Power distribution assembly

Abstract

A consumer unit (fuse disc) assembly includes: a first housing containing circuitry containing a circuit breaker for distributing power from a main power source to branch circuits, and a second housing containing a circuit breaker for distributing the power from the main power source to the branch circuits; a voltage optimizer is housed within the second enclosure to reduce the voltage of the main power supply before the voltage of the main power supply is distributed to the one or more branch circuits. The first shell comprises an external retreating groove, and the second shell is located in the retreating groove and located behind the first shell.

Description

Background Technology

[0001] In the UK, according to European CE standards, mains electricity is supplied at 230V ± 10% of the rated voltage. In practice, the rated supply voltage in the UK is 242V, while many other EU countries use 220V.

[0002] Since standard testing of electrical equipment is conducted at 230V to 230V, there is evidence that some electrical equipment is inefficient or unsafe at the voltages commonly supplied in the UK.

[0003] Because the continental European market is much larger than the UK market, appliances are primarily designed to operate most efficiently at 220V. Therefore, appliances with an energy efficiency rating of "A" may only achieve this rating in laboratory tests at 220V-230V, and their efficiency will significantly decrease when operating at 242V. Furthermore, operating appliances at voltages higher than their design voltage (overvoltage) will generally shorten their lifespan.

[0004] One solution to these problems is to install a voltage optimization system, often called a voltage optimizer, in the main power supply system. This voltage optimizer is designed to provide a controlled step-down voltage of approximately 220V to electrical equipment powered by the supply system. Some voltage optimizers offer fixed voltage regulation, while others offer dynamic regulation to accommodate variations in the input voltage.

[0005] Employing voltage optimization technology not only provides a solution to the above problems, but also achieves energy savings.

[0006] In the UK, voltage optimizers have been installed in residential homes for this purpose since at least 2004, but their use in commercial settings predates that by much earlier.

[0007] Voltage optimizers used in residential buildings are typically housed in an external enclosure, one or more of which have external dimensions similar to those of a modern consumer unit (fuse box). The voltage optimizer is usually installed where the main power feeder enters the building, and therefore often next to the consumer unit.

[0008] Retrofitting a voltage optimizer to an existing residential power supply often presents problems because there is often little or no available space to install the voltage optimizer unit.

[0009] Furthermore, existing consumer units are often installed above the entrance to the building where the main feeder enters, allowing the feeder to enter the consumer unit through its rear panel. In this case, the consumer unit needs to be relocated, or the feeder needs to be routed from the consumer unit and connected to the voltage optimizer.

[0010] British patent GB2591979 discloses a solution that places the voltage optimizer inside the consumer unit, behind the fuse and / or circuit.

[0011] This invention is a further development of that design. Summary of the Invention

[0012] According to a first aspect of the present invention, a power distribution assembly is provided, comprising: A first housing having an internal cavity for accommodating a circuit system for distributing power from a power source to one or more branch circuits; and A second housing contains a voltage optimizer for reducing the voltage of the power supply before it is distributed to the one or more branch circuits; The first housing is configured to define an outer recess, and the first housing and the second housing are arranged adjacent to each other, with the second housing located within the recess.

[0013] This invention retains some of the space-saving advantages of GB2591979, but achieves better thermal isolation between the voltage optimizer and the circuitry within the first housing due to the side-by-side arrangement of independent housings. The inventors recognized this as crucial because the voltage optimizer's operating temperature typically exceeds the maximum permissible temperature within the consumer unit housing. Another advantage is the ability to mount the two housings separately to a supporting wall as needed. Since the voltage optimizer is significantly heavier than the first housing, this feature allows for easy assembly by a single person. The second housing with the voltage optimizer can be installed first, followed by aligning the first housing against the wall and threading the cables (e.g., through its rear side), and finally securing it in place. However, in some embodiments, the first and second housings can also be directly secured together using one or more fasteners.

[0014] If necessary, the assembly may include a heat insulation layer within the recess, located between the first housing and the second housing, to further reduce heat transfer between the voltage optimizer and the internal cavity of the first housing.

[0015] The first housing may have an openable first side (e.g., a front panel) for easy access to the circuitry within the internal cavity.

