CA2633723A1 - Modular power distribution system and methods - Google Patents

Modular power distribution system and methods Download PDF

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Publication number
CA2633723A1
CA2633723A1 CA002633723A CA2633723A CA2633723A1 CA 2633723 A1 CA2633723 A1 CA 2633723A1 CA 002633723 A CA002633723 A CA 002633723A CA 2633723 A CA2633723 A CA 2633723A CA 2633723 A1 CA2633723 A1 CA 2633723A1
Authority
CA
Canada
Prior art keywords
module
distribution system
power distribution
chassis
modular power
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA002633723A
Other languages
French (fr)
Inventor
Joseph Christopher Coffey
Bradley J. Blichfeldt
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Commscope Connectivity LLC
Original Assignee
Adc Telecommunications, Inc.
Joseph Christopher Coffey
Bradley J. Blichfeldt
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Adc Telecommunications, Inc., Joseph Christopher Coffey, Bradley J. Blichfeldt filed Critical Adc Telecommunications, Inc.
Publication of CA2633723A1 publication Critical patent/CA2633723A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
    • H02H3/00—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection
    • H02H3/006—Calibration or setting of parameters
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
    • H02H3/00—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection
    • H02H3/08—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection responsive to excess current
    • H02H3/10—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection responsive to excess current additionally responsive to some other abnormal electrical conditions
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J1/00—Circuit arrangements for dc mains or dc distribution networks
    • H02J1/08—Three-wire systems; Systems having more than three wires
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J1/00—Circuit arrangements for dc mains or dc distribution networks
    • H02J1/10—Parallel operation of dc sources
    • H02J1/108—Parallel operation of dc sources using diodes blocking reverse current flow
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00—Conversion of dc power input into dc power output
    • H02M3/02—Conversion of dc power input into dc power output without intermediate conversion into ac
    • H02M3/04—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters
    • H02M3/10—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M3/145—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M3/155—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/156—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators
    • H02M3/158—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load
    • H02M3/1584—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load with a plurality of power processing stages connected in parallel
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/003—Constructional details, e.g. physical layout, assembly, wiring or busbar connections
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/14—Mounting supporting structure in casing or on frame or rack
    • H05K7/1438—Back panels or connecting means therefor; Terminals; Coding means to avoid wrong insertion
    • H05K7/1439—Back panel mother boards
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/14—Mounting supporting structure in casing or on frame or rack
    • H05K7/1438—Back panels or connecting means therefor; Terminals; Coding means to avoid wrong insertion
    • H05K7/1457—Power distribution arrangements
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/14—Mounting supporting structure in casing or on frame or rack
    • H05K7/1438—Back panels or connecting means therefor; Terminals; Coding means to avoid wrong insertion
    • H05K7/1459—Circuit configuration, e.g. routing signals
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
    • H02H3/00—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection
    • H02H3/08—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection responsive to excess current

Abstract

A modular power distribution system comprises a chassis; and a backplane including a power input, and a plurality of module connection locations. A plurality of modules are mounted in the chassis, each module mounted to one of the module connection locations. Each module includes: (i) an OR-ing diode; (ii) a circuit protection device; (iii) a microprocessor controlling the circuit protection device; and (iv) a power output connection location. A
circuit option switch is located on each module for setting the current limits for each module. A control module is provided connected to the backplane.

Description

MODULAR POWER DISTRIBUTION SYSTEM AND METHODS
Field of the Invention The present invention relates to a power distribution panel with circuit clement modules.

Background of the Invention Electrical circuit panels such as power distribution panels typically include a number of different circuit elements such as fuse holders and fuses, circuit breakers, input and output connectors and alarm signal LED's. For safety and other reasons, the electrical circuits of power distribution panels are enclosed within a housing structure. Therefore, the circuit elements listed above have typically been inserted into holes that have been pre-cut or pre-punched into the housing structure, usually on a front or back panel of the housing structure.
These prior circuit panels are fixed and once the holes are formed in the housing, the type and arrangement of the components is limited. In order to manufacture different fixed circuit panels of the prior systems, a circuit panel manufacturer would punch out different patterns of holes in the front or back panels of the housing structure in order to accommodate different arrangements of circuit elements. Significant retooling time and costs are involved for offering different fixed panels. Assembly of the circuit elements is also difficult when the elements are inserted through holes. One solution is described and shown in U.S. Patent No.
6,456,203.
In addition, such panels are hardwired between the input and output connections, and the fuse and/or breaker locations. In some panels, redundant power connections are provided, controlled by an OR-ing diode including a heat sink.
These features can take up significant space within the panel.
There is a continued need for improved power distribution panels.
Summary of the Invention A modular power distribution system comprises a chassis; and a backplane including a power input, and a plurality of module connection locations. A
plurality of modules are mounted in the chassis, each module mounted to one of the module I

