Patent ID: 12199468

Identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. However, elements disclosed in one embodiment may be beneficially utilized on other embodiments without specific recitation.

DETAILED DESCRIPTION

This description and the accompanying drawings illustrate exemplary embodiments of the present disclosure and should not be taken as limiting, with the claims defining the scope of the present disclosure, including equivalents. Various mechanical, compositional, structural, electrical, and operational changes may be made without departing from the scope of this description and the claims, including equivalents. In some instances, well-known structures and techniques have not been shown or described in detail so as not to obscure the disclosure. Further, elements and their associated aspects that are described in detail with reference to one embodiment may, whenever practical, be included in other embodiments in which they are not specifically shown or described. For example, if an element is described in detail with reference to one embodiment and is not described with reference to a second embodiment, the element may nevertheless be claimed as included in the second embodiment.

Referring now toFIG.1, a schematic diagram is shown for an exemplary power control system (PCS)100that provides electrical power to a facility102. The facility102may be any facility that receives electrical power from a utility power source104, typically a local power station. Examples include industrial facilities, such as chemical processing plants, manufacturing plants, and the like, as well as office buildings, sporting arenas, apartment complexes, certain residential homes, and the like. Backup power for the facility102is provided by one or more backup power sources106, such as a backup power generator.

The PCS100includes an automatic transfer switch (ATS)108that connects the utility power source104for distribution of electrical power to various facility loads110. The ATS108generally resembles any one of the several commercially available automatic transfer switches insofar as there is an exterior cabinet and door that house one or more switching components for connecting an electrical power source to power distribution equipment (e.g., electrical panels, circuit breakers, etc.). An example is the ASCO 7000 series of automatic transfer switches available from Schneider Electric of Boston, Massachusetts.

In general operation, the ATS108continuously monitors electrical power received from the utility power source104for compliance with certain voltage frequency, and phase angle requirements consistent with normal utility power. When the ATS108detects that the received power has deviated from normal utility power, such as when a power outage occurs, the unit automatically switches the facility102to the backup power source106. Likewise, when the ATS108detects that normal utility power has been restored, it automatically switches the facility102back to the utility power source104.

The power monitoring and switching functions of the ATS108is controlled by an ATS controller, generally indicated at112. The ATS controller112, like the ATS108, generally resembles any one of the several commercially available ATS controllers insofar as there is a user interface with display and keys (which may be tactile or touch screen keys) that a user can use to interact with the controller112. An example is the ASCO Group 5 Controller available from Schneider Electric. The user may then configure the ATS controller112with various operational settings and other information required to control operation of the ATS108.

The operational settings for the ATS controller112are typically customized for the requirements of the PCS100in which the ATS108is installed. Examples include voltage and frequency settings (e.g., normal and emergency voltage and frequency pickup and dropout); time delay settings (e.g., bypass running time delay, standard time delays); features settings (e.g., commit on transfer, shed load, phase rotation, in-phase monitor settings); general settings (e.g., reset settings, language, communication, logging, password); and engine exerciser settings (e.g., date and time, exercise programs and parameters). In addition to operational settings, the ATS controller112may also be configured with calibration history, firmware version, event logs, and other information relevant to operation of the ATS108.

In accordance with embodiments of the present disclosure, the ATS controller112is equipped with a mobile memory module that stores one or more, and preferably all, of the operational settings required by the controller to operate, as shown inFIG.2. In addition, in some embodiments, the ATS controller112may be connected to a network114, which may be an intra-company network (e.g., private enterprise Cloud) or a generally available network (e.g., third-party Cloud). The ATS controller112may be connected to the network114via a wired or wireless network connection116(e.g., Ethernet, Bluetooth, Wi-Fi, cellular, satellite, etc.). In these embodiments, the one or more operational settings may be stored in a repository on the network116and downloaded to and stored on the ATS controller112as needed (e.g., on the mobile memory module).

FIG.2is a schematic diagram illustrating a perspective view of the ATS controller112in a partially disassembled state. As this view shows, the ATS controller112has a top cover200that can be latched to a bottom cover202on which an ATS controller board204is attached. The entire unit is then secured to the inside of the ATS108and connected to one or more switching components206therein for controlling operation thereof. The ATS controller board204has various discrete and integrated circuit components mounted thereon, including a microprocessor208programmed to execute instructions that control operation of the ATS108. The microprocessor208in this example is mounted on the underside of the controller board204(dashed lines).

