Circuit protector monitoring assembly

Monitoring assemblies for determining an operational state of a circuit protector in an electrical circuit.

This application also relates to U.S. application Ser. No. 11/223,702 filed Sep. 9, 2005 and entitled System and Method for Circuit Protector Monitoring and Management; U.S. application Ser. No. 11/224,586 filed Sep. 12, 2005 and entitled Circuit Protector Signal Transmission, Methods and System; U.S. application Ser. No. 11/223,618 filed Sep. 9, 2005 and entitled Circuit Protector Monitoring and Management System User Interface Method, System, and Program; U.S. application Ser. No. 11/223,484 filed Sep. 9, 2005 and entitled Multifunctional Handheld Response Tool, Method and System for Circuit Protector Management; and U.S. application Ser. No. 10/828,048, filed Apr. 20, 2004 and entitled Wireless Fuse State Indicator System and Method; and U.S. application Ser. No. 10/973,628 filed Oct. 26, 2004 and entitled Fuse State Indicating and Optical Circuit and System, the complete disclosures of which are also hereby incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

This invention relates generally to circuit protection devices, and more particularly to systems for managing electrical systems including circuit protection devices.

Electrical systems typically include a number of circuit protection devices that protect electrical circuitry, equipment, and components from damage. Overcurrent protection devices, for example, are constructed to physically open or interrupt a circuit path and isolate electrical components from damage upon the occurrence of specified overcurrent conditions in the circuit. Known circuit protection devices include devices such as fuses, circuit breakers, and limiters, which may address overcurrent, overload, and short circuit conditions in an electrical system, and other switching devices. As the size and complexity of electrical systems increase, the number of associated circuit protection devices also typically increases. Managing a complex electrical system having a large number of circuit breakers, any one of which may operate at any given time to isolate portions of the circuitry in the electrical system, is challenging.

DETAILED DESCRIPTION OF THE INVENTION

Exemplary embodiments of systems and processes that facilitate monitoring and management of circuit protection devices in electrical systems, referred to herein as “circuit protectors”, and systems and processes that facilitate rapid response to specified operating conditions of the circuit protectors and associated circuitry are described below in detail. The systems and processes facilitate, for example, detection of operated circuit protectors, notification to responsible personnel of operated circuit protectors and their location in the system for response and attention by authorized personnel, diagnostics and troubleshooting of circuit protectors and electrical systems, and circuit protector inventory control and management for facilities management. A technical effect of the systems and processes described herein include at least one of organization and presentation of circuit protector information and electrical system data for facilities management and system oversight, real time alarm condition detection and notification for circuit protector operation, automated alert notification and summoning of personnel or site technicians to quickly reset and re-store downed circuitry due to operation of one or more circuit protectors, archived installation and performance data of the circuit protectors and associated electrical system for diagnostics and troubleshooting of electrical system perturbation events, and proactive management of electrical systems in anticipation of potential circuit perturbations.

FIG. 1is a schematic block diagram of an exemplary electrical system100representative of the type of system that utilizes circuit protectors. In different embodiments, and as a few examples, the electrical system100could be implemented as a battery powered electrical system for a vehicle, an AC or DC power distribution system for a building, industrial plant and/or control system, a communications network, other system as those in the art will appreciate.

In the illustrated embodiment, the electrical system100includes a power supply or power supply circuitry102, a circuit protector panel, a circuit protector holder, a circuit protector block or a circuit protector cabinet (collectively referred to herein as “the panel104”) coupled to the power supply102by a line L, and a number of electrical loads106operatively connected to the panel104. The panel104includes one or more circuit protectors108that interconnect the power supply102to the respective loads106.

In various embodiments, the loads106may include electrical components such as transformers, inductors, integrated circuits; equipment such as machines, electrical motors and drive components, computers, programmable logic control systems; and sub-circuitry of the larger electrical system100. Additionally, the loads106may serve as a secondary power source to additional loads of the same or different electrical systems.

The circuit protectors108in an exemplary embodiment are overcurrent protection devices, such as, for example, fuses, circuit breakers and/or switches. Each circuit protector108is constructed to physically break, open, or interrupt a circuit path or current path between line and load circuitry and isolate the loads106, for example, from the power supply circuitry102to prevent damage to the loads106upon the occurrence of specified current conditions in the circuit, such as overcurrent, overload, and short circuit conditions. When such conditions occur, the circuit protectors108prevent current flow between the power supply circuitry102and the respective loads106, protecting them from potential damage attributable to current flow in such conditions. That is, in normal current conditions the circuit protectors108are in a current carrying or unopened condition completing an electrical connection through between the power supply102and the loads106, and in response to abnormal or unacceptable current conditions in the circuit, the circuit protectors108change or operate to a non-current carrying state, sometimes referred to as an opened or tripped condition breaking the electrical connection between the power supply102and the loads106.

While one circuit protector panel104is illustrated inFIG. 1, it is understood that the electrical system100may include a plurality of circuit protector panels104in different embodiments. The panels104may be located in the same or different physical locations, and each of the circuit protectors108is associated with specific electrical loads106of the system. While four circuit protectors108are illustrated in the panel104for ease of illustration, it is contemplated that greater or fewer circuit protectors108, including a single circuit protector108, may be employed in the panel104. That is, the circuit protector panel104may be configured or adapted to connect a single circuit protector108to the system100, or alternatively may be adapted to connect a plurality of circuit protectors108as those in the art will appreciate.

In complex electrical systems, many circuit protectors108are typically required in different panels104of various sizes and configurations. Also, complex electrical systems typically include various types and configurations of circuit protectors108to meet particular needs of the loads106and associated electrical subsystems. The combination of large numbers of circuit protectors108, assorted numbers of panels104in different locations, and various types of circuit protectors108in the electrical system100presents difficult problems in locating operated circuit protectors108and resetting or restoring the circuitry when one or more of the circuit protectors108in the electrical system100operates to protect the associated loads106in the system100.

As the size and complexity of electrical system100increases, the potential locations of circuit protectors108in the system100increases too. The panels104containing the circuit protectors108may be located in different places in the electrical system100, including different buildings, areas, compartments and portions of the electrical system site or facility. Therefore, when one or more circuit protectors108operate to open a portion of the circuitry in the electrical system100, it can be a daunting task to locate which of the circuit protector devices108has operated, and to take corrective action to reset or restore affected circuitry and loads106.

An elapsed time between operation of one or more circuit protectors108and re-energizing of the associated circuitry to restore full operation of the electrical system100is significant in many applications. For example, in an industrial plant control system or office building, the time in which affected machines or computers are unavailable due to operated circuit protection devices amounts to lost productivity and economic loss. For virtually any electrical system, and especially for critical electrical systems, minimizing the time and effort required to locate operated circuit protectors108and to take corrective action is desired.

When the circuit protectors108are circuit breakers, once the appropriate location of an operated circuit breaker has been identified, the breaker or breakers can generally be quickly reset. Locating the correct breakers, however, is not always a quick or easy task when there are a large number of breakers in different locations or panels104in the electrical system100. To locate the operated breakers quickly, downed circuitry or equipment typically is matched with the appropriate breakers of the system100, which requires some detailed knowledge of the electrical system100that maintenance personnel may or may not have at any given time. Alternatively, and probably more likely in most cases, maintenance personnel systematically inspect all of the circuit protector breakers in the electrical system to locate tripped breakers. Such an exercise is usually inefficient, except perhaps in situations where by mere chance the personnel starts the inspection in the area of the operated breakers. Also, locating tripped breakers can be complicated when breakers in more than one location are tripped, and in the case of faulty or inoperative breakers which are not tripped, restoring the circuitry of the electrical system100when one or more of the circuit protectors108operates can be extremely difficult and time intensive.

When the circuit protectors108include fuses, operated fuses must be located, replacement fuses must be obtained, and the operated fuses must be replaced to reset the circuitry of the electrical system100. If a replacement fuse is on hand and the location of the operated fuse is known, the fuse can typically be quickly replaced to restore the circuitry. Locating which fuse or fuses has opened, however, and obtaining the proper replacement fuses, is not always easy. Fuses of different types may be located in various places throughout the electrical system100, and locating the proper replacement fuse from a large inventory of different fuse types, whether on site or at a remote location, can be time intensive. As with circuit breakers, locating operated fuses can be complicated when more than one fuse operates, and locating faulty fuses or improperly installed fuses in the electrical system100can be extremely difficult. Additionally, properly managing, maintaining, and replenishing a replacement fuse inventory to meet actual and anticipated needs of the electrical system100can be difficult.