connection locations. Each module includes: (i) an OR-ing diode; (ii) a circuit protection device; (iii) a microprocessor controlling the circuit protection device;
and (iv) a power output connection location. A circuit option switch is located on each module for setting the current limits for each module. A system control module is provided connected to the backplane.
A modular power distribution system comprises a chassis having an open front and an interior; and a backplane positioned opposite to the open front, and including a power input, and a plurality of module connection locations. A
plurality of modules are mounted in the interior of the chassis, each module mounted to one of the module connection locations. Each module includes: (i) a rear connector; (ii) a main body; (iii) a circuit protection device; (iv) a front panel; and (v) a power output connection location on the front panel.

Brief Description of the Drawings FIG. I is a schematic side view of one embodiment of a power distribution panel, with a module partially inserted into the chassis.
FIG. 2 is a schematic side view of another embodiment of a power distribution panel, with a module partially inserted into the chassis.
FIG. 3 is a schematic top view of the power distribution panel of FIG. 1.
FIG. 4 is a schematic top view of an alternative embodiment of a power distribution panel.

Detailed Description of the Preferred Embodiments Referring to FIGS. I and 2, power distribution systems 10, 110 are shown.
Power distribution systems 10, 110 are modular designs including a chassis 12 and removable circuit modules 14, 114. Each circuit module 14, 114 includes an electronic breaker 16, 116 for circuit protection, and a port assembly 18, 118 for output power distribution.
Chassis 12 includes a top 34 and a bottom 36. A backplane 38, such as a printed circuit board, provides the interconnection between modules 14, 114 and power input connector 26. Preferably, a second (redundant) power input connector 27 is provided (see FIG. 3).
Modules 14, 114 are received in chassis 12 through a front opening 20.
Modules 14, 114 can be removed through front opening 20 as desired to repair, replace or service the modules. Modules 14, 114 can be latched or otherwise attached to chassis 12, as desired.

