An alternating current intelligent power distribution module, intelligent power distribution cabinet and power distribution control method

Abstract

This invention discloses an AC intelligent power distribution module, an intelligent power distribution cabinet, and a power distribution control method, belonging to the field of power distribution control technology. The AC intelligent power distribution module integrates a semiconductor switch, a main control module, a current monitoring module, and a voltage monitoring module, and is equipped with multiple protection mechanisms. The current monitoring module and the voltage monitoring module each have independent hardware and software protection circuits, achieving dual fast protection. Through drive control protection, in the event of a short-circuit fault, the gate voltage is first pre-dropped to suppress the current peak before completely shutting off. The module also includes a fuse as backup physical isolation. Through modular design and multiple protection mechanisms, this invention achieves the technical effects of a compact power distribution cabinet structure, fast response speed, strong protection capability, flexible parameter configuration, and remote intelligent monitoring.

Description

Technical Field

[0001] This invention relates to the field of power distribution control technology, and in particular to an AC intelligent power distribution module, an intelligent power distribution cabinet, and a power distribution control method. Background Technology

[0002] Distribution cabinets are key equipment in power systems for power distribution, control, and protection. They are widely used to safely and efficiently distribute power from the upper-level power grid to various nearby electrical loads. Existing distribution cabinets are mainly divided into fixed distribution cabinets and drawer-type distribution cabinets. In fixed distribution cabinets, electrical components are fixedly installed inside the cabinet, while in drawer-type distribution cabinets, the main electrical components are installed in removable drawers, forming standard functional units. Both fixed and drawer-type distribution cabinets use circuit breakers, disconnecting switches, fuses, and relays, along with control and protection devices, to form internal circuits to handle the transmission, switching, and protection of electrical energy.

[0003] The existing power distribution cabinets have the following technical defects: 1. Complex structure and large size. Existing distribution cabinets often use traditional mechanical connections and wiring methods for electrical components such as circuit breakers, disconnect switches, fuses and relays, resulting in low space utilization. This not only increases the overall size but also makes later maintenance and repair inconvenient.

[0004] 2. Long response time and poor protection capability. Specifically, in terms of protection function, traditional distribution cabinets mainly rely on mechanical protection components such as circuit breakers and fuses. When overload, short circuit or other faults occur, these components often require hundreds of milliseconds or even longer to complete the disconnection action from the occurrence of the fault. During this period, excessive fault current may have already damaged the electrical equipment or lines.

[0005] 3. The installation positions and functions of components in traditional power distribution cabinets are relatively fixed, which results in a fixed overall structure, shape and size of the power distribution cabinet, making it inconvenient to adjust the shape and size of the power distribution cabinet so that it can be placed in different usage environments.

[0006] 4. The interface protection parameters of traditional distribution cabinets are relatively fixed, which means that a set distribution cabinet can only be used for a single or a few specific types of loads, and cannot meet the usage requirements of multiple loads, thus increasing the user's operating costs.

[0007] Therefore, there is an urgent need to provide a smart power distribution solution that is compact, has a fast response speed, strong protection capabilities, and flexible configuration of protection parameters. Summary of the Invention

[0008] The purpose of this invention is to overcome the technical problems existing in the prior art and to provide an AC intelligent power distribution module, an intelligent power distribution cabinet and a power distribution control method to realize the drive control, safety protection and status information detection of electrical equipment such as electric pumps, electrically controlled valves, and electric heaters.

[0009] The objective of this invention is achieved through the following technical solution: A first aspect of the present invention provides an AC intelligent power distribution module, comprising: The primary input terminal is used to connect to the power grid, and the primary output terminal is used to connect to the load. The main control module uses a programmable logic device; A semiconductor switch is connected between the primary input terminal and the primary output terminal and is controlled by the main control module; A current monitoring module is connected between the main control module and the semiconductor switch, and is used to collect the current sampling signal flowing through the semiconductor switch; A voltage monitoring module is connected between the main control module and the semiconductor switch, and is used to collect voltage sampling signals across the semiconductor switch. The AC intelligent power distribution module is equipped with multiple protection mechanisms: The software protection is configured to preprocess the current sampling signal and / or the voltage sampling signal, and the main control module performs fault logic judgment based on the preprocessed current sampling signal and / or voltage sampling signal, and outputs a first shutdown control signal to cut off the semiconductor switch when a fault is determined. Hardware protection is configured such that the current monitoring module performs a simulated window comparison on the current sampling signal, and / or the voltage monitoring module performs a simulated window comparison on the voltage sampling signal. When the current sampling signal and / or the voltage sampling signal are detected to exceed the preset hardware safety range, a second shutdown trigger signal is directly output to the main control module. The main control module responds to the second shutdown trigger signal by outputting a second shutdown control signal to cut off the semiconductor switch. The fuse protection is configured to provide a fuse protection circuit between the semiconductor switch and the primary input terminal, which blows when the current flowing through the fuse protection circuit exceeds its rated fusing current.

[0010] In some embodiments, the multiple protection mechanism further includes: The drive control protection, integrated into the main control module, is configured to, when a short circuit fault is detected, first send a pre-drop voltage command to the semiconductor switch to reduce the gate voltage of the semiconductor switch to a preset intermediate voltage value to suppress the short circuit current peak; then, after a predetermined delay or after detecting a current drop, completely block the drive signal to completely turn off the semiconductor switch.

[0011] In some embodiments, the execution logic of the multiple protection mechanism includes: In the event of a short circuit fault, drive control protection shall be executed first. In the event of a non-short-circuit fault, software protection shall be implemented first. Hardware protection is implemented when software protection fails or the software protection response is delayed. When software protection, hardware protection, and driver control protection all fail, fuse protection is activated.

