SYSTEM AND METHOD FOR TRANSFER SWITCH UTILIZING RECLOSER OPERATIONS

A method for performing recloser operations at a transfer switch includes obtaining an input from a first sensor measuring characteristics at an electrical conductor connecting a main power source to a load, comparing the input to one or more thresholds, cycling a first switch between an OFF and ON position for one or more cycles, determining the input exceeds the one or more thresholds when the first switch is cycled ON, and connecting the load to the main power source with the first switch in response to the input being within the one or more thresholds, or connecting the load to a second power source with a second switch in response to determining the input exceeds the one or more thresholds after the one or more cycles. The input may include a source voltage and the one or more thresholds may include an upper and lower voltage threshold.

FIELD

The present disclosure relates to the field of transfer switches. And, more particularly, to transfer switches utilizing recloser operations.

BACKGROUND

Reclosers are high-voltage electric circuit breaker devices connected to one or more phases of a power line and capable of opening to isolate an electric power source from an electrical load based on detecting power fluctuations on the power line which exceed a certain threshold. Typically, after the recloser has opened, the recloser can monitor the electrical current at the line connected to the power source to determine whether the fluctuations have stabilized below the certain threshold. After the recloser determines the power fluctuations have subsided and power has stabilized, the recloser can be reset to restore connection between the electrical power source and the load.

SUMMARY

When switching from a main electrical power source to a secondary electrical power source, or vice versa, the switching operations at a transfer switch can pose certain challenges which affect power quality for an electrical load connected to the transfer switch such as, for example, data center systems. When switching from one power source to the other power source in response to detecting an interruption or power fluctuation, switching to the other power source can draw a high inrush current which can exceed a rated system current. In a number of applications and systems, such high inrush currents can approach or exceed fault protection trip levels and may highly stress or damage a transformer or other components connected to the transformer (e.g., components of the electrical load).

Reclosers open in response to detecting power fluctuations at one of the phase power lines connecting an electrical power source to a load. Recloses can be configured to automatically reclose following the abnormal condition and once the power fluctuations are no longer detected. However, reclosers typically may only be capable of performing a limited number of automatic reclosing attempts before they are mechanically locked into the open position and have to be manually operated to be reconnected.

Additionally, conventional switching devices utilized in transfer switches can include therein various types of solid state switching devices. However, the conventional transfer switches are typically not capable of performing the one or more techniques as described herein corresponding to the recloser operations. Instead, the conventional switching devices are controlled using gating signals to switch from the main power source to the secondary power source in response to detecting power fluctuations or a loss of power at the main power source, or vice versa.

Conventional transfer switches may include therein silicon controlled rectifiers (SCRs) or SCRs with paralleled resonant turn-off (RTO) circuits connecting the electrical load to the main power source and the secondary power source. The SCRs are controlled using gating signals to transfer connection of the electrical load from the main power source to the secondary power source. However, the turn-off time of the primary source is greatly reduced with SCRs. Specifically, these switching devices can include long transfer times (e.g., >10 ms) due to being configured to wait until the next flux-matching point to minimize transformer inrush.

In some embodiments, a method includes obtaining, by a controller, an input from a first sensor measuring electrical characteristics at an electrical conductor connecting a main power source to a load using a transfer switch, comparing, by the controller, the input to one or more thresholds to determine an abnormal condition, cycling, by the controller, a first switch at the transfer switch between an OFF position and ON position for one or more cycles, determining, by the controller, whether the input from the first sensor exceeds the one or more thresholds when the first switch is in the ON position, and connecting, by the controller, the load to the main power source with the first switch in response to determining the input is within the one or more thresholds after the one or more cycles, or connecting the load to a second power source with a second switch in response to determining the input exceeds the one or more thresholds after the one or more cycles.

In some embodiments, the input includes a source voltage.

In some embodiments, the one or more thresholds includes an upper voltage threshold, a lower voltage threshold, and the load is connected to the main power source when the source voltage is less than the upper voltage threshold and greater than the lower voltage threshold, the load is connected to the second power source when the source voltage is greater than the upper voltage threshold or lower than the lower voltage threshold.

In some embodiments, cycling the first switch at the transfer switch between the OFF position and the ON position for the one or more cycles further includes cycling, by the controller for each cycle, the first switch to the OFF position for a first period of time, and cycling, by the controller for each cycle, the first switch to the ON position for a second period of time and measuring the input to determine whether the input exceeds the one or more thresholds.

In some embodiments, the first period of time and the second period of time each includes approximately 0.1 msec.

In some embodiments, connecting the load to the second power source further includes cycling, by the controller, the first switch to the OFF position to disconnect the load from the main power source, and cycling, by the controller, the second switch to the ON position to connect the load to the second power source.

In some embodiments, the first switch includes one or more first solid-state switching devices (SSSDs), the one or more first SSSDs is arranged in a reverse orientation to enable bi-directional flow of a phase current between the load and the main power source.

In some embodiments, the one or more first SSSDs includes at least one of SiC metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), bipolar junction transistors (BJTs), and junction-gate field effect transistors (JFETs).

In some embodiments, the one or more first SSSDs includes SiC MOSFETs.

In some embodiments, the second switch includes one or more second SSSDs, the one or more second SSSDs is arranged in a reverse orientation to enable bi-directional flow of a phase current between the load and the second power source.

