Patent Application
20250007250
The invention relates to a Function Enhancement Control Cabinet Module for a control cabinet of an automation system.
A control cabinet can comprise a variety of application devices which can be used to connect devices to a power distribution system of the control cabinet. The application devices can perform different technical functions within the automation system. The application devices can comprise for instance load switches, motor controllers or frequency inverters. In a conventional automation and control system, monitoring of the operation of application devices and connected load devices as well as monitoring of the operation states of the different devices mounted within the control cabinet is limited since a sufficient database is missing.
Accordingly, it is an object of the present invention to provide a Function Enhancement Control Cabinet Module for a control cabinet providing reliable measurement data for monitoring and/or controlling functions performed by application devices mounted within the respective control cabinet.
This object is achieved by a Function Enhancement Control Cabinet Module comprising the features of claim 1.
The invention provides according to a first aspect a Function Enhancement Control Cabinet Module, FECCM, for a control cabinet, said Function Enhancement Control Cabinet Module, FECCM, being integrated in a housing and comprising:
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, comprises further a control interface for connection of said Function Enhancement Control Cabinet Module, FECCM, to an external controller.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, comprises further a user visualization interface adapted to provide output information to a user and/or adapted to receive user input commands from a user of said control cabinet.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, further comprises one or more switching means adapted to control the energy flow between the forward power supply direction and the reverse power supply direction depending on a type of a device connected to the application device mounted to the application device interface at the front side of the housing of the Function Enhancement Control Cabinet Module, FECCM.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, the switching means are adapted to perform a switching of the energy flow between the forward supply direction and the reverse supply direction under control of a microcontroller integrated in a data processing unit of the Function Enhancement Control Cabinet Module, FECCM.
The switching means can comprise controllable semiconductor switches, in particular thyristors, IGBTs or power MOSFETs. The switching means can be integrated in a power electronic subsystem of the Function Enhancement Control Cabinet Module, FECCM.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, the data processing unit, DPU, of said Function Enhancement Control Cabinet Module, FECCM, is adapted to identify a type of the at least one application device connected to the application device interface at the front side of the housing of the Function Enhancement Control Cabinet Module, FECCM, and/or is adapted to identify the type of the device connected to the application device based on a stored current profile and voltage profile and/or based on application device identification data received by the Function Enhancement Control Cabinet Module, FECCM, from the connected application device via a wired application device control interface or via a wireless application device control interface, wherein the wireless application device control interface comprises an RFID interface, a Near Field Communication interface, a WiFi interface or a Bluetooth interface.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, further comprises at least one measurement unit, MU, provided between the energy interface and the application device interface to provide measurement data, MDATA, to the data processing unit, DPU, of said Function Enhancement Control Cabinet Module, FECCM.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, the data processing unit, DPU, is galvanically isolated from said measurement unit, MU, and is adapted to exchange control information and data with the external controller connected to the control interface of the Function Enhancement Control Cabinet Module, FECCM.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, the measurement unit, MU, included in the housing of the Function Enhancement Control Cabinet Module, FECCM, comprises
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, is adapted to determine an application device operation state of the at least one application device connected to the application device interface provided at the front side of the housing of said Function Enhancement Control Cabinet Module, FECCM, by evaluation of the measurement data, MDATA, received by the data processing unit, DPU, from the measurement unit, MU, of the Function Enhancement Control Cabinet Module, FECCM.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, is adapted to determine a power supply state of the power distribution system connected to the energy interface provided at the rear side of the housing of said Function Enhancement Control Cabinet Module, FECCM, by evaluation of the measurement data, MDATA, received by the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, (1) from the measurement unit, MU, of the Function Enhancement Control Cabinet Module, FECCM.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, the user visualization interface is connected to the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, and is adapted to display the application device operation state, in particular an operation failure state, of the at least one application device connected to the application device interface provided at the front side of the housing of the Function Enhancement Control Cabinet Module, FECCM, and/or is adapted to display a power supply state of the power distribution system connected to the energy interface provided at the rear side of the housing of the Function Enhancement Control Cabinet Module, FECCM.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, the user visualization interface is a touch sensitive user interface adapted to receive user input commands of a user of the control cabinet.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, the data processing unit, DPU, is adapted to receive via a communication channel device operation boundary data and/or device characteristics stored in a configuration memory of the application device connected to the application device interface) via the wired or wireless application device control interface to the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM the device operation boundary data of the application device comprises
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, is adapted to perform automatically a pre-configuration of possible functions of the connected application device and/or a pre-configuration of possible functions of the Function Enhancement Control Cabinet Module, FECCM, on the basis of the application device identification data and/or on the basis of the device operation boundary data and/or the device characteristics received by the data processing unit, DPU, via the wired or wireless application device control interface.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM the current sensor of the measurement unit, MU, being adapted to measure an amplitude or an amplitude change of the electrical current, I, flowing through the internal bidirectional power supply path, PSP, comprises at least one shunt resistor, a Hall sensor, a current transformer or a Rogowski coil being adapted to provide a current sensor signal sampled with a predetermined or adjustable sampling rate, SR, and converted by a first analog to digital converter, ADC1, of the measurement unit, MU, to generate current measurement data, I-MDATA, supplied by the measurement unit, MU, to a local non-volatile data memory of the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, for immediate usage and calculations and/or stored in a local non-volatile data memory of the data processing unit, DPU, as a current profile, I-Profile.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM the voltage sensor of the measurement unit, MU, being adapted to measure an amplitude or an amplitude change of the electrical voltage, V, at the internal bidirectional power supply path, PSP, is adapted to provide a voltage sensor signal sampled with a predetermined or adjustable sampling rate, SR, and converted by a second analog to digital converter, ADC2, of the measurement unit, MU, to generate voltage measurement data, V-MDATA, supplied by the measurement unit, MU, to a local non-volatile data memory of the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, for immediate usage and calculations and/or stored in a local non-volatile data memory of the data processing unit, DPU, as a voltage profile, V-Profile.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM the temperature sensor being adapted to measure a temperature, T, or a temperature change at the internal bidirectional power supply path, PSP, provided within the housing of the Function Enhancement Control Cabinet Module, FECCM, is adapted to provide a temperature sensor signal sampled with predetermined or adjustable sampling rate, SR, and converted by a third analog to digital converter, ADC3, of the measurement unit, MU, to generate temperature measurement data, T-MDATA, supplied by the measurement unit, MU, (6) to a local non-volatile data memory of the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, (1) for immediate usage and calculations and/or stored in the local non-volatile data memory of the data processing unit, DPU, as a temperature profile, T-Profile.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM at least one AC power supply phase, L, is applied to a corresponding electrical contact of the energy interface provided at the rear side of the housing of the Function Enhancement Control Cabinet Module, FECCM, connected to the power distribution system.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM the data processing unit, DPU, included in the housing of the Function Enhancement Control Cabinet Module, FECCM, is adapted to process measurement data, MDATA, application device identification data and/or device operation boundary data of the application device connected to the application device interface of the Function Enhancement Control Cabinet Module, FECCM, in real time to optimize an electrical power supply of the connected application device and/or to provide an overcurrent protection and/or to provide an overload protection to the connected application device or to provide an overcurrent protection and/or to provide an overload protection to a load device connected to the application device and/or to control a state of the connected application device and/or to control a state of a load device and/or of a power generation device connected to the application device.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM measurement data, MDATA, application device identification data and/or device operation boundary data are recorded and stored continuously or event-driven at least temporarily in a local non-volatile data memory of the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, is adapted to evaluate the stored measurement data, MDATA, the stored application device identification data and/or the stored device operation state of the application device connected to the application device interface provided at the front side of the housing of the Function Enhancement Control Cabinet Module, FECCM, to detect or predict a failure of the connected application device and is adapted to notify an internal microcontroller or FPGA of the data processing unit, DPU, or an external controller connected to the control interface of the Function Enhancement Control Cabinet Module, FECCM, about the detected or predicted failure of the connected application device.