[0012] In some embodiments, the AC intelligent power distribution module is connected to: The display module is connected to the main control module and is used to view local parameters in real time. A button control module, connected to the main control module, is used to input user button commands; A communication module, connected to the main control module, is used for data interaction with external devices; A digital input module, connected to the main control module, is used to input external interlock signals or sensor status signals; The switch output module is connected to the main control module and is used to send fault alarm signals and operating status signals to the outside world.

[0013] In some embodiments, the AC intelligent power distribution module is further configured to support three operating modes: local mode, remote mode, and configuration mode; wherein: In the local mode, local parameter query, rapid debugging and emergency operation are realized through the button control module and the display module; In the remote mode, remote start / stop and data monitoring are achieved through the communication module; In the configuration mode, the communication module connects to the host computer and imports preset protection parameters. The main control module configures its internal protection logic according to the imported preset protection parameters to adapt to different types and capacities of loads.

[0014] In some embodiments, the hardware protection includes: Hardware protection circuits are set in the current monitoring module and the voltage monitoring module respectively. The hardware protection circuit in the current monitoring module includes an amplification module, a current window comparator and a digital isolator connected in sequence, and the output terminal of the digital isolator is connected to the main control module. The hardware protection circuit in the voltage monitoring module includes an isolation module and a voltage window comparator connected in sequence, and the output terminal of the voltage window comparator is connected to the main control module.

[0015] In some embodiments, the hardware protection circuit in the voltage monitoring module includes an isolation module and a phase sequence judgment module connected in sequence, and the output terminal of the phase sequence judgment module is connected to the main control module.

[0016] A second aspect of the present invention provides an intelligent power distribution cabinet, including a cabinet body and a plurality of AC intelligent power distribution modules as described in the first aspect disposed within the cabinet body, wherein each AC intelligent power distribution module is connected to the other via a DB interface signal and is configured with hierarchical protection logic.

[0017] In some embodiments, the hierarchical protection logic includes: Each AC intelligent power distribution module has a preset load priority. When any AC intelligent power distribution module detects a fault or overload, it sends a linkage signal to other AC intelligent power distribution modules through the DB interface. When the load priority of the AC intelligent power distribution module receiving the linkage signal is lower than the preset priority threshold, it actively disconnects its own load.

[0018] A third aspect of the present invention provides a power distribution control method based on the AC intelligent power distribution module described in the first aspect, comprising the following steps: S1. The current and voltage sampling signals of the load are collected in real time through the current monitoring module and the voltage monitoring module; S2. Based on the current sampling signal and / or voltage sampling signal acquired in step S1, software protection and hardware protection are executed synchronously. S3. When step S2 fails or the current flowing through the fuse protection circuit exceeds its rated fusing current, the fuse protection is activated.

[0019] In some embodiments, step S2 further includes: When a short-circuit fault is detected, drive control protection is activated: First, a pre-drop voltage command is sent to the semiconductor switch to reduce the gate voltage of the semiconductor switch to a preset intermediate voltage value to suppress the short-circuit current peak; then, after a predetermined delay or after detecting a drop in current, the drive signal is completely blocked to completely turn off the semiconductor switch.

[0020] It should be further noted that the technical features corresponding to the above-mentioned options and embodiments can be combined or substituted with each other to form new technical solutions without conflict.

[0021] Compared with the prior art, the beneficial effects of the present invention are: 1. Compact structure, high space utilization, and improved maintenance convenience: This invention replaces the numerous discrete components and complex mechanical wiring of traditional distribution cabinets, such as circuit breakers, disconnect switches, fuses, and relays, with multiple integrated AC intelligent power distribution modules. Each AC intelligent power distribution module integrates a semiconductor switching circuit, a main control module, a current monitoring module, a voltage monitoring module, and various interfaces. The AC intelligent power distribution module directly connects to the power grid and load via plugs, simplifying the wiring within the cabinet, optimizing the internal space layout, significantly improving space utilization, and effectively reducing the overall size of the distribution cabinet. Furthermore, the modular design of the AC intelligent power distribution modules allows for easy replacement or adjustment of specific modules during later maintenance and repair, eliminating the need for large-scale operations on the complex wiring throughout the cabinet, greatly improving the convenience and efficiency of maintenance.

[0022] 2. Extremely fast response speed and significantly enhanced protection capabilities: The AC intelligent power distribution module of this invention uses semiconductor switches (such as MOS switches, SCR switches, etc.) as the core switching components. These switches have microsecond-level switching speeds, enabling them to comprehensively judge and trigger the semiconductor switching circuit to quickly turn off and disconnect faulty circuits within microseconds. More importantly, the AC intelligent power distribution module incorporates multiple protection mechanisms, which construct a comprehensive safety protection system for the intelligent power distribution cabinet from different levels. Software protection, with its flexible parameter configuration and complex logic operations, achieves accurate identification and protection against various faults such as overcurrent, short circuit, overvoltage, and undervoltage. It can adjust protection thresholds according to different load characteristics, exhibiting strong adaptability. Hardware protection, through independent analog circuits, achieves rapid response, triggering protection actions within microseconds. Especially in extreme cases where software protection fails or response is delayed, it serves as a second line of defense to ensure system safety. Fuse protection, as the final physical isolation barrier, completely cuts off the circuit by melting the fuse when a severe fault occurs that exceeds the capabilities of semiconductor switches and electronic protection circuits, preventing the fault range from expanding. The drive control protection circuit innovatively uses a pre-voltage reduction method to actively suppress current peaks before short-circuit shutdown, reducing the shutdown stress on semiconductor switches, extending their service life, and improving the reliability of protection actions. These four protection mechanisms work synergistically, layer by layer, ensuring both the speed and accuracy of protection while also considering the system's fault tolerance and equipment safety, enabling the intelligent distribution cabinet to operate stably and reliably in complex electrical environments.

