A general-purpose intelligent drop-out fuse capable of being charged and operating and a mounting and operating method thereof

Abstract

The application discloses a general-purpose intelligent drop-out fuse capable of being operated with electricity and a mounting and operating method thereof, and belongs to the technical field of power distribution equipment. The fuse comprises a general-purpose fuse carrying member, a collecting unit and a communication management device. The general-purpose fuse carrying member can match various mainstream models of drop-out high-voltage fuses such as RW3, RW10, RW11, RW12 and NCX. The collecting unit is designed in an integrated manner with the fuse carrying member, and is internally provided with an ultra-low-power current power taking module (0.4A starting and 0.2A maintaining work), a high-precision current measuring module (0.5 level as a whole and 0.2A small current) and a position detecting module, and data is sent to the communication management device through wireless communication. The application realizes intelligent transformation of the stock drop-out fuses without replacing the original fuse support and without power interruption, solves the pain points such as various models of field fuse tubes, 'blind adjustment' of operation conditions and dependence on batteries for power taking, and has the characteristics of quick installation, strong universality, high reliability and long service life.

Description

Technical Field

[0001] This invention relates to the field of power system distribution equipment technology, and in particular to a universal intelligent drop-out fuse that can be operated under energized conditions and its installation and operation method. Background Technology

[0002] Drop-out fuses are widely used short-circuit protection and breaking devices on 10kV power distribution lines and transformers. However, the existing technology has the following problems: Diverse models and poor interchangeability: There are many types of existing drop-out fuses, such as the RW3, RW10, RW11, RW12, and NCX series, whose fuse elements vary in size and structure. Different batches of the same model are also difficult to interchange. When the fuse tube burns out or is damaged, repair personnel often need to carry multiple models of spare parts, which prolongs the power outage time for repairs.

[0003] The equipment is not intelligent and is in a "blind adjustment" state: Currently, the vast majority of distribution transformer areas still use non-intelligent drop-out fuses. Maintenance personnel cannot keep track of the fuse's open / closed position, load current, line faults, transformer overloads, and other information in real time, and can only rely on periodic inspections and user reports, resulting in low power supply reliability.

[0004] Existing intelligent transformation solutions are limited: a small number of online monitoring products use traditional current transformers (CTs) for power, which have a large starting current (usually above 5A). They cannot work properly in areas with low loads and rely heavily on built-in batteries for power, resulting in short product lifespan and poor reliability.

[0005] Therefore, there is an urgent need for an intelligent drop-out fuse solution that is compatible with multiple mainstream models, requires no power outage for installation, has ultra-low power consumption self-powering capability, and can monitor operating conditions in real time. Summary of the Invention

[0006] In view of this, the purpose of this invention is to provide a universal intelligent drop-out fuse that can be operated under energized conditions and its installation and operation method, in order to solve the problems of inconsistent models of existing drop-out fuses, inability to replace them under energized conditions, unknown operating status, and difficulty in obtaining power from existing monitoring products and reliance on short battery life.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: a universal intelligent drop-out fuse capable of being operated energized, comprising: A universal fuse carrier, the structure of which is designed to be compatible with at least two different types of drop-out high-voltage fuses; A data acquisition unit integrated with the general-purpose melting carrier, the data acquisition unit comprising: A current-generating module is used to draw power from the line and supply power to the acquisition unit; The current measurement module is used to collect current data in the circuit. A position detection module is used to detect the opening and closing position status of the melt carrier; The first wireless communication module is used to transmit the current data and the position status data; A communication management device includes a second wireless communication module for communicating with the first wireless communication module, receiving data sent by the acquisition unit, and uploading the data to a remote master station or a smart converged terminal in the distribution area.

[0008] Specifically, the current-generating module is responsible for obtaining electrical energy from the high-voltage line to provide the main operating power for the acquisition unit, and is supplemented by a backup power supply when the line current is extremely low.

[0009] Internal composition: Current transformer (CT): An electromagnetic current transformer made of high-permeability material, connected to a 10kV line. Its design allows it to induce sufficient voltage under extremely small line current.

[0010] Rectifier circuit: Converts the AC current sensed by the CT into DC current. A full-wave rectifier bridge (Schottky diode) is usually used to reduce voltage drop.

[0011] Voltage regulation and conversion circuit: Includes a low dropout regulator (LDO) or DC-DC converter to stabilize the unstable voltage after rectification to the operating voltage required by the acquisition unit (such as 3.3V or 5V), while also having overvoltage protection function.