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM an acquisition of the measurement data, MDATA, the application device identification data and/or of the device operation boundary data is triggered and controlled by by the internal microcontroller or by a FPGA of the data processing unit, DPU, included in the housing of the Function Enhancement Control Cabinet Module, FECCM.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM the acquired measurement data, MDATA, stored in the local non-volatile data memory of the data processing unit, DPU, is evaluated by a processor of the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, to determine specific data patterns representing associated application device operation states of the at least one application device connected to the application device interface provided at the front side of the housing of the Function Enhancement Control Cabinet Module, FECCM, and/or representing associated power supply states of the power distribution system connected to the energy interface provided at the rear side of the housing of the Function Enhancement Control Cabinet Module, FECCM.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM the processor of the data processing unit, DPU, comprises a trained artificial neural network, ANN, adapted to recognize application device operation states of the application device connected to the application device interface provided at the front side of the housing of the Function Enhancement Control Cabinet Module, FECCM, and/or to recognize power supply operation states of the power distribution system connected to the energy interface provided at the rear side of the housing of the Function Enhancement Control Cabinet Module, FECCM, on the basis of measurement data, MDATA, received by the data processing unit, DPU, from the galvanically isolated measurement unit, MU, of the Function Enhancement Control Cabinet Module, FECCM, or read from the local non-volatile data memory of the data processing unit, DPU, and applied to an input layer of the trained artificial neural network, ANN, of the processor of the data processing unit, DPU, to provide a classification result output by an output layer of the trained artificial neural network, ANN, to the internal microcontroller or the FPGA of the data processing unit, DPU.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, is adapted to communicate with an external control cabinet controller connected to the control interface of the Function Enhancement Control Cabinet Module, FECCM, by means of a predefined data transfer protocol including a field bus data transfer protocol or an Ethernet-based data transfer protocol.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM the application device connected to the application device interface provided at the front side of the housing of the Function Enhancement Control Cabinet Module, FECCM, comprises a switchable or non-switchable load connector.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM the energy interface provided at the rear side of the housing of the Function Enhancement Control Cabinet Module, FECCM, comprises several electrical contacts for AC power supply phases, L, of a multiphase power distribution system and the application device interface provided at the front side of the housing of the Function Enhancement Control Cabinet Module, FECCM, comprises several electrical contacts for AC power supply phases, L, of a multiphase application device connectable to the application device interface provided at the front side of the housing of the Function Enhancement Control Cabinet Module, FECCM.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM a processor of a data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, is adapted to calculate a phase relationship between different electrical AC power supply phases, L, supplied via the bidirectional internal power supply path, PSP, of the Function Enhancement Control Cabinet Module, FECCM, and/or to determine a frequency of the electrical AC power supply phases, L, based on the measurement data, MDATA, received by the data processing unit, DPU, from a measurement unit, MU, of the Function Enhancement Control Cabinet Module, FECCM, and/or to calculate a real power, a reactive power and/or an apparent power of each phase, L, and to calculate summed real, reactive and apparent power values of a multi-phase power distribution system, and/or to accumulate energy values related to single phases or related to multiple phases of a multiphase power distribution system.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM the measurement unit, MU, of the Function Enhancement Control Cabinet Module, FECCM, is integrated in a measurement submodule connected via an internal data and control interface to the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, integrated in a separate data processing submodule.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM the data processing unit, DPU, is adapted to perform an automatic rotation field detection and/or an automatic polarity detection based on the measurement data, MDATA, received from the measurement unit, MU, and/or based on a phase relationship between different electrical AC power supply phases, L, calculated by a processor of the data processing unit, DPU.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, comprises a microcontroller or FPGA adapted to control at least one actuator provided in the bidirectional internal power supply path, PSP, or located at the application device side in response to the measurement data, MDATA, received by the data processing unit, DPU, from the measurement unit, MU, of the Function Enhancement Control Cabinet Module, FECCM, to optimize the power supply to the connected application device and/or to provide protection against overcurrent and/or against overload.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, the microcontroller or the FPGA of the data processing unit, DPU, is adapted to control functions of the application device connected to the application device interface provided at the front side of the housing of the Function Enhancement Control Cabinet Module, FECCM, through an application device control interface of the Function Enhancement Control Cabinet Module, FECCM.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM, measurement data, MDATA, supplied by the measurement unit, MU, of the Function Enhancement Control Cabinet Module, FECCM, to the processor or to the FPGA of the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, and/or stored in the local non-volatile data memory of the data processing unit, DPU, and/or failure messages indicating a failure of the Function Enhancement Control Cabinet Module, FECCM, and/or a failure of an application device connected to the application device interface of the Function Enhancement Control Cabinet Module, FECCM, are forwarded via the control interface to the external control cabinet controller connected to the control interface of the Function Enhancement Control Cabinet Module, FECCM, along with a unique identifier, FMCCI-ID, of the Function Enhancement Control Cabinet Module, FECCM, and/or along with position information indicating a mounting position of the affected Function Enhancement Control Cabinet Module, FECCM, within the control cabinet.
In a possible embodiment the Function Enhancement Control Cabinet Module, FECCM the switching means comprises a power electronic subsystem adapted to perform the switching between the forward supply direction and the reverse supply direction under control of a microcontroller integrated in a data processing unit of the Function Enhancement Control Cabinet Module, FECCM.
The invention further provides according to a further aspect a control cabinet for an automation system, said control cabinet comprising one or more Function Enhancement Control Cabinet Modules, FECCMs, according to the first aspect of the present invention.
In a possible embodiment of the control cabinet a multiphase Function Enhancement Control Cabinet Module, FECCM, mounted in the control cabinet comprises for each AC power supply phase, L, of the AC power distribution system an associated measurement unit, MU, and a corresponding data processing unit, DPU.
In a possible embodiment of the control cabinet the measurement units, MUs, and the data processing units, DPUs, of the multiphase Function Enhancement Control Cabinet Module, FECCM, are provided on a common rectangular printed circuit board being enclosed by an elongated housing of the multiphase Function Enhancement Control Cabinet Module, FECCM, and being oriented perpendicular to busbars of the multiphase AC power distribution system or perpendicular to mounting rails of the control cabinet, wherein the printed circuit board is fixed in the housing or is arranged replaceable within the housing of the Function Enhancement Control Cabinet Module, FECCM.
The invention provides according to a further aspect a Function Enhancement Control Cabinet Module for a control cabinet comprising
In a preferred embodiment the Function Enhancement Control Cabinet Module comprises a user visualization interface adapted to provide output information to a user and/or to receive user input commands from a user of said control cabinet.
In a possible embodiment of the Function Enhancement Control Cabinet Module, the module comprises at least one internal bidirectional power supply path provided between the energy interface at a rear side of the housing of the Function Enhancement Control Cabinet Module and the application device interface provided at a front side of the housing of the Function Enhancement Control Cabinet Module.
The internal bidirectional power supply path is adapted to feed electrical power from the power distribution system of the control cabinet connected to the energy interface provided at the rear side of the housing of the Function Enhancement Control Cabinet Module in a forward power supply direction to the application device connected to the application device interface provided at the front side of the housing of the Function Enhancement Control Cabinet Module or is adapted to feed electrical power in a reverse power supply direction from the application device connected to the application device interface provided at the front side of the housing of the Function Enhancement Control Cabinet Module to the power distribution system of the control cabinet connected to the energy interface provided at the rear side of the housing of the Function Enhancement Control Cabinet Module.
On the front face of the application device connected to the application device interface provided at a front side of the housing of the Function Enhancement Control Cabinet Module, one or more electrical loads can be connected to receive electrical power from the application device through said application device interface. In this case, the load devices which consume electrical power receive electrical power from the power distribution system of the control cabinet in a forward power supply direction of the power supply path.
The load wiring also can be placed on top or bottom side of the application device.
It is also possible that power generation devices are connected to the application device feeding power through the application device and through the application device interface and through the power supply path of the Function Enhancement Control Cabinet Module into the power distribution system of the control cabinet. In this case, electrical power is fed in reverse power supply direction from the application device into the power distribution system of the control cabinet.
The application device connected to the application device interface of the Function Enhancement Control Cabinet Module can perform different kinds of functions and may comprise for instance a contactor or load switch, a motor control apparatus, a fuse holder, for instance a frequency inverter. The application device connected to the application device interface of the Function Enhancement Control Cabinet Module can provide overcurrent protection and/or overload protection for a load device connected to the respective application device. The application device may also comprise an adapter device. The application device is in a preferred embodiment only in charge of these functions while connected to and controlled by the FECCM.