[0023] 3. High level of intelligence, possessing remote monitoring and collaborative management capabilities, enhancing system reliability and automation: The AC intelligent power distribution module of this invention can not only be locally controlled via buttons, but also connected to PLC, DCS, or host computer systems via Ethernet and RS485 communication modules to achieve remote control and multi-level interconnection. The main control module can upload real-time collected power distribution status (voltage, current, power, power factor, etc.) and fault information (fault type, occurrence time, etc.) to remote devices or host computer systems via communication interfaces, supporting fault tracing and maintenance decisions, and realizing cloud monitoring and intelligent operation and maintenance. Simultaneously, multiple AC intelligent power distribution modules can be linked via the DB interface to achieve hierarchical protection and load priority management. For example, when a fault occurs in a certain area or device, related AC intelligent power distribution modules can coordinate to cut off non-critical loads according to preset priority strategies, ensuring continuous power supply to important loads, thereby improving the overall reliability and automation level of the power distribution system.

[0024] 4. Flexible protection logic, convenient parameter configuration, and strong scalability: The AC intelligent power distribution module of this invention supports the configuration of protection parameters via a host computer. Users can modify key parameters such as overcurrent protection thresholds and undervoltage thresholds locally or remotely via a host computer, according to different load characteristics and protection requirements, through the display module and button control module. The main control module adopts a programmable logic device (CPLD) and programs and configures its logic functions using hardware description languages ​​(such as VHDL or Verilog). It can reconfigure its internal protection logic according to updated parameters, making the protection function more flexible and diverse, and adaptable to the power supply needs of different types and capacities of electrical loads. This configurability and programmability also facilitate future function upgrades and expansions. New protection algorithms or control strategies can be implemented simply through software upgrades or parameter adjustments without large-scale hardware modifications, enhancing the product's life cycle and market adaptability. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the AC intelligent power distribution module structure shown in an embodiment of the present invention; Figure 2 This is a schematic diagram of the protection logic of the current monitoring module shown in an embodiment of the present invention; Figure 3 This is a schematic diagram of the protection logic of the voltage monitoring module shown in an embodiment of the present invention; Figure 4 This is a schematic diagram of fuse protection logic shown in an embodiment of the present invention; Figure 5 This is a schematic diagram illustrating multiple protection mechanisms in an embodiment of the present invention; Figure 6 This is a schematic diagram of the intelligent power distribution cabinet structure shown in an embodiment of the present invention. Detailed Implementation

[0026] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] It should be noted that the defects in the solutions in the prior art are all the results of the inventors' practice and careful research. Therefore, the discovery process of the above problems and the solutions proposed by the embodiments of this application in the following text should be the inventors' contributions to this application in the process of invention and creation, and should not be understood as technical content known to those skilled in the art.

[0028] In view of the technical problems pointed out in the background art, the present invention provides the following embodiments: In one exemplary embodiment, an AC intelligent power distribution module is provided, such as... Figure 1 As shown, it includes: The primary input terminal is used to connect to the power grid, and the primary output terminal is used to connect to the load. The main control module uses a programmable logic device; A semiconductor switch is connected between the primary input terminal and the primary output terminal and is controlled by the main control module; A current monitoring module is connected between the main control module and the semiconductor switch, and is used to collect the current sampling signal flowing through the semiconductor switch; A voltage monitoring module is connected between the main control module and the semiconductor switch, and is used to collect voltage sampling signals across the semiconductor switch. The AC intelligent power distribution module is equipped with multiple protection mechanisms: The software protection is configured to preprocess the current sampling signal and / or the voltage sampling signal, and the main control module performs fault logic judgment based on the preprocessed current sampling signal and / or voltage sampling signal, and outputs a first shutdown control signal to cut off the semiconductor switch when a fault is determined. Hardware protection is configured such that the current monitoring module performs a simulated window comparison on the current sampling signal, and / or the voltage monitoring module performs a simulated window comparison on the voltage sampling signal. When the current sampling signal and / or the voltage sampling signal are detected to exceed the preset hardware safety range, a second shutdown trigger signal is directly output to the main control module. The main control module responds to the second shutdown trigger signal by outputting a second shutdown control signal to cut off the semiconductor switch. The fuse protection is configured to provide a fuse protection circuit between the semiconductor switch and the primary input terminal, which blows when the current flowing through the fuse protection circuit exceeds its rated fusing current.

[0029] Specifically, when a line abnormality or a sudden increase in fault current is detected, multiple protection mechanisms enable the semiconductor switching circuit to quickly shut down within microseconds, cutting off the fault circuit and preventing equipment damage and the escalation of the accident. Simultaneously, the main control module (controller) uploads status information to remote devices or a host computer system via the communication module (communication interface), supporting fault tracing and maintenance decision-making.

[0030] Preferably, the AC intelligent power distribution module is connected to: The display module is connected to the main control module and is used to view local parameters in real time. A button control module, connected to the main control module, is used to input user button commands; A communication module, connected to the main control module, is used for data interaction with external devices; A digital input module, connected to the main control module, is used to input external interlocking signals or sensor status signals to achieve multi-device collaborative protection; The switch output module is connected to the main control module and is used to send fault alarm signals, operating status signals and other signals to the outside world, supporting system-level linkage and remote monitoring.

[0031] The main control module, as the core logic processing unit of the AC intelligent power distribution module, adopts programmable logic devices, possessing high-speed parallel processing capabilities and flexible logic configuration characteristics. It integrates a large number of programmable logic macrocells, I / O control modules, and internal wiring resources, enabling the programming and configuration of logic functions using hardware description languages ​​(such as VHDL or Verilog) according to actual application requirements. In the control logic of the AC intelligent power distribution module, the main control module is primarily responsible for receiving command signals from the communication module and key control module, external interlocking signals from the switch input module, and monitoring signals from the current monitoring module and voltage monitoring module. It performs real-time logical operations, timing control, and status judgments on these multi-source signals, and further processes and stores the real-time collected electrical parameters, fault status, and other information.

