Circuit protector monitoring assembly kit and method

• US 8,059,005 B2
• Filed: 09/09/2005
• Issued: 11/15/2011
• Est. Priority Date: 09/10/2004
• Status: Expired due to Fees

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Bender, Joan Leslie Winnett, Henricks, Michael Craig, Darr, Matthew R., Douglass, Robert Stephen
• Primary Examiner(s): Lee; Benjamin C
• Assistant Examiner(s): Pham; Lam
• Application Number:
  US11/223,385
• Publication Number:
  US 20060077607A1
• Time in Patent Office: 2,258 Days
• Field of Search: 340635-639, 340/539.1, 340/572.1, 340/572.7, 337/206, 337/208, 337/227, 337/231, 337/241, 337/255, 337/265
• US Class Current: 340/635
• 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

Monitoring assemblies, kits and methods for determining an operational state of a circuit protector in an electrical circuit.

Claims

1. A circuit protector monitoring system comprising:

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

a status element associated with the at least one circuit protector and adapted to detect and communicate a change in operating state of the interruptible current path from an uninterrupted state to an interrupted state as the specified operating condition in the circuit occurs; and

a remotely located electronic management system in communication with the status element, the electronic management system configured to;

determine, based on a communication from the status element, a physical location of the at least one circuit protector and the change in operating state of the interruptible current path without requiring physical inspection of the circuit protector; and

automatically alert and summon responsible personnel to the physical location when the interruptible current path changes to the interrupted state.

2. The system of claim 1, wherein the status element is adapted to wirelessly communicate the change in operating state.

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 is mechanically actuated.

7. The system of claim 1, wherein the status element comprises an optically activated indication circuit.

8. The system of claim 1, wherein the status element is internal to the circuit protector.

9. The system of claim 1, wherein the status element is adapted to collect data regarding the operation of the interruptible current path.

10. The system of claim 1, further comprising a communications link interfacing the status element and the remotely located electronic management system, the communications link selected from the group of 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 the change in state of the interruptible current path 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 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.

13. The system of claim 12, wherein the monitoring module comprises a radio frequency (RF) transmitter.

14. The system of claim 1, wherein the at least one circuit protector comprises a fuse, the status element transmitting data related to operation of the fuse, the data comprising a plurality of data bits selected from the group comprising a unique radio identifier, a manufacturer serial number for the status element, a device type code for the fuse, a location or address code for the fuse, 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.

15. A monitoring assembly for 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 modular 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

a transmitter communicating with the modular status elements, the transmitter sending a wireless data signal to a remote location when any of the circuit paths in the plurality of circuit protectors is interrupted, the data signal including a unique identification code and a location code for the circuit protectors having the interrupted current path.

16. The assembly of claim 15, wherein the transmitter is adapted to generate a digital radio frequency signal.

17. The assembly of claim 15, wherein the modular 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 snap-on installation to the circuit protector.

18. The assembly of claim 15, wherein the modular status element comprises a voltage sensor detecting a voltage change across the circuit protector when the current path is interrupted, the voltage change triggering the sending of the wireless data signal.

19. The assembly of claim 15, wherein at least one of the circuit protectors is a fuse, and the wireless signal comprises a plurality of data 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.

20. The assembly of claim 15, wherein the transmitter is provided in a communications module interconnected with at least one of the modular status elements.

21. The assembly of claim 15, wherein one of the modular status elements comprises a communications module, the communications module powering other of the modular status elements.

22. The assembly of claim 15, wherein the modular status elements comprise a plurality of sensor modules and at least one communications module interconnected with one another, each of the sensor modules transmitting a data signal to the communications module for sending the wireless data signal.

23. A fuse monitoring assembly comprising:

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

a monitoring module responsive to operation of the fuse;

wherein the monitoring module comprises a housing, a mounting element adapted to attach the housing to an exterior surface of the fuse, and first and second conductive arms extending to the respective first and second terminal elements of the fuse; and

a transmitter connected to the monitoring module and mounted at a location proximate the fuse, the transmitter sending a data signal to a remote location, the data signal including a unique identifier for the fuse and a location identifier for the fuse.