The h Function Enhancement Control Cabinet Module may comprise different kinds or types of sensor elements which are adapted to provide sensor signals used to provide measurement data being preprocessed or processed by the data processing unit of the Function Enhancement Control Cabinet Module in real time during the operation of the control cabinet.
In a further possible embodiment, the application device operation state is notified to the data processing unit, DPU, of the Function Enhancement Control Cabinet Module, FECCM, through a communication link of a control entity of the application device connected to the application device interface of said Function Enhancement Control Cabinet Module.
In a possible implementation of the Function Enhancement Control Cabinet Module according to the first aspect of the present invention, the wireless application device control interface comprises an RFID interface, a Near Field Communication, NFC, interface, a WiFi interface or a Bluetooth interface.
Accordingly, the Function Enhancement Control Cabinet Module can comprise in a possible implementation at least one application device interface provided for electrical power supply and an associated application device control interface provided for exchanging control signals between a control entity of the application device and a controller integrated in the data processing unit of the Function Enhancement Control Cabinet Module.
In a further possible embodiment of the Function Enhancement Control Cabinet Module according to the first aspect of the present invention, the data processing unit of the Function Enhancement Control Cabinet Module is adapted to perform automatically a pre-configuration of possible functions of the connected application device on the basis of the application device identification data and/or on the basis of the device operation boundary data and/or on the basis of the device characteristics received by the data processing unit via a wired or wireless application device control interface.
In a further possible embodiment of the Function Enhancement Control Cabinet Module according to the first aspect of the present invention functions of the Function Enhancement Control Cabinet Module can be pre-configured or re-configured automatically depending on a detected type of the application device or depending on an input type of the application device input by a user.
These functions may comprise for instance a matching monitoring algorithm for current monitoring or a coupling of auxiliary outputs to current threshold values voltage threshold values or to temperature threshold values.
In a possible embodiment of the Function Enhancement Control Cabinet Module according to the first aspect of the present invention, the external control cabinet controller connected to the control interface of the Function Enhancement Control Cabinet Module is adapted to trigger a repair or a maintenance or a troubleshooting action to address the notified failure of the application device connected to the application device interface provided at the front side of the housing of the Function Enhancement Control Cabinet Module.
In a still further possible embodiment of the Function Enhancement Control Cabinet Module according to the first aspect of the present invention, the application device connected to the application device interface provided at the front side of the housing of the Function Enhancement Control Cabinet Module comprises a meltable or an electronic-controlled fuse element.
In a further possible embodiment of the Function Enhancement Control Cabinet Module according to the first aspect of the present invention, the measurement submodule is connectable to the data processing submodule via the internal data and control interface to provide the Function Enhancement Control Cabinet Module.
In a still further possible embodiment of the Function Enhancement Control Cabinet Module according to the first aspect of the present invention, an actuator in the bidirectional power supply path, PSP, comprises a controllable semiconductor power switch or comprises an electromechanical power switch.
In a further possible embodiment of the Function Enhancement Control Cabinet Module according to the first aspect of the present invention, the control cabinet controller of the control cabinet is adapted to compare the measurement data received by the control cabinet controller via control interfaces from different Function Enhancement Control Cabinet Modules mounted in the control cabinet to identify a deviating operation behavior of a Function Enhancement Control Cabinet Module.
In a possible embodiment, the Function Enhancement Control Cabinet Module is connected to an internal power distribution busbar system of a control cabinet.
The invention provides according to a further aspect a Function Enhancement Control Cabinet Busbar Module comprising at least one internal bidirectional power supply path provided between an energy interface at a rear side of a housing of the Function Enhancement Control Cabinet Busbar Module and the application device interface provided at a front side of the housing of the Function Enhancement Control Cabinet Busbar Module and adapted to feed electrical power in a forward power supply direction from at least one busbar of a power distribution busbar system connected to the energy interface to the application device connected to the application device interface or is adapted to feed electrical power in a reverse power supply direction from the application device connected to the application device interface to at least one busbar of the power distribution busbar system connected to the energy interface and comprising at least one measurement unit integrated in the housing of the Function Enhancement Control Cabinet Busbar Module and provided at the internal power supply path between the energy interface and the application device interface to provide measurement data to a data processing unit integrated in the housing of the Function Enhancement Control Cabinet Busbar Module, wherein said data processing unit is galvanically isolated from said measurement unit and is adapted to exchange control information and data with an external control cabinet controller of a control cabinet connected to a control interface of the Function Enhancement Control Cabinet Busbar Module provided in the housing of the Function Enhancement Control Cabinet Busbar Module and connected to the integrated data processing unit of the Function Enhancement Control Cabinet Busbar Module.
In a possible embodiment of the Function Enhancement Control Cabinet Busbar Module, the power distribution busbar system of the control cabinet comprises an AC power distribution busbar system having at least one busbar for an associated power supply phase applied to a corresponding electrical contact of the energy interface provided at a rear side of the housing of the Function Enhancement Control Cabinet Busbar Module connected to the power distribution busbar system.
In an alternative embodiment, the Function Enhancement Control Cabinet Busbar Module comprises a DC power distribution busbar system providing a DC power supply applied to at least one busbar of the DC power supply system.
In a further possible embodiment of the Function Enhancement Control Cabinet Busbar Module according to the second aspect of the present invention, the application device connected to the application device interface provided at the front side of the housing of the Function Enhancement Control Cabinet Busbar Module comprises an electrical load including a resistive load, a capacitive load and/or an inductive load or comprises an adapter device used for connection of a load device.
In a further possible embodiment of the Function Enhancement Control Cabinet Busbar Module according to the second aspect of the present invention, the energy interface provided at the rear side of the housing of the Function Enhancement Control Cabinet Busbar Module comprises electrical contacts protruding from the rear side of the housing of the Function Enhancement Control Cabinet Busbar Module pluggable into corresponding slots of busbars of the power distribution busbar system of the control cabinet.
The busbars of the power distribution system can in a possible embodiment be integrated in a touch protected busbar board.
In a still further possible embodiment of the Function Enhancement Control Cabinet Busbar Module according to the second aspect of the present invention, the application device interface provided at the front side of the housing of the Function Enhancement Control Cabinet Busbar Module comprises at least one busbar portion of an internal busbar included in the housing of the Function Enhancement Control Cabinet Busbar Module and forming part of the internal bidirectional power supply path, wherein the busbar portion of the internal busbar comprises slots into which protruding electrical contacts of an application device are pluggable through associated contact openings provided at the front side of the housing of the Function Enhancement Control Cabinet Busbar Module.
In a still further possible embodiment of the Function Enhancement Control Cabinet Busbar Module according to the second aspect of the present invention, the measurement unit and the data processing unit integrated in the electrically isolating housing of the Function Enhancement Control Cabinet Busbar Module are provided on a printed circuit board surrounded by the electrically isolating housing of the Function Enhancement Control Cabinet Busbar Module.
In a possible embodiment the Printed Circuit Board is replaceable.
In a further possible embodiment of the Function Enhancement Control Cabinet Busbar Module according to the second aspect of the present invention, the sensors of the measurement unit of the Function Enhancement Control Cabinet Busbar Module are provided at the at least one internal busbar included in the housing of the Function Enhancement Control Cabinet Busbar Module to provide measurement data to the data processing unit of the Function Enhancement Control Cabinet Busbar Module indicating an amplitude or an amplitude change of an electrical current flowing through the internal busbar and/or indicating an electrical voltage or voltage change of an electrical voltage at the internal busbar of the Function Enhancement Control Cabinet Busbar Module.
In a possible embodiment of the Function Enhancement Control Cabinet Busbar Module, an auxiliary power supply for the data processing unit of the Function Enhancement Control Cabinet Busbar Module is provided through the control interface of the Function Enhancement Control Cabinet Busbar Module.
In a further possible embodiment of the Function Enhancement Control Cabinet Busbar Module according to the second aspect of the present invention, for each AC power supply phase of a multiphase AC power distribution busbar system of the control cabinet, a separate Function Enhancement Control Cabinet Busbar Module is provided.
In a still further possible embodiment of the Function Enhancement Control Cabinet Busbar Module according to the second aspect of the present invention, a sensor provided at the internal power supply path is adapted to generate a sensor signal supplied via gold spring elements to the data processing unit mounted on a printed circuit board of the Function Enhancement Control Cabinet Busbar Module.
