Abstract:
A method and apparatus provides an Intelligent Electronic Device (IED) with new hardware modules. Hardware modules are provided that are configured for electrically connecting with connections of a first IED housing that has a first form factor. A second IED housing is provided having a second form factor that is different from the first form factor. The hardware modules are mounted in the second housing. Adaptor structure is employed to electrically connect the hardware modules with connections of the second housing. The second housing is mounted into an existing wiring and second form factor environment.

Description:
FIELD 
       [0001]    The invention relates to intelligent Electronic Devices (IED) and, more particularly, to the integration of state of the art IED technology into an existing wiring and form factor environment. 
       BACKGROUND 
       [0002]    Intelligent Electronic Devices (IED) are typically used for protection, management and supervision of utility substations and industrial power systems. IEDs are durable electronic equipment that, during their designed life, would span across a number of technological advancements and changes. These changes could affect not only the hardware electronics, but also the form factor and size of that hardware. Replacing older IEDs with similar ones is quite difficult since technologies used in the original IED are outdated and components have reached their End Of Life (EOL). Replacing an older technology IED with a more recent one very often requires changing wiring and sometimes dimensions of racks and panels if a new IED form factor is introduced or a different user Input/output interface is used. 
         [0003]    Thus, there is a need to permit the transfer and integration of current technology into and an IED having an older type form-factor while keeping the customer wiring locations unchanged. 
       SUMMARY 
       [0004]    An object of the invention is to fulfill the need referred to above. In accordance with the principles of the present invention, this objective is obtained by a method that provides an Intelligent Electronic Device (IED) with new hardware modules. Hardware modules are provided that are configured for electrically connecting with connections of a first IED housing that has a first form factor. A second IED housing is provided having a second form factor that is different from the first form factor. The hardware modules are mounted in the second housing. Adaptor structure is employed to electrically connect the hardware modules with connections of the second housing. The second housing is mounted into an existing wiring and second form factor environment. 
         [0005]    In accordance with another aspect of the disclosed embodiment, An Intelligent Electronic Device (IED) includes a plurality of hardware modules configured for directly electrically connecting with connections of a first IED housing that has a first form factor. A second IED housing has a second form factor that is different from the first form factor. The hardware modules are mounted within the second housing. Adaptor structure is constructed and arranged to electrically connect the hardware modules with connections of the second housing. 
         [0006]    Other objects, features and characteristics of the present invention, as well as the methods of operation and the functions of the related elements of the structure, the combination of parts and economics of manufacture will become more apparent upon consideration of the following detailed description and appended claims with reference to the accompanying drawings, all of which form a part of this specification. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0007]    The invention will be better understood from the following detailed description of the preferred embodiments thereof, taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts, in which: 
           [0008]      FIG. 1A  is a perspective view of an IED having a particular form factor for vertically mounted hardware modules. 
           [0009]      FIG. 1B  is a side view of the IED of  FIG. 1A . 
           [0010]      FIG. 2  is front view of a housing for an IED having a form factor for horizontal mounting of hardware modules. 
           [0011]      FIG. 3  is a top view of the IED housing of  FIG. 2 . 
           [0012]      FIG. 4  is a rear perspective view of hardware modules connected with a front panel for an IED having the form factor of  FIGS. 2 and 3 , and also connected with a first adaptor structure, in accordance with an embodiment. 
           [0013]      FIG. 5  is a front perspective view of the hardware modules of  FIG. 4  along with a communication module shown disposed an IED housing having the form factor of  FIGS. 2 and 3 , and connected with a second adaptor structure, in accordance with the embodiment. 
       
