Patent Publication Number: US-2022232722-A1

Title: Modular upgradable low voltage power supply

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of provisional patent application No. 63/199,669, entitled “MODULAR UPGRADABLE LOW VOLTAGE POWER SUPPLY” filed Jan. 15, 2021, is incorporated by reference herein in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to electrical power supplies, and more particularly to low voltage electrical power supplies. Broadly, embodiments of the present invention provide a modular upgradeable low voltage power supply. The invention allows users to modularly configure their power supply system so that it is tailored to changing power demands as power requirements expand or decrease. 
     2. Description of the Related Art 
     The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense but is made merely for the purpose of illustrating the general principles of the invention. 
     Most end-users or contractors would like to increase the power of their current power supply to be able to add more electrical loads. However, with existing power supplies, the user can not increase the power output of the power supply. In these cases, the user has to purchase a new power supply unit and redo the installation to increase electrical capacity. 
     In the event of a power supply failure, the end-user or contractor has to scrap the previous power supply unit and replace it with a new one having a capacity to meet the electrical demands. Separate power supply units occupy a lot of space, especially if a project gets expanded during installation. As can be seen, there is a need for improved low voltage power supply that is modular in construction to permit expansion and repair of the power supply. 
     There are various patents that have issued that have involved modular power supplies or modular transformers, but these have not involved the use of low voltage power supplies. These include, for example: 
     Korean Pat. Publication No. 10-2010-0063676, to General Electric Company, of New York, United States America, Shenecteddy, One River Rowd (72), entitled “Distribution System”, discloses a submarine power distribution system which is stacked and interconnected to meet site expansion requirements and electrical load topology. A plurality of modular transformer building blocks are included on each of the power supply side and the subsea load side. The power distribution system includes a system DC transmission link/bus, wherein the system DC link includes a plurality of submarine load modules configured to transmit HVDC or MVDC power. The topology of the stacked modular substation on the seabed side of the subsea power distribution system is symmetric with the topology of the stacked modular substation on the land/top side of the subsea distribution system. 
     U.S. Pat. No. 7,759,575 B2, entitled “Expandable Power Distribution Unit”, issued to Commscope Technologies LLC, discloses a power distribution unit that includes a first power box including a first chamber having a first termination zone, wherein a first wire set from a supply conduit is configured to be terminated at the first termination zone. The power distribution unit also includes a second power box ganged together with the first power box. The second power box has a second chamber open to the first chamber, and the second chamber has a second termination zone. A second wire set from at least one of the supply conduits and the first termination zone is configured to be terminated at the second termination zone. 
     Neither of the above examples, nor other prior art discloses low voltage modular power supplies. 
     As will be disclosed below, the user-friendly, modular design of the present invention helps the user configure their power supply to existing and emerging electrical power requirements. 
     SUMMARY OF THE INVENTION 
     In a broad aspect, the present invention is a modular power supply system comprising an enclosure and a casing assembly contained within the enclosure. The casing assembly includes a plurality of slots. The casing assembly is configured to accept a plurality of transformer modules configured to slide into the slots. Each of the transformer modules is of a type having a transformer module housing, and a transformer element positioned within the transformer module housing. 
     In a preferred embodiment the casing assembly comprises a frame assembly, a plurality of spaced rails, a plurality of terminal blocks and at least one printed circuit board. The frame assembly comprises a plurality of panel elements. The plurality of spaced rails defines the plurality of slots, the spaced rails being supported by the panel elements. The plurality of terminal blocks is supported by the panel elements. At least one printed circuit board is connected to the panel elements. 
     In an embodiment the at least one printed circuit board comprises a controller printed circuit board. The controller printed circuit board comprises a plurality of PCB components and a PCB mounted transformer. 
     The plurality of PCB components includes an MCU (Microcontroller Unit), a relay, a wireless communication technology module (e.g., Bluetooth or Wi-Fi Module), at least two output current transformers (CT&#39;s), an input current transformer (CT) and an alarm. 
     The MCU is configured to execute machine-readable program code for causing, when executed, the computer to perform selected steps. The relay is operatively connected to the MCU, for shutting off the power to the transformer modules. The wireless communication technology module (e.g., Bluetooth or Wi-Fi Module) is operatively connected to the MCU for communicating with a smartphone app. At least two output current transformers (CT&#39;s) are operatively connected to the MCU for measuring the output current of the modular power supply system. The input current transformer (CT) is operatively connected to the MCU to measure the input current of the modular power supply system. The alarm is connected to the MCU for making a buzzing or beeping noise for certain conditions. 
