A multi-function meter connected to a molded case circuit breaker

Abstract

This invention discloses a multi-functional meter connected to a molded case circuit breaker (MCCB), relating to the field of low-voltage power distribution metering equipment technology. It includes: a base and an end cover; the end cover is installed on the front end face of the base; an AC signal processing PCB board, a digital display LCD processing PCB board, and a communication PCB board are installed inside the base; an LCD display screen is installed on the front end face of the end cover; three-phase primary connection copper busbars are arranged in parallel directions on the upper surface of the base; the input terminals of the primary connection copper busbars are electrically connected to the MCCB, and the output terminals are connected to the load cable; each primary connection copper busbar is fitted with a secondary coil of a current transformer; this multi-functional meter integrates the secondary coil of the current transformer, signal processing, metering, display, and communication functions into one unit, and adopts a structure where the primary connection copper busbars are directly connected to the MCCB, achieving a compact equipment layout, effectively reducing the space occupied by the distribution cabinet, simplifying on-site installation procedures, and significantly improving construction efficiency.

Description

Technical Field

[0001] This invention relates to the field of low-voltage power distribution metering equipment technology, and more specifically to a multi-functional meter connected to a molded case circuit breaker. Background Technology

[0002] In low-voltage 400V power distribution systems such as industrial plants, commercial buildings, and municipal power distribution, in order to achieve refined energy consumption management, power consumption monitoring, and remote data operation and maintenance for each outgoing circuit, it is generally necessary to install current transformers and energy metering instruments in the outgoing circuits of the molded case circuit breakers in the distribution cabinet. The mainstream configuration in the industry is a combination of independent through-core current transformers and split-type multi-functional energy meters. This type of equipment is a standard component in low-voltage power distribution systems and is widely used inside various low-voltage distribution cabinets and power cabinets.

[0003] The existing low-voltage power distribution circuit adopts a combination of split-type through-core current transformers and independent energy meters. The equipment layout is scattered, the supporting construction procedures are complicated, and the through-core of large-section power cables is difficult. Secondary wiring is prone to errors that can cause metering failures. Overall, it occupies a large space and has low construction and maintenance efficiency. Summary of the Invention

[0004] The purpose of this invention is to provide a multi-functional meter that connects to a molded case circuit breaker, in order to solve the problems of large space occupation, difficult cable pulling, easy error in secondary wiring, and low construction efficiency in the existing technology of combining split current transformers and energy meters.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] A multi-function meter connected to a molded case circuit breaker includes: a base and an end cover, the end cover being installed on the front end face of the base, an AC signal processing PCB board, a digital display LCD processing PCB board and a communication PCB board being installed inside the base, and an LCD display screen being installed on the front end face of the end cover;

[0007] The upper surface of the base is provided with three-phase primary connection copper busbars arranged in parallel directions. The incoming end of the primary connection copper busbar is electrically connected to the molded case circuit breaker, and the outgoing end of the primary connection copper busbar is connected to the load cable.

[0008] Each of the primary connecting copper busbars is fitted with a secondary coil of a current transformer. The secondary coil of the current transformer is electrically connected to the AC signal processing PCB board. The AC signal processing PCB board is used to collect current signals and voltage signals and perform electrical energy measurement and metering calculations.

[0009] The AC signal processing PCB board is electrically connected to the digital display LCD processing PCB board and the communication PCB board respectively. The digital display LCD processing PCB board is connected to the LCD screen to display the measurement data, and the communication PCB board is used to realize the communication transmission of the measurement data; thus forming a matching metering device for molded case circuit breakers that integrates current acquisition, voltage acquisition, energy metering, data display and data communication.

[0010] Furthermore, the base is integrally injection molded from flame-retardant composite material, and an insulating partition is provided between adjacent two phase primary connecting copper busbars. Epoxy resin baffles are provided on the inlet and outlet sides of the base, respectively.

[0011] Furthermore, the primary connecting copper busbar is made of T2 oxygen-free copper, the surface of the primary connecting copper busbar is provided with a silver plating layer, the inlet end of the primary connecting copper busbar is provided with an elongated hole, the outlet end of the primary connecting copper busbar is provided with a round hole, and the primary connecting copper busbar is fixed to the surface of the base by M3 screws.

