Electric leakage overload protector control system and control method thereof
Through the leakage overload protector control system, the load resistance is detected by using unbalanced bridges and zero-sequence transformers, and combined with the MOS tube current limiting device, the rapid response leakage and short-circuit protection is achieved, which solves the problem of slow response of traditional electrical protection devices and improves the safety and intelligence of the electrical system.
Patent Information
- Application Number
- CN202510683500.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-05-26
- Publication Date
- 2025-07-25
AI Technical Summary
Traditional electrical protection devices have slow response speed and cannot cut off the circuit in time, resulting in equipment damage and safety accidents, and require manual replacement of fuses, which cannot achieve automatic recovery.
The leakage overload protector control system is adopted, and the load resistance and insulation resistance are detected through an unbalanced bridge. Combined with the zero-sequence transformer and MOS tube current limiting device, it realizes fast-responsive leakage and short-circuit protection, and supports manual and remote control.
It realizes rapid response leakage and short circuit protection, avoids equipment damage and safety accidents, supports remote control, and improves the safety and intelligence of the electrical system.
Smart Images
Figure CN120377183A_ABST
Abstract
Description
Technical Field
[0001] The present invention belongs to the technical field of switches, and specifically relates to a leakage and overload protector control system and its control method. Background Art
[0002] In modern electrical systems, the safe operation of electrical equipment is crucial. Especially in industrial, commercial, and household environments, various faults may occur during the operation of electrical systems, such as short circuits, overloads, and leakage. These faults not only can cause equipment damage but also may trigger safety accidents such as fires and electric shocks, seriously threatening personal and property safety. Traditional electrical protection devices mainly rely on components such as fuses and overload relays to achieve short - circuit and overload protection.
[0003] In traditional electrical protection devices, the fuse needs to be replaced after fusing, unable to achieve automatic recovery, and its response speed is slow, unable to cut off the circuit in time to protect the equipment. Therefore, a leakage and overload protector control system and its control method are proposed to solve the above - mentioned problems. Summary of the Invention
[0004] The purpose of the present invention is to address the deficiencies of the prior art by providing a leakage and overload protector control system and its control method, thereby solving the technical problems raised in the background art.
[0005] For the above - mentioned technical problems, the following technical solutions are adopted: A leakage and overload protector control system and its control method include the following steps; Step 1: Push the switch, and the switch - pushing includes a manual switch - pushing mode and a remote switch - pushing mode; Step 2: Weak - current detection is performed on the output part through an unbalanced bridge. If the test is normal, the relay switches the output to the input to connect the input and output to the display screen, and the indicator light shows normal operation. Moreover, the status data is sent to the server through the wireless communication module, enabling the mobile terminal or cloud platform to view the operating status of the device; Step 3: During operation, the zero - sequence current transformer continuously detects the output neutral line and live wire; when leakage occurs during operation, the zero - sequence current transformer feeds back to the microcontroller; after receiving the leakage signal, the microcontroller controls the relay to switch the output end to the pre - power - on detection end, disconnecting the output end from the input end; Step 4: During operation, when a short - circuit suddenly occurs at the load end, the MOS - tube current - limiting device immediately reduces the output voltage at the output end, keeping the load end at the set maximum current, and transmitting the short - circuit information to the microcontroller; at this time, the microcontroller immediately controls the relay to switch the output end to the pre - power - on detection end, disconnecting the output end from the input end; Step Five: When in operation, after a high-power electrical appliance is removed due to a trip caused by over-power, it can be remotely restarted and switched on through the mobile terminal or the cloud platform. Before remotely starting to switch on, Steps Two to Four should be repeated to perform the detection before switching on, and the detection results should be sent to the mobile terminal and the cloud platform.
[0006] Preferably, the manual switch-on mode is as follows: After correct connection and normal power supply at the input end, the power supply module operates, and the microcontroller, communication module, indicator light, and display screen are powered on preferentially. And the detection relay connects the output end to the pre-power-on detection end, that is, the weak-current part. At this time, press the switch-on button manually.
