Energy Management Module

Abstract

In one aspect, an energy management module is provided having a form factor that fits within one or more slots of a load center or panel board of a structure. The module includes a housing that fits within one or more slots of the load center or panel board. The module has a plurality of current sensor connectors for connecting with current sensors that measure current flowing through breakers in the load center or panel board to circuits within the structure. The module also has one or more power measurement DSPs for measuring power consumption of the circuits. The module includes a microcontroller unit with a wireless network interface for communicating power consumption measurements to a host controller or cloud service, which provides the power consumption measurements for display on an energy management user interface.

Description

[Technical Field]

[0001] The present disclosure relates generally to energy management, and more particularly to devices configured to measure and / or control power consumption of circuits within a structure (e.g., a residential or commercial building). [Background technology]

[0002] Rising electricity costs and increased awareness of environmental impacts have led to increased interest in monitoring and controlling the power supplied to circuits within a structure. This includes the power flowing through the main breaker at the structure's load center or panelboard (often simply referred to as a "breaker box") and the power flowing through individual circuit breakers that power specific loads (e.g., lighting fixtures, wall outlets, appliances, HVAC equipment, etc.). Various energy management systems have been developed to address these tasks. However, existing energy management systems typically require auxiliary components to be installed near (but external to) the load center or panelboard to perform monitoring and control functions. The need for such external auxiliary components complicates installation, consumes additional space in utility rooms, and increases costs. An improved solution is needed that does not require auxiliary components to be located near (but external to) the load center or panelboard. Summary of the Invention [Means for solving the problem]

[0003] In one embodiment, an energy management module (e.g., a standalone energy management (SEM) module) is provided having a form factor adapted to fit within one or more slots in a load center or panel board. The form factor may be that of a two-pole breaker that fits within two slots in the load center or panel board, and the energy management module may be secured within the slots by a combination of one or more tabs that engage with a retainer bar and one or more clips that engage and electrically connect with a hot bus bar. The SEM module includes a plurality of current sensor connectors configured to connect with current sensors (e.g., clip-on / off split-core Hall-effect current sensors) that measure current flowing through the circuit through the breakers (e.g., main breaker and individual circuit breakers). One or more power measurement digital signal processors (DSPs) may be configured to measure power consumption of the circuit using the current and voltage measured on the hot bus bar. The SEM module may include a microcontroller unit having a wireless network interface (e.g., a Wi-Fi interface, a Bluetooth® Low Energy (BLE) interface, etc.) configured to communicate the power consumption measurements to a host controller or cloud service of the energy management system. The host controller or cloud service may provide the power consumption measurements to an energy management user interface of a control application (app) that may run on the mobile device. The SEM module may further include a local user interface configured to locally display at least a portion of the power consumption measurements.

[0004] In some embodiments, the SEM module may further include an integrated panel bridge controller (PBC) configured to communicate over a wireless network interface (e.g., a BLE interface) with one or more companion modules within a load center or panel board associated with each breaker. The PBC may perform energy management functions on behalf of a host controller or cloud service by receiving data from the companion modules and forwarding the data to the host controller or cloud service or by sending control commands to the companion modules.

[0005] It will be understood that various additional features and alternative embodiments may be implemented. This summary is for introductory purposes only and does not suggest or imply that the examples set forth herein are exhaustive of all aspects of the invention, or that they are required or essential aspects of the invention. [Brief explanation of the drawings]

[0006] In the following description, reference is made to the accompanying drawings. [Figure 1] FIG. 1 is a block diagram illustrating an example of an architecture of an energy management system that may include an SEM module. [Figure 2] 1 is a close-up view of an example load center or panel board, showing the interconnections between the SEM module and other components within the load center or panel board. [Figure 3] FIG. 2 is a block diagram illustrating various internal components of a first example SEM module that does not include an integrated PBC. [Figure 4] FIG. 10 is a block diagram illustrating various internal components of a second example SEM module that does not include an integrated PBC. [Figure 5] FIG. 10 illustrates an example of a configuration screen that may be displayed by a controlling app on a mobile device to configure the SEM module. DETAILED DESCRIPTION OF THE INVENTION

[0007] Detailed Description definition As used herein, the term "home automation system" refers to a system that controls at least one of audio / video, lighting, heating, ventilation, and air conditioning (HVAC) or energy functions within a structure (e.g., a residence or commercial building).

[0008] As used herein, the term "energy management system" refers to a system for monitoring and / or controlling energy consumption, generation, and / or storage within a structure (e.g., a residential or commercial building). An energy management system may be a component of a home automation system or may be a stand-alone system.

[0009] As used herein, the term "mobile device" refers to an electronic device that runs a general-purpose operating system and is suitable for portability. Devices such as smartphones should be considered mobile devices. Desktop computers, servers, or other primarily stationary computing devices should generally not be considered mobile devices.

[0010] As used herein, the term "companion module" refers to a device having a form factor adapted to fit within one or more slots of a load center or panel board and configured to monitor and control the circuits of associated circuit breakers of the load center or panel board.