In addition, circuit protectors108tend to operate with little or no advanced warning. Thus, troubleshooting the electrical system100and/or taking preemptive action before the circuit protectors108operate is difficult, if not impossible, in many electrical systems. Additionally, diagnosing the electrical system100to determine why or how certain circuit protectors108operated is often an after-the-fact analysis and can be speculative in nature.

B. The Circuit Protector Management System

In an exemplary embodiment, and to alleviate these and other difficulties, each of the circuit protectors108is associated with a status element110located internal or external to the circuit protector108. That is, the status element110may be located interior to or inside the circuit protector108, on an external surface of or otherwise outside of the circuit protector108, or even at another location at a distance from the circuit protector108. As described further below, in different embodiments the status elements110may be implemented in electronic form or be mechanically actuated to interface the status elements110to the circuit protector management system112. When a circuit protector108operates to open a circuit path in the electrical system100, the associated status element110aids in identifying the circuit protector so that the circuitry can be efficiently re-energized with minimal time delay.

Each of the status elements110of the circuit protectors108is responsive to operation of the respective circuit protector108, and in exemplary embodiments the status elements110transmit or communicate signals or data to an circuit protector management system112. The status elements110in some embodiments may be used as data collectors regarding operating conditions of the circuitry in the electrical system100, as explained further below.

In an exemplary embodiment, the circuit protector management system112may include in whole or in part a communications device114in communication with the status elements110of the circuit protectors108, a communications interface or link116, an overview and response dispatch system118in communication with the link116, and an inventory management system120in communication with the link116and/or the overview and response dispatch system118.

During operation of the electrical system100, signals are sent from the status elements110of the circuit protectors108, through the communications device114and the communication link116, to the overview and response dispatch system118. The communications device114allows the status elements110associated with the circuit protectors108to communicate with the overview and response dispatch system118and the inventory management system120via the communications interface116. In particular, when any of the circuit protectors108operates to interrupt, break, or open a circuit path to one or more of the loads106, a signal is communicated from the respective identification element112via the communications device114and the communication link116to the overview and response dispatch system118and/or to the inventory management system120.

The overview and response dispatch system118and/or the inventory management system120are, in turn, associated with an inventory122of circuit protectors and an automated or manual dispensing system124for stocking and replenishing the inventory122as the inventory is used. The inventory122may be located on site or at another location from the electrical system100.

In an exemplary embodiment, the communications device114is located proximate to the circuit protectors108, either integrated into the construction of the panel104or in a location proximate to the panel104. The communications interface or link116may be a hard-wired communications link, optical link, wireless communications link, satellite link, and equivalents thereof as explained further below. Additionally, the communications interface or link116may utilize existing infrastructure in the electrical system100, and may operate, for example, using known power line frequency carrier technology or equivalents thereof over existing wires and conductors in the electrical system100. Combinations of such communications links may likewise be provided in different embodiments of the management system112.

The communications link116may be a dedicated interface or link used only for circuit protector management purposes by the management system112, or may also serve other unrelated purposes and be used for transmission of other signals, data and communications as desired. Communication between the communications device114and the overview and response dispatch system118may be established using known data transmission protocols and network communication technologies such as DeviceNet and Datahiway protocols. Ethernet connections multiplexing communication schemes, wireless technologies, satellite transmission schemes, equivalents thereof, and the like may also be used as those in the art will appreciate.

While one communications device114is illustrated inFIG. 1, it is contemplated that more than one communications device114may be employed in the circuit protector management system112. Multiple communication devices114may furthermore be employed in the same panel104depending upon the number of circuit protectors108in the panel104and the sophistication of the management system112. In exemplary embodiments, as further explained below, one communication device114may be used to monitor multiple circuit protectors108and transmit information to the overview and response dispatch system118.

In various embodiments, the overview and response dispatch system118may be a network-based system, a personal computer, a computer workstation, a programmable logic controller or other electronic controller, a processor-based hand held device or another electronic device or equivalent that may receive and process or interpret signals from the link116. In one embodiment, the overview and response dispatch system118may include a user display126to alert an operator or maintenance personnel of an issue with the electrical system100, such as an operated circuit protector108which has broken a circuit path in the electrical system100.

In different embodiments, the inventory management system120is a network-based computer system, a personal computer, a computer workstation, a processor-based hand held device, a programmable logic controller or an electronic controller or other electronic device which receives signals from the link116and/or the overview and response dispatch system118and is capable of responding appropriately. The inventory management system120may be integrated into the overview and response dispatch system118as desired, or may be a separate device in the same or different location from the overview and response dispatch system118. The inventory management system120is associated, directly or indirectly, with the inventory122, and is in communication with the automated dispensing system124. The automated dispensing system124may be of a known type currently used in industrial and business facilities to provide uninterrupted access to supplies. Such automated dispensing systems are commercially available and sometimes referred to as Smart Inventory Systems. The automated dispensing system124electronically receives and processes orders for circuit protection products so that the product orders are filled and the circuit protection products are delivered to the inventory122with minimal delay. Alternatively, a manual inventory system may be employed to dispense and replenish the circuit protection devices.

While one automated dispensing system124is shown inFIG. 1, it is appreciated that the overview and response dispatch system118and inventory management system120may communicate with more than one automated dispensing system124to obtain inventory products from the same or different circuit protection product vendors, distributors or suppliers as desired. Additionally, the overview and response dispatch system may communicate with known computerized maintenance management system (CMMS), supervisory control and data acquisition (SCADA) systems, industrial control and automation systems, enterprise resource planning (ERP) systems, Electronic Data Interchange (EDI) systems, Manufacturing Resources Planning (MRP) systems, and supply chain management systems in addition to or in lieu of the inventory management system120.

By virtue of the status elements110associated with the fuses108, and as further explained below, the overview and response dispatch system118may direct an operator or maintenance personnel to a precise location and to one or more specific circuit protectors108in the electrical system100for resetting or restoring the circuitry. Additionally, the overview and response dispatch system118may locate proper replacement circuit protectors in the inventory122and direct personnel to a precise location to obtain the proper replacement circuit protectors, while contemporaneously ordering additional circuit protectors via the manual or automated dispensing system124to replenish the inventory122as it is used. Thus, the electronic management system112can provide precise instruction to personnel regarding the circuit protectors108to minimize down time of the associated load106for the operated circuit protector112. The circuit protectors108may therefore be attended to as efficiently as possible, and automated ordering of replacement parts for the circuit protector inventory122ensures prompt replenishing of the inventory and eliminates error in inventory management. Factory automation technologies and equivalents thereof may be used to ensure that replacement circuit protectors are available for use and pinpoint their location in a physical plant for retrieval by maintenance personnel, and inventory management is accomplished in an automated manner without human intervention or action by maintenance personnel.

FIG. 2is a flowchart of an exemplary method130for monitoring circuit protectors108utilized the circuit protector management system112shown inFIG. 1. The method130facilitates efficient re-energizing affected circuitry in an electrical system100when one or more of the circuit protectors108operates to isolate one portion of an electrical system100from another portion of the electrical system100, such as isolating one or more of the loads106from the power supply102.

In an exemplary embodiment, the method130includes providing132status elements, embodiments of which are explained below, proximate to the respective circuit protectors of interest in the electrical system, and providing134the electronic overview and response dispatch system responsive to the status elements. Once the status elements are installed136, they may be used to monitor138an operating state of the circuit protectors.

Based upon the sensed state of the circuit protectors, a data signal may be transmitted140from at least one of the status elements to a remote device or location when one of the circuit protectors has operated to isolate a portion of the electrical system. The data signal, may include, for example, an identification code and an address code to identify the location of the operated circuit protector, and detailed information and instruction to appropriate personnel to reset or restore the circuitry quickly and efficiently. When interpreted at the remote location by the overview and response dispatch system, the data signal may be converted to an instruction to an operator or technician that may include, for example, information regarding the location of operated circuit protectors, information needed to properly reset or restore the circuitry affected by the operated circuit protectors, inventory information for replacement circuit protectors needed to properly restore the circuitry, and information pertaining to operating conditions of the circuitry for diagnostic and troubleshooting purposes. The instruction to personnel may further include specific information regarding potential hazards in the location of the circuit protector, and information regarding precautions that should be taken and personal protection equipment that should be utilized when responding to an operated circuit protector.