In some embodiments, the one or more second SSSDs includes at least one of SiC metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), bipolar junction transistors (BJTs), junction-gate field effect transistors (JFETs), silicon controlled rectifiers (SCRs), and SCRs with paralleled resistive turn-off (RTO) circuits.

In some embodiments, the one or more second SSSDs includes SCRs with paralleled RTO circuits.

In some embodiments, a system includes a main power source, a second power source, a load, a transfer switch including a first switch located between the main power source and the load, and a second switch located between the second power source and the load, and a controller including a processor, and a non-transitory computer-readable medium having stored thereon instructions executable by the processor to control an operation of the transfer switch including obtain an input from a first sensor measuring electrical characteristics at an electrical conductor connecting the main power source to the load using the transfer switch, compare the input to one or more thresholds to determine an abnormal condition, cycle, for each cycle of one or more cycles, the first switch to an OFF position for a first period of time, cycle, for each cycle of the one or more cycles, the first switch to an ON position for a second period of time and measure the input to determine whether the input exceeds the one or more thresholds, determine whether the input from the first sensor exceeds the one or more thresholds when the first switch is in the ON position, and connecting, by the controller, the load to the main power source with the first switch in response to determining the input is within the one or more thresholds after the one or more cycles, or connecting the load to a second power source with a second switch in response to determining the input exceeds the one or more thresholds after the one or more cycles, and the first period of time and the second period of time each includes approximately 0.1 msec.

In some embodiments, the input includes a source voltage, and the one or more thresholds includes an upper voltage threshold, a lower voltage threshold. In some embodiments, the load is connected to the main power source when the source voltage is less than the upper voltage threshold and greater than the lower voltage threshold, and the load is connected to the second power source when the source voltage is greater than the upper voltage threshold or lower than the lower voltage threshold.

In some embodiments, connecting the load to the second power source further includes cycling, by the controller, the first switch to the OFF position to disconnect the load from the main power source, and cycling, by the controller, the second switch to the ON position to connect the load to the second power source.

In some embodiments, the first switch includes one or more first solid-state switching devices (SSSDs) including at least one of SiC metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), bipolar junction transistors (BJTs), and junction-gate field effect transistors (JFETs), the one or more first SSSDs is arranged in a reverse orientation to enable bi-directional flow of a phase current between the load and the main power source.

In some embodiments, the one or more first SSSDs includes SiC MOSFETs.

In some embodiments, the second switch includes one or more second SSSDs including at least one of SiC metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), bipolar junction transistors (BJTs), junction-gate field effect transistors (JFETs), silicon controlled rectifiers (SCRs), and SCRs with paralleled resistive turn-off (RTO) circuits, the one or more second SSSDs is arranged in a reverse orientation to enable bi-directional flow of a phase current between the load and the second power source.

In some embodiments, the one or more second SSSDs includes SCRs with paralleled RTO circuits.

In some embodiments, a transfer switch device including a first switch located between a main power source and a load and including one or more first solid-state switching devices (SSSDs), each first SSSD includes at least one of SiC metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), bipolar junction transistors (BJTs), and junction-gate field effect transistors (JFETs), a second switch located between a second power source and the load and including one or more second SSSDs, each second SSSD includes at least one of SiC metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), bipolar junction transistors (BJTs), junction-gate field effect transistors (JFETs), silicon controlled rectifiers (SCRs), and SCRs with paralleled resistive turn-off (RTO) circuits, and a controller including a processor and a non-transitory computer-readable medium having stored thereon instructions executable by the processor to perform operations including obtain a source voltage from a first sensor measuring electrical characteristics at an electrical conductor connecting the main power source to the load using the transfer switch, compare the source voltage to an upper voltage threshold and a lower voltage threshold to determine an abnormal condition, cycle, for each cycle of one or more cycles, the first switch to an OFF position for a first period of time, cycle, for each cycle of the one or more cycles, the first switch to an ON position for a second period of time and measure the source voltage to determine whether the source voltage exceeds the upper voltage threshold and the lower voltage threshold, determine whether the source voltage from the first sensor exceeds the upper voltage threshold or the lower voltage threshold when the first switch is in the ON position, and connecting, by the controller, the load to the main power source with the first switch in response to determining the source voltage is less than the upper voltage threshold and greater than the lower voltage threshold after the one or more cycles, or connecting the load to a second power source with a second switch in response to determining the source voltage is greater than the upper voltage threshold or less than the lower voltage threshold after the one or more cycles, the first period of time and the second period of time each includes approximately 0.1 msec.

DETAILED DESCRIPTION

Among those benefits and improvements that have been disclosed, other objects and advantages of this disclosure will become apparent from the following description taken in conjunction with the accompanying figures. Detailed embodiments of the present disclosure are disclosed herein; however, it is to be understood that the disclosed embodiments are merely illustrative of the disclosure that may be embodied in various forms. In addition, each of the examples given regarding the various embodiments of the disclosure which are intended to be illustrative, and not restrictive.

Various embodiments of the present disclosure relate to systems, devices, and methods for performing reclosing operations utilizing a transfer switch including a main switch including one or more solid state switching devices (SSSDs) therein that are capable of high frequency switching operations in order to protect against power quality issues from a main power source and to provide added protection to the electrical load by keeping the main power source connected to the electrical load and reducing a likelihood of performing switching operations to an alternate power source due to power fluctuations at the main power source. In this regard, the present embodiments include any appropriate combination of hardware components and computer readable software in accordance with the present disclosure capable of performing the recloser operations at the transfer switch as will be described herein.