[0011] As used herein, the term "panel bridge controller" or PBC refers to a device configured to communicate with one or more companion modules associated with each breaker in a load center or panel board and to receive data from and send control commands to one or more companion modules as part of an energy management system. A PBC may be a stand-alone device or may be incorporated into a multi-function device.

[0012] Example of an embodiment 1 is a block diagram illustrating an example of an energy management system architecture 100 that may include an SEM module. A load center or panel board (often simply referred to as a "breaker box") 110 receives power from a utility power grid 142, local generation (e.g., solar, wind, etc.) 144, and / or a local battery or generator 146 via an automatic transfer switch (ATS) 140. The ATS 140 may be an intelligent power source switching device having a microprocessor-based controller configured to automatically switch between power sources to balance the load.

[0013] The load center or panel board 110 includes a main breaker 122 through which all power flows and several individual circuit breakers 124 that each distribute power to one or more circuits that supply various loads within the structure (e.g., lighting fixtures, wall outlets, appliances, HVAC equipment, etc.). In some cases, the individual circuit breakers 124 may be associated (e.g., wired in series) with their own companion modules 132 that monitor and control the circuits contained within the circuit breakers 124. Each companion module 132 may include one or more relays configured to control (i.e., turn on or off) its respective circuit, one or more current sensors (e.g., Hall-effect current sensors) configured to measure current through its respective circuit, a power measurement DSP configured to measure power consumption (e.g., instantaneous power consumption, average power consumption, peak power consumption, etc.) of a load coupled to the circuit, a microcontroller with an integrated wireless network interface (e.g., a BLE interface) configured to transmit data and receive and execute control commands, and a local user interface (e.g., an LCD screen and switches / buttons) configured to display data locally and / or receive local control commands. If a companion module 132 is associated with a circuit breaker, the current and voltage may be measured by the companion module. However, in some embodiments, some circuit breakers may not have an associated companion module 132 or may not have a companion module at all. Additionally, in some embodiments, there may not be a convenient nearby component (eg, a dedicated PBC) to receive data and send control commands to the companion module 132 .

[0014] To address these issues, the load center or panel board 110 may include one or more SEM modules 134. The SEM modules 134 are configured to measure the power consumption of the loads on the circuits of the individual circuit breakers 124 and the total power consumption through the main breaker 122. Each SEM module 134 may include a microcontroller and a wireless network interface for communicating power consumption measurements to the host controller 150 or cloud service 160 (e.g., using Wi-Fi, BLE, etc.). In some embodiments, the SEM module 134 may further include an integrated PBC configured to receive data from and send control commands to the companion module 132 via the wireless network interface (e.g., BLE) on behalf of the host controller 150 or cloud service 160. As described further below, the SEM module 134 may have a form factor (e.g., that of a two-pole breaker) adapted to fit within one or more slots in the load center or panel board 110.

[0015] The host controller 150 can execute host software configured to monitor and control the operation of the structure's home automation system components (e.g., an energy management system, etc.). When executed, the host software can provide various functions, such as interpreting a user interface (UI), managing and monitoring the system, synchronizing with a cloud service 160 via the Internet 155, activity logging, activity prediction, and / or other types of functionality. The host software can manage a home database that stores configuration information for the home automation system components, including energy management system components such as the companion module 132 and the SEM module 134. At least a portion of the data in the home database may be managed (e.g., redundantly) by the cloud service 160. The host controller 150 can communicate (e.g., via Wi-Fi) with one or more mobile devices 170 configured to execute a control app 172. The control app 172 may be configured to display a user interface for monitoring and controlling the operation of home automation functions. At least a portion of the user interface may be an energy management user interface for monitoring and controlling energy-related functions.

[0016] FIG. 2 is an expanded view of an example load center or panel board 110, illustrating the interconnections between the SEM module 134 and other components within the load center or panel board. In one embodiment, the load center or panel board 110 is a single-phase 240-volt (V) electrical panel with a current rating of up to 200 amps (A). However, it should be understood that the load center or panel board 110 may alternatively have a different specification (e.g., three-phase with different voltage and current ratings). As in FIG. 1, the load center or panel board 110 includes a main breaker 122 and multiple individual circuit breakers 124 associated with companion modules 132. In this example, a single SEM module 134 is installed. However, it should be understood that in some embodiments, multiple SEM modules 134 may be installed on the load center or panel board 110.

[0017] The SEM module 134 may have a housing (e.g., a plastic housing) similar to a circuit breaker (e.g., a two-pole breaker) sized to fit within one or more slots (e.g., two slots) in the load center or panel board 110. The SEM module 134 may be secured within the slots by a combination of engagement between a protrusion on the load center or panel board's retainer bar 210 and one or more tabs molded into the housing, and engagement between the hot bus bars 220, 230 of the load center or panel board 110 and one or more metal clips protruding through the housing. In addition to providing a securing function, the one or more metal clips may also provide electrical connection to the hot bus bars 220, 230. Terminals protruding through the housing may provide electrical connection (e.g., via wire) to the neutral bus bar 240 of the load center or panel board 110. Through such electrical connection, the SEM module 134 may obtain power to support its operation. Additionally, the SEM module 134 can also measure the voltage on the hot bus bars 220, 230 of the load center or panel board 110 for use in power measurements.