[0016] A region of the internal cavity can be located directly between the first side and the portion of the second housing located within the recess. Thus, a portion of the internal cavity of the first housing can extend directly in front of the second housing. This region can be used to arrange the circuitry. Preferably, the voltage optimizer is at least partially located within the recess. In this case, this region of the internal cavity will be directly between the first side and the voltage optimizer.

[0017] The first housing may accommodate support rails (such as DIN rails) and distribution strips (such as busbars). The support rails are used to mechanically support one or more electrical components of the circuit system. The distribution strips may extend substantially parallel to the support rails and are adapted to be directly electrically connected to one or more components in a branch circuit, thereby distributing power to each branch circuit. The support rails and / or distribution strips extend within this region of the internal cavity. Thus, in use, the support rails and / or distribution strips may be located directly in front of the second housing. Furthermore, one or more electrical components may be located within this region, thus directly in front of the second housing. The support rails and / or distribution strips may be directly supported on a recessed wall of a second side of the first housing, opposite the first side and facing this region of the internal cavity.

[0018] Electrical components carried by the support rail may include: electrical switches (such as main switches) that control power from the main feeder to all branch circuits, and / or one or more electrical safety devices. These electrical safety devices may include one or more of the following: circuit breakers, such as fuses and / or miniature circuit breakers (MCBs); residual current devices (RCDs); surge protection devices (SPDs); arc fault detection devices (AFDDs); and residual current circuit breakers (RCBOs) with overcurrent protection.

[0019] The recess may be in the form of a groove. The groove may extend to the second (i.e., rear) side of the first housing, which faces the supporting wall of the mounting assembly in use.

[0020] Preferably, the second housing portion is located within the recess, such that a portion of the second housing is located outside the recess. This allows for enhanced heat dissipation away from the first housing from the second housing. Multiple (e.g., at least eighty) ventilation holes may be provided on one or more walls of the second housing located outside the recess to exhaust heat from the interior of the second housing. In contrast, the portions of the second housing walls located within the recess and / or directly opposite the first housing may have fewer or no ventilation holes.

[0021] The power distribution assembly may include one or more power cables for electrically connecting the voltage optimizer to a circuit system within a first housing. These power cables extend between the first and second housings, pass through a first opening in a wall of the second housing located within a recess, and pass through corresponding openings in the wall of the first housing opposite the wall of the second housing. Preferably, the two walls are closely spaced or in contact with each other, in which case the openings of the two housings are aligned.

[0022] The second housing may include a removable first side (e.g., a front panel) to access a voltage optimizer within the second housing.

[0023] The voltage optimizer can employ an autotransformer. An autotransformer can be configured with multiple electrical outputs, each providing a different voltage division of the supply voltage.

[0024] The power distribution assembly can be equipped with multiple power supply cables, each connected to one of the different electrical outputs of the voltage optimizer, thereby selectively providing different voltage divisions to the branch circuits.

[0025] The first housing can accommodate a multi-pole electrical connector for receiving multiple power supply cables and for selectively connecting a specific output of the voltage optimizer to the circuit system. Each power supply cable can be connected to a first terminal of a different pole of the multi-pole electrical connector. Subsequently, cables supplying power to branch circuits within the first housing can be selectively connected to terminals of the electrical connector that provide the required voltage from the voltage optimizer output.

[0026] In one embodiment, the housing may house a main switch and an independent circuit breaker device associated with each branch circuit; the main switch has a first pole in its input terminals adapted for connection to a main power supply; a first electrical connection extends between a first housing and a second housing to electrically connect the output terminal of the first pole of the main switch to the input terminal of a voltage optimizer; a second electrical connection extends between the first housing and the second housing to deliver the output power transformed by the voltage optimizer to one or more branch circuits. The second electrical connection may be accessed through the input terminal of a second pole of the main switch, while the output terminal of the second pole is electrically connected to the branch circuit via a distribution strip. The first housing may house a multi-pole electrical connector for receiving multiple power supply cables and for selectively connecting one of them to a branch circuit.