[0007] Preferably, the remote switch-on mode is as follows: After correct connection and normal power supply at the input end in the same way as the manual switch-on mode, the power supply module operates, and the microcontroller, communication module, indicator light, and display screen are powered on preferentially. And the detection relay connects the output end to the pre-power-on detection end, that is, the weak-current part. At this time, switch on through the mobile terminal or the cloud platform.
[0008] Preferably, in Step Three, if the currents of the live wire and the neutral wire are inconsistent, it indicates that there is a leakage situation at the load end, with an accuracy of 10 mA. That is, if the leakage current is greater than 10 mA, it is judged as a leakage.
[0009] Preferably, Step Three further includes that the microcontroller controls the indicator light and the display screen to show the output leakage state, and the microcontroller sends the state to the server through the wireless communication module, so that the mobile terminal or the cloud platform controls the display screen to show the working state of this device.
[0010] Preferably, in Step Four, the microcontroller controls the indicator light and the display screen to show the output over-power state, and the microcontroller sends the state to the server through the wireless communication module, and the mobile terminal or the cloud platform controls the display screen to show the working state of this device.
[0011] Preferably, in Step Two, the weak-current detection of the output part by the unbalanced bridge is specifically as follows: Before power-on, measure the resistance value between the load end and the live wire and neutral wire and the insulation resistance value of the live wire and neutral wire to the ground, and then calculate whether the load power is within the rated range of the normal load power.
[0012] Preferably, a leakage and overload protector control system, the control system includes: A power supply module, the power supply module is DC12V, and is used to supply power for the operation of this system; A microcontroller module, the microcontroller module includes software operation algorithms, and is used to judge whether the circuit is leaking and short-circuited; A wireless communication module, the wireless communication module is used to realize the data transmission of this device, so that the mobile terminal and the cloud platform can grasp the operation state of this system in real time; A display module, which includes an indicator light and a display screen, and is used to indicate and display the operating status of the system; A zero-sequence current transformer, which is used to feedback the leakage or grounding fault signal of the operating circuit to the microcontroller module; A MOS transistor current limiting device, which is used to immediately reduce the output voltage and keep the maximum current set at the load end when a sudden short circuit occurs at the load end during normal circuit operation; A relay.
[0013] Preferably, the software operation algorithm includes sampling the resistance between the live wire and the neutral wire at the load end, the resistance between the neutral wire and the ground, and the resistance between the live wire and the ground, calculating the resistive power and leakage current of the output load based on these resistance values, then judging whether there is over-power or short circuit according to the resistive load, and judging whether there is leakage according to the resistance between the live wire and the neutral wire and the ground.
[0014] Advantages of the present invention: Before power-on, detect the problems of short circuit, over-power and leakage at the load end through weak electricity, effectively avoid the occurrence of wire burning and electric shock caused by forced power-on when there are problems such as short circuit and leakage at the load, and can realize remote start without manual on-site switch pushing; It can detect the resistance between the live wire and the neutral wire at the load end and the insulation between the live wire and the neutral wire and the ground before power-on, and perform real-time monitoring on the output after power-on. When short circuit, leakage and other situations occur, the output can be cut off within a few microseconds to achieve fast response and protect the safety of equipment and personnel. BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for description in the embodiments will be briefly introduced below. Obviously, the following described drawings are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.
[0016] In the drawings: Figure 1 is the circuit control diagram of the present invention. DETAILED DESCRIPTION OF THE INVENTION
[0017] The following describes exemplary embodiments of the present disclosure, including various details to assist in understanding, which should be considered merely exemplary. Therefore, those of ordinary skill in the art should recognize that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of the present disclosure. Similarly, for the sake of clarity and conciseness, descriptions of well-known functions and structures are omitted below.
[0018] Specific embodiments are given below.
