Patent Description:
As is known to those skilled in the art, industrial control systems are used to control operation of a machine or process. The controlled machine or process may include multiple motors or actuators which require power at different times to achieve the desired operation. A process line, for example, may include a conveyor with multiple drive motors spaced apart along the length of the conveyor. The process line may further include a load station and an unload station at which a product is moved onto and removed from the conveyor, respectively. Additional stations between the load and unload stations may perform actions on tire product, such as filling, labelling, sorting, machining, and the like. Each station may require one or more motions, each with one or more actuators, to perform the specified action at that station.

Each actuator requires power be supplied to the actuator at the proper time to achieve the desired operation. Typically, a control cabinet is provided in which a main power feed enters and a power distribution system is established within the control cabinet to supply power to each actuator. In some applications a single control cabinet may be provided or, optionally, multiple control cabinets may be provided at a central location with wiring being run from the control cabinet(s) to each actuator. In other applications, control cabinets may be distributed around the controlled machine or process with each cabinet having a power feed into the cabinet and separate power distribution systems within each control cabinet.

The power distribution system within each control cabinet includes the main power feed and multiple branches. Each branch may be configured to supply power to one actuator. The actuator may be a solenoid energizing, an electronic motor, a valve to engage a piston or the like. A typical branch will include a circuit breaker that provides overcurrent protection, a contactor or starter that is selectively actuated to provide power the actuator at a desired time, and a control circuit to enable/disable the contactor or starter and to monitor operation of the branch circuit. Historically, each of these components has been provided as a separate device. The circuit breaker may be mounted to a control panel or to a rail, such as the rail defined by Deutsches Institut für Normung (DIN) also referred to as DIN rail, where the DIN rail is mounted to the control panel. The contactor or starter is similarly mounted to the control panel or to a rail mounted on the control panel.

Electrical interconnections to supply power must be made between a main circuit breaker, receiving the power feed, and each branch circuit breaker. Additional electrical interconnections for supplying power must be made between the branch circuit breaker and the contactor or starter. Still further electrical interconnections for supplying power are made from the contactor or starter to the actuator being controlled by the branch circuit. In addition to electrical interconnections for supplying power, electrical interconnections are made for control and monitoring of the branch circuit. Each circuit breaker may be electronically actuated and/or include current transducers generating a signal corresponding to an amplitude of current flowing through the circuit breaker. The circuit breakers may also include a status signal providing feedback to a central controller, such as a programmable logic controller (PLC) or a programmable activity controller (PAC), whether the circuit breaker is open or closed. Each of these control or feedback signals requires electrical interconnections. Similarly, a contactor or starter may be electronically actuated and include feedback signals indicating whether the contact is open or closed or whether the starter is enabled or disabled. A starter may include still additional feedback signals and/or serial communications between the starter and the central controller. Each of these control signals, feedback signals, or serial communications require electrical interconnections. Multiple circuit breakers and contactors or starters may be mounted to a single control panel. The number of electrical interconnections for power and/or control on a control panel is significant, requires extensive manufacturing and assembly time, and creates potential for wiring errors.

Recently, there has been a trend to providing modules which include a circuit breaker and a contactor or starter in a single package. The circuit breaker and contactor may be mounted to a base, where the base is mounted to the control panel or DIN rail. Providing the circuit breaker and contactor in a package reduces the potential for running electrical interconnections incorrectly between two devices mounted at different locations on the control panel. However, the circuit breaker and contactor typically still require electrical interconnections to be made between the devices while mounted on the base. The potential exists for miswiring between different control signals, different power connections, or even miswiring power and control connections. Additionally, the interconnections require assembly time and are typically completed at screw terminals, requiring a screwdriver to establish the connection.

Thus, it would be desirable to provide a modular power distribution device that provides modular interconnections for ease of assembly.