[0027] The present invention also relates to innovative circuit design, and therefore, according to a second aspect of the invention, a power distribution assembly for distributing power from a main power source to one or more branch circuits is provided, the power distribution assembly comprising: a first housing having an internal cavity housing a main switch and an independent circuit breaker device associated with each branch circuit, the first input terminal of the main switch being adapted to connect to the main power source; a second housing housing a voltage optimizer for providing a transformer-powered voltage to each branch circuit; the transformer-powered voltage being a voltage divider of the main power source voltage; a first electrical connection extending between the first and second housings to electrically connect the output of the main switch to the input of the voltage optimizer; and a second electrical connection extending between the first and second housings to transmit the output power from the voltage optimizer to one or more branch circuits.

[0028] Compared to existing circuits known to the inventors (where the main power supply is directly connected to the voltage optimizer), the circuit of the present invention simplifies the installation process for installers, especially when the assembly of the present invention replaces an existing consumer unit, because the first housing can be located in the same position as the existing consumer unit, which means that the existing meter tail wires can be connected with minimal modification.

[0029] The second electrical connection can be connected to the input terminal of the second pole of the main switch, while the output terminal of the second pole can be connected to the branch circuit. In this configuration, the main switch can be a multi-pole single-throw switch.

[0030] The voltage optimizer may include multiple electrical outputs, each of which can be configured to provide a different voltage division of the main power supply voltage. The assembly includes multiple power supply cables extending between a first housing and a second housing, each power supply cable being connected to a different output of the voltage optimizer.

[0031] The first housing can accommodate a multi-pole electrical connector for receiving each of a plurality of power supply cables and for selectively connecting one of the plurality of power supply cables to a branch circuit, thereby providing a voltage divider output of the voltage optimizer to the branch circuit.

[0032] The first electrical connection may include a circuit breaker device (optionally housed within the first housing) between the main switch and the voltage optimizer input, such as a miniature circuit breaker (MCB). This circuit breaker device may be mounted on a support rail.

[0033] The main power cable, which supplies power from the main power source, can extend through a hole in the first housing and connect to the main switch.

[0034] Voltage optimizers may include autotransformers. Attached Figure Description

[0035] The present invention will now be described by way of example with reference to the following figures: Figure 1 This is a 3D view of the power distribution assembly from the front left side; Figure 2 This is a three-dimensional view of the power distribution assembly from the right rear side; Figure 3 This is a 3D view of the power distribution assembly from the front right side; Figure 4 This is a front view of the power distribution assembly; Figure 5 This is a rear view of the power distribution assembly; Figure 6 This is a top view of the power distribution assembly; Figure 7 A right front perspective view showing the internal cavity and unconnected circuit components by removing the front wall; Figure 8The front walls of both the first and second housings of the power distribution assembly are removed to reveal a front view of the interior of both housings; Figure 9 A three-dimensional view of the lower rear side of the main shell; Figure 10 A three-dimensional view of the right front side of the sub-shell; Figure 11 To and Figure 10 A 3D view from the same angle, in which the front panel of the secondary housing is removed to expose the autotransformer; Figure 12 Front view of the sub-shell with the front panel removed; Figure 13 This is a circuit diagram of the power distribution assembly; Figure 14 This is a three-dimensional view of the external structure of an autotransformer. Detailed Implementation

[0036] Referring to the accompanying drawings, a power distribution assembly 1 suitable for household power supply is shown, including a main housing 100 and a secondary housing 200.

[0037] The main housing 100 (also referred to as the consumer unit or fuse box) defines the internal cavity 101 (see [link]). Figure 7 and Figure 8 The internal cavity houses the circuitry for distributing power from the power feeder 300 to branch circuits 310 (e.g., ring trunk circuits and / or radial circuits). The sub-casing 200 houses a voltage optimizer, implemented in this example via an autotransformer 250 (see [link to sub-casing]). Figure 8 , Figure 10 , Figure 11 and Figure 12 ).

[0038] The main housing 100 and the secondary housing 200 are arranged side by side. The main housing 100 defines a rearward external recess 102 (see details). Figure 9 The sub-casing 200 and voltage optimizer 250 are partially located in external recesses. This design reduces the overall wall space required for the power distribution assembly 1.

[0039] The main housing 100 includes a front side 110, a rear side 120, a left side 130, a right side 140, a top side 150, and a bottom side 160. Each side is formed by one or more walls made of a thin metal sheet (e.g., steel plate). One or more walls are provided with knockout sections 103 to allow cables to be introduced from the top side 150, bottom side 160, right side 140, and rear side 120.

