TREA

Modular power distribution and control system

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Information

  • Patent Application
  • 20080291607
  • Publication Number
    20080291607
  • Date Filed
    April 22, 2008
    16 years ago
  • Date Published
    November 27, 2008
    16 years ago
Information
Abstract
The principals and methods described in our application—provide essential tools for designing a convenient, safe, cost efficient power distribution and control system, which could become industry-standard method, benefiting: providers, users and service personnel of the system.
Description
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.


REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX

Not applicable.


BACKGROUND OF THE INVENTION

A majority of hi-power AC electrical wiring of residential and commercial structures, as one of important steps in providing completed structure with required power, has fallen drastically behind the progress attained in other areas of construction, such as: wiring for communications, including phone lines, LAN, internet, etc. Based on existing methods of wiring AC electrical power, the installation time, installation quality, reliability, repeatability and end-result safety of installations—depends heavily on hi-skill manual labor. As result, overall quality of each practical installation is at a mercy of an installation crew, which must maintain required: workmanship skills; detailed attention to specifications, including wiring diagrams, which are more complex these days due to demands for larger and sophisticated structures; installation quality at a rather intensive schedule of completion; etc. In addition to problems stated above, the associated costs of electrical power wiring of a structure—is constantly going up, not so much due to better quality of materials, but rather due to increases in labor costs.


While demand for new construction varies, and respective builders could complete them at rather comfortable time schedules, there is a high demand currently in the areas within the U.S.A. affected by devastating flooding and fires. These re-building projects, which should be completed as soon as possible, could not afford, for example, extra expenses associated with paying high rates for expediting installations of electrical power.


While the costs of building materials in general went up significantly, and while the buildings themselves have appreciated substantially, the existing electrical components and technology used for wiring electrical power has remained disproportionably behind. The existing technology is utilizing primarily individual wires, not cables, and as result, it would be rather challenging to reduce electromagnetic interferences produced by power devices and propagated along these wires, which could: present health risks to individuals near by; and impact operating environment for other devices.


The existing technology places a burden on an installer to implement a required load switching scheme. Some of the switching schemes could be rather complicated, and as result, have a higher risk of mistake made by installer, which may not be discovered by installation inspector, and those impacting the quality and safety of an installation.


In addition, a majority of electrical and electro-mechanical equipment, including machinery and stand alone devices, require adequate means for connecting to required electrical power sources. For simplicity, the applicable equipment in this application will be referred as device.


There are a number of applications, where electrical power to devices is provided via interface modules, including ones that resemble a standard power strip. There is a range of equipment, such as ATM machines, Vending machines, and Process machines in general, etc., that could be considered a main device, which could incorporate other secondary devices within them, such as: display monitor, printer, etc., which also require electrical power applied to them.


The existing power entry methods, although being adequate in electrical power ratings, are not conveniently packaged to provide cost-efficient power entry from outside power source to the main device and then power distribution within the main device to secondary devices. Simply put, there is no off-the-shelf solution, which would conveniently interface a main device to a power source, and then provide convenient power distribution within the main device to other secondary devices.


As a result, designers of main devices have little choice, but to employ a number of off-the-shelf individual components, such as: power inlet, power protection, etc. interfaced via custom wiring, packaged in custom housings, etc., which potentially could create unnecessary challenges in meeting respective safety agency requirements, such as UL, and others. In addition, any “in-house” custom wiring of power components within or outside a device, due to possible lack of solid quality control procedures, which, in contrast, are enforced on off-the-shelf components, could represent a potential safety hazard for individuals responsible for device operation and maintenance.


The existing power entry and distribution methods for a number of devices do not provide convenient power monitoring and diagnostics to ensure the respective device(s) performance has not degraded below projected levels, which if not noticed and then timely attended to by conducting required maintenance, etc., could costs the user of the device in terms of: higher energy costs, potential loss of a device, etc.


The existing power entry and distribution methods do not provide a cost efficient solution to the growing demands for devices aimed at automating a number of businesses, such as: grocery, retails, etc.


BRIEF SUMMARY OF THE INVENTION

This application covers a “Modular Power Distribution and Control System” (MPD&CS), which provides a comprehensive system level solution to current and future requirements in regard to:

    • 1) Electrical power wiring, power distribution, power monitoring of structures, which could include: residential, commercial, and industrial
    • 2) Electrical power entry, power distribution, monitoring and control for variety of devices, such as: electro-mechanical machines, self-check-out machines, etc,


For power distribution designs for industrial, commercial and residential applications—the new technology represents a giant step forward in terms of:


a) Superior Level of Quality and Safety.

    • Only standard, agency approved, pre-assembled, tested, and inspected Modules could be used, without a single custom-made wire on outside, or a custom connection required. All components and Modules could be assembled at the factory with required level of automation to ensure repeatable quality for every installation regardless of size, complexity, location or time schedule. All components and Modules could be agency pre-approved. All pre-assembled Modules could be tested to the highest safety levels, including hi-pot, etc. Since the proposed technology could utilize described in this application Plug-n-Power methods, and together with Power-Safe or Plug-n-Safe Interfacing, based on standard cables instead of individual wires, the entire installation could be significantly safer and more reliable compared to any existing methods. As required, a section of a system or an entire system, consisting of modules, devices and components, could be shielded to isolate the environment from power related electromagnetic interferences, and result, could improve operating environment for other devices, as well as reduce safety health hazard on individuals near by. As required, a section or an entire system could be designed to confirm with respective environmental conditions. All existing power control, switching schemes, together with a new requirements, could be implemented via standardized Modules, which could be assembled-tested-inspected individually, and then inter-connected as required to implement the desired switching combination, and tested-inspected at the factory, prior for shipping as a kit to an installation location with clear instructions for ease of installation.


b) Exceptional Efficiency and Effectiveness.

    • For each new or existing project, regardless of complexity of a custom design or a track development, a pre-manufactured kit, which could include—all essential power distribution, interface and control components and Modules—could be prepared, tested, inspected and delivered to the construction site, as needed. The installation, approaching industry term “plug-n-play”, with simple point-to-point connections via standardized cables, could significantly lower the time to complete the wiring of a structure, with no compromise in quality or safety. In addition, the overall layout and workmanship for any track development, would be highly consistent, which could important for future expansion, modifications, etc. With adequate automation at the factory producing required components and Modules, the costs of materials could be less affected by labor disputes or other factors.


The bottom line—the proposed new technology could advance the electrical power wiring of structures to a required level, so that support of new construction, as well as re-build of structures damaged, could be accomplished in a most effective and efficient way.


For designs of: electrical power entry, power distribution, monitoring and control—for a variety of systems, devices, apparatuses, MPD&CS, which could consist of existing and unique components, which could be packaged as a module, or a number of modules, could:

    • a) Provide a more convenient and cost-efficient power connection to a main device, and then power distribution within the main device to other devices, as needed, as well as to provide convenient interface for other functions, such as network connection, etc. The packaging of each module could be made out of metal or plastic, with overall package design meeting respective agency regulation requirements.
    • b) Be configured and/or expanded, as needed, to include a required number of Outlets for power distribution within the main device to other secondary devices, as well as to conveniently accommodate interface to other outside sources or devices, which could include network connections and others.
    • c) Consist of components, such as power disconnects, power safety, etc., which could be conveniently located throughout the main device to provide the most effective power distribution and safety features, as needed.
    • d) Have all related components manufactured as a standard set of modules, and approved by respective safety agencies, such as UL, etc. The MPD&CS and all related components have an opportunity to become industry standards for power entry and power distribution within a main device, simplifying designs, lowering associated costs, and providing direct compliance to respective safety regulations.
    • e) Include components and modules, which could be mounted at various locations within the main device, could be interfaced via industry standard power cables, the specifications of which (length, ratings, quality, etc.) could be selected to meet respective safety requirements. This could, potentially, completely eliminate the existing methods of custom cut, prepped and wired power cables within the main device.
    • f) Significantly improve safety and reliability of power wiring inside a device or a machine, by utilization of Power-safe or Plug-in-Safe interface technology
    • g) Reduce electromagnetic interferences of power distribution lines by employing pre-made shielded cables
    • h) Employ respective technologies in conducting required power monitoring and self-diagnostics of respective components with an objective to alarm the users of possible degradation of: device, component, connection, etc. which could negatively impact the business in terms of costs due to: excessive energy consumption, process costs due to device mal-function, etc. These intelligent components or modules could be set or programmed to disconnect a device or number of devices, which have exceeded one or more of monitored power parameters, such as: power consumption, power factor, power quality, etc., to avoid the negative impact of a potentially faulty device on business performance.


In summary, the MPD&CS could become an industry leading equipment power-entry and distribution method, which could accomplish, among others, three very important objectives:

    • 1) Lowering costs (installation, operation, maintenance) for providers of the respective devices
    • 2) Improving respective products, overall systems reliability and safety, by standardizing the methods and principals of power entry and distribution
    • 3) Improving business performance by self-monitoring power quality and power consumption parameters, and making real-time intelligent corrective decisions to minimize impact of aging or faulty devices on respective processes


In addition, MPD&CS could employ respective technologies in conducting required Power Monitoring and self-diagnostics of respective components with an objective to alarm the users of possible degradation of: device, component, connection, etc. which could negatively impact the operating electrical costs due to: excessive energy consumption, process costs due to device malfunction, etc. These intelligent components or Modules could be set or programmed to disconnect a device or number of devices, which have exceeded one or more of monitored power parameters, such as: power consumption, power factor, power quality, etc., to avoid the negative impact of a potentially faulty device on business performance.





