Improved aspects of switchboards and power distribution systems

Abstract

A pre-assembled switchboard has a housing with a plurality of busbars and a cable entry for a plurality of subcircuit cables, and a subcircuit termination block with conductor coupling elements configured to be connected to the conductors of the plurality of subcircuit cables. Circuit protection devices are connected between the busbars and the subcircuit termination block, the conductor coupling elements are grouped by subcircuit, such that the conductors of each subcircuit cable can be terminated adjacent to each other.

Description

Technical Field

[0001] This invention relates to improved switchboards and power distribution systems. It is particularly applicable to household switchboards and household or family power distribution systems. Background Technology

[0002] Every modern residential home typically requires some form of distribution panel. A distribution panel is a central or centralized location that draws power from the mains power grid (i.e., the grid provided by the electricity supplier) and distributes it to all the sub-circuits throughout the unit or house. Distribution panels serve as enclosures or housings for electrical safety and circuit protection devices, circuit measurement and control devices, and more recently, as locations where electricity meters are installed and positioned.

[0003] Most components in a traditional residential distribution panel must be selected, assembled, and connected individually based on the house's load and circuit protection requirements. The installation of a single distribution panel can take several hours, often spread across multiple inspections. The installation of panel components, the internal wiring and testing between components, and the connection of the distribution panel to the mains power supply and electrical sub-circuits are all very time-consuming.

[0004] Typical residential distribution panels usually have the minimum level of circuit protection required by the relevant electrical installation standards or regulations. These may vary by country, but generally include short-circuit protection, overload protection, and ground fault protection for each sub-circuit connected to the distribution panel. However, many older homes still lack these minimum requirements and may only have fuses installed for lines that provide overcurrent protection. Typically, each circuit protection device in the distribution panel has a fixed current rating, at which it will trip and prevent power from being supplied to the sub-circuit it protects. However, these devices are often manufactured with fixed current ratings, meaning that each sub-circuit connected to the distribution panel is unlikely to have adequate and / or accurate safety protection, and each circuit protection device may operate inconsistently under different fault conditions. This problem can mean that dangerous faults such as undetected series arcing faults can occur in connected sub-circuits, potentially leading to property damage, fire risk, and even personal injury.

[0005] In this specification, references to patent specifications, other external documents, or other sources of information are generally used to provide an environment for discussing the features of the invention. Unless otherwise expressly stated, references to such external documents should not be construed as an admission that such documents or sources of information are prior art or part of common general knowledge in the art in any jurisdiction. Summary of the Invention

[0006] The purpose of at least some preferred embodiments of the present invention is to provide improved switchboards and / or other aspects of power distribution systems, and / or at least to provide useful alternatives to the public.

[0007] In one aspect, a pre-assembled distribution panel is provided for connecting to a plurality of sub-circuit cables, each sub-circuit cable including a plurality of insulated conductors, the distribution panel comprising:

[0008] The housing has multiple busbars and cable inlets for multiple sub-circuit cables;

[0009] A sub-circuit termination block having a plurality of conductor coupling elements configured to be connected to conductors of a plurality of sub-circuit cables;

[0010] Multiple circuit protection devices are connected between the busbar and the sub-circuit terminal block;

[0011] The conductor coupling elements are grouped into sub-circuits, wherein the conductors for each sub-circuit cable can terminate adjacent to each other.

[0012] Preferably, at least one circuit protection device is remotely configurable.

[0013] Preferably, each circuit protection device includes a selectively removable module.

[0014] Preferably, the sub-circuit termination block includes multiple termination blocks.

[0015] Preferably, each circuit protection device includes a circuit termination block.

[0016] Preferably, the termination block for each circuit protection device provides a conductor coupling element group for terminating the conductor of the sub-circuit cable.

[0017] Preferably, the coupling elements are arranged in one or more rows.

[0018] Preferably, rows of coupling element termination devices are disposed on the side of the housing.

[0019] Preferably, the row of coupling element termination devices is located at the center of the housing.

[0020] Preferably, two cable inlets are provided, along with two rows of coupling elements and two cable channels.

[0021] Preferably, a row of coupling elements is provided on each side of the housing.

[0022] Preferably, two rows of coupling elements are arranged at the center of the housing.

[0023] Preferably, each module includes a wall, and the wall includes a cable tray channel or a portion of each cable tray channel.

[0024] Preferably, the module is laterally oriented relative to the cable tray channel or each cable tray channel.

[0025] Preferably, each sub-circuit protection device or module includes a button or switch that can be operated by a user, and wherein a cable channel is provided between the button or switch and the sub-circuit coupling element or each row of sub-circuit coupling elements.

[0026] Preferably, the sub-circuit coupling element for each sub-circuit cable includes a phase coupling element and a neutral coupling element.

[0027] Preferably, the sub-circuit coupling element for each sub-circuit cable includes a phase coupling element, a neutral coupling element, and a ground coupling element.

[0028] On the other hand, a pre-assembled switchboard or residential power distribution and management system is provided, comprising:

[0029] A mains power isolation device configured to provide electrical isolation from external power grid supply;

[0030] One or more sub-circuit protection devices or modules, said one or more sub-circuit protection devices or modules being electrically connected to the mains isolation device via pre-assembled electrical connectors; and

[0031] One or more sub-circuit termination devices, each of which is electrically connected to a corresponding sub-circuit protection module via pre-assembled electrical connectors, and each is configured to electrically connect the system to an external sub-circuit.

[0032] On the other hand, a circuit protection device is provided, comprising:

[0033] A first termination for connecting to the busbar and a second termination for connecting to the sub-circuit;

[0034] A disconnection device configured to electrically isolate the first termination from the second termination upon receiving a disconnection signal;

[0035] The outer wall defines a portion of the cable storage channel;

[0036] The first and second terminations are located on either side of the cable storage channel.

[0037] Preferably, a user-operable button or switch is provided, which is operable to actuate a disconnection device, and wherein a cable retraction channel is provided between the second termination and the button or switch.

[0038] Preferably, the cable storage channel includes a cable tray.

[0039] Preferably, the cable storage channel is disposed in the housing and is located between the first termination and the second termination.

[0040] In another aspect, the present invention broadly relates to switchboards, including:

[0041] The housing has multiple busbars and cable inlets for sub-circuit cables;

[0042] Multiple circuit protection modules are connected to a busbar, each module including or connected to a sub-circuit termination device configured to connect to a sub-circuit cable.

[0043] Sub-circuit termination devices, which are arranged in a row;

[0044] A cable channel that extends from the cable inlet and is parallel to a row of sub-circuit termination devices.

[0045] In some implementations, the cable channel includes a cable tray.

[0046] On the other hand, a self-testing method is provided, wherein the controller can periodically send signals to the test winding of the fluxgate sensor while disabling the circuit disconnection function.

[0047] On the other hand, a system is provided in which signals from a primary current sensor, a residual current sensor, and a line voltage sensor are provided to a controller to provide arc fault detection.

[0048] In another aspect, the present invention broadly relates to pre-configured or pre-wired distribution panels or residential power distribution and management systems, comprising: a grid connection module configured to electrically connect the system to an external grid power source; a mains isolation module electrically connected to the grid connection module via pre-configured or pre-wired electrical connectors and configured to provide electrical isolation from the external grid power source; one or more sub-circuit protection modules electrically connected to the mains isolation module via pre-configured or pre-wired electrical connectors; and one or more sub-circuit termination devices, each electrically connected to a corresponding sub-circuit protection module via pre-configured or pre-wired electrical connectors and each configured to electrically connect the system to an external sub-circuit.

[0049] In some embodiments, any one of the power grid connection module, the mains isolation module, and / or one or more sub-circuit protection modules includes a circuit protection system, as mentioned in the following subsequent aspects of the invention. In such embodiments, any one of the power grid connection module, the mains isolation module, and / or one or more sub-circuit protection modules may include or have any one or more of the features mentioned in the following aspects of the invention.

[0050] In an implementation, the pre-configured or pre-wired electrical connections between one or more modules include one or more of the following: phase connections or active connections, neutral connections and / or ground connections or grounding connections.

[0051] In implementations, the pre-configured or pre-wired distribution panel or residential power distribution and management system also includes a separate pre-configured or pre-wired grounding connection system that electrically connects the grounding conductor of one or more external devices to the electrical ground.

[0052] In one implementation, one or more sub-circuit protection modules may be configured to electrically connect a pre-configured or pre-wired distribution panel or residential power distribution and management system to an external distributed generation supply or source. The distributed generation supply or source may include one or more of the following: vehicle-to-grid (V2G) sources or electric vehicle (EV) sources, battery sources, and / or solar energy including one or more solar panels. In such an implementation, each auxiliary power module is an operable switch to facilitate electrical connection to the external distributed generation supply or source. Each module may also be configured to draw power from the external distributed generation supply or source (e.g., solar energy or battery source) for use in the power distribution system.

[0053] In one implementation, each of the one or more sub-circuit protection modules is operatively connected to a centralized sub-circuit controller. In such an implementation, the connection to the centralized sub-circuit controller is provided via a serial communication protocol.

[0054] In some implementations, the centralized subcircuit controller can be configured to receive measurement or monitoring data related to the corresponding connected subcircuit as input from one or more connected subcircuit connection modules. In these implementations, the measurement or monitoring data includes power consumption data, operating conditions, and / or data analysis.

[0055] In one embodiment, each of the one or more sub-circuit termination devices includes a pre-configured sub-circuit connection module, as mentioned with respect to later aspects of the invention. In such an embodiment, one or more sub-circuit termination devices may include or have any or more features of the pre-configured sub-circuit connection module mentioned with respect to later aspects of the invention.

[0056] In some embodiments, each subcircuit termination device includes a plurality of subcircuit conductor terminations, each configured to electrically connect to a conductor of an external subcircuit. In these embodiments, each subcircuit conductor termination may include an electrical coupling element configured to electrically connect to the end of a line terminal of the subcircuit conductor.

[0057] In some embodiments, the pre-configured or pre-wired distribution panel or residential power distribution and management system also includes a system controller. The system controller is operatively connected to one or more modules. The system controller is operatively connected to the controller of each module. In these embodiments, the system controller may also include a communication module operatively connected to the controller and / or communication module of each of the one or more modules. In some embodiments, the system controller is electrically connected to each controller of the module via a wired communication link. The wired communication protocol may be, for example, CAN bus or Ethernet.

[0058] In some implementations, the controller for each module is configured to send measurement or monitoring data to the system controller. The measurement or monitoring data may be associated with the corresponding module. The measurement or monitoring data may include power consumption data, data related to operating conditions, and / or data analysis. For example, the module controller is operable to send at least voltage and / or current data as input to the system controller. In these implementations, the system controller is configured to monitor the voltage and / or current passing through each module in real time.

[0059] In some embodiments, the system controller is configured to send one or more control signals as inputs to the connected module or each connected module. In these embodiments, the control signals are operable to disconnect and / or close the circuitry of the module or each module. In some embodiments, the control signals are also operable to control electrical relays or disconnecting devices of the module to disconnect or close the corresponding circuitry of the module or each module.

[0060] In some embodiments, the system controller corresponds to the centralized control system or server mentioned in subsequent aspects of the invention. In such embodiments, the system controller may include or have any or more of the features mentioned in the centralized control system or server mentioned in subsequent aspects of the invention.

[0061] In some implementations, the system controller is configured to detect and / or learn specific current characteristics of circuits and / or loads configured to be connected to each module, based on one or more of power consumption data, operating condition-related data, and / or data analysis provided by the controllers of one or more modules. In some implementations, the system controller is configured to provide load-specific consumption data analysis based on power consumption data, operating condition-related data, and / or data analysis provided by the controllers of each module.

[0062] In some implementations, the system controller is configured to use one or more machine learning algorithms to detect specific load characteristics of circuits and / or loads configured to be connected to the module, based on power consumption data, operating condition-related data, and / or data analysis provided by the controller of the module or each module. In other implementations, the system controller is configured to use one or more machine learning algorithms to track performance and understand fault conditions associated with each circuit and / or load configured to be connected to the module.

[0063] In some embodiments, the system controller is also configured to provide data transmission and / or software or firmware updates to the connected modules. In some embodiments, the system controller is also configured to provide one or more of the following: remote monitoring of the circuitry of one or more connected modules, power consumption monitoring, and / or status monitoring.

[0064] A system controller integrated with the grid connection module is configured to provide a power meter. In one implementation, the power meter is configured to provide net metering. The net metering may conform to IEC standard 62053-22. The net metering may include any of the following: mains power quality measurement, bidirectional current sensing, and / or on / off supply control.

[0065] In some implementations, the system controller is configured to determine or calculate the net power consumption of the switchboard or residential power distribution and management system based on data provided by the module or each module.

[0066] In this implementation, the system controller is also configured to connect to an LCD screen. The LCD screen, which may be an LCD touchscreen, is configured to receive input from a user and / or serve as a local human-machine interface (HMI), and is further configured to display data or information related to the distribution panel or residential power distribution and management system. The LCD screen may be configured to display real-time monitoring or consumption data of the distribution panel or residential power distribution and management system to the user. The LCD touchscreen may be configured to allow receiving control input from the user relating to the control of one or more modules connected to the system controller.

[0067] In one implementation, the system controller has an embedded communication module. In such an implementation, the embedded communication module is configured to allow communication and bidirectional data transmission with an external server or system. The communication module is configured to allow wired or wireless communication and bidirectional data transmission with an external server or system using any one or more of the following communication modules: cellular (3G, 4G, 5G), Wi-Fi, Ethernet, and / or fiber optic. In these implementations, the communication module is configured to allow communication and bidirectional data transmission with an external server or system to transmit real-time retail billing data.

[0068] In some implementations, the external server or system includes a database. The database is configured to store data received from the system controller. The data received from the system controller relates to consumption and / or usage data of one or more modules. In some implementations, the external server or system is cloud-based. In some implementations, the external server or system is also configured to provide analysis, demand, or consumption analysis of the received consumption and / or usage data of one or more modules.

[0069] In some implementations, an external server or system is configured to send one or more control signals to the system controller. In such implementations, the control signals are configured to control one or more modules of the system. Specifically, the control signals are configured to open or close one or more relays or disconnectors of one or more modules.

[0070] In this implementation, external grid power includes the supply of electrical energy. This supply may be provided by one or more external grid suppliers. In some implementations, the external grid suppliers may have access to external servers or systems. In such implementations, one or more grid suppliers may receive data related to the consumption and / or usage data of one or more modules, and / or send one or more control signals from the external server or system to open or close any one or more relays or disconnectors of one or more modules. In such implementations, the grid supplier may send one or more control signals to shut down heavy loads during periods of peak demand from the external grid.

[0071] In one implementation, a distribution panel or power management and distribution system, when electrically connected to an external grid power source and one or more sub-circuits, provides power distribution and management from the external grid power source to a household comprising one or more sub-circuits.

[0072] In one implementation, the system controller and / or external server or system are configured to provide economical and / or energy-efficient power distribution and management based on input received from the module and the external server or system. In another implementation, the system controller and / or external server or system are configured to provide management of the energy supply to one or more sub-circuits, thereby reducing the peak load on the grid supplier by selectively supplying energy to sub-circuits with higher load consumption during periods of low grid demand.

[0073] In this implementation, the system controller and / or external server or system are configured to individually open or close individual subcircuits based on load consumption data from one or more modules and / or electricity demand or grid supply prices provided by a third party. The third party is an electricity retailer or distributor.