Modules 14, 114 are similar in many respects for distributing and monitoring the power in systems 10, 110. Modules 14, 114 each include a printed circuit board 42 with circuitry for linking the input power to the output power. Modules 14, differ in the arrangements for the power outputs at port assemblies 18, 118.
Module includes a single power output connector 72, such as a high power connector 10 including a DB9-2W2 connector; whereas inodule 1 10 includes a plurality of separate power output connectors 172, such as lower power connectors including screw terminals.
The electronic breakers 16, 116 are part of active circuit modules 14, 114 to replace discrete fuses and circuit breaker used in prior art power distribution panels.
The end user adds, removes, or upgrades ports in the power distribution system as required by adding or removing circuit modules 14, 114.
Each circuit module 14, 114 can be used as a lA, 2A, I OA, etc. breaker by setting current liinit options switches 22. For example, 2 position DIP
switches could be used. Prior art panels with discrete fuses and breakers have a single trip value. Control logic 24 including microcontroller 28 monitors the output current via current sensors 30, 130. If the output current exceeds the limits set by option switches 22, microcontroller 28 will turn-off ("trip") a breaker device 32, which is preferably a solid-state device. The current limit set by the option switches 22 can also be overridden via a software interface from a remote terminal through a control module 40 (see FIGS. 3 and 4). Microprocessor 28 is networked to an external processor through control module 40. If a breaker device 32 is tripped due to the detection of an over current condition, microcontroller 28 will periodically re-enable breaker device 32 to see if the fault still exists. This can eliminate a service visit if the over current was caused by a momentary transient condition.
Microcontroller 28 provides control over breaker device 32. This eliminates disconnects caused by source or load transients. Microcontroller 28 can also set a breaker trip point based on load monitoring over time. Microcontroller 28 is also equipped with a history file that records various conditions local to the individual circuit modules 14, 114. This information is accessible via the control module 40.
Microprocessor 28 can include a load dependent trip control algorithm. This option allows microprocessor 28 to set the breaker trip point for a given load based on a learning algorithm. Microprocessor 28 monitors outgoing current over time (can be a user selectable time period). Microprocessor 28 is configured to calculate a margin of error, then use the new value to create a trip value for each circuit module 14, 114. For example, one circuit module 14 is used in a 30 amp circuit.
However, typically the circuit only draws a 27 amp load. Mireroprocessor 28 recognizes the 27 amp load by monitoring the current load over time, then adds a margin of error (e.g., 1% - 5%) to create a load dependent trip value.
"t'herefore, the circuit will trip before 30 amps is ever drawn. Such a system prevents over fusing, and damaged equipment.
Low voltage disconnect (LVD) is localized to the circuit modules 14, 114.
Under voltage conditions are monitored by microcontroller 28 with an under voltage sensor 46. If the voltage drops below the recommended level, microcontroller will turn breaker device 32 off to disconnect the load. The same process will occur if an over voltage condition occurs. Over voltage conditions are monitored by microcontroller 28 with an over voltage sensor 48.
To support redundant (dual feed) applications, the OR-ing diodes 54 are localized to the individual circuit modules 14, 114. Prior art power distribution panels that used OR-ing diodes placed them in the input circuits which required very large diodes and heat sinks and created a single point of failure for the system. The arrangement of systems 10, 110 allows the heat dissipated by the OR-ing diodes to be evenly distributed in chassis 12 preventing a localized hot spot. The noted arrangement also reduces the size of the diodes and their respective heat sinks, and eliminates the singlc point of failure common in prior art power distribution panels.
Circuit modules 14, 114 can also include a temperature sensor 50 for monitoring high temperature conditions.
An LED indicator 62 on each circuit module 14, 114 provides a visual status of input and output voltage, output current, teinperature, over/under voltage conditions, and breaker trip. A local reset switch 68 is also provided to reset the breaker device 32 after a trip condition has occurred.

In circuit module 14, all input and output to the electronic breaker 16 is via a high current connector 18 to prevent accidental contact by service personnel.
Circuit module 14 includes a front connector 72, and a rear connector 76. Front connector 72 connects to cable connector 82 and cable 86 for the output power. Rear connector 76 connects to chassis backplane connector 84 for input power to module 14. The high power connector also prevents polarity reversals.
Front connectors 172 of circuit module 114 each connect to a power output connector 182 and cable 186. Power output connector 182 may be a lug for screw connection to front connector 172.
Systems 10, 110 eliminate intemal wiring normally required in prior art power distribution panels. All power and signaling is confined to PCB traces, planes, and bus bars, which improves reliability and reduces assembly cost.
Chassis 12 is a passive component that can be reconfigured for a variety of applications.
Systems 10, 110 also reduce the number of connections and thermal loss associated with each connection.
All circuit modules 14, 114 in chassis 12 communicate with control module 40. Control module 40 provides access to systems 10, 110 via a laptop serial or network connection for status and alarm information. Control module 40 also provides the external aianns signals common in Telco application. Access to control module 40 is through a front connector 56, or through a rear connector 58 on a back of backplane 38.
Chassis 12 in FIG. 3 has rear input power connectors 26, 27, and front accessible circuit modules 14. A inodified chassis 112 in system 10' as shown in FIG. 4 includes front accessible input power connectors 126, 127.
Circuit modules 14, 114 and control module 40 can be provided with front face plates 86 to protect the interior circuit features. Ventilation holes 88 can be added through front face plates 86, to allow for airflow through systems 10, 10', 110 for cooling of system components.
The above noted panels include inodular arrangements for the individual or groupings of circuits. Additional modules can be added as additional circuits are added to the system. By utilizing localized OR-ing, smaller diodes and smaller heat sinks can be used. Additional advantages arise from the localized components associated with each module. In particular, with a localized low voltage disconnect elements, there is no need for a large low voltage disconnect contactors associated with a dedicated panel. Local LED indicators show indicators for each module allowing for improved diagnostics.