[0040] Use relative terms: front, back, left, right, top, bottom to improve readability. These terms reflect the relative orientation of the power distribution assembly 1, as commonly observed when it is mounted on a wall during use. Figure 1 , Figure 3 , Figure 4 , Figure 7 , Figure 8 As shown.

[0041] The front panel 111 is detachably attached (e.g., by fasteners) to the remainder of the main housing 100 so that it can be temporarily removed when access to the internal cavity 101 is required (e.g., for electrical installation or circuit inspection). The front panel 111 is provided with a hinged door member 112 that covers an opening (not shown) through the front panel 111, thereby allowing access to the circuit switches (e.g., toggle switches and / or push-button switches) without removing the front panel 111.

[0042] The rear side 120 and left side 130 of the main housing respectively include a first panel 121 on the rear side, a first panel 131 on the left side, a second panel 122 on the rear side, and a second panel 132 on the left side. The first panel 121 on the rear side 120 and the first panel 131 on the left side 130 are recessed inward relative to the second panel 122 on the rear side and the second panel 132 on the left side, thereby forming a recess 102 at the left rear corner of the main housing 100.

[0043] A first opening 133 is provided through the recessed left side panel 132 (see...) Figure 7 and Figure 9 Electrical tap connector 320 (see) Figure 8 It extends through the first opening to electrically connect the autotransformer 250 to the circuit system within the internal cavity 101.

[0044] like Figure 7 As clearly shown, a portion 101A of the internal cavity 101 is located directly in front of the recess 102, that is, between the recessed rear panel 121 and the front panel 111. Therefore, this portion 101A is shallower than the rest of the internal cavity 101.

[0045] The second panel 122 of the rear side 120 is provided with a fixing groove or mounting boss 122A (or an equivalent structure - such as a mounting boss)], and the main housing 100 can be supported on a vertical surface, such as the interior wall of a building, by means of appropriate fasteners around these fixing grooves or mounting bosses.

[0046] The sub-casing includes a front side 201, a rear side 202, a left side 203, a right side 204, a top side 205, and a bottom side 206. Each side is constructed of a metal plate. An internal cavity 210 defined by these sides houses an autotransformer 250. The panel forming the front side 201 is detachably connected to the rest of the sub-casing 201 for easy access to the voltage optimizer 250.

[0047] The depth of the sub-shell (i.e., its front-to-back dimensions) is substantially matched with the depth of the recess 102 (from the front to the rear), such that when the sub-shell 200 is placed within the recess 102 and the front side 201 is directly opposite and abuts against the recessed rear panel 121 (see... Figure 6 The outer surface of the rear panel 202 is substantially flush with the outer surface of the second panel 122 of the rear side 120 of the main housing 100.

[0048] The rear panel 202 also includes a fixing recess 202A, through which the sub-casing 200 can be supported on a vertical surface by suitable fasteners, adjacent to the second panel 122 of the rear side 120 of the main casing 100.

[0049] The lateral dimension of the recess 102 (i.e., the dimension between its left and right sides) is smaller than the width of the sub-shell 200 (i.e., the dimension between its left and right sides), such that a portion of the sub-shell 200 is located outside the recess 102, while a portion 201A of the first side 202 extends laterally beyond the main shell 100. This arrangement increases the surface area of ​​the sub-shell 200 that is not directly opposite the main shell 100, thereby facilitating heat dissipation from the sub-shell 200 in a direction away from the main shell 100.

[0050] The left side panel 203, top side panel 205, rear side panel 202, bottom side panel 206, and a portion 201A of the front side panel are each provided with multiple ventilation holes 220 to facilitate heat dissipation from the second unit 202 through convection. In contrast, the surface of the sub-shell 200 facing the main shell 100, namely the surface formed by the right side panel 204 and a portion 201A of the front side panel 201, does not have ventilation holes to minimize heat transfer from the sub-shell 200 to the main shell 100.

[0051] To further reduce heat transfer, a non-combustible insulation layer (not shown) may be provided between the main housing 100 and the secondary housing 200, or within either the main housing 100 or the secondary housing 200. Examples of suitable insulation layers include flexible or rigid ceramic insulation materials, such as ZircoFlex (RTM)™ branded products, or heat-resistant rubber shielding materials.