BRIEF DESCRIPTION
Drawing Content and Listing

Our application contains drawings listed in Table 1, below.









TABLE 1







List of Drawings.









Drawing
Figure
Description












1

Power Entry Module (PEM)



1
3-D view of PEW with local power disconnect component (switch), power




conditioning component (EMC filter), over-current protection component (fuse)



2
Top view of PEM with local power disconnect component (switch), power




conditioning component (EMC filter) and over-current protection component (fuse)



3
View from the power entry side of PEM with local power disconnect component




(switch), power conditioning component (EMC filter), over-current protection




component (fuse)



4
View from power distribution side of PEM with local power disconnect component




(switch), power conditioning component (EMC filter), over-current protection




component (fuse)



5
3-D view of PEM with: local power disconnect component (switch), power




conditioning component (EMC filter), over-current protection component (fuse);




interface for a remote module; interface for wired LAN



6
View from power entry side of PEM with: local power disconnect component (switch),




power conditioning component (EMC filter), over-current protection component




(fuse); interface for remote module; interface for wired LAN



7
Top view of PEM with: local power disconnect component (switch), power




conditioning component (EMC filter) and over-current protection component (fuse);




interface for remote module; interface for wired LAN



8
View from power distribution side of PEM with: local power disconnect component




(switch), power conditioning component (EMC filter), over-current protection




component (fuse), dual power Outlet section switched ON/OFF locally; section for




interface to remote module, off-set for clear distinction; dual power Outlet section




switched ON/OFF locally or remotely; interface for wired LAN



9
View from the power entry side of PEM with local power disconnect component




(switch), power conditioning component (EMC filter), over-current protection




component (fuse), overall/central device power monitoring and diagnostics




component (embedded controller) with hi-speed power-line data communication




interface to remote modules within and outside main device



10
PEM wiring diagram: local power disconnect component (switch), power conditioning




component (EMC filter), over-current protection component (fuse), four power




Outlets switched ON/OFF


2

Remote Module (RM)



1
3-D view of RM with: power disconnect/over-current protection component (breaker




switch), Inlet port power conditioning component (EMC filter) and Outlet component



2
Operator side view of RM with: power disconnect/over-current protection component




(breaker switch), Inlet port power conditioning component (EMC filter) and Outlet




component



3
Bottom view of RM with: power disconnect/over-current protection component




(breaker switch), Inlet port power conditioning component (EMC filter) and Outlet




component



4
3-D view of RM with: power emergency push-pull disconnect component




(E-stop switch), Inlet component and Outlet component



5
Top view of RM with: power emergency push-pull disconnect component




(E-stop switch), Inlet component and Outlet component



6
Operator view of RM with: power emergency push-pull disconnect component




(E-stop switch), Inlet component and Outlet component



7
Operator side view of RM with: power disconnect/over-current protection component




(breaker switch), Inlet port power conditioning component (EMC filter), Outlet




component, Outlet power monitoring and diagnostics




component (embedded controller) with hi-speed power-line data communication to




central power monitoring and diagnostics component of the entry module



8
RM wiring diagram: power disconnect/over-current protection component (breaker




switch), Inlet port power conditioning component (EMC filter), Outlet power




monitoring and diagnostics component (embedded controller) with hi-speed power-




line data communication interface to central power monitoring and diagnostics




component of the entry module, Outlet component


3

Modular Power Distribution and Interface System (MPD&CS)



1
3-D view of MPD&CS for a Main Device with Secondary Devices: Computer,




Touch-screen LCD, Printer; Remote Module with Remote Switch and Protection;




Power strip component



2
3-D view of MPD&CS with centralized and remote power monitoring, diagnostics and




control for a Main Device with Secondary Devices: Computer, Touch-screen LCD,




Printer, two Conveyors with respective Controllers.



3
Wiring diagram of MPD&CS for a Main Device with Secondary Devices switched




and protected locally: Computer, Touch-screen LCD, Printer.



4
Wiring diagram of MPD&CS shown on FIG. 1



5
Wiring diagram of MPD&CS shown on FIG. 2


4

Wiring Diagram - Power Modules



1
Single Switch Lamp Fixture Wiring



2
2-way Lamp Fixture Switching Wiring



3
2-way Lamp Fixture Switching Logic Schematic



4
Components Symbols


5

System Wiring Diagram



1
Power Distribution and Control 115 VAC/230 VAC System


6

Power Modules and Components



1
3-D View Dual 115 VAC 15 A Feed-through Outlet Module



2
3-D View Dual 115 VAC 20 A Outlet Module



3
Top View Dual 115 VAC 15 A Feed-through Outlet Module



4
Bottom View Dual 115 VAC Feed-through 15 A Outlet Module



5
Front View Dual 115 VAC Feed-through 15 A Outlet Module



6
Side View Dual 115 VAC Feed-through 15 A Outlet Module



7
Front View Dual 115 VAC 20 A Outlet Module



8
Side View Dual 115 VAC 20 A Outlet Module



9
Top View Dual 115 VAC 20 A Outlet Module



10
3-D View Single Switch Feed-through 115 VAC 15 A Module



11
Front View Single Switch Feed-through 115 VAC 15 A Module



12
Side View Single Switch Feed-through 115 VAC 15 A Module



13
Bottom View Single Switch Feed-through 115 VAC 15 A Module



14
Top View Single Switch Feed-through 115 VAC 15 A Module



15
Power Distribution Module 115 VAC/230 VAC 15 A


7

Electrical Panel Layout 115 VAC/230 VAC



1
3-D View Electrical Panel - Front Cover Assembly



2
3-D View Electrical Panel - Front Cover Removed



3
Front View Electrical Panel - Front Cover Removed



4
Top View Electrical Panel



5
Front View Electrical Panel












DRAWING CONVENTION AND FORMAT

Drawings with this application, in addition to USPTO requirements, are:


a) Not to scale.


b) Referenced to “X-Y-Z” coordinate system, which is consistent throughout all Drawings.


Definitions

Our application contains definitions of specific components or processes, which are scripted in “bold italic”, and listed below in alphabetical order.


Notes:





    • 1. All materials, components, Modules, process, etc. defined and/or described in these applications, are to comply with respective agency, national and/or local, in regard to safety, and other respective regulations.

    • 2. While for simplicity majority of illustrations are based on power distribution of 115VAC, the proposed methods and technology could be successfully used for power distribution of 230VAC, and other voltage systems, as needed.

    • 3. All materials, components, Modules, etc. could have proper agency approvals, and to could be used according to their manufacturer's approved specifications, including: power rating, environment, etc.

    • 4. All power cable connection to have agency required safety connectors, and when connected, shall have a proper strain-relief provided

    • 5. All components, including cables, Modules, etc. could be designed to reduce electromagnetic interferences (EMI) produced by power devices, and could: reduce health risks to individuals near by; improve operating environment for other devices.

    • 6. Modules could be designed with their respective power connections located such as to accommodate the most cost efficient wiring during installation and/or convenient connection of devices by users.

    • 7. Since the proposed technology for interfacing between all Modules could utilize only standard cables instead of individual wires, these cables could be shielded, as needed.

    • 8. Each Module could be designed to be housed inside an enclosure, with only input power plug or plugs and output power receptacle or receptacles exposed outside enclosure. Module's mounting hardware and Earth ground wire could be the only components exposed, as needed. As needed, enclosures could be made out of metal, which together with proper use of shielded cables and proper Earth grounding—could ensure the environment surrounding each Module, component or cable, could be free of EMI and static charge.

    • 9. Each Module and component, as required by local or national safety code, could have a designated Earth ground wire connected to it's enclosure, and which could be used for connecting to Earth ground during installation.

    • 10. All Modules and components of the proposed technology designed to implement existing power switching schemes, such as: 2-way switching, 3-way switching, etc. could all be fabricated-tested-inspected at the factory, and shipped to destination with clear instructions for ease of installation.

    • 11. All Modules and components could have required label, which could represent: power rating; functional application; operating environment; etc. Label information could be designed as required to meet respective safety agency regulations.

    • 12. Illustrated orientation of components, number and/or location of power inlets and outlets, etc. serves to demonstrate the principals of this application, and could be changed, as needed, for any specific application.

    • 13. As shown, per respective national and local safety regulations—both NEMA and/or IEC type interface connections could be used for wiring 115VAC and 230VAC devices.

    • 14. Although due to simplicity a limited variety of power interface connectors are shown in this application, the proposed principals could allow utilization of a wide variety of power connectors approved by respective safety agency, and could include twist-lock type, and others, for a more reliable connections.





DEFINITIONS
Control Module





    • An intelligent device, which could be a local or remote computer, which could be assigned among other functions, to interface to Local and Remote Diagnostics of a Main Device(s), and to monitor and control power distribution within Main Device(s), based on performance criteria set by business





Distribution Module





    • Could be defined as a Module, which could contain components, which could include: one plug for accepting power and a number of output receptacles for distribution of connected power to other Modules or components plugged into its output receptacles.





