WO2016016689A1

WO2016016689A1 - Smart power management system for electrical circuits

Info

Publication number: WO2016016689A1
Application number: PCT/IB2014/063576
Authority: WO
Inventors: Kumudu Sanjeeva COORAY MUTHUTANTHREE
Original assignee: Cooray Muthutanthree Kumudu Sanjeeva
Priority date: 2014-07-31
Filing date: 2014-07-31
Publication date: 2016-02-04

Abstract

The invention is directed to a System for centralized smart management of power in an electrical circuit with inbuilt all-in-one functionality of breakers, metering, power protection, multi-source power supply The invention discloses an intelligent unit that integrates all the conventional components of a building electrical wiring system. A touch display is identified as the user interface of the system. The system is customized according to the specific need of individual customer.

Description

SMART POWER MANAGEMENT SYSTEM FOR ELECTRICAL CIRCUITS

DESCRIPTION

1. BACKGROUND OF THE INVENTION

The present invention relates to residential or industrial electrical wiring system and provides for a novel system for smart breaker, metering, power protection and multi-source power management of building wiring circuits. The present system has integrated the conventional physical component of electrical wiring system into an intelligent device and created a user friendly system keeping up with the modern trends and requirements.

2. SUMMARY OF THE INVENTION

For the purpose of comprehending, the present invention is discussed in detail with reference to the FIGURE 01 of the drawings adduced herein below.

The present invention introduces a System for Smart Breaker, metering, power protection and multi- source power management of building wiring circuits. The system comprises of, a Touch Display (101), SD Card Storage (102), Main Microcontroller 1 (103), Main Microcontroller 2 (104), a plurality of Sub Microcontroller Units (105), Sub Micro-controller Unit-EL (106), Sub Micro-controller Unit-Main (107), Built-in EEPROM, DC Power Supply (108), Main Contactor (109) and Sub Circuit Contactors (110).

The Touch Display (101), is configured as the user interface and is designed to display Accumulated total usage of electricity in units (kWh) and in value ($), Load segment-wise accumulated usage of electricity in units (kWh) and in value($), Contemporary usage of load segment in units (W), real-time varying load and maximum assigned load in units (Amperes) and graphically of each segment of circuit, real-time overall power status including active power sources and active segments, Backup power source status (inverter with battery bank, fuel powered generator, hydrogen powered system, etc); Alternative power source status (Solar/wind power source, secondary utility power connection), Logs of historical monthly usage segment-wise in units (kWh) and in value ($), Logs of power failures, earth leakages, current over loads, over/under voltage conditions.

The Touch Display (101) is further configured to provide user input facilities for parameter loading, Manual operation of individual circuits via graphically displayed virtual miniature circuit breakers (MCB), main switches, earth leakage current operated circuit breakers with overload and over voltage protection ( CBOV), Manual operation via graphically displayed virtual change-over switches to backup power, static switches for uninterrupted switch over among alternative power sources to trigger physical function via relevant contactor, to set usage limits/tabs to monitor segment-wise budget and actual consumption in units (kWh) and in Values ($).

At the time of customization, the Touch Display is pre-programmed and customized to meet the specific requirements of the wiring circuit.

The SD Card Storage (102) executes the Procedures of Parameter Loading to the system and Data/event Logging. The Parameter Loading Procedure is initialized when the system restarts and the Data/event Logging Procedure is initialized on a timed manner and in an incident of alarm/warning or fault condition. The configuration settings of segment wise load levels, backup/alternative power sources and the other selection criteria can be configured with a PC application and will be saved to SD card. The system will read the configuration file and load the settings with user interaction for safe operation.

The Main Microcontroller 1 (103) is configured to operate as the Touch Display Controller, to operate as the SD Storage Controller, to coordinate on parameter passing/updating sub functions to support operations of Main Microcontroller 2 and to maintain EEPROM segment with parameter value copies for fail-safe operation.

The Main Microcontroller 2 (104) is configured to format Sensor Data and send same to the Data Logging Procedure, to format Event Data and send same to the Event Logging Procedure, to function as an Auto Recovery agent for pre-defined circuit recovery procedures/loops and to function as an agent for Power backup/Alternative power source coordination.