[0052] Hole 204A (see) Figure 10 , Figure 11The hole is located in the right side 204 of the sub-shell 200, and is aligned with the hole 133 on the recessed left side panel 131 to form a channel between the main shell 100 and the sub-shell 200.

[0053] Special reference Figures 10 to 12 and Figure 14 The autotransformer 250 includes windings (not shown), with a first tap connector 320A serving as an electrical input, a second tap connector 320B as a neutral connection, and multiple (three in this example) additional tap connectors 320C serving as electrical outputs, each providing a different voltage division value based on its position on the winding. One or more of the tap connectors 320 can be implemented using multiple parallel cables electrically connected together at both ends. Using multiple cables, each with a thinner gauge than a single thick-gauge cable, facilitates the bending and extension of the tap connectors from the autotransformer and sub-housing 200.

[0054] The structure and working principle of autotransformers are well-known technologies and will not be elaborated here.

[0055] Each electrical tap connector 320 extends from the secondary housing 200 into the interior of the main housing 100 through the orifice 133 and the hole 204A.

[0056] refer to Figure 7 and Figure 8 An internal cavity 101 houses a support rail (typically a DIN rail) 401 for mechanically supporting the main switch 402 (through which all electrical energy passes first) and one or more electrical safety devices 403 in the circuit system. The support rail 401 extends laterally through the unit 100, with a portion located directly in front of the recessed rear wall 121 and the recess 102. The support rail 401 can be directly mechanically supported by the recessed rear wall 121.

[0057] One or more electrical safety devices may include: one or more residual current devices (RCDs); one or more circuit breakers, such as miniature circuit breakers (MCBs); combined devices, such as residual current overload devices (RCBOs); and surge protectors.

[0058] The internal cavity 101 also accommodates one or more busbars 404 (two in this example: 404A and 404B) and corresponding neutral and ground busbars 405 for distributing electrical energy from the main switch 402 to the circuit breakers 408 (implemented via RCD 409 in this example). One or more of the busbars 404 and / or one or more of the neutral and ground busbars 405 also extend within the cavity region 101A, located directly in front of the recessed rear wall 121.

[0059] In addition, an electrical terminal block 406 is housed within the internal cavity 101. This terminal block 406 is mounted on the inward-facing side of the rear panel 122, near the opening 133, but other locations are also possible. The terminal block 406 has multiple (five in this example) terminals. Each tap 320 connects to a different terminal on one side of the terminal block 406 for connection to the circuit system as described below.

[0060] Figure 13 A feasible circuit layout within the main housing 100 is shown. The main switch 402 employs a three-pole single-throw configuration. The first terminal of each of the first two poles 402A and 402B is reserved for direct connection (live and neutral) to the incoming power supply 300 (e.g., from a meter). The third pole 402C is connected (Lout) via connector 406 to a selected output of the autotransformer 250, V3OUT in this example.

[0061] The second terminal of the first pole 402A connects the live wire feeder (Lin) of the incoming power supply to the input terminal of the autotransformer 250 via the terminal block 406 through the circuit breaker 407.

[0062] The output terminal of the third pole 402C of the main switch 402 distributes the power from the selected output terminal of the autotransformer 250 to the MCB 408 of each branch circuit 310 in a conventional manner via RCD 409 and bus 404.

[0063] When installing the power distribution assembly 1, the sub-casing with the voltage optimizer is mounted to the wall using fasteners that pass through the fixing notch 202A. If not yet complete, the installer inserts the meter tail wire and branch circuit 310 cable into the internal cavity 101 of the main casing and knocks out the corresponding knockout holes 103 as needed. Each cable 320 of the autotransformer 250 also needs to pass through the cavity 133. Then, using fasteners that pass through the notch 122A, the main unit 100 is mounted to the wall, positioned above the sub-casing 200.

[0064] Wiring of branch circuit 310 is installed. Each cable 320 is connected to a different terminal of terminal block 406. By connecting to the corresponding terminals of terminal block 406, the wiring from main switch 402 to autotransformer 250 is completed. Finally, main switch 402 is connected to main power feeder 300.