In response to the data signals communicated140to the overview and response dispatch system, the overview and response dispatch system generates142an alert and summons to responsible personnel, informing them of the operated circuit protector and the location of the operated circuit protector. For example, the overview and response dispatch system may directly communicate with an operator, maintenance personnel, or others via a remote device such as a computer, pager, dispatcher, a hand-held device such as a personal digital assistant (PDA), personal information manager (PIM), or electronic organizer, cellular phone or equivalent device which is either networked with the overview and response dispatch system or in communication with the overview and response dispatch system and capable of reaching appropriate personnel. That is, the overview and response dispatch system may be active instead of passive, and instead of simply providing an alert and waiting for human response, the overview and response dispatch system is capable of actually seeking and directly contacting specific persons in multiple ways, and summoning them to respond and intervene as needed to properly manage the electrical system.

The alert and summons may be provided, for example, in an email notification, a fax notification, a pager notification, a web page notification, a voice notification, or other means. The overview and response dispatch system may wait144for acknowledgment of the alert and summons by one or more of the designated personnel, and if no acknowledgement is received, another alert and summons is sent. Optionally, the overview and response dispatch system may escalate146the frequency or intensity of the alerts and summons depending upon responsiveness of the designated personnel or actual operating conditions of the electrical system. For example, if multiple circuit protectors open at about the same time, a larger problem with the electrical system could be implicated and the management system may more urgently generate alarms, alerts and summons to address potential problems.

Optionally, the overview and response dispatch system may also automatically undertake and initiate148other desired actions without human intervention, such as activating auxiliary power to the affected loads corresponding to specific machines or equipment, shutting down at risk systems or loads corresponding to specific machines or equipment, saving key circuit data for analysis, etc. when the circuit protectors108operate to open portions of the electrical system100, and communicating such undertakings and actions to designated personnel for further evaluation and response.

More than one person may be contacted by the overview and response dispatch system and summoned to help re-energize affected circuitry, for example, by replacing operated fuses. Alerts and requests for action by designated personnel may be sent repeatedly from the overview and response dispatch system within specified time periods until acknowledged by appropriate personnel, and escalated alerts and summons may be generated and special procedures implemented as appropriate to deal with different situations depending upon the sophistication of the circuit protector management system112.

Because the alert and notifications are sent more or less contemporaneously with the operation of the circuit protectors, and because the overview and response dispatch system actively attempts to find, contact and summon personnel and provides complete information needed to re-energize affected circuitry, including at least the type and location of operated circuit protectors, downed circuitry may be quickly re-energized and the full electrical system restored in as quick a time as possible. Automated alerts and summons may be sent around the clock without human intervention as needs arise. The information pertaining to operated circuit protectors can be presented to the end user in an easy to use tabular or graphical form in real time as the circuit protectors operate, and the end recipient of the information need not gather additional information to complete the task of re-energizing circuitry.

By actively seeking and contacting appropriate personnel, as opposed to a reactive system that is dependent upon human response, the overview and response dispatch system is not dependent upon specific persons and designated personnel being in any specific location, such as a workstation, terminal, or working area to receive an alert notification of an operated circuit protector. Rather, the overview and response dispatch system directly seeks out designated persons and contacts them wherever they may be found. Thus, should the persons or personnel be away from a desk, workstation, terminal or working area during working or non-working hours, the overview and response dispatch system is capable of reaching them by other means and instantly notifying them of operated circuit protectors, rather than having to wait for them to return to receive an alert message at their desk, workstation, terminal or working area.

When used as data collectors, the status elements may facilitate monitoring, troubleshooting, and diagnosis of the electrical system as the circuit protectors are monitored138and signals are communicated140to the overview and response dispatch system. Through monitoring and analysis of such data, potential problems in the system may be more accurately identified and resolved, and more reliable operation of the electrical system may be achieved. In such an embodiment, the alert or summons generated142by the overview and response dispatch system may include a warning or alarm to system operators or personnel to anticipate potential circuit opening events and circuit perturbations that may otherwise cause the circuit protectors to operate, potentially providing time for preemptive measures to be taken before one or more of the circuit protectors operate to break the associated circuit paths in the electrical system. The associated time, cost, expense and inconvenience of opened circuitry in the electrical system and the associated time, cost, expense and inconvenience involved in resetting, restoring or re-energizing the circuitry due to operated circuit protectors may therefore potentially be avoided in the first instance with proactive management of the electrical system.

The overview and response dispatch system may further initiate150a replacement order to replenish, for example, a fuse inventory when the operated fuse or fuses in the electrical system has been replaced.

C. The Status Elements and Circuit Protector Monitoring

It is contemplated that may different status elements and circuit protector monitoring assemblies may be provided in the circuit protector management system112. Exemplary embodiments will now be described for illustrative purposes only. It is understood that other monitoring assemblies may be used in addition to the examples set forth below with equal effect.

FIG. 3is a perspective view of an exemplary circuit protector108and panel104that may be used in the circuit protector management system112and the method130wherein the status elements110are provided in the form of a monitoring module assembly300. The monitoring module assembly300is associated with a plurality of circuit protectors in the form of fuses302, and the assembly includes a plurality of monitoring modules304that are attached to the bodies306of the respective fuses302. In an exemplary embodiment, the monitoring modules304are individually mounted to the fuse bodies306via a clip308to an exterior surface of the respective fuse bodies306, thereby facilitating retrofit installation to the fuses302in an electrical system. As previously explained, the fuses302may be housed and arranged in the panel104in the electrical system to interconnect power supply circuitry102and various loads106in the electrical system.

The monitoring modules304may each include contact arms310extending outwardly from the modules304in a direction substantially parallel to the respective fuse body306. The contact arms310of the respective modules304mechanically and electrically engage the terminal elements312of the fuses302so that the fuses302may be monitored in use. A primary fuse element313defines an interruptible current path between the terminal elements312of each of the fuses302, and when the current path is opened or interrupted in an overcurrent condition, the modules304sense the operation of the fuses302in real time.

In an exemplary embodiment, the monitoring modules304include sensor modules314associated with some of the fuses302and a communications module316associated with one of the fuses302. The sensor modules314and the communications module316may be interconnected to one another via interface plugs318and three wire connections, for example, as illustrated inFIG. 3.

Referring now toFIG. 4, the construction of the sensor modules314and the communications module316will be described. Each sensor module314includes a sensor330, an input/output element332connected to the sensor330, and a signal port334. The sensor330is connected to the contact arms310that are connected to the terminal elements T1and T2of one of the circuit protector fuses302A. In one embodiment, the sensor330is a voltage sensing latch circuit having first and second portions optically isolated from one another. When the primary fuse element313of the fuse302A opens to interrupt the current path through the fuse302A, the sensor330detects the voltage drop across the terminal elements T1and T2of the fuse302A. The voltage drop causes one of the circuit portions, for example, to latch high and provide an input signal to the input/output element332. Acceptable sensing technology for the sensor330is available from, for example, SymCom, Inc. of Rapid City, S. Dak.

While in the exemplary embodiment, the sensor330is a voltage sensor, it is understood that other types of sensing could be used in alternative embodiments to monitor and sense an operating state of the circuit protector302A, including but not limited to current temperatures and temperature sensors that could be used to determine whether the primary fuse element313has been interrupted in an overcurrent condition to isolate a portion of the associated electrical system.

In a further embodiment, one or more additional sensors or transducers331may be provided, internal or external to the sensor module314, to collect data of interest with respect to the electrical system and the load connected to the fuse302A. For example, sensors or transducers331may be adapted to monitor and sense vibration and displacement conditions, mechanical stress and strain conditions, acoustical emissions and noise conditions, thermal imagery and thermalography states, electrical resistance, pressure conditions, and humidity conditions in the vicinity of the fuse302A and connected loads. The sensors or transducers331may be coupled to the input/output device332as signal inputs. Video imaging and surveillance devices333may also be provided to supply video data and inputs to the input/output element332.

In an exemplary embodiment, the input/output element332may be a microcontroller having a microprocessor or equivalent electronic package that receives the input signal from the sensor330when the fuse302A has operated to interrupt the current path through the fuse302A. The input/output element332, in response to the input signal from the sensor330, generates a data packet in a predetermined message protocol and outputs the data packet to the signal port334. The data packet may be formatted in any desirable protocol, but in an exemplary embodiment includes at least an identification code, a fault code, and a location or address code in the data packet so that the operated fuse may be readily identified and its status confirmed, together with its location in the electrical system. Of course, the data packet could contain other information and codes of interest, including but not limited to system test codes, data collection codes, security codes and the like that is desirable or advantageous in the communications protocol.