The various embodiments described herein may include transfer switches and/or systems including the transfer switch that may be capable of performing the one or more techniques described herein to provide a backup protection scheme for the transfer switches. The reclosing operations at the transfer switch may reduce a frequency of switching from the main power source to the secondary power source, thereby reducing excessive wear on the transfer switch components. Accordingly, the transfer switch may also reduce a likelihood that downstream inrush current may be produced during the switching operations from the main power source to the secondary power source, thereby avoiding the saturation region of the transformer and reducing a likelihood of causing damage to the transformer or the electrical load at the secondary side of the transformer. Additionally, the transfer switch as described herein may be capable of performing recloser operations to provide enhanced electrical protection capabilities to enable the transfer switch to be manufactured using other types of switching devices (e.g., SCRs) having a lower manufacturing cost installed between the secondary power source and the electrical load, rather than requiring higher costing SSSDs (e.g., SiC MOSFETs) which are capable of faster switching frequencies to reduce inrush current during the switching operation.

FIG.1illustrates a schematic diagram of a system100, according to some embodiments.

The system100includes a transfer switch102which is conductively coupled to a first electrical power source104, hereinafter referred to as main source104, via a first mechanical circuit breaker (MCB)106, and a second electrical power source108, hereinafter referred to as secondary source108, which is conductively coupled with the transfer switch102via a second MCB110. The system100may include a transformer112including a primary side which is conductively coupled with the transfer switch102via a third MCB114and a fourth MCB116, and a secondary side which is conductively coupled with a load120, according to some embodiments.

The main source104and the secondary source108may be a number of forms and types of electrical power sources, for example, a utility grid, a microgrid, a nanogrid, a backup generator, an uninterruptable power supply (UPS) or backup battery, a flywheel operatively coupled with a motor/generator, a PV array, a wind farm, a fuel cell installation, or any of a number of other sources of electrical power as will occur to one of skill in the art with the benefit of the present disclosure. One of the main source104and the secondary source108may be a primary or preferred power source for the system100and the other of the main source104and the secondary source108may be a secondary or backup power source for the system100. In some embodiments, the main source104may be a utility grid serving as a primary power source and the secondary source108may be one or more UPS serving as a backup power source. In some embodiments, the transfer switch102may also be considered and referred to as a bypass switch or a UPS bypass switch. The load120may be any of a variety of types of load systems, for example, a datacenter, educational facility, governmental facility, hospital or other healthcare facility, manufacturing, chemical or other industrial plant, water treatment plant, or other types of loads or load systems as will occur to one of skill in the art with the benefit of the present disclosure.

The MCB106,110,114,116are configured and operable to provide fault protection by transitioning from a closed-circuit state to an open-circuit state in response to a fault condition, such as an over-current condition, an over-voltage condition, and/or another fault condition. Furthermore, the MCB106,110,114,116may be configured and operable to provide passive fault protection, active fault protection, or other active opening or closing operation (e.g., in response to control signals received from the electronic control system (ECS)122), or both. It shall be appreciated that certain embodiments may omit one or more of the MCB106,110,114,116. Furthermore, certain embodiments may comprise additional or alternate fault protection devices as will occur to one of skill in the art with the benefit of the present disclosure.

The system100may also include a fifth MCB124, which may be conductively coupled between the main source104and the transformer112, and a sixth MCB126, which may be conductively coupled between the secondary source108and the transformer112, according to some embodiments. The MCB124,126are configured to selectably provide a closed circuit connection between the main source104and the secondary source108, respectively, bypassing the transfer switch102and may be actively controlled by the ECS122, hereinafter referred to as controller122. It shall be appreciated that certain embodiments may omit one or both of the MCB124,126. Furthermore, certain embodiments may include additional or alternate bypass devices as will occur to one of skill in the art with the benefit of the present disclosure.

The controller122may include a processor and a memory. The memory may be a non-transitory computer-readable medium having stored thereon instructions executable by the processor to perform operations in accordance with the present disclosure. The controller122may include one or more other components, including components capable of placing the controller122in electrically communicable connection with the transfer switch102and to monitor and control the operation of the transfer switch102based on one or more parameters measured at the transfer switch102such as, for example, by one or more sensors (not shown). In some embodiments, the controller122may be operatively coupled with the transfer switch102. Additionally, in some embodiments, the controller122may in some forms also be operatively coupled with one or more of the MCB106,110,114,116,124,126and may monitor and/or actively control one or more of the MCB106,110,114,116,124,126.

The controller122may be provided as a portion or component of the transfer switch102(e.g., provided in a common housing or as a common unit), as one or more separate components, or distributed among one or more components forming a portion of the transfer switch102and one or more separate components. The controller122may include one or more integrated circuit-based (e.g., microprocessor-based, microcontroller-based, ASIC-based, FPGA-based, and/or DSP-based) control units as well as related driver, input/output, signal conditioning, signal conversion, non-transitory machine-readable memory devices storing executable instructions, and other circuitry.