A mobile memory module210is removably mounted on the top side of the controller board204in data communication with the microprocessor208. As mentioned, the mobile memory module210is a discrete, nonvolatile memory module that stores various operational settings and other information required by the microprocessor208to control operation of the ATS108. The microprocessor208can retrieve these operational settings and other information from the mobile memory module210as needed and also store updated or new operational settings on the mobile memory module210as required.

The removability of the mobile memory module210allows easy transfer and reuse of the operational settings and other information on one ATS controller112at another ATS controller112. All operational settings, calibrations, firmware version, events logs, and other information stored on the mobile memory module210at the time of removal can be transported to the new ATS controller112with minimal effort. This makes it extremely convenient for technicians to install and configure a new ATS controller112in the event of transfer switch failure, controller malfunction, controller upgrade, backing up a controller, and the like.

The mobile memory module210also simplifies technical field service support. Technicians can easily install and commission a new ATS108or multiple new transfer switches of the same (or similar) types by removing a mobile memory module210from a properly configured ATS controller112and installing the memory module210on another ATS controller112that requires the same operational settings, calibrations, firmware version, event logs, and the like. The technician can also copy the operational settings and other information stored on the mobile memory module210to another mobile memory module210.

FIGS.3A-3Dare schematic diagrams illustrating front, side, top, and bottom views, respectively, of an exemplary protective outer housing300for the mobile memory module210according to some embodiments. As these views show, the housing300has a generally rectangular or block shape with four side walls, each of which is labeled302, and a top wall304that together with the side walls302define a hollow interior. The corners between adjacent side walls302may be beveled and taper from the top toward the bottom of the side walls302in some embodiments, but this feature is optional for aesthetic purposes. As another optional feature, the housing300may include a generally planar grip or handle306extending generally perpendicular from the top wall304that a user can easily pinch or grab between thumb and forefinger to facilitate installing and removing the mobile memory module210from the ATS controller board204.

Mounting pegs308a-cprotrude from the bottom of the housing300at the corners thereof to facilitate physically mounting the mobile memory module210on the ATS controller board204. The mounting pegs308a-cmay be formed as an integral part of the housing300via a molding or similar process, or each mounting peg308a-cmay be attached to the housing300via a suitable chemical or mechanical attachment means (e.g., adhesives, snapped into place, etc.). Note that are three mounting pegs308a-cin the example shown, each having equal length and width, to ensure proper orientation of the mobile memory module210on the ATS controller board204. Alternative poka-yoke mounting mechanisms may of course be used, such as two adjacent mounting pegs or pegs with different cross-sections and/or widths (with corresponding mounting apertures on the ATS controller board204).

An opening310, which may be threaded, is provided in the top wall304of the housing300for receiving a removable fastener, such as a locking pin, screw, and the like (seeFIGS.5A-5C). The removable fastener allows the mobile memory module210to be releasably secured to the ATS controller board204and facilitates removal of the module210as needed. A retention ring312may be provided in some embodiments to help keep the removable fastener from falling out of the housing300during the mounting or removal process. The dimensions of the housing300may be selected as needed for a particular application, but preferably the housing300is less than an inch in both height and width due to tight space constraints on the ATS controller board204.

In some embodiments, the housing300may be hardened to withstand impact, shock, extreme heat, and the like due to catastrophic ATS failure or controller board malfunction. For example, a power surge may cause certain components on the ATS controller board to catch on fire. As another example, inclement weather, earthquakes, and the like, may cause random objects or tree branches to crash into the ATS. As such, the housing300may be made of an impact, shock, and/or fire resistant material, such as steel. Alternatively, where such precautions are not needed or too costly, the housing300may be made of a lighter material, such as aluminum or plastic.

FIGS.4A-4Bare schematic diagrams illustrating top and side views, respectively, of an exemplary memory board400for the mobile memory module210according to some embodiments. As shown here, the memory board400is a printed circuit board that has several components mounted thereon, including a nonvolatile memory chip402and a jumper header404. A leads header406having a plurality of plug-in leads408extending therefrom may be mounted on the underside of the memory board400. The plug-in leads408electrically connect the nonvolatile memory chip402for data communication with the ATS controller board204(and the microprocessor208thereon) via appropriate selection of jumpers on the jumper header404.