It would also be desirable to provide tool-less connection and plug-in interconnections between modules mounted on a single base. <CIT> A describes a load feeder of modular construction. The load feeder includes a feeder assembly and a base lower part with integrated cable and/or bus sections. The base lower part can be expanded to form a modular support system, with a cable and bus system, by arranging in a row and making contact with further physically identical base lower parts, in order to accommodate further feeder assemblies or input and output assemblies. <CIT> relates to a motor starter assembly made up of sub-assemblies each formed from a circuit breaker and a contactor and positioned on a baseplate with which a set of power bars is associated. <CIT> relates to a consumer junction which comprises a distribution apparatus, a protection apparatus as well as a linking element located between the distribution apparatus and the protection apparatus and directing a load current line from the protection apparatus to the distribution apparatus. <CIT> D4 relates to an improved contactor control system comprising several modules, such as a contactor module, an overload/controller module, a communication module, a bell alarm module, and a power terminal module which are electrically interconnected through a plug-in unit, and mechanically interconnected through one or more snap-in units, and which modules can be interchangeable and arranged relative to the overload/controller module according to particular industrial application.

According to the invention, a modular power distribution device includes a base, a circuit protection device, an electronically actuated power distribution device, and an electronic control module. The base has a first side and a second side, where the first side is configured to be mounted to a control panel, the second side is opposite the first side, and the second side includes a first mounting section and a second mounting section. The circuit protection device is configured to be mounted to the first mounting section of the base. The circuit protection device includes multiple input terminals configured to receive power conductors and multiple output connections. The electronically actuated power distribution device is configured to be mounted to the second mounting section of the base. The electronically actuated power distribution device includes multiple input connections and multiple output terminals configured to receive conductors for supplying power to a controlled device. The input connections are configured to connect to the output connections of the circuit protection device. The electronic control module is configured to physically mount to either the circuit protection device or the electronically actuated power distribution device. The electronic control module includes a plug configured to receive a network connection, an electrical connection to the circuit protection device, and an electrical connection to the electronically actuated power distribution device.

According to the invention, a modular power distribution system includes a communication module and at least one power distribution device. The communication module includes a first port configured to be connected to an industrial network and a second port configured to be connected to a plurality of industrial control devices. Each modular power distribution devices includes a base having a first mounting section and a second mounting section, a circuit protection device configured to slidably engage the first mounting section of the base, an electronically actuated power distribution device configured to slidably engage the second mounting section of the base, and an electronic control module configured to mount via a snap-fit to either the circuit protection device or the electronically actuated power distribution device. The electronic control module includes a plug configured to receive a network connection from the communication module, an electrical connection to the circuit protection device, and an electrical connection to the electronically actuated power distribution device.

These and other advantages and features of the invention will become apparent to those skilled in the art from the detailed description and the accompanying drawings. It should be understood, however, that the detailed description and accompanying drawings, while indicating preferred embodiments of the present invention, are given by way of illustration and not of limitation.

The subject matter disclosed herein describes a modular power distribution device that provides tool-less interconnections of modules for ease of assembly. A base is provided that may be snap-fit onto a DIN rail. The base includes a first mounting section and a second mounting section. The first mounting section is configured to receive a circuit protection device, and the second mounting section is configured to receive an electronically actuated power distribution device. The two mounting sections are offset from each other to align the circuit protection device with the electronically actuated power distribution device. The circuit protection device is configured to slide on to the first mounting section and includes multiple input terminals, configured to receive power conductors, and multiple output connections. The electronically actuated power distribution device is configured to slide on to the second mounting section and includes multiple input connections configured to engage the output connections of the circuit protection device as the power distribution device slides on to the second mounting section. The electronically actuated power distribution device also includes multiple output terminals configured to supply power to a device in the controlled machine or process. An electronic control module is snap-fit to either the circuit protection device or the electronically actuated power distribution device. As the electronic control module is physically mounted to the assembly, a first electrical connection is made between the electronic control module and the circuit protection device and a second electrical connection is made between the electronic control module and the electronically actuated power distribution device. The electronic control module includes a port by which control signals are received and feedback signals may be transmitted. The circuit protection device, electronically actuated power distribution device, and electronic control module are all configured to be manually mounted to the base or to each other by tool-less connections and plug-in interconnections between the modules mounted on a single base.

