Patent Application
20200101612
The present invention relates generally to Motor Control Centers (MCC's) and Switchgear equipment, and more particularly, to a system for maintaining such equipment in which an autonomous machine moves in three dimensions with respect to the equipment and a system controller commands the autonomous machine to conduct mechanical operations for maintaining the equipment.
A wide range of applications exist for electrical enclosures and cabinets such as Motor Control Centers (MCC's) and Switchgear equipment. Such industrial control equipment is often used for distributing power and/or data in industrial control systems such as factories. This equipment typically comprises enclosures for both small and large individual units, such as for housing contactors and/or other switchgear. Larger enclosures are also common, such as for housing various power electronics equipment, control circuits, motor drives, and so forth. For instance, in industry it is common to find large enclosures divided into bays or segments for single and multi-phase switchgear, motor controllers, programmable logic controllers, data and power network interfaces, and so forth. This equipment can also include push buttons, indicator lights, variable-frequency drives, programmable logic controllers and/or metering equipment, and can be used to de-energize equipment to allow work to be done and to clear faults downstream.
Like other electrical components, equipment associated with MCC's and Switchgear may be susceptible to failures over time. Consequently, such equipment typically requires periodic maintenance to ensure units continue to operate correctly. However, one particular challenge in the maintenance of such equipment relates to the mechanical and thermal effects of internal arcing faults (also called an arc, arc fault, arc flash or arcing flash). In particular, certain types of electrical faults can produce arcs that can heat and even vaporize neighboring components and cause sudden pressure increases and localized overheating. The possibility of such arc fault conditions can render equipment maintenance a dangerous task, often requiring numerous safeguards before any such undertaking. Another challenge in the maintenance of such equipment is the difficulty in maneuvering in the tight quarters in which such equipment is often placed. What is needed is an improved way for maintaining such equipment which minimizes the dangers and/or difficulties associated with such maintenance.
An autonomous machine is wirelessly controlled by a system controller in an industrial control environment, such as a factory with industrial processes and machines, to move to a coordinate location corresponding to a unit of a Motor Control Center (MCC) or Switchgear equipment supporting the industrial control system to maintain, repair, monitor and/or troubleshoot the equipment without the need to place a human operator in harm's way of energized circuits. The system controller, which could be a Programmable Logic Controller (PLC) controlling the industrial control system, can monitor operational statuses with respect to each unit, and can dispatch the autonomous machine as required. The autonomous machine can include a mechanical arrangement operable to connect and disconnect power with respect to a unit and/or to withdraw and replace a unit with respect to the equipment.
In one aspect, the invention can include a system or method to maintain, repair, monitor and or, troubleshoot MCC or Switchgear equipment without the need to place humans in harm's way of energized circuits. This can include but not limited to machine removal and/or replacement of units in an MCC that are in an “off” condition while other units around the off unit are still powered (in an “on” condition). A system or method for removal of units can use a quick disconnect electrical connection. This can be done, for example, with a split collet, fixed pin and/or socket implementation and/or any other type of connection that allows for un-tooled connection and disconnection. The ability to “know” where a unit location is in within three dimensional space of an MCC lineup can also be done through use of a database similar to IntelliCENTER as available from Rockwell Automation, Inc., an analytics edge engine and/or Artificial Intelligence (AI). The foregoing can be accomplished using a Global Positioning System (GPS) or other location tracking service with location coordinates externally mapped, like a site map, and/or internally mapped with location tags built into the units, so that data can be collected and/or updated in real time as units are replaced and/or moved, with a connection directly back to a database, analytic edge engine or AI. This could be limited in not only with respect to a factory floor, for example, but also with respect to an Electrical Equipment house or “E-House.” Predictive or pre-emptive analytics can be applied to determine potential failure of a unit. Accordingly, the machine can be used to manage good and problematic inventory on a factory floor or an E-House environment. On the factory floor, defined replacement locations can allow the machine to retrieve good units and a location defined to deposit failed or predicted or pre-emptive failure units. Autonomous machines could also monitor real-time thermal conditions and over time and suggest module movement to balance thermal loads. In addition, machine vision can be employed to help provide guidance for insertion and/or removal of units and provide a level and degree of safety. Tying this to a larger database or an AI can provide the machine with increasing capabilities. Such learning could be done in a cloud computing environment such that each machine can install and/or disconnect units that the machine had not previously installed or withdrawn. Once a unit of any type is installed anywhere, all machines can instantly determine how to install such units at any location.
