System and method to automatically configure a component of the system

A system and method for automatically configuring a component, such as an MCC cell), of the system includes the component, which further includes a module having storage, and a data concentrator device that is in communication with the component. The data concentrator device is in communication with a database, which may be a local ID database or a master ID database. The module stores a unique configuration code that is provided to the data concentrator device. The data concentrator device determines whether the database stores configuration information for the module that corresponds to the unique configuration code. The data concentrator device accesses the configuration information and uses it to automatically configure the component.

BACKGROUND

The disclosed concept pertains generally to systems and, more particularly, to systems, such as, for example and without limitation, motor control center (MCC) systems that include MCC cells that require configuration. The disclosed concept also pertains to methods of automatically configuring components of systems.

2. Background Information

Known motor starters, load monitoring relays and other components of motor control centers (MCCs) are configured by manually selecting parameters (e.g., manually from a component user interface or manually from a user interface of a processor or other component configuration device) for each component type. Hence, manually induced errors can and do occur.

U.S. Pat. No. 5,225,987 discloses a generic tool that is a set of software groups and subgroups specifying at each stage the elements to be manipulated and assembled within a theoretical global vertical structure. The generic tool is, thus, an abstract complex configuration representing an assembled product in its broadest spatial, structural and functional sense and it allows, for each particular application, the system to be narrowed down by calling specific features as needed at the in-plant order level. More generally, this is applicable to a machine; to a mechanical, or electrical, apparatus or system; to panel boards, switchboards, or motor control centers; to a warehouse and its stored articles; to office furniture at the supply, or at the demand end; to marketing and sales for negotiation; to a plurality of consulting advices or requests; and the like.

There is room for improvement in systems that configure system components.

There is also room for improvement in methods of configuring components of systems.

SUMMARY

These needs and others are met by embodiments of the disclosed concept, which determine if a unique configuration code for a component of a system is in a database, and responsively input configuration information from the database and automatically configure the component with the configuration information.

In accordance with one aspect of the disclosed concept, a system to automatically configure a component of the system from a database operatively associated with the system comprises: a number of components, each of the number of components comprising: a module having a unique configuration code, and a first communication interface; and a processor comprising: a second communication interface structured to communicate with the first communication interface, an interface to the database, and a routine structured to input the unique configuration code from the module, determine if the unique configuration code is in the database, and responsively input configuration information from the database and automatically configure a corresponding one of the number of components with the configuration information.

The database may be a main database; the processor may further comprise a local database operatively associated with the number of components; and the routine may be further structured to input the unique configuration code from the module, determine if the unique configuration code is in the local database, and responsively input configuration information from the local database and automatically configure the corresponding one of the number of components with the configuration information from the local database.

As another aspect of the disclosed concept, a method of automatically configuring a component of a system from a database operatively associated with the system comprises: employing the system comprising a number of components, each of the number of components comprising a module having a unique configuration code; inputting the unique configuration code from the module; and determining if the unique configuration code is in the database, and responsively inputting configuration information from the database and automatically configuring a corresponding one of the number of components with the configuration information.

The method may employ the database as a main database; operatively associate a local database with the number of components; input the unique configuration code from the module; and determine if the unique configuration code is in the local database, and responsively input configuration information from the local database and automatically configure the corresponding one of the number of components with the configuration information from the local database.

The method may employ a look-up table operatively associated with the database; and determine if the unique configuration code is in the look-up table before responsively obtaining the configuration information from the database and automatically configuring the corresponding one of the number of components with the configuration information.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As employed herein, the term “processor” shall mean a programmable analog and/or digital device that can store, retrieve, and process data; a computer; a workstation; a personal computer; a microprocessor; a microcontroller; a microcomputer; a central processing unit; a mainframe computer; a mini-computer; a server; a networked processor; a data concentrator; a programmable logic controller (PLC); or any suitable processing device or apparatus.

As employed herein, the terms “configuration information” or “configuration parameters” shall mean information employed to either configure a memory or other electronic storage device of an installed component of a system, or to monitor and/or maintain such installed component of a system. The terms “configuration information” or “configuration parameters” expressly exclude information employed to physically install a component in a system.