[0012] Start-up and control logic: A threshold detection circuit is designed to ensure that power is drawn when the line current is ≥0.4A; when the current drops to 0.2A, the output voltage can still be maintained to ensure that the core function of the acquisition unit is not interrupted.

[0013] Backup power interface: Disposable lithium battery (3.6V, 4Ah): switches power supply when the main power supply is insufficient or the line is disconnected.

[0014] Supercapacitor bank: Connected in parallel with lithium battery or used as a buffer, it provides short-term power (>4 hours) during instantaneous line fluctuations, and can also absorb peak energy from CT power supply.

[0015] Working principle: The line current is induced by the CT to generate AC voltage, which is rectified into DC and then regulated to supply the acquisition unit. When the line current is lower than 0.2A or when the power is cut off, the battery and supercapacitor seamlessly continue to supply power.

[0016] The current measurement module is used to accurately collect line current, which is used for both load monitoring (metering) and fault protection (protection).

[0017] Internal composition: Low-power electromagnetic sensors: A separate measuring CT is used, with a rated current ratio of 100A / 1V (i.e., a primary current of 100A corresponds to a secondary output voltage of 1V).

[0018] The core material is selected from permalloy or nanocrystals with high magnetic permeability and low loss to reduce the excitation current and meet the requirements of low power consumption.

[0019] Dual signal output (three-in-one compatible): Protection output branch: The output is unfiltered, with fast response speed and accuracy level reaching 5P10, used for instantaneous overcurrent protection judgment.

[0020] Metering output branch: The output is precision rectified and actively filtered, achieving an accuracy level of 0.5S, and is used for load monitoring and precise measurement of small currents (accuracy of 0.2A for currents below 5A).

[0021] Signal conditioning circuit: This includes operational amplifiers (low power, rail-to-rail), precision resistor divider networks, and anti-aliasing filters (RC filters).

[0022] The secondary output voltage of the sensor is conditioned to the range of 0~3.3V to match the ADC input of the MCU.

[0023] Analog-to-digital conversion interface: directly connected to the ADC pin of the main control unit (e.g., ADC_IN2 is used for fault current and ADC_IN3 is used for rated current in the document), and the MCU samples cyclically through DMA.

[0024] Working principle: The line current is converted into a voltage signal by the measuring CT, and then enters the protection and metering channels for conditioning, ADC sampling, MCU calculation of the current effective value and peak value, and comparison with the set value.

[0025] The position detection module is used to detect the open / closed state of the fuse carrier and the stationary contact, that is, whether the fuse is in the closed position.

[0026] Internal composition: Non-contact position sensor (based on the technical description in the document, it is speculated that one or a combination of the following is used): Magnetic induction sensor (reed switch or Hall element): A permanent magnet is embedded at the position where the fuse is closed. When the fuse is closed, the magnetic force causes the reed switch to close or the Hall output level to change.

[0027] Micro switch (contact type): Installed on the fuse carrier or the housing of the acquisition unit, the micro switch contacts are mechanically activated to close when the fuse carrier is pressed into place.

[0028] Signal shaping circuit: It includes pull-up resistors and Schmitt triggers (or RC filters) to eliminate mechanical jitter and output stable high and low level signals.

[0029] Status indication: Some designs may be equipped with local LED indicators to directly display the current open / closed position (closed on / opened off).

[0030] Interface: Connect the final status signal (digital value, such as closed = high level, open = low level) directly to the GPIO pin of the MCU.

[0031] Working principle: When the molten metal carrier is correctly installed and engaged with the upper and lower stationary contacts, the position sensor is triggered, the shaping circuit outputs a "closed" signal, and the MCU reads a high level. When the molten metal carrier is dropped or removed, the sensor resets, and the MCU reads a low level (disengaged). This status information, along with the current data, is wirelessly transmitted to the communication management device.

[0032] In a preferred embodiment, the general-purpose fuse carrier is configured to be compatible with at least two types of drop-out high-voltage fuses selected from RW3-12kV, RW10-12kV, RW11-12kV, RW12-12kV, and NCX-10kV.

[0033] In a preferred embodiment, the starting current of the current-generating module is 0.4A, and the sustaining current is 0.2A.

[0034] In a preferred embodiment, the overall measurement accuracy of the current measurement module is 0.5 class, and the measurement accuracy is 0.2A in the low current region below 5A.

[0035] In a preferred embodiment, the acquisition unit further includes a backup power supply, which includes a lithium battery and / or a supercapacitor, wherein the supercapacitor has a battery life of more than 4 hours.