Specifically then, one aspect of the present invention can provide a system for maintaining an MCC or Switchgear equipment, the equipment including multiple units for industrial control, each unit being configured to receive power from a common bus in the equipment, the system including: an autonomous machine configured to move in three dimensions with respect to the equipment, the autonomous machine having a processor, a wireless communication system, a location tracking system, and a mechanical arrangement operable to disconnect power with respect to a unit of the equipment; and a system controller executing a program stored in non-transient medium to: monitor an operational status with respect to each unit; and command the autonomous machine through the wireless communication system to move to a coordinate location corresponding to a unit of the equipment undergoing service and to disconnect power to the unit undergoing service. The operational status could include, for example, an indication of power being connected or disconnect with respect to the unit and/or an indication of a fault with respect to the unit.
Another aspect of the present invention can provide a method for maintaining an MCC or Switchgear equipment, the equipment including multiple units for industrial control, each unit receiving power from a common bus in the equipment, the method including: monitoring an operational status with respect to each unit; and commanding an autonomous machine through a wireless communication system, the autonomous machine moving in three dimensions with respect to the equipment using a location tracking system, the autonomous machine including a mechanical arrangement for disconnecting power with respect to a unit of the equipment, to move to a coordinate location corresponding to a unit of an equipment undergoing service and to disconnect power to the unit undergoing service.
These and other objects, advantages and aspects of the invention will become apparent from the following description. The particular objects and advantages described herein can apply to only some embodiments falling within the claims and thus do not define the scope of the invention. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention and reference is made, therefore, to the claims herein for interpreting the scope of the invention.
Preferred exemplary embodiments of the invention are illustrated in the accompanying drawings in which like reference numerals represent like parts throughout, and in which:
Referring now to
The units 12 may each include a door for covering an assembly of components 18 that are supported within each unit 12 via known methods, such as screwed (“fixed feed” or “frame mounted”) or snap-in (“withdrawable”) engagement, thereby providing mechanical and electrical connection to the equipment 10. Exemplary components 18 of the units 12 may include a starter, overload relay, motor drive or circuit breaker, and electrical control modules for controlling such components, such as a Programmable Logic Controller (PLC), among other things. Doors for the units 12 may include, for example, a lever (such as a rotary lever to turn ON and OFF a Circuit Breaker inside the unit and enabling opening of the door when the Circuit Breaker is OFF), a lock for preventing the door from opening, a light for indicating a safe condition for opening the door, and/or target indicia 13 for identifying the unit (such as a barcode, QR code and/or serial number). A latch rail (not shown) may be provided in each section 14 to interface with latches on the individual doors of the units 12. Accordingly, each unit 12 can be configured to receive power from a common bus in the equipment 10, such as by engagement with vertical power distribution bus bars connected to the horizontal power distribution bus bars 16. With additional reference to
The sections 14 may also include wire-ways 20 in which line and load wiring, cabling and so forth may be installed to service the components 18. The sections 14 may optionally include preconfigured isolation areas 22 for variations in which greater electrical isolation between sections 14 is desired, such as in compliance with IEC 61439-2 Forms 3, 3a, 4 or 4b.
Referring now to
Each autonomous machine 34 is configured to move in three dimensions with respect to the equipment 10, such as according to the multi-dimension, Cartesian axes (X, Y, Z) illustrated in
The motion arrangement 50 can allow the autonomous machine 34 to move autonomously and wirelessly, and in particular, to move autonomously and wirelessly with respect to the equipment 10 in directions and angles which may be referenced by the Cartesian axes (X, Y, Z) on a factory floor or E-House. The mechanical arrangement 52 is operable to allow the autonomous machine 34 to directly interact with units 12 undergoing service, such as a mechanical arm operable to connect or disconnect power with respect to a unit 12 (such as actuating a lever to turn ON or OFF a Circuit Breaker inside the unit), to withdraw a unit 12 partially or fully from the equipment 10 (such as opening a lock and/or door, disconnecting a split collet, fixed pin and/or socket implementation and/or other un-tooled connection, and pulling the unit away from the equipment 10), and/or to replace a unit 12 with a different (replacement) unit 12.
