display of information or by user interaction, e.g. supervisory control and data acquisition systems [SCADA] or graphical user interfaces [GUI]
• CPC Class Codes: H02J 13/00036 the elements or equipment being or involving switches, relays or circuit breakers circuits for indication of single switches H01H9/167
• CPC Class Codes: H02J 13/0004 involved in a protection system
• CPC Class Codes: Y02E 60/00 Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
• CPC Class Codes: Y04S 10/20 using protection elements, arrangements or systems
• CPC Class Codes: Y04S 10/40 Display of information, e.g. of data or controls
• CPC Class Codes: Y04S 10/50 Systems or methods supporting the power network operation or management, involving a certain degree of interaction with the load-side end user applications
• CPC Class Codes: Y04S 10/52 Outage or fault management, e.g. fault detection or location

Abstract

A system and method for circuit protector monitoring and management includes at least one circuit protector defining an interruptible current path therethrough upon an occurrence of specified operating condition in a circuit; a status element associated with the circuit protector and adapted to monitor an operating state of the current path; and an electronic management system in communication with the status element, wherein the management system is adapted to automatically alert and summon responsible personnel when the circuit protector has operated to open the circuit path, and identify the location of the operated circuit protector.

Claims

1. A circuit protector system comprising:

at least one circuit protector defining an interruptible current path therethrough upon an occurrence of specified operating condition in a circuit;

a status element associated with the circuit protector and adapted to monitor an operating state of the current path, the status element adapted to communicate data comprising a unique identification code for the circuit protector and a location code for the circuit protector; and

an electronic management system in communication with the status element and receiving the data communicated from the status element at a location remote from the circuit protector, wherein the management system is adapted to automatically alert and summon responsible personnel when the circuit protector has operated to open the circuit path, and identify the location of the operated circuit protector.

2. The system of claim 1, wherein the status element wirelessly communicates with the management system.

3. The system of claim 1, wherein the status element comprises an RFID chip.

4. The system of claim 1, wherein the status element comprises a transmitter.

5. The system of claim 1, wherein the status element comprises a smart card.

6. The system of claim 1, wherein the status element comprises a mechanical actuator.

7. The system of claim 1, further comprising an optically activated indicating circuit.

8. The system of claim 1, wherein the status element collects data and information regarding the operation of the circuit protector, thereby facilitating diagnostic evaluation and troubleshooting of an electrical system.

9. The system of claim 1, wherein the management system is adapted to alert and summon personnel by a remote device, the remote device being selected from the group comprising a computer, a pager, a dispatcher, a cellular phone, a facsimile device, a response tool, a hand held electronic device, and combinations thereof.

10. The system of claim 1, further comprising a communications link interfacing the status element and the management system, the communications link being selected from the group comprising a hard-wired communications link, an optical communications link, a network communications link, a wireless communications link, a satellite communications link, a power line frequency carrier, and combinations thereof.

11. The system of claim 1, wherein the status element is adapted to identify operation of the circuit protector via at least one of a polling method, current monitoring, voltage monitoring, temperature sensing, vibration and displacement sensing, mechanical stress and strain sensing, acoustical emission sensing, noise sensing, thermal imagery and thermalography, electrical resistance sensing, pressure sensing, humidity sensing and video surveillance.

12. The system of claim 1, wherein the management system electronically communicates with at least one of a circuit protector inventory management system to replenish a depleted circuit protector inventory as inventory is used, a computerized maintenance management system, a supervisory control and data acquisition system, an industrial control and automation system, an enterprise resource planning system, an electronic data interchange system, a manufacturing resources planning system, and a supply chain management system.

13. The system of claim 1, wherein the status element comprises a monitoring module mechanically and electrically connected to terminal elements of the circuit protector at a location exterior to the circuit protector, the module adapted for retrofit installation to the circuit protector.

14. The system of claim 13, wherein the monitoring module comprises a radio frequency (RF) transmitter.

15. The system of claim 14 further comprising at least one router/repeater element receiving an RF signal from the monitoring module, the router/repeater element forwarding the RF signal to an intelligent gateway device that processes the RF signal and converts the signal to a predetermined message protocol that is different from a protocol of the RF signal.

16. The system of claim 1 wherein the management system is adapted to alert and summon personnel via at least one of an email notification, a fax notification, a pager notification, a web page notification, and a voice notification.

17. The system of claim 1, wherein the data comprises multiple bits selected from the group comprising a unique radio identifier, a manufacturer serial number for the status element, a device type code for the circuit protector, a location or address code for the circuit protector, a power/control code, an equipment identification code, a testing code, a fault code, a customer code, a temperature code, a vibration code, a displacement code, a mechanical stress code, a mechanical strain code, an acoustical emission code, a noise code, a thermal imagery code, an electrical resistance code, a pressure code, a humidity code and a video code.

