Generator overload protection system

Abstract

The utility model provides an overload protection system for a generator, which comprises an embedded control system, an alternating current contactor and a waterproof shell, and is suitable for occasions where a standby power supply is used under the condition of power failure or unstable power grid. The embedded control system is installed in the waterproof shell, and load management of the generator is achieved through the power module, the frequency detection module, the microcontroller module and the alternating current contactor control module. The frequency detection module collects alternating current signals, processes the frequency signals and transmits the processed frequency signals to the microcontroller module, and the microcontroller module controls the alternating current contactor according to the frequency signals to achieve management of an electric loop. The user interaction module comprises an input module and an indication module, and provides operation feedback and system state display. The waterproof housing is reasonable in design, has waterproof and dustproof functions, ensures the reliability and durability of the system in a severe environment, and improves the convenience and applicability of the system.

Description

Technical Field

[0001] The utility model relates to the field of power electronics, and particularly relates to a generator overload protection system. Background Art

[0002] In the field of power electronics, it is a common practice in many occasions to use a backup power source, especially a generator, in case of power outage or unstable power grid. The generator is used to supply power to multiple electrical devices, including lights, mechanical equipment, communication equipment, etc. Due to the different usage frequencies and power consumptions of different devices, it often leads to unbalanced loads in multiple power consumption circuits at the back end. Some circuits may bear a large load, while other circuits have a light load. When the load is unbalanced and some circuits are overloaded, the generator may operate overloaded, which may cause overheating, overload or even damage of the generator. Especially in the case of long-term operation, this situation may have a serious impact on the generator and even affect the stability and reliability of power supply.

[0003] Most of the existing generator overload protection systems are cumbersome to operate. Users need to adjust the working frequency of the generator through an electrical box or other complex settings, which results in a poor user experience and inconvenient operation; some of the existing generator overload protection systems are designed relatively fixed and are difficult to cooperate with different types of household backup generators and transfer switches, restricting their application scope and flexibility; in addition, the existing generator overload protection systems are usually integrated with the generator, which makes the overall volume of the system larger and the portability decreased. When users need to install the generator in different places or environments, they are often restricted to a certain extent. Summary of the Utility Model

[0004] The utility model provides a generator overload protection system. After introducing this system, it has significant advantages in terms of convenience, applicability, and durability of the system, can effectively improve the deficiencies of the generator overload protection system in the prior art, enhance the overall performance and user experience of the system, and improve the applicability and flexibility of the system.

[0005] To achieve the purpose of the utility model, a generator overload protection system provided herein includes an embedded control system, a contactor, and a waterproof housing, and the embedded control system and the contactor are installed inside the waterproof housing.

[0006] The embedded control system includes a power supply module, a frequency detection module, a microcontroller module, an AC contactor control module, and a user interaction module. The input end of the frequency detection module is used to connect to the output of the generator, and the output end of the frequency detection module is connected to the frequency signal detection end of the microcontroller module. The control end of the microcontroller module is connected to the control end of the AC contactor control module, and the output end of the AC contactor control module is connected to the control end of the AC contactor. The switch action end of the microcontroller module is connected to the signal interface of the user interaction module. The input end of the AC contactor is used to connect to the output of the generator, and the output end of the AC contactor is used to externally connect to the user load.

[0007] Further, the frequency detection module includes a voltage transformer, a zero-crossing detection circuit, and a signal shaping circuit. The input end of the voltage transformer collects the AC power signal of the generator and outputs the AC power signal to the zero-crossing monitoring circuit. The zero-crossing detection circuit detects the zero-crossing of the AC power signal and transmits the generated square wave signal to the signal shaping circuit. The signal shaping circuit receives the square wave signal of the zero-crossing detection circuit and performs noise reduction processing. The output end of the signal shaping circuit serves as the output end of the frequency detection module.

[0008] Further, the AC contactor control module includes an optocoupler, a driving transistor, and a freewheeling diode. The low-voltage end of the optocoupler is used to receive the low-voltage control signal and isolate the high-voltage circuit. The output end of the optocoupler is connected to the gate of the driving transistor. The driving transistor is an N-channel enhancement-mode MOSFET, and the source of the driving transistor is grounded. The positive pole of the freewheeling diode is connected to the drain of the driving transistor, and the negative pole of the freewheeling diode is connected to the coil end of the AC contactor.

[0009] Preferably, the user interaction module includes an input module and an indication module. The indication module includes one or more of an LED, a display screen, and a buzzer. The input module includes one or more of a switch, a touch screen, and a knob.