[0032] Furthermore, the main control module connects to the display module via its general-purpose I / O ports or dedicated interfaces. It displays processed data (such as the effective values ​​of three-phase voltage and current in the power distribution status, the fault type and occurrence time in the fault information, and power and power factor in the electrical parameters) in real time on the display module according to a preset format. The display module allows real-time viewing of the power distribution status, fault information, and electrical parameters. The button control module supports local command input, enabling manual operation and parameter setting. The button control module consists of several independent buttons or a matrix keypad, each button corresponding to a different function command (such as parameter query, parameter setting, manual closing / opening, etc.). When a user presses a button, the button control module generates a corresponding level change signal, which is transmitted to the main control module and recognized by the main control module. Based on the recognized button command, the main control module executes the corresponding operation, such as entering the parameter setting interface, receiving new parameter values ​​(such as overcurrent protection thresholds) input by the user via buttons, and reconfiguring its internal protection logic (performing fault logic judgment) based on the updated parameters.

[0033] like Figure 1 As shown, the communication module is equipped with both an Ethernet communication module and an RS485 communication module, enabling bidirectional data interaction with a remote monitoring system or host computer. Through these two communication modules, the main control module can transmit locally collected data such as power distribution status, fault information, and electrical parameters to the monitoring system or host computer in real time. It can also receive control commands from the monitoring system or host computer, such as remote closing / opening and remote setting of protection parameters, thereby achieving remote monitoring and management of the AC intelligent power distribution module.

[0034] By connecting various external functional modules to the AC intelligent power distribution module, this AC intelligent power distribution module supports local mode, remote mode, and configuration mode. The three operating modes can be switched as needed: in local mode, the button control module and display module enable quick debugging and emergency operation; in remote mode, the dual communication channels of the Ethernet communication module and RS485 communication module enable remote start / stop and data monitoring; in configuration mode, preset protection parameters are imported through a remote monitoring system or host computer, allowing this AC intelligent power distribution module to flexibly adapt to various different loads.

[0035] Furthermore, in the actual operation of the AC intelligent power distribution module, the main control module controls the current monitoring module and voltage monitoring module to sample the current and voltage of the semiconductor switches. As the control core, the main control module is responsible for fault logic judgment and signal processing, receiving input signals from buttons, communication interfaces, and sensors, and coordinating the on / off timing of the semiconductor switches. The current monitoring module and voltage monitoring module collect electrical parameters from the load side in real time, feeding them back to the main control module for calculation and analysis, enabling rapid identification of abnormal states such as overcurrent, short circuit, and undervoltage, and triggering corresponding protection actions.

[0036] The digital input module consists of an optoelectronic coupler and a signal conditioning circuit. External interlock signals or sensor status signals (such as the operating status signals of other devices, cabinet door switch signals, etc.) enter through the input terminal of the digital input module, are electrically isolated by the optoelectronic coupler to avoid external interference, and then the signal is shaped into a digital level signal recognizable by the main control module through the signal conditioning circuit, and then transmitted to the corresponding input pin of the main control module. Based on these digital signals received, the main control module combines the internal programmed logic control algorithm to determine whether to start the cooperative protection mechanism. For example, when receiving the fault signal of a certain associated device, the main control module can trigger the protection action of this device or adjust the operating status after logical judgment.

[0037] The digital output module also includes a drive circuit and an isolation circuit. When the main control module needs to send signals such as fault alarms and operating status to the outside, its internal logic will convert the corresponding status information into a digital control signal and send it to the digital output module through the output port. The drive circuit in this module amplifies the low-level signal output by the main control module to drive execution elements such as relays or optocouplers, and then outputs a standard digital signal. These signals can be connected to external audible and visual alarms, PLC systems or remote monitoring terminals to achieve local alarm of faults and system-level linkage control.

[0038] Furthermore, the AC intelligent power distribution module has multiple protection mechanisms, significantly improving the system fault tolerance and reliability. The following describes the specific implementation methods of the multiple protection mechanisms.

[0039] First, as Figure 2 shown, the current monitoring module has a hardware protection circuit and a software protection circuit, which cooperate to achieve multi-level and low-delay fault protection. Its hardware protection circuit consists of a filtering module, an amplification module, a current window comparator and a digital isolator. The software protection circuit consists of a filtering module, an amplification module and an ADC module. Both the hardware protection circuit and the software protection circuit are connected to the main control module.

[0040] In the software protection circuit, after the current sampling resistor in the current monitoring module converts the real-time current in the semiconductor switch into a current sampling signal, it is sent to the ADC module for analog-to-digital conversion after passing through the filtering module and the amplification module in sequence. The main control module performs logical operations of fault criteria such as overcurrent and short circuit according to the configured protection parameters. Once an abnormal state is recognized, the corresponding control logic inside the main control module will be immediately triggered, and a control signal will be sent to the external protection actuator (semiconductor switch) through its output port to make the protection actuator act and cut off the load power supply, thus achieving fast protection. The software protection circuit of the AC intelligent power distribution module performs logical operations of fault criteria by combining the read real-time sampling signals with the protection parameter thresholds configured in the main control module, and has good flexibility and scalability.

[0041] Simultaneously, the hardware protection circuit sends the current sampling signal from the current sampling resistor through a filtering module and an amplification module, before sending it to a current window comparator and a digital isolator. The current window comparator monitors the signal in real time to see if it exceeds the preset hardware safety range. Once an abnormality such as overvoltage or undercurrent is detected, it immediately outputs an alarm level, which is transmitted to the main control module via the digital isolator. After receiving the fast response signal from the hardware protection circuit, the main control module triggers the protection action according to its internal judgment logic, ensuring that the system can reliably cut off the power supply even under extreme fault conditions (such as the failure of the software protection circuit), thus improving overall safety and stability.