[0012] Furthermore, the base is provided with several inserts, which cooperate with the cable partition of the molded case circuit breaker. After the inserts are inserted into the corresponding positions of the molded case circuit breaker, the device is positioned and installed.

[0013] Furthermore, the secondary coil of the current transformer includes an amorphous nanocrystalline alloy core and a copper core enameled wire wound around the outside of the amorphous nanocrystalline alloy core. The secondary coil of the current transformer is cured by a vacuum pressure impregnation process to form an integral structure, and its accuracy class is 0.2S or 0.5.

[0014] Furthermore, the AC signal processing PCB board includes a current sampling circuit, a voltage sampling circuit, an analog-to-digital conversion circuit, and a measurement and metering calculation circuit, used to calculate three-phase current, three-phase voltage, active power, reactive power, power factor, and active and reactive energy parameters.

[0015] Furthermore, the digital display LCD processing PCB board is connected to the LCD screen, and the end cover is also provided with operation buttons. The LCD screen is used to display parameter switching and function settings.

[0016] Furthermore, the communication PCB board is connected to pluggable terminals and a 4G / 5G transceiver antenna. The pluggable terminals include RS485A terminals, RS485B terminals, neutral terminals, power pulse P+ terminals, and power pulse P- terminals. The communication PCB board supports one or more communication methods among RS485 communication, 4G / 5G wireless communication, and power line carrier communication.

[0017] The base is provided with fixing holes and partition slots, and a cable isolation baffle can be detachably installed in the partition slots.

[0018] Compared with existing technologies, the present invention provides a multi-functional meter connected to a molded case circuit breaker. By integrating the secondary coil of the current transformer, signal processing, metering, display, and communication functions into one unit, and adopting a structure with a direct connection of the copper busbar to the molded case circuit breaker, the device achieves a compact layout, effectively reduces the space occupied by the distribution cabinet, simplifies the on-site installation process, and significantly improves construction efficiency. The integrated structure, combined with high-precision sampling components, ensures accurate and reliable power metering. Multiple communication methods can flexibly meet the needs of local viewing and remote data transmission. The overall structure is stable, the wiring is simple, and the operation is highly stable. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0020] Figure 1 This is a schematic diagram of the overall structure provided in an embodiment of the present invention;

[0021] Figure 2 This is a schematic diagram of the internal structure of the base.

[0022] Explanation of reference numerals in the attached figures:

[0023] 1. Primary connection copper busbar; 2. Elongated hole; 3. Insert; 4. Base; 5. End cap; 6. Operation button; 7. LCD display; 8. Plug-in terminal; 9. Round hole; 10. Fixing hole; 11. Partition slot; 12. 4G / 5G transceiver antenna; 13. Current transformer secondary coil; 14. Digital display LCD processing PCB board; 16. Communication PCB board; 17. AC signal processing PCB board. Detailed Implementation

[0024] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0025] As attached Figure 1 To be continued Figure 2 As shown:

[0026] Example 1: The present invention provides a multi-functional meter connected to a molded case circuit breaker, including: a base 4 and an end cover 5. The end cover 5 is assembled and fixed on the front end face of the base 4. The two have the same width and form a sealed protective cavity after assembly, which protects the internal circuit board, coil and other electrical components from dust, collision and oil. It is suitable for the dusty and vibrating working environment inside the distribution cabinet.

[0027] The base 4 is made of recyclable flame-retardant composite material through an integrated injection molding process. It has the characteristics of V0 flame retardancy, high insulation, aging resistance and mechanical impact resistance, and is fully compatible with the complex electrical environment inside the distribution cabinet. The interior of the base 4 is a hollow cavity with a partitioned layout. The upper surface of the base 4 is arranged with three-phase primary connection copper busbars 1 in parallel, which strictly correspond to the A, B and C three-phase power supply circuits.

[0028] An integrated, heightened insulating partition is integrally formed between the primary connecting copper busbars 1 of two adjacent phases. The partition is higher than the copper busbar body, which can effectively prevent short circuit hazards caused by cable splicing or foreign objects falling between phases. An integrated epoxy resin baffle is installed on both the inlet and outlet sides of the base 4 to further enhance the overall insulation protection performance and prevent debris from entering the device.