Entry Module





    • Could be defined as the Module, which could accommodate connection of the Main Device and its Secondary Devices to AC power source. Entry Module could also provide such functions, as: AC power safety disconnect, AC power conditioning, etc. In addition, Entry Module could be used for convenient interface of wired LAN, etc. Main Device could have several Entry Modules, as needed. Entry Module in this application is also referred to as PEM.

    • NOTE: For simplicity, the examples of Entry Modules presented in document “Drawings” are for illustration purposes of respective principals, while the actual layout, arrangement of components—could be changed to meet requirements of a specific application.





Entry Plug





    • One of the components of Entry Module, which could be an industry standard component or module for connecting power cord to the Main Device. The Entry Plug could be selected to meet specific device power ratings and configured per respective power distribution standards, such as: NEMA, IEC, etc. For simplicity, Entry Plug is shown as IEC 60320-C14 type. As needed, the Entry Plug could be an integral part of Local Conditioning component





Local Outlet





    • One of the components of Entry Module, which could be used for power distribution to other Modules and/or Devices within the Main Device. For simplicity, Local Outlets are shown as IEC C13 type, but depending on application could be any respectively approved Outlet





Local Switch





    • One of the components of Entry Module, which could be an industry standard component or module, and could serve as the main disconnect of incoming power, which could be located conveniently next to the Entry Plug. Depending on specific safety requirements, Local Switch could be single or multi-pole disconnect switch, or remotely controlled single or dual-pole relay. Local Switch type (toggle, push-pull, illuminated, etc.) could be selected per respective functional and safety regulation requirements.





Local Protection





    • One of the components of Entry Module, which could be an industry standard component or module, which could be a part of Local Switch module or Entry Plug module, and which could serve as the main over-current protection. In addition, Local Protection module could also employ over-voltage protection, etc. Depending on specific safety requirements, Local Protection could be single or multi-pole protection. Local Protection type (fuse, circuit-breaker, etc.) could be selected per respective functional and safety regulation requirements.





Local Conditioning





    • One of the components of Entry Module, which could be an industry standard component or module, which could be a part of Entry Plug, and could serve any combination of the following functions: incoming power conditioning, suppression of noise coming out of the device, etc.





Local Diagnostics





    • One of the components of Entry Module, which could be an industry standard component or module, which could employ intelligent power monitoring/control components, and which could serve as: visual and/or audible indicator, representing specific state of the power at an Entry Module; and which could communicate via hi-speed power-line data interface with Remote Module(s), as needed, to sustain safe and efficient operation of Main Device, and Secondary Devices within it.





Local Controller





    • One of the components of Entry Module, which in addition to Diagnostics, could perform control functions of Remote Module(s), and control could be as simple as turning ON/OFF a smart relay, or as complicated as real-time interaction via hi-speed power-line data communication interface with other Controller(s), such as: motion, temperature, etc., which could reside within a Module or be connected to Remote Module, or Remote Controller, as needed, to sustain safe and efficient operation of Main Device, and Secondary Devices within it. Local Controller, as needed, could be connected within Entry Module in such a manner, so when power is disconnected due to emergency, or any other reasons, the power line communications between Local Controller are intact to sustain required data and control information exchange with other Controllers.

    • NOTE: As needed, the Local Controller could have non-volatile memory, battery back-up and other features, and could be wired in a such a matter (i.e. parallel to power lines, etc.), that could allow it to perform other functions, such as: recording data preceding power failures related to Main Device, power outages, over-current conditions, etc, which could be then communicated to other Controllers or computers over Module Networking and/or dedicated communication networks (i.e. serial, LAN, etc.), and respective data could be used to analyze the performance of Main Device with objectives to prevent unnecessary failures, excessive use of power, etc.





Main Device





    • Could be defined as a stand-alone device, equipment, machine, etc, which could be powered by an AC power source, and could consist of other stand-alone devices within itself, which could be powered by AC power source. Example of Main Devices: ATM machines, Vending machines, Process machines in general, etc.

    • NOTE: For simplicity, the examples of Main Devices presented in document “Drawings” are for illustration purposes of respective principals, while the actual layout, arrangement of Devices, Modules and components—could be changed to meet requirements of a specific application.





MPD&CS





    • For designs of wiring industrial, commercial and residential applications, Modular Power Distribution and Control System could be defined as a System, which could consist of: all Modules, devices, components, interfaces, etc., which are defined and described in this application, together with applicable industry-standard components, which fall within required specifications for an MPD&CS type installation. MPD&CS methods and technology could provide superior quality, reliability and efficiency compared to any existing power distribution methods.

    • For designs of power distribution systems for devices, Modular Power Distribution and Control System could be defined as a System, which could consist of an Entry Module(s) and a number of optional Modules, Local and Remote, installed within a Main Device, and which could provide such functions within the Main Device, as: AC power entry, AC power safety disconnect, AC power conditioning, AC power distribution to Secondary Devices, AC power monitoring and control, etc. As needed, MPD&CS could also serve as a convenient interface housing for connecting the Main Device and its respective Secondary Devices to outside devices via wired-type LAN, etc.

    • NOTE: All components employed in the design of MPD&CS could be considered to:

    • 1) Comply with respective safety agency regulations and local safety requirements

    • 2) Could be individually approved by respective agency

    • 3) Could be manufactured and sold, as a component, with appropriate label, reflecting among other things, component rating and approvals





Module Controller





    • Could be defined as a component, which could be installed inside a Module, or attached to a Module, and which could provide one or combination of any of the following functions:

    • a) Monitoring total power consumption by the entire Module, or by a selected section of a Module

    • b) Wired or wireless interface for—remote diagnostics, data transfer, remote control—by designated Controller Module, or remote Controller, which could include one from an Utility company

    • c) Monitoring parameters, including—quality of incoming power; utilized power efficiency (power factor, etc.)

    • d) Providing local user interface for: setting specific limitations on monitored parameters and reporting when the limits have been exceeded; setting up controls, when a specific limit or a number of selected limits have been exceeded, and control could automatically disconnect the power to respective loads connected to Module

    • Module Controller could be designed based on an embedded Controller, and could have user interface, which could be in a form of a LCD with few entry buttons, or ATM type touch-screen display, etc. Module Controller could present on its display important parameters in terms of power utilization and efficiency, or display any number of monitored parameters, selected by a user.





Module Interface





    • Could be defined as interface cabling between various Modules and/or Devices within a MPD&CS, and which could be entirely based on industry standard off-the-shelf components, such as power cables, and which could be approved by respective safety agencies for specific applications.

    • NOTE: For simplicity, examples presented in document “Drawings” are based on utilization of properly rated and approved industry standard IEC power cords for power distribution and power line networking of respective Devices and Modules. Sections of the Module Interface, which could be dedicated to Devices only, could be referenced as Device Interface.





Module Networking





    • Could; be defined as interconnections of various Modules and/or Devices within Main Device via Module Interface, and which could be used for: power connection, data and/or control exchange between Controllers and/or Devices connected, etc. The diagnostics/control communication between Modules could be accomplished via: existing or newly developed power line communication technologies over power line cables; high-speed interfaces, such as serial RS-232, USB, etc.; etc.

    • NOTE: One of the important features of the MPD&CS is its ability to interface Modules, Local and Remote, including Controllers, and/or Devices via standard off-the-shelf power cables, which in addition to providing the basic power, could also employ respective existing and new power line communication technologies to successfully carry the hi-speed data communication interface between respective Diagnostics and Control components, which could be strategically embedded inside respective Modules. Module Networking could be accomplished via power lines, and Controllers could be interconnected in a such manner, so when power is disconnected due to emergency, the power line communications are intact to sustain required data and control information exchange between respective Controllers, as needed. Sections of the Module Networking, which could be dedicated to Devices only, could be referenced as Device Networking.





Module Packaging





    • Each module of the MPE&IS could be designed to meet respective agencies regulations and requirements, which could be reflected in proper selection of: packaging and interface materials; components, including interface wiring and terminations; clearances and creepages between power components; etc. In addition, Module Packaging design could be optimized in terms of its: size, weight, components mounting, appearance, costs, etc. to set an industry standards for volume production.





Panel Module





    • Could be defined as a main power distribution Panel, which could replace the existing technology electrical panels, and which could interface to all Secondary Devices via standard cables. A Panel Module, including all components such as Panel enclosure and/or housing, Power Receptacles, interface cables, etc. could use weather-proof versions of these components, as needed. A Panel Module, depending on rated power (voltage, current), could have industry standard Power Receptacles, providing required power to Secondary Devices. Example for 115V/230VAC power distribution: NEMA 5-15R for 115VAC/15A; NEMA 5-20R for 115VAC/20A; NEMA 6-20R for 230VAC/20A. As needed, the entire Panel Module could be shielded to provide required levels of environmental protection





Panel Controller





    • Could be defined as a Module, which could be installed at a Panel Module, and which could provide one or combination of any of the following functions:

    • a) Monitoring total power consumption by the Panel Module

    • b) Wired or wireless interface for—remote diagnostics, data transfer, remote control—by designated Controller Module, or remote Controller from an Utility company

    • c) Monitoring parameters, including—quality of incoming power; utilized power efficiency (power factor, etc.)