[0036] In a preferred embodiment, the static power consumption of the acquisition unit is less than or equal to 80 μA.

[0037] In a preferred embodiment, the current measurement module employs a low-power electromagnetic sensor with a rated current ratio of 100A / 1V, and is compatible with both protection class 5P10 and metering class 0.5S.

[0038] In a preferred embodiment, the acquisition unit or the communication management device further includes a fault alarm module for generating phase-to-phase short-circuit fault alarms and overload alarms based on the current data.

[0039] The present invention also provides an installation and operation method for a universal intelligent drop-out fuse that can be operated while energized, comprising the following steps: Adaptation steps: Select or adjust the universal fuse carrier according to the model of the existing drop-out fuse on site to match the model on site; Live installation steps: With the 10kV line energized, install the universal fuse carrier with the acquisition unit onto the bracket of the field drop-out fuse; Communication establishment steps: The acquisition unit starts up and establishes a wireless communication connection with the communication management device; Data acquisition and uploading steps: The acquisition unit acquires the phase current and the switching position status in real time, and sends the data to the communication management device through the first wireless communication module, and then the communication management device uploads it to the remote master station.

[0040] In a preferred embodiment, the live installation step further includes: using the current-generating module to obtain at least 0.4A of current from the line to start the acquisition unit, and maintaining the acquisition unit in operation even when the line current drops to 0.2A.

[0041] Compared with the prior art, the present invention has the following beneficial effects: 1. Highly versatile and quick to repair: The innovatively designed universal fuse carrier can be matched with more than 5 mainstream drop-out fuse models in the field. Maintenance personnel only need to carry one spare part to deal with multiple faults, which greatly shortens the power outage time and improves the power supply service level.

[0042] 2. Live-line operation without power outage: The product's appearance and operation method are completely consistent with conventional fusion tubes. It can be directly replaced and installed while the power is on using the insulated operating rod. It is especially suitable for intelligent transformation of existing transformer substations with high power supply reliability requirements and where power outages are not allowed.

[0043] 3. Ultra-low power consumption and high reliability: Adopting internationally advanced ultra-low current power supply technology (0.4A startup, 0.2A maintenance), the CT power supply truly becomes the main power source, with the built-in battery serving only as a backup. This solves the problems of similar products relying on batteries and having short lifespans (typically 1-2 years), extending the overall product lifespan to over 8 years.

[0044] 4. High-precision monitoring, eliminating blind adjustments: It integrates a high-precision current sensor (0.5 grade) and a position sensor, which can accurately monitor the load of the distribution area, the status of fuses and line faults in real time, providing a data foundation for proactive repair and lean operation and maintenance, and realizing observability and measurability at the end of the distribution network.

[0045] 5. Economical and efficient, easy to promote: The product retains the original fuse bracket, only replacing the fuse carrier and data acquisition unit, resulting in low single-point modification costs. The integrated design and wireless communication method simplify installation and wiring, making it suitable for large-scale deployment and application. Attached Figure Description

[0046] Figure 1 This is a system overall block diagram of a general-purpose intelligent drop-out fuse that can be operated under energized conditions, as described in an embodiment of the present invention.

[0047] Figure 2 This is a circuit diagram of the main control unit of the acquisition unit in an embodiment of the present invention.

[0048] Figure 3 This is a circuit diagram of the RF short-range wireless communication module of the acquisition unit in an embodiment of the present invention.

[0049] Figure 4 This is a schematic diagram of the current acquisition circuit of the acquisition unit in an embodiment of the present invention.

[0050] Figure 5 This is a schematic diagram of the installation operation method provided in an embodiment of the present invention. Detailed Implementation

[0051] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0052] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0053] It should be noted that the terminology used herein is for the purpose of describing particular implementations only and is not intended to limit the exemplary implementations according to this application; as used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise; furthermore, it should be understood that when the terms “comprising” and / or “including” are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0054] Example 1: Intelligent Drop-Out Fuse Structure This embodiment provides a universal intelligent drop-out fuse that can be operated while energized.

[0055] like Figure 1 As shown in the overall block diagram, the intelligent drop-out fuse mainly consists of two parts: the intelligent fuse body (acquisition unit) installed high up on the line and the communication management device installed below the pole.

[0056] (a) Intelligent fuse body The intelligent fuse body includes a universal fuse carrier and an integrated data acquisition unit.