[0042] Both the software protection circuit and the hardware protection circuit are connected to the main control module. Any abnormal signal triggered by either circuit can independently drive the main control module to perform protection actions.

[0043] Please see Figure 3 The voltage monitoring module also features both hardware and software protection circuits, which work together to provide multi-level and low-delay fault protection. The hardware protection circuit consists of an isolation module and a voltage window comparator, while the software protection circuit comprises a filter module and an ADC module. Both the hardware and software protection circuits are connected to the main control module.

[0044] Similarly, the voltage sampling signal from the semiconductor switch, acquired through the voltage divider resistor, is transmitted to the main control module via both software and hardware protection circuits. The main control module performs logical operations based on fault criteria such as overvoltage, undervoltage, and voltage range. Once an abnormal state is detected, the corresponding control logic within the main control module is immediately triggered, sending a control signal to the external protection actuator (semiconductor switch) through its output port. This causes the protection actuator to activate, cutting off the load power supply and thus achieving rapid protection.

[0045] It should be noted that the preset hardware safety range refers to a set of fixed electrical threshold ranges pre-set in the hardware protection circuit, directly determined by the hardware circuit parameters. This range is used to determine whether the current sampling signal or voltage sampling signal is in a normal state. Once the signal exceeds this range, the hardware protection circuit can trigger an alarm within microseconds without software intervention. Unlike the "programmable protection threshold" in software protection circuits, the hardware safety range is fixed in the circuit and does not depend on analog-to-digital conversion and software calculations. Therefore, the response speed is extremely fast, but the adjustment is not flexible enough (usually requiring the replacement of hardware components such as resistors to change it).

[0046] Optionally, the hardware protection circuit in the voltage monitoring module includes an isolation module and a phase sequence judgment module connected in sequence. The output terminal of the phase sequence judgment module is connected to the main control module. The phase sequence judgment module is used to determine the forward / reverse rotation when the load is a motor, pump, compressor, or other equipment. The function of the phase sequence judgment module is to continuously monitor whether the phase sequence on the power grid side is consistent with the preset correct phase sequence before the load is energized or during operation. Once a phase sequence error is detected, a protection action is immediately triggered to prevent damage to motor-type loads due to reverse rotation. For example, taking a motor as an example, the alarm signal output by the phase sequence judgment module is directly connected to the dedicated interrupt input pin of the main control module (belonging to the "second shutdown trigger signal" of the hardware protection channel). After receiving the alarm signal, the main control module immediately outputs a shutdown control signal without software logic judgment, cutting off the semiconductor switch and disconnecting the load from the power grid. The entire protection action time (from the occurrence of the phase sequence error to the de-energization of the load) can be controlled within 5 microseconds, which is much faster than the time for mechanical damage caused by motor reversal (usually tens of milliseconds or more).

[0047] It should be noted that the hardware protection circuit in the voltage monitoring module is divided into two parallel execution paths: one for phase sequence judgment and the other for voltage window comparison.

[0048] In addition, such as Figure 4 As shown, this AC intelligent power distribution module also includes a fuse protection circuit between the semiconductor switch and the primary input terminal. This fuse protection circuit serves as the final safety barrier for the circuit. When the semiconductor switch fails to disconnect the circuit in time due to a malfunction or an extreme situation such as a severe short circuit occurs, causing the circuit current to exceed the rated fusing current of the fuse, the fuse element inside the fuse quickly melts, completely disconnecting the circuit and protecting the core components inside the AC intelligent power distribution module and the safety of the entire power distribution system. The rated current value of the fuse is designed to match the maximum operating current of the intelligent power distribution cabinet and the protection capability of the semiconductor switch, ensuring that the fuse does not trip under normal operating current and only functions when a fault exceeding the protection capability of the semiconductor switch occurs. Together with the semiconductor switch, current monitoring module, and voltage monitoring module, it forms a multi-layered, hierarchical protection system.

[0049] Preferably, the multiple protection mechanism further includes: The main control module incorporates a drive control and protection circuit. Upon detecting a short circuit, the main control module does not immediately and completely block the drive signal. Instead, it first sends a pre-voltage reduction command to the semiconductor switch (MOS switch) via the drive control and protection circuit. This command rapidly reduces the gate voltage of the semiconductor switch from the normal conduction drive voltage (e.g., 15V) to a preset intermediate voltage value (e.g., 8V-10V). This intermediate voltage value still maintains the switch in the conducting state, but significantly increases its on-resistance. Through this pre-voltage reduction operation, the conduction loss of the semiconductor switch increases instantaneously, causing the main circuit current to begin to decrease within a very short time (typically 1µs-3µs), effectively reducing the peak value of the short-circuit current. In the initial stage of the current decrease, the main control module then completely blocks the drive signal, causing the semiconductor switch to turn off completely. This pre-voltage reduction mechanism proactively weakens the energy of the short-circuit current before turn-off, further shortening the time the semiconductor switch withstands high current and reducing its junction temperature rise, thereby significantly improving the solid-state power controller's resistance to damage and protection reliability under short-circuit faults.