Additionally, signal inputs from the sensor or transducer331may be input the input/output element332, and the input/output element332may generate a data packet in a predetermined message protocol and output the data packet to the signal port334. The data packet may include, for example, codes relating to vibration and displacement conditions, mechanical stress and strain conditions, acoustical emissions and noise conditions, thermal imagery and thermalography states, electrical resistance, pressure conditions, and humidity conditions in the vicinity of the fuse302A and connected loads. Video and imaging data, supplied by the imaging and surveillance devices333may also be provided in the data packet.

The communications module316in an exemplary embodiment may also include a sensor330, an input/output element332, and a signal port334. Like the sensor module314, the sensor330of the communications module316is connected to the contact arms310that are connected to the terminal elements T1and T2of one of the circuit protector fuse302B, and the sensor330of the communications module316operates substantially in the same manner as described above to sense an operating state of a primary fuse element313in the fuse302B. However, when the sensor330detects operation of the fuse302B, the input/output element332generates and outputs a corresponding data packet to a transmitter340that communicates with the overview and response dispatch system118. The transmitted data packet from the communications module316, in addition to the data packet codes described above, also includes a unique transmitter identifier code so that the overview and response dispatch system may identify the particular communications module316that is sending a data packet.

In one embodiment, the transmitter340is a low power radio frequency (RF) signal transmitter that digitally transmits the data packet in a wireless manner. Point-to-point wiring in the electrical system for fuse monitoring systems is therefore avoided, although it is understood that point-to-point wiring could be utilized in some embodiments of the invention. Additionally, while a low power digital radio frequency transmitter has been specifically described, it is understood that any of the aforementioned wireless communication schemes and equivalents could alternatively be used if desired.

The communications module316further includes an onboard battery power supply342that powers the electronic sensor330and/or the input/output element332and the transmitter340of the communications module316. The battery342may also supply power, through the interface plugs318, to the input/output element332and/or the sensor330of the communications module316. Thus, multiple sensor modules314may be powered by a single communications module316to monitor a plurality of fuses302. For example, one of the three wire connections shown inFIG. 3may be a power line connecting the battery342to one or more sensor modules314. The battery342may be replaceable as needed to extend the life of the monitoring assembly300, and a test button, for example, may be provided in the communications module316to ensure that the battery342is powered and the module electronics in the communications module316and connected sensor modules314are working properly. Reset buttons may also be provided in the modules for testing and diagnostic purposes. A power harvesting device343, such as rechargeable batteries and the like that store energy when not in use may be utilized in addition to or in lieu of the battery342. A backup power supply345, or other circuits of the electrical system may also be used to power the sensor and communications modules314,316. Energy storage components such as capacitors may also be employed, and switching devices may be provided to switch between energy storage elements, power harvesting devices, batteries, and backup power supplies, or other circuitry to power communications after circuit protector302A has operated.

Also, the signal port334of the sensor module314may communicate, via the interface plug318with the signal port334of the communications module316. Thus, for example, considering the embodiment ofFIG. 4, when the primary fuse element313opens in the fuse302A associated with the sensor module314, the sensor module input/output element332generates a data packet that is sent to the sensor module signal port334through the interface plug318and to the communications module input/output element332for transmission via the transmitter340. Thus, signals are simply passed through the respective signal ports334via the interface plug318, and multiple sensor modules314may be connected to a single communications module316via interconnecting the interface plugs318to the signal ports334. In such a manner, the number of communication modules316and transmitters340in the circuit protector management system may be reduced, together with associated costs and maintenance issues.

Additionally, status indicators and the like such as light emitting diodes (LED's) may be provided in the sensor and communication modules314,316to locally indicate an operated fuse302. Thus, when maintenance personnel arrives at the location of the operated fuse302, the status indicators may provide local state identification of the fuses associated with the modules314,316.

Notably, the monitoring modules304, including the sensor modules314and communications modules316are provided in modular form wherein different sized mounting clips308and differently dimensioned contact arms310may be provided to accommodate fuses of varying sizes and configurations. By providing various mounting clips and mounting structure, together with various contact arms and contact structure to establish electrical contact with the fuses, the modules304are readily adaptable to accommodate most if, not all, types of fuses, and the modules304may be retrofitted to complex electrical systems with snap-on engagement, thereby minimizing installation time and complexity in existing electrical systems.

FIG. 5, for example, illustrates a single phase monitoring assembly350including a monitoring module304and a circuit protector in the form of a fuse352. The module304includes a body or housing354, a sensor board356, a communications board358, and a battery360mounted therein and forming a protective enclosure thereabout. The sensor board356includes, for example, sensing circuitry330to detect operation of the fuse, such as the aforementioned voltage sensing, current sensing, or temperature sensing circuitry, and the communications board includes, for example, the input/output element332and the transmitter340for generating data messages and signals when the fuse352operates to open the circuit.

The signal port334is exposed through an outer surface362of the module304, and in an exemplary embodiment, the signal port334includes contacts364that interface with, for example, mating interconnect plugs such as the plugs318. The module304may therefore be connected to another monitoring module304in the larger electrical system.

With the communications board358and battery360, the module304may function as the communications module316described above. Without the communications board358and battery360, the module304may function as a sensor module314as described above. The communications board358may include a low power radio frequency transmitter as described above, or may alternatively communicate with a remote device by any of the aforementioned methods.

A test/reset button366extends through the outer surface362of the housing354, and a status indicator opening368is provided in the outer surface362. A light emitting diode (LED), for example, may be connected to the sensor board356and may be illuminated when the fuse352opens to isolate a portion of electrical circuitry connected thereto, thereby providing visible local indication in the housing354. Contact arms370are attached to the housing354and are electrically connected to the sensor board356for monitoring of the fuse352when the contact arms370are mechanically engaged to the terminal elements of the fuse352.

A mounting element372attaches to the exterior surface of the fuse body, thereby permitting retrofit installation to the fuse352when the fuse352is installed in an electrical system.

Various adaptations of the monitoring modules304may be made to use the modules304on various types of circuit protectors and systems. For example, modules suitable for single phase, three phase, and polyphase circuit breaker systems may be provided. Modules may be provided as sensor modules or communication modules. Various types of contact arms and mounting structure may be provided for use with various types of circuit protectors and for circuit protectors of varying size, and the modules may be provided in kit form having various interchangeable component parts that may be assembled to meet the needs of a variety of circuit protectors. Such kits may be assembled quickly by hand and without tools due to snap-fit connections, for example, of such component parts, thereby providing a convenient and low cost monitoring assembly for circuit protectors. Modular construction and assembly of the monitoring modules, mounting elements and contact arms permits wide application of the monitoring modules to existing electrical systems having fuses of various sizes, shapes and configurations. When used in a circuit protector management system112such as that described above to communicate signals to the overview and response dispatch system118, the monitoring modules and monitoring assemblies provide an effective monitoring status and detection scheme for an electrical system having a variety of different types of circuit protectors.

While the modules described above may be effectively used on a variety of circuit protectors in electrical systems, they are disadvantaged for certain circuit protectors, particularly those that are housed within protective enclosures. For example,FIG. 6illustrates circuit protectors380A,380B, and380C situated within an enclosure382, and a monitoring module384that is adapted to fit within the enclosure. As illustrated inFIG. 6, the enclosure382may be a three phase device that houses three circuit protectors380for each current phase. It is contemplated, however, that single phase or polyphase embodiments having varying numbers of circuit protectors380may alternatively be provided.

The enclosure382may be fabricated from metal in one embodiment and may be formed into a box-like base386defining a compartment or cavity388therein that receives and contains the circuit protectors380. A cover or lid390, which may also be fabricated from metal, may be coupled to the base386and close the compartment388. The lid390may be, for example, entirely removable from the base386, may be hingedly attached to the base386, or may be otherwise connected to the base386and movable relative to the base386to expose the compartment388for installation, service and repair of the circuit protectors and termination structure.

The base386may include conductive clips, terminations, and the like to complete electrical connections through the circuit protectors380, which may be overcurrent protection fuses in an exemplary embodiment. The base386may also include insulative barriers389to separate the circuit protectors380from one another and to prevent accidental shorting of the circuit protectors380in use. The enclosure382may therefore sometimes be referred to as a fuseholder, a fuse box, a fuse block, etc. It is appreciated, however, that non-fuse circuit protectors are also sometimes enclosed in housings, boxes, blocks and panels as is known in the art. It is appreciated that non-metallic enclosures may also be provided in other embodiments.