[0057] Universal type fuse carrier: Utilizing an adjustable mechanical structure, its key dimensions and interfaces are designed to accommodate mainstream drop-out fuse models such as RW3-12kV, RW10-12kV, RW11-12kV, RW12-12kV, and NCX-10kV. During on-site installation, simple adjustments based on the existing bracket model are sufficient for compatibility; no replacement of the upper and lower stationary contacts is required.

[0058] The data acquisition unit has the following internal functional modules: Operating power supply: Consists of a main power supply (self-powered by the line) and a backup power supply. The self-powered module uses a high-permeability magnetic material CT and a low-power rectification and voltage regulation circuit, enabling it to start when the line current is only 0.4A and maintain the core functions of the acquisition unit even when the current drops to 0.2A. The backup power supply consists of a 3.6V / 4Ah disposable lithium battery and a set of supercapacitors. The supercapacitors can continuously supply power for more than 4 hours after a power outage (such as a line power failure), ensuring the upload of position signals in the event of a power failure.

[0059] Current measurement: A low-power electromagnetic sensor is used to achieve a rated current ratio of 100A / 1V. The sensor signal is divided into two paths: one path enters the protection circuit (5P10 class) for instantaneous tripping and overcurrent detection; the other path enters the metering circuit (0.5S class) for load monitoring. Figure 4 As shown, the current acquisition circuit sends the current to the ADC pin of the main control unit after precision rectification and filtering.

[0060] Main control unit: such as Figure 2 As shown, a low-power microcontroller (MCU) is used, which integrates an ADC module and a DMA controller. The software code implements cyclic DMA acquisition of the ADC sampling, and the specific initialization code has been disclosed in the original technical materials. The main control unit calculates the effective value based on the current data and compares it with the set instantaneous trip setting (10A-500A adjustable) and overcurrent setting (5A-500A adjustable). The action time can be adjusted within 100-1000ms.

[0061] Position detection: Using non-contact sensing or micro-switches, the system detects whether the molten component is reliably fastened to the bracket, generating a "closed" or "separated" signal.

[0062] Wireless communication: such as Figure 3 As shown, a short-range RF chip operating in the 450-480MHz frequency band is used, with a communication distance of ≥50 meters and a transmit power consumption of less than 25mA@+10dBm. This module transmits data such as current and position to the communication management device below.

[0063] (ii) Communication management device The communication management device has the following interfaces and functions: Local communication: Built-in RF receiver module (450-480MHz) that is compatible with the acquisition unit, which can simultaneously receive data from up to 3 (corresponding to phases A, B, and C) or more acquisition units.

[0064] Remote communication: Built-in 4G / 3G / 2G five-mode adaptive communication module, supports 101 / 104 power distribution automation protocol, and can upload data to the master station.

[0065] Other interfaces: Provides RS232 (local maintenance) and RS485 interfaces, which can interact with devices such as the intelligent converged terminal unit (TTU) in the distribution area.

[0066] Power supply: AC220V power supply, with built-in supercapacitor as short-term backup.

[0067] Example 2: Installation Operation Method This embodiment describes a method for on-site live installation and commissioning using the aforementioned intelligent drop-out fuse. The process is as follows: Figure 5 As shown.

[0068] Scenario: In a 10kV distribution line area, the original RW11-12kV drop-out fuse has been damaged, and there has been a long-term blind spot in load monitoring in this area, so intelligent transformation is required.

[0069] step: Preparation: Based on the logbook information, the maintenance personnel confirmed that the site was an RW11-12kV model. They then took out one set of the intelligent fuse of this invention and adjusted the universal fuse carrier to the RW11 position.

[0070] Live-line installation: Maintenance personnel should wear insulated protective gear and use an insulated operating rod to hook the operating ring at the upper end of the smart fuse. Without interrupting power to the 10kV line, slowly push the fuse into the upper stationary contact, then close the lower stationary contact, listening for a "click" sound to confirm proper installation. At this point, the fuse carrier is in the closed position.

[0071] Automatic Start-up: The line current is assumed to be 15A. After the fuse is installed, the internal power-taking current transformer (CT) senses the electrical energy, which is then rectified and regulated before the data acquisition unit starts. First, the MCU is initialized (ADC, DMA, etc., refer to the original code), then the position sensor is read (to confirm the closed position), and current data acquisition begins.

[0072] Communication Establishment: The acquisition unit sends a heartbeat packet and initial data to the communication management device via the RF module. After receiving the data, the communication management device establishes a connection with the master station via the 4G module and completes registration.