[0050] In summary, please refer to Figure 5 The intelligent AC power distribution module incorporates multiple protection mechanisms, including software protection circuits, hardware protection circuits, fuse protection circuits, and drive control protection circuits. These mechanisms construct a comprehensive safety protection system for the intelligent power distribution cabinet from different levels. The software protection circuit, with its flexible parameter configuration and complex logic operations, accurately identifies and protects against various faults such as overcurrent, short circuit, overvoltage, and undervoltage. It can adjust protection thresholds according to different load characteristics, exhibiting strong adaptability. The hardware protection circuit achieves rapid response through independent analog circuits, triggering protection actions within microseconds. Especially in extreme cases where software protection fails or response is delayed, it serves as a second line of defense to ensure system safety. The fuse protection circuit acts as the final physical isolation barrier. In the event of a severe fault exceeding the capabilities of semiconductor switches and electronic protection circuits (such as when both software and hardware protection fail), it completely cuts off the circuit by melting the fuse, preventing the fault from escalating. The drive control protection circuit innovatively uses a pre-voltage reduction method to actively suppress current peaks before short-circuit shutdown, reducing the shutdown stress on semiconductor switches, extending their service life, and improving the reliability of protection actions. These four protection mechanisms work together in a progressive manner, ensuring both the speed and accuracy of protection, while also taking into account the system's fault tolerance and equipment safety, enabling the intelligent power distribution cabinet to operate stably and reliably in complex electrical environments.

[0051] For example, the following provides the execution logic of a multi-protection mechanism: In the event of a short circuit fault, drive control protection shall be executed first. In the event of a non-short-circuit fault, software protection shall be implemented first. Hardware protection is implemented when software protection fails or the software protection response is delayed. When software protection, hardware protection, and driver control protection all fail, fuse protection is activated.

[0052] For example, the following provides another example of the execution logic of multiple protection mechanisms under different circumstances: 1. When a general overload, overvoltage, or undervoltage occurs (without triggering the hardware threshold), the execution sequence is as follows: software protection → if the software fails, hardware protection (but general faults will not trigger the hardware threshold) → fuse (does not operate).

[0053] 2. When a severe short circuit triggers the hardware threshold, the execution sequence is as follows: hardware protection detection → after the main control module receives the signal, it prioritizes the execution of drive control protection → the main control module performs a complete shutdown → software protection is used as a redundant backup (if it is not shut down after 250μs, it will shut down again) → fuse (only operates when all electronic protection fails).

[0054] 3. When software protection fails (e.g., ADC failure), hardware protection can still be triggered independently.

[0055] 4. Software protection can still be triggered when hardware protection fails (e.g., comparator failure).

[0056] 5. If the drive control protection fails (pre-voltage reduction is not executed), the hardware protection can still trigger a complete shutdown.

[0057] 6. All electronic protections fail (main controller crashes, drive circuit damage, etc.), and fuses blow (the last physical barrier).

[0058] This AC intelligent power distribution module uses semiconductor switches as the execution components for the circuit cutoff. Specifically, MOS switches can be selected as semiconductor switches. The response time of these semiconductor switches can basically reach the nanosecond level (the response time of a semiconductor switch refers to the time required from the start of a control signal transition to the completion of the change in the output state of the semiconductor switch).

[0059] Meanwhile, the AC intelligent power distribution module within the intelligent power distribution cabinet is equipped with a main control module, a current monitoring module, and a voltage monitoring module. When the intelligent power distribution cabinet is connected to a load and is in operation, the main control module controls the current and voltage monitoring modules to monitor and collect the current and voltage on the load. When a fault occurs, the main control module makes a judgment based on the collected current or voltage and outputs a control signal to cause the semiconductor switch to disconnect the load circuit. Compared to the nanosecond-level response time of the semiconductor switch itself, when the semiconductor switch is used in a specific circuit, the overall response time of the circuit is much longer than the response time of the semiconductor switch itself due to limitations in circuit design and the performance parameters of other components. However, the response time of this AC intelligent power distribution module reaches the microsecond level (µs). Here, response time refers to the time from the occurrence of a load fault to the circuit disconnection, specifically the time from when the main control module receives the collected current and voltage, makes a judgment, and controls the semiconductor switch to disconnect the circuit.

[0060] This AC intelligent power distribution module reduces the involvement of software computation in traditional circuits by controlling the circuit, acquiring voltage, and determining faults through the main control module. Based on the rapid processing capabilities of the main control module, a programmable logic device, the response time of the AC intelligent power distribution module is closer to the theoretical response time of a semiconductor switch, achieving a response time in the microsecond range (µs). Specifically, the main control module is connected to both hardware and software protection circuits. When protection actions are executed through the software protection circuit, the response time of the intelligent power distribution cabinet is less than 200-300µs; when protection actions are executed through the hardware protection circuit, the response time is less than 2-3µs.

[0061] In another exemplary embodiment, based on the aforementioned AC intelligent power distribution module, an intelligent power distribution cabinet is provided for realizing drive control, safety protection, and status information detection of electrical equipment such as electric pumps, electrically controlled valves, and electric heaters. Figure 6 As shown, it includes a cabinet and multiple AC intelligent power distribution modules installed inside the cabinet. Different models of AC intelligent power distribution modules correspond to different output powers to match the power supply requirements of different types and capacities of electrical loads.

[0062] like Figure 6 As shown, the AC intelligent power distribution module is assembled inside the chassis, which is located within the intelligent power distribution cabinet. By replacing different chassis or the AC intelligent power distribution module inside the chassis, this intelligent power distribution cabinet can simultaneously adapt to various electrical loads of different power levels. Furthermore, when the power distribution cabinet malfunctions, the corresponding chassis or AC intelligent power distribution module can be directly replaced, eliminating the cumbersome troubleshooting process required when traditional power distribution cabinets malfunction and significantly shortening maintenance time.

[0063] The AC intelligent power distribution module has primary input and primary output terminals connected to it. The primary input terminal connects to the power grid, allowing the intelligent distribution cabinet to accept AC power of different voltages (such as 220V or 380V). The primary output terminal connects to the load, supplying power to it. Internal semiconductor switching circuits within the AC intelligent power distribution module control the switching on and off of these circuits (such as MOS switches and SCR switches) to achieve rapid power supply and disconnection to the load. By directly connecting to the power grid and load terminals, the AC intelligent power distribution module simplifies wiring within the cabinet, optimizes the internal space layout, significantly improves space utilization, and effectively reduces the overall size of the distribution cabinet.