In a further possible embodiment of the Function Enhancement Control Cabinet Busbar Module according to the second aspect of the present invention, the user visualization interface comprises a set of light emitting diodes located at the application device interface and adapted to indicate a connection state and/or an operation state of an application device connected to the application device interface of the Function Enhancement Control Cabinet Busbar Module and comprises a set of light emitting diodes, located at the energy supply interface and adapted to indicate a connection state and/or an operation state of the power distribution busbar system of the control cabinet connected to the energy supply interface of the Function Enhancement Control Cabinet Busbar Module.
In a still further possible embodiment of the Function Enhancement Control Cabinet Busbar Module according to the second aspect of the present invention, the application device connected to the application device interface provided at the front side of the housing of the Function Enhancement Control Cabinet Busbar Module comprises an RFID tag storing application device identification data and/or device operation boundary data read by an RFID reading unit of the Function Enhancement Control Cabinet Busbar Module and supplied to a processor of the data processing unit of the Function Enhancement Control Cabinet Busbar Module and/or stored in a local non-volatile data memory of the data processing unit.
The invention provides according to a further third aspect a control cabinet including one or more Function Enhancement Control Cabinet Modules according to the first or second aspect of the present invention.
The invention provides according to the third aspect a control cabinet including one or more Function Enhancement Control Cabinet Modules according to the first or second aspect of the present invention being mounted in the control cabinet, wherein the Function Enhancement Control Cabinet Module comprises an energy interface connected to an AC power distribution system or to a DC power distribution system of the control cabinet and comprises an application device interface for connection of at least one application device via a bidirectional internal power supply path of the Function Enhancement Control Cabinet Module to the AC or DC power distribution system of the control cabinet and further comprises a control interface provided for connection of the respective Function Enhancement Control Cabinet Module to a control cabinet controller of the control cabinet, wherein the Function Enhancement Control Cabinet Modules of the control cabinet are adapted to communicate with each other and/or to communicate with the control cabinet controller of the control cabinet by means of wired or wireless communication interfaces.
In a possible embodiment of the control cabinet according to the third aspect of the present invention, busbars of the power distribution busbar system of the control cabinet are encapsulated by a touch protection busbar board having slots to receive protruding electrical contacts of the energy interface of the Function Enhancement Control Cabinet Module being pluggable through contact openings provided at the front side of the touch protection busbar board into corresponding slots of the encapsulated busbars of the power distribution busbar system of the control cabinet lying directly beneath the contact openings of the respective touch-protected busbar board.
In a possible embodiment of the control cabinet according to the third aspect of the present invention, the busbars of the power distribution busbar system of the control cabinet are mounted in a horizontal direction within the control cabinet.
The busbars of the power distribution busbar system of the control cabinet can be mounted on a mounting platform of the control cabinet, wherein the mounting platform comprises a mounting plate or mounting support poles of the control cabinet.
In a further possible embodiment of the control cabinet according to the third aspect of the present invention, a multiphase application device having protruding electrical contacts is pluggable through corresponding contact openings provided at the front side of the housing of the multiphase Function Enhancement Control Cabinet Module into slots of internal busbars included in the housing of the multiphase Function Enhancement Control Cabinet Module to establish an electrical contact via the bidirectional internal power supply path of the multiphase Function Enhancement Control Cabinet Module with the electrical contacts of the energy interface provided at the rear side of the housing of the multiphase Function Enhancement Control Cabinet Module and for establishing an electrical connection with the busbars of the power distribution busbar system of the respective control cabinet.
In a possible embodiment of the control cabinet according to the third aspect of the present invention, the multiphase Function Enhancement Control Cabinet Module mounted in the control cabinet comprises for each AC power supply phase of the multiphase AC power distribution busbar system an associated measurement unit and a corresponding data processing unit.
In a possible embodiment of the control cabinet according to the third aspect of the present invention, the data processing units of a multiphase Function Enhancement Control Cabinet Module are provided on a common rectangular printed circuit board being enclosed by an elongated housing of the multiphase Function Enhancement Control Cabinet Module and being oriented perpendicular to the busbars on mounting rails of the multiphase power distribution busbar system of the control cabinet.
In a further possible embodiment of the control cabinet according to the third aspect of the present invention, the control cabinet controller of the control cabinet is connected to a user interface of the control cabinet adapted to display operation states and/or to display a predicted or detected failure of a plurality of application devices connected to the Function Enhancement Control Cabinet Modules included in a housing of the control cabinet.
In a further possible embodiment of the control cabinet according to the third aspect of the present invention, the rear side of the housing of the Function Enhancement Control Cabinet Module is mountable to a rail or a mounting plate of the respective control cabinet.
In the following, possible embodiments of the different aspects of the present invention are described in more detail with reference to the enclosed figures.
The Function Enhancement Control Cabinet Module 1 illustrated in
The Function Enhancement Control Cabinet Module 1 further comprises at least one application device interface 3 for connection and power supply of at least one application device 15 to the Function Enhancement Control Cabinet Module 1. The application device interface 3 as shown in
The Function Enhancement Control Cabinet Module 1 further comprises in the illustrated embodiment of
The Function Enhancement Control Cabinet Module 1 according to the present invention comprises further in a possible embodiment a user visualization interface 5 as shown in
As can be seen in the block diagram of
The internal circuitry of the Function Enhancement Control Cabinet Module 1 comprises at least one measurement unit 6 provided between the energy interface 2 and the application device interface 3 to provide measurement data MDATA for a data processing unit 7 of the Function Enhancement Control Cabinet Module 1. The data processing unit 7 is galvanically isolated from the measurement unit 6. The data processing unit 7 is further adapted to exchange control information and data via the control cabinet controller 17 of the control cabinet 13 connected to the control interface 4 of the Function Enhancement Control Cabinet Module 1.
The control cabinet controller or control device 17 can for instance comprise a PLC or PC system. In a possible implementation, also auxiliary energy can be supplied to the internal circuitry mounted on a printed circuit board PCB of the Function Enhancement Control Cabinet Module 1 via the control interface 4. The energy interface 2 can be connected to an internal power distribution system 14 of the control cabinet 13.
Also, on the front side of the housing of the Function Enhancement Control Cabinet Module 1, there can be different ways to connect an application device 15 to the application device interface 3 of the Function Enhancement Control Cabinet Module 1. For instance, the application device interface 3 can comprise internal busbars 31 having slots 32 for receiving protruding electrical contacts 33 of application devices 15 connected to the respective contacts of the application device interface 3 as also illustrated in
The internal bidirectional power supply path PSP is provided between the energy interface 3 at the rear side of the housing of the Function Enhancement Control Cabinet Module 1 and the application device interface 3 at the opposite front side of the housing of the Function Enhancement Control Cabinet Module 1. The internal bidirectional power supply path PSP is adapted to feed electrical power from the power distribution system 14 connected to the energy interface 2 provided at the rear side of the housing of the Function Enhancement Control Cabinet Module 1 in a forward power supply direction through the application device 15 to a load device 21A connected to the application device interface 3 provided at the front side of the housing of the Function Enhancement Control Cabinet Module 1 as shown in
The application device interface 3 is adapted to provide electrical connection to different kinds of application devices 15 or application device adapters. For instance, the application device 15 connected to the application device interface 3 can comprise a motor controller, a load switch or a fuse holder. The application device 15 connected to the application device interface 3 can also comprise for instance a power feeding element, a frequency inverter or a contactor device. The application device 15 connected to the application device interface 3 can also comprise a power supply control apparatus and/or a power supply protection apparatus providing protection to an electrical load device 21A connected to the application device 15. For instance, an inductive load 21A such as an electrical motor can be connected to an application device 15 being in turn connected to the application device interface 3 on the front side of the housing of the Function Enhancement Control Cabinet Module 1. The motor controller or motor starter forming an application device 15 can be used to control the power supply to the motor load device 21A connected to the application device 15. The Function Enhancement Control Cabinet Module 1 as shown in the block diagram of
In most use cases, the electrical power supply flows in forward power supply direction from the internal power distribution system 14 of the control cabinet 13 through the energy interface 2, the internal power supply path PSP, the application device interface 3, through the application device 15 into the power-consuming load device 21A connected to the application device 15 as shown in
In a preferred embodiment, the Function Enhancement Control Cabinet Module 1 also comprises means to switch between a forward power supply direction shown in
In a possible embodiment, switching between the forward power supply direction and the reverse power supply direction can be performed by switches under control of a microcontroller 23 integrated in the data processing unit 7 of the Function Enhancement Control Cabinet Module 1.