[0074] In one implementation, the system controller and / or external server or system are configured to receive data related to real-time electricity pricing, which is associated with the supply of electrical energy from an external grid supplier. In such an implementation, the system controller and / or external server or system are configured to analyze or compare real-time electricity pricing data and real-time load consumption or usage for the system and / or one or more modules. The system controller and / or external server or system are also configured to calculate the most economical and / or energy-efficient power allocation and management for the system based on the analysis or comparison of the system's real-time electricity pricing data and real-time load consumption data. In some implementations, the system controller and / or external server or system are configured to manage the electrical energy supplied to sub-circuits to optimally reduce household electricity bills based on real-time analysis of electricity pricing data and load consumption for one or more modules and / or the system.

[0075] In some implementations, the system controller and / or external server or system are configured to optimally switch between available alternative power sources or supplies to reduce household electricity bills and / or reduce demand on external grid sources. In such implementations, the system controller and / or external server or system are configured to control one or more modules of a distribution panel or power distribution and management system based on analysis of real-time electricity pricing data and real-time load consumption data to ensure that electricity used by the household remains at the lowest possible price or rate. For example, this could include any of the following: charging one or more batteries or EVs based on auxiliary power sources when electricity is at a cheaper comparative rate, and / or using one or more auxiliary power sources to provide power to the system when electricity is at a more expensive comparative rate, and / or transferring electricity from one or more auxiliary power sources to external grid sources to sell the electricity back to the external grid supplier when electricity is at a more expensive comparative rate.

[0076] In the implementation, the system controller and / or external server or system are configured to provide management of the power supply to one or more sub-circuits, thereby reducing the peak load of the external grid supplier by selectively supplying energy to sub-circuits with higher load consumption during periods of low grid demand.

[0077] In some implementations, the system controller and / or external server system are configured to operatively connect to one or more connected Internet of Things (IoT)-enabled devices. In such implementations, the system controller and / or external server system are configured to operatively connect to one or more IoT-enabled devices using a communication module or each communication module. For example, the communication module or each communication module is configured to operatively connect to one or more IoT-enabled devices using one or more of the following communication protocols: Zigbee, IEEE 802.15.4, Bluetooth Low Energy (BLE), LoRa, and / or Wi-Fi. In some implementations, the system controller and / or external server system are configured to receive data related to one or more connected IoT-enabled devices, and in some implementations, the controller is configured to receive data related to the power consumption or usage of the connected IoT-enabled devices.

[0078] In some implementations, the system controller and / or external server system is configured to: store data received from connected IoT-enabled devices, and establish a selection or directory of connected and / or previously connected IoT-enabled devices based on data received from one or more IoT-enabled devices. In some implementations, the system controller and / or external server system is also configured to: send one or more command signals to one or more connected IoT-enabled devices. In such implementations, the system controller and / or external server system is further configured to: send one or more command signals to turn one or more connected IoT-enabled devices on or off.

[0079] In some implementations, the system controller and / or external server system are operable to determine the load characteristics of the connected IoT devices. The system controller and / or external server system may also be configured to match or pair the load characteristics of the connected IoT devices with the load characteristics of one or more sub-circuits (such as those measured by one of the sub-circuit protection modules). In some implementations, the system controller and / or external server system are operable to use the load characteristics of the connected IoT devices as input to a machine learning algorithm. In such implementations, the machine learning algorithm is capable of determining one or more characteristics of the sub-circuit connected to the sub-circuit protection module.

[0080] In one implementation, the pre-configured or pre-wired switchboard or residential power distribution and management system is configured to be housed within a enclosure or enclosure. In such an implementation, the enclosure or enclosure is a typical or existing residential switchboard enclosure or enclosure.

[0081] In some embodiments, the pre-configured or pre-wired electrical connectors that electrically connect one or more modules are pre-configured or pre-wired busbars. In some embodiments, the busbars are copper busbars.

[0082] In some implementations, the modules are electrically connected to one or more pre-configured or pre-wired connection points. In other implementations, one or more pre-configured or pre-wired connection points are electrically connected to one or more pre-configured or pre-wired electrical connections between modules.

[0083] In some embodiments, the pre-configured or pre-wired electrical connectors of the electrical connection modules are fixed in place. In other embodiments, the pre-configured or pre-wired electrical connectors of the electrical connection modules are configured to define the location of each module within a pre-configured or pre-wired distribution panel or residential power distribution and management system.

[0084] In another aspect, the invention also broadly relates to a method for installing a pre-manufactured switchboard as mentioned in the foregoing aspects of the invention, the method comprising: electrically connecting an external grid power supply to a grid connection module; and electrically connecting the wire terminal ends of one or more sub-circuit conductors to corresponding sub-circuit termination devices. The pre-manufactured switchboard installed as part of the method of the second aspect may include or have any or more of the features mentioned in the foregoing aspects of the invention.

[0085] In some implementations, the method also includes connecting one or more auxiliary power sources or external distributed generation supplies or source power to one of the auxiliary power modules.

[0086] On the other hand, the present invention broadly relates to a circuit protection system for use in a switchboard or power distribution and management system, comprising: one or more electrical input connectors configured to be connected to at least one power source; one or more electrical output connectors configured to provide power to an electrical output; one or more circuits disposed between the one or more electrical input connectors and the one or more electrical output connectors; a load monitoring device operatively connected to the one or more circuits and operable to determine one or more characteristics or properties of the one or more circuits; and an electrical relay or disconnecting device electrically connected to... Between the electrical input connector and the electrical output connector, and operable to open or close one or more circuits based on control signals; and a controller operably connected to the electrical relay device and the load monitoring device, the controller being configured to receive one or more characteristics or attributes of one or more circuits as input from the load monitoring device, to determine whether one or more fault conditions exist in one or more circuits based on the analysis of one or more characteristics or attributes of one or more circuits, and, if a fault condition is detected based on the analysis of one or more characteristics or attributes of one or more circuits, to send one or more control signals to the electrical relay device to open or close one or more circuits.

[0087] In this implementation, the electrical relay device is configured to receive a control signal from the controller. The control signal is operable to trigger the electrical relay device to open or close one or more circuits.

[0088] In some embodiments, the electrical relay device includes one or more electrical relays, each corresponding to a circuit in the circuit, wherein each electrical relay device is operable to open and close its corresponding circuit based on a control signal. In some embodiments, the electrical relay device or each electrical relay device is a unipolar relay and / or a bistable or latching relay.

[0089] In one embodiment, the load monitoring device is operatively connected in series in one or more circuits between the electrical input connector and the electrical output connector. The load monitoring device may also be operatively connected in the circuit preceding the electrical relay device. In an alternative embodiment, the load monitoring device is operatively connected in parallel with one or more circuits between the electrical input connector and the electrical output connector.

[0090] In implementations, one or more characteristics or properties of one or more circuits include voltage and / or current through one or more circuits. These characteristics or properties of one or more circuits may also include real-time voltage and / or current readings. These characteristics or properties of one or more circuits may also include waveforms or wave patterns of voltage and / or current through one or more circuits.

[0091] In some embodiments, the load monitoring device includes a current sensor and / or a voltage sensor. In some embodiments, the current sensor is a current transformer. In such embodiments, the current transformer is configured as a high-frequency and / or low-frequency current transformer. In some embodiments, the current sensor is a Hall effect sensor. In some embodiments, an RCD is provided. The RCD may include a fluxgate sensor. The fluxgate sensor may include a test winding. Testing the RCD may include energizing the test winding. In response to user activation of a device such as a button or switch, the test winding may be energized by a controller.

[0092] In one implementation, the controller is configured to receive voltage and / or current readings from one or more circuits as input from a load monitoring device. In another implementation, the controller is configured to receive waveforms or wave patterns of voltage and / or current from the load monitoring device as input via one or more circuits.

[0093] In one implementation, the controller is configured to analyze one or more characteristics or properties (e.g., voltage and / or current) of one or more circuits and determine whether these characteristics or properties indicate one or more fault conditions in the circuit.

[0094] In this implementation, the controller is configured to determine whether one or more fault conditions exist in one or more circuits, including: short circuit, circuit overload, circuit overvoltage, circuit overcurrent, AC and / or DC ground leakage, and / or dangerous arcing fault detection. One or more fault conditions may have specific thresholds or tripping curves, wherein the controller indicates a fault condition if one or more characteristics or attributes of one or more circuits exceed the threshold or tripping curve.

[0095] In this implementation, the controller is also configured to adjust a specific threshold or tripping curve for each of one or more fault conditions. The specific threshold or tripping curve for each of the one or more fault conditions can be adjusted based on the real-time load requirements of the circuit.

[0096] In an implementation, if a fault condition is detected based on the analysis of one or more characteristics or properties of one or more circuits, the controller is configured to send one or more control signals to an electrical relay device to open or close one or more circuits.

[0097] In this implementation, the controller's response time for determining the fault condition and sending a control signal to the electrical relay device is on the order of microseconds or nanoseconds. This short response time allows dangerous arcing faults to be detected and eliminated in one or more circuits.

[0098] In this implementation, the controller is also operatively connected to a centralized control system or server. This connection can be provided via a serial communication protocol. In this implementation, the centralized control system or server is configured to connect to one or more different circuit protection systems.

[0099] In this implementation, the controller is configured to send measurement or monitoring data to a centralized control system or server. The measurement or monitoring data may include power consumption data, operating condition-related data, and / or data analysis.

[0100] In this implementation, the controller is also configured to receive external control commands from a centralized control system or server. In this implementation, the external control signal is operable to control or trigger an electrical relay device to open or close a corresponding circuit.

[0101] In one implementation, the centralized control system or server is configured to detect and learn specific current characteristics of a circuit and / or load configured to be connected to an electrical output connector, based on power consumption data provided by the controller, operating condition-related data, and / or data analysis. In another implementation, the centralized control system or server is configured to provide load-specific consumption data analysis based on power consumption data provided by the controller, operating condition-related data, and / or data analysis.

[0102] In one implementation, the centralized control system or server is configured to use one or more machine learning algorithms to detect specific load characteristics of circuits and / or loads configured to be connected to the electrical output connector, based on power consumption data provided by the controller, data related to operating conditions, and / or data analysis. In another implementation, the centralized control system or server is configured to use one or more machine learning algorithms to track performance and understand fault conditions associated with each circuit and / or load configured to be connected to the electrical output connector.

[0103] In some embodiments, one or more electrical input connectors are configured to connect to an active or phase conductor and / or a neutral conductor. In some embodiments, a first electrical input connector is configured to connect to an active or phase conductor, and a second electrical input connector is configured to connect to a neutral conductor.

[0104] In some embodiments, one or more electrical input connectors are configured to connect to an active conductor or phase conductor and / or a neutral conductor. In some embodiments, a first electrical output connector is configured to connect to an active conductor or phase conductor, and a second electrical output connector is configured to connect to a neutral conductor.

[0105] In one embodiment, a first circuit is disposed between a first electrical input connector and a first electrical output connector, the first circuit including an active circuit or a phase circuit, and a second circuit is disposed between a second electrical input connector and a second electrical output connector, the second circuit including a neutral circuit.

[0106] In one implementation, the electrical input connector and the electrical output connector are configured to match one or more pre-manufactured connection points so that the circuit protection system can be easily installed in a distribution panel or power distribution and management system.

[0107] In some embodiments, the circuit protection system also includes a status indicator. The status indicator may include a physical indicator mechanically coupled to a movable contact of a disconnecting device such as a relay. The status indicator may be in the form of one or more light-emitting diodes (LEDs). In some embodiments, the LEDs are operatively connected to a controller. In these embodiments, the LEDs are operatively configured to indicate one or more fault conditions in one or more circuits of the circuit protection system, as determined by the controller.

[0108] In another aspect, the present invention broadly relates to a subcircuit connection system comprising: a subcircuit connection block including a plurality of spaced-apart connection layers, wherein each of the plurality of connection layers is configured to connect one or more associated subcircuit conductors of one or more external subcircuit circuits; and one or more pre-configured subcircuit connection modules housed within the subcircuit connection block, each subcircuit connection module including: a plurality of subcircuit conductor terminations, each termination configured to electrically connect a conductor line of an external subcircuit circuit, each subcircuit conductor termination corresponding to one of the plurality of connection layers of the subcircuit connection block, and including an electrical coupling element configured to electrically connect a line terminal end of a subcircuit conductor; and at least one internal electrical connector configured to electrically connect a subcircuit conductor to a power distribution bus and / or a grounding connection.

[0109] In one implementation, the sub-circuit is configured to be electrically coupled to a pre-configured sub-circuit connection module via a three-core cable. In such an implementation, each core of the three-core cable is configured to provide a conductor wire corresponding to a sub-circuit conductor termination. In another implementation, each of one or more sub-circuit conductor terminals is configured to be connected to a conductor wire or core of the three-core cable. In some implementations, the conductor wire or core of the three-core cable corresponds to any of the following: an active conductor or phase conductor, a neutral conductor, and a ground or earth conductor.

[0110] In the implementation, each pre-configured sub-circuit connection module includes: a first sub-circuit conductor termination corresponding to the first layer of the sub-circuit connection block, a second sub-circuit conductor termination corresponding to the second layer of the sub-circuit connection block, and a third sub-circuit conductor termination corresponding to the third layer of the sub-circuit connection block.

[0111] In an implementation, each pre-configured sub-circuit connection module includes: a first sub-circuit conductor termination including an electrically coupled element configured to electrically connect to the end of a ground or ground conductor terminal of an external sub-circuit; a second sub-circuit conductor termination including an electrically coupled element configured to electrically connect to the end of a neutral conductor terminal of an external sub-circuit; and a third sub-circuit conductor termination including an electrically coupled element configured to electrically connect to the end of a phase or active conductor terminal of an external sub-circuit.

[0112] In an implementation, each pre-configured sub-circuit connection module includes: a first internal electrical termination including an electrical coupling element configured to electrically connect the ground or ground conductor terminal of an external sub-circuit to a ground or ground connector; a second internal electrical termination including an electrical coupling element configured to electrically connect the neutral conductor terminal of an external sub-circuit to a power distribution bus; and a third internal electrical connector including an electrical coupling element configured to electrically connect the phase or active conductor terminal of an external sub-circuit to the power distribution bus.

[0113] In one embodiment, a second internal electrical termination, including an electrical coupling element, is configured to electrically connect the neutral conductor terminal of an external subcircuit to a neutral connector of a power distribution bus.

[0114] In one embodiment, a third internal electrical terminal, including an electrical coupling element, is configured to electrically connect the phase or active conductor terminal end of an external subcircuit to the phase or active connector of a power distribution bus.

[0115] In such an implementation, the power distribution bus is configured to electrically connect external sub-circuits to the circuit protection module and / or the power distribution system.

[0116] In another embodiment, the power distribution bus is configured to electrically connect (one or more) external sub-circuits to the circuit protection system as described in the foregoing aspects of the invention. The circuit protection system described in the foregoing aspects of the invention may also include or have any or more of the features mentioned in the foregoing aspects of the invention.

[0117] In this implementation, each pre-configured sub-circuit connection module is configured to be individually electrically isolated.

[0118] In one embodiment, the housing includes a proximal end and a distal end. In one embodiment, each of the spaced-apart connection layers is stepped vertically downward from the distal end toward the proximal end. In another embodiment, a plurality of sub-circuit conductor terminations are laterally spaced along the width of the housing.