[0064] Preferably, each AC intelligent power distribution module is connected via a DB interface and configured with hierarchical protection logic. DB interface: usually refers to a D-type ultra-small connector. The DB interface is used as a physical signal connection channel between multiple AC intelligent power distribution modules to transmit switch quantities or level signals such as fault status, operating status, and enable / block signals (corresponding to signal interaction through switch quantity input modules and switch quantity output modules).

[0065] The hierarchical protection logic includes: Each AC intelligent power distribution module has a preset load priority. When any AC intelligent power distribution module detects a fault or overload, it sends a linkage signal to other AC intelligent power distribution modules through the DB interface. When the load priority of the AC intelligent power distribution module receiving the linkage signal is lower than the preset priority threshold, it actively disconnects its own load.

[0066] Specifically, certain states of an AC intelligent power distribution module (such as detecting overcurrent faults, output short circuits, and load anomalies) can be directly transmitted to other connected modules via the DB interface. Upon receiving this signal, other modules automatically execute corresponding actions based on their internal preset logic (such as cutting off non-critical loads, delaying restarts, and issuing alarms). This linkage does not require a host computer or remote monitoring system; it is a direct hard-wired interlocking or simple communication between modules, resulting in fast response and high reliability. In graded protection, loads are divided into different priority levels based on their importance (e.g., Level 1 loads (critical equipment, such as fire pumps and servers), Level 2 loads (important equipment, such as production lines), and Level 3 loads (general lighting, air conditioning, etc.)). When power supply capacity is insufficient or a fault occurs requiring load reduction, loads are cut off sequentially from low to high priority, ensuring power supply to high-priority loads first.

[0067] For example, in the case of multiple AC intelligent power distribution modules working collaboratively, each module is responsible for one or more loads, and the modules share status signals such as "fault / overload" through the DB interface. When a short-circuit fault occurs in a certain area (e.g., a certain motor), the AC intelligent power distribution module where the fault occurs will immediately cut off its own output and send a "system overload / load reduction" signal to other AC intelligent power distribution modules through the DB interface. Other AC intelligent power distribution modules determine whether the priority of their own load is lower than a certain threshold according to their internal preset priority strategy. If so, they will actively cut off their own output, thereby reserving the limited power supply capacity for more important loads and preventing the main incoming switch from tripping and causing a large-scale power outage.

[0068] In another exemplary embodiment, based on the above-described AC intelligent power distribution module, a power distribution control method is provided, comprising the following steps: S1. The current and voltage sampling signals of the load are collected in real time through the current monitoring module and the voltage monitoring module; S2. Based on the current sampling signal and / or voltage sampling signal acquired in step S1, software protection and hardware protection are executed synchronously. S3. When step S2 fails or the current flowing through the fuse protection circuit exceeds its rated fusing current, the fuse protection is activated.

[0069] Based on the above method, a specific power distribution control process is given below.

[0070] Wiring and Initialization: Connect the primary input terminal of the AC intelligent power distribution module to the power grid (such as 220V or 380V AC), and connect the primary output terminal to the target load (such as an electric pump, electrically controlled valve, or electric heater). After the system is powered on, the main control module completes initialization, loads preset protection parameters (including overcurrent protection threshold, undervoltage threshold, overvoltage threshold, etc.), and displays the ready status through the display module.

[0071] Normal operating mode: The main control module controls the semiconductor switch to turn on and supply power to the load normally according to local key commands or remote host computer commands. During operation, the current monitoring module and voltage monitoring module collect the current sampling signal and voltage sampling signal at the load end in real time, and send these signals to the software protection circuit and hardware protection circuit simultaneously.

[0072] Software protection process: In the software protection circuit, the current sampling signal is filtered and amplified, then converted into a digital signal by the ADC module and sent to the main control module; the voltage sampling signal is filtered and converted into a digital signal by the ADC module and sent to the main control module. The main control module compares the collected RMS current and voltage values ​​with preset protection thresholds and performs logical operations for fault criteria such as overcurrent, short circuit, overvoltage, and undervoltage. If an abnormal state is detected (e.g., the current exceeds the overcurrent protection threshold and the duration exceeds the inverse delay curve setting value), the main control module immediately sends a shutdown signal to the semiconductor switch through its output port to cut off the load power supply, thus realizing software protection.

[0073] Hardware protection process: In the hardware protection circuit, the current and voltage sampling signals are filtered and amplified before being sent to a current / voltage window comparator. The current / voltage window comparator determines in real time whether the current sampling signal exceeds the preset hardware safety range. If an overcurrent or undercurrent abnormality is detected, the current / voltage window comparator immediately outputs an alarm level, which is transmitted to the main control module via a digital isolator.

[0074] Drive control protection process (short-circuit pre-drop voltage): When the main control module determines a short-circuit fault through software or hardware protection circuitry, it first sends a pre-drop voltage command to the semiconductor switch via the drive control protection circuitry, reducing the gate voltage from the normal on-state voltage (e.g., 15V) to an intermediate voltage value (e.g., 8-10V). At this intermediate voltage, the semiconductor switch remains on, but its on-resistance increases significantly, and the peak short-circuit current begins to decrease within 1-3 microseconds. Subsequently, the main control module completely blocks the drive signal, causing the semiconductor switch to turn off completely.

[0075] Fuse backup protection: When an extreme fault occurs that exceeds the capabilities of the semiconductor switch and electronic protection circuit (such as a short circuit caused by the semiconductor switch itself), the main circuit current continues to increase and exceeds the rated fusing current of the fuse. The fuse element inside the fuse melts rapidly, completely disconnecting the circuit and achieving physical isolation protection.