Claims (17)

1. A modular power distribution system comprising:
(a) a chassis;
(b) a backplane including:
(i) a power input;
(ii) a plurality of module connection locations;
(c) a plurality of modules mounted in the chassis, each module mounted to one of the module connection locations, each module including:
(i) an OR-ing diode;
(ii) a circuit protection device;
(iii) a microprocessor controlling the circuit protection device; and (iv) a power output connection location.
2. The modular power distribution system of claim 1, further comprising a circuit option switch located on each module.
3. The modular power distribution system of claim 1, further comprising a redundant power input connected to the backplane.
4. The modular power distribution system of claim 1, further comprising a control module mounted in the chassis.
5. The modular power distribution system of claim 1, wherein the circuit protection device includes a solid state breaker device.
6. The modular power distribution system of claim 1, wherein each module includes:
(a) an over voltage sensor;
(b) an under voltage sensor; and (c) a temperature sensor.
7 7. The modular power distribution system of chain 1, further comprising a load dependent trip control device.
8. A modular power distribution system comprising:
(a) a chassis having an open front and an interior;
(b) a backplane positioned opposite to the open front including:
(i) a power input;
(ii) a plurality of module connection location;
(c) a plurality of modules mounted in the interior of the chassis, each module mounted to one of the module connection locations, each module including:
(i) a rear connector for connecting to the backplane to receive input power from the power input;
(ii) a main body including a rear and a front, the rear connector located at the rear of the main body;
(iii) a circuit protection device on the main body connected to the rear connector;
(iv) a front panel located at the front of the main body;
(v) a power output connection location located on the front panel connected to the circuit protection device.
9. The modular power distribution system of claim 8, further comprising a microprocessor controlling the circuit protection device and a circuit option switch located on each module.
10. The modular power distribution system of claim 8, further comprising a redundant power input connected to the backplane.
11. The modular power distribution system of claim 8, further comprising a control module mounted in the chassis.
12. The modular power distribution system of claim 8, wherein the circuit protection device includes a solid state breaker device.
13. The modular power distribution system of claim 8, wherein each module includes:
(a) an over voltage sensor;
(b) an under voltage sensor; and (c) a temperature sensor
14. The modular power distribution system of claim 8, further comprising a load dependent trip control device.
15. The modular power distribution system of claim 8, wherein the power input is located on a rearward facing surface of the backplane.
16. The modular power distribution system of claim 8, wherein the power input includes a front accessible input power connector located adjacent to the open front.
17. A method for assembly of a power distribution system comprising:
(a) providing a chassis having an open front, and a rear backplane;
(b) selecting a plurality of modules;
(c) mounting each module to the chassis wherein:
(i) each module slides into an open front of the chassis;
(ii) each module connects to the backplane to provide each module with input power;
(iii) each module includes a circuit protection device;
(iv) each module provides output power along a front panel of each module, protected by the circuit protection device of each module.
CA002633723A 2006-01-20 2007-01-18 Modular power distribution system and methods Abandoned CA2633723A1 (en)

Applications Claiming Priority (7)

Application Number Priority Date Filing Date Title
US76059806P 2006-01-20 2006-01-20
US60/760,598 2006-01-20
US76291506P 2006-01-27 2006-01-27
US60/762,915 2006-01-27
US11/654,367 US7554796B2 (en) 2006-01-20 2007-01-17 Modular power distribution system and methods
US11/654,367 2007-01-17
PCT/US2007/001408 WO2007084654A2 (en) 2006-01-20 2007-01-18 Modular power distribution system and methods

Publications (1)

Publication Number Publication Date
CA2633723A1 true CA2633723A1 (en) 2007-07-26

Family

ID=38094550

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002633723A Abandoned CA2633723A1 (en) 2006-01-20 2007-01-18 Modular power distribution system and methods

Country Status (5)

Country Link
US (5) US7554796B2 (en)
EP (2) EP3484036B1 (en)
BR (1) BRPI0706653B1 (en)
CA (1) CA2633723A1 (en)
WO (1) WO2007084654A2 (en)

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US8451590B2 (en) 2013-05-28
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US10554036B2 (en) 2020-02-04
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US20070223160A1 (en) 2007-09-27

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