In a possible embodiment, an energy flow in the forward power supply direction and in the reverse power supply direction can be monitored under control of a microcontroller 23 integrated in the data processing unit 7 of the Function Enhancement Control Cabinet Module 1. For instance in a building with renewable power sources such as photovoltaic modules connected through inverters to a local power supply grid or having motors with reverse power feeding capabilities or generators the energy flow, in particular its energy flow direction, can change continuously. A change of the energy flow can be observed by sensors of the Function Enhancement Control Cabinet Module 1 and notified to a user.
In a possible implementation, the user visualization interface 5 can comprise display means to display whether electrical power is flowing in the forward power supply direction as shown in
The measurement unit 6 as illustrated in
An application device operation state of the at least one application device 15 connected to the application device interface 3 provided at the front side of the housing of the Function Enhancement Control Cabinet Module 1 and/or an operation state of a load device 21A or a power source 21B connected to the application device 15 can be determined in a possible embodiment by the data processing unit 7 of the Function Enhancement Control Cabinet Module 1 by performing an evaluation of the stored measurement data MDATA received by the data processing unit 7 from the associated measurement unit 6 of the Function Enhancement Control Cabinet Module 1. In a possible embodiment, the application device operation state and/or the operation state of the load device 21A or power source 21B can be notified to the data processing unit 7 of the Function Enhancement Control Cabinet Module 1 through a communication link by a control entity 15A of the application device 15 connected to the application device interface 3 of the Function Enhancement Control Cabinet Module 1. Further, a power supply state of the power distribution system 14 of the control cabinet 13 being connected to the energy interface 2 provided at the rear side of the housing of the Function Enhancement Control Cabinet Module 1 can be determined in real time through evaluation and analysis of the measurement data MDATA received by the data processing unit 7 of the Function Enhancement Control Cabinet Module 1 from the measurement unit 6 of the respective Function Enhancement Control Cabinet Module 1.
The Function Enhancement Control Cabinet Module 1 as illustrated in the block diagram of
The user visualization interface 5 can comprise in a possible embodiment also a camera or an optical sensitive element to observe the immediate surrounding of the Function Enhancement Control Cabinet Module 1 mounted on the mounting platform of the control cabinet 13. This camera is provided in a possible embodiment on the front side of the housing of the Function Enhancement Control Cabinet Module 1. The camera can be integrated in a display unit of the user visualization interface 5. The camera of the user visualization interface 5 can be adapted to generate pictures if tis surrounding in a visible frequency range or in a not visible frequency range, in particular the infrared frequency range. The camera pictures can be processed to detect specific events within the control cabinet 13 such as light arcs or to locate heat sources within the control cabinet 13.
The user visualization interface 5 can comprise in a possible implementation an OLED display layer. The user visualization interface 5 can comprise in a possible implementation further a microphone to receive acoustic commands from a user U. The user visualization interface 5 can comprise a foldable display including an OLED display layer. By unfolding this display the available display area is increased allowing to display more and more complex information to user with a higher resolution.
In a possible embodiment the user virtualization interface 5 is removable as an entity from the housing of the Function Enhancement Control Cabinet Module 1. In a preferred implementation the user visualization interface 5 remains operative after removal from the housing of the Function Enhancement Control Cabinet Module 1 at least within a predetermined transmission range. After removal of the user visualization interface 5 a data exchange between the user visualization interface 5 and the data processing unit 7 can be performed via a wireless data link. A power supply of the removed user visualization interface 5 can be provided by a battery integrated in the user visualization interface 5.
In a still further embodiment GUIs of several neighboring application devices 15 mounted on one or more neighboring Function Enhancement Control Cabinet Modules 1 are switched automatically together by the Function Enhancement Control Cabinet Module 1 or by the control cabinet controller 17 to provide a common virtual display unit with an increased display area in response to an input user command or depending on the kind of information to be displayed. With the enlarged display area of the virtual display unit it is possible to display more complex information such as repair instructions, circuit diagrams, component lists of internal components of the respective application devices and their load devices 21A or power source devices 21B to a user. The enlarged display area of the virtual display unit allows also to display information with a higher resolution.
In a possible embodiment, the Function Enhancement Control Cabinet Module 1 as illustrated in
In a possible embodiment of the Function Enhancement Control Cabinet Module 1, device operation boundary data and/or device characteristics stored in a configuration memory 15B of the application device 15 connected to the application device interface 3 can be transmitted via a communication channel of the wired or wireless application device control interface 22 to the data processing unit 7 of the Function Enhancement Control Cabinet Module 1 as shown in
In a possible embodiment of the Function Enhancement Control Cabinet Module 1, the data processing unit 7 of the Function Enhancement Control Cabinet Module 1 is adapted to perform automatically a pre-configuration of possible functions of the connected application device 15 on the basis of the application device identification data and/or on the basis of the device operation boundary data and/or on the basis of the device characteristics received by the data processing unit 7 via the wired or wireless application device control interface 22 illustrated in
In a further possible embodiment of the Function Enhancement Control Cabinet Module 1 according to the first aspect of the present invention required functions of the Function Enhancement Control Cabinet Module 1 can be pre-configured or re-configured automatically depending on a detected type of the application device 15 or its load devices 21A or its power source devices 21 B or depending on an input type of the application device 15 input by a user by means of the user interface. These configurable functions may comprise for instance matching algorithms such as a current monitoring algorithm for current monitoring or for coupling of auxiliary outputs to current threshold values voltage, threshold values or to temperature threshold values. The algorithm or function does match the type of the application device 15 and/or its load or source devices. The functional algorithm can be loaded through the control interface 4 from a database or function library or can be loaded from a local memory into the microcontroller 23 of the data processing unit 7.
The power distribution system 14 of the control cabinet 13 comprises in a possible embodiment an internal AC power distribution system 14 having at least one AC power supply phase L applied to a corresponding electrical contact of the energy interface 2 provided at the rear side of the housing of the Function Enhancement Control Cabinet Module 1 connected to the AC power distribution system 14 of the control cabinet 13. In an alternative embodiment, the power distribution system 14 of the control cabinet 13 can also comprise a DC power distribution system.
In a possible embodiment of the Function Enhancement Control Cabinet Module 1 as illustrated in
In a possible implementation of the Function Enhancement Control Cabinet Module 1 according to the first aspect of the present invention, the stored device operation boundary data loaded into the data memory 11 comprises a maximum and minimum admissible supply current, a maximum and minimum admissible supply voltage, a maximum and minimum admissible operation temperature, an I2t value and/or a maximum switching frequency of the connected application device 15.
By processing the available measurement data MDATA, the application device identification data and the device operation boundary data, a processor or controller 23 of the data processing unit 7 can optimize an electrical power supply to the application device 15 connected to the application device interface 3. Further, by processing the available data, the controller 23 of the data processing unit 7 can provide in a possible implementation an effective overcurrent protection or overload protection of the application device 15 connected to the application device interface 3. The microcontroller 23 of the data processing unit 7 can further provide in a possible implementation also an overcurrent protection and/or an overload protection of any load device 21A connected to the application device 15 on the basis of the available measurement data MDATA, the available application device identification data and/or on the basis of the available device operation boundary data stored in the data memory 11 of the data processing unit 7. In a possible embodiment, the microcontroller 23 of the data processing unit 7 can further be adapted to control in real time an operation state of the connected application device 15 and/or to control an operation state of a load device 21A or power source device 21B connected to the application device 15 on the basis of the available measurement data, the available device operation boundary data and/or the application device identification data stored in the data memory 11 of the data processing unit 7.