As employed herein, the term “unique configuration code” means being the only one used anywhere for a particular type of component. For example, a unique configuration code may be duplicated for multiple copies of the same type of component at a number of customer sites. As a further more specific example, a particular motor starter type having a common set of configuration parameters can be duplicated to provide the same application for one or more customers.

Referring toFIG. 1, a system2includes a number of databases4,6, a number of components, such as the example motor control center (MCC) cells8,8A,8B, switchgear8′ and motor starter8″, and a processor, such as the example data concentrator10. As will be explained, the system2automatically configures the MCC cells8,8A,8B from one of the databases4,6operatively associated with (e.g., without limitation, the database4is in communication with the data concentrator10of the example system2; the database6is part of the example system2) the system2. As best shown inFIG. 2, each of the example MCC cells8,8A,8B and switchgear8′ includes a module, such as12,12A,12B,12C, having a unique configuration code, such as the example configuration ID (CID)14, and a first communication interface16. The motor starter8″ includes a motor starter module12′. The data concentrator10includes a second communication interface18structured to communicate with the first communication interface16, an interface20to the database4(FIG. 1), and a routine22(shown inFIG. 3) structured to input the CID14from the module12, determine if the CID14is in the database4, and responsively input configuration information24from the database4and automatically configure the corresponding MCC cell, such as8, with the configuration information24.

The disclosed concept is described in association with the example system2being a motor control center (MCC) and the plurality of MCC cells8,8A,8B being smart MCC motor starters, although the disclosed concept is applicable to a wide range of systems having a wide range of any number of suitable components. For example and without limitation, the disclosed concept may find applicability in other power connectivity configurations, adapted or apart from MCCs. A non-limiting example of supply power commonly used in MCCs is 480 V three-phase alternating current (AC) power distributed over three separate supply bus bars. In addition, references to MCC components shall be understood to include the various types of devices and control components which may be housed in a MCC bucket or cell for connection to the supply power. Such devices and components include, for example and without limitation, contactors, relays, motor controllers, disconnects, and circuit protective devices. Alternatively, the system2may be switchgear on a custom motor control panel.

As a further non-limiting example, the number of components can include motor starters, switchgear, circuit interrupters, and feeders.

The interface20to the database4can be, for example and without limitation, a global communication network, such as the Internet, or a non-volatile memory (e.g., without limitation, a CD; a USB memory device). The main database4can be a global database for all components supplied by a particular vendor or marketing channel, such that each of those components is identified by a unique configuration code.

The module12can be a smart motor starter module including an input/output (IO) module33in which the unique CID14(e.g., without limitation, 32 bits; any suitable count of bits to provide a unique configuration code) is loaded upon successful completion of factory testing. For example, a suitable test fixture, such as the data concentrator10or a device (not shown) that mimics all or part of the data concentrator10, embeds the CID14into a register34(FIG. 2) located within the IO module33upon successful completion of testing.

The configuration information24can be, for example and without limitation, monitoring information, maintenance information, and a plurality of algorithms.

Further to Example 5, the configuration information24can be, for example and without limitation, a bill of material, a cell size, a wiring diagram, a picture, a setting range, protection device information, a load type, an input/output type, an input/output configuration, a protection scheme, and an algorithm.

Each smart MCC cell, such as8, of the example smart MCC system2is embedded with a unique CID14. This unique configuration code is imbedded in a smart component of the smart MCC cell8and is used in a look-up table (LUT)26that is integrated into the smart MCC data concentrator10or the Internet based database4. The database4is automatically accessed when the smart MCC cell8is first installed into the smart MCC system2and, as a result of a successful look-up, all pertinent data is pre-loaded into the smart MCC data concentrator10from the Internet based database4, including, for example and without limitation, bills of material, cell sizes, wiring diagrams, pictures (e.g., without limitation, starter image; protection device image; assembly image; MCC cell image), internal graphics (for displayed configuration pages), setting ranges (e.g., without limitation, short circuit; thermal; ground fault), protection devices (e.g., without limitation, graphic elements; short circuit settings; overload settings; ground fault settings; protection settings; monitoring settings), load types (e.g., without limitation, full voltage non-reversing (FVNR) starter; full voltage reversing (FVR) starter; feeder; variable speed drive (VSD); soft starter), load monitoring relay type and configuration (e.g., without limitation, a number of conductors; CT ratio; current range of device (maximum and minimum defaults); number of loops through current transformers; algorithms for analysis based on load type (e.g., without limitation, valve; variable speed drive; soft-start); internal protection settings of a load monitoring relay (e.g., without limitation, unbalance; ground fault); protection scheme (e.g., without limitation, what device is being used for protection)), algorithms, size of MCC cell (e.g., without limitation, for an MCC overview page), and other suitable configuration parameters.