The transfer switch102may be a static transfer switch including a first switch130at a first leg connecting the main source104to the load120and a second switch132at a second leg connecting the secondary source108to the load120. Each of the first switch130and second switch132can be controlled to energize (or deenergize) the transformer112by conductively coupling (or decoupling) the transformer112with the main source104or the secondary source108, respectively.

The first switch130may include therein a solid-state switching device (SSSD)134to cycle on/off in response to gating control signals to connect/disconnect the load from the main power source104. According to some embodiments, the first switch130may include one or more SSSDs134. The second switch132may include therein a solid-state switching device (SSSD)136to cycle on/off in response to gating control signals to connect/disconnect the load from the second power source. The second switch132may include therein one or more SSSDs136. The one or more SSSDs134and one or more SSSDs136may be arranged in the first switch130or the second switch132, respectively, in a reverse orientation to enable a bi-directional flow of phase current. Additionally, the one or more SSSDs134of the first switch130may be operable to perform a reclosing operation in response to detecting power fluctuations at the main source104, as will be further described herein. In some embodiments, the controller122may control an operation of the first switch130via one or more gating pulse signals to cycle on/off to connect/disconnect to the load120and to perform the recloser operations. In some embodiments, the one or more SSSDs136of the second switch132may also be capable of performing the reclosing operations in response to detecting power fluctuations at the secondary source108, in accordance with the present disclosure.

The transfer switch102includes first switch130, which conductively couples the main source104with the transformer112(provided that the MCB106,114are in a closed state) in response to the controller122cycling the first switch130to a closed state, and which conductively decouples the main source104with the transformer112in response to the controller122cycling the first switch130to an open state. The transfer switch102also includes second switch132, which conductively couples the secondary source108with the transformer112(provided that the MCB110,116are in a closed state) in response to the controller122cycling the second switch132to a close state, and which conductively decouples the secondary source108with the transformer112in response to the controller122cycling the second switch132to the open state.

The first switch130includes therein one or more SSSDs134capable of fast switching frequencies for performing the recloser operations as described herein, and which do not require waiting until the next flux-matching point to cycle on for reclosing purposes. In some embodiments, the one or more SSSDs134may be capable of switching frequencies of approximately 10 msec. In other embodiments, the one or more SSSDs134may be capable of switching frequencies of less than 10 msec. In yet other embodiments, the one or more SSSDs134may be capable of switching frequencies of approximately 0.1 msec. In some embodiments, the one or more SSSDs134may be capable of switching frequencies of less than 0.1 msec. For example, the one or more SSSDs134may by cycled on for less than 0.1 msec and, if the power source is still unavailable, cycling off again in less than 0.1 msec.

The one or more SSSDs134of first switch130may include SiC metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), bipolar junction transistors (BJTs), junction-gate field effect transistors (JFETs), or any combinations thereof. In some embodiments, the first switch130may include one or more SiC MOSFETs. In other embodiments, the first switch130may include IGBTs. In yet other embodiments, the first switch130may include BJTs. In other embodiments, the first switch130may include JFETs.

The second switch132includes therein one or more SSSDs136capable of switching frequencies of approximately 10 msec. In this regard, the second switch132and the one or more SSSDs136may operate at a switching frequency such that the one or more SSSDs136waits until the next flux-matching point to cycle on. In some embodiments, the one or more SSSDs136may also be capable of switching frequencies for performing the recloser operations as described herein, and which may not require waiting until the next flux-matching point to cycle on for reclosing purposes.

The one or more SSSDs136of the second switch132may include silicon-controlled rectifiers (SCRs), SCRs with paralleled resonant turn-off (RTO) circuit144, or combinations thereof. In some embodiments, the one or more SSSDs136may include SCRs. In other embodiments, the one or more SSSDs136may include SCRs with the paralleled RTO circuit144. In some embodiments, the one or more SSSDs136may also include SiC metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), bipolar junction transistors (BJTs), junction-gate field effect transistors (JFETs), or any combinations thereof.

It shall be appreciated that system100may be provided in a single-phase form, a three-phase form, or other multi-phase forms. In such multi-phase forms, the main source104and the secondary source108may be multi-phase power sources (e.g., three-phase power sources). In such forms, the MCB106,110,114,116,124,126, the transfer switch102and its constituent first switch130and second switch132may be provided in corresponding multi-phase forms and arrangements (e.g., three-phase forms and arrangements) wherein an additional instance of these components may be provided to service each additional phase. Furthermore, while system100is illustrated as comprising a main source104and a secondary source108, it shall be appreciated that additional sources may also be present in certain embodiments and that such additional sources may include additional respective MCB components for fault protection and bypass operation and additional respective constituent first switch130and/or second switch132of the transfer switch102.

The controller122may operate the components of the transfer switch102to coordinate the recloser operations during abnormal condition upstream of the transfer switch102. For example, the controller122may detect fluctuations in the input phase voltage due to a ground short between the power source and the transfer switch102. In this regard, in instances where there is an abnormal condition downstream causing fluctuations measured by the one or more sensors, the controller122may control the respective switch, e.g., first switch130or second switch132, to cycle on/off. For example, in some embodiments, the controller122may include a first current sensor located between the main source104and the first switch130and a second current sensor located between the first switch130and the transformer112, and the controller122may determine a fault is occurring from a downstream source by comparing the obtained measurements from the first current sensor and the second current sensor. Additionally, the controller122may control the MCB106,110,114,116,124,126to perform one or more other operations associated with connecting the main source104or the secondary source108to the transformer112and the load120. For example, in some embodiments, the controller122may cause the MCB106and the MCB114to trip open and to close MCB124to bypass the first switch130.