[0119] In one implementation, there are three spaced-apart connection layers: a first connection layer provides a row of one or more active conductors, a second connection layer provides a row of one or more neutral conductors, and a third connection layer provides one or more ground conductors.

[0120] In one embodiment, one or more standardized connection identifiers are present on the housing, each corresponding to a sub-circuit connection module. In one embodiment, each of the one or more standardized connection identifiers has an associated color or other visual identifier. In one embodiment, the one or more standardized connection identifiers are configured to convey information about a sub-circuit, which is operable and electrically connected. In one embodiment, the one or more standardized connection identifiers correspond to a sub-circuit diagram of a distribution panel. In one embodiment, the one or more standardized connection identifiers facilitate easy installation of the sub-circuit to the distribution panel.

[0121] In one embodiment, the housing is formed from a pre-made plastic mold. In another embodiment, the housing is operable to open and close, thereby allowing access to one or more pre-configured sub-circuit connection modules.

[0122] In one embodiment, the sub-circuit connection system is configured to form components of a residential distribution panel or power distribution and management system. In another embodiment, the sub-circuit connection system is further configured to be housed within a power distribution unit cabinet, or a distribution panel enclosure and / or cabinet.

[0123] In one embodiment, the sub-circuit connection system is configured to allow easy electrical installation or wiring from the terminal ends of the sub-circuit to a residential distribution panel or power distribution and management system. In another embodiment, the spaced-apart connection layers of the housing facilitate the installation of one or more sub-circuits.

[0124] In another aspect, the present invention broadly relates to a method for connecting one or more external sub-circuits to a sub-circuit connection system as described in the foregoing aspects of the invention, wherein the method comprises: connecting the wire terminal ends of one or more sub-circuit conductors to each of a plurality of sub-circuit conductor terminations using an electrical coupling element. One or more external sub-circuits installed as part of the method of the fifth aspect may include or have any or more of the features mentioned in the foregoing aspects of the invention regarding one or more external sub-circuits.

[0125] In another aspect, the present invention broadly relates to a method for installing a subcircuit connection system as mentioned in the foregoing aspects of the invention in a residential distribution panel or power management system, comprising the steps of: connecting the wire terminal ends of one or more subcircuit conductors to each of a plurality of subcircuit conductor terminations using electrical coupling elements; and connecting each subcircuit input termination to a power distribution bus and / or grounding connection. The subcircuit connection system installed as part of the method of the sixth aspect may include or have any or more of the features mentioned in the foregoing aspects of the invention regarding the subcircuit connection system.

[0126] In another aspect, the present invention broadly relates to a pre-configured or pre-wired distribution panel or residential power distribution and management system, comprising: a sub-circuit connection system as mentioned in the foregoing aspects of the invention; a grid connection module configured to electrically connect the system to an external grid power source; a mains isolation module electrically connected to the grid connection module via pre-configured or pre-wired electrical connectors and configured to provide electrical isolation from the external grid power source; and each auxiliary power module configured to electrically connect the system to an external or auxiliary power source or power source; one or more sub-circuit protection modules electrically connected to the mains isolation module and one or more auxiliary power modules via pre-configured or pre-wired electrical connectors; and one or more sub-circuit protection modules electrically connected to the mains isolation module via pre-configured electrical connectors, each sub-circuit protection module being electrically connected to the sub-circuit connection module of the sub-circuit connection system via pre-configured electrical connectors.

[0127] As mentioned in the foregoing aspects of the present invention, a pre-configured or pre-wired distribution panel or residential power distribution and management system may include or have any or more of the features mentioned in the foregoing aspects of the present invention.

[0128] As mentioned in the foregoing aspects of the present invention, the power grid connection module, mains isolation module, one or more auxiliary power modules, one or more sub-circuit connection modules, and / or one or more sub-circuit protection modules may each include or have any or more of the features mentioned in the circuit protection system of the foregoing aspects of the present invention.

[0129] As will be understood, the first to seventh aspects of the invention may include or have any or more of the features mentioned in the other aspects of the invention.

[0130] Definitions, terms, or phrases.

[0131] Unless the context otherwise requires, the term "distribution panel" as used in this specification and indicative claims should be understood to include means or systems for directing or distributing electricity or power from one or more supply sources to one or more smaller areas of use or subcircuits. The term "distribution panel" may also be understood to include means or systems capable of managing, monitoring, and / or controlling distributed electricity or power from one or more power sources to one or more smaller areas of use or subcircuits. This includes distribution panels and distribution boxes for residential and / or commercial applications.

[0132] Unless the context otherwise implies, the phrase or term “sub-circuit” as used in this specification and indicative claims should be considered as including an electrical circuit or one or more loads and / or means electrically connected to a distribution panel, and is intended to supply or receive electrical energy for one or more electrical appliances or devices.

[0133] Unless the context otherwise implies, the terms “grounded” or “grounded” as used in this specification and indicative claims should be considered to include a reference point in a circuit for measuring voltage, a common return path for current, or a direct physical connection to ground.

[0134] Unless the context otherwise implies, the interchangeable terms “pre-assembled,” “pre-configured,” and “pre-wired” used in this specification and indicative claims should be considered to include systems, apparatuses, or devices having one or more components or modules that are assembled, configured, or manufactured prior to their intended use, and more specifically in the case of electrical systems, where such components or modules may be wired or otherwise electrically connected prior to the intended use of the electrical system.

[0135] The term "comprising" as used in this specification and the indicative claims claims to "consist of at least in part...". When interpreting each expression of the term "comprising" in this specification and the indicative independent claims, additional features or features beginning with that term may also be present. Related terms, such as "comprising" and "including", should be interpreted in the same manner.

[0136] The phrase "computer-readable medium" should be considered to include a single medium or multiple media. Examples of multiple media include centralized or distributed databases and / or associated caches. These multiple media store one or more computer-executable instruction sets. The phrase "computer-readable medium" should also be considered to include methods or methods capable of storing, encoding, or carrying instruction sets for execution by a processor of a computing device and causing the processor to perform any one or more of the methods described herein. Computer-readable media can also store, encode, or carry data structures used by or associated with these instruction sets. The phrase "computer-readable medium" includes solid-state storage, optical media, and magnetic media.

[0137] Number range

[0138] The references to numerical ranges disclosed herein (e.g., 1 to 10) also include references to all rational numbers within that range (e.g., 1, 1.1, 2, 3, 3.9, 4, 5, 6, 6.5, 7, 8, 9, and 10) and any range of rational numbers within that range (e.g., 2 to 8, 1.5 to 5.5, and 3.1 to 4.7). Therefore, all subranges of all ranges explicitly disclosed herein are hereby explicitly disclosed. These are merely examples of specific intentions, and all possible numerical combinations between the listed minimum and maximum values ​​should be considered to be expressly stated in a similar manner in this application.

[0139] As used herein, the term “and / or” means “and” or “or”, or both.

[0140] As used in this article, “(one or more)” before a noun refers to the plural and / or singular form of that noun.

[0141] This invention may also be broadly defined to include any components, elements, and features individually or jointly mentioned or indicated in the description of this application, as well as any or all combinations of any two or more of the said components, elements, or features, and where a particular integer mentioned herein has an equivalent known in the relevant field of this invention, such known equivalent is considered to be incorporated herein as if set forth separately.

[0142] The present invention includes the foregoing, and also contemplates the following constructions, which are given as examples only. Attached Figure Description

[0143] Preferred embodiments of the present invention will be described by way of example only and with reference to the accompanying drawings, wherein:

[0144] Figure 1 It is a high-level schematic diagram of a system architecture for a distribution panel according to an implementation method;

[0145] Figure 2It is a schematic diagram of a pre-configured or pre-wired distribution panel or residential power distribution and management system according to the implementation method.

[0146] Figure 3 It is a schematic diagram of a pre-configured or pre-wired distribution panel or residential power distribution and management system according to the implementation method.

[0147] Figure 4 It is a schematic diagram of a pre-configured or pre-wired distribution panel or residential power distribution and management system according to the implementation method.

[0148] Figure 5 It is a schematic diagram of a pre-configured or pre-wired distribution panel or residential power distribution and management system according to the implementation method.

[0149] Figure 6 It is a schematic diagram of a pre-configured or pre-wired distribution panel or residential power distribution and management system according to the implementation method.

[0150] Figure 7 It is a schematic diagram of a circuit protection system according to an implementation method;

[0151] Figure 8 It is a schematic diagram of a circuit protection system according to an implementation method;

[0152] Figure 9 It is a schematic diagram of a sub-circuit protection device, module, or system according to the implementation method;

[0153] Figure 10 This is a front view of the sub-circuit connection system connection block or housing according to the embodiment;

[0154] Figure 11 yes Figure 10 A three-dimensional image;

[0155] Figure 12 This is a partial perspective view of the protection module and busbar according to the implementation method;

[0156] Figure 13 This is a partial perspective view of the protection module and busbar according to the implementation method;

[0157] Figure 13A This is a partial perspective view of the protection module and busbar according to the implementation method;

[0158] Figure 13B This is a partial perspective view of the protection module and busbar according to the implementation method;

[0159] Figure 14 This is a partial perspective view of the protection module and busbar according to the implementation method;

[0160] Figure 14AThis is a partial perspective view of the protection module and busbar according to the implementation method;

[0161] Figure 14B This is a partial perspective view of the protection module and busbar according to the implementation method;

[0162] Figure 14C This is a partial perspective view of the protection module and busbar from below, according to the implementation method;

[0163] Figure 15 This is a partial perspective view of the connection or termination block according to the implementation method;

[0164] Figure 16A This is a partial perspective view of the protection module according to the implementation method;

[0165] Figure 16B It's viewed from the back. Figure 16A A partial 3D view of the protection module;

[0166] Figure 16C yes Figure 16A A partial 3D view of one end of the protection module;

[0167] Figure 17 This is a partial perspective view of the circuit protection module assembly according to the implementation method;

[0168] Figure 17A It's viewed from the back. Figure 17 A partial 3D view of the circuit protection module group;

[0169] Figure 17B yes Figure 17A A partial 3D view of the circuit protection module group connected to the busbar;

[0170] Figure 18 This is a partial perspective view of the distribution panel according to the implementation method;

[0171] Figure 19 This is a partial front view of the distribution panel according to the implementation method;

[0172] Figure 20 This is a partial perspective view of the distribution panel according to the implementation method;

[0173] Figure 21 This is a partial perspective view of the distribution panel according to the implementation method;

[0174] Figure 22 This is a partial perspective view of the distribution panel according to the implementation method;

[0175] Figure 23 This is a perspective view of the distribution panel according to the embodiment, showing possible installations;

[0176] Figures 23A to 23DA front view of a distribution panel according to an embodiment is shown during the installation phase;

[0177] Figure 24 A rear perspective view of the distribution panel according to an embodiment is shown;

[0178] Figure 25 A front view of a partially installed distribution panel according to an embodiment is shown;

[0179] Figure 26 A cross-sectional view of a distribution panel according to an embodiment is shown. Detailed Implementation

[0180] In the following description, specific details are set forth to provide a thorough understanding of the implementation methods. However, those skilled in the art will understand that these implementation methods can be practiced without these specific details. For example, modules, including those in the form of software modules, functions, circuits, etc., may be shown in the block diagrams to avoid obscuring the implementation methods with unnecessary details. In other instances, well-known modules, structures, and techniques may not be shown in detail to avoid obscuring the implementation methods.

[0181] Additionally, it should be noted that the implementation can be described as a process depicted as a flowchart, flow diagram, structure diagram, or block diagram. Although a flowchart can describe operations as a sequential process, many operations can be executed in parallel or simultaneously. Furthermore, the order of operations can be rearranged. A process terminates when its operations are completed. A process can correspond to a method, function, program, subroutine, subroutines, etc., in a computer program. When a process corresponds to a function, its termination corresponds to the function returning to the calling function or the main function.

[0182] The aspects of the systems and methods described below can operate on any type of general-purpose computer system or computing device, including, but not limited to, desktop computers, laptop computers, notebook computers, tablet computers, smart TVs, microprocessors, or mobile devices. The term "mobile device" includes, but is not limited to, wireless devices, mobile phones, smartphones, mobile communication devices, user communication devices, personal digital assistants, mobile handheld computers, laptop computers, wearable electronic devices such as smartwatches and head-mounted devices, e-book readers and reading devices capable of reading electronic content, and / or other types of mobile devices that are typically carried by an individual and / or have some form of communication capability (e.g., wireless, infrared, short-range radio, cellular, etc.).

[0183] 1. Pre-assembled, pre-configured, or pre-wired distribution panels

[0184] This invention generally relates to pre-assembled, pre-configured, or pre-wired distribution panels or residential power distribution and management systems, and aspects thereof.

[0185] refer to Figure 1 This shows a high-level schematic diagram of a system architecture 100 for a distribution panel according to an embodiment.

[0186] The grid connection module 202 connects the distribution panel to the utility grid 120. Following the grid connection module 202 is the mains isolation module 206. The distribution panel enclosure or housing 240 is connected to the ground, and the main switch 150 is located in the active or phase line between the mains isolation module 206 and the phase busbar 160. Multiple ground neutral links 140 are provided between the neutral busbar and the ground busbar. Protection modules 216 and 210 interconnect the busbars with load (and optionally power supply or generation) circuits 170, as will be further described below.

[0187] Also provided are metering systems, such as smart meters 130 and optional displays, along with a system control module 240 having associated connectivity or communication modules 242 and 232, as will be further described below.

[0188] refer to Figure 2 An example of a physically pre-configured, pre-manufactured, or pre-wired distribution panel or residential power distribution and management system 200 according to an embodiment is shown.

[0189] like Figure 2As shown, the pre-wired distribution panel 200 includes at least: a power grid connection module 202 configured to electrically connect the system 200 to an external power grid 204; a mains isolation module 206 electrically connected to the power grid connection module 202 via pre-configured or pre-wired electrical connectors 208 and configured to provide electrical isolation from the external power grid 204; and one or more auxiliary power modules 210a, 210b, 210c, each electrically connected to the mains isolation module 206 via pre-configured or pre-wired electrical connectors 209 and each configured to electrically connect the system to a corresponding mains isolation module 204. The system includes an external or auxiliary power source 212a, 212b, 212c; one or more sub-circuit protection modules 216a, 216b electrically connected to the mains isolation module 206 and one or more auxiliary power modules 210a, 210b, 210c via pre-configured or pre-wired electrical connectors 218; and one or more sub-circuit termination devices 220, each electrically connected to a corresponding sub-circuit protection module 216a, 216b via pre-configured or pre-wired electrical connectors 222, and each configured to electrically connect the system to an external sub-circuit. It should be noted that in some embodiments, the auxiliary power modules may be omitted, as will be further described below. The invention includes sub-circuit protection modules that are inherently bidirectional, meaning that the sub-circuit protection modules can allow current to be supplied from an external power source (e.g., a solar panel, wind turbine, or EV battery) to which the sub-circuit is connected, enabling the return of power to the grid.

[0190] Furthermore, the present invention includes a switchboard that can operate in islanded mode, thereby disconnecting the switchboard from the power grid so that a local power source connected to one or more sub-circuits can be used to power the islanded system. Islanded mode can be invoked remotely via the mains isolation module or, in some embodiments, manually to disconnect the switchboard from the power grid. This may occur, for example, in the event of a grid failure.