Particularly for metal enclosures, however, applicable electrical standards, such as Underwriter's Laboratories (U.L.) Standards 67, 98 and 508 requires a minimum separation, gap or clearance, designated as D inFIG. 6, between an upper surface of the circuit protectors380A,380B, and380C and an inner surface of the lid390. The minimum clearance D is provided for safety reasons between conductive portions of the circuit protectors380and the grounded metal surfaces of the lid390. The spacing D that is required by such standards is dependent on the voltage rating of the circuit protectors380, and exemplary values of D according to exemplary standards and voltage ratings are set forth below in Table 1.

The module350shown inFIG. 5, for example, is generally ill equipped for use on a circuit protector380in the enclosure382because a height of the module350when connected to the circuit protectors380would extend well beyond the clearance D that is provided in the enclosure382. The module350would therefore interfere with and/or prevent the lid390from closing. Especially when the enclosure382is provided to protect the circuit protectors380from harsh operating environment that could impair the operation and reliability of the circuit protectors380if they were otherwise exposed, any interference with proper closing of the lid390is undesirable. Different modules384, shown in phantom inFIG. 1, that have a lower profile to fit within a relative small clearance D are therefore needed.

FIG. 7illustrates a circuit protector monitoring assembly392including a module384and a circuit protector380. Like the modules described above, the module384may include a nonconductive housing394that may be provided with a sensor board, and optionally may be provided with a communications board if the module384is configured as a communications module. Also like the modules described above, the module384may include contact arms (not visible inFIG. 7) that establish a parallel electrical connection to the conductive terminal elements396of the circuit protector380so that the operating state of the circuit protector380may be monitored, and a mounting element398that allows for retrofit installation to the circuit protector380with, for example, snap-fit engagement that does not require tools.

Unlike the module350shown inFIG. 5, for example, the module384has a relatively low profile height H measured from an upper surface of the circuit protector. The low profile height H is generally less than the clearance D shown inFIG. 6so that the module384may occupy and fit within the clearance D above the circuit protector within the enclosure382(FIG. 6) without interfering with the lid390(FIG. 6). That is, considering the values of Table 1, for example, H in an exemplary embodiment may be selected to be generally less than 1 inch to satisfy applicable standards. To achieve the low profile H, and also to facilitate signal transmission from inside the enclosure382, an antenna397projects outwardly from the housing194and extends along a generally linear axis399that is parallel to the longitudinal axis400of the circuit protector380. The parallel axes399,400of the antenna397and circuit protector382provides for a height reduction in the dimension H as compared to embodiments, for example, wherein the antenna axis and the circuit protector axis are perpendicular.

As best shown inFIG. 8, the housing394may further be provided with a non-conductive touch safe cover portion402proximate to but spaced from the circuit protector380. The touch safe cover portion402may be substantially rectangular and may generally extend well beyond the longitudinal length and lateral width of the circuit protector380, thereby providing a relatively large surface area overlying the circuit protector380. The cover portion402may be a generally planar member as shown, and may extend generally parallel to the axis400of the circuit protector380. The larger surface area of the touch safe cover portion402prevents a user from inadvertently contacting conductive portions of the circuit protector380and provides a degree of safety in that a human may safely touch the module housing394and the cover portion402generally without risk of electric shock. The cover portion402may be sized and dimensioned to extend across all open areas in the compartment388of the enclosure382(FIG. 6) so that no energized components are exposed and accessible when the enclosure lid390is opened. As illustrated inFIG. 8, the cover portion402may be provided with one or more ventilation openings406to facilitate airflow to the circuit protector380in use.

The module384may also be provided with a cover408that is positionable relative to the housing394to provide access to interior portions of the module384. As shown inFIG. 8, a light pipe410may extend through the surface of the cover408for local fuse identification of the circuit protector state, and a switch actuator412such as a push button may extend through the cover408. The light pipe410may provide for transmission of light from an illuminated LED on a circuit board internal to the module384. The actuator412may control a switch for module testing or reset purposes. Additionally, fasteners such as set screws414may securely retain the cover408to the housing394in a closed position.

FIG. 9illustrates the cover408in an open position wherein the set screws are released and the cover408is rotated about a hinge416at one end thereof. When so opened, the cover408provides clear access to an interior418of the housing394. As shown inFIG. 9, a communications board420may be located just beneath the cover408, and the communications board420may include a processor and a transmitter (not visible inFIG. 9), and multiple batteries422powering the processor and the transmitter. The batteries may be connected in parallel to collectively power the communications board420, and the batteries420are positioned so that they are fully accessible for replacement once the cover408is opened.

In an exemplary embodiment, each of the batteries may be a BR1225 Poly-carbonmonofluoride Lithium Coin Battery, manufactured by Panasonic Corporation of Secaucus, N.J. having an overall thickness measured in a generally perpendicular direction from a surface of the board420of about 2.5 mm, and an overall diameter of about 12.5 mm. The relatively small size of the batteries in part provides for a compact size of the housing394that allows the module384to fit in the clearance D (FIG. 6) of the enclosure382. As illustrated inFIG. 8, the batteries422may be arranged side-by-side in a generally coplanar relationship to the surface of the board420, allowing for the low profile height H (FIG. 7).

An insulative battery tab424fabricated from a polyethylene film or other equivalent materials may be provided that prevents electrical connection of the batteries422to the board420unless removed by a user. The module384may accordingly be packaged and shipped with the batteries installed to a site of installation without risk of the batteries draining.

FIG. 10illustrates additional aspects of the module384, and in particular illustrates the antenna construction. As shown inFIG. 10, a helical antenna430may extend from an end of the communications board420. The helical antenna430extends for a number of turns along the axis399(FIG. 7) and in one embodiment is a ⅛ wave guide antenna. The antenna430may be fabricated from brass spring temper wire in a known manner, and provides for an increased signal transmission and reception capability in a smaller physical space than other known, non-helical antenna constructions. A protective shroud or shield432may be fabricated from plastic or another non-conductive material and fitted over the antenna430to prevent accidental contact with the antenna430that may damage it. The shield432, however, does not physically touch the antenna430and does not affect its signal transmission capabilities.

FIG. 11illustrates the module384with the communications board420(FIGS. 9 and 10) removed. A sensor board440may be located beneath the communications board in the housing394. The board440may include voltage sensing circuitry and the like that may include an optoisolator442for example. In such an embodiment, the sensor board440may include first and second portions optically isolated from one another. More specifically, the sensor board440may include high voltage portions444at each opposing end that interface with the terminal elements396of the circuit protector380at voltages up to 600V, for example. Meanwhile, a low voltage portion446of the board440extends between the high voltage portions and operates at comparatively lower voltage of 3V, for example. To facilitate isolation of the high and low voltage portions444and446of the sensor board, electrical insulation materials448, such a silicon caulking, may be provided on the surface of the board at its end portions. For example, GE 162 electrical grade silicon caulk, a caulk such as a Loctite 5088 compound, or equivalent materials may be utilized. Alternatively, conformal coatings or potting compounds applied to substantially the entire board may be utilized.

When the circuit protector380operates to interrupt the current path through the circuit protector380, which may arise through operation of a fuse element in the circuit protector380, a voltage drop across the terminal elements396may be detected, causing the optoisolator442to latch high, ultimately resulting in an input signal to the communications board420for wireless transmission to a remote location.

The sensor board440and the communications board420may be generally parallel to one another and may extend parallel to the axis400(FIG. 7) of the circuit protector380. That is, the major surfaces of each board440and420extend generally perpendicular to the dimension H (FIG. 7) such that only the thickness of each board, as opposed to the dimensions in the plane of each board, contributes to the height H of the module384as it is assembled. Also, the plane of the circuit boards440and420extend parallel to the cover408on the top of the module384and perpendicular to the side walls of the module housing394that extend in the direction of dimension H. The parallel boards when stacked in such a manner offer considerable reduction in the dimension H in comparison to the module350ofFIG. 5, for example, wherein the major surfaces of the circuit boards are oriented vertically rather than horizontally as in the module384.

It is anticipated that signal ports and interface plugs may be utilized to connect multiple modules384to one another as described above in relation toFIGS. 3 and 4if desired. Thus, the modules384may be configured as sensor modules or communication modules. In the case of sensor modules, for example, the communications board, or some of the components thereof such as the transmitter and the antenna may not be required and may be omitted.

FIG. 12is a perspective view of another embodiment of a monitoring module460that, instead of directly attaching a circuit protector, may be attached to a DIN rail upon which a circuit protector may be mounted.