FIG.2illustrates a flow diagram of a method200, according to some embodiments.

At202, the method200may include determining a main source104is connected to the transfer switch102. The controller122may determine the main source104is connected to the transfer switch102based on obtaining an input from one or more sensors in connection with the transfer switch102(e.g., controller122) and indicative of one or more operational parameters of the main source104. In some embodiments, the parameters may include a source voltage VS. In other embodiments, the parameters may include a frequency. It is to be appreciated by those having skill in the art that the electrical parameters detected by the one or more sensors is not intended to be limiting and may a plurality of parameters in accordance with the present disclosure.

In some embodiments, the main source104may include therein a controller in communicable connection with controller122, the controller122obtaining one or more electrical signals from the controller of the main source104corresponding to the main source104supplying power to the transfer switch102.

The one or more sensors (not shown) on the transfer switch102may measure one or more characteristics or parameters including, but not limited to, current, resistance, voltage, impedance, frequency, other characteristics, or any combinations thereof. The controller122may obtain the measurements from the one or more sensors to determine one or more operating parameters in accordance with the present disclosure. In some embodiments, the one or more sensors may measure the source voltage VSof the main source104, the secondary source108, or both. In some embodiments, the controller122may obtain the source voltage VSof the main source104from the one or more sensors. In other embodiments, the controller122may obtain the source voltage VSof the second power source108.

At204, the method200includes obtaining the input from the one or more sensors. In some embodiments, the input may correspond to the source voltage VSfrom the main source104at transfer switch102. The transfer switch102includes a first switch130connecting a load120to the main source104and a second switch132operable to connect the load120to a secondary source108. The transfer switch102may be connected to a primary side of the transformer112and the load120may be connected to a secondary side of the transformer112, according to some embodiments.

At206, the method200includes comparing the input to an upper threshold or comparing the input to a lower threshold to determine fluctuation in the input. In some embodiments, the input may include a source voltage VS, which is then compared to an upper threshold voltage VTH1and a lower threshold voltage VTH2.

The source voltage VSis compared to the threshold voltages to determine fluctuations in the source voltage VS. Fluctuations in the source voltage VSmay be indicative of instability at the main source104. The voltage fluctuations may be caused by a plurality of reasons such as, for example, an electrical short in the electrical conductor connecting the main source104to the transfer switch102and which causes the source voltage VSto exceed one of the threshold voltages.

At208, if the input exceeds one of the thresholds (e.g., upper threshold or lower threshold), the method200includes cycling the first switch130between an off position and an on position for one or more cycles.

At210, during the cycling of the first switch130, the input is monitored by the one or more sensors to determine whether the abnormal condition is present. In some embodiments, monitoring the input includes monitoring the source voltage VSwhen the first switch130is cycled on to determine whether the abnormal condition is present. In other embodiments, monitoring the input includes monitoring the frequency when the first switch130is cycled on to determine whether the abnormal condition is present between the main source104and the transfer switch102.

To trigger the cycling of the first switch130, the controller122may send one or more first gating signals to the first switch130, and the one or more SSSDs134therein. In some embodiments, each cycle may include sending gating signals to turn the first switch130off for a first period of time to disconnect the main source104from the load120and turning the first switch130on for a second period of time to connect the main source104to the load120. Additionally, during the cycling of the first switch130, the inputs from the one or more sensors may continuously be monitored to determine whether the abnormal condition is still present or whether the abnormal condition has stabilized back to within the thresholds. In some embodiments, continuing to monitor the abnormal condition includes measuring the source voltage VSfrom the main source104during the second period of time to determine whether the source voltage VSis less than the threshold voltage VTHindicative of fluctuations at the main source104. If after each second period of time the measured source voltage VSis less than the threshold voltage VTH, the first switch130may be cycled off for the first period of time and cycled on again for the one or more cycles.

The first period of time may be approximately 0.1 msec. In some embodiments, the first period of time may be 0.1 msec. In other embodiments, the first period of time may be less than 0.1 msec. Additionally, the second period of time may be approximately 0.1 msec. In some embodiments, the second period of time may be 0.1 msec. In other embodiments, the second period of time may be less than 0.1 msec.

At212, if at the end of the cycling of the first switch130the input measured by the one or more sensors is less than the upper threshold and greater than the lower threshold (e.g., within the upper and lower thresholds), the main source104remains connected to the load120and normal operation is resumed. In some embodiments, if the source voltage VSof the main source104is less than the upper threshold voltage VTH1and greater than the lower threshold voltage VTH2, the first switch130remains cycled on and the main source104remains connected to the transformer112and the load120.