[0191] The module, namely the grid connection module, the mains isolation module, one or more auxiliary power modules, and / or one or more sub-circuit protection modules, includes the circuit protection system or module 100, as mentioned in Section 2 below. In such an embodiment, any one of the grid connection module, the mains isolation module, one or more auxiliary power modules, and / or one or more sub-circuit protection modules may include or have any or more of the features mentioned in relation to the circuit protection system or module 100 of the present invention.

[0192] In an implementation, the pre-configured or pre-wired electrical connections between any one or more modules include one or more of the following: phase connections or active connections, neutral connections and / or ground connections or grounding connections. The pre-configured or pre-wired electrical connections between any one or more modules include one or more pre-wired busbars, for example, pre-wired busbars including phase connections and / or neutral connections. The pre-configured or pre-wired distribution panel or residential power distribution and management system 200 may additionally include a pre-configured or pre-wired grounding connection system that electrically connects the grounding conductor of one or more sub-circuits to an electrical ground.

[0193] In one embodiment, one or more sub-circuit termination devices 220 each include one or more sub-circuit conductor terminations 220a, 200b, 200c, each of which is configured to electrically connect to the conductor line of an external sub-circuit.

[0194] In an example implementation, the grid connection module 202 is configured to electrically connect the system 200 to the phase and neutral connections of one or more external grid power sources 204, which are operable to connect to the system 200. The mains isolation module 206 is configured to be electrically connected to the grid connection module 202 via a pre-wired busbar 208 and is configured to provide electrical isolation from the external grid power sources 204. One or more auxiliary power modules 210a, 210b, 210c are configured to each be electrically connected to the mains isolation module 206 via a pre-wired busbar 209 and are each configured to electrically connect the system to a corresponding external or auxiliary power source or source 212a, 212b, 212c, each operable to connect to the system 200. One or more sub-circuit protection modules 216a, 216b are configured to be electrically connected to the mains isolation module 206 and one or more auxiliary power modules 210a, 210b, 210c via pre-wired busbar 218. Finally, one or more sub-circuit termination devices 220 are each configured to be electrically connected to the corresponding sub-circuit protection module 216a, 216b via pre-wired busbar 222, and each is configured to electrically connect the system to an external sub-circuit operable to connect to system 200.

[0195] In this implementation, the system modules are connected via pre-wired busbars, and the only external connection required by the electrician installing the distribution panel is to connect one or more external mains power supplies 204, optionally one or more external or auxiliary power supplies 212a, 212b, 212c (if needed), and one or more external sub-circuits.

[0196] In these implementations, pre-wired distribution panels typically eliminate most of the internal wiring, allowing electricians to power the installation and connect sub-circuits. Compared to typical distribution panels in the prior art, this not only reduces time lost during assembly and wiring but also eliminates any potential human error failures that can occur when wiring such an installation. It will be understood that in some implementations, not all of the modules described herein may be required in any given installation. For example, modules such as mains connection modules or mains isolation modules may be replaced by other functional devices under the regulations of various states, territories, or countries.

[0197] Module 1.1

[0198] One or more auxiliary power modules 210a, 210b, 210c are each configured to electrically connect a pre-configured or pre-wired distribution panel or residential power distribution and management system to an external distributed generation supply or source. The distributed generation supply or source may include one or more of the following: vehicle-to-grid (V2G) sources or electric vehicles (EVs), battery sources, and / or solar energy including one or more solar panels. In such embodiments, each auxiliary power module is operable as a switch to facilitate electrical connection to the external distributed generation supply or source. Each auxiliary power module may also be configured to draw power from the external distributed generation supply or source (e.g., solar energy or battery source) for use in the power distribution system. As mentioned above, a sub-circuit protection module may also provide this functionality and is therefore used in some embodiments instead of the auxiliary modules.

[0199] Now for reference Figure 3 Each of one or more subcircuit protection modules 216a, 216b is operatively connected to a centralized subcircuit controller 230. In such an embodiment, the connection to the centralized subcircuit controller 230 is provided via a communication module 232, preferably via a serial communication protocol. The centralized subcircuit controller 230 can be configured to receive measurement or monitoring data associated with the corresponding connected subcircuit as input from one or more connected subcircuit connection modules 216a, 216b. The measurement or monitoring data may include data associated with the connected subcircuit or each connected subcircuit, such as power consumption data, operating conditions, and / or data analysis.

[0200] In one embodiment, each of the one or more sub-circuit termination devices 220 includes a pre-configured sub-circuit connection module, as mentioned with respect to the sub-circuit connection system of the present invention, and detailed in Section 3 below. In such an embodiment, one or more sub-circuit termination devices may include or have any or more features of the pre-configured sub-circuit connection module mentioned with respect to the sub-circuit connection system of the present invention.

[0201] In some embodiments, each sub-circuit termination device 220 includes a plurality of sub-circuit conductor terminations 220a, 220b, 220c, each configured to electrically connect to a conductor of an external sub-circuit. In these embodiments, each sub-circuit conductor termination 220a, 220b, 220c may include an electrically coupled element configured to electrically connect to the end of a wire terminal of a sub-circuit conductor.

[0202] In some implementations: the sub-circuit protection module is configured to meet the numerous electrical safety requirements of a residential distribution panel installation; the grid connection module is configured to provide metering capabilities; and one or more auxiliary power modules are configured to provide distribution termination points, such as, but not limited to, vehicle-to-grid inverters, solar inverters, and battery storage inverters. In some implementations, each module is configured to be inserted into a pre-assigned location in a distribution panel with pre-manufactured wiring and load connections already in place. This means that unprotected power supply (line) from the grid and protected power supply (load) to the sub-circuit are already in place, requiring no further internal work beyond connecting each sub-circuit to a sub-circuit termination device.

[0203] In some implementations, one or more modules are configured to have identical or similar hardware components, with the difference between the modules being the embedded firmware controlling the functionality of each module. This standardizes and simplifies the process if it is necessary to replace modules in a distribution panel and remove protection devices with different ratings or sizes. In some implementations, the module, or each module, will be equipped with a single-pole relay that will be software-operated to open and close circuits. This will be controlled via a serial communication protocol and can be configured for remote control by one or more third parties (e.g., homeowners, energy retailers, and / or distributors).

[0204] In some implementations, one or more modules may have color-changing LED operation indicators. These indicators are configured to illuminate when a fault condition is active or present, and may also be configured to display the present fault using a corresponding color. In other implementations, each module is configured to monitor or measure at least the voltage and current data associated with that module, and transmit this data to a module or circuit protection controller, or to a centralized controller. In these implementations, each module is configured to perform all responsibilities (data acquisition and transmission, control) in real time and will communicate with the desired controller via a wired serial communication protocol. In further implementations, real-time granular consumption data collected from each module may be used for load unpacking supported by machine learning.

[0205] In one implementation, each of the one or more auxiliary power modules is configured to facilitate the switching of any connected external or auxiliary power source or source, or private distributed generation supply. The module is also configured to control / switch each of the external or auxiliary power sources or sources to control the power distribution of the house. In another implementation, each auxiliary power module is also configured to allow the user to select various types of electrical safety parameters required for connecting loads. Furthermore, each auxiliary power module may be configured to transmit data, for example, related to power quality and / or net consumption, to a controller.

[0206] In this implementation, the mains isolation module is configured to provide a main isolation point for the distribution panel. In this implementation, the mains isolation module is configured to provide short-circuit and overload protection because it protects the entire installation, not just specific connected loads.

[0207] 1.2 Control Aspects

[0208] like Figure 4 and Figure 5 As shown, the pre-configured or pre-wired distribution panel or residential power distribution and management system 200 also includes a system controller 240. The system controller 240 is operatively connected to one or more modules. In embodiments where the module or each module has a controller, the system controller may also be operatively connected to one or more controllers of each module. In these embodiments, the system controller 240 may also include a communication module 242, which is operatively connected to the controller and / or communication module of each of the one or more modules. In some embodiments, the communication module 242 of the system controller 240 is electrically connected to each controller of the module via a wired communication link. The wired communication protocol may be, for example, CAN bus or Ethernet.

[0209] refer to Figure 4 and Figure 5 The module, or the controller of each module, is configured to send measurement or monitoring data to the system controller 240. The measurement or monitoring data may be associated with a specific module. The measurement or monitoring data may include power consumption data, data related to operating conditions, and / or data analysis. For example, the module's controller is operable to send at least voltage and / or current data as input to the system controller 240. In these embodiments, the system controller is configured to monitor the voltage and / or current passing through each module in real time.

[0210] like Figure 6 As shown, system controller 240 is configured to connect to sub-circuit controller 230. In such an embodiment, sub-circuit controller 230 is as previously described... Figure 3The discussed configuration receives and processes data related to one or more sub-circuit connection modules 216a, 216b, and is operable to send control signals to one or more sub-circuit connection modules 216a, 216b. The received data is then provided to a system controller 240, which is configured to perform the functions discussed below. The system controller 240 is also configured to provide control signals to one or more sub-circuit connection modules 216a, 216b via the sub-circuit controller 230.

[0211] refer to Figure 4 , Figure 5 and Figure 6 The system controller 240 is configured to send one or more control signals as inputs to the connected module or each connected module. In these embodiments, the control signals are operable to disconnect and / or close the circuitry of the module or each module. In some embodiments, the control signals are further operable to control the electrical relay devices of the module to disconnect or close the corresponding circuitry of the module or each module.

[0212] In the implementation, the system controller 240 corresponds to the centralized control system or server 120 mentioned in relation to the circuit protection system of the present invention, as described in Section 2 below and regarding... Figure 8 As will be understood, the system controller 240 may also include or have any or more of the features mentioned in relation to the centralized control system or server 120 of the circuit protection system of the present invention.

[0213] System controller 240 is configured to detect and / or learn specific current characteristics of circuits and / or loads configured to be connected to each module, based on one or more of power consumption data, operating condition-related data, and / or data analysis provided by the controllers of one or more modules. In some embodiments, system controller 240 is also configured to provide load-specific consumption data analysis based on power consumption data, operating condition-related data, and / or data analysis provided by the controllers of each module.

[0214] System controller 240 is configured to use one or more machine learning algorithms to detect specific load characteristics of circuits and / or loads configured to be connected to each module, based on data received or monitored from one or more modules (e.g., data including one or more of the following: power consumption data provided by the module or the controller of each module, data related to operating conditions, and / or data analysis). System controller 240 is configured to use one or more machine learning algorithms to track performance and understand fault conditions associated with each circuit and / or load configured to be connected to the module.

[0215] System controller 240 may also be configured to provide data transmission and / or software or firmware updates to the connected module or each connected module to update the software or firmware of one or more modules, for example, to introduce new features or fix bugs. In some embodiments, system controller 240 is also configured to provide one or more of the following: remote monitoring of the circuitry of one or more connected modules, power consumption monitoring, and / or status monitoring.

[0216] System controller 240 can also be configured to be electrically connected to an electricity meter. Alternatively or additionally, the system controller, combined with the grid connection module, is configured to provide an electricity meter. The electricity meter can be configured, for example, to provide net metering for a distribution panel in a household. The net metering can conform to IEC standard 62053-22. The provided net metering can include any of the following: mains power quality measurement, bidirectional current sensing, and / or on / off power supply control.

[0217] In some implementations, the system controller is configured to determine or calculate the net power consumption of the switchboard or residential power distribution and management system based on data provided by the module or each module.

[0218] like Figure 5 and Figure 6 As shown, the system controller is also configured to connect to an LCD screen 244. The LCD screen 244 may be an LCD touchscreen, configured to receive input from a user and / or serve as a local human-machine interface (HMI), and is also configured to display data or information related to the distribution panel or residential power distribution and management system. The LCD screen 244 may be configured to display real-time monitoring or consumption data of the distribution panel or residential power distribution and management system to the user. The LCD touchscreen may be configured to allow receiving control input from the user relating to control of one or more modules connected to the system controller.

[0219] refer to Figure 5 and Figure 6 The system controller 240 may also have an embedded communication module 242. In such an embodiment, the embedded communication module 242 is configured to allow communication and bidirectional data transfer with one or more external servers or systems 246. The communication module 242 is configured to allow wired or wireless communication and bidirectional data transfer with the external servers or systems 246 using any one or more of the following communication modules: cellular (3G, 4G, 5G), WIFI, Ethernet, and / or fiber optic. In these embodiments, the communication module 242 is configured to allow communication and bidirectional data transfer with the external servers or systems to transmit real-time retail billing data.

[0220] The external server or system 246, or each external server or system 246, may include at least one database 248. One or more databases are configured to store data received from the system controller 240. The data received from the system controller 240 relates to the consumption and / or usage data of any one or more modules. In some embodiments, the external server or system 246 is cloud-based. In some embodiments, the external server or system 246 is also configured to provide analysis, demand, or consumption analysis of the received consumption and / or usage data of one or more modules.

[0221] The external server or system 246 is also configured to send one or more control signals to the system controller 240. In such an implementation, the control signals are configured to control any one or more modules of the system. The control signals are configured to switch or trigger any one or more relays of any one or more modules to open or close, which, as will be understood, will cause or trigger the circuitry of the module to be open or closed.

[0222] As will be understood, external grid power includes the supply of electrical energy. The supply of electrical energy may be provided by one or more external grid suppliers. In some embodiments, the external grid supplier may have access to an external server or system 246. In such embodiments, one or more grid suppliers may receive data related to the consumption and / or usage data of one or more modules, and / or send one or more control signals from the external server or system to turn any or more relays of one or more modules on or off. In such embodiments, the grid supplier may send one or more control signals to shut down heavy loads during peak demand periods of external grid power.

[0223] The distribution panel or power management and distribution system 200 of the present invention is configured, when electrically connected or operably connected to an external grid power source and one or more sub-circuits, to provide power distribution and management from the external grid power source to a household comprising one or more sub-circuits.

[0224] System controller 240 and / or external server or system 246 are also configured to provide economical and / or energy-efficient power distribution and management based on input received from the module and external server or system. System controller and / or external server or system are configured to provide management of the energy supply to one or more sub-circuits, thereby reducing peak loads on the grid supplier by selectively supplying energy to sub-circuits and / or appliances with higher load consumption during periods of low grid demand.

[0225] System controller 240 and / or external server or system 246 are configured to provide individual switching on or off of individual subcircuits based on load consumption data from one or more modules and / or power demand or grid supply prices provided by a third party. In these implementations, the third party is a power retailer or distributor.

[0226] System controller 240 and / or external server or system 246 are configured to receive data related to real-time electricity pricing, which is associated with the supply of electrical energy from an external grid supplier. In such embodiments, system controller 240 and / or external server or system 246 are configured to analyze or compare real-time electricity pricing data and real-time load consumption or usage of the system and / or one or more modules. System controller 240 and / or external server 246 or system are also configured to calculate the most economical and / or energy-efficient power allocation and management of the system based on the analysis or comparison of the system's real-time electricity pricing data and real-time load consumption data. In some embodiments, system controller 240 and / or external server or system 246 are configured to manage the electrical energy supplied to sub-circuits to optimally reduce household electricity bills based on real-time analysis of electricity pricing data and load consumption of one or more modules and / or system.