Turning initially to <FIG>, an exemplary control cabinet <NUM> in a power distribution system <NUM> is illustrated. The control cabinet receives a power feed <NUM>, which may be a single-phase alternating current (AC) power feed, a multi-phase AC power feed, or a direct current (DC) power feed according to the application requirements. A main circuit breaker <NUM> within the control cabinet <NUM> receives the power feed <NUM> and may be manually activated to enable/disable power within the control cabinet <NUM>. According to the illustrated embodiment, the main circuit breaker <NUM> includes a first branch <NUM> and a second branch <NUM> at the output of the main circuit breaker <NUM>. The illustrated embodiment is intended to be exemplary and illustrates only two branches for convenience. It is contemplated that any number of power branches may be distributed from the main circuit breaker <NUM>.

The first branch circuit <NUM> is connected to a secondary circuit breaker <NUM> and supplies power to an industrial controller <NUM>. The industrial controller <NUM> may be, for example, a programmable logic controller (PLC) or a programmable activity controller (PAC). The illustrated industrial controller <NUM> includes a power supply module <NUM>, a processor module <NUM>, a network module <NUM>, an input module <NUM> and an output module <NUM>. It is contemplated that the industrial controller may be made up of numerous different modules connected together in a rack or mounted to a rail. Additional modules may be added or existing modules removed and the industrial controller <NUM> reconfigured to accommodate the new configuration. Optionally, the industrial controller <NUM> may have a predetermined and fixed configuration.

The second branch circuit <NUM> includes still two additional branches. A third branch <NUM> is connected to multiple modular power distribution devices <NUM>, <NUM>, and a fourth branch <NUM> is shown extending on to still other devices not shown in the figure. The third branch <NUM> is connected to a communication module <NUM>, two modular power distribution devices <NUM> which include a contactor module <NUM> (see <FIG>) and to two modular power distribution devices <NUM> which include a motor starter <NUM> (see <FIG>).

The communication module <NUM> is part of an industrial network that extends between the industrial controller <NUM> and various devices within a machine or process that is being controlled by the industrial controller <NUM>. A network cable <NUM> is connected between the network module <NUM> and the communication module <NUM>. It is contemplated that the network cable <NUM> may be a custom cable configured to communicate via a proprietary interface or may be a standard industrial cable for a non-proprietary network. Exemplary non-proprietary networks include Ethernet/IP®, DeviceNet®, or ControlNet®. The network cable <NUM> connects the industrial controller <NUM> to the communication module <NUM> in a point-to-point configuration. It is contemplated that other network arrangements are possible for coupling the elements of the network, including arrangements that have switches that allow for redundancy communication paths, daisy-chain arrangements, star (simple or multi-layered) arrangements, ring-networks or more complicated topologies such as redundant local area networks (LANs). The network module <NUM> and communication module <NUM> are each configured to communicate according to the protocol of the network to which it is connected and may be further configured to translate messages between two different network protocols. Although illustrated as a wired network, where the connection is established via a network cable <NUM>, it is further contemplated that the network may also include wireless connections.

Turning next to <FIG>, the communication module <NUM> includes a first port <NUM> configured to receive a connector on the network cable <NUM>. The communication module <NUM> further includes a second port <NUM> configured to communicate with the modular power distribution devices <NUM>, <NUM>. A ribbon cable <NUM> has a terminal connector <NUM> on one end that plugs in to the second port <NUM> and pass-through connectors <NUM> that plug into a communication port <NUM> on each of the modular power distribution devices <NUM>, <NUM>. Optionally, each of the modular power distribution devices <NUM>, <NUM> may include a pair of communication ports <NUM> and separate cables, rather than a single ribbon cable, may be run between adjacent devices.