The pre-determined segment-wise power supply plan is copied to the Main Microcontroller 1 and 2. The Sub Microcontroller Units (105) are configured to function as individual circuit monitors and to update sensor and tripping information to the Main Microcontroller 2, said Sub Microcontroller Units are connected to the Main Microcontroller 2 via SPI Data Bus (111). The Sub Microcontroller Units are preprogrammed at the time of customization with number of load segments, allowed load limits per segment, level of power protection per segment, on off time delays per segment and alternative/backup power supply requirement in order to make segment specific independent decisions.

The Sub Microcontroller Unit-EL (106) is configured to detect leakages in the earth circuit and to shut down main contactor in an event of earth leakage is detected. The Sub Microcontroller Unit-EL is connected to the Main Microcontroller 2 and other Sub Microcontroller Units via SPI Data Bus.

The Sub Microcontroller Unit-Main (107) is configured to detect over currents in the complete circuit, to activate Main contactor shut down procedure in the events of over current, under voltage or over voltage, to coordinate alternate power sources and/or backup power sources in the event of grid power failure and to update information related to main current/voltage to the Main Microcontroller 2. The Sub Microcontroller Unit-Main is connected to the Main Microcontroller 2 via SPI Data Bus (112).

The system consists of an EEP OM, which is configured to be saved the parameter values that are transferred from the SD Card Storage and thereupon to act as backup memory of the system in the event of SD Card failure. EEPROM of Sub Microcontroller Units saves data as to current limits and time delays for specific circuit for fast and local operation.

The DC Power Supply (108) is configured to provide operating power to the system in 5V and 12V DC voltages via AC Mains Grid Supply (113).

The Main Contactor (109) is configured to operate switching of main physical circuit based on instructions given by the Sub Microcontroller Unit-Main.

The Sub Circuit Contactors (110) are configured to operate switching of individual circuits based on instructions given by the respective Sub Microcontroller Units. A backup power source (114) is programmed to the system to channel backup power to required segments at an event of main power supply outage.

An alternative power source (115) is also programmed to the system to channel power to specified segments as per user discretion.

The system disclosed herein above is also configured to record power usage based on main, alternative and back-up power sources, interruptions, failures, over/under voltages, leakages and over loads.

3. DETAILED DESCRIPTION OF THE INVENTION

In a conventional residential or industrial electrical wiring system there is a) A kilo-watt hour meter to account for the electricity usage.

b) Main Switch (MS) to disconnect power supply to the circuit.

c) Trip Switch (Residual Current Circuit Breaker With Overload) (RCBO) to break circuit when there is a leakage or overload of Power (Some models additionally has over voltage protection).

d) Miniature circuit breakers (MCB) to segment the load limit and protect circuits from overload segment-wise. Previously fuses were used in place of MCBs which has to be replaced each time it was fused.

e) Spike and surge protectors to protect appliances from power irregularities.

All these devices that are essential components of an electrical wiring system are hardware based switching devices and operate independently from each other. Each component is designed to achieve an essential purpose by operating its core functionality.

There is no coordination or inter-relation among the said components. Due to the said components being operated separately malfunction of any component is notified only when the same is physically identified. In the said conventional system, the Kilo-watt hour meter gives total usage of Power. However it is not possible to identify as to which appliance use more electricity or section-wise consumption without using independent meters.

While electricity is available MCB/MS/RCBO can trip off keeping the load without power until physically identified (Ex: Due to this house can be in darkness until owner returns).

Each device of a conventional system as described above has common components that are repetitively used due to independent nature of the said devices (Ex: MCBs, MS, RCCB have its own wire connecting terminals, on/off switch, self-test button).

In a conventional system, when requirements grow over the time, in order to cater such requirements some components of the said electrical wiring system have to be physically replaced. Also, when the mechanical devices of the said components are worn out due to ware and tare it is essential to replace the complete device.

In the present day context, in a house, power cannot be turned down as garage doors, locks, surveillance systems will be off-line disabling access. Hence, it is a need that the Electrical system to have intelligence to take required decision at a given time without human intervention and notify designated personnel. For example, there are CCTV and electrical fences installed for security and MCB switches off due to thunder, the complete security system will be off line until physical intervention and rectification. Hence, the need is so that the electrical system restarts circuit by itself or switch over to backup power source depending on the condition.