[0029] The base 4 has several inserts 3 integrally formed on the side. The size of the inserts 3 is precisely matched with the cable partition of the molded case circuit breaker. During on-site installation, the inserts 3 are aligned with the position of the circuit breaker cable partition and inserted horizontally. The device is quickly positioned by relying on the elastic clamping of the inserts. No additional position adjustment is required, and the positioning accuracy is high.

[0030] The base 4 has two sets of fixing holes 10 symmetrically opened at the bottom. The staff can use bolts, clips and other fasteners to pass through the fixing holes 10 to fix the entire device to the standard installation strip of the distribution cabinet. Combined with the positioning of the plug 3, a double fixing structure is formed to prevent the equipment from loosening or shifting during long-term operation. The base 4 has a full-length partition slot 11 on the cable outlet side.

[0031] The three sets of primary copper busbars are the core components for circuit conductivity. They are all made of T2 oxygen-free copper, which has low oxygen content and low resistivity, and its conductivity is far superior to that of ordinary pure copper. The surface of the copper busbar is treated with overall silver plating. The silver layer is uniform and dense, which not only greatly improves conductivity but also isolates air and moisture, enhances oxidation and corrosion resistance, and extends the service life of the equipment in outdoor and humid cabinets.

[0032] The copper busbar 1 has an elongated hole 2 at its inlet end. The hole 2 can be adjusted in the horizontal direction within ±10mm to flexibly adapt to the terminal spacing of different brands and specifications of molded case circuit breakers, thus enhancing compatibility. The outlet end has a round hole 9 with a diameter matching that of conventional power cable terminals for connecting to the load power cable.

[0033] The primary connection copper busbar 1 is locked and fixed to the pre-set studs on the surface of the base 4 with M3 Phillips head screws. The studs and the base are integrally injection molded, which makes the assembly firm and easy to disassemble and assemble. At the same time, the primary connection copper busbar 1 with the corresponding cross-sectional area can be selected according to the different rated current level (63A~1250A) of the molded case circuit breaker to accurately meet the current carrying requirements of different current-carrying circuits.

[0034] The copper busbar 1 is suspended outside and fitted with the secondary coil 13 of the current transformer. There is an insulation gap between the secondary coil 13 of the current transformer and the copper busbar, and there is no rigid contact to avoid vibration and friction damage to the insulation layer.

[0035] The secondary coil 13 of the current transformer uses an amorphous alloy nanocrystalline material for its core, which has high permeability, low excitation loss, and stable sampling accuracy. It is tightly wound with high-strength copper core enameled wire. After winding, it is cured by vacuum pressure impregnation process, which integrates the coil, enameled wire, and core into one unit, resulting in a compact structure, vibration resistance, and high insulation level. The accuracy of the secondary coil 13 of the current transformer is selected as 0.5 or 0.2S class. The output terminal of the secondary coil 13 of the current transformer uses high-temperature resistant insulated soft lead wire, which is connected to the cavity through the reserved wiring hole in the base and electrically connected to the preset pad of the AC signal processing PCB board 17 to realize the induction and acquisition of large current on the primary side.

[0036] The hollow cavity of the base 4 adopts a layered staggered arrangement to fix the AC signal processing PCB board 17, the digital display LCD processing PCB board 14, and the communication PCB board 16 in sequence. The three circuit boards are installed in the air by insulating pillars, with heat dissipation gaps between the boards. The circuits are neat and they are electrically connected to each other by high-temperature resistant onboard connectors, avoiding the messy problem of traditional flying wires.

[0037] The AC signal processing PCB board 17 is the core board for signal processing and calculation of this device, integrating current sampling circuit, voltage sampling circuit, A / D analog-to-digital conversion circuit, measurement and calculation circuit, and built-in switching power supply.

[0038] During operation, the three-phase power frequency high current on the primary copper busbar 1 is converted into a standard small current analog signal by the secondary coil 13 of the current transformer according to the transformation ratio; the three-phase voltage is directly taken from the primary copper busbar through the voltage divider circuit to form a voltage analog signal.