The nonvolatile memory chip402may contain any type of nonvolatile memory, such as flash memory, that has sufficient data storage capacity for the purposes herein. Examples of a suitable nonvolatile memory chips include the I2C-Compatible (Two-Wire) Serial EEPROM 1-Mbit memory chip, part number AT24CM01, available from Microchip Technology Inc., of Chandler, Arizona. Similarly, the jumper header404and leads header406may be any suitable commercially available component designed for the purpose, including part number 951206-8622-AR, available from the Electronic Materials Solutions Division of the 3M Company in Austin, Texas.

The memory board400itself may be a conventional 2-layer printed circuit board with electrically conductive traces running between the layers to provide a signal path for the various components thereon. The dimensions of the memory board400may be selected as needed for a particular application, and are preferably small, about 0.5 inches or less in both length and width, due to space limitations.

FIGS.5A-5Bare schematic diagrams illustrating front and side views, respectively, of the housing300with the memory board400enclosed therein, whileFIG.5Cillustrates a cutaway top view ofFIG.5Aalong lines C-C. As these views show, a removable fastener500, such as a locking pin, screw, and the like, may be used to releasably secure the mobile memory module210to the ATS controller board204and facilitate removal of the module210as needed. The fastener500is inserted through the hole310in the top wall304of the housing300(FIGS.3C-3D) preferably until the fastener head502is flushed against the top wall304. The fastener body504meanwhile protrudes from the bottom of the housing300into the ATS controller board204to secure the housing300to the controller board204.

One or more globs of epoxy or a similar substance, generally indicated at506(FIG.5C), may be deposited on top of the memory board400to securely attach the memory board400to the housing300, specifically to the underside of the top wall304. Note in the above embodiments that the housing300has a height “H” that is sufficiently tall to ensure the plug-in leads408from the leads header406do not protrude from the bottom of the housing300. This prevents the leads408from inadvertently contacting the ATS controller board204during mounting and removal of the mobile memory module210.

FIG.6is a schematic diagram illustrating a top perspective view of the ATS controller board204on which the mobile memory module210may be mounted in some embodiments. As this view shows, the ATS controller board204has a set of mounting holes, indicated at600, for mounting the mobile memory module210on the controller board. Once mounted, the mobile memory module210(and the nonvolatile memory chip402thereon) is connected for data communication with the microprocessor208via one or more electrically conductive traces, generally indicated by line602, that provide a signal path between the mobile memory module210and the microprocessor208.

In theFIG.6example, the set of mounting holes600includes mounting holes608a-cthat correspond in size, shape, and relative position to the mounting pegs308a-c(FIGS.3A-3D) discussed above. As noted, however, alternative hole sizes, shapes, number, and arrangements may be used to ensure foolproof mounting of the mobile memory module210in the proper orientation. Also provided on the ATS controller board204is a hole610(which may be threaded) for receiving the fastener500(FIGS.5A-5C) to secure the mobile memory module210to the controller board204. A socket header606is mounted on the ATS controller board204for receiving the plug-in leads408from the leads header406(FIGS.4A-4B) to electrically connect the mobile memory module210to the signal path602in the controller board204.

Thus far, a number of specific embodiments of the mobile memory module have been described. Following now inFIG.7is a general method that may be used by or with the mobile memory module according to embodiments of the present disclosure

FIG.7is a flow diagram illustrating a method700of commissioning an ATS for a power control system using a mobile memory module according to embodiments of this disclosure. Commissioning refers to process of verifying that the ATS is properly installed and operating according to specifications. The commissioning process typically includes configuring the ATS with specific operational settings that control how the ATS monitors and responds when a power outage is detected. The operational settings are usually customized for the particular power control system in which the ATS is installed and may vary from installation to installation.

The method700generally begins after an ATS has already been physically installed and all required mechanical and electrical connections have been made. At702, as an optional step, a mobile memory module is preloaded or reloaded with various operational settings and other information required to control operation of the ATS. This step is particularly useful for instances where the commissioning process is being performed on a replacement ATS controller and the required information was previously stored in a repository of such information (e.g., on a private or public Cloud).