    • d) Providing local user interface for: setting specific limitations on monitored parameters and reporting when the limits have been exceeded; setting up controls, when a specific limit or a number of selected limits have been exceeded, and control could automatically disconnect the power to respective Secondary Devices

    • Panel Controller could be designed based on an embedded Controller, and could have user interface, which could be in a form of a LCD with few entry buttons, or ATM type touch-screen display, etc. Panel Controller could present on its display important parameters in terms of power utilization and efficiency, or display any number of monitored parameters, selected by an user.





Plug-n-Play Assembly





    • Could be defined as a process of assembling MPD_CS for any given application, which could be truly described as a Plug-n-Play step-by-step process, utilizing only off-the-shelf pre-approved Modules and components. For the majority of applications, the Plug-n-Play Assembly process of a rather complicated Device, could be accomplished in a matter of minutes versus hours, which are currently required using existing methods based on custom designs and assembly processes.





Plug-n-Power





    • Could be defined as a method of designing power distribution systems based on MPD_CS principals, which could be accomplished based on standardized, agency approved interface components and cables, which could be pre-manufactured and tested at a designated factory, and then delivered and installed at a construction site, or an installation facility without a need for a single wire cut or crimp, those providing exceptional quality, reliability, safety and minimize electromagnetic emissions from cycling power lines





Plug-n-Safety





    • Could be defined as a method of interfacing power distribution and control Modules, devices, Components, etc. described in this application via pre-manufactured, agency approved cables, which could allow direct plug-in interface between all devices within a system, and as result—offer unprecedented safety by eliminating presence of bare wire, terminal or any metal, which could carry a line voltage.





Power-Proof





    • Could be defined as a method of designing power distribution systems based on MPD_CS principals, utilizing standardized interface methods, which eliminate any metal component, including: bare wire, terminals, etc., which could potentially carry line voltages, or health hazard signals, from being exposed outside an enclosure or module, and as result, could substantially improve safety during installation, utilization and maintenance. Could also be referred as Power-Safe





Remote Module





    • Number of components, grouped inside a Module, which could be located apart from the Entry Module within or outside a Main Device, and which could provide the following functions: remote AC power safety disconnect, remote AC power conditioning, Remote Diagnostics, Remote Controller, etc. In addition, Remote Module could be used for convenient interface of wired LAN, etc. Main Device could have several Remote Modules, as needed.





Remote Plug





    • One of the components of Remote Module, which could be an industry standard component or module for connecting power cord to a Remote Module. The Remote Plug could be selected to meet specific device power ratings and configured per respective power distribution standards, such as: NEMA, IEC, etc. For simplicity, Remote Plug is shown as IEC C14 type. As needed, the Remote Plug could be an integral part of Remote Conditioning component





Remote Outlet





    • One of the components of Remote Module, which could be used for power distribution to other Modules and/or Devices within the Main Device. For simplicity, Remote Outlets are shown as IEC C13 type, but depending on application, could be any respectively approved Outlet





Remote Switch





    • One of the components of Remote Module, which could be an industry standard component or module, and could serve as the main or secondary disconnect of incoming power, or disconnect of specific power distribution branch within the Main Device intended to power selected number of Secondary Devices. Depending on specific safety requirements, Remote Switch could be single or multi-pole disconnect. Remote Switch type (toggle, push-pull, illuminated, etc.) could be selected per respective functional and safety regulation requirements.





Remote Protection





    • One of the components of Remote Module, which could be an industry standard component or module, which could serve as main (in-place of Local Protection), or secondary (in addition to Local Protection), or stand-alone (protection of a specific power distribution branch within the Main Device). In addition, Remote Protection module could also employ over-voltage protection, etc. Depending on specific safety requirements, Remote Protection could be single or multi-pole protection. Remote Protection type (fuse, circuit-breaker, etc.) could be selected per respective functional and safety regulation requirements.





Remote Conditioning





    • One of the components of Remote Module, which could be an industry standard component or module, which could perform any combination of the following functions: incoming power conditioning, suppression of noise coming out of a device or number of devices, etc. Remote Conditioning could complement the Local Conditioning functions, and could serve to protect environments surrounding specific Secondary Device from possible power related noise, which could potentially impact the performance of that device. Remote Conditioning component could incorporate Remote Power Inlet plug.





Remote Diagnostics





    • One of the components of Remote Module, which could be an industry standard component or module, which could serve as a visual and/or audible indicator, representing specific state of the power at a location apart from an Entry Module. Similar to Local Diagnostics, Remote Diagnostics could employ intelligent power monitoring/control components, and which could serve as: visual and/or audible indicator, representing specific state of the power at a Remote Module in general, or specific power Outlet component of the Remote Module, and which could communicate with other Remote Module, as needed, to sustain safe and efficient operation of Main Device, and Secondary Devices within it.





Remote Controller





    • One of the components of Remote Module, which could be an industry standard component or module, which in addition to Diagnostics, could perform control functions of other Remote Module(s), or other components within Remote Module, or device(s) connected to Remote Module, and control could be as simple as turning ON/OFF a smart relay, or as complicated as real-time interaction via high-speed power-line data communication interface with another Controller (motion, temperature, etc.), connected to Remote Module, or Remote Controller, as needed, to sustain safe and efficient operation of Main Device, and Secondary Devices within it Remote Controller, as needed, could be connected within Remote Module in such a manner, so when power is disconnected due to emergency, or any other reasons, the power line communications between Remote Controller are intact to sustain required data and control information exchange with other Controllers.

    • NOTE: As needed, the Remote Controller could have non-volatile memory, battery back-up and other features, and could be wired in a such a matter (i.e. parallel to power lines, etc.), that could allow it to perform other functions, such as: recording data preceding power failures related to Secondary Devices, power outages, over-current conditions, etc, which could be then communicated to other Controllers or computers over Module Networking and/or dedicated communication networks (i.e. serial, LAN, etc.), and respective data could be used to analyze the performance of respective Secondary Devices with objectives to prevent unnecessary failures, excessive use of power, etc.





Receptacle Module





    • Could be defined as a Module, which could contain components, which could include: one or more power input plugs, and one or more output receptacles.





Secondary Devices





    • For designs of wiring industrial, commercial and residential applications, Secondary Devices could be defined as Modules and components, which could be connected to Panel Module either directly via cable, or indirectly via other Modules. Example of Secondary Devices: Outlet Module; devices, such as lamp fixtures, etc. connected to Outlet Modules; Distribution Module; etc.

    • For designs of power distribution for devices, Secondary Devices could be defined as a stand-alone device, which could perform a specific function within a Main Device, and which could be powered via AC power means, including: AC/DC power bricks, etc., which could be connected to AC power distribution within the Main Device. Example of Secondary Devices: Printer, LCD monitor, Computer, etc.

    • NOTE: For simplicity, the examples of Secondary Devices presented in document “Drawings” are for illustration purposes of respective principals, while the actual layout, arrangement of Devices, Modules and components—could be changed to meet requirements of a specific application.





Switch Module





    • Could be defined as a Module, which could contain components, which could include: one or more power input plugs, and one or more output receptacles, with some or all of output receptacles controlled by a switch.





2-Way Module





    • Could be defined as a Switch Module, which could be used in combination with another Switch Module for implementation of a 2-way switching of a load connected directly to one of the 2-way Modules, or indirectly connected via Receptacle Module, which in turn could be connected to a respective 2-way Module. As with many other currently used switching methods, the proposed technology could support these methods by utilization of standard switching Modules, which in contrast to existing technology, would be assembled-tested-inspected at the factory with clear labeling and instructions provided for ease of installation via standardized cables, which could be also assembled-tested-inspected at the factory. An entire power switching combination could be pre-tested and inspected at the factory prior to installation.





Project Kit





    • Could be defined as a Kit, which could be prepared, tested and inspected at a factory, per respective specifications of a power distribution project. The Kit could include: all required Modules and components, which could be labeled according to their ratings, functionality; detailed instructions for installation; factory test and quality reports; installation instructions and other helpful material, in support of efficient and effective installation for a given project; etc. As needed, the Kit could be shipped directly from the factory to installation site. Project Kits could be particularly useful for wiring projects, which are based on track-type development, i.e. consisting of repeatable construction sites. For these track-type installation, an initial Kit could be designed and filed-tested in terms of its performance, content, etc. Based on filed report, the Kit could be optimized, including: required Modules, Modules type, lengths of cables, etc. and then the optimized Kit could be delivered to remaining sites of a track-development for most efficient and effective installation.





Interface Module





    • Could be defined as a Module, which could be configured to provide a specific interface between the supply power connected to its incoming power plug or plugs and power available at respective power outlet or outlets. Interface Module could contain variety of components, which could include: incoming power inlet plugs, switches, outgoing power receptacles; Controller and its respective support components; etc. Interface Module could be standardized to provide a specific function, such as: 3-way switching, etc., and could also be used for custom-specific configuration, as needed. As with all Modules, Interface Modules shall comply with respective national and/or local safety and electrical code.





Power Feed-Through





    • Could be defined as a method, which could allow an incoming power to a Module via power cable connected to a plug connector of the Module to be connected inside the Module directly to outgoing receptacle connector of the Module, so that a another power cable could be plugged into it to provide power to other Module or device, as needed.





Touch-Proof Connections





    • Could be defined as power wire terminations, which have no exposed metal parts, such as bare wires, terminals, etc., which could carry high voltage power. Since the entire system could be assembled using factory terminated cables, all connections within MPD&CS could be touch-proof, significantly improving reliability and safety during installation, inspection, maintenance, etc.