The present invention puts multiple devices of the conventional electric wiring circuit in to a single product and enable the system to intelligently interact with each other key functions to provide an efficient, useful, well managed result. Further, the present invention brings all decision making processes in to a microprocessor and a comprehensive firmware that takes decisions based on owners' preprogrammed instructions. Mechanical components are replaced by firmware driven touch interface where user can change mode from touch interface to select any of the conventional components functionality in soft form. The present invention provides one single device for both residential and industrial applications which can set limits in soft form to fit the requirements. Wire connection terminals and cutouts are separated to be able to choose to match the amperage requirements of the load.

In soft form electrical circuit can be divided in to sections and maximum load limits can be customized during programming by qualified personnel replacing the MCB functionality. CCB and MS functionality is pre-programmed in to the firmware.

In case of a breaker off due to a section overload, system will automatically try to reset multiple times as programmed by the user. Backup power connection can also be assigned for critical loads if programmed and wired accordingly.

Televisions, refrigerators, air conditioners, industrial machinery, IT hardware, and other appliances are getting increasingly computer controlled and sophisticated. Therefore clean power is a vital and specific to appliance. Level of power protection differs from refrigerator to a sophisticated television to a LED security lamp. As opposed to conventional load segmentation done area wise, the present invention introduces segmentation based on load type. Then the soft MCBs per each section can be programmed with level of power protection, time delays, how to react when there is thunder etc. For example during thunder, television load segment and refrigerator load segment will be automatically power down while security LED lamps, electric fence and CCTV cameras will continue to be powered while providing optimum power protection.

In the present invention, the electricity tariff meter keeps track of segment wise power usage. Accordingly user will know the cost for audio/video, refrigerators/air-conditioners, lighting separately and at any given point of time. User can set tabs segment-wise to know when they reach independent usage limits. Unlike in the case of readings in the conventional Watt hours meters, actual electricity cost will be displayed in a user friendly manner in the present invention.

The present invention has brought multiple passive devices with multiple and specific functionality in to a single active intelligent device with a high level of coordination among overall functionality. The present invention is capable of managing wiring system based on technical, financial and climatic conditions without any human intervention. The present invention is capable of changing parameters when required and version upgradability with completely new and improved features due to firmware based architecture.

In the present invention there are inbuilt provisions to connect solar power and backup power systems conveniently without having to rewire.

The present invention accounts for usage independently and log when such multiple energy sources are connected, where financial/technical records are logged for optimized management. Cascaded use of components like switching/self-test mechanisms, wire connection terminals are replaced with a single set.

One of the main objectives of the present invention is to find an effective solution for a well-managed power supply to various types of loads in an electrical system hence the present invention introduces a well-designed device to meet the present day requirements of various types of loads, applications and energy sources.

The main elements of the present invention are as follows; Touch Display

Touch Display is the main User interface of the device and its main functions are, display accumulated total usage, display current values of each segment/circuit, provide User input facilities for Parameter loading and manual operation of individual circuits.

Secure Digital (SD) Card Storage

SD card functions in two major procedures. First is the Parameter Loading procedure to the system. The second is the data/event logging procedure. The Parameter Loading procedure will be initialized upon each system restart, and will transfer the Parameter values saved in the SD storage to the main EEP OM Memory of the system. In an event of SD card failure, the system will use the existing parameters already saved in the main EEPROM. The Data/Event Logging procedure will be initialized on a timed manner and in an incident of alarm/warning or fault condition. The direction of the data will be from the system to the SD storage. Main Micro-Controller-1

Main Micro-Controller 1 is responsible in handling following tasks of the system.

1. Operates as the Touch Display controller

2. Operates as the SD storage controller

3. Coordinates on Parameter passing/updating sub-functions to support Main Micro-controller 2 operations.

4. Maintains an EEP OM segment with parameter value copies for fail-safe operation. Main Micro-Controller 2

Main Micro-controller-2 will be responsible in handling following tasks of the system.