The database4is a master ID database accessible over a global communication network, such as the Internet. The database4includes a suitable server28for both local and Internet access.

As will be explained, below, in connection withFIG. 3, the data concentrator routine22automatically accesses the database4with the unique CID14when one of the smart MCC cells8,8A,8B is first installed into the MCC system2. The routine22confirms that the unique CID14is in the database4and responsively automatically configures the corresponding smart MCC cell8with the configuration information24. The look-up table26is operatively associated with (e.g., is part of the main database4or part of the local database6) the database4, and the routine22determines if the unique CID14is in the look-up table26before it responsively obtains the configuration information24and automatically configures the corresponding smart MCC cell8.

In addition, the data concentrator routine22can output the configuration information24to a non-volatile memory (e.g., without limitation, a compact flash card30) when one of the smart MCC cells8,8A,8B is first installed into the MCC system2.

As shown inFIG. 2, the smart MCC cell8can include a circuit breaker9, a load monitoring relay11and a contactor13. The first and second communication interfaces16,18are communication interfaces to a communication network, such as a communication link32between the data concentrator10and the number of smart MCC cells8,8A,8B. The communication link32can be any suitable communication network or bus (e.g., without limitation, DeviceNet™; CANopen; Modbus®). A non-limiting example of the load monitoring relay11is a MOTORMENTOR® motor protection and load monitoring relay marketed by Eaton Corporation of Mississauga, Ontario, Canada.

As shown inFIG. 2, the module12includes the 10 module33(e.g., without limitation, a load monitoring relay10module) having the register34readable from the communication interface16by the data concentrator communication interface18. The unique CID14is stored in the register34.

Every smart MCC starter that uses, for example and without limitation, a load monitoring relay IO module is assigned a unique CID, such as CID14. This CID14is embedded into the register34located within the IO module33upon successful completion of automatic starter testing. The CID14links to the main or master database4(FIG. 1) (e.g., without limitation, located on the server28that loads a recipe file and all supporting documents). The main database4provides the configuration information24, such as configuration data, settings and reference information, to both the smart MCC cell8(FIG. 1) and to the data concentrator10. The configuration information24pre-sets the smart MCC cell8(e.g., without limitation, load monitoring relay settings; IO module settings). A subset of the main database4(e.g., for starter assemblies used in a particular smart MCC cell, such as8) is loaded into the data concentrator10and provides user configuration information that can be automatically loaded either by the user or by the smart MCC cell8after it is connected to the communication link32.

Although one IO module33is shown inFIG. 2, the load monitoring relay11can include any suitable number of IO modules. The configuration information24may include a plurality of IO module settings.

The data concentrator database6is operatively associated with (e.g., is part of the example MCC system2including the MCC cells8,8A,8B) the various MCC cells8,8A,8B and is a subset (e.g., without limitation, for the smart MCC starters used in the particular system, such as2) of the main database4. This provides user configuration information that can be automatically loaded either by the user or by the smart MCC cell8after it is connected to the communication link32. For example, the data concentrator routine22inputs the unique CID14from the IO module33, determines if the unique CID14is in the local database6, and responsively inputs local configuration information36from the local database6and automatically configures the corresponding one of the MCC cells8,8A,8B with the local configuration information36.