At214, if after the one or more cycles of the first switch130the input measured by the one or more sensors is greater than the upper threshold or lower than the lower threshold, the first switch130may be disconnected from the load120and the second switch132may be cycled on to connect the load120to the secondary source108. In some embodiments, the first switch130may be cycled on/off for one or more cycles and the input may be monitored during each cycling such as to determine whether the input is less than the upper threshold and greater than the lower threshold. In some embodiments, if the source voltage VSof the main source104is greater than the upper threshold voltage VTH1or less than the lower threshold voltage VTH2, the first switch130is cycled off and the secondary source108may be connected to the transformer112and the load120. In some embodiments, during the second period of time, if the input is measured as being below than the upper threshold and greater than the lower threshold, the first switch130may be cycled on to maintain the load120connected to the main source104. Additionally, in some embodiments, during the second period of time, the input is greater than the upper threshold or less than the lower threshold, the method200may cycle off the first switch130to disconnect the load120from the main source104and connect the load120to the secondary source108.

In some embodiments, the first switch130may cycle on/off for a plurality of cycles. In yet other embodiments, the first switch130may cycle on/off for a certain defined number of cycles. The number of cycles the first switch130may be cycled on/off may be defined based on the time it takes for the first switch130to cycle between the on position and the off position. In some embodiments, the number of cycles the first switch130may also be defined based on a threshold period of time the load120may be connected to a fluctuating power source such as, for example, based on a design parameter of the system100.

In some embodiments, connecting the load120to the secondary source108may include cycling the first switch130to the OFF position to disconnect the load from the main power source, and cycling the second switch132to the ON position to connect the load to the second power source108. In some embodiments, the controller122may send the first set of gating signals to cycle on/off the first switch130for the one or more cycles and the second set of gating signals to connect the load120to secondary source108after the certain number of recloser attempt cycles. For example, the controller122may control the transfer switch102to cycle the first switch130on/off five times and to cycle on second switch132to connect the load120to the secondary source108after the source voltage VS remains below the voltage threshold VTHafter five recloser attempts on the first switch130.

FIG.3illustrates a graph representative300showing aspects of an example process of the system100, according to some embodiments.

The graph representative300includes a first graph302representative of the inrush current that may be produced from the transformer112during a switching operation at the transfer switch102, where the load120and the transformer112is disconnected from the main source104by cycling off the first switch130and connected to the secondary source108by cycling on second switch132without the recloser operations as described herein. As shown inFIG.3, the inrush current continues to gradually increase during the switching operation when the load120and the transformer112is disconnected from the main source104by cycling off the first switch130and connecting the load120and the transformer112to the secondary source108by cycling on the second switch132.

The graph representative300also includes a second graph304representative of the inrush current that may be produced from the transformer112during the switching operation with the recloser operations as described herein. As shown inFIG.3, the inrush current decreases during the switching operations as described herein including performing the recloser operations, where the first switch130is cycled on and off for one or more cycles in response to the source voltage VSfalling below the threshold voltage VTH. Additionally, cycling on/off the first switch130for the one or more cycles may be applied to reduce the inrush current from the transformer112to enable smoother switching operations when connecting the load120and the transformer112from the main source104to the secondary source108.

FIG.4is a schematic diagram illustrating a non-limiting example of a transfer switch400, according to some embodiments.

The transfer switch400includes a switch430conductively coupled to a first electrical power source404, hereinafter referred to as main source404, via a mechanical circuit breaker (MCB)406, and a switch432conductive coupled to a second electrical power source408, hereinafter referred to as secondary source408, via a MCB410. The transfer switch400selectively operates the switch430and switch432to couple the load420a, load420b, through load420n, which may hereinafter be referred to as loads420, to the main source404and/or the secondary source408. The switch430and switch432may include one or more fast switching SSSDs such as, for example, SSSDs134and SSSDs136inFIG.1, respectively.

Similar to the transfer switch102inFIG.1, the main source404and the secondary source408may be a number of forms and types of electrical power sources, for example, a utility grid, a microgrid, a nanogrid, a backup generator, an uninterruptable power supply (UPS) or backup battery, a flywheel operatively coupled with a motor/generator, a PV array, a wind farm, a fuel cell installation, or any of a number of other sources of electrical power as will occur to one of skill in the art with the benefit of the present disclosure. One of the main source404and the secondary source408may be a primary or preferred power source for the loads420, and the other of the main source404and the secondary source408may be a secondary or backup power source for the loads420. In some embodiments, the main source404may be a utility grid serving as a primary power source and the secondary source408may be one or more UPS serving as a backup power source. In some embodiments, the transfer switch400may also be considered and referred to as a bypass switch or a UPS bypass switch. The load420may be any of a variety of types of load systems, for example, a datacenter, educational facility, governmental facility, hospital or other healthcare facility, manufacturing, chemical or other industrial plant, water treatment plant, or other types of loads or load systems as will occur to one of skill in the art with the benefit of the present disclosure.

According to some embodiments, transfer switch400may include one or more other components similar to the transfer switch102(shown inFIG.1) to enable the loads420to be selectively electrically coupled to the main source404and the secondary source408in response to abnormal conditions being detected at the main source404and/or the secondary source408. For example, the transfer switch400may include one or more sensors to detect one or more characteristics including, but not limited to, input from main source404, input from secondary source408, an output, other parameters, or any combinations thereof.

The MCB406,410may be configured and operable to provide fault protection by transitioning from a closed-circuit state to an open-circuit state in response to a fault condition such as where the recloser operations fail at the switch430and/or the switch432, such as during an over-current condition, an over-voltage condition, and/or another fault condition. Furthermore, the MCB406,410, may be configured and operable to provide passive fault protection, active fault protection, or other active opening or closing operation (e.g., in response to control signals received from the ECS), or both. It shall be appreciated that certain embodiments may omit one or more of the MCB406,410. Furthermore, certain embodiments may comprise additional or alternate fault protection devices as will occur to one of skill in the art with the benefit of the present disclosure.