[0227] System controller 240 and / or external server or system 246 are also configured to optimally switch between available alternative power sources or supplies to reduce household electricity bills and / or reduce demand on external grid sources. In such an implementation, system controller 240 and / or external server or system 246 are configured to control one or more modules of a distribution panel or power distribution and management system based on analysis of real-time electricity pricing data and real-time load consumption data to ensure that electricity used by the household remains at the lowest optimal price or rate. For example, this may include any of the following: charging one or more batteries or EVs based on auxiliary power sources when electricity is at a cheaper comparative rate, and / or using one or more auxiliary power sources to provide power to the system when electricity is at a more expensive comparative rate, and / or transferring electricity from one or more auxiliary power sources to external grid sources to sell the electricity back to the external grid supplier when electricity is at a more expensive comparative rate.

[0228] System controller 240 and / or external server or system 246 are configured to provide management of the power supply to one or more sub-circuits, thereby reducing peak loads on the external grid supplier by selectively supplying energy to sub-circuits with higher load consumption during periods of low grid demand. It will be noted that using individual circuit protection devices or modules means that energy usage for each sub-circuit can be monitored.

[0229] System controller 240 and / or external server or system 246 are configured to receive data relating to the consumption of at least one or more modules and to send control commands to one or more modules. This sending and receiving enables each home to be controlled and flexibly managed for home energy via a distribution panel. In an implementation, distribution panel 200 is configured, at least via controller and / or external server or system, to provide its own unique portal that can utilize data collected from one or more modules to create a real-time virtual power information platform. Within this platform, homeowners or other parties can access information such as real-time consumption data and the operating status of any connected loads within the installation, usage time analysis, and predictive recommendations based on energy usage patterns. The platform is also configured to facilitate remote control of connected sub-circuitages or loads within the home, for example, through demand response programs, controlled energy retailing plans, and general homeowner controls. Controller and / or external server or system can also host sub-circuitage or load decompositions supported by machine learning algorithms and provide unique insights into energy usage characteristics and performance down to the appliance / installation level.

[0230] System controller 240 and / or external server or system 246 are also configured to adjust the current protection of each connected subcircuit to its actual load requirements. The module or each module is configured to have trip curve ratings based on one or more connected loads or subcircuits. Each trip curve rating determines the level at which the module will trip instantaneously (i.e., short-circuit) and the time required to trip under more progressive overload conditions. The module or each module is configured to adjust the trip curve ratings according to the exact requirements of the (one or more) connected loads and / or subcircuits. Some connected appliances or devices, depending on their age or construction, typically require higher starting currents than normal. The system controller and / or external server or system is configured to detect this specific load characteristic and accurately adjust the trip curve ratings to provide a higher level of operational safety and avoid false trips. System controller 240 and / or external server or system 246 can do this using one or more machine learning algorithms. This will provide the most flexible and accurate short-circuit and overload circuit protection for any residential environment.

[0231] Any fault data recorded or measured by one or more modules and received and / or processed by system controller 240 and / or external server or system 246 through one or more machine learning algorithms is configured to continuously develop and understand potential fault conditions in the residential distribution panel or installation. Each subcircuit device or load connected within a subcircuit will have its own unique sinusoidal characteristics, regardless of the presence of a fault. The system controller and / or external server or system is configured to quickly and accurately learn the separation between the characteristics of each load, down to the specific appliance connected to a subcircuit, such as a refrigerator, toaster, kettle, heat pump, etc.

[0232] System controller 240 and / or external server or system 246 are configured to employ one or more machine learning algorithms that can differentiate the effective performance of each sub-circuit and / or each (one or more) device, load, or appliance comprising a sub-circuit. The machine learning algorithms can also track the performance of each sub-circuit and / or each load, device, or appliance comprising a sub-circuit over time. Having this key performance data will result in the ability to understand when each load, device, or appliance comprising a sub-circuit is not operating at its intended efficiency, which will help assist the sub-circuit and / or each load, device, or appliance comprising a sub-circuit that is using excessive power. Just because an appliance or device is working does not mean that the appliance or device is functioning well. This can also lead to accurate predictions of when an appliance might fail soon and prevent any malfunctions or harmful equipment damage.

[0233] System controller 240 and / or external server or system 246 are configured to continuously or periodically analyze subcircuit load consumption (including for fault detection) to ensure that the circuit always has the correct protection level and is operable to quickly protect the subcircuit from faults. All monitored or measured data enables system controller 240 and / or external server or system 246 to adapt to newer technologies and to more fragmented load distribution problems. It can do this using one or more machine learning algorithms. Each module, either through its own controller or through system controller 240 and / or external server or system 246, is configured to continuously adapt to its specific subcircuit and / or load distribution by monitoring and analyzing the power consumed. In some implementations, updates can be remotely applied to each module via system controller 240 and / or external server or system 246 when updates have been tested and approved to improve electrical safety performance.

[0234] Using one or more machine learning algorithms, the system controller and / or external server or system are configured to adapt to the specific load consumption of each installation. This means that regardless of how or when electricity is used in the house, the system controller and / or external server or system are configured to adapt and learn from the data received using it.

[0235] System controller 240 and / or external server or system 246, in conjunction with one or more auxiliary power modules 210a, 210b, 210c, are configured to facilitate the management of privately generated electricity supplies (e.g., those from solar power, vehicle-to-grid (V2G), batteries, or generators). By monitoring the wholesale electricity pricing market, system controller 240 and / or external server or system 246 are configured to efficiently switch between available alternative energy supplies during peak hours and ensure that electricity remains at the lowest possible rate for homeowners, while also minimizing environmental impact as well as that of generators and distributors. When electricity is available at its lowest priced form, system controller 240 and / or external server or system 246 are configured to take advantage of this and charge, for example, any possible battery-centralized products. The following examples outline different example scenarios for this functionality:

[0236] Example 1 illustrates a scenario where an electric vehicle is connected to an inverter in a house and its battery is full, but power demand is at its highest and the cost of consuming electricity is highest. The system controller and / or external server or system is configured to utilize a V2G inverter connected to one of the auxiliary power modules and draw power from the electric vehicle to power the house. For example, this might involve drawing power from the electric vehicle to drive a dryer or to power an electric kettle. The battery capacity of a typical electric vehicle is sufficient to power an average house for up to 4 days.

[0237] Example 2 illustrates a scenario where an electric vehicle or battery is connected to an inverter in the home and electricity pricing is at its lowest possible level. The system controller and / or external server or system is configured to draw power from the external grid supply and charge the battery and / or electric vehicle unit to prepare them for peak pricing periods. Once they have accumulated sufficient charge and peak periods begin to approach, matching against machine learning data on the home's consumption history and usage time, the system controller and / or external server or system will be able to disconnect from the external grid supply and manage the stored battery energy in a way that can efficiently power the home.

[0238] Example 3 illustrates a scenario where a home has the capacity to store energy, for example, through one or more batteries or electric vehicles, and its peak load consumption occurs when overall supply and demand are low, and therefore pricing is low. The system controller and / or external server or system is configured to manage when it is best to sell any excess stored electricity back to the grid during peak demand and pricing periods. This allows homeowners to gain financial benefits and alleviates pressure on distributors to meet peak demand. When this event occurs and demand is low again, the system controller and / or external server or system can draw power from the grid or utilize solar energy (if available) to recharge the batteries at a lower price.

[0239] The approach behind this is to provide economical and energy-efficient solutions for any homeowner, regardless of their size or consumption level.

[0240] 1.3 IoT Connectivity

[0241] The system controller and / or external server system are also configured to be operatively connected to one or more Internet of Things (IoT) enabled devices, located within or associated with a home equipped with a distribution panel. In such embodiments, the system controller and / or external server system are configured to operatively connect to one or more IoT enabled devices using a communication module or each communication module. For example, the communication module or each communication module is configured to operatively connect to one or more IoT enabled devices using one or more of the following communication protocols: Zigbee, IEEE 802.15.4, Bluetooth Low Energy (BLE), LoRa, and / or Wi-Fi. The system controller and / or external server system are configured to receive data associated with one or more connected IoT enabled devices, and in some embodiments, the controller is configured to receive data associated with the power consumption or usage of the connected IoT enabled devices.

[0242] The system controller and / or external server system are configured to: store data received from connected IoT-enabled devices, and establish a selection or directory of connected and / or previously connected IoT-enabled devices based on data received from one or more IoT-enabled devices. In some embodiments, the system controller and / or external server system are also configured to: send one or more command signals to one or more connected IoT-enabled devices. In such embodiments, the system controller and / or external server system are further configured to: send one or more command signals to turn one or more connected IoT-enabled devices on or off.

[0243] In some implementations, the system controller and / or external server system may also be operable to determine the load characteristics of one or more connected IoT devices. The system controller and / or external server system may also be configured to match or pair the load characteristics of the connected IoT devices with the load characteristics of one or more sub-circuits (such as those measured by one of the sub-circuit protection modules). In some implementations, the system controller and / or external server system is operable to utilize the load characteristics of the connected IoT devices as input to a machine learning algorithm. In such implementations, the machine learning algorithm is capable of determining one or more characteristics of the sub-circuit connected to the sub-circuit protection module.

[0244] This interaction with connected devices enables system controllers and / or external servers or systems to build a selection of appliances / devices for each house, further enhancing their ability to monitor, manage, and / or control specific items within the house. This leverages real-time connectivity to enhance system functionality and its machine learning capabilities, accelerating the learning process by which system controllers and / or external servers or systems discover appliance / device load characteristics.

[0245] 1.4 Housing and Installation

[0246] Pre-configured or pre-wired switchboards or residential power distribution and management systems are configured to be housed within a enclosure or enclosure. In such embodiments, the enclosure or enclosure is a typical or existing residential switchboard enclosure or enclosure.

[0247] Pre-configured or pre-wired electrical connectors that electrically connect one or more modules are pre-configured or pre-wired busbars. In some embodiments, busbars are copper or aluminum busbars, or flat strips of copper or aluminum. Busbars are operable to carry large currents between modules of the distribution panel to which they are connected. They may be supported by insulators, leaving only the connection points exposed, or they may be bare busbars.

[0248] Each module can be configured to be electrically connected to one or more pre-configured or pre-wired connection points. In some embodiments, one or more pre-configured or pre-wired connection points are electrically connected to one or more pre-configured or pre-wired electrical connectors between modules. Furthermore, the pre-configured or pre-wired electrical connectors for the electrical connection modules can be fixed in place relative to the distribution panel. In some embodiments, the pre-configured or pre-wired electrical connectors for the electrical connection modules are configured to define the location of each module within a pre-configured or pre-wired distribution panel or residential power distribution and management system.

[0249] This invention also broadly relates to a method for installing a pre-wired distribution panel, the method comprising the steps of: electrically connecting an external grid power supply to a grid connection module; and electrically connecting the wire terminal ends of one or more sub-circuit conductors to corresponding sub-circuit termination devices. The method further includes connecting one or more auxiliary power supplies or external distributed generation supplies or source power to one of the auxiliary power modules. The pre-manufactured distribution panel installed as part of this method may include or have any or more of the features mentioned regarding the pre-wired distribution panel of this invention.

[0250] 2. Circuit protection module

[0251] refer to Figure 7 This illustration shows an example embodiment of another aspect of the invention, relating to a circuit protection system 100 for use in a switchboard or power distribution and management system. The circuit protection system 100 includes: one or more electrical input connectors 108 configured to connect to at least one power source; one or more electrical output connectors 110 configured to provide power to an electrical output; one or more circuits 106 disposed between the one or more electrical input connectors 108 and the one or more electrical output connectors 110; a load monitoring device 104 operably connected to the one or more circuits 106 and operable to determine one or more characteristics or attributes of the one or more circuits 106; and an electrical relay device 102 electrically connected between the electrical input connectors 108 and the electrical output connectors 110. Between 0 and 104, and operable to open or close one or more circuits 106 based on control signals; and a controller 112 operably connected to the electrical relay device 102 and the load monitoring device 104, the controller 112 being configured to receive one or more characteristics or attributes of one or more circuits 106 as input from the load monitoring device 104, determine whether one or more fault conditions exist in one or more circuits 106 based on the analysis of one or more characteristics or attributes of one or more circuits, and if a fault condition is detected based on the analysis of one or more characteristics or attributes of one or more circuits, send one or more control signals to the electrical relay device 102 to open or close one or more circuits 106.

[0252] 2.1 Control and monitoring devices

[0253] Still referencing Figure 7The electrical relay device 102 is configured to receive a control signal from the controller 112. The control signal is operable to trigger the electrical relay device to open or close one or more circuits 106. The electrical relay device 102 includes one or more electrical relays, each corresponding to one of the circuits 106. Each electrical relay device 102 is operable to open or close its corresponding circuit 106 based on the control signal. As will be understood, the electrical relay device, or each electrical relay device 102, is a unipolar relay and / or a bistable or latching relay, or any other type of relay device.

[0254] The load monitoring device 104 is operatively connected in series in one or more circuits 106 between the electrical input connector and the electrical output connector. The load monitoring device 104 may also be operatively connected in the circuit 106 preceding the electrical relay device 102. In an alternative embodiment, the load monitoring device 104 is operatively connected in parallel with one or more circuits 106 between the electrical input connector and the electrical output connector.

[0255] The characteristics or properties of one or more circuits measured or determined by the load monitoring device 104 include at least the voltage and / or current through one or more circuits 106. These characteristics or properties of one or more circuits may also include real-time voltage and / or current readings. These characteristics or properties of one or more circuits may also include waveforms or wave patterns of the voltage and / or current through one or more circuits.

[0256] The load monitoring device 104 includes at least a current sensor and / or a voltage sensor. In some embodiments, the current sensor is a current transformer. In such embodiments, as will be understood, the current transformer is configured as a high-frequency and / or low-frequency current transformer, or any other type of load measuring device.

[0257] 2.2 Control aspects of the circuit protection module

[0258] The controller 112 is configured to receive voltage and / or current readings from one or more circuits as input from the load monitoring device 104. In some embodiments, the controller is configured to receive waveforms or wave patterns of voltage and / or current from the load monitoring device as input via one or more circuits.

[0259] Controller 112 is configured to analyze one or more characteristics or attributes (e.g., voltage and / or current) of one or more circuits and determine whether these characteristics or attributes indicate one or more fault conditions in the circuits. Controller 112 is configured to determine whether one or more fault conditions exist in one or more circuits 106, which include at least any of the following: short circuit, circuit overload, circuit overvoltage, circuit overcurrent, AC and / or DC ground leakage, and / or dangerous arcing faults. One or more fault conditions may have specific thresholds or tripping curves, wherein the controller indicates a fault condition if one or more characteristics or attributes of one or more circuits exceed the threshold or tripping curve. Controller 112 is also configured to adjust the specific threshold or tripping curve for each of the one or more fault conditions. The specific threshold or tripping curve for each of the one or more fault conditions may be adjusted based on the real-time load requirements of the circuit.

[0260] If a fault condition is detected based on the analysis of one or more characteristics or properties of one or more circuits, the controller 112 is configured to send one or more control signals to the electrical relay device 102 to cause one or more circuits 106 to open or close.

[0261] The response time of controller 112 in determining the fault condition and sending control signals to the electrical relay device is preferably on the order of microseconds or nanoseconds. This short response time allows dangerous arcing faults to be detected and eliminated in one or more circuits.