[0073] Real-time monitoring: On the main station system, the fuse icon for this distribution area changes to "closed" and begins displaying the real-time current value (e.g., 14.8A). Maintenance personnel can view this remotely through the main station system.

[0074] Fault Alarm: Assume a phase-to-phase short-circuit fault occurs on the line. The acquisition unit detects that the current instantaneously exceeds the instantaneous trip setting (e.g., 200A). The main control unit determines the fault within 50ms and sends an "instant trip action" signal via the RF module. The communication management device immediately reports to the main station via 4G, and the local indicator light flashes. The main station pops up an alarm window, prompting maintenance personnel with the specific line and fault nature. After the fault is cleared, maintenance personnel can replace the fuse again while the line is powered on to restore power.

[0075] Summary of Results: This embodiment demonstrates that the intelligent fuse enables the replacement and intelligent upgrade of older equipment without interrupting external power supply. Its ultra-low power consumption technology ensures normal operation even in lightly loaded areas (requiring only 0.4A of current), significantly expanding its applicability. The wireless communication method eliminates the need for secondary wiring, achieving truly simple installation and immediate use.

Claims

1. A universal intelligent drop-out fuse capable of being operated energized, characterized in that, include: A universal fuse carrier, the structure of which is designed to be compatible with at least two different types of drop-out high-voltage fuses; A data acquisition unit integrated with the general-purpose melting carrier, the data acquisition unit comprising: A current-generating module is used to draw power from the line and supply power to the acquisition unit; The current measurement module is used to collect current data in the circuit. A position detection module is used to detect the opening and closing position status of the melt carrier; The first wireless communication module is used to transmit the current data and the position status data; A communication management device includes a second wireless communication module for communicating with the first wireless communication module, receiving data sent by the acquisition unit, and uploading the data to a remote master station or a smart converged terminal in the distribution area.

2. The universal intelligent drop-out fuse capable of being operated energized according to claim 1, characterized in that, The structure of the general-purpose fuse carrier is configured to be compatible with at least two types of drop-out high-voltage fuses selected from RW3-12kV, RW10-12kV, RW11-12kV, RW12-12kV, and NCX-10kV.

3. The universal intelligent drop-out fuse capable of being operated energized according to claim 1, characterized in that, The starting current of the current-generating module is 0.4A, and the sustaining current is 0.2A.

4. A universal intelligent drop-out fuse capable of being operated energized according to claim 1, characterized in that, The overall measurement accuracy of the current measurement module is 0.5 class, and the measurement accuracy is 0.2A in the low current range below 5A.

5. The universal intelligent drop-out fuse capable of being operated energized according to claim 1, characterized in that, The acquisition unit also includes a backup power supply, which includes a lithium battery and / or a supercapacitor, wherein the supercapacitor has a battery life of more than 4 hours.

6. The universal intelligent drop-out fuse capable of being operated energized according to claim 1, characterized in that, The static power consumption of the acquisition unit is less than or equal to 80μA.

7. The universal intelligent drop-out fuse capable of being operated energized according to claim 1, characterized in that, The current measurement module uses a low-power electromagnetic sensor with a rated current ratio of 100A / 1V, and its accuracy class is compatible with both protection class 5P10 and metering class 0.5S.

8. The universal intelligent drop-out fuse capable of being operated energized according to claim 1, characterized in that, The acquisition unit or the communication management device further includes a fault alarm module, used to generate phase-to-phase short-circuit fault alarms and overload alarms based on the current data.

9. An installation and operation method for a universal intelligent drop-out fuse capable of being operated energized, based on any one of claims 1 to 8, characterized in that, Includes the following steps: Adaptation steps: Select or adjust the universal fuse carrier according to the model of the existing drop-out fuse on site to match the model on site; Live installation steps: With the 10kV line energized, install the universal fuse carrier with the acquisition unit onto the bracket of the field drop-out fuse; Communication establishment steps: The acquisition unit starts up and establishes a wireless communication connection with the communication management device; Data acquisition and uploading steps: The acquisition unit acquires the phase current and the switching position status in real time, and sends the data to the communication management device through the first wireless communication module, and then the communication management device uploads it to the remote master station.

10. The installation and operation method of a general-purpose intelligent drop-out fuse capable of being operated energized according to claim 9, characterized in that, The live installation step further includes: using the current extraction module to obtain at least 0.4A of current from the line to start the acquisition unit, and continuing to operate the acquisition unit when the line current drops to 0.2A.

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