1. Formats the Sensor Data and send to the Data Logging procedure.

2. Formats the event Data and send to the Event logging procedure.

3. Functions as an Auto recovery agent for pre-defined circuit recovery procedures/loops.

4. Functions as an agent for Power backup/Alternative power source coordination.

Sub Micro-Controller Units(MCU) 1-X

Sub Micro-controllers function as individual circuit monitors and undertake fast tripping in events of fault/short circuit or over current situations. These MCUs will update all the sensor and tripping information to the Main Micro-controller 2 via SPI bus. The EEPROM of this MCU will keep current limits and time delays for the specific circuit for fast and local operation. These MCUs operates at the speed of 4MHz and the average time duration between fault detection and prevention activation will be less than one micro second.

Sub Micro-Controller Unit - EL

Sub Micro-controller Unit (MCU) - EL will detect leakages in the domestic earth circuit and activate Main contactor shutdown procedure. This will also update information related to the earth leakage currents to Main Micro-controller 2 for data logging purposes.

Sub Micro-Controller unit (MCU) - Main

Sub Micro-controller - Main detects, over currents in the complete domestic circuit and activate Main contactor shutdown procedure in an event of over current, under voltage and over voltage. This will also coordinates alternative power sources (solar/wind power) and backup power sources (Backup power inverters/fuel powered generators), in the event of grid power failure. This MCU will update information related to the Main current/voltage to Main Micro-controller 2 for data logging purposes.

DC Power supply -

Provides operating power to the device, consisting of 5V and 12V DC voltages. Main Contactor -

Main physical circuit switching device that operate based on instructions given by the Sub MCU - main. Sub circuit contactors -

Individual circuit switching devices that operates based on instructions given by the respective Sub MCUs.

THE METHOD

Via the touch display, device is programmed and customized to meet the specific requirement of the wiring circuit. Segment-wise power supply plan is hardcoded on to SD card, downloaded to controllers and will retain a copy on SD card as a backup for automatic self-recovery during a firmware failure. Number of load segments; allowed load limits per segment; level of power protection per segment; on/off time delays per segment are programmed in to SUB-MCUs during customization. Segments of circuits are divided load type-wise. Example; Refrigerators, deep-freezers, air-conditioners and the like in to one or more segments, sophisticated electronics in to another set of segments, lighting in to another and security system related up-time vital appliances to another segment, etc. The system is so programmed that Segment-wise sub-MCUs make independent decisions for the particular segment based on the settings. Segment specific overload, over/under/irregular voltage conditions are detected and processed as per pre-programmed instructions by these controllers. During a trip off of a segment due to an overload or specific conditions, sub-MCUs are programmed to automatically restart given number of instances. Backup power source is programmed to channel backup power to required segments like security and lighting segments so that during main power supply outage backup power can keep the required circuits powered. Backup power supplied by generators or inverter systems are automatically connected by detection of primary power source failure. Sub MCU - EL will instantly shutdown main contactors in case of an earth leakage is detected. In case of any failure detected in any controller, the related segment or complete wiring circuit in case of main controller failure will shut down by default. Individual segments, backup power sources, alternative power sources and main power source can be shut down manually via the touch interface. Power usage based on main, alternative and backup power sources, interruptions, failures, irregularities and other conditions are logged. This information can be downloaded to a computer for reporting and analysis. Utility Power Company can be given access to obtain electricity usage via the touch interface. In an event of alternative power source usage (Solar/wind), independent usage can be monitored and logged. Configurations saved on SD card can be reprogrammed to meet changing requirements of the wiring circuit. Sub-MCU load limits, operation sequence etc can be changed to meet new requirements. Segments can be increased or decreased as required.

One of the Key features of the present invention is the method of load segmentation of the circuit.

In most developing countries and during bad weather condition in any part of the world, utility power quality may not be reliable and common to experience power sags (voltage drop); sudden increase (surge); failures (blackouts); Short time failures (Brownouts); minor to major spikes. In such situations, as a solution to protect electrical equipment, voltage stabilizers, power conditioners, surge protectors, backup inverters, UPS systems and power generators are used.