The measurement data, the application device identification data and the device operation boundary data can be recorded and stored in a possible embodiment continuously or event-driven in a local non-volatile data memory 11 of the data processing unit 7 of the Function Enhancement Control Cabinet Module 1. The processor 12 of the data processing unit 7 is adapted to evaluate the stored measurement data, the stored application device identification data and the stored device operation state of the application device 15 connected to the application device interface 3 provided at the front side of the housing of the Function Enhancement Control Cabinet Module 1 to detect or predict a failure of the connected application device 15. In a possible embodiment, the detected or predicted failure is notified to the internal microcontroller 23 or FPGA of the data processing unit 7 or to an external control cabinet controller 17 of the control cabinet 13 connected to the control interface 4 of the Function Enhancement Control Cabinet Module 1 to trigger corresponding countermeasures to overcome the failure of the application device 15 or its load device 21.
In a possible implementation, the external control cabinet controller 17 connected to the control interface 4 of the Function Enhancement Control Cabinet Module 1 is adapted to trigger automatically a repair or a maintenance action or a troubleshooting action to address the notified failure of the application device 15 connected to the application device interface 3.
The acquisition of the measurement data MDATA and the acquisition of the application device identification data and/or the acquisition of the device operation boundary data can be triggered and controlled in a possible embodiment by a control entity 15A of the application device 15 connected to the application device interface 3 as shown in
The acquired measurement data MDATA stored in the local non-volatile data memory 11 of the data processing unit 7 is evaluated in a possible embodiment by a processor 12 of the data processing unit 7 of the Function Enhancement Control Cabinet Module 1 to determine specific data patterns representing associated application device operation states of the at least one application device 15 connected to the application device interface 3 and/or representing associated power supply states of the power distribution system 14 of the control cabinet 13 connected to the energy interface 2 of the Function Enhancement Control Cabinet Module 1.
The data processing unit 7 shown in
The data processing unit 7 of the Function Enhancement Control Cabinet Module 1 as shown in
The application device 15 connected to the application device interface 3 provided at the front side of the housing of the Function Enhancement Control Cabinet Module 1 as illustrated schematically in
In a possible embodiment, the energy interface 2 provided at the rear side of the housing of the Function Enhancement Control Cabinet Module 1 can comprise several electrical contacts for AC power supply phases L of a multiphase power distribution system 14. Also, the application device interface 3 provided at the front side of the housing of the Function Enhancement Control Cabinet Module 1 can comprise several electrical contacts for different AC power supply phases L of a multiphase application device 15 connectable to the application device interface 3 provided at the front side of the housing of the Function Enhancement Control Cabinet Module 1.
The at least one data processor 12 of the data processing unit 7 as shown in
In a further possible embodiment, the processor 12 of the data processing unit 7 is further adapted to calculate automatically a real power, a reactive power and/or an apparent power for each phase L of the multiphase electrical AC power supply system. Further, the processor 12 can calculate in a possible implementation also a summed real, reactive and apparent power value for the multiphase power distribution system 14. The processor 12 does accumulate energy values related to single phases or related to multiple phases of a multiphase power distribution system 14 of the control cabinet 13. The calculation of the phase relationship and/or of the power and energy values are performed by execution of a programmable calculation algorithm stored in a program memory accessible by the processor 12 of the data processing unit 7. The program can be loaded in a possible embodiment through the control interface 4 of the Function Enhancement Control Cabinet Module 1 from a server or central control unit 20 of the automation system shown in
In a possible embodiment of the Function Enhancement Control Cabinet Module 1 as illustrated in the block diagram of
The data processing submodule 7 comprises the control interface 4 and the user visualization interface 5. The data processing unit 7 can be optimized to meet user demands like comprehensive visualization and flexible connectivity. In the embodiment illustrated in
In a possible embodiment, the measurement data MDATA stored in the memory 11 of the data processing unit 7 can be forwarded to the external control cabinet controller 17 connected to the control interface 4 of the Function Enhancement Control Cabinet Module 1 along with a unique identifier (FECCM-ID) of the Function Enhancement Control Cabinet Module 1 for further processing. The transmission of the measurement data MDATA can be performed according to the applied data transfer protocol. Also, failure messages indicating a failure of the Function Enhancement Control Cabinet Module 1 and/or a failure of an application device 15 connected to the application device interface 3 or a connected load device 21 can be forwarded to the external control cabinet controller 17 connected to the control interface 4 along with the unique identifier of the Function Enhancement Control Cabinet Module 1 for further data evaluation. Also, information indicating a mounting position of the affected Function Enhancement Control Cabinet Module 1 can be forwarded through the control interface 4 to the control cabinet controller 17 and be taken into account for performing the necessary counter actions. The control cabinet controller 17 of the control cabinet 13 is adapted to compare the measurement data MDATA received by the control cabinet controller 17 via the different control interfaces 4 from the different Function Enhancement Control Cabinet Modules 1 mounted in the control cabinet 13 to identify a deviating operation behavior of an affected Function Enhancement Control Cabinet Module 1. In case that the Function Enhancement Control Cabinet Module 1 shows a significantly deviating operation behavior to other Function Enhancement Control Cabinet Modules 1, an data analyzing routine can be triggered to determine what kind of failures have occurred in the affected Function Enhancement Control Cabinet Module 1.
The measurement unit 6 of the Function Enhancement Control Cabinet Module 1 can comprise different kinds of sensor elements to generate sensor signals which are converted into measurement data MDATA. In a possible embodiment, the measurement unit 6 comprises at least one current sensor 9A adapted to measure an electrical current I flowing through the power supply path PSP of the Function Enhancement Control Cabinet Module 1. The current sensor 9A of the measurement unit 6 is adapted to measure the electrical current I flowing through the internal power supply path PSP and can comprise at least one shunt resistor as illustrated in
In an alternative embodiment, to overcome drawbacks caused by power dissipated related to a shunt resistor R, a Rogowski coil 9A can be used for generation of a current measurement signal as illustrated in
To extend the capability of DC measurements without drawbacks of too much power dissipation, a Hall sensor 9A can be used as a sensing element of the measurement unit 6 as illustrated in
The direction of the magnetic field lines of the magnetic field generated by the flowing electrical current I measured by the current sensor 9A can be determined in a possible embodiment to detect a flowing direction of the electrical current I based on the measurement data MDATA provided by the current sensor 9A of the measurement unit 6 to the data proceeding unit 7. In this way it is can be determined whether the electric power supply current I is flowing in a forward power supply direction as shown in
The use of a Rogowski coil, a current transformer or a Hall sensor as the sensor element 9A provides intrinsic galvanic isolation from the current carrying power supply path PSP.
In a possible implementation, an integrated Hall sensor 9 can be used where the electrical load current I is passed through the sensor housing. With this setup, a common field suppression and calibration can be performed directly by the device manufacturer. This can lead to a compact subsystem in industry standard integrated circuit packages. This eases the efforts for the end user.
In contrast, the shunt resistor R as illustrated in
The voltage sensor 9B is adapted to measure the electrical voltage V at the internal power supply path PSP and is adapted to provide a voltage sensor signal sampled and converted by a second analog to digital converter 10B of the measurement unit 6 to generate voltage measurement data V-MDATA supplied by the measurement unit 6 to the data processing unit 7 of the Function Enhancement Control Cabinet Module 1 and stored in the local non-volatile data memory 11 of the data processing unit 7 as a voltage profile V-PROFILE.
In a further embodiment, a temperature sensor 28A of the measurement unit 6 (shown in
In a possible embodiment, the microcontroller 23 of the data processing unit 7 can be adapted to control the sampling rate SR of the employed analog to digital converters 10A, 10B as shown in
The analog to digital converters 10 of the measurement unit 6 can use a common time grid applicable to all Function Enhancement Control Cabinet Modules 1 installed in the control cabinet 13. In this way, it is possible to compare measurement data MDATA stored in data memories 11 of different Function Enhancement Control Cabinet Modules 1 mounted in the control cabinet 13 an identified by their unique FMCCI-IDs. In a possible embodiment, the current samples i generated by the analog to digital converter 10A and the voltage samples v generated by the analog to digital converter 10B are tagged with a time stamp so that a set of current and/or voltage samples generated by different measurement units 6 located at different positions within the control cabinet 13 can be compared to each other during operation of the automation system in real time to detect causal relationships between different entities mounted within the control cabinet 13 based on the stored current profiles, I-PROFILEs, and/or voltage profiles, V-PROFILEs. In a possible embodiment, the control cabinet controller 17 can comprise a clock signal generator generating a clock signal CLK distributed through the control interfaces 4 of the different Function Enhancement Control Cabinet Modules 1 to the measurement units 6 and the data processing units 7 of the Function Enhancement Control Cabinet Modules 1 to provide a common time grid.