[0019] Embodiment Please refer to Figure 1 , the present invention provides a leakage and overload protector control system and its control method. The control method includes the following steps; Step 1, Push the switch. Pushing the switch includes a manual switch-pushing mode and a remote switch-pushing mode; Step 2, Perform weak-current detection on the output part through an unbalanced bridge to measure the resistance value between the live wire and the neutral wire and the insulation resistance value of the live wire and the neutral wire to the ground at the load end before power-on, and then calculate the load power situation. If the test is normal and the load power is within the rated range, the relay turns the output to the input to connect the input and output, the display screen shows normal operation, and the status data is sent to the server through the wireless communication module, so that the mobile terminal or the cloud platform can view the operation status of the device; Step 3, During operation, the zero-sequence current transformer continuously detects the output neutral wire and live wire; when leakage occurs during operation, the zero-sequence current transformer feeds back to the microcontroller; after receiving the leakage signal, the microcontroller controls the relay to turn the output end to the detection end before power-on, so that the output end is disconnected from the input end; By continuously detecting the output neutral wire and live wire through the zero-sequence current transformer, the leakage situation during operation can be captured in real time, and the leakage signal is promptly fed back to the microcontroller to achieve a fast response to leakage; after receiving the signal, the microcontroller controls the relay to act, switches the output end to the detection end before power-on, and quickly disconnects the output end from the input end, which can effectively avoid safety hazards such as electric shock accidents and electrical fires caused by leakage, ensure the safety of personnel and the normal operation of equipment. At the same time, this mechanism has an automatic power-off protection function, improving the safety, reliability and intelligence of the power consumption system, reducing the risk of electrical faults and potential losses; Step 4, During the operation process, when a short circuit suddenly occurs at the load end, the MOS tube current-limiting device immediately reduces the output voltage at the load end to keep the maximum current set at the load end, and transmits the short-circuit information to the microcontroller; at this time, the microcontroller immediately controls the relay to turn the output end to the detection end before power-on, so that the output end is disconnected from the input end; When a short circuit occurs at the load end, the MOS tube current-limiting device can instantly reduce the output voltage at the load end, limit the load current to the set maximum value, avoid serious consequences such as overheating of the line and equipment burnout caused by excessive current due to short circuit, and play an effective overcurrent protection role; at the same time, the short-circuit information is promptly transmitted to the microcontroller, and the microcontroller quickly controls the relay to act to disconnect the output end from the input end to achieve fault isolation, prevent the short-circuit fault from further expanding, ensure the safe and stable operation of the entire electrical system, and the whole set of processes has a fast response and a high degree of automation, which can effectively reduce equipment damage and safety risks caused by short-circuit faults, reduce maintenance costs and potential economic losses; Step 5: When in operation, after a high-power trip, remove high-power electrical appliances, and the switch can be remotely restarted and closed through the mobile terminal or the cloud platform. Before remotely starting the closing, repeat Steps 2 to 4 to perform the detection before closing and send the detection results to the mobile terminal and the cloud platform.
[0020] Further, as Figure 1 shown, the manual switch-on mode is as follows: After correct connection and normal power supply at the input end, the power supply module works, and the microcontroller, communication module, indicator light, and display screen are powered on first. And the detection relay connects the output end to the detection end before power-on, that is, the weak-current part. At this time, press the switch-on button manually.
[0021] Further, as Figure 1 shown, the remote switch-on mode is as follows: After correct connection and normal power supply at the input end, which is the same as the manual switch-on mode, the power supply module works, and the microcontroller, communication module, indicator light, and display screen are powered on first. And the detection relay connects the output end to the detection end before power-on, that is, the weak-current part. At this time, switch on through the mobile terminal or the cloud platform.
[0022] Further, as Figure 1 shown, in Step 3, if the currents of the zero line and the live line are inconsistent, it indicates that there is a leakage situation at the load end. The accuracy is 10 mA, that is, when the leakage current is greater than 10 mA, it is judged as leakage.
[0023] Further, as Figure 1 shown, Step 3 also includes that the microcontroller controls the indicator light and the display screen to display the output leakage state, and the microcontroller sends the state to the server through the wireless communication module, so that the mobile terminal or the cloud platform controls the display screen to display the working state of this device.
[0024] Further, as Figure 1 shown, in Step 4, the microcontroller controls the indicator light and the display screen to display the output over-power state, and the microcontroller sends the state to the server through the wireless communication module. The mobile terminal or the cloud platform controls the display screen to display the working state of this device.