DETAILED DESCRIPTION OF THE INVENTION
Notes:

1) For simplicity, the examples of Systems, Devices, Modules and components within them, presented in document “Drawings”, are for illustration purposes of respective principals. The actual design, layout and arrangement—could be changed to meet requirements of a specific application. Although the main intent of this application is to standardize respective principals of AC power entry, distribution and control within Structures and machines, and as a result, provide off-the-shelf cost effective solutions, still—customization of various elements could be accomplished within outlined principals, to further optimize the results for any given application, while retaining the essence of Plug-n-Play, Plug-n-Power and Power-n-Safety features.


2) For simplicity, optional features, such as: component shielding, grounding, strain-relief, environmental seals, etc. are not shown on all drawings


Drawing 1
5 Pages

Drawing 1 illustrates various packaging configurations of Entry Module. The location of various components within Entry Module could vary to provide the most efficient and convenient access to the operator, as well as interfaces to other Modules or Devices.


FIG. 1—3-D view of PEM (1) with Local Switch (2), Local Protection component—fuse holder with fuse inside (4)


Figure elements are labeled as follows:

1—Power Entry Module (PEM), basic configuration

2—Incoming power Local Switch

3—Incoming power Inlet plug, which as an option, could be incorporated with power conditioning component-EMC filter (not shown)

4—Fuse holder with a fuse inside, which could be properly rated per given application

6—Earth ground wire, which is internally connected to incoming plug Earth ground terminal, and could serve as a convenient Earth ground termination for the Main Device


FIG. 2—Top view of PEM illustrated on FIG. 1.


Figure elements are labeled as follows:

7—Power distribution Outlets (4 shown), which could be controlled by main disconnect switch component of PEM (1)

8—Round terminal ring, part of Earth ground wire (6), which could be used for attaching the Earth ground wire to dedicated Earth ground stud of the Main Device


Remaining elements are labeled same as on FIG. 1.


FIG. 3—View from the power entry side view of PEM illustrated on FIG. 1.


Figure elements are labeled as follows:

5—Mounting holes for PEM

9—Section of PEM, which could be added to packaging, as needed, and which could be used for convenient housing of other interfaces (LAN, etc.) of the Main Device to/from outside devices, etc.


Remaining elements are labeled same as on previous Figures.


FIG. 4—View from power distribution side of PEM. Elements are labeled same as on previous Figures.


FIG. 5—3-D view of PEM with local power disconnect component—switch (2), over-current protection component—fuse holder with fuse inside (4), interface to Remote Module, LAN connection


Figure elements are labeled as follows:

13—Section of Power Entry Module, designed to house LAN interface related components

14—Interface connection for LAN network


Remaining elements are labeled same as on previous Figures.


FIG. 6—View from power entry side of PEM shown of FIG. 5. Elements are labeled same as on previous Figures.


FIG. 7—Top view of PEM shown of FIG. 5.


Figure elements are labeled as follows:

10—Power Outlet for Remote Module, which could have a disconnect switch (toggle, push-button, etc.), which could be used to disconnect the incoming power to the Main Device.


Remaining elements are labeled same as on previous Figures.


FIG. 8—View from power distribution side of PEM shown of FIG. 5. Elements are labeled same as on previous Figures.


FIG. 9—View from power distribution side of PEM with: local power disconnect component—switch (2); optional power conditioning component-EMC filter, part of (3); over-current protection component—fuse (4); dual power Outlet section switched ON/OFF locally (not visible here); section consisting of power Outlet and Inlet—for interface to a Remote Module (not visible here); dual power distribution Outlet section switched ON/OFF locally or remotely (not visible here); interface for wired LAN (14).


Figure elements are labeled as follows:

38—Local Controller, which could perform power monitoring, diagnostics and control within the Main Device, communicate, via Module Interface and/or Networking, and exchange data and controls with other Controllers within or outside the Main Device.


Remaining elements are labeled same as on previous Figures.


FIG. 10—Wiring diagram of PEM illustrated on FIG. 9.


Figure elements are labeled as follows:

103—Earth ground wire



104—Power Entry Module


105—Dual-pole incoming power Local Switch

106—Fuse holder with fuse as Local Protection

107—Power distribution Outlets

121—Earth ground electrical connection

122—Local Conditioning component with integrated Entry Plug


Drawing 2
4 Pages

Drawing 2 illustrates various packaging configurations or Remote Module. The location of various components within Remote Module could vary to provide the most efficient and convenient access to the operator, as well as interfaces to other Modules or Devices.


FIG. 1—3D view of a Remote Module (15) with Remote Switch (16), and an Earth ground wire (37)


FIG. 2—front view of a Remote Module shown on FIG. 1.


Figure elements are labeled as follows:

17—Mounting holes for Remote Module

18—Remote Conditioning component with integrated Remote Plug (19)

20—Remote Outlet, which could be controller by Remote Switch (16)

37—Remote Module Earth ground wire


FIG. 3—bottom view of a Remote Module shown on FIG. 1. Elements are labeled same as on previous Figures.


FIG. 4—3-D view of a Remote Module (15) with Remote Switch (16) selected as an emergency push-pull button type. Remaining elements are labeled same as on previous Figures.


FIG. 5—top view of a Remote Module (15) shown on FIG. 4.


FIG. 6—operator view of a Remote Module (15) shown on FIG. 4.


FIG. 7—operator view of a Remote Module (15) shown with Remote Switch (16), Remote Conditioning (18) with integrated Power Entry (19).


Remaining elements are labeled as follows:

17—Mounting holes for Remote Module (15)



20—Power Outlet of the Remote Module (15)


37—Earth ground wire of the Remote Module (15)


FIG. 8—Wiring diagram of the Remote Module illustrated on FIG. 7.


Figure elements are labeled as follows:



115—Outlet of Remote Module (120)


117—Remote Switch (dual-pole) and Remote Protection components of the Remote Module

119—Remote Controller, which could perform:

    • a) Power monitoring/diagnostics of incoming power via Remote Inlet/Conditioning component (123)
    • b) Power monitoring/diagnostics of power provided to Devices and/or Modules connected via Outlet (115)
    • c) Exchange of data and controls with other Controllers within and outside the Main Device via power line networking

      121—Earth ground connection within the Remote Module

      131—Remote Earth ground wire with round ring terminal


Drawing 3
5 Pages

Drawing 3 illustrates various configurations of MPD&CS, which could be assembled within minutes, utilizing proposed standard off-the-shelf Modules and components. In illustrated examples, the design of the Main Device and layout of Secondary Devices could be dictated by specifications for a given application, while design of power distribution to and within the Main Device could be such as to take advantage of off-the-shelf available Modules and components. As result, manufacturing costs of such Devices could be significantly lower, with improvements in reliability and serviceability. As required, the entire system could be designed based on Plug-n-Power, Plug-n-Safety, Power-Proof principals, which are defined and described in this application.


FIG. 1—3-D view of MPD&CS for Main Device (22) with: Secondary Devices:


Computer (23), Touch-screen LCD (24), Printer (31) which could have a dedicated power conversion component (32); Remote Module (15), which could house Switch and Protection components; Standard power strip (30), which could be used for convenient power distribution in between PEM (1)—Remote Module (15) and Secondary Devices (21, 31). In this configuration, the main power disconnect to the Devices could be accomplished: by pulling the incoming power cord (51) out of PEM (1), or by turning OFF power to all power outlets via Remote Switch component of Remote Module (15)


Remaining figure elements are labeled as follows:

6—Earth ground wire from PEM (1), which could be connected to the chassis of the Main Device via dedicated Earth ground stud (50), which could be labeled per respective agency regulations

14—PEM (1) housing of LAN interface, which could include LAN conditioning component

25—Power cable connecting Remote Module (15) Inlet to dedicated PEM (1) non-switched Remote Outlet

29—Cable connecting Computer (23) to LAN

27—Power cable connecting Computer (23) to one of PEM (1) Remotely Switched and Protected Outlet

28—Power cable connecting Standard power strip (30) to one of PEM (1) Remotely Switched and Protected Outlet

33—Power cable connecting Touch-screen LCD (24) to one of Remotely Switched and Protected Outlet of the Standard power strip (30)

49—Cable providing incoming power to the Main Device via PEM (1)

50—Earth ground connection from PEM (1), which could be connected to chassis of the Main Device


FIG. 2—3-D view of MPD&CS with centralized and remote power monitoring, diagnostics and control for a Main Device (22) with Secondary Devices: Computer (23), Touch-screen LCD (24), Printer (31), two Conveyors with respective controllers (45). In this configuration, the main power disconnect to the Devices could be accomplished: by pulling the incoming power cord (51) out of PEM (1), or by turning OFF power to all power outlets via Remote Switch component of Remote Module (15A). In addition, power to conveyor motor controllers (45) and Printer (31) could be disconnected via push-pull disconnect switch component of Remote Module (15B), which could be used as a local convenient power disconnect in events of emergency, etc. The illustrated example of an MPD&CS is fairly sophisticated, and includes a number of powerful features, yet all power distribution components within the system could be all off-the-shelf standard cost effective components, and the assembly of the entire system could be accomplished in record time, significantly lower compared to what could be required using existing methods.