24. The assembly of claim 23, wherein the housing comprises a voltage sensor connected to the conductive arms.

25. The assembly of claim 23, wherein the transmitter comprises a low power radio frequency (RF) transmitter.

26. The assembly of claim 23, wherein the data signal is a digital radio frequency signal.

27. The assembly of claim 23, wherein the mounting element comprises a mounting clip, the mounting clip engaging the exterior surface of the fuse with snap-fit engagement.

28. The assembly of claim 23, wherein the data signal comprises a plurality of data 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.

29. The assembly of claim 23, further comprising a signal port exposed on a surface of the housing, and an interface plug for connecting the module to the transmitter.

30. A method of monitoring operation of a circuit protector in an electrical system, the circuit protector operable to interrupt a conductive circuit path and isolate one portion of the 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 a transmitter responsive to the status elements and generating a data signal to a remote location when any one of the circuit protectors has operated to isolate a portion of the electrical system, the data signal comprising a plurality of data bits selected from the group comprising 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;

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

based upon the sensed state of the circuit protectors, transmitting the data signal to a remote location, wherein the data signal includes a unique identifier and a location identifier for an operated circuit protector.

31. The method of claim 30, wherein sensing an operating state of the circuit protectors comprises sensing a voltage drop across the circuit protectors.

32. The method of claim 30, wherein transmitting a data signal from at least one of the status elements comprises wirelessly transmitting the data signal.

33. The method of claim 30, 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.

34. A circuit protector monitoring assembly comprising:

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

means for attaching the means for sensing to the circuit protectors without modifying the electrical system; and

means for transmitting a data signal in response to a sensed change in operating state of any of the plurality of circuit protectors, the data signal corresponding to a sensed operation of one or more of the circuit protectors, the data signal uniquely identifying one or more operated circuit protectors and the locations of one or more operated circuit protectors in the electrical system.

35. The assembly of claim 34, wherein the means for transmitting comprises means for transmitting a low power wireless signal.

36. The system of claim 34, wherein the circuit protectors comprise fuses, the means for sensing an operating state comprising a voltage sensor.

37. The system of claim 34, wherein the means for attaching the means for sensing to the circuit protectors is adapted for snap-fit engagement with the circuit protector.

50. The assembly of claim 34, 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.

38. A fuse state monitoring kit for a fuse having a fuse body and first and second terminal elements connected to the body, the kit comprising:

a housing;

a sensor in the housing;

a mounting element dimensioned to engage an outer surface of the fuse body and affix the housing to the body; and

first and second contact arms attachable to the housing and dimensioned to extend from the housing to the first and second terminal elements, respectively, the first and second contact arms being connected to the sensor.

39. The kit of claim 38, wherein the housing comprises a signal port connected to the sensor, the kit further comprising an interface plug adapted to mate with the signal port.

40. The kit of claim 38, further comprising a wireless transmitter in the housing.

41. The kit of claim 38, wherein the sensor comprises a voltage sensor.

42. The kit of claim 38, further comprising a power source being selected from the group of a battery, a power harvesting device, an energy storage element, a backup power supply, an auxiliary power supply, or a circuits of an electrical system being monitored.

43. The kit of claim 38, wherein the mounting element engages the fuse body with snap-fit engagement.

44. The kit of claim 38, wherein the contact arms are adjustable to fit a variety of different fuses.

45. The kit of claim 38, wherein the mounting element is adjustable to fit a variety of different fuses.

46. The kit of claim 38, wherein the housing comprises multiple sensors for monitoring multiple fuses.

47. The kit of claim 38, further comprising third and fourth contact arms attachable to the housing.

48. The kit of claim 38, wherein the first and second contact arms are rotatable relative to the housing to mechanically and electrically engage a fuse alongside the housing.

49. The kit of claim 38, further comprising a removable battery access door attached to the housing.

51. A circuit protector state monitoring assembly comprising:

a circuit protector comprising first and second terminal elements; and

a retrofit monitoring module coupled to an exterior surface of the circuit protector and mechanically and electrically engaged to the first and second terminal elements, the module adapted to determine an operating state of the circuit protector and communicate a unique identification code for the circuit protector and a location code for the circuit protector to a remote location when the operating state of the circuit protector changes.