[0025] Further, as Figure 1 shown, in Step 2, the specific weak-current detection of the output part by the unbalanced bridge is as follows: Before power-on, measure the resistance value between the load end and the zero and live lines and the insulation resistance value of the zero and live lines to the ground, and then calculate whether the load power is within the rated range of the normal load power.
[0026] Further, as Figure 1 shown, a leakage and overload protector control system includes: A power supply module, the power supply module is DC12V and is used to supply power for the operation of this system; The microcontroller module, which includes a software operation algorithm for determining whether there is a leakage or short circuit in the circuit; The wireless communication module, which is used to realize the data transmission of this device, so that the mobile terminal and the cloud platform can grasp the operation status of this system in real time; The display module, which includes an indicator light and a display screen, and is used to indicate and display the operation status of this system; The zero-sequence current transformer, which is used to feedback the leakage or grounding fault signal of the operating circuit to the microcontroller module; The MOS transistor current limiting device, which is used to immediately reduce the output voltage when a sudden short circuit occurs at the load end during the normal operation of the circuit, so that the load end maintains the set maximum current; The relay, which is used for the input, output and detection jump of this system in the circuit. The relay is an electrical control device that plays the role of automatic regulation, safety protection and circuit conversion in the circuit.
[0027] Further, as Figure 1 shown, the software operation algorithm includes sampling the resistance between the zero wire and the live wire at the load end, the resistance between the zero wire and the ground, and the resistance between the live wire and the ground, calculating the resistive power and leakage current of the output load based on these resistance values, and then judging whether there is over-power or short circuit according to the resistive load, and judging whether there is leakage according to the resistance between the zero wire and the ground and the resistance between the live wire and the ground; In this embodiment, the core of the software operation algorithm is to realize the calculation of relevant electrical parameters and fault judgment by sampling the resistance at different positions of the load end: first, sample the resistance between the zero wire and the live wire at the load end, the resistance between the zero wire and the ground, and the resistance between the live wire and the ground, and then calculate the resistive power and leakage current of the output load based on these sampled resistance values. The resistive power can be calculated by relevant electrical formulas (such as the relationship between power, resistance and voltage), and the leakage current is related to factors such as the difference in the resistance between the zero wire and the ground and the resistance between the live wire and the ground; then, according to the calculated resistive load situation, compare it with the set power threshold and short circuit judgment condition to judge whether there is over-power or short circuit. If the resistive load exceeds the rated power, it is over-power. If the resistance value is extremely small and approaches zero, it may be judged as a short circuit; at the same time, according to the value and change of the resistance between the zero wire and the ground and the resistance between the live wire and the ground, judge whether there is leakage. When the resistance between the zero wire and the ground shows an abnormal decrease or the difference between the two exceeds the safe range, it can be considered that there is a leakage situation, so as to realize the monitoring of the operation status of the electrical load and the fault warning; Assume that the voltage at the load end is 220V. The measured resistance between the live wire and the neutral wire is 50Ω, the resistance between the neutral wire and the ground is 200Ω, and the resistance between the live wire and the ground is 2000Ω. The resistive power is calculated to be 968W (220² / 50) using the formula P = U² / R. Since the resistance between the neutral wire and the ground is much lower than that between the live wire and the ground, the leakage current can be estimated to be about 1.1A (220V / 200Ω). If the system sets the power threshold to 1000W and the short - circuit resistance threshold to 10Ω, then currently the power is not exceeded and there is no short - circuit. However, the leakage current far exceeds the safety value, usually 30mA, and the difference in the resistance between the live - wire - to - ground and the neutral - wire - to - ground is significant, so the system will determine that there is a leakage.