The present invention introduces a circuit segmentation method to overcome the concerns faced by the conventional system and organize the circuit to be able to manage modern requirements better. Load in an electrical circuit is segmented based on electrical equipment category and usage. Security related mission critical equipment that needs to be powered and to be active even at risk of damage due to power related problems will be categorized in to one segment. This segment will be provided with backup power on highest priority and will operate even under adverse conditions to ensure security will be intact. Sophisticated Televisions, AV equipment, LED lights and fans will be in one segment where backup power and high level of active power protection will be provided. Hence, it is assured that normal operations are continued without any interruption even during power failures and sophisticated equipment is protected from power related problems. Refrigerators, deep-freezers, air-conditioners can be on another segment where different level of power protection can be provided and may not require backup power as they could be kept shut down during short power failures. Backup power can be programmed to fed only in to backup power required segments. This will save power storage for more important mission critical activities, as backup power has usage limits either use fuel or battery storage. This will also reduce load and enable to achieve the objective with a lower capacity power source. Power protection can be varied segment-wise. Appliances with a compressor like refrigerators and air conditioners can be switched on with a 4-5mins time delay each time there is a brownout to avoid sudden on/off. But this feature is not good for TV or lights, where you would not need or like to wait for 5mins each time it goes off. But sophisticated TVs will need much higher and faster response active power protection unlike in the case of a refrigerator. Less critical segments usage can be restricted once monthly budgeted consumption is nearing or during peak tariff hours. During alternative power (Solar Power) is active power can be consumed in excess.

4. BRIEF DESCRIPTION OF THE DRAWINGS

FIGURE 01 shows one embodiment of a system diagram.

FIGURE 02 shows one embodiment of Touch Display with regards to segments.

Each segment has a virtual switch. This is equivalent to conventional MCBs. This shows each segment is on or off. If there is an overload for example the segment will trip off and display virtual switch as off. Then user can manually on this just like a real breaker.

FIGURE 03 shows one embodiment of Touch Display with regards to details of a segment.

This shows summary details for the segment. Back-up power allowed to the segment or not, Power consumption up to date in value and units, When power goes off if there is an on time delay or not (this is required for refrigerators and ACs etc), Allowed maximum load in Amperes etc.

FIGURE 04 shows one embodiment of Touch Display with regards to main earth leakage.

This shows pre-configured earth leakage current, max-min voltage levels, response time when reach limits etc.

FIGURE 05 shows one embodiment of Touch Display with regards to the main screen.

This shows overall electricity usage in units and values, date range considered, EPO for emergency power off.

Claims

CLAIMS The invention claimed is-

1. A System for Smart Electric circuit, the system comprising;

Touch Display (101), wherein said Touch Display is configured as the user interface and is designed to display Accumulated total usage of electricity in units (kWh) and in value ($), Load segment-wise accumulated usage of electricity in units (kWh) and in value($), Contemporary usage of load segment in units (W), real-time varying load and maximum assigned load in units (Amperes) and graphically of each segment of circuit, real-time overall power status including active power sources and active segments, Backup power source status, Alternative power source status, Logs of historical monthly usage segment-wise in units (kWh) and in value ($), Logs of power failures, earth leakages, current over loads, over/under voltage conditions, said Touch Display is further configured to provide user input facilities for parameter loading, Manual operation of individual circuits via graphically displayed virtual miniature circuit breakers (MCB), Main switches, Earth leakage current operated circuit breaker with overload and over voltage protection ( CBOV), Manual operation via graphically displayed virtual change-over switches to backup power, static switches for uninterrupted switch over among alternative power sources to trigger physical function via relevant contactor, to set usage limits/tabs to monitor segment-wise budget and actual consumption in units (kWh) and in Values ($).