[0039] After the two types of analog signals are sent to the circuit board, they are converted into digital signals by a high-precision analog-to-digital converter. These digital signals are then processed by a dedicated energy metering chip and peripheral circuitry to accurately calculate all electrical parameters, including three-phase phase current, three-phase phase voltage, total active power, total reactive power, overall power factor, forward / reverse active energy, and forward / reverse reactive energy. Simultaneously, the onboard switching power supply draws power from a single-phase circuit, converting the low-voltage AC power to multiple stable low-voltage DC power supplies, providing continuous power to all circuit boards, displays, and buttons on the instrument.

[0040] The digital display LCD processing PCB board 14 receives and processes the digital parameter signals transmitted from the AC signal processing PCB board 17 via pin headers. It has a built-in LCD driver chip that converts the digital signals into driving signals recognizable by the LCD screen. This circuit board is electrically connected to the LCD display screen 7 on the end cover 5 via a flexible ribbon cable, driving the screen to display various monitoring data in real-time and in a polling manner.

[0041] The communication PCB board 16 is equipped with an industrial-grade RS485 wired communication circuit, featuring lightning protection and anti-interference protection circuits. The circuit board leads are connected to the plug-in terminals 8 on the outside of the end cover 5.

[0042] The pluggable terminal 8 has a total of 5 independent interfaces, namely RS485A, RS485B, neutral, power pulse P+, ​​and power pulse P-. All terminals adopt a spring pluggable structure, and wiring, maintenance, and line replacement do not require tools, making operation convenient. The power pulse port can output standard power pulse signals to the outside, which can be adapted to external pulse metering and acquisition equipment and testing.

[0043] The end cover 5 serves as the carrier for the equipment operation and display panel. It features snap-fit ​​slots around its perimeter, corresponding one-to-one with the base snap-fit, ensuring simple assembly and disassembly and excellent sealing performance. A liquid crystal display screen 7 is embedded in the center of the front of the end cover. The outer side of the screen has a one-piece molded transparent high-strength PC window, providing dustproof, scratch-proof, and screen protection. Below the liquid crystal display screen 7, four independent multi-functional operation buttons 6 are horizontally arranged in an array. These buttons are made of waterproof silicone, offering a clear tactile feel and are waterproof and dustproof. Operators can use the operation buttons 6 to perform operations such as switching display pages, manually querying parameters, configuring equipment parameters, resetting power data, and setting communication addresses.

[0044] Overall installation process:

[0045] (1) Equipment pre-installation: Select the primary connection copper busbar 1 with the corresponding cross-sectional area according to the rated current of the molded case circuit breaker in advance, and put the secondary coil 13 of the current transformer into the three-phase copper busbar in sequence. Use M3 screws to fasten the copper busbar to the preset studs on the base 4; complete the connection of the three internal PCB board connectors, and finally snap the end cover 5 into the base to complete the pre-installation of the whole machine.

[0046] (2) On-site positioning and installation: Align the insert 3 on the base 4 with the cable partition of the molded case circuit breaker and insert it horizontally to complete the horizontal positioning; use the outlet bolt of the molded case circuit breaker to tighten the copper busbar long strip hole 2, or use the fixing hole 10 at the bottom of the base with bolts to lock the device on the distribution cabinet mounting strip to complete the double fixing.

[0047] (3) Main circuit wiring: The outgoing terminals of the molded case circuit breaker are connected to the long strip hole 2 at the inlet end of the copper busbar 1 by connecting bolts. After adjusting the position of the copper busbar according to the terminal spacing, it is locked. The load power cable terminal is connected to the round hole 9 at the outgoing end of the copper busbar and tightened. No cable pulling operation is required throughout the process.

[0048] (4) Secondary wiring and power-on: Connect the RS485 communication line, neutral line and pulse signal line on the plug-in terminal 8 as needed. After checking that the wiring is correct, turn on the power distribution circuit and the device will automatically power on and start.

[0049] (5) Operation and debugging: The LCD screen 7 automatically enters the default display interface and displays various electrical parameters in rotation; press the operation button 6 to switch the interface and configure parameters. After debugging, it is put into normal use.