Remaining figure elements are labeled as on FIG. 1, with additional elements as follows:

38—Local Controller, which could perform power monitoring, diagnostics and control within the Main Device (22), communicate, via Module Interface and/or Networking, and exchange data and controls with other Controllers within the Main Device (22), which could include Remote Controller (42) located inside Remote Module (15A), or outside the Main Device.

41—LAN conditioning component of the PEM (1)

42—Remote Controller component located inside the Remote Module (15A), which could perform power monitoring, diagnostics and control of Secondary Devices connected to Remote Module (15B), and could communicate, via Module Interface and/or Networking, and exchange data and controls with other Controllers within or outside the


Main Device (22).


43—Power cable between the PEM (1) and Remote Module (15A), which could be used as a communication link component of Module Interfacing and/or Networking.

44—Power cable between the PEM (1) and Computer (23), which could be used as a communication link component of Module Interfacing and/or Networking

45—Conveyor motor controller/driver, one for each conveyor

46—Power cable between the PEM (1) and motor controller/drivers (45), which could be used as a communication link component of Module Interfacing and/or Networking

47—Power cable between the Remote Module (15A) and the Remote Module (15B), which could be used as a communication link component of Module Interfacing and/or Networking

48—Power cable between the Remote Module (15B) and the PEM (1), which could be used as a communication link component of Module Interfacing and/or Networking


FIG. 3—Illustrates an example of a wiring diagram of MPD&CS for a relatively simple application: there are 3 Secondary Devices (125, 126, 127), which are connected to one PEM (100) of a Main Device via power cables (111). As needed, shown Secondary Devices could also communicate with each other via power cables (111), as Module Networking or Device Networking via available power lines, and as needed, any of them, could also communicate with computers or Modules outside the Main Device, that could be connected to PEM (100) via incoming power cable (not shown) connected to (122)


Figure elements are labeled as follows:

103—Earth ground wire of PEM, which could be connected to Main Device enclosure's dedicated Earth ground stud

105—Local Switch, shown as single throw, dual-pole type, which could serve as power disconnect for the Main Device and Secondary Devices within it

106—Local Protection, shown as a fuse

107—Local Outlets, 3 shown for simplicity

100—PEM, shown with: Local Protection and integrated Power Inlet (122), dual pole Local Switch (105), single phase Local Protection (106), and 3 Outlets (107)

111—Power cables, each consisting of 3 conductors properly rated and approved for this application. As needed, these cables could be shielded, and could serve for Module Networking

121—Earth ground connection within PEM

122—Local Conditioning component with integrated Entry Plug

125—Touch screen LCD, which could be connected to one of the Outlets of PEM

126—Computer, which could be connected to one of the Outlets of PEM

127—Printer, which could be connected to one of the Outlets of PEM

FIG. 4-Wiring diagram of MPD&CS, shown of FIG. 1. There are 3 Secondary Devices (125, 126, 127), which are connected as follows: Computer (126) to one of available Outlets on PEM (100), Touch screen LCD (125) and Printer (127) are connected to standard power strip (132), which in turn is connected to the other available Outlet on PEM (100). In this example, all available Outlets (4 shown) on PEM are Remotely Switched and Remotely Protected via Remote Module (120).


The remaining figure elements are labeled as follows:

103—Earth ground wire of PEM, which could be connected to Main Device enclosure's dedicated Earth ground stud

133—PEM Local Outlet, which could be connected to Remote Inlet (114) of Remote Module (120)

134—PEM Local Inlet, which could be connected to Remote Outlet (115) of Remote Module (120), and which could have Remote Switching and Remote Protection

135—PEM Local Outlets, which could be controlled and protected by Remote Module (120)


FIG. 5—Wiring diagram of MPD&CS, shown of FIG. 2. In this example, there are 2 Remote Modules (112, 120) and 5 Secondary Devices (125, 126, 127,129, 130), which are connected to one PEM (100) of a Main Device via power cables (111). As shown, both the PEM (100) and Remote Module (120) could have Local and Remote Controllers (118, 119) respectively. Either of these Controllers, as needed, could have non-volatile memory, battery back-up and other features, and could be wired in a such a matter (i.e. parallel to power lines, etc.—not shown for simplicity), that could allow it to perform other functions, such as: recording data preceding power failures related to respectively connected Secondary Devices, power outages, over-current conditions, etc. The Local Controller (118) could monitor and/or control incoming power to the Main Device, and all Devices and/or Modules connected to PEM (100), while Remote Controller (119) could monitor and/control Remote Modules and/or Secondary Devices connected to the Outlet (115) of Remote Module (120). All connected Modules and/or Devices could communicate with each other, and/or with remote computer via Module and/or Device Networking over installed power lines.


The layout shown, could be used for implementing the following features:

    • a) Power monitoring (quality, consumption, etc.) of the entire Main Device via installed Local Controller (118)
    • b) Power monitoring (quality, consumption, etc.) and power control of the selected Secondary Devices (129, 130) via installed Remote Controller (119)
    • c) On-site emergency power disconnect to Secondary Devices (124, 128) via Remote Module (112), which could be conveniently located for prompt operator action, as needed
    • d) Over-current Protection Local (106) and Remote (117), which could also have over-voltage protection installed, as needed
    • e) Both Controllers, Local (118) and Remote (119) via Device and/or Module Networking could exchange required data and controls between themselves and remote computer(s) to ensure safe and reliable operation of each Device


      With all the powerful features, the illustrated MPD&CS could be assembled and running in a matter of minutes, utilizing industry standard Modules and components, which could be designed and produced based on methods described in this application.


      Remaining elements are labeled as follows:

      109—Locally switched Outlet, which could be designated for connecting Remote Module (120). For simplicity of identification, this Outlet could be mounted differently from other Outlets (offset vertically, rotated 90°, etc.)—an example shown on FIG. 3
      110 —Remotely switched Inlet, which could be designated to be controlled locally and via Remote Module (120). For simplicity of identification, this Inlet could be mounted together with the respective Outlet (109)—an example shown on FIG. 3
      116 —PEM Outlets, which could be switched locally via Switch (105), or remotely, via Remote Modules (120) or (112). These PEM Outlets, could have Local Protection via (106) and Remote Protection via (117)


Drawing 4
3 Pages

Drawing 4 illustrates wiring diagrams of various power Modules. As noted below, some of the Modules could be used for 115/230VAC power distribution. As required, all Modules could be designed based on Plug-n-Power, Plug-n-Safety, Power-Proof principals, which are defined and described in this application.


FIG. 1—Illustrates wiring diagram of a 115VAC Switch Module (204) to a 115VAC lamp fixture (200)


Figure elements are labeled as follows:

200—115VAC lamp fixture, which could have 115VAC power inlet plug NEMA 5-15P (202)

201—Lamp bulb inside the lamp fixture (200)

203—Earth ground wire for grounding the enclosure of the lamp fixture (200)

204—115VAC fully enclosed Switch Module, which as shown, includes following components: power inlet NEMA 5-15P (207); switch (206); power outlet NEMA 5-15R (208); Earth ground wire (205), which could be used for connecting metal enclosure (when used) to Earth grounding at the installation site, as required by national and/or local safety code.

206—115VAC switch, which could be wired inside enclosure of (204), as shown

209—section of the 115VAC power incoming cable, with mating connector NEMA 5-15R to be connected to (207)

210—115VAC power cable for providing 115VAC switched power from outlet (208) of Switch Module (204) to power inlet (202) of the 115VAC lamp fixture (200)


FIG. 2—Illustrates wiring diagram of a 115VAC 2-way Switching of a 115VAC lamp fixture (200)


Figure elements are labeled as follows:

211—115VAC Switch Module #2, which as shown, includes following components: power inlet NEMA 14-15P (212) for connecting to power cable (215) to receive incoming switched 115VAC power from Switch Module #1 (216); switch (214); power outlet NEMA 5-15R (213); Earth ground wire (223), which could be used for connecting metal enclosure (when used) to Earth grounding at the installation site, as required by national and/or local safety code.

216—115VAC Switch Module #1, which as shown, includes following components: power inlet NEMA 5-15P (218) for connecting to power cable (209) to receive incoming 115VAC power, which could come directly from a Panel Module (not shown), switch (219); power outlet NEMA 14-15R (217); Earth ground wire (224), which could be used for connecting metal enclosure (when used) to Earth grounding at the installation site, as required by national and/or local safety code.


Remaining elements are labeled same as on FIG. 1.


FIG. 3—Illustrates wiring schematic of 115VAC 2-way Switching shown on FIG. 2.


These type of wiring schematics could be useful in designing of custom switching schemes, to verify the proper logic, and most convenient interface, with an objective to use standardized cabling in-between various control Modules and the respective load.


Figure elements are labeled as follows:

220—schematic representation of 115VAC Switch Module #1, shown on FIG. 2 as (216)

221—schematic representation of 115VAC Switch Module #2, shown on FIG. 2 as (211)

220—schematic representation of 115VAC lamp fixture, shown on FIG. 2 as (200)


FIG. 4—Illustrates graphical symbols of a variety of Modules, which could be used in designing required MPD&CS. These graphical symbols, as illustrated in this example, could be used for creating wiring diagrams and other documentation, which could assist in designing and installation. For simplicity, these graphical representations do not show:


a) The Earth ground wire, which could be part of each Module, as required by national and/or local safety code


b) Devices and components shielding options


c) Devices and components environmentally sealed packaging options.