[0010] Further, the waterproof housing includes a housing body and a housing cover. The housing cover is connected to the housing body by a hinge. The housing body is a cuboid. On the outer bottom side of the housing body, there are four brackets for connecting and fixing the housing body. These brackets are evenly distributed at the four corners of the housing body. Each bracket is integrally formed with the housing body, and pre-drilled fixing holes are designed on the brackets for installing bolts or screws.

[0011] Further, the waterproof housing further includes a waterproof seal for sealing protection, which is arranged at the joint of the housing body. The waterproof housing further includes a base for supporting the embedded control system and the AC contactor. The base is installed inside the housing body. The base is a perforated plate with openings covering the entire surface of the perforated plate, and the openings are evenly distributed in a regular manner.

[0012] Preferably, the present utility model further includes a mounting panel for supporting and fixing the embedded control system. The mounting panel is of a rectangular structure and is vertically installed with respect to the base. One side of the mounting panel is provided with an L-shaped structure folded along the edge of the mounting panel, and there are openings thereon for bolt connection with the base; on the other side close to the flip cover of the waterproof housing, there is also an L-shaped structure folded along the edge of the mounting panel, and there are openings for connecting the light guide column and mounting openings for the user interaction module thereon. The mounting panel is further provided with at least four support rods for connecting the embedded control system.

[0013] Furthermore, the present utility model further includes a light guide column for displaying the system status. One end of the light guide column is connected to the position corresponding to the LED on the mounting panel, and the other side of the light guide column extends to the outside of the shell cover of the waterproof housing. The light guide column is a cylinder made of transparent plastic or glass.

[0014] A generator overload protection system provided by the present utility model realizes generator load management through an embedded control system; by adding a user interaction module, it enhances the user's visual perception and operation experience of the system status, and improves the convenience of the system; by integrating the waterproof design and the improvement of the base and mounting panel structures, it improves the applicability and durability of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic diagram of the overall generator overload protection system according to an embodiment of the present utility model;

[0016] Figure 2 It is a schematic diagram of the installation of the waterproof housing of the generator overload protection system according to an embodiment of the present utility model;

[0017] Figure 3 It is a schematic diagram of the overall waterproof housing of the generator overload protection system according to an embodiment of the present utility model;

[0018] Figure 4 It is a schematic diagram of the circuit structure of the control board of the generator overload protection system according to an embodiment of the present utility model. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0019] The embodiments of the present utility model are described in detail below. The examples of the embodiments are shown in the drawings. The exemplary embodiments can be implemented in various forms and should not be construed as limited to the examples described herein; on the contrary, these embodiments are provided to make the present utility model more comprehensive and complete, and to fully convey the concept of the exemplary embodiments to those skilled in the art. The same or similar reference numerals represent the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the drawings are exemplary and are only used to explain the present invention and should not be construed as a limitation of the present invention.

[0020] In the description of the present utility model, it should be noted that unless otherwise clearly specified and defined, the terms "installation", "connection", and "coupling" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can be the communication inside two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0021] A generator overload protection system according to this embodiment is as Figure 1 and Figure 2 shown, including an embedded control system 1, an AC contactor 3, and a waterproof housing 6. The embedded control system 1 and the AC contactor 3 are installed inside the waterproof housing 6.

[0022] The waterproof housing 6 is as Figure 2 and Figure 3 shown, including a housing 12 and a cover 13 of the waterproof housing. The waterproof housing 6 is a plastic housing, which is integrally in a cuboid structure. On the outer bottom side of the housing 12, four brackets 14 for connecting and fixing the housing are provided. These brackets are evenly distributed at the four corners of the housing. Each bracket 14 is integrally formed with the housing 6, and pre-drilled fixing holes are designed on the brackets for installing bolts or screws.

[0023] The cover 13 is connected to the housing 12 through a hinge, and the module is hermetically protected through a waterproof seal 15 arranged at the joint on the top of the housing 12.

[0024] A base 4 for supporting the embedded control system 1 and the AC contactor is provided inside the waterproof housing 6. As Figure 1 shown, the base is a perforated plate, which has openings 8 covering the entire surface of the perforated plate. The openings are evenly distributed in a regular manner, facilitating the installation of screws, fixing components, and providing ventilation.

[0025] An installation panel 2 perpendicular to the base 4 for supporting the embedded control system 1 is installed on the base 4. The installation panel 2 is in a rectangular structure. One side is provided with an L-shaped structure folded along the edge of the installation panel. The bottom of the L-shaped structure has an opening for bolt connection with the base; on the other side close to the flip cover of the waterproof housing, an identical L-shaped structure is provided, which has an opening for connecting a light guide column and an opening for a user interaction module. At least four support rods 10 for connecting the embedded control system 1 are also provided on the installation panel.