[0050] Working principle: When the low-voltage power distribution system is powered on normally, the three-phase AC power output of the molded case circuit breaker (A, B, and C phases) is continuously transmitted to the downstream load through the three-phase primary connection copper busbar 1 of this device, forming a stable power supply path in the main circuit.

[0051] Phase 1: Signal Acquisition. The three-phase primary copper busbar 1 carries the load operating current. The secondary coil 13 of the current transformer, which is mounted on the outside of the copper busbar, linearly converts the large current of several thousand amperes on the primary side into a standard current analog signal of milliamperes according to the principle of electromagnetic induction and a preset transformation ratio. This signal is then transmitted to the current sampling circuit of the AC signal processing PCB board 17 through insulated leads. At the same time, the voltage sampling circuit directly performs voltage division and sampling on the three-phase primary copper busbar to acquire the three-phase line voltage and phase voltage analog signals.

[0052] The second stage: Analog-to-digital conversion and energy calculation. Analog signals, including current and voltage, enter the onboard A / D converter circuit and are converted into digital signals recognizable by the microcontroller. These digital signals are then fed into a dedicated energy metering and calculation unit. Using power calculation formulas, the unit calculates in real-time electrical parameters such as three-phase current, three-phase voltage, active power, reactive power, power factor, and bidirectional active / reactive energy. All calculated data is cached in real-time in the onboard memory chip to prevent data loss in case of power failure. Simultaneously, the onboard switching power supply draws power from the single-phase voltage circuit. After rectification, filtering, and voltage regulation, it outputs multiple stable DC voltages to provide uninterrupted power to all electronic components within the device.

[0053] Phase Three: Local Display and Interaction. The calculated digital electrical parameters are transmitted to the digital display LCD processing PCB board 14 via an in-board connector. The driver chip parses the digital signals into LCD driving instructions, controlling the LCD screen 7 to display various parameters in real-time in digital and character format. Operators can press the operation button 6 on the end cover to issue operation commands to the digital display LCD processing PCB board 14, enabling human-computer interaction functions such as interface switching, parameter setting, and data clearing.

[0054] Phase 4: Wired Data Transmission. The buffered electrical parameters are synchronously transmitted to the RS485 communication circuit on the communication PCB board 16. The circuit packages and encodes the data according to the standard Modbus communication protocol and transmits it outwards in differential signal form to the background power distribution monitoring host, PLC, and energy management system via the RS485A and RS485B interfaces on plug-in terminal 8. The energy pulse circuit outputs standard pulse signals according to the accumulated energy, meeting the docking requirements of pulse acquisition devices.

[0055] The entire system requires no external secondary wiring and automatically completes the entire process, from signal acquisition, processing, storage, local display to wired remote transmission.

[0056] Example 2: The difference lies in replacing the accuracy class of the secondary coil 13 of the current transformer with a 0.5 class instead of a 0.2S class. The 0.2S class is a domestically designated class for low-voltage, high-precision metering. Compared to the 0.5 class transformer, its metering error range under light load, overload, and load fluctuation conditions is significantly reduced, allowing for precise capture of minute load current changes.

[0057] The secondary coil 13 of the current transformer still uses an amorphous alloy nanocrystalline iron core and copper core enameled wire winding, and a vacuum pressure impregnation and curing process. The mechanical structure, installation method, and external dimensions remain unchanged, and it can be directly replaced and installed in its original position without affecting the equipment's versatility. This configuration fully meets the stringent high-precision metering requirements of power supply departments for electricity billing, internal energy consumption assessments for enterprises, and power consumption monitoring of precision equipment.

[0058] The communication PCB board 16 retains the original RS485 wired communication circuit, lightning protection circuit, and power pulse output circuit. It also integrates an industrial-grade 4G / 5G wireless communication module, which includes a built-in full-network compatible RF chip, signal processing unit, and SIM card slot. An antenna mounting position is provided on the side of the base, housing an external 4G / 5G transceiver antenna 12. The antenna is electrically connected to the wireless module on the communication PCB board 16 via an RF coaxial cable. The antenna uses a magnetic mounting method, making installation and removal convenient and ensuring stable signal reception.