The module460may include a nonconductive housing462that may be provided with a sensor board, and optionally may be provided with a communications board if the module384is configured as a communications module. The housing462may be formed with a DIN rail slot464for mounting of the module460on the DIN rail. The DIN rail slot464may dimensioned for insertion onto, for example a 35 mm DIN rail known in the art. Panel mounting flanges473are also provided in either side of the housing462for alternatively mounting the module to a panel using known fasteners. Box lugs466may also be provided in the housing462that accept, for example, stripped ends of connecting wires. Using the box lugs466, the module460may be connected in parallel to an existing circuit protector.

Additionally, and as illustrated inFIG. 12, the side edges468of the housing462may include opposed pairs of vertically oriented flanges470spaced from one another and projecting away from the box lugs466. The flanges470, sometimes referred to as fins or wings, provide an increased surface area of the housing462in a horizontal plane extending between the between the box lug terminals466on the opposing side edges468of the housing462than would otherwise occur if the flanges470were not present. That is, a peripheral outer surface area path length extending in a plane parallel to the lower DIN rail slot464includes the sum of the exterior surface dimensions of one of the pairs of flanges470extending from one of the lugs466, the exterior dimensions of the respective front or rear panel472,474of the housing462, and the exterior surface dimensions of the opposing flanges470extending to the opposite lug466.

FIG. 13is a side sectional view of the module460wherein the box lugs466are depicted in more detail. The lugs define access ports480that receive ends482of connecting wires484. Opposing ends of the wires484are connected to the terminals T1and T2of a circuit protector486that may be an overcurrent protection fuse to connect the circuit protector486in parallel with the circuit protector380. Box clamp terminals488are provided in each box lug466and set screws in the terminals may be turned to retain or release the wire ends482from the terminals488.

Connecting terminals490are also provided in each box lug466to complete electrical connections between the wire ends482and the sensor board440. The sensor board440, the communications board420, the antenna397and the cover408are provided substantially as described above with similar benefits. The sensor board440extends generally parallel to the DIN rail slot464and the radio board extends generally parallel to the sensor board440, resulting in a relatively compact and low profile arrangement in contrast to, for example the module350ofFIG. 5wherein the circuit boards vertically arranged.

It is anticipated that signal ports and interface plugs may be utilized to connect multiple modules460to one another as described above in relation toFIGS. 3 and 4if desired. Thus, the modules460may be configured as sensor modules or communication modules. In the case of sensor modules, for example, the communications board, or some of the components thereof such as the transmitter and the antenna may not be required and may be omitted.

Using the modules316,350,384and460described above, versatile, relatively low cost, expandable and adaptable circuit protector monitoring systems are provided that may be retrofitted to existing electrical systems without modifying the electrical system and infrastructure. It is understood, however, that in future equipment, or perhaps for smaller electrical systems, the monitoring, communications, and management components could be built-in to the electrical system and circuit protector products themselves.

While the foregoing embodiments of modules and circuit protectors108are described in the context of fuses, similar technologies and methodologies could be employed with other types of circuit protectors such as, for example, circuit breakers and switches to detect operation of the devices to more efficiently locate and reset tripped breakers and opened switch paths, as well as to facilitate monitoring, diagnostics and troubleshooting of the electrical system.

D. The Signal Transmission System

FIG. 14schematically illustrates an exemplary signal transmission system580for use with the circuit protector management system112shown inFIG. 1and the method130shown inFIG. 2. A plurality of circuit protector panels104are distributed throughout the electrical system, and each circuit protector panel104in the electrical system that is to be monitored includes, for example, a monitoring assembly such as those described above for transmitting data signals corresponding to the operational state one or more circuit protectors, such as fuses, in the panels104. In the manner described above, the modules316,350,384and460may generate a wireless data signal or data packet when one of the fuses associated with the monitoring assemblies opens.

The wireless data signals from the modules316,350,384and460(collectively designated as316inFIG. 14) may be received, for example, by one or more repeater/router elements582located within the transmission range of the communications module transmitter340. In an exemplary embodiment, the repeater/router elements582may be wireless, radio frequency transmission devices or equivalent devices that receive, for example, a digitally transmitted RF data signal from the communications modules and forward the data signal to a signal collection and conditioning device, referred to herein as a gateway device584. The gateway device is, in turn, in communication with the overview and response dispatch system118. Alternatively, the repeater/router elements582may be another electronic device that functions to feed transmitted data from the one of the communications modules316,350,384and460to the gateway device584. For example, USB, serial port connections or other connection means and their equivalents may be utilized to interconnect the repeater/router elements582and the gateway device584.

In an exemplary embodiment, a plurality of repeater/router elements582are provided around and about the various panels104, and the repeater/router elements582form a mesh network defining multiple signal paths to forward signal transmissions from the communication modules to a single gateway device584in communication with the overview and response dispatch system118. Repeater/router elements582and mesh network configurations are commercially available from, for example, RF Monolithics, Inc. of Dallas, Tex. Many different mesh topologies are known and may be employed, including but not limited to star configurations, ring configurations, cloud configurations, linear configurations and the like. The mesh network may be algorithmically based and configured to meet specific needs for specific installations.

The network of repeater/router elements582in one embodiment is self-configuring and self healing with autorouting and rerouting capability as the network changes, and is highly scalable wherein thousands of circuit protectors may be monitored in the circuit protector management system112. Considering that the various panels104may be located in different locations, and even in different buildings, the management system112is versatile and adaptable to existing electrical systems100, and is accommodating to addition or subtraction of additional electrical loads and circuit protectors in the electrical system.

While a plurality of repeater/router elements582are illustrated inFIG. 14, it is understood that as few as one repeater/router element582could be provided in an alternative embodiment. Likewise, more than one gateway device584could be employed if desired.

The gateway device584may be a network based computer server system, a personal computer, a computer workstation, a programmable logic controller or other electronic controller, a processor-based hand held device or another electronic device or equivalent thereof that may receive, condition, process or interpret signals from repeater/router elements582, and communicate the signals to the overview and response dispatch system118.

FIG. 15schematically illustrates the signal transmission system580providing data communication between the repeater/router elements582and the overview and response dispatch system118via the gateway device584.

As shown inFIG. 15, the gateway device584may be an embedded computer device including a receiver588for receiving, for example, wireless data transmission from the repeater/router elements582when one or more of the status elements, such as the monitoring modules304described above signal the repeater/router elements582of an operated circuit protector that has isolated portions of electrical circuitry in an electrical system. The receiver588may be a part of the gateway device584or may be separately provided and interfaced with the gateway device584to receive incoming signal transmissions from the repeater/router elements582.

Data packets may be transmitted repeatedly from the circuit protector monitoring assemblies and/or the repeater/router elements582within specified time periods to ensure that the data packets are completely received, processed, and optionally acknowledged by a gateway device584and/or the overview and response dispatch system118. Repeated transmission of data signals avoids collision of signals when more than one of the circuit protectors operates at approximately the same time. Also, the repeater/router elements582may add a routing code, a time stamp or other information to the data packet so that the overview and response dispatch system118may monitor the communication system and signal path between the monitoring modules and the overview and response dispatch system118.

As shown inFIG. 15, the gateway device584includes gateway application software590for processing incoming data signals through the repeater/router elements582. The gateway application software may be implemented on, for example a Linux, UNIX or Windows-based operating system and equivalents thereof as those in the art will appreciate.

The application software590may include, for example, configuration and monitoring algorithms592and interactive graphic user displays for assisting the monitoring assembly installers and system or site technicians594with setting up, testing and troubleshooting the communications between the status elements, the repeater/router elements582and the gateway device584. The installers or technicians594may be logged on to the gateway device584at a remote location from the gateway device through, for example, a web server596connected to the gateway device584, or installers or technicians may work directly with a local user interface associated with the gateway device584itself. More than one installer or technician could log on to the gateway device584for access to the application software590to supply and receive necessary information to install, maintain, or modify the configuration of the monitoring components and the signal transmission components associated with circuit protectors.

Using the configuration and monitoring algorithms592and interactive graphic user displays, status elements and repeater/router elements may be deemed, considered, determined or identified by the system according to an operating mode thereof. For example, applicable monitoring modes for the status elements may include a “registered” status wherein the status elements are authorized and compatible with the gateway device; a “discovered” status wherein the status element is installed but not activated to communicate with the management system; an “activated” status wherein the status elements are associated with a specific circuit protector and communicating with the management system; a “suspended” status wherein the status element has been caused not to function; a “deactivated” status wherein the element is uninstalled and not associated with any circuit protector; or an “offline” status wherein the status element is activated but not reporting to the management system112. The signal transmission components, including but not limited to the repeater/router elements582, may likewise be designated and identified by the management system.