Figure elements are labeled as follows:

304—115VAC 15A power Distribution Module. The incoming power connection could be via NEMA 5-15P (307), and power connection for each load (three shown) could be via NEMA 5-15R (326).

306—dual 115VAC/15A power Outlet Module with power plug NEMA 5-15P (307) for connecting to incoming 115VAC power supply cable

308—dual 115VAC/15A Feed-through power Outlet Module with power plug NEMA 5-15P (307) for connecting to incoming 115VAC/15A power supply cable, and power outlet NEMA 5-15R (309), which could be used for passing 115VAC power to the next Module, as needed.

310—dual 115VAC/20A power Outlet Module with power plug NEMA 5-20P (312) for connecting to incoming 115VAC/20A power supply cable

311—dual 115VAC/20A Feed-through power Outlet Module with power plug NEMA 5-20P (312) for connecting to incoming 115VAC/20A power supply cable, and power outlet NEMA 5-20R (313), which could be used for passing 115VAC power to the next Module, as needed.

314—115VAC/15A power Switch Module with following components: power plug NEMA 5-15P (307) for connecting to incoming 115VAC/15A power supply cable; 115VAC/15A switch; power outlet NEMA 5-15R (315) for providing switched 115VAC/15A power to connected load.

316—115VAC/15A power Switch Module, which could be used for 2-way switching installation, and which could contain the following components: power plug NEMA 5-15P (307) for connecting to incoming 115VAC/15A power supply cable; 115VAC/15A 2-way switch; power outlet NEMA 14-15R (317) for providing switched 115VAC/15A power to the other Switch Module (not shown) for implementation of 2-way switching.

318—115VAC/20A power Switch Module with following components: power plug NEMA 5-20P (320) for connecting to incoming 115VAC/20A power supply cable; 115VAC/20A switch; power outlet NEMA 5-20R (319) for providing switched 115VAC/20A power to connected load.

321—dual 230VAC/20A power Outlet Module with power plug NEMA 620P (322) for connecting to incoming 230VAC/20A power supply cable. 230VAC/20A outlets could be NEMA 6-20R, or other standard configuration, as required.

323—Interface Module, which could be based on providing a standard function, or custom function as needed. The number and type of inlet power plugs, as well as number and type of outlet power receptacles could be selected per respective specifications. The symbol shown, is a general symbol. For any specific application, Interface Module could be represented by a more specific symbol, which could better reflect interface capabilities of an Interface Module.

324—Power Monitoring Module, which could be designed to perform specific functions, as needed

325—3-load 115VAC 15A total Power Distribution Module with Power Monitoring Module. The incoming power connection could be via NEMA 5-15P (307), and power connection for each load could be via NEMA 5-15R (326). As needed, Power Monitoring Module could be designed to monitor power for each individual load, and/or total power consumed by all three loads. Power Monitor user interface could allow entry of desired limits in regard to: power consumption; power availability to each or all loads as function of real time; remote control access by other Controller within the System; etc.

327—2-load 115VAC 15A total Power distribution Module with Power Monitoring Module. The incoming power connection could be via NEMA 5-15P (307), and power connection for each load could be via NEMA 5-15R (326). As needed, Power Monitoring Module could be designed to monitor power for each individual load, and/or total power consumed by both loads. Power Monitor user interface could allow entry of desired limits in regard to: power consumption; power availability to each or all loads as function of real time; remote control access by other Controller within the System; etc.

344—Electrical Panel, which could have four functional sections: Power Distribution section of 115VAC 15A (348)—four outlets, which could be NEMA 5-15R, each protected by 115VAC 15A circuit-breaker switch (353); Power Distribution section of 115VAC 20A (349)—two outlets, which could be NEMA 5-20R, each protected by 115VAC 20A circuit-breaker switch (354); Power Distribution section of 230VAC 15A (350)—one outlet, which could be


NEMA 6-15R, protected by dual 230VAC 15A circuit-breaker switch (355);

345—Power Monitoring and Control Module for Electrical Panel (344), which could be designed to support any combination of the following functions: monitor incoming power to Electrical Panel (344); monitor and/or control power consumption by each or all power distribution sections of (344); interface to local or remote Controller via hi-speed serial interface wired or wireless-connection (346); interface to Utility company LAN, as needed, connection (347); Power Monitor user interface could allow entry of desired limits in regard to: power consumption; power availability to each or all sections as function of real time; remote control access by other Controller within the System; etc.

351—opening in the Electrical Panel (344) enclosure for incoming power interface

352—openings in the Electrical Panel (344) enclosure for power distribution cables to exit the Electrical Panel (344) to provide power to respective Modules.


Drawing 5
1 Page

Drawing 5 illustrates System Wiring Diagram for applications, which could include residential buildings. The System could provide 115VAC and 230VAC power distribution. Similar designs could be accomplished using methods described in this application for commercial and industrial sites. As required, the entire system could be designed based on Plug-n-Power, Plug-n-Safety, Power-Proof principals, which are defined and described in this application.


Drawing elements are labeled as follows:

300—section of the System, which could be dedicated to real-time Power Monitoring and control of selected power outlet Modules, as shown 3 dual 115VAC 15A Power Outlets (357)

302—section of the System, which could be dedicated to 2-way Switching

303—115VAC Lamp Fixture, which could be controlled via 2-way Switching Modules (316) and (318)

359—Interface cable between 2-way Switching Modules (316) and (318)

356—115VAC Lamp Fixture, which could be controlled via single Switch Module (314)

344—main Electrical Power Distribution Panel, which could be used for this application. For simplicity, shown Panel could consist of: 115VAC 15A Power Distribution section—4 outlets; 115VAC 20A Power Distribution section—2 outlets; 230VAC 15A Power Distribution section—1 outlet. All Power Outlet Modules could have over-current protection devices, such as circuit-breaker switch. As needed, a GFIC circuit-breaker, and any other devices required by national and/or local safety agency, could be added. Other components are labeled as on FIG. 4 of Drawing 4.


Drawing 6
3 Pages

Drawing 6 illustrates mechanical packaging of various 115VAC and 230VAC Modules and components, which could be used for 115/230VAC power distribution.


For simplicity, some of the Figures may not show:

    • a) Earth ground wire, which could be installed for each Module, as required by national and/or local safety agency
    • b) Mechanical mounting components
    • c) Strain-relief component, which could be used to secure a cable plugged into a Module


      As shown, all Modules could be fully enclosed inside a metal or plastic enclosure, which is one of important options of the new technology, in providing additional safety, even “behind the wall”. For simplicity, power interface connectors for each Module are shown per respective IEC standards, which could be more convenient than NEMA, since IEC connector are rated 230VAC. As required, all enclosures, packaging components, etc. could be designed based on Plug-n-Power, Plug-n-Safety, Power-Proof principals, which are defined and described in this application.


      FIG. 1—Illustrates 3-D view of dual 115VAC/15A Feed-through power Outlet Module (400) with power plug IEC320 C14 (401) for connecting to incoming 115VAC/15A power supply cable, and power outlet IEC320 C13 (406), which could be used for passing 115VAC power to the next Module, as needed. Both power Outlets (404), as shown, could be NEMA 5-15R.


      FIG. 2—Illustrates 3-D view of dual 115VAC/20A power Outlet Module (402) with power plug IEC C20 (403) for connecting to incoming 115VAC/20A power supply cable. Both power Outlets (405), as shown, could be NEMA 5-20R.


      FIG. 3—Illustrates top view of dual 115VAC/15A Feed-through power Outlet Module (400) shown on FIG. 1.


      FIG. 4—Illustrates bottom view of dual 115VAC/15A Feed-through power Outlet Module (400) shown on FIG. 1.


      FIG. 5—Illustrates front view of dual 115VAC/15A Feed-through power Outlet Module (400) shown on FIG. 1.


      FIG. 6—Illustrates side view of dual 115VAC/15A Feed-through power Outlet Module (400) shown on FIG. 1.


      FIG. 7—Illustrates front view of dual 115VAC/20A power Out/et Module (402) with power plug IEC C20 (403) for connecting to incoming 115VAC/20A power supply cable. Both power Outlets (405), as shown, could be NEMA 5-20R.


      FIG. 8—Illustrates side view of dual 115VAC/20A power Outlet Module (402) shown on FIG. 7.


      FIG. 9—Illustrates top view of dual 115VAC/20A power Outlet Module (402) shown on FIG. 7.


      FIG. 10—Illustrates 3-D view of 115VAC/15A power Switch Module (407) with power plug IEC320 C14 (401) for connecting to incoming 115VAC/15A power supply cable and power outlet IEC320 C13 (406), which could be used for connecting switched 115VAC/15A power to the next Module or device, as needed.