With reference next to <FIG>, a base <NUM> is provided on which a circuit protection device <NUM> and an electronically actuated power distribution device is mounted. It is contemplated that the electronically actuated power distribution device may be a contactor <NUM>, motor starter <NUM>, or motor drive (not shown). As illustrated in <FIG>, the electronically actuated power distribution device is a contactor <NUM>. With reference also to <FIG>, the base <NUM> includes a first side <NUM> configured to be mounted to a control panel and a second side <NUM>, where the second side is opposite the first side. The first side <NUM> includes a channel <NUM> configured to receive a DIN rail within the channel. The DIN rail is first secured to the control panel and the modular power distribution device <NUM> is mounted, in turn, to the DIN rail. The second side <NUM> includes a first mounting section <NUM> and a second mounting section <NUM>.

The first mounting section <NUM> is configured to receive the circuit protection device <NUM>, and the second mounting section <NUM> is configured to receive the electronically actuated power distribution device. The circuit protection device <NUM> slides on to the first mounting section <NUM>. A flexible tab <NUM> may be deflected downward as the circuit protection device <NUM> is slid on to the base <NUM> and returns to its original position into a recess on the circuit protection device <NUM> as the circuit protection device fully engages the base <NUM> such that the flexible tab <NUM> positively retains the circuit protection device <NUM> on the base <NUM>. The tab <NUM> may be manually deflected downward to release the circuit protection device <NUM> and to allow it to be slid off of the base <NUM>. The contactor <NUM> slides on to the second mounting section <NUM>. A flexible tab <NUM> may be deflected downward as the contactor <NUM> is slid on to the base <NUM> and returns to its original position into a recess on the contactor <NUM> as the contactor fully engages the base <NUM> such that the flexible tab <NUM> positively retains the contactor <NUM> on the base <NUM>. The tab <NUM> may be manually deflected downward to release the contactor <NUM> and to allow it to be slid off of the base <NUM>. Both the circuit protection device <NUM> and the electronically actuated power distribution device may be mounted to the base <NUM> without requiring a tool for mounting. Further, the base <NUM> may be snap fit onto the DIN rail such that each of the components in the modular power distribution device <NUM>, <NUM> are mounted to the other without requiring tools for installation.

In operation, each modular power distribution device <NUM>, <NUM> is controlled to selectively supply power from the third branch <NUM> to a device on the controlled machine or process. The circuit protection device <NUM> includes a plurality of input terminals <NUM> configured to receive power conductors from the third power branch <NUM>. It is contemplated that the circuit protection device <NUM> may be configured to receive single-phase AC voltage and include two input terminals <NUM> for power conductors. Single phase power includes a "hot" and a neutral conductor. Optionally, the circuit protection device <NUM> may be configured to receive a multi-phase (e.g., three-phase) AC voltage and include an input terminal <NUM> for each phase. The power conductors are electrical wires of suitable construction (e.g., solid or stranded) and of suitable wire gauge according to the current requirements of the application. The input terminals <NUM> may be screw terminals, as shown, requiring a screw driver for the connection of the conductors to the modular power distribution device <NUM>.

With reference also to <FIG>, the input terminals <NUM> are connected through a switching member <NUM> to output connections <NUM> on the circuit protection device <NUM>. The switching member <NUM> may be manually opened or closed. A dial <NUM>, lever, or other such manual switching device is provided and may be turned, flipped, toggled, or the like to move the switching member <NUM> between an open and a closed position. In the open position, no current may be conducted through the circuit protection device <NUM>. In the closed position, the current may be conducted, via the switching member <NUM> between the input terminals <NUM> and the output connections <NUM>. The circuit protection device <NUM> also includes overcurrent protection. The overcurrent protection may be of any suitable method of detecting excessive current in the device including, but not limited to thermal, magnetic, or current transformers. When the current exceeds a rating for the circuit protection device <NUM>, the switching member <NUM> is opened by the overcurrent protection. The circuit protection device may be manually or electronically reset after the excessive current flow is no longer present.

Under normal operating conditions, the circuit protection device <NUM> selectively conducts the voltage from the branch circuit <NUM> to an electronically actuated power distribution device. With reference to <FIG>, the electronically actuated power distribution device may be a motor starter <NUM>. With reference to <FIG>, the electronically actuated power distribution device may be a contactor <NUM>. According to still another embodiment, the electronically actuated power distribution device may be a motor drive. The electronically actuated power distribution device is any device that receives an electronic control signal and selectively delivers power from the circuit protection device <NUM> to another device in the controlled system.