     The PCB mounted transformer is operatively connected to the PCB components. The PCB mounted transformer has a high voltage AC input and a low voltage AC output, the low voltage AC output being converted to DC to power the PCB components. 
     In another broad aspect, the present invention is embodied as a transformer module including: a transformer module housing and a transformer element positioned within the transformer module housing. The transformer module is configured to be accepted within a modular power supply system of a type having an enclosure, and a casing assembly contained within the enclosure. The casing assembly includes a plurality of slots. 
     Thus, the system includes a plurality of transformer modules that can be easily added or removed from a power supply system to increase or decrease the power capacity of the unit. In case one module fails, the end user can remove and easily insert a new transformer module without buying and installing a whole unit. Thus, the user is able to repair the power supply unit by easily replacing the failed transformer module, instead of scrapping the whole power supply unit. 
     To increase the power capacity, the user adds one or more transformer modules. To decrease the power capacity, the user can remove one or more transformer modules. The transformer module may be readily transferred to another location where additional power output may be required. 
     The modular low voltage power supply unit saves substantial space for contractors, distributers, etc. as there is no need to carry multiple of power supply units with redundant parts due to their being packaged in a separate power supply. Instead, the user can carry small modules for any expansions during installations. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is perspective illustration of the modular power supply system of the present invention.  FIG. 1B  is a perspective view of a removable lid thereof. 
         FIG. 2A  shows the casing assembly contained within the frame assembly.  FIG. 2B  shows removal of and removed transformer modules from the casing assembly.  FIG. 2C  shows a transformer module being inserted into the casing assembly. 
         FIG. 3A  shows the casing assembly partially removed from the enclosure.  FIG. 3B  shows the enclosure with the casing assembly removed therefrom. 
         FIG. 4  is another view showing the casing assembly partially removed from the enclosure. 
         FIG. 5  shows the casing assembly removed from the enclosure, revealing the components thereon. 
         FIG. 6A  shows the casing assembly removed from the enclosure, revealing the components of connection PCB and showing a transformer module partially removed. 
         FIG. 6B  is another view of the casing assembly showing a transformer module being slid into the slots. 
         FIG. 7  is a perspective illustration of a transformer module. 
         FIG. 8  shows the transformer module housing, the transformer element having been removed. 
         FIG. 9  is an exploded perspective view of the transformer module. 
         FIG. 10  shows an example hardware flowchart for in a case where there are six transformer modules transforming voltage from 110V to 15V and 12V. 
         FIG. 11  shows an example software flowchart showing the steps to determine the ON and OFF mode of the modular power supply system of the present invention. 
         FIGS. 12A-12H  show example screenshots taken from an app that can be utilized by a smart device to monitor and control the modular power system of the present invention. 
     
    
    
     The same elements or parts throughout the figures of the drawings are designated by the same reference characters. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings and the characters of reference marked thereon,  FIGS. 1-12  illustrate a preferred embodiment of the modular power supply system of the present invention, designated generally as  10 . As can be seen in  FIG. 1A , the modular power supplies system  10  includes an enclosure, designated generally as  12 . A casing assembly  14  is contained within the enclosure  12 . The casing assembly  14  includes a plurality of slots  16  (see e.g.,  FIG. 2B ). The casing assembly  14  is configured to accept a plurality of transformer modules  18 . The enclosure  12  is preferably formed of stainless steel; however, other suitable resilient materials maybe utilized such as for example plastic, powder coated steel. Referring to  FIG. 1B , the enclosure  12  includes a removable lid  19 . 
       FIG. 2A  shows the casing assembly  14  contained within a frame assembly  20 .  FIG. 2B  shows removal of and removed transformer modules  18  from the casing assembly  14 .  FIG. 2C  shows a transformer module  18  being inserted into the casing assembly  14 . 
       FIG. 3A  shows a casing assembly  14  partially removed from the enclosure  12 .  FIG. 3B  shows the enclosure  12  with the casing assembly  14  removed therefrom. 