[0028] Working principle: Connect this system to the application circuit to ensure that the neutral wire, live wire, and ground wire are correctly connected. When powering on, this system can not only manually push the switch, but also remotely push the switch through the mobile device. Manual switch - pushing mode: After correctly connecting and powering on the input terminal, when the power supply module starts working, the micro - controller, communication module, indicator lights, and display screen are powered on first, and the detection relay connects the output terminal to the pre - power - on detection terminal, that is, the weak - electricity part. Then press the switch - pushing button manually. Remote switch - pushing mode: After correctly connecting and powering on the input terminal in the same way as the manual switch - pushing mode, when the power supply module starts working, the micro - controller, communication module, indicator lights, and display screen are powered on first, and the detection relay connects the output terminal to the pre - power - on detection terminal. Then the switch can be pushed through the remote mobile phone applet. After completing the first step of the work, the device first performs weak - electricity detection on the output part. Specifically, it measures the resistance between the neutral wire - live wire, neutral wire - ground, and live wire - ground respectively. If the test is normal, the relay switches the output to the input to connect the input and output, and the display screen and indicator lights show normal operation. And the status data is sent to the server through the wireless communication module so that the mobile device or cloud platform can view the operating status of the device. After the device runs normally according to the previous steps, the load end is powered on. During operation, the zero - sequence current transformer continuously detects the output neutral wire and live wire. If the currents of the neutral wire and live wire are inconsistent, it indicates that there is a leakage situation at the load end with an accuracy of 10mA, that is, when the leakage current is greater than 10mA, it is judged as leakage. Generally, the fatal current for human body electric shock is greater than 10mA. When leakage occurs during operation, the zero - sequence current transformer feeds back to the micro - controller. After receiving the leakage signal, the micro - controller controls the relay to switch the output terminal to the pre - power - on detection terminal to disconnect the output terminal from the input terminal, that is, trip, and there is no strong electricity at the load end. Then the micro - controller controls the indicator lights and display screen to show the output leakage state, and the micro - controller sends the status to the server through the wireless communication module so that the mobile phone or the background control large screen can display the working state of this device. During normal operation, a short circuit suddenly occurs at the load end. At this time, the MOS transistor current limiting device will immediately reduce the output voltage. The response speed is in the order of microseconds, keeping the maximum current set at the load end so as not to burn the wire and transmitting the short circuit information to the microcontroller. Then, the microcontroller immediately controls the relay to switch the output terminal to the detection terminal before power-on, disconnecting the output terminal from the input terminal, that is, tripping so that there is no high voltage at the load end. Then, the microcontroller controls the indicator light and the display screen to show the output over-power state. A short circuit is also a type of over-power situation. And the microcontroller sends the status to the server through the wireless communication module so that the mobile phone or the background control large screen can display the working state of this device. When tripping due to over-power during operation, such as tripping caused by connecting a high-power electrical appliance to the load end, after removing the high-power electrical appliance, it can be restarted and switched on remotely through the mobile terminal (mobile phone) or the background control panel, etc.
[0029] In the description of the present invention, it should be understood that various forms of processes shown above can be used, reordering, adding or deleting steps. For example, the steps described in this disclosure can be executed in parallel, sequentially or in different orders, as long as the desired results of the technical solutions provided in this disclosure can be achieved. No limitations are imposed herein.
[0030] The above is only the preferred specific implementation manner of the present invention and does not constitute a limitation to the protection scope of this disclosure. Those skilled in the art should understand that various modifications, combinations, sub-combinations and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions and improvements made within the spirit and principle of this disclosure shall be included within the protection scope of this disclosure.
Claims
1. A control method for a leakage and overload protector, characterized in that It includes the following steps; Step 1: Push the switch, and the switch pushing includes a manual switch pushing mode and a remote switch pushing mode; Step 2: Perform weak current detection on the output part through a non-balanced bridge. If the test is normal, the relay switches the output to the input to connect the input and output to the display screen, and the indicator light shows normal operation. And the status data is sent to the server through the wireless communication module, so that the mobile terminal or the cloud platform can view the operating status of the device; Step 3: During operation, the zero-sequence current transformer continuously detects the output neutral line and live wire; when leakage occurs during operation, the zero-sequence current transformer feeds back to the microcontroller; after receiving the leakage signal, the microcontroller controls the relay to switch the output end to the pre-power-on detection end, so that the output end is disconnected from the input end; Step 4: During operation, when a short circuit suddenly occurs at the load end, the MOS tube current limiting device immediately reduces the output voltage at the load end to keep the maximum current set at the load end, and transmits the short circuit information to the microcontroller; at this time, the microcontroller immediately controls the relay to switch the output end to the pre-power-on detection end, so that the output end is disconnected from the input end; Step 5: When, during operation, after a high-power electrical appliance is removed due to over-power tripping, the switch can be remotely restarted and closed through the mobile terminal or the cloud platform. Before remotely starting the switch closing, steps 2 to 4 need to be repeated to achieve the detection before closing, and the detection results are sent to the mobile terminal and the cloud platform.