Similarly, a multiphase application device 15 may also comprise protruding electrical contacts 33 being pluggable through corresponding contact openings 34 provided at the front side of the housing of the multiphase Function Enhancement Control Cabinet Module 1 into slots 32 of internal busbars 31 included in the housing of the multiphase Function Enhancement Control Cabinet Module 1. In this way, it is possible to establish an electrical contact via the bidirectional internal power supply paths PSPs of such a multiphase Function Enhancement Control Cabinet Module 1 with the electrical contacts 29 of the energy interface 2 provided at the rear side of the housing of the multiphase Function Enhancement Control Cabinet Module 1 and to provide a connection with the power distribution busbar system 14 of the control cabinet 13.
In a possible embodiment, the application device interface 3 comprises a motor controller to which an electrical motor is connected as a load device 21A. In a possible embodiment, the processor 12 of the data processing unit 7 is adapted to perform an automatic rotation field detection and/or an automatic polarity detection based on the measurement data MDATA stored in the data memory 11 of the data processing unit 7 for the different electrical AC power supply phases L1, L2, L3. The microcontroller 23 or FPGA of the data processing unit 7 can further perform a control function of the application device 15 connected to the application device interface 3 and the application device control interface 22 provided at the front side of the housing of the Function Enhancement Control Cabinet Module 1 through the application device interface 3 of the Function Enhancement Control Cabinet Module 1 as also illustrated in the block diagram of
In a further possible implementation, the data processing unit 7 of the Function Enhancement Control Cabinet Module 1 can also comprise a microcontroller 23 or FPGA adapted to control at least one actuator provided within the bidirectional internal power supply paths PSP1, PSP2, PSP3 in response to the measurement data MDATA received by the data processing unit 7 from the measurement units 6-i of the Function Enhancement Control Cabinet Module 1 to optimize the power supply of the connected application device 15 and/or to provide protection of the application device 15 or its connected load device 21 such as the electrical multiphase motor against overcurrent and/or against overload. The actuator can comprise in a possible implementation a controllable semiconductor power switch or an electromechanical power switch such as a relay.
In a possible implementation, the application device 15 connected to the application device interface 3 provided at the front side of the housing of the Function Enhancement Control Cabinet Busbar Module 1 can comprise an RFID tag, storing application device identification data and/or device operation boundary data. The application device identification data and/or the device operation boundary data of the application device 15 can be read in a possible implementation by an RFID reading unit of the Function Enhancement Control Cabinet Busbar Module 1 and supplied to the processor 12 of the data processing unit 7 of the Function Enhancement Control Cabinet Busbar Module 1 and stored in a local non-volatile data memory 11 of the data processing unit 7 for further processing.
Both sensing and communication capabilities of the Function Enhancement Control Cabinet Module 1 allow in a preferred embodiment for a standardized communication with an external cabinet controller 17 of the control cabinet 13 such as a PLC via a control cabinet bus system 16 without requirement of wiring the application device 15 to the PLC of the control cabinet 13. This greatly eases the setup of a control cabinet 13 and/or of the automation system shown in
The Function Enhancement Control Cabinet Module 1 provides for a more comprehensive monitoring of the application side. Also, detailed information and measurement data of the energy input side is available. This covers for example also voltage levels and/or i.e. rotational field detection related to a multiphase AC power distribution system of the control cabinet 13.
Further, in case that environmental parameters have changed compared to a recent work cycle, a user U and/or a control cabinet controller 17 can be informed about this specific issue. In this way, repair and maintenance work can be facilitated, in particular thanks to the user visualization interface 5 of the Function Enhancement Control Cabinet Module 1. In a possible embodiment, the user visualization interface 5 can comprise a set of light emitting diodes LEDs located at the side of the application device interface 3 and adapted to indicate a connection state and/or an operation state of an application device 15 connected to the application device interface 3 of the Function Enhancement Control Cabinet Busbar Module 1. The Function Enhancement Control Cabinet Busbar Module 1 can further comprise a second set of light emitting diodes LEDs located at the side of the energy supply interface 3 and adapted to indicate a connection state and/or an operation state of the power distribution busbar system 14 connected to the energy supply interface 2 of the Function Enhancement Control Cabinet Busbar Module 1. Accordingly, if a critical operation state occurs on the side of the energy interface 2, a corresponding set of LEDs can make a user U aware of the problem residing on the energy supply side of the Function Enhancement Control Cabinet Module 1. In contrast, if the other opposing set of LEDs on the other side of the housing of the Function Enhancement Control Cabinet Module 1 indicates a critical state, a user U becomes aware that the problem or failure is most likely at the application side of the Function Enhancement Control Cabinet Module 1.
With the Function Enhancement Control Cabinet Module 1 according to the present invention, a control cabinet controller 17 such as a PLC or a system level controller of the automation system can be fed with detailed information and data about a specific load device 21 controlled via an application device 15 and a Function Enhancement Control Cabinet Module 1 connected to the power distribution system 14 of the control cabinet 13. Besides the provision of instantaneous measurement values or measurement data MDATA, the Function Enhancement Control Cabinet Module 1 according to the present invention allows also to monitor a long-term drift of measurement values or measurement data MDATA. If a significant or abrupt change of data is detected, the cabinet controller 17 can be informed instantaneously. Additionally, user information can be presented to a user U by means of the user visualization interface 5.
The application device 15 connected to the application device interface 3 can comprise in a possible simple application a non-switchable load connector providing a connection between the application device interface 3 and the load device 21. The Function Enhancement Control Cabinet Module 1 provides temperature monitoring as well as voltage and current measurements or profiles to monitor the operation of the connected load.
In a further exemplary use case, the application device 15 can comprise an unfused load switch. In a possible embodiment, the state of the switch can be notified to the data processing unit 7 of the Function Enhancement Control Cabinet Module 1, for instance via a small auxiliary switch or a light barrier. In case a user U can only operate the load switch manually, the state is in this case known to the overall automation system. Consequently, in this use case, a supervision of the switch also becomes possible, since the load current I is only allowed to flow if the switch is in a closed position.
In some use cases, the load devices 21A connected to the power distribution system 14 require fusing. The fuses can be typically located on specific products mounted on a busbar adapter. Following the previous examples, now a fused, manually operated load switch is discussed. In this case, it is of interest to also monitor the state of the fuses. This can be done in several ways as follows. If a fuse has blown a significant voltage will drop over the respective fuse element. This can be detected by performing a different voltage measurement over the fuse contacts. In a possible embodiment, the sensed voltage is fed to an RFID tag of the application device 15. The data in turn is read out by the Function Enhancement Control Cabinet Module 1. Also, feeding the sensed voltage to a photocoupler providing this information with classical wiring to the Function Enhancement Control Cabinet Module 1 is possible. Further, the use of two sets of voltage sensor elements can provide the same functionality. The first set of sensors is connected to the feeding side of the fuses and the second set of sensors is connected on a load side of the fuses.
In a further alternative implementation, a monitoring algorithm executed by the data processing unit 7 is adapted to monitor a fuse stress of fuse elements based on a load current as well as on the basis of a stored load current history. For providing this way of fuse monitoring, the Function Enhancement Control Cabinet Module 1 does know the type and rating of the used fuses. Further, the fuses can also be provided with an RFID tag which may hold this kind of information about the type and reading. This overcomes the problem that wrong parameters may be entered by a user which may affect the sensitivity of the detection algorithm.
In a possible embodiment, the application device interface 3 of the Function Enhancement Control Cabinet Module 1 is also capable of driving contactors or solid-state relays. The Function Enhancement Control Cabinet Module 1 can also be adapted in a possible embodiment to evaluate a state of auxiliary inputs. With the automation system according to the present invention employing the Function Enhancement Control Cabinet Module 1, different kinds of automated or electrical controllable load switches can be set up. The measurement capabilities allow also for a very specific load protection including a motor protection algorithm. The application device 15 may comprise a motor controller or motor starter. By the use of the Function Enhancement Control Cabinet Module 1, motor starter applications become quite smart because the Function Enhancement Control Cabinet Module 1 also provides electrical current monitoring for overload protection. Due to the software implementation of a motor protection algorithm, it is possible that the data processing unit 7 is able to adjust rated electrical current and trip class settings.