[0059] The overall communication logic is designed for dual communication modes that can be used in parallel or switched. The two communication links are independent of each other and do not interfere with each other. The internal circuitry of the device includes a communication switching logic unit, allowing operators to select single wired transmission, single wireless transmission, or simultaneous wired + wireless dual-link transmission via panel button 6.

[0060] Wireless communication configuration steps: After powering on the device, enter the communication settings interface by operating button 6, select the communication mode, insert the IoT dedicated SIM card, and configure parameters such as IP address, port, and communication protocol. After configuration, the wireless data transmission function can be enabled; the wired communication part is used in the same way as the example.

[0061] Working principle: The load current of the three-phase primary connection copper busbar 1 is sampled by the secondary coil 13 of a 0.2S class current transformer. This class of transformer has higher linearity and can guarantee minimal metering error across the entire range of 1% to 120% of the rated current. Even under light load, standby, or intermittent load fluctuations, it can accurately acquire analog current signals. The acquired current and voltage signals are sent to the AC signal processing PCB board 17, where, in conjunction with a high-precision metering chip, the overall metering error is further reduced, ensuring that the calculated results of parameters such as energy and power meet high-precision metering standards. All calculation, data caching, and local display processes are consistent with those in Example 1.

[0062] The calculated electrical parameters are synchronously distributed to the two main communication units on the communication PCB board 16, enabling two independent transmissions:

[0063] ①RS485 wired communication link: The working principle is the same as in Example 1. After the data is encoded according to the Modbus protocol, it is transmitted to the local monitoring cabinet, the nearest PLC, and the energy consumption system of wired networking through differential wired signals. It is suitable for centralized wiring of power distribution cabinets and local computer room monitoring scenarios.

[0064] ②4G / 5G wireless communication link: The wireless module receives digital electrical parameters transmitted locally and encapsulates the data according to common IoT protocols such as TCP / IP and MQTT. The module converts the digital signal into a radio frequency signal through the radio frequency circuit and transmits it to the operator's base station via the 4G / 5G transceiver antenna 12. Then, the data is transmitted over a long distance to the cloud energy consumption platform, remote monitoring center, and mobile phone maintenance terminal via the public network.

[0065] The two communication modes can work independently or simultaneously online as backups for each other: when the wired line fails or breaks, the wireless link can automatically take over the data transmission task, ensuring uninterrupted monitoring data; in scenarios where wiring is difficult, such as without network cables, with scattered distribution cabinets, or outdoor transformer substations, wireless communication can be activated independently, freeing users from the constraints of wired cables. The power pulse output function works normally and can continue to connect to traditional pulse acquisition equipment.

[0066] In summary, this example relies on high-precision instrument transformers to achieve accurate metering, and leverages wired + wireless dual communication modes to enhance the equipment's environmental adaptability, balancing metering accuracy with networking flexibility.

[0067] Example 3: Communication PCB board 16 retains the RS485 wired and 4G / 5G wireless communication modules, and adds a low-voltage power line carrier communication module.

[0068] The power line carrier module is coupled to the device's voltage sampling circuit, eliminating the need for additional wiring terminals and utilizing existing three-phase power cables as the data transmission medium.

[0069] The entire unit forms a three-in-one communication architecture of RS485 wired + 4G / 5G wireless + power line carrier. The hardware of the three communication modes is independent of each other, and the software can set mode selection, priority configuration, and automatic link switching functions. Operators can freely select single-mode operation, dual-mode combined operation, or three-mode simultaneous operation through the panel buttons. They can also set the communication link priority. When the main link fails, the system automatically switches to the backup link. The original 4G / 5G transceiver antennas 12 and pluggable terminals 8 are all retained, and the antenna installation position and interface functions remain unchanged.

[0070] To address the issues of numerous outgoing circuits, dense cables, and messy wiring in large industrial park power distribution cabinets, the structure of the four outgoing cable sides of the base was optimized:

[0071] ① The base cable outlet side partition slot 11 is widened and lengthened, upgrading the single slot structure to multiple sets of parallel modular slots, increasing the number of slots to 6 sets, increasing the depth of the slots and improving strength.