       FIG. 4  is another view showing the casing assembly  14  partially removed from the enclosure  12 .  FIG. 5  shows another view of the casing assembly  14 . Referring to both  FIGS. 4 and 5 , the casing assembly  14  includes the frame assembly  20  having a plurality of panel elements  22 ; a plurality of spaced rails  24  defining said plurality of slots  16  supported by the panel elements  22  (i.e. shown in  FIGS. 2A-2B ); a plurality of terminal blocks  26  supported by the panel elements  22 ; at least a printed circuit board, i.e., controller PCB  28 , connected to the panel elements  22 ; a second PCB, i.e., a connection PCB  50 , is also connected to the panel elements  22 , as shown in  FIG. 5 ; a power switch  29  supported by the panel elements  22 ; and, a reset button  31  supported by the panel elements  22 . 
     As best seen in  FIG. 5 , the controller printed circuit board (PCB)  28  includes a plurality of PCB components, designated generally as  30 , and a PCB mounted transformer  32  operatively connected to the PCB components  30 . The plurality of PCB components  30  includes an MCU (Microcontroller Unit)  34  configured to execute machine-readable program code for causing, when executed, the computer to perform selected steps. The MCU  34  may be, of the ARM series type with the required I/O ports, timer, Inter-integrated circuit (I2C), pulse width modulation (PWM), Serial Peripheral Interface (SPI), and Analog-to-Digital Converter (ADC). The PCB mounted transformer  32  has a high voltage AC input and a low voltage AC output. The low voltage AC output is converted to DC to power the PCB components  30 . 
     The set of PCB components  30  includes a relay  36  operatively connected to said MCU  34 , for shutting off the power to the transformer modules. This feature will act as a circuit breaker or fuse to shut off power and protect the system from any electrical overloads or shortages. The relay may be, 5-10 Amps. 
     The set of PCB components  30  includes a real time clock  38  operatively connected to the MCU  34 . Real time clock  38  provides the time information to the MCU  34 . A preferable type of real time clock is marketed as MAXIM DS1302ZN+ or MAXIM DS1307ZN+, manufactured by Maxim Integrated. 
     The set of PCB components  30  includes an alarm (such as a buzzer  40  or LED indicator light  41 ) operatively connected to the MCU  34 , for making a buzzing or beeping noise or lighting up, for certain conditions. 
     The set of PCB components  30  includes a EEPROM  42  operatively connected to the MCU  34 , for saving the settings and history of the records. A preferable type of the EEPROM is model No. W25Q64FVSSIGE or GD GD25Q64CSIG, manufactured by WINBOND. 
     The set of PCB components  30  includes an energy measuring module  44  operatively connected to the MCU  34 , for measuring the power consumption, current, and voltage and reporting the same to the MCU. 
     The set of PCB components  30  includes a wireless communication technology module, e.g. Bluetooth Low Energy (BLE)  46  operatively connected to said MCU  34 , to allow the modular power supply system to communicate with a digital selected platform. However, the wireless communication technology module  46  can communicate with in various ways, for example WiFi, WiMAX, NFC, GPS, Zigbee, Satellite Communication, UWB, Mobile Communication Systems, RF, to a selected digital platform. 
     The set of PCB components  30  includes AC to DC convertors  48  operatively connected to the MCU  34 , to convert the AC voltage to DC voltage and power up the MCU  34  and the BLE module  46 . 
     The set of PCB components  30  includes at least two output current transformers (CT&#39;s)  54  operatively connected to the MCU  34  for measuring the output current of the modular power supply system  10 . An input current transformer (CT)  56  is operatively connected to the MCU  34  to measure the input current of the modular power supply system  10 . 
     Still referring to  FIG. 5 , a rear side of a connection printed circuit board (PCB)  50  can be seen. As better seen in  FIG. 6A , the connection PCB  50  includes a plurality of female pluggable terminal sets  52  operatively connected in parallel to each other. One of the sets provides the input to the transformer module  18  and the other set provides the outputs to the terminal blocks  26 . A preferable type of female pluggable terminal, marketed as Goldfinger Slot, is manufactured by WING TAT and identified as S-12M-2.54-5.  FIG. 6B  is another view of the casing assembly  14  showing a transformer module  18  being slid into the slots  16 . 
     Referring now to  FIG. 7 , a transformer module  18  is illustrated. In  FIG. 8 , the transformer element  58  has been removed to reveal only a transformer module housing  60 .  FIG. 9  is an exploded perspective view of the transformer module  18 . A Goldfinger PCB  62  is operatively connected to a transformer element  58  input lead wires  64  and to output lead wires  66 . 