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0014]    With reference to  FIGS. 1A and 1B , an IED is shown, generally indicated at  10 , having a housing  11  with a form factor enabling mounting of hardware modules (not shown) in a vertical arrangement therein. The modules are directly electrically connected to connections  13  at a rear of the IED  10  and to connectors (not shown) adjacent to the front panel  15 . The IED  10  has a height H of 6.97″, a width W of 6.97″ and a depth D of 7.91″. The IED  10  is used for protection, management and supervision of utility substations and industrial power systems. 
         [0015]    As noted above, there are times when replacing older IEDs with newer ones is needed.  FIGS. 2 and 3  shows an older type IED housing  12  that has a form factor for enabling the hardware modules to be mounted in a horizontal arrangement therein. The housing  12  of the embodiment has a height H of 5.22″, a width W of 17.12″ and a depth D of 9.00″ (for 19″ U form-factor). Below, a process and components are described that enables the hardware modules made for the IED of  FIGS. 1A ,  1 B to be used in the housing  12  of  FIGS. 2 and 3  so that the customer can transfer and integrate current technology into an older type IEDs form factor, while advantageously keeping the customer wiring locations unchanged. 
         [0016]    With reference to  FIG. 4 , a Power Supply Module (PSM) or circuit board, generally indicated at  14 , and a Binary Input/Output (BIO) circuit board or module, generally indicated at  16 , are shown mounted in a horizontally adjacent manner to a tray  18  that is coupled to a front panel  20 . The new front panel  20 , for operator input, is coupled to an open end  21  of the housing  12  ( FIG. 2 ). A protective cover  22  is provided over the module  16  and a second protective cover  24  is provided over the module  14 . The modules  14  and  16  are of the type configured for vertical mounting in housing  11  ( FIG. 1A ) and include current or updated technology. To be used in the older type housing  12  and mounted horizontally adjacent therein, first adaptor structure, generally indicated at  26  is provided. In the embodiment, the first adaptor structure is preferably a rigid printed circuit board  28  having connectors  30  thereon that receive mating connectors  32  of the modules  14  and  16 , which would otherwise been connect directly to connectors  13  associated with the back panel  34  of the IED  10  of  FIG. 1B . With reference to  FIG. 5 , the circuit board  28  is also connected to connectors  36  that are associated with certain of the connections  35  ( FIG. 3 ) on the back panel  38  of the housing  12 . Thus, the circuit board  28  bridges the physical gap between the modules  14  and  16  and the back panel  34 . Connection between PSM and BIO modules to the external Input/outputs is achieved through the circuit board  28 . It is noted that the covers  22  and  24  are not shown in  FIG. 5  for clarity of illustration. 
         [0017]    With reference to  FIG. 5 , a second adaptor structure  26 ′ is employed to connect the communication (COM) circuit board or card  40  to the backplane  41  rather than connecting the COM card  40  directly to the backplane as in the IED  10  of  FIG. 1A . In the embodiment, the second adaptor structure  26 ′ is preferably a rigid printed circuit board  42  having a connector  44  that receives a mating portion of the COM card  40 . A portion  46  of the circuit board  42  is electrically received by a connector  48  of the backplane  41 , which is adjacent to the front panel  20  of the housing  12 . Thus, the circuit board  42  bridges the physical gap between the COM card  40  and the backplane  41 . This arrangement facilitates the access of the COM ports  50  ( FIG. 3 ) from the back panel  38  by providing the ports  50  in the same plane like other rear terminals. 
         [0018]    Thus, the utilization of the adapter structures  26 ,  26 ′ to electrically connect the hardware modules (configured for a first form factor) within the housing  12  (configured for a second form fact that is different from the first form factor), allows power utilities to adopt state of the art technology for their IEDs, without the need to change the physical wiring locations and input/output interface associated with the housing  12 . 
         [0019]    One of the challenging tasks of any electrical enclosure is electrical grounding. The adaptor structures used in the embodiment are used to extend user interface inputs and outputs from one form factor to another. Appropriate grounding of the adaptor structures can be achieved with the use of springs, brackets, or the like. 
         [0020]    Instead of using circuit boards as the first and second adaptor structures, ribbons, flexible cables, or flexible circuit boards can be employed having the appropriate electrical connections. 
         [0021]    Advantages and benefits of the embodiment include:
       1) IED users will be able to integrate state of the art technological advancement in the IED industry in existing environments (e.g., racks of the form factor of housing  12 ) without having to re-wire and change input/output interfacing to their existing IEDs.   2) Since these newer IEDs are compatible in form-factor and are wire-alike, they will allow a drop-in replacement which will shorten the IED replacement time, and hence the outage time for such replacement.   3) Since these newer IEDs provide customers with state-of-the-art technology with a reduced replacement overhead, they will give the manufacturer an edge for faster and more efficient retrofit application of their products into the market.   4) The adaptor structure  26 ,  26 ′ application will allow the use of hardware modules configured for an IED (X) having one form factor, to be used for another IED (Y) with a different form factor. The adaptor structures will allow IED (X) to be wired-alike and form-factor-alike as the IED (Y).   5) The flexibility to adopt any hardware of one form-factor to a different IED form factor and wire-alike mentioned in (4) could be extended to allow adaptability between any two IEDs regardless of their manufacturer.   6) Using platform PCBs designed for different form-factors without any PCB modifications makes it possible to use same module and product testing harnesses and tools for new the products.       
 
         [0028]    The foregoing preferred embodiments have been shown and described for the purposes of illustrating the structural and functional principles of the present invention, as well as illustrating the methods of employing the preferred embodiments and are subject to change without departing from such principles. Therefore, this invention includes all modifications encompassed within the spirit of the following claims.