[0026] In this embodiment, the light guide column 5 is fixed on one side of the mounting panel 2 close to the waterproof housing flip cover and is connected to the LED 7 on the embedded control system 1. Its extended part passes through the waterproof housing 6 and extends to the outside of the waterproof housing. The light guide column 5 is used to guide the light of the LED 7 and display it on the outside of the waterproof housing 6. The light guide column is a plastic light guide column with good transparency and optical properties to effectively transmit the light emitted by the LED 7.

[0027] The structural design of the waterproof housing and the support structure is reasonable. Users can easily install it on the generator and set and adjust it through simple operations, improving the convenience of the system. The system has waterproof and dustproof functions, enabling it to work normally under harsh environmental conditions and improving the durability of the system.

[0028] In this embodiment, the connection methods of the various modules in the embedded control system 1 are as Figure 4 shown. The power supply module 17 receives the AC input of the generator, converts the AC power into DC power to supply power to the AC contactor control module 18 and the microcontroller module 19.

[0029] The frequency detection module 20 is used to monitor the AC frequency output by the generator. The frequency of the generator is determined by its rotational speed. In the light load or no-load state, the rotational speed and frequency of the generator are close to the rated value because the engine can easily maintain a stable rotational speed. If the load increases too much, the engine may not be able to provide enough power, resulting in a decrease in the rotational speed of the generator, thereby reducing the output frequency. This frequency decrease is because the rotational speed and frequency are directly related. Therefore, the frequency detection module needs to collect and process the AC signal output by the generator, measure its frequency, and convert the frequency information of the AC power to provide it to the microcontroller for analysis.

[0030] In this embodiment, the frequency detection module includes a voltage transformer, a zero-crossing detection circuit, and a signal shaping circuit. The input end of the voltage transformer collects the AC signal of the generator and outputs the AC signal to the zero-crossing monitoring circuit. The zero-crossing detection circuit detects the zero-crossing of the AC signal and transmits the generated square wave signal to the signal shaping circuit. The signal shaping circuit denoises the square wave signal received from the zero-crossing detection circuit and transmits it to the frequency signal detection end of the microcontroller.

[0031] The microcontroller 19 serves as the core control unit, monitors the AC frequency of the generator output voltage by receiving the signal of the frequency detection module 20, controls the AC contactor control module 18, and manages each power consumption circuit.

[0032] The AC contactor control module 18 includes an optocoupler, a driving transistor, and a freewheeling diode. The low-voltage end of the optocoupler is used to receive a low-voltage control signal and isolate the high-voltage circuit. The output end of the optocoupler is connected to the gate of the driving transistor. The driving transistor is an N-channel enhancement-mode MOSFET, and the source of the driving transistor is grounded. The positive pole of the freewheeling diode is connected to the drain of the driving transistor, and the negative pole of the freewheeling diode is connected to the coil terminal of the AC contactor 3. Connect the contacts of the AC contactor 3 to the electrical load to be controlled. When the coil of the AC contactor 3 is energized, the contacts close; when the relay coil is de-energized, the contacts open. By disconnecting or connecting the electrical load, the management of each electrical circuit is realized.

[0033] In this embodiment, the user interaction module includes an input module and an indication module. The indication module includes one or more of an LED, a display screen, and a buzzer. The input module includes one or more of a switch, a touch screen, and a knob. The microcontroller adjusts the connection status, operation mode, priority, and reset settings of the intelligent management module according to the input signal of the input module and prompts the system status through the indication module.

[0034] In this embodiment, the input module includes a microswitch 7, a two-position toggle switch 8, and a rotary switch 9. Among them, the two-position toggle switch 8 has two states (restoring state or locking state) and is used to select the overload protection mode of the system. The microswitch 7 is used to switch the frequency mode of the system and control the disconnection and restoration of the load. The rotary switch 9 is used to specify the priority of different circuits to ensure that under overload conditions, the load is disconnected according to different delays set according to the preset priority, thereby protecting the generator and ensuring the power supply of key equipment. The user can select the output frequency of the generator to be 50Hz or 60Hz according to different power system standards and specify the priority of different circuits. This flexible adjustment function enables the user to better adapt to the needs of different electrical equipment and improves the convenience and applicability of the system.