Additional characterization, grouping, or labels of the status elements for the circuit protectors may be provided for informational purposes to provide an overview of the entire management system and status of the monitoring and signal transmission components as the system is expanded, contracted, or changed in use, and as more electrical loads or configuration of the electrical system are changed or adapted over time. The operating modes may be automatically detected by the gateway device584, or may be manually entered by installers, technicians, and service personnel for the status elements. The gateway device584may therefore intelligently manage the addition or subtraction of circuit protector status elements and repeater/router elements582to and from the circuit protector management system112.

Timestamp alert algorithms598and associated displays may also be included in the application software590for inspection and maintenance purposes wherein the communications systems between the status elements, the repeater/router elements582and the gateway device584are periodically verified to ensure operation of the monitoring and communication components in the circuit protector management system112. As one example, the circuit protector status elements and/or the repeater/router elements582may be programmed to communicate or report with the gateway device584on a periodic basis or interval, sometimes referred to as a watchdog interval, and the gateway device584, through the application software590, could monitor the operating status or health of the management system by comparing signals received from the status elements and the repeater/router elements with information entered into the system, via the configuration and monitoring algorithms and displays592, of the status elements and repeater/router elements known to be in the circuit protector management system112. If, for example, one of the repeater/router elements582or one of the circuit protector status elements does not report in a predetermined time frame, an error flag may be set and alert may be generated to the installer/site technician594, either directly from the gateway device584or indirectly through the overview and response dispatch system118. The timestamp alert algorithms598and the configuration and monitoring algorithms592may then be accessed by site technicians594to diagnose and troubleshoot the circuit protector management system112.

Data reduction algorithms600may be included in the application software590for processing signal transmissions from the repeater/router elements582before communicating with the overview and response dispatch system118. For example, the gateway device584may filter incoming data signals and identify duplicate signal transmissions that may occur, for example, when more than one of the repeater/router elements582transmits the same signal to the gateway device, or as another example, when the same status element signals the repeater/router elements582more than once to avoid for example, collision of data signals. Duplicate signals may be discarded or deleted by the gateway device584prior to communicating signals to the overview and response dispatch system118.

The data reduction algorithms600may also reduce or eliminate information from the data signals that are not necessary for the overview and response dispatch system118functionality. For example, messaging protocol information pertinent to the radio frequency transmission of the data signals but not pertinent to the network messaging protocol for communication with the overview and response dispatch system118, may be stripped, eliminated, or deleted from the data signals before transmission to the overview and response dispatch system118.

Data logging algorithms602and associated displays may also be included in the gateway application software590for supplying and receiving information and data and generating reports of management system activity. Such information and reports, as explained above, could be a useful tool for proactive management of an electrical system to identify issues in the electrical system that may cause operation of one or more circuit protectors to isolate portions of the circuitry, and perhaps allow for technicians594to take steps to control and manage the electrical system in a way that opening of the circuit protectors is avoided altogether, which is especially advantageous in critical applications, such an electrical system for a hospital.

The data logging algorithms602and displays could also be used to initiate special procedures responsive to real time operation of the electrical system, such as shutting down certain machines or portions of the circuitry at high risk when one or more of the circuit protectors operates. Such procedures may be particularly appropriate, for example, when one phase of a three phase electrical power supply becomes isolated or interrupted due to an operated circuit protector, and a machine or load is temporarily powered by only two phases of electrical current.

Each of the configuration and monitoring algorithms592, the timestamp alert algorithms598, the data reduction algorithms600and the data logging algorithms602are interconnected with a database604or memory storage medium needed to store inputted, collected, and received data, operating parameters and settings, and the machine readable operating software codes and algorithms, etc. that the gateway device584may require.

A communications interface606, a communications driver608, and interface drivers610may also be provided in the gateway application software590to provide communication between operative components in the circuit protector management system112.

The gateway device584may also perform authentication, verification, or security algorithms to ensure the integrity of the management system communications, as well as perform diagnostic, testing, and troubleshooting procedures to ensure proper installation and operation of the circuit protector status elements and repeater/router elements582in the overall circuit protector management system112.

In an exemplary embodiment, a portal monitoring and communications application612may be provided for further processing of data signals to convey information to the overview and response dispatch system118. The communications application612may include protocol algorithms614to convert message data from the incoming radio frequency data transmission protocol, for example, to a preferred network messaging protocol, including but not limited to HTTPS, SOAP, and XML protocols and their equivalents known in the art, and internet protocol algorithms616for transmitting the network messaging protocol data packets to the remote overview and response dispatch system118via, for example, an Ethernet connection618.

In an exemplary embodiment, the incoming radio frequency data protocol is a byte oriented protocol having multiple bits representative of information of interest. For example, the status elements may transmit digital data signals including bits corresponding to 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, and state parameter codes such as testing codes, faults codes, and codes pertaining to operating conditions of the circuit protector and/or circuitry associated with the status elements. The data signals may also include codes relating to the ambient environment of the circuit protector or the associated electrical system and loads, such as temperature codes, vibration codes, displacement codes, mechanical stress codes, mechanical strain codes, acoustical emission codes, noise codes, thermal imagery codes, electrical resistance codes, pressure codes, humidity codes and video surveillance codes.

The repeater/router elements582may add bits to the signal protocol corresponding to a serial number of the respective repeater/router element, a device type code for the repeater/router, a wireless address for the repeater/router, a data packet sequence number, a location code for the repeater/router, and state parameters pertaining to operating conditions of the repeater/router elements.

The gateway device584converts the radio frequency transmission protocol to a second, and different messaging protocol for transmission to the overview and response dispatch system118. The second message protocol may also be byte oriented and include bits corresponding to the unique radio identifier, a serial number of an operated circuit protector, a device type code for the operated circuit protector, a location code for the operated circuit protector, a wireless address, an IP address for the gateway device, a time/date stamp, a software revision code for the gateway application software and/or the communications application loaded on the gateway device, a hardware revision code for the gateway device, a packet count, an error count, and a predetermined number of error codes. When received by the overview and response dispatch system118, the gateway data message can be used to quickly determine operation of the circuit protectors, locate operated circuit protectors in the electrical system, and notify and summon responsible personnel and technicians for quickly re-energizing downed circuitry. Furthermore, all of the codes and data relating to signal events in the system are logged for future use, retrieval, study and analysis to evaluate the performance of the overall circuit protector management system112.

While some exemplary message codes have been described, it is understood that other types of codes, information and data representative of circuit protector products and operating status may be included in alternative embodiments, and it is also recognized that less than all of the exemplary protocol bits and codes could be used in other embodiments of the signal transmission system580. Implementation of the message protocols may be conventionally provided and is not specifically described in further detail herein.

The gateway application software590and the communications application612may run on a known operating system620loaded on the gateway device584, including but not limited to Windows, PocketPC, and Linux operating systems and their equivalents known in the industry. Having now described the various operating algorithms functionally, programming of the modules to operate in the manner described may be conventionally provided by those in the programming arts without further explanation.

In an exemplary installation, the gateway device584may be located at the electrical system site, and the overview and response dispatch system118may be located remotely, although the overview and response dispatch system118could be located at the site of the electrical system as well.

FIG. 16is a flowchart of a method630executable by the gateway device584in an exemplary embodiment. The gateway device584awaits signals from the repeater/router elements, and receives the signals632in any manner described above. Data reduction is performed634on the incoming signals in the manner described above, and the incoming message protocol is converted636to a second message protocol, different from the incoming message protocol. Once the message protocol is converted636, the gateway device communicates638the converted data message to the remote overview and response dispatch system118for action or attention in the manner described above.

As appropriate or as needed, the gateway device runs640the configuration and monitoring algorithms and runs642the timestamp algorithms as described above. If an error is detected644, the gateway device may notify646a technician and perform data reduction procedures634to prepare to send an error signal to the overview and response dispatch system. If an error is not detected644during the time stamp algorithms and procedures, the gateway devices reverts to a dwell state until another message is received632from the repeater/router elements.

Optionally, incoming messages may be authenticated648or other verification and security algorithms and procedures may be implemented to ensure the integrity of the system communications. Data logging procedures are run650as needed during operation of the gateway device584, and data may be accessible by or be communicated to the remote overview and response dispatch system as desired.