Turning next to <FIG> and <FIG>, the contactor <NUM> includes multiple input connections <NUM> and multiple output terminals <NUM>. The input connections <NUM> are configured to engage the output connections <NUM> of the circuit protection device <NUM>, According to the illustrated embodiment, the output connections <NUM> of the circuit protection device <NUM> are screw terminals, which are configured to receive the input connections <NUM> of the electronically actuated power distribution device <NUM>. The input connections <NUM> are fixed metal conductors extending from the electronically actuated power distribution device <NUM>. The distal end of each connection <NUM> is pronged such that it may fit around the screw in the screw terminal <NUM> of the circuit protection device <NUM>. Although the illustrated embodiment requires a screw driver to secure the pronged connector in the screw terminal, no separate wiring is required between the two devices, eliminating the potential for miswiring between the devices. Instead, each pronged connector <NUM> on the electronically actuated power distribution device <NUM> is inserted into the corresponding output connection <NUM> of the circuit protection device <NUM> as the electronically actuated power distribution device <NUM> slides on to the base <NUM>. The screw terminals may be required according to application requirements related, for example, to connecting power terminals of devices and to the current ratings of each device. It is contemplated that, if application requirements permit, the output connections <NUM> may include spring-terminals to positively engage the input connections <NUM> as the electronically actuated power distribution device is fit onto the base <NUM>.

The contactor <NUM> is configured to selectively connect the output terminals <NUM> with the input connections <NUM> of the contactor <NUM><NUM>. As seen in <FIG>, a switching member <NUM> is movable between a first position (as shown) and a second position. The switching member <NUM> is a conductive material which includes a set of contacts <NUM> on one surface. A complementary set of contacts <NUM> are included on the interior end of the input connections <NUM> and the interior end of the output terminals <NUM>. In the second position, the switching member <NUM> moves downward such that the contacts <NUM> on the switching member <NUM> engage the contacts <NUM> on the input connections <NUM> and the output terminals <NUM>, thereby establishing an electrical conduction path therebetween. A control signal, received at the contactor <NUM> energizes an actuator, such as a coil clement, where the coil element establishes an electromagnetic field which, in turn, causes translation motion on a plunger, or metal rod within the coil element. The plunger is, in turn, connected to the switching member <NUM> to move the switching member between the open and closed position. When the control signal is removed, a spring <NUM> causes the switching member <NUM> to return to its original position.

With reference to <FIG>, a motor starter <NUM> may be fit onto the base <NUM> in the place of the contactor <NUM> previously discussed. The motor starter <NUM> is similarly configured with input connections configured to engage the output connections <NUM> of the circuit protection device <NUM>. However, rather than only providing a conductive path between the circuit protection device <NUM> and external devices, die motor starter <NUM> is configured to provide a variable output voltage at the output terminals <NUM>. The output voltage may have a variable amplitude and frequency and is used to accelerate a motor connected to the output terminals <NUM> according to a predefined acceleration profile. The motor starter <NUM> may include a number of control parameters, configurable to define a desired acceleration profile. The motor starter <NUM> receives a control signal indicating operation of the motor connected to the output terminals <NUM> is desired and, in turn, accelerates the motor up to a desired operating speed and then maintains operation of the motor at the desired speed while the control signal is present.