Connected between the switch430and the switch432and the loads420includes MCB450a, MCB450b, through MCB450n, and which may hereinafter be referred to as MCBs450. According to some embodiments, without the one or more reclosing techniques described herein, the switch430(and the SSSDs therein) may demonstrate poor coordination with the downstream breakers. As a result, a fault at one of the loads420can cause the switch430to trip before the corresponding one of the MCBs450. For example, in response to a fault at load420a, the switch432may trip open before MCB450a. As such, the switch432tripping open disconnects each of the loads420a,420b, through420nfrom the main source404. In some embodiments, the transfer switch400may be in electrical connection with a controller, such as controller112ofFIG.1, which performs the reclosing techniques described herein, which includes using the recloser operations to control the cycling of the SSSDs in switch430during the fault at one of the loads420to allow the respective one of the downstream MCBs450(e.g., MCB450a, MCB450b, through MCB450n) to trip before the SSSDs in switch430to maintain the other loads420connected to the main source404. For example, in response to a fault condition at load420a, the switch430may cycle on/off for one or more cycles to enable MCB450ato trip before the switch430trips open to keep load420bthrough load420nconnected to the main source404.

All prior patents and publications referenced herein are incorporated by reference in their entireties.

As used herein, the term “cycle” or “cycles” refers to turning on and/or off the switching device(s) (e.g., SSSDs) at a switch to connect/disconnect a power source to a load. In addition, the cycling of the switching device can be independent of the cycle of the input phase voltage of the power source connected to the load. For example, the switching device(s) can be cycled a plurality of times during a positive phase of the input phase voltage.

As used herein, the term “between” does not necessarily require being disposed directly next to other elements. Generally, this term means a configuration where something is sandwiched by two or more other things. At the same time, the term “between” can describe something that is directly next to two opposing things. Accordingly, in any one or more of the embodiments disclosed herein, a particular structural component being disposed between two other structural elements can be:disposed directly between both of the two other structural elements such that the particular structural component is in direct contact with both of the two other structural elements;disposed directly next to only one of the two other structural elements such that the particular structural component is in direct contact with only one of the two other structural elements;disposed indirectly next to only one of the two other structural elements such that the particular structural component is not in direct contact with only one of the two other structural elements, and there is another element which juxtaposes the particular structural component and the one of the two other structural elements;disposed indirectly between both of the two other structural elements such that the particular structural component is not in direct contact with both of the two other structural elements, and other features can be disposed therebetween; orany combination(s) thereof.

As used herein “embedded” means that a first material is distributed throughout a second material.

Aspects

Various Aspects are described below. It is to be understood that any one or more of the features recited in the following Aspect(s) can be combined with any one or more other Aspect(s).

Aspect 1. A method comprising: obtaining, by a controller, an input from a first sensor measuring electrical characteristics at an electrical conductor connecting a main power source to a load using a transfer switch; comparing, by the controller, the input to one or more thresholds to determine an abnormal condition; cycling, by the controller, a first switch at the transfer switch between an OFF position and ON position for one or more cycles; determining, by the controller, whether the input from the first sensor exceeds the one or more thresholds when the first switch is in the ON position; and connecting, by the controller, the load to the main power source with the first switch in response to determining the input is within the one or more thresholds after the one or more cycles, or connecting the load to a second power source with a second switch in response to determining the input exceeds the one or more thresholds after the one or more cycles.

Aspect 2. The method according to aspect 1, wherein the input comprises: a source voltage.

Aspect 3. The method according to any of the preceding aspects, wherein the one or more thresholds comprises: an upper voltage threshold, a lower voltage threshold, and wherein the load is connected to the main power source when the source voltage is less than the upper voltage threshold and greater than the lower voltage threshold, wherein the load is connected to the second power source when the source voltage is greater than the upper voltage threshold or lower than the lower voltage threshold.

Aspect 4. The method according to any of the preceding aspects, wherein cycling the first switch at the transfer switch between the OFF position and the ON position for the one or more cycles further comprises: cycling, by the controller for each cycle, the first switch to the OFF position for a first period of time; and cycling, by the controller for each cycle, the first switch to the ON position for a second period of time and measuring the input to determine whether the input exceeds the one or more thresholds.

Aspect 5. The method according to any of the preceding aspects, wherein the first period of time and the second period of time each comprises approximately 0.1 msec.

Aspect 6. The method according to any of the preceding aspects, wherein connecting the load to the second power source further comprises: cycling, by the controller, the first switch to the OFF position to disconnect the load from the main power source; and cycling, by the controller, the second switch to the ON position to connect the load to the second power source.

Aspect 7. The method according to any of the preceding aspects, wherein the first switch comprises: one or more first solid-state switching devices (SSSDs), wherein the one or more first SSSDs is arranged in a reverse orientation to enable bi-directional flow of a phase current between the load and the main power source.

Aspect 8. The method according to aspect 7, wherein the one or more first SSSDs comprises at least one of: SiC metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), bipolar junction transistors (BJTs), and junction-gate field effect transistors (JFETs).