[0262] 2.3 Centralized Control and Communication

[0263] refer to Figure 8 The controller 112 is also operably connected to the centralized control system or server 120. This connection can be provided via a communication module 114. The communication module can use a serial communication protocol to connect to the centralized control system or server 120. The centralized control system or server is configured to connect to the controller 112 of one or more different circuit protection systems 100.

[0264] Controller 112 is configured to send measurement or monitoring data to a centralized control system or server 120. The measurement or monitoring data may include at least power consumption data, operating condition-related data, and / or data analysis. In some embodiments where the circuit protection system 100 is used as at least one module of a pre-configured or pre-wired distribution panel or residential power distribution and management system 200, the centralized control system or server 112 corresponds to system controller 240 and / or external system or server 246. In embodiments where the centralized control system or server 112 corresponds to external system or server 246, it will be understood that controller 112 can communicate with an intermediate controller (such as an intermediate controller that may correspond to system controller 240) and then with the external system or server 246.

[0265] The controller 112 is also configured to receive external control commands from a centralized control system or server 120. The external control signals are operable to control or trigger the electrical relay device 102 to open or close the corresponding circuit 106.

[0266] The centralized control system or server 120 is configured to detect and learn specific current characteristics of the circuit 106 and / or load configured to be connected to the electrical output connector 110 based on one or more of power consumption data, operating condition-related data, and / or data analysis provided by the controller. The centralized control system or server is configured to provide load-specific consumption data analysis based on at least one of power consumption data provided by the controller 112, operating condition-related data, and / or data analysis.

[0267] The centralized control system or server 120 is configured to use one or more machine learning algorithms to detect specific load characteristics of the circuits 106 and / or loads configured to be connected to the electrical output connector 110, based at least on power consumption data, operating condition-related data, and / or data analysis provided by the controller 112. The centralized control system or server is also configured to use one or more machine learning algorithms to track performance and understand fault conditions associated with each circuit and / or load configured to be connected to the electrical output connector.

[0268] Load monitoring device 104 is configured to measure voltage and / or current on one or more circuits 106. Circuit 106 may include phase lines and a neutral line. Alternatively, one circuit may be a phase line and another a neutral line. Load monitoring device 104 is configured to measure current in one or more circuits 106 using separate load monitoring devices across the phase and neutral lines. The load monitoring device is preferably a current transformer. The current transformer measures different variations that may occur under different load conditions, including short circuits and overloads, AC & DC ground leakage, and arcing faults.

[0269] Using measurements acquired via load monitoring device 104, controller 112 is configured to develop a load characteristic profile and simulate a sine wave calculated from the records. Circuit protection system 100 is configured to generate its own specific load profile based on the load connected to output connector 110. Using, for example, existing AS / NZS installation and power standards and regulations for all forms of circuit protection, controller 112 is configured to determine the required level of protection for the circuit based on measurements from load monitoring device 104.

[0270] Controller 112 is configured to have an existing set of parameters that can represent specific fault characteristics for each type of circuit protection. The load profile is continuously matched against this existing set of parameters to determine whether current consumption is operating under normal conditions or if a fault exists. During this process, if any data is found to be very close to the existing set of parameters, that data is recorded and an alarm is issued for further investigation using machine learning. If no fault exists, the process of measuring or monitoring circuit 106 is repeated. If a fault exists, a decision is made to interrupt circuit 106 using electrical relay device 102.

[0271] If the controller 112 determines that a fault condition exists, the controller sends a control signal or command to the electrical relay device 102 of the trigger or interrupt circuit 106. The controller 112 records the control signal along with the load profile and the tripping time, and an alarm is issued for further investigation.

[0272] 2.4 Inputs and Outputs

[0273] One or more electrical input connectors 108 are configured to connect to an active or phase conductor and / or a neutral conductor. In some embodiments, a first electrical input connector is configured to connect to an active or phase conductor, and a second electrical input connector is configured to connect to a neutral conductor.

[0274] Accordingly, one or more electrical input connectors 110 are configured to connect to an active conductor or phase conductor and / or a neutral conductor. In some embodiments, a first electrical output connector is configured to connect to an active conductor or phase conductor, and a second electrical output connector is configured to connect to a neutral conductor.

[0275] Subsequently, a first circuit is disposed between the first electrical input connector and the first electrical output connector, the first circuit including an active circuit or a phase circuit, and wherein a second circuit is disposed between the second electrical input connector and the second electrical output connector, the second circuit including a neutral circuit.

[0276] Additionally, one or more electrical input connectors 108 and one or more electrical output connectors 110 are configured to match one or more pre-manufactured connection points so that the circuit protection system can be easily installed in a distribution panel or power distribution and management system.

[0277] The circuit protection system 100 also includes a status indicator. The status indicator may be in the form of one or more light-emitting diodes (LEDs). In some embodiments, the LEDs are operatively connected to the controller 112. In these embodiments, the LEDs are operatively configured to indicate one or more fault conditions of one or more circuits in the circuit protection system, as determined by the controller 112. As will be described below, in some embodiments, the status indicator may include a physical indicator, such as a visually observable feature, that physically moves to allow a user to observe and identify an operational or inoperable state.

[0278] Turning Figure 9 A system diagram of module 100, substantially as disclosed above, will now be described based on embodiments or examples. Examples of physical modules will be further described below, but for the purposes of this description, module 100 may be integrally connected as a pre-wired component of a distribution panel. Thus, connectors 108 for module 100 are pre-wired or pre-connected to busbars 160, 162, and 164 of the distribution panel.

[0279] An isolation transformer 170, which may also be a step-down transformer, has a primary winding connected between the active line and the neutral line, and transmits an isolated and preferably low voltage at its secondary side, which can be suitably regulated at 172 in a known manner to provide one or more low-voltage power supplies for powering sensing and control circuitry systems. The power outputs to the various sensing and control circuits are shown as line 174. The transformer feeds power to the low-voltage side of module 100. The separation between the isolated low-voltage area and the high-voltage area of ​​module 100 is achieved by… Figure 9 The isolation line 176 is illustrated in the diagram.

[0280] exist Figure 9 In the example shown, an isolation component including a mechanical air gap disconnect unit (such as a mechanical relay) and a solid-state relay connected in series with the mechanical air gap disconnect unit is provided to enable the circuit breaker function in the event of a detected fault. This allows for the provision of a fail-safe system that combines the fast turn-off capability of a solid-state switch with the mechanical reliability of disconnected electrical contacts, as will now be described.

[0281] Relay 179 has double-pole single-throw contacts 180, which are normally open, electrically and physically isolating the sub-circuit connected to the module from phase busbar 160 and neutral busbar 162. Relay driver 182 is operable to open or close the relay (which, as shown in this example, may include a microcontroller) according to a control signal from controller 112. The air gap present in the open position can be cumulatively measured to be at least approximately 4 mm in some examples.

[0282] In one embodiment, relay contact 180 is mechanically connected to indicator 186 and can be actuated by locking mechanism 188, such as a physical lever, like a switch biased in the OFF position. In some examples, the arrangement is such that when the switch is physically off, the relay driver cannot operate the OFF setting; that is, the relay contact cannot be closed. However, if switch 188 is in the ON position and the relay driver switches the relay contact to the OFF position, the mechanical switch will turn to the OFF position and remain in the OFF position until the user turns the switch to the ON position. In other examples, the switch can be toggled between the ON and OFF positions, but can be locked in the OFF position if needed.

[0283] The additional set of contacts 190 is linked to the main set of bipolar contacts. Contacts 190 are connected to a sensing interface 192, allowing the sensing interface to be used to determine the state of contacts 180. Thus, the sensing interface 192 can notify the controller 112, for example, whether switch 188 has been moved to the off state. This information can be used by the controller 112 to ensure that the solid-state relay 306 remains in the OFF state. In some examples, contacts 190 are physically actuated between closed (i.e., contacted) and open states before contacts 180 are moved between closed and open states. In this way, the controller 112 can control the solid-state relay 306 (described further below) to operate appropriately. For example, the microcontroller 112 can detect that contacts 180 will be disconnected by the user, and therefore disconnect the solid-state relay before disconnecting contacts 180 to prevent or minimize arcing between contacts 180. Similarly, if the user uses a switch or other command to reset relay 179, the controller 112 can close relay contacts 180 before (or before fully closing) the solid-state relay 306.

[0284] The indicator 186 can take many different forms. It may include, for example, a switch trigger or slider, or another feature that moves to provide indication, such as a green or red surface that becomes visible when the relay contact 180 is physically in the OFF or ON state.

[0285] A residual current detector is provided to detect current imbalances in the phase and neutral lines. Those skilled in the art will understand that a variety of different detection circuits can be employed. In this example, a fluxgate sensor is used, comprising a loop coil 190 having a drive coil 192 driven by a fluxgate driver circuit 196 and a test coil 194. The driver circuit is configured to detect any current imbalance exceeding a predetermined threshold (which can be established or set by the microcontroller 112) and provide this information to the microcontroller. Alternatively, the fluxgate driver circuit provides an output representing the phase and neutral currents, which is interpreted by the microcontroller 112 such that upon receiving a detection output indicating a fault, it can take appropriate action, i.e., disconnect relay 179 and solid-state relay 306.

[0286] A primary current sensor is also provided so that overcurrent can be detected to disconnect relays 179 and 306. Those skilled in the art will understand that a variety of different current sensing circuit topologies can be employed. In this example, a Hall effect sensor is used, having an interface 300 that provides a sensor output to the microcontroller 112, so that when a sensor output indicating a fault is received, it can take appropriate action, namely, disconnect relays 179 and 306.

[0287] As briefly described above, it provides Figure 9 The solid-state relay is represented by SiC switch 306. This offers the significant advantage of a very fast switching time, while also exhibiting good thermal performance in the ON state. The solid-state relay is driven by gate drivers 308, which are in turn operated by a microcontroller 112 via an isolated interface such as an optocoupler. The gate drivers are powered by an isolated gate driver power supply 312.

[0288] Buffer 314 and rheostat 316, including an MOV (metal oxide rheostat) in this example, are positioned on the switch to accommodate transients.

[0289] The SiC switch 306 has one or more heat sinks 302 thermally coupled to the switch. To ensure proper thermal safety protection, a temperature sensor 304 is used to monitor the heat sink temperature. The temperature sensor output is provided to the microcontroller 112, enabling it to take appropriate action, such as switching the relay 306 to the OFF state, when a temperature threshold is exceeded.

[0290] A line voltage sensor 318 is also provided to monitor the voltage of the phase line. An isolation interface 320 for the voltage sensor allows the sensor output to be provided to the microcontroller 112, enabling the microcontroller to take appropriate action when a voltage threshold is exceeded, such as switching relays 306 and / or 179 to the OFF state. In other examples, the line voltage sensor is located at other locations, such as on an active line adjacent to one or both sides of relay 179. These additional sensors can be used to provide additional information about the presence of a fault or conditions that may lead to a fault. Furthermore, in some embodiments, the voltage sensor can be used to detect zero-crossing of the voltage and thus provide information to the microcontroller, allowing the microcontroller to determine the appropriate or optimal time to switch the solid-state relay 306 between the ON and OFF states. In some embodiments, relay 306 can also be operated by the microcontroller to control or regulate the power delivered to the sub-circuit it is connected to.

[0291] It will be apparent to those skilled in the art that additional sensors and sensing circuitry can be added, and in some implementations, not all of the sensors described in the examples above may be provided, depending on the intended use and the application of the circuit protection module and / or on the regulations in the state or country where the module is used.

[0292] like Figure 9As shown, each module may have an ON / OFF button or switch that can activate the locking mechanism 188 and the trigger or slide indicator 186 to provide a visible mechanical (and electrical, e.g., via LED) status indication. An RCD test button 326 and an optional display 324 are also provided. In the example or embodiment, activation (e.g., pressing) of the RCD test button causes the microcontroller 112 to send a test command or signal to the fluxgate driver 196. This, in turn, causes the driver to energize the test winding 192, resulting in a change in the sensed magnetic field. If the sensor is functioning correctly, it will detect a magnetic field imbalance or interference, causing the driver to send a fault signal to the microcontroller. Therefore, RCD testing can be performed without a physical connection to an active wire.

[0293] One implementation of the RCD function includes a self-test method in which the microcontroller 112 periodically signals the fluxgate driver 196 to engage the test winding 192 while simultaneously preventing the received signals from causing the solid-state relay 306 or relay 179 to disconnect. In this way, the system can determine that the RCD sensing function remains functionally intact. It will be apparent to those skilled in the art that such a mechanism must be coordinated without compromising normal RCD safety functions. In one example of a device implementing this, the self-test can be performed over a period of several microseconds, as a true RCD fault requires a tripping time measured in milliseconds.

[0294] Another implementation of the system uses a software algorithm in the microcontroller 112 to combine signals from the primary current sensor, residual current sensor, and line voltage sensor to provide an arc fault detection mechanism. Upon detecting a signal indicating an arc fault, the microcontroller can signal relays 179 and 306 to disconnect, thereby ensuring the safety of the sub-circuit.

[0295] Another implementation of the system utilizes the microcontroller 112 for detecting various types of faults (e.g., current overload, short circuit, residual current fault, and arcing fault), thus eliminating ambiguity about the fault cause for the user by displaying the fault cause on the display 324. In this way, the user can better understand the cause of the fault.

[0296] It is also apparent that the circuit protection module can be configured locally or remotely via controllers 112 and / or 240 to provide appropriate protection for load circuits operating bidirectionally or as local power sources. Bidirectional load circuits may include, for example, electric vehicle (EV) charging interfaces, where EV batteries can be charged from a distribution panel, or the distribution panel may act as a grid connection point or local distribution point to receive power from EV batteries when needed. Local power sources may include, for example, solar panels or wind turbines.

[0297] 3. Sub-circuit connection system

[0298] refer to Figure 10 The illustration shows an example embodiment of another aspect of the invention, relating to a sub-circuit connection system 10 used in a switchboard or power distribution and management system.

[0299] As shown in the figure, the sub-circuit connection system 10 includes: a sub-circuit termination block or housing 12, which includes a plurality of spaced-apart connection layers 14a, 14b, 14c, wherein each of the plurality of connection layers is configured to connect one or more associated sub-circuit conductors 16a, 16b, 16c of one or more external sub-circuit circuits; and one or more pre-configured sub-circuit connection modules 18, which are housed within the housing 12, each sub-circuit connection module 18 including: a plurality of sub-circuit conductor coupling elements, The plurality of sub-circuit conductor coupling elements include terminations 16a, 16b, and 16c, each configured to electrically connect to a conductor line of an external sub-circuit. Each sub-circuit conductor termination 16a, 16b, and 16c corresponds to one of the plurality of connection layers 14a, 14b, and 14c of the housing 12 and includes an electrical coupling element configured to electrically connect to the end of a line terminal of the sub-circuit conductor; and at least one internal electrical connector configured to electrically connect the sub-circuit conductor to power distribution buses 20b and 20c and / or ground connection 20a. As can be seen, the coupling elements are arranged in rows. In one embodiment, the coupling elements include phase coupling elements and neutral coupling elements. In another embodiment, as shown, the multiple rows of coupling elements include a row of phase coupling elements, a row of neutral coupling elements, and a row of ground coupling elements. Each of the phase and neutral lines, or phase, neutral, and ground elements of any individual sub-circuit connection element, is positioned adjacent to each other, i.e., in the same or substantially the same position in each row. In this way, the coupling elements of each sub-circuit are grouped according to the cable connections of that sub-circuit. Therefore, each sub-circuit cable can be conveniently terminated at the desired location.