At704, the mobile memory module is mounted in the controller of the ATS to be commissioned. The mobile memory module may be a new module, or it may be one that has already been previously loaded with the proper operational settings and other information for the ATS to be commissioned. For example, the ATS and/or controller may be a replacement ATS and/or controller and the mobile memory module is one that was pulled from the original ATS and/or controller. Alternatively, the operational settings and other information may be downloaded to the mobile memory module from another mobile memory module that was pulled from the original ATS and/or controller, or from a repository of such information as discussed above.

At706, the operational settings and other information stored in the mobile memory module are transferred or otherwise imported to the ATS controller. This may be accomplished via any suitable data transfer process that can read the operational settings and other information stored on the mobile memory module and copy such data to the ATS controller. Once the transfer is completed, then the ATS controller is tested at708using the transferred operational settings to confirm the controller is operating according to specification.

At710, a determination is made whether additional commissioning is needed. If the determination is yes, then at712, the mobile memory module is removed from the ATS controller and a blank mobile memory module is substituted in place. The operational settings and other information in the ATS controller is then exported or otherwise transferred to the substitute mobile memory module using the data transfer process referenced above. The method then returns to704and the process is repeated for the ATS to be commissioned using the removed mobile memory module.

If the determination at710is no, then the ATS operates as normal at714until such time when additional commissioning is needed. This includes the ATS storing in the mobile memory module any updates or changes to the operational settings, as well as any other information or data that is typically logged during normal operation of the ATS. If the determination at710is yes, then the mobile memory module is removed from the ATS controller at712and the method returns to702to repeat the process. As an optional step, the information stored on the mobile memory module can be transferred or otherwise uploaded to the repository for subsequent reuse before or after the mobile memory module is removed from the ATS.

In the preceding, reference is made to various embodiments. However, the scope of the present disclosure is not limited to the specific described embodiments. Instead, any combination of the described features and elements, whether related to different embodiments or not, is contemplated to implement and practice contemplated embodiments. Furthermore, although embodiments may achieve advantages over other possible solutions or over the prior art, whether or not a particular advantage is achieved by a given embodiment is not limiting of the scope of the present disclosure. Thus, the preceding aspects, features, embodiments and advantages are merely illustrative and are not considered elements or limitations of the appended claims except where explicitly recited in a claim(s).

The various embodiments disclosed herein may be implemented as a system, method or computer program product. Accordingly, aspects may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects may take the form of a computer program product embodied in one or more computer-readable medium(s) having computer-readable program code embodied thereon.

Any combination of one or more computer-readable medium(s) may be utilized. The computer-readable medium may be a non-transitory computer-readable medium. A non-transitory computer-readable medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the non-transitory computer-readable medium can include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. Program code embodied on a computer-readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.

Computer program code for carrying out operations for aspects of the present disclosure may be written in any combination of one or more programming languages. Moreover, such computer program code can execute using a single computer system or by multiple computer systems communicating with one another (e.g., using a local area network (LAN), wide area network (WAN), the Internet, etc.). While various features in the preceding are described with reference to flowchart illustrations and/or block diagrams, a person of ordinary skill in the art will understand that each block of the flowchart illustrations and/or block diagrams, as well as combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer logic (e.g., computer program instructions, hardware logic, a combination of the two, etc.). Generally, computer program instructions may be provided to a processor(s) of a general-purpose computer, special-purpose computer, or other programmable data processing apparatus. Moreover, the execution of such computer program instructions using the processor(s) produces a machine that can carry out a function(s) or act(s) specified in the flowchart and/or block diagram block or blocks.

The flowchart and block diagrams in the figures illustrate the architecture, functionality and/or operation of possible implementations of various embodiments of the present disclosure. In this regard, each block in the flowchart or block diagrams may represent a module, segment or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.

It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other implementation examples are apparent upon reading and understanding the above description. Although the disclosure describes specific examples, it is recognized that the systems and methods of the disclosure are not limited to the examples described herein, but may be practiced with modifications within the scope of the appended claims. Accordingly, the specification and drawings are to be regarded in an illustrative sense rather than a restrictive sense. The scope of the disclosure should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.