Aspect 9. The method according to aspects 7 or 8, wherein the one or more first SSSDs comprises SiC MOSFETs.

Aspect 10. The method according to any of the preceding aspects, wherein the second switch comprises: one or more second SSSDs, wherein the one or more second SSSDs is arranged in a reverse orientation to enable bi-directional flow of a phase current between the load and the second power source.

Aspect 11. The method according to aspect 10, wherein the one or more second SSSDs comprises at least one of: SiC metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), bipolar junction transistors (BJTs), junction-gate field effect transistors (JFETs), silicon controlled rectifiers (SCRs), and SCRs with paralleled resistive turn-off (RTO) circuits.

Aspect 12. The method according to aspects 10 or 11, wherein the one or more second SSSDs comprises SCRs with paralleled RTO circuits.

Aspect 13. A system comprising: a main power source; a second power source; a load; a transfer switch comprising: a first switch located between the main power source and the load, and a second switch located between the second power source and the load; and a controller comprising: a processor, and a non-transitory computer-readable medium having stored thereon instructions executable by the processor to control an operation of the transfer switch including: obtain an input from a first sensor measuring electrical characteristics at an electrical conductor connecting the main power source to the load using the transfer switch, compare the input to one or more thresholds to determine an abnormal condition, cycle, for each cycle of one or more cycles, the first switch to an OFF position for a first period of time, cycle, for each cycle of the one or more cycles, the first switch to an ON position for a second period of time and measure the input to determine whether the input exceeds the one or more thresholds, determine whether the input from the first sensor exceeds the one or more thresholds when the first switch is in the ON position, and connecting, by the controller, the load to the main power source with the first switch in response to determining the input is within the one or more thresholds after the one or more cycles, or connecting the load to a second power source with a second switch in response to determining the input exceeds the one or more thresholds after the one or more cycles, wherein the first period of time and the second period of time each comprises approximately 0.1 msec.

Aspect 14. The system according to aspect 13, wherein the input comprises: a source voltage; wherein the one or more thresholds comprises: an upper voltage threshold, a lower voltage threshold, and wherein the load is connected to the main power source when the source voltage is less than the upper voltage threshold and greater than the lower voltage threshold, wherein the load is connected to the second power source when the source voltage is greater than the upper voltage threshold or lower than the lower voltage threshold.

Aspect 15. The system according to aspects 13 or 14, wherein connecting the load to the second power source further comprises: cycling, by the controller, the first switch to the OFF position to disconnect the load from the main power source; and cycling, by the controller, the second switch to the ON position to connect the load to the second power source.

Aspect 16. The system according to aspects 13, 14, or 15, wherein the first switch comprises one or more first solid-state switching devices (SSSDs) comprising at least one of: SiC metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), bipolar junction transistors (BJTs), and junction-gate field effect transistors (JFETs), wherein the one or more first SSSDs is arranged in a reverse orientation to enable bi-directional flow of a phase current between the load and the main power source.

Aspect 17. The system according to aspect 16, wherein the one or more first SSSDs comprises SiC MOSFETs.

Aspect 18. The system according to aspects 13, 14, 15, 16, or 17, wherein the second switch comprises one or more second SSSDs comprising at least one of: SiC metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), bipolar junction transistors (BJTs), junction-gate field effect transistors (JFETs), silicon controlled rectifiers (SCRs), and SCRs with paralleled resistive turn-off (RTO) circuits, wherein the one or more second SSSDs is arranged in a reverse orientation to enable bi-directional flow of a phase current between the load and the second power source.

Aspect 19. The system according to aspect 18, wherein the one or more second SSSDs comprises SCRs with paralleled RTO circuits.

Aspect 20. A transfer switch device comprising: a first switch located between a main power source and a load and comprising: one or more first solid-state switching devices (SSSDs), wherein each first SSSD comprises at least one of SiC metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), bipolar junction transistors (BJTs), and junction-gate field effect transistors (JFETs), a second switch located between a second power source and the load and comprising: one or more second SSSDs, wherein each second SSSD comprises at least one of SiC metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), bipolar junction transistors (BJTs), junction-gate field effect transistors (JFETs), silicon controlled rectifiers (SCRs), and SCRs with paralleled resistive turn-off (RTO) circuits; and a controller including a processor and a non-transitory computer-readable medium having stored thereon instructions executable by the processor to perform operations including: obtain a source voltage from a first sensor measuring electrical characteristics at an electrical conductor connecting the main power source to the load using the transfer switch, compare the source voltage to an upper voltage threshold and a lower voltage threshold to determine an abnormal condition, cycle, for each cycle of one or more cycles, the first switch to an OFF position for a first period of time, cycle, for each cycle of the one or more cycles, the first switch to an ON position for a second period of time and measure the source voltage to determine whether the source voltage exceeds the upper voltage threshold and the lower voltage threshold, determine whether the source voltage from the first sensor exceeds the upper voltage threshold or the lower voltage threshold when the first switch is in the ON position, and connecting, by the controller, the load to the main power source with the first switch in response to determining the source voltage is less than the upper voltage threshold and greater than the lower voltage threshold after the one or more cycles, or connecting the load to a second power source with a second switch in response to determining the source voltage is greater than the upper voltage threshold or less than the lower voltage threshold after the one or more cycles, wherein the first period of time and the second period of time each comprises approximately 0.1 msec.