[0300] The sub-circuit connection system provides a centralized location or positioning, allowing electricians to complete all necessary sub-circuit connections with minimal effort during installation. In some embodiments or examples, the sub-circuit connection system is configured to insert the distribution panel at a pre-assigned location where all other internal components are pre-wired, as discussed in other aspects of the invention previously. A distribution panel with a sub-circuit connection system and pre-wired wiring also enables the elimination of the need to quantify or detail the circuit protection devices or other devices required for installation. The pre-wired or pre-configured distribution panel of the present invention can have a set number of circuit protection devices. For example, when a house has an electrical layout / plan, the pre-wired or pre-configured distribution panel is configured with different size sets, which may include, but are not limited to, 15 circuit protection modules, 30 circuit protection modules, and / or 45 circuit protection modules per board. As will be understood, other variations in the number and configuration of circuit protection modules are contemplated. Each sub-circuit is configured to be replaceable and swappable out of another. In these embodiments, the distribution panel may also have sub-circuit connection systems of different sizes, with a certain number of sub-circuit connection modules housed within a housing. For example, if a pre-wired distribution panel has 15 circuit protection modules, then the sub-circuit connection module can have 15 sub-circuit connection modules.

[0301] The sub-circuit is configured to be electrically coupled to a pre-configured sub-circuit connection module 18 via a three-core cable. In such an embodiment, each core of the three-core cable is configured to provide a conductor line corresponding to a sub-circuit conductor termination 16a, 16b, 16c. In another embodiment, each of one or more sub-circuit conductor terminals 16a, 16b, 16c is configured to connect to a conductor line or core of the three-core cable. In some embodiments, the conductor line or core of the three-core cable corresponds to any of the following: an active conductor or phase conductor, a neutral conductor, and a ground or earth conductor.

[0302] like Figure 11 As shown, housing 12 includes a plurality of spaced-apart connection layers 14a, 14b, 14c. Housing 12 also includes a proximal end 22 and a distal end 20. Each spaced-apart connection layer 14a, 14b, 14c is stepped vertically downward from the distal end 20 toward the proximal end 22. In an embodiment, a plurality of sub-circuit conductor terminations are laterally spaced along the width W of housing 12. Figure 11 As shown, in this embodiment there are three spaced-apart connection layers: the first connection layer 14a provides a row of one or more active conductors, the second connection layer 14b provides a row of one or more neutral conductors, and the third connection layer 14c provides one or more ground conductors.

[0303] refer to Figure 10 and Figure 11Each pre-configured sub-circuit connection module 18 includes: a first sub-circuit conductor termination 16a corresponding to the first layer 14a of the housing, a second sub-circuit conductor termination 16b corresponding to the second layer 14b of the housing, and a third sub-circuit conductor termination 16c corresponding to the third layer 14c of the housing.

[0304] Each pre-configured sub-circuit connection module 18 includes: a first sub-circuit conductor termination 16a, the first sub-circuit conductor termination 16a including an electrically coupled element configured to electrically connect to the end of a ground or ground conductor terminal of an external sub-circuit; a second sub-circuit conductor termination 16b, the second sub-circuit conductor termination 16b including an electrically coupled element configured to electrically connect to the end of a neutral conductor terminal of an external sub-circuit; and a third sub-circuit conductor termination 16c, the third sub-circuit conductor termination 16c including an electrically coupled element configured to electrically connect to the end of a phase or active conductor terminal of an external sub-circuit.

[0305] refer to Figure 10 Each pre-configured sub-circuit connection module 18 includes: a first internal electrical termination including an electrical coupling element configured to electrically connect the ground or ground conductor terminal of an external sub-circuit to a ground or ground connector 20a; a second internal electrical termination including an electrical coupling element configured to electrically connect the neutral conductor terminal of an external sub-circuit to a power distribution bus 20b; and a third internal electrical connector including an electrical coupling element configured to electrically connect the phase or active conductor terminal of an external sub-circuit to a power distribution bus 20c.

[0306] A second internal electrical terminal, including an electrical coupling element, is configured to electrically connect the neutral conductor terminal of the external sub-circuit to the neutral connector of the power distribution bus 20b. A third internal electrical terminal, including an electrical coupling element, is configured to electrically connect the phase or active conductor terminal of the external sub-circuit to the phase or active connector of the power distribution bus 20c.

[0307] Power distribution buses 20b and 20c are configured to electrically connect external sub-circuits to the circuit protection module and / or the power distribution system. Power distribution buses 20b and 20c are configured to electrically connect to the circuit protection system as previously mentioned with respect to the present invention. The circuit protection system may also include or have any or more of the features mentioned previously with respect to the circuit protection system of the present invention. In an embodiment, each pre-configured sub-circuit connection module 18 is configured to be individually electrically isolated.

[0308] 3.1 Shell and Identifiers

[0309] refer to Figure 11The sub-circuit termination block or housing 12 includes a proximal end and a distal end. In this embodiment, each of the spaced-apart connection layers 14a, 14b, and 14c is stepped vertically downward from the distal end toward the proximal end. In this embodiment, a plurality of sub-circuit conductor terminations are laterally spaced along the width W of the housing 12. As shown, there are three spaced-apart connection layers: a first connection layer 14a provides a row of one or more active conductors, a second connection layer 14b provides a row of one or more neutral conductors, and a third connection layer 14c provides one or more ground conductors.

[0310] In some embodiments, one or more standardized connection identifiers may be present on the housing, each corresponding to a sub-circuit connection module. Each of the standardized connection identifiers may have an associated color or other visual identifier. The standardized connection identifiers are configured to convey information about a sub-circuit that is operatively connected to each sub-circuit module 18. The standardized connection identifiers correspond to a sub-circuit diagram of the distribution panel. In some embodiments, the standardized connection identifiers facilitate easy installation of the sub-circuit to the distribution panel.

[0311] In one embodiment, the housing is formed from a pre-made plastic mold. In another embodiment, the housing is operable to open and close, thereby allowing access to one or more pre-configured sub-circuit connection modules.

[0312] Turning Figure 12 As in 15, another implementation or example will now be described. Figure 12 An isometric view of a portion of a circuit protection module 100 connected to busbars 160 and 162 of a distribution panel is shown. The terms circuit protection module and sub-circuit protection module are used interchangeably in this document. Module 100 is electrically and physically connected to the busbar via pins 161 connected to the busbar. Pins 161 extend through pre-drilled holes in a PCB or similar non-conductive substrate 330 on which module electronics are mounted. In some embodiments, module 100 is fully pre-wired by being electrically connected to the busbar as part of an assembly unit. In other embodiments, module 100 is removable and replaceable, and / or can be connected to the distribution panel individually or in groups. For clarity, Figure 12 Only a portion of one module is shown in the image.

[0313] Figure 12 Module 100, when fully assembled, includes, for example, the above-mentioned, such as Figure 9 The functionality described in the example. In Figure 12In the simplified example shown, the ON / OFF and test buttons, as well as visual indicators, have been removed for clarity. Phase conductor 166 and neutral conductor 168 are connected via relays 179 and 306 from distribution panel busbars 160 and 162 to terminal block 332 (…). Figure 13 The sub-circuit termination module (shown) provides power, and associated sub-circuit circuits are electrically connected to this termination module. In some embodiments, the termination module includes a conductive area at the end of the module chassis or mounting plate 330. These allow the module to be electrically connected to a terminal block, such as block 332, which may be pre-connected to a distribution panel. In other embodiments, module 100 is provided such that terminal block 332 is already connected to the rest of the module, allowing the module including the terminal block to be attached to a distribution panel as an assembly unit.

[0314] Relays 179 and 306 are conveniently separated, leaving space in the middle of the module for mounting a microcontroller and other sensor circuitry. However, those skilled in the art will understand that other arrangements can be implemented. In some embodiments, coil 164 may be provided to allow sensing functionality, such as providing a fluxgate or current sensor.

[0315] Turning Figure 13 , showed Figure 12 An exploded isometric view of module 100 is shown, but the upper wall 340 of the module housing is also shown in this view. This arrangement and configuration causes wall 340 to extend from a terminal block 336 at one end to an angled wall portion 342 at the other end, defining a valley or recess 338 therebetween. Recess 338 provides a portion of a cable tray formed when multiple modules 100 are arranged adjacent to each other, as will be described further below.

[0316] Wall 342 extends to upper wall portion 344, which includes an opening or interface portion 348 for ON / OFF button 346, an RCD (residual current detector) test button 347, a display 345, and a status indicator 349 for viewing the visual status representing the status of relay 179.

[0317] refer to Figure 13A For clarity, another embodiment of module 100 is shown with the upper component removed. In this embodiment, region 384 of mounting plate 330 is provided for mounting or clamping the module into a terminal block such as block 332. It will be seen that larger (e.g., elongated) terminal blocks with terminations or terminal connectors for multiple modules can be provided. Therefore, as... Figure 13A The multiple modules 100 shown can be inserted into a single terminal block, or otherwise electrically connected to a single terminal block.

[0318] Figure 13AExample of functional components located below wall portion 344 is also shown. An RCD test button 326 and an ON / OFF button 332 are shown. In use, areas 346 and 347 may include flexible portions of wall 344 that allow the user to press the wall portion to activate buttons 332 and 326. Display 324 is visible through window 345 in wall 344. The visible state of relay 179 is provided by a movable indicator 386, which in this example slides to indicate the state between ON and OFF positions. Indicator 386 is connected to arm 388, which in turn is connected to shaft 390, which is angularly arranged depending on whether relay 179 is open or closed.

[0319] Figure 13B Describing as Figure 13A The example shown is of module 100, but in which walls 340, 342 and 344 and terminal block 332 are in place.

[0320] Figure 14 Multiple adjacent modules 100 are shown. The combined action of the recesses 338 in the walls of each module forms a cable tray 350.

[0321] Figure 14A Another multiple arrangement of module 100 is shown, wherein each module is substantially as follows: Figure 13A As shown. Similarly, Figure 14B Examples of multiple modules are shown, where each module 100 is essentially as follows: Figure 13B As shown. Figure 14C It shows Figure 14A The rear isometric view of the arrangement of the modules shown.

[0322] Figure 15 An example or implementation of a termination block is shown, having multiple sub-circuit termination devices for cables connected to sub-circuits. Block 332 includes termination openings 334 configured to receive exposed conductors of the phase, neutral, and ground wires. Openings 336 allow access to locking mechanisms such as screw heads 337, which are operable to move electrically coupled elements, such as conductors 335 of the termination block, to make physical and electrical contact with the wires present in the openings 334.

[0323] Other terminations or terminal blocks can be provided. Figures 16A to 16C Another example or implementation is shown, wherein, according to the above regarding Figures 12 to 15The description provides module 100; however, the termination block is in the form of a spring clip or lever clip. Lever 352 rotates about axis 354 to clamp onto a line provided in opening 334 by cam or spring action. The module has connection structures 390 and 392, which in this example are provided at each end of the module. Region 390 has protrusions 394 that can mechanically engage with complementary recesses provided on the distribution panel. Region 392 has recesses 396, each recess 396 including one or more conductive portions. These are configured to receive and electrically connect to busbars.

[0324] As mentioned above, these modules can be installed side-by-side, adjacent to each other. This is in Figure 17 The example is shown. Reference Figure 17 There are two rows of modules 100. Each row has modules connected side-by-side to each other. The two rows of modules are arranged back-to-back. Therefore, busbars 160, 162 can extend centrally below the two rows, with each row electrically connected to the busbar. In some embodiments, the modules 100 are pre-wired. In some embodiments, they can be arranged as follows: Figure 17 The diagram shows the removal of individual modules, allowing them to be maintained or replaced as needed. As you will see, Figure 17 The arrangement of the modules shown allows cable tray 350 to be provided by or associated with each row of modules. Multiple rows of modules provide a row of termination connectors or electrical coupling elements parallel to the cable tray or each cable tray. As will be seen, a row of termination connectors can be provided by long termination blocks, such as the termination blocks described above with reference numeral 12, and module 100 can be pre-connected or inserted into the termination block at one end and pre-connected or inserted into the busbar at the other end. Furthermore, as is apparent from the figures described below, for example, terminal connectors or electrical coupling elements such as 335 are grouped according to sub-circuit connectors. In other words, each sub-circuit cable (which will include at least two and typically three insulated conductors) can be completely terminated using adjacent coupling elements 335. Thus, the phase conductor and neutral conductor, or the phase wire, neutral wire, and conductor as part of each sub-circuit cable, can be conveniently terminated. This means that the electrician or personnel connecting the sub-circuit cables can cut the cable to the required length and make the determination without having to change the conductor length according to different installation paths. This can save a significant amount of time and streamline the process. Furthermore, since each circuit protection device or module is configurable, all sub-circuit terminations can be performed, and each module can then be appropriately configured based on the load (or power supply) requirements of the sub-circuit.

[0325] Turn now Figure 18The illustration depicts an implementation or example in which two rows of modules 100 are arranged within a distribution panel housing 240. For clarity, the housing 240 is shown without a cover. Covers, doors, or similar closures may be provided as separate components. In use, the housing 240 is, or forms part of, a power distribution unit cabinet, or a distribution panel enclosure and / or cabinet.

[0326] Unit 368 provides mains connection and isolation module, as well as central power disconnect switch 370. A multi-ground neutral (MEN) link 369 is provided. This is conveniently located in an easily accessible area of ​​the housing (e.g., near or as part of the mains isolation module). The link can be easily removed or installed as needed. A cavity 362 at the base of housing 240 provides space for other components such as controllers, communication interfaces, metering, etc. Cable inlet and outlet channels 360 are provided, having closures 364 that pivot around an end or axis 366 to secure cables and provide a seal around the cables to help physically isolate the contents of the housing from the external environment, as will be further described below.

[0327] Figure 19 A front view of an embodiment or example of a distribution panel including assembly modules is shown. In this figure, the termination block 332 is peripherally disposed or mounted on or adjacent to the side of the housing.

[0328] Figure 20 A front view of an embodiment or example of a distribution panel including assembly modules is shown. In this figure, the termination block 332 is centrally located or mounted at the center of the housing or adjacent to the center of the housing.

[0329] It will be apparent that the distribution panel can be installed vertically or horizontally, meaning that module 100 can be provided in rows extending horizontally or vertically. In some cases, in accordance with regulations and requirements, the distribution panel can be installed horizontally.

[0330] Figure 21 A distribution panel is shown in which cables 400 enter through an opening or channel 360 at one end of housing 240 and extend along cable tray 350 such that the individual wires 404 of each cable terminate at a suitable location in a termination block.

[0331] The cables extend laterally relative to the orientation of each module 100 as they enter the housing; that is, the cable tray 350 extends substantially laterally or vertically relative to the longitudinal axis of each module 100.

[0332] exist Figure 21 For clarity, the closure member 364 is not shown. However, Figure 22The arrangement of the closures is shown in more detail. Each cable entry channel 360 is lined or padded with a suitable elastic material such as closed-cell foam 380. Brushes or similar materials may also be used. Small gaps may exist (e.g., less than 5 mm). Similarly, the inner surface of each closure 364 is lined with a layer 382 of elastic material that is the same as or similar to the elastic material of the lining 380. During cable installation, the closures 364 are open, as... Figure 22 As shown on the left. Once the cable 400 has been installed, the closure 364 rotates about the pivot end or axis 366 to close them, as shown on the right. Closing the closure 364 has the effect of securely clamping the cable between the layers 380 and 382 of the elastic material, thus securing the cable and providing a seal around the cable to help physically isolate the contents of the housing from the external environment. In some examples, the material forming layers 380 and 382 is a flame-retardant material. It will be understood that the closing door of the housing 240 can provide the closing closure 364. In other words, the door of the housing can support layer 382.