[0035] In this embodiment, the interaction module uses red LEDs, green LEDs, and orange LEDs to display different states of the system. When the system is in the powered-on state, the interaction module uses LEDs of different colors to distinguish different power system standard frequencies 50HZ / 60HZ. According to the toggling of the switch, the LEDs will provide feedback on the operation and system status through different blinking modes. By clearly displaying different system states through the LEDs, the user's observation and understanding of the system operation are improved, and the convenience of the system is enhanced. The specific function table of the interaction module is shown in Table 1:

[0036]

[0037]

[0038] Table 1

[0039] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit them. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be modified or equivalently replaced without departing from the spirit and scope of the technical solutions of the present invention, and they should all be covered by the scope of the claims of the present invention.

Claims

1. A generator overload protection system, characterized in that: It includes an embedded control system, an AC contactor and a waterproof housing, wherein the embedded control system and the AC contactor are installed inside the waterproof housing; The embedded control system includes a power supply module, a frequency detection module, a microcontroller module, an AC contactor control module and a user interaction module; The input end of the frequency detection module is used to connect to the output of the generator, and the output end of the frequency detection module is connected to the frequency signal detection end of the microcontroller module; The control end of the microcontroller module is connected to the control end of the AC contactor control module, and the output end of the AC contactor control module is connected to the control end of the AC contactor; The switch action end of the microcontroller module is connected to the signal interface of the user interaction module; The input end of the AC contactor is used to connect to the output of the generator, and the output end of the AC contactor is used to connect to an external user load.

2. A generator overload protection system according to claim 1, characterized in that: The frequency detection module includes a voltage transformer, a zero-crossing monitoring circuit and a signal shaping circuit; The voltage transformer input end collects the alternating current signal of the generator and outputs the alternating current signal to the zero-crossing detection circuit; the zero-crossing detection circuit detects the zero-crossing point of the alternating current signal and transmits the generated square wave signal to the signal shaping circuit; The signal shaping circuit receives the square wave signal of the zero point detection circuit and performs noise reduction processing, and the output end of the signal shaping circuit serves as the output end of the frequency detection module.

3. A generator overload protection system according to claim 1, characterized in that: The AC contactor control module includes an optical coupler, a drive transistor and a freewheeling diode; The low voltage end of the optical coupler is used to receive a low voltage control signal and isolate the high voltage circuit, and the output end of the optical coupler is connected to the gate of the driving transistor; The driving transistor is an N-channel enhancement type MOSFET, and the source of the driving transistor is grounded; The positive electrode of the freewheeling diode is connected to the drain of the driving transistor, and the negative electrode of the freewheeling diode is connected to the coil end of the AC contactor.

4. A generator overload protection system according to claim 1, characterized in that: The user interaction module includes an input module and an indication module; The indication module includes one or more of an LED, a display screen, and a buzzer; the input module includes one or more of a switch, a touch screen, and a knob.

5. A generator overload protection system according to claim 1, characterized in that: The waterproof shell includes a shell and a shell cover, the shell cover is connected to the shell by a hinge, and the shell is a rectangular parallelepiped; on the outer bottom side of the shell, four brackets for connecting and fixing the shell are provided, and these brackets are evenly distributed at the four corners of the shell, each bracket is integrally formed with the shell, and the bracket is designed with pre-drilled fixing holes for installing bolts or screws.

6. A generator overload protection system according to claim 5, characterized in that: The waterproof shell also includes a waterproof seal for sealing protection, which is arranged at the seam of the shell.

7. A generator overload protection system according to claim 5, characterized in that: The waterproof housing also includes a base for supporting the embedded control system and the AC contactor; the base is installed inside the housing and is a porous plate with openings covering the entire surface of the porous plate, and the openings are evenly distributed in a regular manner.

8. A generator overload protection system according to claim 7, characterized in that: The waterproof housing also includes an installation panel for supporting and fixing the embedded control system, the installation panel is a rectangular structure, and is installed vertically to the base; one side of the installation panel is provided with an L-shaped structure folded along the edge of the installation panel, and has openings on it for connecting with the base bolts; on the other side close to the shell cover, there is an L-shaped structure also folded along the edge of the installation panel, and has openings on it for connecting the light guide column and the installation openings for the user interaction module; the installation panel is also provided with at least four support rods for connecting the embedded control system.

9. A generator overload protection system according to claim 8, characterized in that: The waterproof housing also includes a light guide column for displaying the system status, one end of the light guide column is connected to the position corresponding to the LED on the installation panel, and the other side of the light guide column extends to the outside of the housing cover.

10. A generator overload protection system according to claim 9, characterized in that: The light guide column is a cylinder made of transparent plastic or glass.

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