      FIG. 11—Illustrates front view of 115VAC/15A power Switch Module (407) shown on FIG. 10

      FIG. 12—Illustrates side view of 115VAC/15A power Switch Module (407) shown on FIG. 10

      FIG. 13—Illustrates top view of 115VAC/15A power Switch Module (407) shown on FIG. 10

      FIG. 14—Illustrates bottom view of 115VAC/15A power Switch Module (407) shown on FIG. 10

      FIG. 15—Illustrates 3-D view of 115-230VAC/15A power Distribution Module (408) with power plug IEC320 C14 (401) for connecting to incoming 115-230VAC/15A power supply cable and six power outlets IEC320 C13 (406), which could be used for connecting 115-230VAC/15A power to Modules and/or devices, as needed. The illustrated design could differ from the existing designs by offering optional shielding, conditioning, environmental seal, etc.


Drawing 7
4 Pages

Drawing 7 illustrates mechanical packaging of an Electrical Panel, which could be used for variety of applications, including residential housing projects, etc.


For simplicity:

    • a) Only major components for power distribution of 115VAC 15A and 20A are shown
    • b) Earth ground wire connections to the Panel and its respective components, as required by national and/or local safety agencies, are not shown
    • c) Mechanical mounting of respective components


      As required, the entire design of an Electrical Panel could be designed based on Plug-n-Power, Plug-n-Safety, Power-Proof principals, which are defined and described in this application.


      FIG. 1—Illustrates 3-D view of an Electrical Panel (409), which could have three functional sections: Power Distribution section of 115VAC 15A—ten outlets, which could be NEMA 5-15R, each protected by 115VAC 15A circuit-breaker switch; Power Distribution section of 115VAC 20A—four outlets, which could be NEMA 5-20R, each protected by 115VAC 20A circuit-breaker switch; Power Monitoring and Control Module for Electrical Panel (413), which could be designed to support any combination of the following functions: monitor incoming power to Electrical Panel (409); monitor and/or control power consumption by each or all power distribution sections of (409); interface to local or remote Controller via hi-speed serial interface wired or wireless—connection (414); interface to Utility company LAN, as needed, connection (415); Power Monitor user interface could allow entry of desired limits in regard to: power consumption; power availability to each or all sections as function of real time; remote control access by other Controller within the System; etc.


      Figure elements are labeled as follows:

      411—opening in the Electrical Panel (409) enclosure for incoming power interface

      412—openings in the Electrical Panel (344) enclosure for power distribution cables to exit the Electrical Panel (409) to provide power to respective Modules.

      410—Front Cover of Electrical Panel (409) with a see-through window (416), which could be used for viewing status of the Power Monitor (413), when Front Cover (410) is installed


      FIG. 2—Illustrates 3-D view of an Electrical Panel (409) without the front cover


      FIG. 3—Illustrates front view of an Electrical Panel (409) without front cover.


      Figure elements are labeled as follows:

      417—115VAC/15A Power Module, which could include: 115VAC/15A disconnect breaker (418), NEMA 5-15R outlet (404), etc.

      421—115VAC/20A Power Module, which could include: 115VAC/20A disconnect breaker (422), NEMA 5-20R outlet (405), etc.

      420—one of the sections, which could be used for routing power cables connected to the Panel (409) to various loads, such as: Power Modules, etc.


      Remaining elements are labeled same as on FIG. 1.


      FIG. 4—Illustrates top view of an Electrical Panel (409)


      FIG. 5—Illustrates front view of an Electrical Panel (409)

Claims
  • 1. A method of designing and fabrication of power distribution modules, devices and components, such as: power distribution and power control panels, power outlets, power switching, light fixtures, power monitoring devices, etc., which could be designed and enclosed, as needed, and which could be interfaced to other devices and/or components via interface components such as cables, and all devices and components could be designed to comply with required safety agency, such as: UL, CSA, etc., and all interface components, including connectors and cables, could be designed to comply with respective industry standards, and all modules, devices and components could be designed and fabricated to comply with defined in this application principals, such as: plug-n-power, power-n-safe, touch-proof, etc., and installation of these devices and components could be accomplished without a need for on-site support of skilled operations, such as: wire crimping, wire hook-up, etc., and all required devices and components could be fabricated, inspected and tested at a designated factory, and could be delivered for installation at a designated location in a form of a kit, which could significantly simplify installation, and could significantly reduce costs, and could improve reliability, and could significantly improve quality, and could reduce power emissions.
  • 2. A method according to claim 1 further wherein power distribution and control devices could be installed within standardized and custom enclosures, which could be designed to provide required levels of shielding to improve electromagnetic compatibility and these features could also apply to device interface connectors and interface cables, as needed, reducing health hazard to humans and interference with other equipment.
  • 3. A method according to claim 1 further wherein power distribution and control devices could be installed within standardized and custom enclosures, which could be designed to provide hermetically sealed devices, as needed, to withstand required environment, and these features could also apply to device interface connectors.
  • 4. A method according to claim 1 further wherein design of power distribution and control devices, and the design of the respective interface connectors within these devices, could provide the most convenient standardized interface between: these type of devices, devices and other power consumption devices or loads, and the entire installation of these devices could be accomplished without a need for a custom made cable or connection
  • 5. A method according to claim 1 further wherein design of power distribution, control and interface enclosures, which could have other modules, components incorporated and wired inside, and which could use respective standardized connectors to interface to incoming power sources to the enclosure, and which could use respective standardized connectors to interface the enclosure to provide output power to devices and other users
  • 6. A method according to claim 1 further wherein the power modules could incorporate within their enclosure other devices or components, which could be capable of providing safety features such as: protection fuse or circuit breaker function to prevent over-current; over-voltage protection; monitoring of power quality monitoring, power control—which could safely power down the respective loading, as needed, including when any or all of power parameters fall outside the required operating limits
  • 7. A method according to claim 1 further wherein the power modules could incorporate within their enclosure other devices, such as embedded controllers, which could monitor power parameters and report power status to a remote controller via industry standard LAN, and which could also execute power control requested by a remote controller residing on the LAN
  • 8. A method according to claim 1 further wherein: power modules, interface cables and components could be manufactured, tested, quality inspected, at designated factories, and delivered to the installation site for systems and/or apparatuses as a kit, based on a specific requirement submitted by the design team of a building, structure, or a machine; and the kit could be optimized, based on the tryout installation at the prototype sites
  • 9. A method according to claim 1 further wherein a device, module or component, including interface cables, could be assign an unique standardized symbol, which could be used in representing the respective device, module or component, and could be used on design drawings, and other documentation, as needed, for convenience, etc.
  • 10. A method according to claim 1 further wherein modules, devices, components could have multiple interface connectors, and all connectors or a number of could be standardized, strain relief, shielded, environmentally safe, etc.
  • 11. A method according to claim 1 further wherein enclosures, housings, packaging, which could be used for enclosing modules, devices, components could be made out of respective materials, such as: plastic, metal, etc., and all enclosures or a number of them could be standardized, shielded, environmentally safe, etc.
  • 2. A method of designing power distribution and power control systems for residential, commercial and industrial structures, which could be based on standardized power distribution and power control modules and devices, and standardized interface components, and all system modules, devices and components could be designed and fabricated to comply with defined in this application principals, such as: plug-n-power, power-n-safe, touch-proof, etc., and which could support on-site installation without a need for a custom interface, such as: cables, wires, etc.; and could provide benefits of: lowered costs, improved safety and reliability
  • 12. A method according to claim 2 further wherein design of a system could employ standardized symbols, which could represent respective devices, modules and components
  • 13. A method according to claim 2 further wherein all or number of modules, devices and components of a system could be manufactured, tested, quality inspected at designated factories, and delivered to the installation site for a system as a kit, based on a specific requirement, which could be submitted by a design team of a building, structure, etc., and the kit could be optimized, based on the tryout installation at the prototype sites
  • 3. A method of designing power distribution and power control systems for power consumption equipment and machines, which could be based on standardized power distribution and power control devices, and standardized interface components proposed in this application, and all modules, devices and components could be designed and fabricated to comply with defined in this application principals, such as: plug-n-power, power-n-safe, touch-proof, etc., and which could support on-site installation without a need for a field made custom interface, such as: crimped wires, etc.; and could provide benefits of: lowered costs, improved safety and reliability
  • 14. A method according to claim 3 further wherein design of power entry module could be such, as to allow power entry connection from one side of the module, facing the power source, and then provide power outlets from the opposite side, facing the devices of an apparatus or a machine, and which could include optional components such as: power switching, power protection, power conditioning, power monitoring, etc.
  • 15. A method according to claim 3 further wherein design of power distribution system within a machine or apparatus could be accomplished via standardized agency approved modules and cables
  • 16. A method according to claim 3 further wherein design of power distribution system or section of within a machine or apparatus could be accomplished via standardized agency approved shielded modules and shielded cables
  • 17. A method according to claim 3 further wherein design of a system could employ standardized symbols, which could represent respective devices, modules and components
  • 18. A method according to claim 3 further wherein all or a number of modules, devices and components of a system, or section of could be manufactured, tested, quality inspected at designated factories, and delivered to the installation site for a system as a kit, based on a specific requirement, which could be submitted by a design team of a machine, apparatus, etc., and the kit could be optimized, based on the tryout installation for the prototype units
CROSS-REFERENCE TO RELATED APPLICATIONS

We claim the benefits of Provisional Application No. 60/931,792 filed on May 25, 2007, title “Modular power distribution and interface system”, and Provisional Application No. 61/002,964 filed on Nov. 14, 2007, title “Modular power distribution and control system”.

Provisional Applications (2)
Number Date Country
60931792 May 2007 US
61002964 Nov 2007 US