[0333] 3.2 Distribution panel and installation

[0334] The sub-circuit connection system 10 is configured to form components of a residential distribution panel or power distribution and management system. In an embodiment, the sub-circuit connection system 10 is further configured to be housed in a power distribution unit cabinet, or a distribution panel enclosure and / or cabinet. Figure 23 The diagram shows a sub-circuit board 10 (e.g.) Figure 10 and Figure 11 Example of the use and installation of the distribution panel (shown).

[0335] The sub-circuit connection system 10 is configured to allow easy electrical installation or wiring of the wire 404 terminal ends from the sub-circuit to a residential distribution panel or power distribution and management system. The spaced-apart connection layers 14a, 14b, 14c of the housing 12 are designed to facilitate the installation of one or more sub-circuits, wherein the coupling elements or termination points of the conductors in each sub-circuit cable are grouped together, i.e., positioned adjacent to each other, so that the cable can be easily cut to length and terminated without employing any complex cable routing.

[0336] A method of connecting one or more external subcircuits to a subcircuit connection system 10 includes connecting the wire terminal ends of one or more subcircuit conductors to each of a plurality of subcircuit conductor terminations 16a, 16b, 16c using corresponding electrical coupling elements. One or more external subcircuits installed as part of this method may include or have any or more of the features mentioned for the foregoing embodiments of the present invention.

[0337] A method for installing a subcircuit connection system 10 in a residential distribution panel or power management system is also provided, the method comprising the steps of: connecting the wire terminal ends of one or more subcircuit conductors to each of a plurality of subcircuit conductor terminations 16a, 16b, 16c using corresponding electrical coupling elements; and connecting each subcircuit input termination 16a, 16b, 16c to power distribution buses 20b, 20c and / or grounding connection 20a.

[0338] Now for reference Figures 23A to 23D The installation according to one embodiment is illustrated graphically. From Figure 23A Initially, as shown in the figure, the pre-assembled distribution panel according to an embodiment of the invention has a housing 240 and multiple circuit protection devices such as module 100, each module terminating in a termination block 332 having multiple coupling elements 334, 336, thus providing coupling elements grouped by sub-circuit. Cable channels or trays 350 are also shown. Figure 23A The distribution panel is shown in a form that is essentially available for purchase and ready for installation.

[0339] from Figure 23B Transfer out, Figure 23A The distribution panel is shown with sub-circuit cables 400 introduced into the distribution panel housing, wherein each sub-circuit cable 400 terminates at a coupling element of a corresponding circuit protection device or module. The grouping of coupling elements 334, 336 according to each sub-circuit is clearly shown.

[0340] exist Figure 23C The next step in the installation is shown in the figure, where the cover 239 is placed on top of the housing 240. The cover 239 has a central hole 439 that allows the user to interact with the circuit protection device, such as displaying a toggle switch to check the device status. The cover 239 provides a protective mounting portion outside the central hole 439, which protects the user from contact with the connecting blocks or connecting coupling elements 334, 336. The cover 239 also provides optional ventilation holes 436.

[0341] exist Figure 23D In the middle, the installation is complete, in which the housing closure for 440 (which can be pivotally connected to the rest of the housing) is in place and closed.

[0342] The housing 240 can be flush-mounted or surface-mounted in or on a suitable structure, such as an inner or outer wall. Surface mounting can be achieved using fasteners that pass through holes in the housing or mounting lugs. (See reference) Figure 24The housing 240 may include a mounting member 410, which may facilitate flush mounting, either as part of a component or as a separate component. The member 410 has a sidewall 412 for engaging with the sidewall of the housing 240, and a flange member 414. In use, the flange member 414 may rest against an object such as a wall frame member (e.g., a timber or post) to allow the housing 240 to be positioned at the desired distance from the wall, and thus achieve flush mounting.

[0343] Figure 25 and Figure 26 An example of the installation setup is shown below. Figure 25 The housing is vertically mounted between two wall posts 416. The device can also be mounted horizontally if the wall posts are adjusted. Cables 420 and 422 have plugs 424 and 426, allowing connection to external components such as batteries or other interfaces.

[0344] Figure 26 A schematic cross-section of an example distribution panel according to an embodiment is shown, wherein a heat sink 302 is shown located between module 100 and the rear surface or wall 241 of housing 240. A front closure 239 for housing is also shown. The heat sink 302 may be provided as a set or a row, and in some embodiments may be connected together or provided as a single item connected to multiple modules. In some embodiments, the heat sink 302 is physically connected to each other or to the housing, and in other embodiments, the connection may be purely thermal. Furthermore, in some embodiments, the heat sink 302 may be thermally coupled to the wall 241 of the housing. In other embodiments, the heat sink 302 may be thermally coupled to other portions of housing 240. By thermally bonding the heat sink 302 to housing 240, heat from the solid-state switch 360 can be easily transferred to an object with a larger thermal mass and / or to two objects that allow for easy heat dissipation.

[0345] In some implementations, housing 240 can be thermally coupled to other suitable heat sinks. Figure 26 In the example shown, thermal management of the component can be achieved by providing a region within the housing 240 where thermal management can be circulated. Therefore, refer to... Figure 26Regions 430 and 432 can be provided within the housing to allow air circulation through multiple radiators or radiator 302. Additionally, a gap 434 can be provided to allow air from other components of the housing to circulate through radiator 302 to the rear of the housing. Furthermore, a ventilation gap 436 can be provided within the housing 240, located between the housing sidewall and the closure 232. Gap 436 allows air to circulate into and out of the housing from an external location, thereby providing thermal management. Possible airflow paths through radiator 302 are shown by arrow 438. It will be apparent that gaps 434 and 436 can be provided at other locations within the assembly. Furthermore, in some embodiments, active airflow circulation can be employed using any moving device, such as a fan, placed within the housing 240.

[0346] 4. Other exemplary implementation methods

[0347] Referring to previous embodiments of the present invention, a pre-configured or pre-wired distribution panel or residential power distribution and management system has been described. The pre-wired distribution panel includes: a sub-circuit connection system 10, as mentioned in Section 3 of the specification above; a grid connection module configured to electrically connect the system to an external grid power source; a mains isolation module electrically connected to the grid connection module via pre-configured or pre-wired electrical connectors and configured to provide electrical isolation from the external grid power source; and one or more auxiliary power modules, each electrically connected to the mains power source via pre-configured or pre-wired electrical connectors. The system includes an isolation module, and each auxiliary power module is configured to electrically connect the system to an external or auxiliary power source; one or more sub-circuit protection modules, which are electrically connected to the mains isolation module and one or more auxiliary power modules via pre-configured or pre-wired electrical connections; and one or more sub-circuit protection modules, which are electrically connected to the mains isolation module and one or more auxiliary power modules via pre-configured electrical connections, each sub-circuit protection module being electrically connected to a sub-circuit connection module of the sub-circuit connection system via a pre-configured electrical connection.

[0348] The pre-configured or pre-wired distribution panel or residential power distribution and management system mentioned above may include or have any or more of the features of the pre-configured or pre-wired distribution panel or residential power distribution and management system 200 discussed above. For example, the grid connection module, mains isolation module, one or more auxiliary power modules, one or more sub-circuit connection modules and / or one or more sub-circuit protection modules mentioned above may each include or have any or more of the features mentioned in the circuit protection system of the circuit protection module of the present invention discussed above.

[0349] Furthermore, implementations can be carried out using hardware, software, firmware, middleware, microcode, or any combination thereof. When implemented in software, firmware, middleware, or microcode, program code or code segments that perform the necessary tasks can be stored in a machine-readable medium such as a storage medium or (one or more) other memory. The processor can perform the necessary tasks. Code segments can represent procedures, functions, subroutines, programs, routines, subroutines, modules, software packages, classes, or any combination of instructions, data structures, or program statements. Code segments can be coupled to another code segment or hardware circuitry by passing and / or receiving information, data, arguments, parameters, or memory contents. Information, arguments, parameters, data, etc., can be passed, forwarded, or transmitted via any suitable means, including memory sharing, messaging, token passing, network transmission, etc.

[0350] In the foregoing, storage medium can refer to one or more devices for storing data, including read-only memory (ROM), random access memory (RAM), disk storage media, optical storage media, flash memory devices, and / or other machine-readable media for storing information. The terms "machine-readable media" and "computer-readable media" include, but are not limited to, portable or fixed storage devices, optical storage devices, and / or various other media capable of storing, containing, or carrying (one or more) instructions and / or data.

[0351] The various illustrative logic blocks, modules, circuits, elements, and / or components described with reference to the examples disclosed herein may be implemented or executed using a general-purpose processor, digital signal processor (DSP), application-specific integrated circuit (ASIC), field-programmable gate array (FPGA) or other programmable logic component, discrete gate or transistor logic, discrete hardware component, or any combination thereof, designated to perform the functions described herein. The general-purpose processor may be a microprocessor, but in alternative embodiments, the processor may be any conventional processor, controller, microcontroller, circuit, and / or state machine. The processor may also be implemented as a combination of computing components, such as a combination of a DSP and a microprocessor, multiple microprocessors, one or more microprocessors combined with a DSP chip, or any other such configuration.

[0352] The methods or algorithms described in conjunction with the examples disclosed herein can be embodied directly in hardware, in processor-executable software modules, or a combination of both, as processing units, program instructions, or other uses, and can be contained in a single device or distributed across multiple devices. Software modules can reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disks, removable disks, CD-ROMs, or any other form of storage medium known in the art. The storage medium can be coupled to the processor, enabling the processor to read information from and write information to the storage medium. Alternatively, the storage medium can be integrated into the processor.

[0353] Without departing from the invention, one or more components and functions shown in the figures may be rearranged and / or combined into a single component or embodied in several components. Additional elements or components may also be added without departing from the invention. Additionally, the features described herein may be implemented as a commercial method in software, hardware, and / or combinations thereof.

[0354] In its various aspects, the invention can be embodied in computer-implemented processes, machines (such as electronic devices, or general-purpose computers, or other means providing a platform on which computer programs can be executed), processes performed by such machines or articles manufactured. Such articles may include computer program products or digital information products, wherein computer-readable storage media contain computer program instructions or computer-readable data stored thereon, and processes and machines for creating and using such manufactured articles.

[0355] The foregoing description of the present invention includes its preferred form. Modifications may be made thereto without departing from the scope of the invention.

Claims

1. A pre-assembled distribution panel for connecting to a plurality of sub-circuit cables, each sub-circuit cable including a plurality of insulated conductors, the pre-assembled distribution panel comprising: A housing having multiple busbars and cable inlets for multiple sub-circuit cables; One or more sub-circuit termination blocks, one or more of the sub-circuit termination blocks having a plurality of conductor coupling elements configured to be connected to a plurality of insulated conductors of the plurality of sub-circuit cables, wherein the plurality of conductor coupling elements are grouped by sub-circuit, and wherein the insulated conductors for each sub-circuit cable are configured to terminate adjacent to each other; Multiple circuit protection devices are electrically connected between the busbar and one or more of the sub-circuit termination blocks, and each circuit protection device is electrically connected to a corresponding conductor coupling element group. in: The housing includes a cable channel extending between a cable inlet and one or more of the sub-circuit termination blocks, and The cable channel extends adjacent to multiple sets of conductor coupling elements corresponding to the multiple circuit protection devices.

2. The pre-assembled distribution panel as described in claim 1, wherein, Each of the circuit protection devices includes a module that can be selectively removed from the housing.

3. The pre-assembled distribution panel as described in claim 1 or 2, wherein, The pre-assembled distribution panel includes multiple sub-circuit termination blocks.

4. The pre-assembled distribution panel as described in claim 3, wherein, Each circuit protection device includes a corresponding sub-circuit termination block.

5. The pre-assembled distribution panel as described in claim 1, wherein, The sub-circuit termination block for each circuit protection device provides a conductor coupling element group for terminating the conductor of the corresponding sub-circuit cable.

6. The pre-assembled distribution panel as described in claim 1, wherein, The conductor coupling elements are arranged in one or more rows.

7. The pre-assembled distribution panel as described in claim 1, wherein, A row of conductor coupling elements is disposed on the side of the housing, or a row of conductor coupling elements is disposed on each of the two opposite sides of the housing.

8. The pre-assembled distribution panel as described in claim 1, wherein, Each circuit protection device includes a wall, and the wall includes a portion of the cable channel.

9. The pre-assembled distribution panel as described in claim 8, wherein, Multiple circuit protection devices extend adjacent to each other to form a cable receiving channel.

10. The pre-assembled distribution panel as claimed in claim 1, wherein, The longitudinal axis of each circuit protection device is oriented substantially laterally relative to the longitudinal axis of the cable channel.

11. The pre-assembled distribution panel as claimed in claim 1, wherein, Each circuit protection device includes a button or switch that can be operated by a user, wherein the cable channel is disposed between the button or switch and a corresponding set of conductor coupling elements.

12. The pre-assembled distribution panel as claimed in claim 1, wherein, The cable channel is disposed between at least one of the busbars and one or more of the sub-circuit termination blocks.

13. The pre-assembled distribution panel as described in claim 1, wherein, The cable channel includes cable trays.

14. The pre-assembled distribution panel as claimed in claim 1, wherein, Each circuit protection device includes: A first termination for connecting to one of the busbars and a second termination for connecting to a corresponding sub-circuit termination block in the sub-circuit termination blocks; and A disconnection device configured to electrically isolate the first termination from the second termination upon receiving a disconnection signal.

15. The pre-assembled distribution panel as described in claim 14, wherein, Each circuit protection device also includes an outer wall defining a portion of the cable channel, and the first termination and the second termination are disposed on either side of the cable channel.

16. The pre-assembled distribution panel of claim 14, further comprising a user-operated button or switch operable to actuate the disconnecting device, and wherein, The cable channel is positioned between two components, one of which is the second termination and the other of which is the button or switch.

17. The pre-assembled distribution panel as described in claim 14, wherein, Each circuit protection device also includes a load monitoring device electrically connected to a sub-circuit termination block associated with the circuit protection device, and the load monitoring device is operable to determine one or more characteristics or attributes of one or more circuits connected to the load monitoring device.

18. The pre-assembled distribution panel of claim 17, further comprising a controller configured to: Receive the one or more characteristics or attributes of the one or more circuits determined by the load monitoring device of one or more of the circuit protection devices; Based on the analysis of the one or more characteristics or properties of the one or more circuits, it is determined whether one or more fault conditions exist in the one or more circuits; as well as Based on the determination of one or more fault conditions, a control signal is sent to actuate the disconnection device, thereby electrically isolating the first termination from the second termination.

19. The pre-assembled distribution panel as claimed in claim 1, wherein, The groups of conductor coupling elements used for each sub-circuit cable include phase coupling elements and neutral coupling elements.

20. The pre-assembled distribution panel as claimed in claim 1, wherein, The groups of conductor coupling elements used for each sub-circuit cable include phase coupling elements, neutral coupling elements, and ground coupling elements.

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