[0076] Status reporting and remote control: The main control module transmits the power distribution status (three-phase voltage, RMS current, power, power factor, etc.) and fault information (fault type, occurrence time, etc.) to the remote monitoring system in real time via an Ethernet communication module or an RS485 communication module. Simultaneously, the main control module can receive control commands from the remote monitoring system, such as remote closing / opening and remote setting of protection parameters, enabling remote monitoring and management of the intelligent distribution cabinet.

[0077] The above detailed embodiments are a description of the present invention. It should not be considered that the specific embodiments of the present invention are limited to these descriptions. For those skilled in the art, several simple deductions and substitutions can be made without departing from the concept of the present invention, and all of these should be considered to fall within the protection scope of the present invention.

Claims

1. An AC intelligent power distribution module, characterized in that, include: The primary input terminal is used to connect to the power grid, and the primary output terminal is used to connect to the load. The main control module uses a programmable logic device; A semiconductor switch is connected between the primary input terminal and the primary output terminal and is controlled by the main control module; A current monitoring module is connected between the main control module and the semiconductor switch, and is used to collect the current sampling signal flowing through the semiconductor switch; A voltage monitoring module is connected between the main control module and the semiconductor switch, and is used to collect voltage sampling signals across the semiconductor switch. The AC intelligent power distribution module is equipped with multiple protection mechanisms: The software protection is configured to preprocess the current sampling signal and / or the voltage sampling signal, and the main control module performs fault logic judgment based on the preprocessed current sampling signal and / or voltage sampling signal, and outputs a first shutdown control signal to cut off the semiconductor switch when a fault is determined. Hardware protection is configured such that the current monitoring module performs a simulated window comparison on the current sampling signal, and / or the voltage monitoring module performs a simulated window comparison on the voltage sampling signal. When the current sampling signal and / or the voltage sampling signal are detected to exceed the preset hardware safety range, a second shutdown trigger signal is directly output to the main control module. The main control module responds to the second shutdown trigger signal by outputting a second shutdown control signal to cut off the semiconductor switch. The fuse protection is configured to provide a fuse protection circuit between the semiconductor switch and the primary input terminal, which blows when the current flowing through the fuse protection circuit exceeds its rated fusing current.

2. The AC intelligent power distribution module according to claim 1, characterized in that, The multiple protection mechanisms also include: The drive control protection, integrated into the main control module, is configured to, when a short circuit fault is detected, first send a pre-drop voltage command to the semiconductor switch to reduce the gate voltage of the semiconductor switch to a preset intermediate voltage value to suppress the short circuit current peak; then, after a predetermined delay or after detecting a current drop, completely block the drive signal to completely turn off the semiconductor switch.

3. An AC intelligent power distribution module according to claim 2, characterized in that, The execution logic of the multiple protection mechanisms includes: In the event of a short circuit fault, drive control protection shall be executed first. In the event of a non-short-circuit fault, software protection shall be implemented first. Hardware protection is implemented when software protection fails or the software protection response is delayed. When software protection, hardware protection, and driver control protection all fail, fuse protection is activated.

4. The AC intelligent power distribution module according to claim 1, characterized in that, The AC intelligent power distribution module is connected to: The display module is connected to the main control module and is used to view local parameters in real time. A button control module, connected to the main control module, is used to input user button commands; A communication module, connected to the main control module, is used for data interaction with external devices; A digital input module, connected to the main control module, is used to input external interlock signals or sensor status signals; The switch output module is connected to the main control module and is used to send fault alarm signals and operating status signals to the outside world.

5. An AC intelligent power distribution module according to claim 4, characterized in that, The AC intelligent power distribution module is also configured to support three operating modes: local mode, remote mode, and configuration mode; wherein: In the local mode, local parameter query, quick debugging and emergency operation are realized through the button control module and the display module; In the remote mode, remote start / stop and data monitoring are achieved through the communication module; In the configuration mode, the communication module connects to the host computer and imports preset protection parameters. The main control module configures its internal protection logic according to the imported preset protection parameters to adapt to different types and capacities of loads.

6. An AC intelligent power distribution module according to claim 1, characterized in that, The hardware protection includes: Hardware protection circuits are set in the current monitoring module and the voltage monitoring module respectively. The hardware protection circuit in the current monitoring module includes an amplification module, a current window comparator and a digital isolator connected in sequence, and the output terminal of the digital isolator is connected to the main control module. The hardware protection circuit in the voltage monitoring module includes an isolation module and a voltage window comparator connected in sequence, and the output terminal of the voltage window comparator is connected to the main control module.

7. An AC intelligent power distribution module according to claim 6, characterized in that, The hardware protection circuit in the voltage monitoring module includes an isolation module and a phase sequence judgment module connected in sequence, and the output terminal of the phase sequence judgment module is connected to the main control module.

8. An intelligent power distribution cabinet, comprising a cabinet body and a plurality of AC intelligent power distribution modules as described in any one of claims 1-7 disposed within the cabinet body, characterized in that, Each AC intelligent power distribution module is connected via a DB interface signal and is configured with hierarchical protection logic.

9. The intelligent power distribution cabinet according to claim 8, characterized in that, The hierarchical protection logic includes: Each AC intelligent power distribution module has a preset load priority. When any AC intelligent power distribution module detects a fault or overload, it sends a linkage signal to other AC intelligent power distribution modules through the DB interface. When the load priority of the AC intelligent power distribution module receiving the linkage signal is lower than the preset priority threshold, it actively disconnects its own load.

10. A power distribution control method based on the AC intelligent power distribution module according to any one of claims 1-7, characterized in that, Includes the following steps: S1. The current and voltage sampling signals of the load are collected in real time through the current monitoring module and the voltage monitoring module; S2. Based on the current sampling signal and / or voltage sampling signal acquired in step S1, software protection and hardware protection are executed synchronously. S3. When step S2 fails or the current flowing through the fuse protection circuit exceeds its rated fusing current, the fuse protection is activated.

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