[0072] ② Multiple sizes of detachable cable isolation baffles are provided as accessories. The baffles are available in single-hole, double-hole, and multi-hole styles, which can be flexibly selected and freely combined according to the number and diameter of the outgoing cables. After the baffle is inserted into the slot, it can isolate and organize multiple outgoing cables in sections, avoiding tangling and friction between cables of different circuits, and facilitating subsequent inspection and troubleshooting.

[0073] ③ The epoxy resin baffle on the outgoing side is widened simultaneously, increasing the protection area and further improving the insulation protection level under dense multi-cable working conditions.

[0074] The current transformer still adopts the 0.2S high-precision configuration; the structure, materials and installation methods of the base, end cover, primary connection copper busbar, internal sampling and calculation circuit board, display buttons and other components are completely the same as those in Embodiment 2, ensuring the mechanical compatibility and metering accuracy of the equipment.

[0075] Installation and usage process: The mechanical installation, main circuit wiring, and basic parameter configuration process are the same as in Example 2.

[0076] Adding power line carrier configuration steps: After powering on the device, enter the communication settings interface, enable the power line carrier function, set the carrier network address, frequency band, and network group. All devices equipped with power line carrier modules in the same distribution area can automatically form a network and complete data interaction based on power lines.

[0077] Multiple sets of cable isolation baffles are sequentially inserted into the slot 11 on the cable outlet side of the base according to the number of cables on site, thus completing the cable zoning and organization.

[0078] Working principle: The high-precision sampling and calculation unit, with a 0.2S-level current transformer secondary coil 13, completes full-range high-precision current sampling. In conjunction with the voltage sampling circuit, AD conversion circuit, and dedicated metering chip, it calculates various electrical parameters in real time. The data storage, local LCD display, and button interaction logic remain consistent with the previous two embodiments, continuously ensuring overall metering accuracy.

[0079] The calculated electrical parameters are synchronously distributed to three independent communication units on the communication PCB board 16. The three transmission modes each perform their own function and are mutually redundant, adapting to the multi-level networking requirements of large campuses.

[0080] ①RS485 wired communication: As a local short-range networking link, it is used for data interaction between multiple instruments, PLCs and local monitoring terminals inside a single power distribution cabinet. It has stable transmission and strong real-time performance, and is suitable for centralized monitoring inside the cabinet.

[0081] ②4G / 5G wireless communication: As a long-distance public network transmission link, it uploads data from each power distribution point to the park's central cloud platform and remote operation and maintenance center, enabling unified supervision across regions and on a large scale, and adapting to the park's distributed power distribution points.

[0082] ③ Power line carrier communication: As an internal network link within the distribution transformer area, this module modulates digital signals onto the power frequency waveform through a coupling circuit, directly utilizing existing low-voltage power cables as the transmission channel, without the need for additional communication network cabling. Within the same distribution transformer area, this device can automatically form a local area network based on power lines, enabling direct data exchange between instruments and between instruments and the distribution transformer concentrator, solving the problems of numerous locations in large industrial parks, large wiring workloads, and the inability to add wiring to old distribution cabinets.

[0083] Operators can preset communication priorities, such as setting the power line carrier as the primary link. When the power line carrier signal weakens or the link is interrupted, the device automatically switches to the RS485 wired link. If the wired link also fails, the 4G / 5G wireless link is automatically activated as a backup, ensuring continuous uploading of energy consumption data throughout the process and preventing data interruption or loss. All three communication channels can independently output power pulse signals, making them compatible with various traditional data acquisition devices.

[0084] The optimized outgoing cable partition structure works as follows: Multiple modular partition slots 11 on the outgoing side of the base 4, combined with detachable cable isolation baffles, physically isolate multiple load cables according to their circuit and purpose. This prevents friction damage to the outer sheaths of cables from different circuits, reducing the risk of leakage and short circuits. The organized cable layout is clear, allowing maintenance personnel to quickly distinguish each outgoing circuit, significantly improving the efficiency of inspection, maintenance, and line modification. The deepened and widened epoxy resin baffles further prevent dust and moisture from entering the device, extending its service life, especially in situations with densely packed cables.