SD Card Storage (102), wherein said SD Card Storage executes the Procedures of Parameter Loading to the system and Data/event Logging, said Parameter Loading Procedure is initialized when the system restarts; said Data/event Logging Procedure is initialized on a timed manner and in an incident of alarm/warning or fault condition; and

Main Micro-controller 1 (103), wherein said Main Microcontrollers 1 is configured to operate as the Touch Display Controller, to operate as the SD Storage Controller, to coordinate on parameter passing/updating sub functions to support operations of Main Micro-controller 2 and to maintain EEP OM segment with parameter value copies for failsafe operation; and

Main Microcontroller 2 (104), wherein said Main Microcontroller 2 is configured to format Sensor Data and send same to the Data Logging Procedure, to format Event Data and send same to the Event Logging Procedure, to function as an Auto Recovery agent for pre-defined circuit recovery procedures/loops and to function as an agent for Power backup/Alternative power source coordination; and a plurality of Sub Microcontroller Units (105), wherein said Sub Microcontroller Units are configured to function as individual segment circuit monitors and to update sensor and tripping information to the Main Microcontroller 2 , said Sub Microcontroller Units are connected to the Main Microcontroller 2 via SPI Data Bus (111); said and

Sub Microcontroller Unit-EL (106), wherein said Sub Microcontroller Unit-EL is configured to detect leakages in the domestic earth circuit and to shut down main contactor in an event of earth leakage is detected, said Sub Microcontroller Unit-EL is connected to the Main Microcontroller 2 and other Sub Microcontroller Units via SPI Data Bus; and

Sub Microcontroller Unit-Main (107), wherein said Sub Microcontroller Unit-Main is configured to detect over currents in the complete domestic circuit, to activate Main contactor shut down procedure in the events of over current, under voltage or over voltage, to coordinate alternate power sources and/or backup power sources in the event of grid power failure and to update information related to main current/voltage to the Main Microcontroller 2, said Sub Microcontroller Unit-Main is connected to the Main Microcontroller 2 via SPI Data Bus (112); and

EEPROM, wherein said EEPROM is configured to save the parameter values that are transferred from the SD Card Storage and thereupon to act as backup memory of the system in the event of SD Card failure; and DC Power Supply (108), wherein said DC Power Supply is configured to provide operating power to the system in 5V and 12V DC voltages via AC Mains Grid Supply (113); and

Main Contactor (109), wherein said Main Contactor is configured to operate switching of main physical circuit based on instructions given by the Sub Microcontroller Unit-Main; and

Sub Circuit Contactors (110), wherein said Sub Circuit Contactors are configured to operate switching of individual circuits based on instructions given by the respective Sub Microcontroller Units.

2. A System for Smart Electric Circuit as per claim 01, wherein the system is designed categorizing similar loads in to segments.

3. A System for Smart Electric Circuit as per claim 01 and 02, the Touch Display is pre-programmed and customized to meet the specific requirements of wiring circuit.

4. A System for Smart Electric Circuit as per claim 01, 02 and 03, wherein the SD Card Storage is hardcoded with pre-determined segment-wise power supply plan.

5. A System for Smart Electric Circuit as per claim 01, 02, 03 and 04, wherein the pre-determined segment-wise power supply plan is copied to the Main Microcontroller 1 and 2.

6. A System for Smart Electric Circuit as per claim 01, 02, 03, 04 and 05, wherein the Sub Microcontroller Units are pre-programmed at the time of customization with number of load segments, allowed load limits per segment, level of power protection per segment, on off time delays per segment.

7. A System for Smart Electric Circuit as per claim 01, 02, 03, 04, 05 and 06, wherein the Sub Microcontroller Units are further pre-programmed in order to make segment specific independent decisions.

8. A System for Smart Electric Circuit as per claim 01, 02, 03, 04, 05, 06 and 07, wherein the EEP OM of Sub Microcontroller Units saves data as to current limits and time delays for specific circuit for fast and local operation.

9. A System for Smart Electric Circuit as per claim 01, 02, 03, 04, 05, 06, 07 and 08, wherein a backup power source (114) is programmed to the system to channel backup power to required segments at an event of main power supply outage.

10. A System for Smart Electric Circuit as per claim 01, 02, 03, 04, 05, 06, 07, 08 and 09, wherein an alternative power source (115) is programmed to the system to channel power to specified segments as per user discretion.

11. A System for Smart Electric Circuit as per claim 01, 02, 03, 04, 05, 06, 07, 08, 09 and 10, wherein the system is configured to record power usage based on main, alternative and back-up power sources, interruptions, failures, over/under voltages, leakages and over loads.