If a reversing motor starter is required two contactors can be used on the application device side. Communication to the control cabinet controller 17 can be done through the control interface 4 of the Function Enhancement Control Cabinet Module 1. Also, contactor drive and monitoring via an auxiliary switch can be performed by the Function Enhancement Control Cabinet Module 1.
In a use case where a high frequency switching is desired, solid-state relays can be used instead of classical contactors. Also, in this use case, driving and monitoring the switching elements can be performed by the Function Enhancement Control Cabinet Module 1 according to the present invention. The Function Enhancement Control Cabinet Module 1 can also provide efficient short circuit protection with minimum delay times and/or an overcurrent protection by controlling actuators, in particular semiconductor power switches provided in the power supply path PSP.
Conventional automation system applications are normally set up once and remain unchanged during a long life cycle of the automation system. Thanks to the flexible connector structure, the Function Enhancement Control Cabinet Module 1 can also provide assistance for maintenance, repair and troubleshooting within the automation system. For example, a user U can detect an increasing amount of errors or defects or failures on a subpart of the automation system. By using the Function Enhancement Control Cabinet Module 1 it is possible to add and insert the flat Function Enhancement Control Cabinet Module 1 in a plugand-play manner to a specific load connection for further investigation.
Depending on the application or use case, the user U of the control cabinet 13 can start a recording of the voltage V and electrical current I at the power supply paths PSPs of the Function Enhancement Control Cabinet Module 1 and acquire data related to the event of interest.
Also, a control entity connected via control wires to the application device control interface 22 can be used to trigger and control data acquisition.
Depending on the scope of the data analysis or whether a storage of recorded data and events in a local non-volatile memory 11 of the Function Enhancement Control Cabinet Module 1 is desired, the user U uses a PC application to get a real-time view on the assistance status or events of interest based on the stored data. Measurement data MDATA and other data such as the identification data can be logged during the operation of the automation system.
With increasing complexity of the automation system, also the tasks of ensuring availability and planning maintenance of entities within the automation system become more complicated. The Function Enhancement Control Cabinet Module 1 provides efficient real-time data allowing a seamless, robust and reliable monitoring of different entities within the automation system.
Whether a specific defect or failure can be predicted depends on the specific application. In any case, a lot of processes performed in an automation system comprise patterns that repeat itself very often. With the Function Enhancement Control Cabinet Module 1 comprising in a possible embodiment a trained artificial neural network ANN, it is possible to auto-discover specific data patterns and events occurring in the monitored automation system.
The internal structure of the Function Enhancement Control Cabinet Module 1 provides all necessary components or elements to run specific algorithms directly on the data processing unit 7 of the Function Enhancement Control Cabinet Module 1. These algorithms can be performed by a processor 12 of the data processing unit 7 including the acquiring of measurement data MDATA, the preprocessing of measurement data MDATA the correlation of measurement data MDATA with each other and comparing the measurement data MDATA with previously stored measurement data MDATA and/or with measurement data MDATA provided by other Function Enhancement Control Cabinet Modules 1 of the control cabinet identified by their FMCCI-IDs. The evaluation of the measurement data MDATA is facilitated in a possible embodiment by a common time grid provided by a distributed clock signal CLK of the control cabinet 13.
In a possible embodiment, after some work cycles, the controller or artificial neural network ANN within the data processing unit 7 of the Function Enhancement Control Cabinet Module 1 does learn how for instance electrical current patterns drawn by a specific electrical motor connected as a load 21 via an application device 15 to the Function Enhancement Control Cabinet Module 1 will look like. For instance, if it can be seen from a long-term drift of the sampled values that the electrical motor current tends to increase, a revision and/or cleaning of the pump or other machine driven by the electrical motor can be necessary. In this way, the maintenance and repair scheduling of entities within the automation system can be simplified.
In this case, a flowmeter on the fluid side of a pump driven by the electrical motor can be added. In this use case, a direct correlation between the amount of fluid and the electrical motor current I can be recorded using the Function Enhancement Control Cabinet Module 1 according to the present invention. Again, the data processing unit 7 of the Function Enhancement Control Cabinet Module 1 can be trained on typical working cycles.
In case that some unexpected behavior is detected, for instance by the trained artificial neural network ANN, the electrical motor as a load device 21A can be stopped automatically in response to a control command or a control signal CRTL output by the data processing unit 7 through the application device control interface 22 to the control entity of the electrical motor. Simultaneously, a user U can be notified about the motor failure through the user visualization interface 5 of the Function Enhancement Control Cabinet Module 1. In most cases, defects or failures of a component of the automation system do not occur suddenly but a degradation of the system or a system component takes slowly place over time. With the evaluation of the measurement data MDATA, it is possible to perform predictive maintenance and to plan maintenance activities before the affected equipment or application device 15 or load device 21A completely fails. In another use case where an electrical switching equipment is used, a voltage drop during on-state, a switching transition time and leakage current in the off-state can provide insight to a switch health status. The Function Enhancement Control Cabinet Module 1 provides the necessary sensing elements 9 within the measurement unit 6 to determine the momentary health status of most kinds of electrical switching equipment.
The Function Enhancement Control Cabinet Module 1 can be used in a wide variety of different automation systems and for different kinds of application devices 15 and control cabinets 13.
The Function Enhancement Control Cabinet Module 1 according to the present invention comprises a bidirectional internal power supply path PSP. Accordingly, it is possible to connect both power-consuming load devices 21A but also power generation devices 21B to corresponding application devices 15 as illustrated in
In a possible embodiment, the user visualization interface 5 of the Function Enhancement Control Cabinet Busbar Module 1 comprises also a display unit having a foldable display area. In this way, more complex information concerning the Function Enhancement Control Cabinet Busbar Module 1 and the application device 15 or its connected load device 21A or connected power source 21B can be displayed to a user U of the control cabinet 13.
Any application device 15-i as illustrated in
In a possible embodiment the busbar board 47 shown in
The Function Enhancement Control Cabinet Module 1 is able to determine the direction of the power flow (energy flow) from the correlation between the measured electrical current, I, and the measured electrical voltage, V.
In possible embodiment, if the measured electrical current, I, and the measured electrical voltage, V, have the same signs, i.e. a phase relationship between 0 degrees and 180 degrees, this is interpreted as power flow from a source to a load (forward power supply direction) whereas if the measured electrical current, I, and the measured electrical voltage, V, have different directions, i.e. opposing directions, this is interpreted as a power flow from load to source (reverse power supply direction).
In a possible embodiment the energy flow direction of the energy flow and/or the amplitude of the energy flow can be displayed on a display unit of the user visualization interface 5 to the user during operation of the Function Enhancement Control Cabinet Module, FECCM, 1.
Grid coupling of grids A, B with a power electronic subsystem 60 allows to exchange electrical energy between power grids with different voltage levels, different operation frequencies or with different topologies.
The choice of converter operation points allows to choose the direction of the energy flow. Since the operation points can be adjusted by a controller in real time, a regulation and control of the energy flow is possible even if parameters of the coupled grids or coupled devices change rapidly over time.
The provision of power electronic subsystem 60 allows to control the energy flow direction of the electrical power flowing between the source and the load via the bidirectional power supply path, PSP.
In possible embodiment a user may set the power flow direction and the system may control the power flow direction accordingly by setting the corresponding set values.
The system may also set an operation point or set value depending on other defined parameters.
For example a battery as a load device can comprise as parameters its state of charge SoC and the effective grid voltage.
If the battery is discharged (SoC=0) electrical power is taken from the grid.
If the battery is fully charged (SoC=1) it operates in the idle mode and the state of charge is maintained.
If the battery is charged and the grid voltage drops energy is fed into the grid for support.
The power electronic subsystem 60 within the housing of the Function Enhancement Control Cabinet Module, FECCM, 1 can in a possible embodiment of the Function Enhancement Control Cabinet Module, FECCM, 1 be replaced for different use cases or applications.
| Number | Date | Country | Kind |
|---|---|---|---|
| 21208070.9 | Nov 2021 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/081643 | 11/11/2022 | WO |