[0065] Measure (e.g., using a voltmeter) the voltage output (specifically, the root mean square value) provided by each of the three output terminals of the autotransformer 250. Connect the output terminal with the voltage closest to the preferred voltage to the third terminal of the main switch 402 to provide the selected voltage to the branch circuit. In the UK, this output terminal is typically the one with the voltage closest to but higher than 220V. This is done by connecting the corresponding terminal of terminal block 406 to the third terminal of the main switch 402 via a cable.

[0066] In another design, the recess 102 can be located in other positions, including, for example, the rear right side of the main unit.

[0067] It should be understood that other alternative electrical terminal blocks 406 may also be used.

[0068] Voltage optimizers can also be implemented using techniques other than autotransformers.

Claims

1. An electrical distribution assembly comprising: a first housing having an internal cavity for housing circuitry for distributing electrical power from a power source to one or more branch circuits; and a second housing containing a voltage optimizer for reducing the voltage of the power source prior to distribution to the one or more branch circuits; wherein the first housing is configured to define an external recess, and the first and second housings are arranged adjacent to one another, the second housing being located within the recess. The second housing is located partially within the recess.

2. The power distribution assembly of claim 1, wherein, The first housing has an openable first side to access the circuitry within the internal cavity; and wherein a region of the internal cavity is located directly between the first side and the portion of the second housing located within the recess.

3. The power distribution assembly of claim 1 or 2, wherein, The first housing houses a support rail for carrying one or more electrical components of the circuitry, and a distribution bar adapted for direct electrical connection to one or more of the electrical components; and wherein the support rail and / or the distribution bar are located within the region of the internal cavity.

4. The power distribution assembly of claim 3, wherein, The one or more power supply cables extend between the first and second housings through a first aperture provided in a wall of the second housing located within the recess and a corresponding second aperture in a wall of the first housing directly opposite the first aperture.

5. The power distribution assembly of any of the preceding claims, comprising one or more power supply cables for electrically connecting the voltage optimizer to the circuitry within the first housing; wherein, 6. The electrical distribution assembly of claim 5, comprising at least two power supply cables to connect to different electrical outputs of the voltage optimizer to selectively provide different divided voltages of the power source to the branch circuits. The first housing houses a multi-pole electrical connector for receiving the two power supply cables and for selectively electrically connecting one of them to the circuitry.

7. The power distribution assembly of claim 6, wherein, The voltage optimizer comprises a self-coupled transformer.

8. The power distribution assembly of any of the preceding claims, wherein, The external recess is a rebate, and in use, when the assembly is supported on an upwardly extending support surface, the portion of the second housing located within the recess is located directly between the first housing and the support surface.

9. The power distribution assembly of any of the preceding claims, wherein, 10. An electrical distribution assembly for distributing electrical power from a main power source to one or more branch circuits; the electrical distribution assembly comprising: a first housing having an internal cavity housing a main switch and independent circuit breaker means associated with each branch circuit; the main switch having a first pole input adapted to be connected to the main power source; a second housing containing a voltage optimizer for providing a stepped voltage to each of the branch circuits; the stepped voltage being a divided voltage of the voltage of the main power source; a first electrical connection extending between the first and second housings for electrically connecting an output of the main switch to an input of the voltage optimizer; a second electrical connection extending between the first and second housings for transmitting an output power supply from the voltage optimizer to the one or more branch circuits. ​ 11. The assembly of claim 10, wherein, The second electrical connection is connected to an input of a second pole of the main switch, and an output of the second pole is connected to the branch circuit.

12. The assembly of claim 10 or 11, wherein, The voltage optimizer includes a plurality of electrical outputs each configured to provide a different divided voltage of the voltage of the main power source, and the assembly includes a plurality of power supply cables extending between the first housing and the second housing, each of the power supply cables being connected to a different electrical output of the voltage optimizer.

13. The assembly of any one of claims 10-12, wherein, The first electrical connection includes a circuit breaker device between the main switch and the input of the voltage optimizer.

14. The power distribution assembly of claim 13, wherein, A main power supply cable for supplying power from the main power source extends through an aperture provided on the first housing for connection to the main switch.

15. The power distribution assembly of any one of claims 10 to 14, wherein, The voltage optimizer includes a autotransformer.

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