[0085] Overall operating logic: After power-on, the equipment continuously completes signal acquisition, metering calculation, and local display; the three communication modules transmit data synchronously or in a time-sharing manner according to preset modes, and automatically switch to the optimal communication link based on the on-site network status; the outgoing side isolation baffle provides zoned protection and organization for multiple cables. The entire set of equipment can meet the full-level energy consumption management needs of large industrial parks, from single-cabinet local monitoring and transformer area networking to park-wide cloud-based remote operation and maintenance, while also taking into account high-precision metering, ease of construction, and long-term operational stability.

[0086] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A multi-function meter connected to a molded case circuit breaker, characterized in that, include: The base (4) and end cap (5) are installed on the front end face of the base (4). An AC signal processing PCB board (17), a digital display LCD processing PCB board (14) and a communication PCB board (16) are installed inside the base (4). An LCD screen (7) is installed on the front end face of the end cap (5). The upper surface of the base (4) is provided with three-phase primary connection copper busbars (1) arranged in parallel directions. The incoming end of the primary connection copper busbar (1) is electrically connected to the molded case circuit breaker, and the outgoing end of the primary connection copper busbar (1) is connected to the load cable. Each of the primary connecting copper busbars (1) is fitted with a secondary coil (13) of a current transformer. The secondary coil (13) of the current transformer is electrically connected to the AC signal processing PCB board (17). The AC signal processing PCB board (17) is used to collect current signals and voltage signals and perform energy metering calculations. The AC signal processing PCB board (17) is electrically connected to the digital display LCD processing PCB board (14) and the communication PCB board (16) respectively. The digital display LCD processing PCB board (14) is connected to the LCD screen (7) to display the measurement data. The communication PCB board (16) is used to realize the communication transmission of the measurement data.

2. A multi-function meter connected to a molded case circuit breaker according to claim 1, characterized in that: The base (4) is integrally injection molded from flame-retardant composite material. An insulating partition is provided between the adjacent two phase primary connecting copper busbars (1). Epoxy resin baffles are provided on the inlet side and outlet side of the base (4).

3. A multi-function meter connected to a molded case circuit breaker according to claim 1, characterized in that: The primary connecting copper busbar (1) is made of T2 oxygen-free copper. The surface of the primary connecting copper busbar (1) is provided with a silver plating layer. The inlet end of the primary connecting copper busbar (1) is provided with an elongated hole (2). The outlet end of the primary connecting copper busbar (1) is provided with a round hole (9). The primary connecting copper busbar (1) is fixed to the surface of the base (4) by M3 screws.

4. A multi-function meter connected to a molded case circuit breaker according to claim 3, characterized in that: The base (4) is provided with several inserts (3).

5. A multi-function meter connected to a molded case circuit breaker according to claim 1, characterized in that: The secondary coil (13) of the current transformer includes an amorphous nanocrystalline alloy core and a copper core enameled wire wound around the outside of the amorphous nanocrystalline alloy core. The secondary coil (13) of the current transformer is solidified by a vacuum pressure impregnation process to form an integral structure.

6. A multi-function meter connected to a molded case circuit breaker according to claim 1, characterized in that: The AC signal processing PCB board (17) includes a current sampling circuit, a voltage sampling circuit, an analog-to-digital conversion circuit, and a measurement and metering calculation circuit, which are used to calculate three-phase current, three-phase voltage, active power, reactive power, power factor, and active and reactive energy parameters.

7. A multi-function meter connected to a molded case circuit breaker according to claim 1, characterized in that: The digital display LCD processing PCB board (14) is connected to the LCD screen (7), and the end cover (5) is also provided with operation buttons (6). The LCD screen (7) is used to display parameter switching and function settings.

8. A multi-function meter connected to a molded case circuit breaker according to claim 1, characterized in that: The communication PCB board (16) is connected to a plug-in terminal (8) and a 4G / 5G transceiver antenna (12). The plug-in terminal (8) includes an RS485A terminal, an RS485B terminal, a neutral terminal, an energy pulse P+ terminal and an energy pulse P- terminal. The communication PCB board (16) supports RS485 communication, 4G / 5G wireless communication and power line carrier communication. The base (4) is provided with a fixing hole (10) and a partition slot (11).

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