     The transformer element  58  may be, an EI-type, a UI-type, or a toroidal. The transformer element  58  may be encapsulated inside of the transformer module housing  60  by, for example, a suitable resin. The plurality of transformer modules  18  may be selectively inserted into the casing assembly  14  by supporting each of the plurality of transformer modules  18  within a pair of slots  16 . Each of the transformers may then be connected to the connection PCB  50  to upgrade the unit. 
     Referring now to  FIG. 10 , a hardware flowchart is illustrated, illustrating the hardware on controller PCB  28  and connection PCB  50  that are feeding data to MCU  34 . The example shown shows six transformer modules  18  (MODULE-1, MODULE-2, . . . MODULE-6) that transform voltage from 110V to 15V and 12V. It is noted that this is shown for the purposes of illustration, not limitation. The data from the energy measuring module  44 , input current transformer  56 , output current transformer  54 , EEPROM  42 , alarm  40 , and wireless communication technology module  46  will be used to determine if any modules have been inserted or removed. Also, with the received data the MCU  34  will determine if the modular power supply  10  should be on or off. The relay  36  will be triggered from MCU  34  to turn the modular power supply  10  on, or off. 
     Referring now to  FIG. 11 , a software flowchart is illustrated to show the steps that MCU  34  takes to provide the normal output to terminal blocks  26  or shut off the power. Based on the collected variables from plurality of PCB components  30  and user selected timer option (manual or Sunrise/Sunset), MCU  34  will act accordingly. 
       FIG. 12A  is a screenshot showing the home page of the application with the buttons used to configure the system. 
       FIG. 12B  is a screenshot showing the list of the Bluetooth Low Energy (BLE) devices that have been added to the app. 
       FIG. 12C  is a screenshot showing the delete menu for the added Bluetooth Low Energy (BLE) devices from the app. 
       FIG. 12D  is a screenshot showing the selection menu of the connected devices which, when clicked, will take you to the settings of the chosen device. 
       FIG. 12E  is a screenshot showing the area where you can set a name to the connected device. 
       FIG. 12F  is a screenshot showing the input power status page of the application. 
       FIG. 12G  is a screenshot showing the output power status page of the application. 
       FIG. 12H  is a screenshot showing the varying configurations and selections of timers. 
     The transformer modules  18  are dimensioned to be contained within the frame assembly  20  and slide into slots  16  via the spaced rails  24 . The system may be utilized to power any low voltage system that may need a reconfigurable wattage as an upgrade or downgrade as power requirements vary for an installation. By way of non-limiting example, the system may be utilized in an irrigation control system, power security system, lighting, and other such systems. 
     The system of the present invention may include at least one computer with a user interface. The computer may include any computer including, but not limited to, a desktop, laptop, and smart device, such as a tablet and smartphone. The computer includes a program product including a machine-readable program code for causing, when executed, the computer to perform steps. The program product may include software which may either be loaded onto the computer or accessed by the computer. The loaded software may include an application on a smart device. The software may be accessed by the computer using a web browser. The computer may access the software via the web browser using the internet, extranet, intranet, host server, internet cloud and the like. 
     The computer-based data processing system and method described above is for purposes of example only, and may be implemented in any type of computer system or programming or processing environment, or in a computer program, alone or in conjunction with hardware. The present invention may also be implemented in software stored on a non-transitory computer-readable medium and executed as a computer program on a general purpose or special purpose computer. For clarity, only those aspects of the system germane to the invention are described, and certain product details well known in the art are omitted. For the same reason, the computer hardware is not described in further detail. It should thus be understood that the invention is not limited to any specific computer language, program, or computer. It is further contemplated that the present invention may be run on a stand-alone computer system, or may be run from a server computer system that can be accessed by a plurality of client computer systems interconnected over an intranet network, or that is accessible to clients over the Internet. In addition, many embodiments of the present invention have application to a wide range of industries. To the extent the present application discloses a system, the method implemented by that system, as well as software stored on a computer-readable medium and executed as a computer program to perform the method on a general purpose or special purpose computer, are within the scope of the present invention. Further, to the extent the present application discloses a method, a system of apparatuses configured to implement the method are within the scope of the present invention. 
     It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth herein. 
     Other embodiments and configurations may be devised without departing from the spirit of the invention and the scope of the appended claims.