18. The system of claim 1, wherein the management system is adapted to identify a monitoring mode of the status elements, and wherein the monitoring mode is selected from the group comprising a registered status, a discovered status, an activated status, a suspended status, a deactivated status, and an offline status.

19. The system of claim 1, further comprising a multifunctional response tool communicating with the management system, the tool comprising multiple devices selected from the group of a communications device, a positioning device, a scanner device, a multimeter device, a thermometer device, an entertainment device, an audio/video device, an instruction device, an imaging device, and a spectrum analyzer device.

20. The system of claim 1, wherein the management system is adapted to convey information regarding potential hazards in the location of the circuit protector, and precautions to be utilized when responding to an operated circuit protector.

21. The system of claim 1, wherein the circuit protector is a fuse.

22. A circuit protector system comprising:

a plurality of circuit protectors, each of the circuit protectors defining an interruptible current path therethrough upon an occurrence of specified operating conditions in an electrical system;

a status element associated with each of the circuit protectors, each of the status elements adapted to monitor an operating state of the respective current path, and at least one of the status elements adapted to transmit a data signal when one or more of the current paths are interrupted as the circuit protectors operate, the data signal including a unique identification code and a location code for an operated circuit protector;

a gateway device adapted to receive the data signal from the at least one status element; and

an electronic management system in communication with the gateway device, wherein the management system is adapted to alert and summon responsible personnel when the circuit protector has operated to open the circuit path, and identify the location of the operated circuit protector.

23. The system of claim 22, wherein the status elements communicate wirelessly with the gateway device.

24. The system of claim 22, wherein the electronic management system is adapted to initiate special procedures in response to operation of the circuit protectors.

25. The system of claim 22, wherein the status element comprises a monitoring module mechanically and electrically connected to terminal elements of the circuit protector at a location exterior to the circuit protector, the module adapted for retrofit installation to the circuit protector.

26. The system of claim 25, wherein the monitoring module comprises a voltage sensor detecting a voltage change across the circuit protector when the current path is interrupted, the voltage change triggering transmission of the data signal to the gateway device.

27. The system of claim 22, wherein the monitoring module comprises a radio frequency (RF) transmitter.

28. The system of claim 27, further comprising at least one repeater/router element receiving an RF signal from the monitoring module, the repeater/router element forwarding the RF signal to the gateway device, the gateway device processing the RF signal and converting the signal to a predetermined message protocol that is different from a protocol of the RF signal.

29. The system of claim 22, wherein the management system is adapted to alert and summon personnel via at least one of an email notification, a fax notification, a pager notification, a web page notification, and a voice notification.

30. The system of claim 22, wherein the at least one circuit protector comprises a fuse, the status element transmitting data related to operation of the fuse, the data comprising multiple bits selected from the group comprising a unique radio identifier, a manufacturer serial number for the status element, a device type code for the circuit protector, a location or address code for the circuit protector, a power/control code, an equipment identification code, a testing code, a fault code, a customer code, a temperature code, a vibration code, a displacement code, a mechanical stress code, a mechanical strain code, an acoustical emission code, a noise code, a thermal imagery code, an electrical resistance code, a pressure code, a humidity code and a video code.

31. A circuit protector system comprising:

a plurality of overcurrent protection fuses, each of the overcurrent protection fuses having a primary fuse element extending between first and second terminal elements, the primary fuse elements defining an interruptible current path therethrough upon an occurrence of specified current conditions through the primary fuse element;

a status element associated with each of the circuit protectors, the status elements comprising monitoring modules adapted to sense a voltage differential across the first and second terminal elements of the respective fuses, and at least one communications module comprising a low power radio frequency (RF) transmitter, the communications module adapted to generate an RF data signal when a voltage drop across the first and second terminal elements is sensed, the RF data signal including a unique identification code and a location code for the fuses when the voltage drop is sensed;

a plurality of radio repeater/router elements adapted to forward RF data signals from any of the status elements to an intelligent gateway device;

the gateway device adapted to receive data signals forwarded through the repeater/router elements; and

an overview and response dispatch system in communication with the gateway device, wherein the overview and response dispatch system is adapted to alert and summon responsible personnel of one or more operated fuses, and identify the locations of the operated fuses for replacement to efficiently re-energize affected circuitry.

32. The system of claim 31, wherein the data signal comprises a digital radio frequency signal.

33. The system of claim 31, wherein the monitoring modules are mechanically and electrically connected to the first and second terminal elements of the respective fuses at a location exterior to a body of the fuse, thereby providing retrofit installation to an installed fuse.

34. The system of claim 31, wherein the gateway device processes the RF signal and converts received signals to a predetermined message protocol that is different from a protocol of the RF signal.

35. The system of claim 31, wherein the management system is adapted to alert and summon personnel via at least one of an email notification, a fax notification, a pager notification, a web page notification, and a voice notification.