FIG. 17schematically illustrates the signal transmission system580connected to an electrical system100and the management system112. The electrical system100includes a power supply or power supply circuitry102connected to multiple circuit protectors such as fuses302in a circuit protector panel104. Each of the fuses302is associated with a sensor module or a communications module in accordance with one of the foregoing embodiments, and each of the fuses302is connected to an electrical load106. The interface plugs318interconnect the sensor modules314to one another and to one of the communication modules in the manner described above. Due to the interconnection of the sensor and communication modules, when any of the fuses302operates to isolate any of the loads106, a data packet is presented to the transmitter340of the associated communication module, and a wireless signal660is transmitted by the communications module. The wireless signal660is received and forwarded by at least one of the repeater/router elements582to the gateway device584. The gateway device584, protected by a firewall586, then communicates the information to the overview and response dispatch system118.

The management system112includes the overview and response dispatch system118, a user interface or display662connected to the overview and response dispatch system118, and may be in communication with the inventory management system120for automatic ordering of replacement fuses. A memory or database664may also be provided to log system activity and store needed information for the overview and response dispatch system. For example, the database664may be used to decode incoming data packet transmissions from the gateway device584, and the user interface662may be used to present information to responsible personnel in tabular and graphic form with menu-driven displays described below. The database664may also be used for storage and retrieval of contact information for locating and summoning maintenance personnel.

FIG. 18is an exemplary site diagram of an electrical facility680housing an electrical system having many circuit protectors302to be monitored in various panels104in the facility680. Monitoring modules, whether communication modules or sensor modules as described above, are associated with circuit protectors such as fuses302scattered throughout the facility680. A number of repeater/router elements582are also strategically located in different locations in the facility680within the operating range of the monitoring modules, and specifically the communications modules. The repeater/router elements582, in turn, are in communication with a centralized gateway device584that communicates with the overview and response dispatch system118at a remote location via, for example, the Internet.

AsFIG. 18demonstrates, the management system can efficiently monitor a large number of fuses302, and as the size and complexity of the facility680increases, the system is readily adaptable by adding additional monitoring modules304and repeater/router elements582. The overview and response dispatch system118directly interacts with facilities management to provide real time system performance data and immediate information so that downed circuitry may be re-energized as quickly as possible.

FIG. 19further illustrates additional features of the management system shown inFIGS. 17 and 18in one implementation thereof. The fuse monitoring modules304, which may be any of the modules described above, are interfaced with a network690of repeater/router elements582that are, in turn, interfaced with the gateway device584. The gateway device584may be connected to local network interfaces and process monitoring interfaces of, for example, the facility680. The portal communications application612of the gateway device584, implemented in software or machine readable code, processes incoming signals from the repeater/router network690. After processing by the portal communications application612, the gateway device584communicates with the Internet via an Ethernet connection618and ultimately with the overview and response dispatch system118. In response to communications from the gateway device584, the overview and response dispatch system118communicates with responsible personnel for the electrical system through the Internet and communication towers692, for example, to contact designated personnel by phone694, pager696, facsimile698, email700, or via a customer web site to provide direction and information regarding operated circuit protectors and re-energizing circuitry.

The systems and processes described above are not limited to the specific embodiments described herein. Components of each system and each process can be practiced independent and separate from other components and processes described herein. Each component and process also can be used in combination with other components, systems and processes.

For example, while the communication modules802are described as being adapted for retrofit installation to existing circuit protectors, the functionality of the communication modules802could alternatively be built-in to circuit protector panels or other infrastructure, or into the circuit protectors themselves in other embodiments. Also, while the sensor and communication modules are described and illustrated for use with fuses, other types of circuit protectors providing overvoltage, overcurrent, overload, and short circuit protection, for example, may be monitored with appropriate modification of the modules.

Also, the foregoing circuit protector communication modules802and the monitoring and management system112may be implemented in whole or in part to meet the needs of a particular electrical system100or for cost management reasons. In other words, the communication modules802and the management system112need not include all of the described components, or perform all of the described functions set forth above.

As still another example, the communication modules802and the management system112could identify and determine operational status and data regarding the circuit protector and circuitry and communicate and transmit data to the overview and response dispatch system118, but not communicate with an inventory management system.

It should now be apparent that the system components may be mixed and matched to generate varying systems which obtain the benefits of the present invention to varying degrees.

An embodiment of a circuit protector monitoring assembly is disclosed herein. The assembly comprises at least one circuit protector defining an interruptible current path therethrough upon an occurrence of specified current conditions through the interruptible current path; a status element connected in parallel with the circuit protector and adapted to sense an operating state of the current path and wirelessly transmit information regarding the operating state of the current path, the information including a circuit protector identifier and a circuit protector location; and the status element comprising a housing and an antenna projecting from the housing.

Optionally, the status element may occupy a clearance above the circuit protector that is generally less than one inch. The antenna may comprise a helical antenna. The circuit protector may have a longitudinal axis, and the antenna may extend generally parallel to the longitudinal axis. The circuit protector may be located in an enclosure having a lid, with the status element fitting between the circuit protector and the lid. The status element may comprise multiple batteries connected in parallel, with the batteries generally positioned in a plane extending parallel to the longitudinal axis. The status element may comprise a battery tab preventing electrical connection of the batteries.

Also optionally, the status element may comprises a housing and a hinged cover mounted to the housing. The housing may comprise a fin increasing a surface area of the housing. A touch safe cover portion may extend from the housing, and the cover portion may comprise at least one ventilation opening. The housing may also comprise a DIN rail slot. The status element may comprise a monitoring module mechanically and electrically connected to terminal elements of the circuit protector at a location exterior to the circuit protector, with the module adapted for retrofit installation to the circuit protector. The circuit protector may comprise a fuse, with the status element transmitting data related to operation of the fuse, and 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 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. The status element may also comprise a circuit board interfacing a high voltage portion and a low voltage portion, and silicon caulking insulating and isolating the high voltage portion from the low voltage portion.

Another embodiment of a circuit protector monitoring assembly is also disclosed herein. The assembly comprises an enclosure and a lid collectively defining a closeable container for at least one circuit protector; at least one circuit protector situated within the enclosure and defining an interruptible current path therethrough upon an occurrence of specified current conditions through the interruptible current path; a status element connected in parallel with the circuit protector and adapted to sense an operating state of the current path and wirelessly transmit information regarding the operating state of the current path, the information including a circuit protector identifier and a circuit protector location; and the status element occupying a clearance between the circuit protector and the lid.

Optionally, the clearance between the circuit protector and the lid is generally less than one inch. The status element may comprise a housing and an antenna projecting from the housing. The antenna comprises a helical antenna. The circuit protector may have a longitudinal axis, with the antenna extending generally parallel to the longitudinal axis. The status element may comprise multiple batteries connected in parallel, with the batteries generally positioned in a plane extending parallel to the longitudinal axis. The status element may further comprise a battery tab preventing electrical connection of the batteries. The module may comprise a housing and a hinged cover mounted to the housing. The housing may comprise a fin increasing a surface area of the housing. The status element may comprise a touch safe cover portion extending from the housing, and the cover portion may comprise at least one ventilation opening. The status element may comprise a monitoring module mechanically and electrically connected to terminal elements of the circuit protector at a location exterior to the circuit protector, with the module adapted for retrofit installation to the circuit protector.

Also optionally, the circuit protector may comprise a fuse, with the status element transmitting data related to operation of the fuse, and 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 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. The status element may comprise a circuit board interfacing a high voltage portion and a low voltage portion, and silicon caulking insulating and isolating the high voltage portion from the low voltage portion.

Another embodiment of a circuit protector monitoring assembly is also disclosed herein. The assembly comprises: at least one circuit protector defining an interruptible current path therethrough upon an occurrence of specified current conditions through the interruptible current path; a status element connectable in parallel with the circuit protector and adapted to sense an operating state of the current path and wirelessly transmit information regarding the operating state of the current path, the information including a circuit protector identifier and a circuit protector location; and the status element comprising a housing defining a DIN rail slot, and a sensor board extending generally parallel to the DIN rail slot.

Optionally, the sensor board may comprise a high voltage portion and a low voltage portion, and silicon caulking insulating and isolating the high voltage portion from the low voltage portion. The status element may further comprise a radio board, with the radio board extending generally parallel to the sensor board. The status element may comprise an antenna projecting outwardly from the housing, and the antenna may extend generally parallel to the DIN rail slot. The status element may comprise multiple batteries arranged in a plane extending generally parallel to the DIN rail slot. A hinged cover may be mounted to the housing of the status element.