The system controller 32 can be connected to system storage 60 and a controller communication device 62. In one aspect, the system controller 32 can also be in communication with the one or more units 12 of the equipment 10, such as for monitoring the units 12 and/or controlling aspects of the industrial control process or machine 26 through the units 12. In particular, the system controller 32 could be a Programmable Logic Controller (PLC). The system controller 32 can also be in communication a computer terminal 64 providing an with an I/O interface for controlling the system 30 and, as a result, aspects of the industrial control process or machine 26. The system controller 32 can comprise a processor 66 executing a program 68 which could be stored in the system storage 60. The program 68 can reference unit and machine data structures 70 and 72, respectively, to monitor operational statuses of the units 12 and command the autonomous machines 34. In particular, the system controller 32 can execute to monitor operational statuses of the units 12, including indications of power being connected or disconnect with respect to the unit 12, and/or indications of faults, through monitor lines 74 (which may be connected to components 18 of the units 12). The system controller 32 can also execute to wirelessly command one or more of the autonomous machines 34, through the controller communication device 62 to the wireless communication system 46, to move to a coordinate location corresponding to a unit 12 of the equipment 10 undergoing service. The system controller 32 can further command the autonomous machines 34, for example: to disconnect power to the unit 12 undergoing service; to withdraw the unit 12 partially or completely from the equipment 10; to replace the unit 12 undergoing service with a different unit 12′; and/or to connect power to the unit 12 undergoing service (or the different unit 12′). Also, the system controller 32 can advantageously command the autonomous machines 34 to variously conduct one or more of the aforementioned operations while other units 12 of the equipment 10, including adjacent units 12 of the equipment 10, are continuously connected to power and operating to control the industrial control process or machine 26. Moreover, the system controller 32 can advantageously coordinate locations and commands of multiple autonomous machines 34 to efficiently resolve and/or avoid faults.
In one aspect, the autonomous machines 34 could be assigned by the system controller 32 to separately maintain their own equipment 10, such as the first autonomous machine 34a being assigned to maintain the first equipment 10a, while the second autonomous machine 34b is assigned to maintain the second equipment 10b. Moreover, movement of the autonomous machines 34 can be bounded by geo-fences to avoid crossing into one another's zones, such as the first autonomous machine 34a being bounded by a first geo-fence containing the first equipment 10a, while the second autonomous machine 34b is bounded by a second geo-fence containing the second equipment 10b.
the first and second autonomous machines are bounded by first and second geo-fences containing the first and second equipment, respectively
By way of example, with additional reference to
At the commanded location, the autonomous machine 34 can raise to a Z coordinate in a plane perpendicular to the floor 82, corresponding to a location in front of the particular unit 12 undergoing service, here the unit 12c. The autonomous machine 34 can raise to the Z coordinate by extension of the motion arrangement 50 in the Z direction and/or by actuation of the mechanical arrangement 52. Then, the autonomous machine 34 can sense target indicia 13 of the unit 12c undergoing service for positively identifying the unit as indicated by the command, using the sensing arrangement 44. The autonomous machine 34 can then actuate the mechanical arrangement 52 to disconnect power to the unit 12c undergoing service, and then withdraw the unit 12c from the first equipment 10a, partially or completely. Moreover, the autonomous machine 34 can be commanded remove the unit 12c while other units 12 of the equipment 10, including unit 12a and adjacent unit 12b, are continuously connected to power and operating to control the industrial control process or machine 26. Accordingly, use of the autonomous machine 34 in this way can avoid the need to place a human operator in harm's way of energized circuits of the equipment 10 on the factory floor or E-House 80.
With additional reference to
With additional reference to
In addition, the system controller 32 can use predictive analytics to determine potential failures of units 12. Also, the system controller 32 and/or autonomous machines 34 can utilize AI to provide maintenance operations with increasing capabilities. As a result, the system controller 32 and the autonomous machines 34 can provide an effective system to manage good and problematic inventory on the factory floor or E-House 80.
The present invention may be part of a “safety system” used to protect human life and limb in a field, construction or other environment. Nevertheless, the term “safety,” “safely” or “safe” as used herein is not a representation that the present invention will make the environment safe or that other systems will produce unsafe operation. Safety in such systems depends on a wide variety of factors outside of the scope of the present invention including: design of the safety system, installation and maintenance of the components of the safety system, and the cooperation and training of individuals using the safety system. Although the present invention is intended to be highly reliable, all physical systems are susceptible to failure and provision must be made for such failure.
Certain terminology is used herein for purposes of reference only, and thus is not intended to be limiting. For example, terms such as “upper,” “lower,” “above,” and “below” refer to directions in the drawings to which reference is made. Terms such as “front,” “back,” “rear,” “bottom,” “side,” “left” and “right” describe the orientation of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import. Similarly, the terms “first,” “second” and other such numerical terms referring to structures do not imply a sequence or order unless clearly indicated by the context.
When introducing elements or features of the present disclosure and the exemplary embodiments, the articles “a,” “an,” “the” and “said” are intended to mean that there are one or more of such elements or features. The terms “comprising,” “including” and “having” are intended to be inclusive and mean that there may be additional elements or features other than those specifically noted. It is further to be understood that the method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein and the claims should be understood to include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as coming within the scope of the following claims. All of the publications described herein including patents and non-patent publications are hereby incorporated herein by reference in their entireties.