Each of the contactor <NUM> and the motor starter <NUM> require control signals in order to selectively provide the voltage from the circuit protection device <NUM> to a remote device connected at their respective output terminals <NUM>, <NUM>. An electronic control module <NUM> is connected to the modular power distribution device <NUM>, <NUM> to receive these control signals. The electronic control module <NUM> is configured to physically mount to either the circuit protection device <NUM>, the electronically actuated power distribution device <NUM>, <NUM>, or a combination thereof. A tab <NUM> protruding downward from the electronic control module <NUM> is configured to be snap fit to a complementary tab <NUM>, <NUM>. The tab on the electronic control module <NUM> extends down between the circuit protection device <NUM> and the electronically actuated power distribution device <NUM>, <NUM>, Consequently, the complementary tab may be on one device or the other. Optionally, both devices may include a tab to more securely retain the electronic control module <NUM> to the modular power distribution device. The snap-fit of the electronic control module <NUM> allows the module to be mounted to the rest of the modular power distribution device <NUM>, <NUM> without requiring a tool for installation. A first electronic control module 140A is illustrated in <FIG> as mounting to a contactor module <NUM>, and a second electronic control module 140B is illustrated in <FIG> as mounting to a starter module <NUM>. It is contemplated that the electronic control modules <NUM> include identical components but are sized differently to cover the respective electronically actuated power distribution device to which they are mounted.

The electronic control module <NUM> includes a communication port <NUM> to which a ribbon cable connector <NUM> and the corresponding network cable <NUM> are connected. The ribbon cable <NUM> provides for a daisy chain connection between the communication module <NUM> and each modular power distribution device <NUM>, <NUM>. With reference also to <FIG>, each electronic control module includes a printed circuit board <NUM> configured to include a control circuit. The control circuit is configured to receive data, such as control signals, from the communication port <NUM> and to transmit the control signals to either the circuit protection device <NUM> or the electronically actuated power distribution device <NUM>, <NUM>. The control circuit is also configured to receive feedback signals from either the circuit protection device <NUM><NUM> or the electronically actuated power distribution device <NUM>, <NUM> and to package the feedback signals into data packets according to the network protocol for transmission from the communication port <NUM>. The feedback signals correspond to the present operating conditions of either the circuit protection device <NUM> or the electronically actuated power distribution device <NUM>, <NUM>. The circuit protection device <NUM> may include, for example, a microswitch providing a signal corresponding to the status of the switching member <NUM>. The circuit protection device <NUM> may also include a current transformer measuring an amplitude of current. As still another option, the circuit protection device <NUM> may generate a fault signal indicating when the overcurrent protection in the device has tripped. If the electronically actuated power distribution device includes a contactor module <NUM>, feedback signals may be provided indicating whether the switching member <NUM> is in an open or closed state. If the electronically actuated power distribution device is a motor starter module <NUM>, various feedback signals may be generated indicating, for example, when the motor is accelerating, up to speed, at zero speed or the like. Each of the control signals and/or feedback signals corresponds to a signal which traditionally has been transferred back to a central controller <NUM> via individual conductors. Transmitting the control signals and/or feedback signals via the ribbon cable <NUM> reduces wiring complexity and the potential for wiring errors.

Claim 1:
A modular power distribution device (<NUM>; <NUM>), comprising:
a base (<NUM>) having a first side (<NUM>) and a second side (<NUM>), wherein:
the first side is configured to be mounted to a control panel,
the second side is opposite the first side, and
the second side includes a first mounting section (<NUM>) and a second mounting section (<NUM>);
a circuit protection device (<NUM>) configured to be mounted to the first mounting section of the base, the circuit protection device including:
a plurality of input terminals (<NUM>) configured to receive power conductors, and
a plurality of output connections (<NUM>);
an electronically actuated power distribution device (<NUM>; <NUM>) configured to be mounted to the second mounting section of the base, the electronically actuated power distribution device including:
a plurality of input connections (<NUM>), wherein the plurality of input connections are configured to connect to the plurality of output connections of the circuit protection device; and
a plurality of output terminals (<NUM>) configured to receive conductors for supplying power to a controlled device, wherein the electronically actuated power distribution device is configured to slidably engage the second mounting section of the base and the plurality of input connections on the electronically actuated power distribution device are configured to slidably engage the plurality of output connections on the circuit protection device as the electronically actuated power distribution device slidable engages the second mounting section; and
an electronic control module (<NUM>) configured to physically mount to either the circuit protection device or the electronically actuated power distribution device, the electronic control module including:
a plug (<NUM>) configured to receive a network connection,
an electrical connection (<NUM>) to the circuit protection device, and
an electrical connection (<NUM>) to the electronically actuated power distribution device.