The data concentrator routine22can add a motor starter type designation into the register34in an IO module, such as33, of one of the MCC cells8,8A,8B. This can also add database information to the non-volatile memory, such as the example smart MCC compact flash card30, when a look-up program of the routine22is triggered by start of communication with a starter bucket, or when a user triggers this from a virtual button of a service page for a cell, as will be described.

Outputting the configuration information24to the non-volatile memory (e.g., without limitation, the compact flash card30) when one of the MCC cells8,8A,8B is first installed into the MCC system2can be accomplished by a look-up program of the routine22triggered by start of communication with a starter bucket. After a particular MCC cell, such as8, is connected to the communication link32, it starts to send an “I'm alive message” to the data concentrator10. When the data concentrator10notices that a new device has connected to the communication link32, that was not previously there (e.g., by detecting a new CID, such as14), the data concentrator10updates the parameters associated with this MCC cell8based on its CID.

As another non-limiting example, the configuration information24can be output to the non-volatile memory, such as the example compact flash card30, when a user triggers this action from a user interface15(FIG. 2) of the data concentrator10(e.g., a virtual button of a service page for a cell). In some instances, where the unique CID14does not reside in the local database6, the data concentrator10will not be able to find the MCC cell's parameters within that database. In this case, default parameters are used. However, after the local database6has been updated (e.g., without limitation, by using a USB memory device; a LAN; the Internet), then the cell data can be automatically updated by forcing the data concentrator10to treat the MCC cell8as being newly installed from the data concentrator user interface15.

Typically, default values for the MCC cells8,8A,8B come from the internal or local database6. In some instances, these values need to be adjusted for a particular load (e.g., without limitation, the example motor38ofFIG. 2).

A suitable field device (not shown), such as a personal computer or other device that mimics the example data concentrator10, can provide the configuration information24from the main database4to spare modules (not shown), such as spare IO modules, for the example MCC system2.

A suitable device, such as the example data concentrator10or a device (not shown), such as a personal computer or other device that mimics the data concentrator10, can store a subset of the main database4on a non-volatile memory, such as a CD, a compact flash drive or the example compact flash card30.

The data concentrator routine22is shown inFIG. 3. First, at40, after a new MCC cell, such as8, is added to the system2and it sends its unique CID14to the data concentrator10, the routine22reads that unique CID14. Next, at42, the routine22determines if the new CID14is in the look-up table26in the local database6. If so, then the new MCC cell8is automatically configured at44using the local configuration information36from the local database6. On the other hand, if the new CID14is not in the look-up table26in the local database6(or if there is no look-up table26or no local database6), then the routine22requests the configuration information24from the main database4, at46, after which automatic configuration is performed at44. Alternatively, as was discussed above in connection with Examples 3 and 16, the routine22can obtain this information from either the non-volatile memory, such as the example compact flash card30, or the data concentrator user interface15.

The disclosed concept eliminates manually selecting parameters for each starter type, thereby reducing errors. This allows the example system2to be dynamically configured, via the master database4or the local database6, by, for example and without limitation, an end-user or system designer, without any direct engineering requirement. The disclosed concept provides relatively faster engineering since starter parameterization can be done by a system designer or end-user, and there is no need to manually load cell information into a smart MCC cell. Also, since this is automated, automatic testing and configuration leads to relatively quicker engineering and less rework due to mistakes. This also provides relatively closer integration, with a one-product-for-all concept, and greater flexibility for new component additions or starter retrofits since a new recipe needs to be created just one time.

The disclosed concept provides better testing and documentation since an automatic test fixture (not shown, but see the example data concentrator10) can check configurations just by knowing the CID, such as14. Automatic test reports can be generated and logged to the main database4. This also reduces after sales support due to an improper configuration, provides simpler ordering of replacement cells, logs server logins for marketing campaigns and follow-ups, and provides the ability to offer the same product to brand label channels.

The disclosed concept can be configured without direct engineering support, permits field replacements and upgrades to be done relatively easily by updating the local database6from the server28, allows for direct marketing channel customization (e.g., without limitation, tracked by server login), permits simpler ordering of replacement cells, and allows for relatively easy brand labeling and protection. For example, a CID, such as14, can be restricted to only work with a particular marketing channel product.