2. The control method of a leakage and overload protector according to claim 1, characterized in that: The manual switch pushing mode is as follows: after the connection is correct and the input end is powered on normally, the power supply module works, the microcontroller, the communication module, the indicator light and the display screen are powered on preferentially, and the detection relay connects the output end to the pre-power-on detection end, that is, the weak current part. At this time, press the switch pushing button manually.
3. A method for controlling a leakage and overload protector according to claim 1, characterized in that: The remote switch pushing mode is as follows: after the connection is correct and the input end is powered on normally in the same way as the manual switch pushing mode, the power supply module works, the microcontroller, the communication module, the indicator light and the display screen are powered on preferentially, and the detection relay connects the output end to the pre-power-on detection end, that is, the weak current part. At this time, push the switch through the mobile terminal or the cloud platform.
4. A leakage and overload protector control method according to claim 1, characterized in that: In step 3, if the currents of the neutral line and the live wire are inconsistent, it indicates that there is a leakage situation at the load end, and the accuracy is 10 mA, that is, when the leakage current is greater than 10 mA, it is judged as leakage.
5. A leakage and overload protector control method according to claim 1, characterized in that: Step 3 further includes that the microcontroller controls the indicator light and the display screen to display the output leakage state, and the microcontroller sends the state to the server through the wireless communication module, so that the mobile terminal or the cloud platform controls the display screen to display the working state of this device.
6. The control method of a leakage and overload protector according to claim 1, characterized in that: In step 4, the microcontroller controls the indicator light and the display screen to display the output over-power state, and the microcontroller sends the state to the server through the wireless communication module, and the mobile terminal or the cloud platform controls the display screen to display the working state of this device.
7. A method for controlling a leakage and overload protector according to claim 1, characterized in that: In step 2, the weak current detection of the output part by the non-balanced bridge is specifically as follows: before power-on, measure the resistance value between the load end and the zero and live wires and the insulation resistance value of the zero and live wires to the ground, and then calculate whether the load power is within the rated range of the normal load power.
8. A leakage and overload protector control method according to any one of claims 1 to 7 is applied to a leakage and overload protector control system, characterized in that: The control system includes: A power supply module, the power supply module is DC12V and is used to supply power for the operation of this system; A microcontroller module, the microcontroller module includes a software operation algorithm for judging whether the circuit is leaking electricity and short - circuiting; A wireless communication module, the wireless communication module is used to realize the data transmission of this device, so that the mobile terminal and the cloud platform can grasp the operation status of this system in real - time; A display module, the display module includes an indicator light and a display screen, which are used to indicate and display the operation status of this system; A zero - sequence current transformer, the zero - sequence current transformer is used to feedback the leakage or grounding fault signal of the operating circuit to the microcontroller module; A MOS - tube current - limiting device, the MOS - tube current - limiting device is used to immediately reduce the output voltage when a sudden short - circuit occurs at the load end during the normal operation of the circuit, so that the load end maintains a set maximum current; A relay.
9. The leakage and overload protector control system according to claim 8, wherein: The software operation algorithm includes sampling the resistance between the live wire and the neutral wire at the load end, the resistance between the neutral wire and the ground, and the resistance between the live wire and the ground, calculating the resistive power and leakage current of the output load according to these resistance values, then judging whether there is over - power or short - circuit according to the resistive load, and judging whether there is leakage according to the resistances of the live wire and the neutral wire to the ground.