36. The system of claim 31, wherein the data signal comprises multiple bits selected from the group comprising a unique radio identifier, a manufacturer serial number for the status element, a device type code for the circuit protector, a location or address code for the circuit protector, a power/control code, an equipment identification code, a testing code, a fault code, a customer code, a temperature code, a vibration code, a displacement code, a mechanical stress code, a mechanical strain code, an acoustical emission code, a noise code, a thermal imagery code, an electrical resistance code, a pressure code, a humidity code and a video code.

37. The system of claim 31, wherein the management system is adapted to await acknowledgement of an alert to responsible personnel, and if no acknowledgment is received in a predetermined time period, re-alert and re-summon responsible personnel of the operated fuses and identify the locations of the operated fuses.

38. The system of claim 31, wherein the electronic management system is adapted to initiate special procedures in response to operation of the circuit protectors, the special procedures selected from the group of activating auxiliary power, shutting down equipment, and saving circuit data for analysis.

39. A method of efficiently re-energizing affected circuitry in an electrical system when a circuit protector operates to isolate one portion of an electrical system from another portion of the electrical system, the method comprising:

providing a status element proximate to the respective circuit protectors of interest, and an electronic management system responsive to the status elements;

sensing, using the status elements, an operating state of the circuit protector when installed in the electrical system; and

based upon the sensed state of the circuit protectors, communicating a data signal from at least one of the status elements to a remote location when one of the circuit protectors has operated to isolate a portion of the electrical system, the data signal comprising a unique identification code and a location code for the operated circuit protector.

40. The method of claim 39, further comprising, in response to the communicated signals, generating an alert and summons from the electronic management system to responsible personnel of the operated circuit protector and the location of the operated circuit protector.

41. The method of claim 39, further comprising, in response to the communicated signals, conveying information regarding potential hazards in the location of the circuit protector, and precautions to be utilized when responding to an operated circuit protector.

42. The method of claim 39, wherein the circuit protectors comprise fuses, the method further comprising communicating with at least one remote system relating to maintenance of the electrical system, the at least one remote system being selected from the group of a circuit protector inventory management system to replenish a depleted circuit protector inventory as inventory is used, a computerized maintenance management system, a supervisory control and data acquisition system, an industrial control and automation system, an enterprise resource planning system, an electronic data interchange system, a manufacturing resources planning system, and a supply chain management system.

43. The method of claim 39, wherein sensing an operating state of the circuit protectors comprises sensing a voltage drop across the circuit protectors.

44. The method of claim 39, wherein communicating a data signal from at least one of the status elements comprises wirelessly transmitting the data signal.

45. The method of claim 44, further comprising:

providing a plurality of repeater/routers in the vicinity of the circuit protectors of interest, and an intelligent gateway device connected an overview and response dispatch system;

receiving the communicated data signal from at least one of the status elements with one of the repeater/routers;

forwarding, utilizing the repeater/routers, the received signals to the gateway device; and

processing, using the gateway device, signals received from the repeater/routers, before communicating with the management system.

46. The method of claim 39, further comprising generating an alert and summons from the electronic management system via at least one of an email notification, a fax notification, a pager notification, a web page notification, and a voice notification.

47. The method of claim 39, wherein providing a status element proximate to the respective circuit protectors of interest comprises attaching a sensing module to an exterior surface of the circuit protectors of interest, thereby facilitating retrofit installation to existing fuses of an electrical system.

48. A circuit protector system comprising:

means for sensing an operating state of a plurality of circuit protectors in an electrical system;

means for communicating a data signal corresponding to a sensed operation of one or more of the circuit protectors, thereby isolating at least one portion of the electrical system from another portion of the electrical system;

means for receiving the data signal corresponding to a sensed operation of one or more of the circuit protectors; and

means for generating an alert and summons to responsible personnel, without human intervention, of the type and location of operated circuit protectors to permit efficient re-energization of the circuitry;

wherein the data signal includes a unique identification code and a location code for an operated circuit protector.

49. The system of claim 48, wherein the means for communicating comprises means for transmitting a low power wireless signal.

50. The system of claim 48, wherein the means for receiving comprises an intelligent gateway device element.

51. The system of claim 48, wherein the means for generating an alert and summons comprises means for generating an alert and summons via at least one of an email notification, a fax notification, a pager notification, a web page notification, and a voice notification.

52. The system of claim 48, wherein the circuit protectors comprise fuses, the means for sensing an operating state comprising means for attaching a voltage sensor to an exterior surface of the fuse.

53. The system of claim 48, wherein the means for sensing an operating state comprises one of a means for sensing an overcurrent condition, means for sensing an overload condition, means for sensing a short circuit condition, means for sensing an overvoltage condition, and means for sensing a temperature overlimit condition.