[0018] The SEM module 134 may include several (e.g., 12) current sensor connectors extending through the housing (e.g., on pluggable terminal blocks) that may be configured to connect via wires to current sensors (e.g., clip-on split-core Hall-effect current sensors) 250, 260 associated with (e.g., clipped around) wires in the load center or panel board 110. Each current sensor may have a respective current rating (e.g., 20 A, 50 A, 150 A, 250 A, 400 A, 600 A, etc.) that indicates the maximum amount of current it can measure. The current sensors may include a current sensor 250 on the positive wire connected to the main breaker 122 (measuring current flowing through the main breaker to all circuits) and a current sensor 260 on the positive wire connected to individual circuit breakers (measuring current flowing to individual circuits supplying power to loads within the structure). Depending on the embodiment, current sensors 250, 260 may be provided for all circuits or for selected circuits.

[0019] It should be noted that, in addition to the physical interconnection, the SEM module 132 may further have a wireless connection (e.g., via Wi-Fi, BLE, etc.) with the host controller 150 via its wireless network interface, and in embodiments including an integrated PBC, the SEM module 132 may further have a wireless connection (e.g., via BLE) with the companion module 132. In embodiments where the SEM module 134 includes an integrated PBC, in addition to the current measurements obtained by the current sensors 250, 260, additional current measurements may be obtained using an internal current sensor (e.g., a Hall effect current sensor) of the companion module 132.

[0020] The SEM module 134 may further include an LCD screen and switches / buttons (e.g., two switches and one button) that extend through the front face of the housing to provide a local user interface for the SEM module that may be used to display at least some power consumption measurements and receive local control commands (e.g., to change the type of display and make selections therein).

[0021] 3 is a block diagram illustrating various internal components of a first example SEM module 134 that does not include an integrated PCB. At the heart of the module 134 is a microcontroller unit 310 with an integrated wireless network interface (e.g., a Wi-Fi / BLE network interface). A plurality of current sensor connectors 320 (e.g., on four pluggable terminal blocks with eight connection points each) are configured to connect to a set of current sensors (e.g., 12 clip-on split-core Hall-effect current sensors) that measure current flowing through breakers on the load center or panel board 110 to circuits within the structure. The current sensor connectors 320 are coupled to one or more power measurement DSPs (e.g., six two-channel DSPs) via PCB-to-PCB connectors 330. The one or more power measurement DSPs are configured to measure the power consumption (instantaneous power consumption, average power consumption, peak power consumption, etc.) of the loads coupled to the circuit using current measurements and voltages on one or more hot bus bars 220, 230 of the load center or panel board and provide those measurements to the microcontroller unit 310. The microcontroller unit 310 is configured to communicate those power consumption measurements using its integrated wireless network interface via an antenna 350 coupled by a connector (e.g., a Sub-Miniature Version A (SMA) connector) to the host controller 150 or cloud service 160, which provides the power consumption measurements for display in an energy management user interface.

[0022] Also connected to the microcontroller unit 310 is a UI module 360. The UI module 360 provides a local user interface for displaying at least a portion of the power consumption measurements and / or receiving local control commands. The UI module 360 may include an LCD screen 362 and switches / buttons 364, 366. The UI module 360 may further include an accelerometer 368 configured to determine the orientation of the SEM module 134. Depending on the orientation of the SEM module 134, the image displayed on the LCD screen 362 may be rotated to ensure that on-screen text and / or graphics are properly oriented. Components of the SEM module 134, such as the microcontroller unit 310 and the UI module 360, may be powered by an AC-DC power supply 370 that converts power from the hot busbars 220, 230 of the load center or panel board 110.

[0023] 4 is a block diagram illustrating various internal components of a second example SEM module 134 including an integrated PBC. At the heart of the module is a microcontroller unit 410 connected to memory (dynamic random access memory (DRAM) 412 and solid-state storage (embedded multimedia card (eMMC)) 414) in which an operating system (e.g., a Linux operating system) and application code for the PBC functions are stored. A plurality of current sensor connectors 320 (e.g., on four pluggable terminal blocks each with eight connection points) are configured to interface with a set of current sensors (e.g., twelve clip-on split-core Hall-effect current sensors) that measure current flowing through breakers on the load center or panel board 110 to circuits within the structure. The current sensor connectors 320 are coupled via PCB-to-PCB connectors 330 to one or more power measurement DSPs (e.g., six two-channel DSPs). The one or more power measurement DSPs are connected to one or more power measurement DSPs on the load center or panel board. The microcontroller unit 410 is configured to use the current measurements and voltages on the hot bus bars 220, 230 to measure power consumption (e.g., instantaneous power consumption, average power consumption, peak power consumption, etc.) of a load coupled to the circuit and provide the power consumption measurements to the microcontroller unit 410. The microcontroller unit 410 is configured to communicate the power consumption measurements to the host controller 150 or the cloud service 160 using a wireless network interface (e.g., a Wi-Fi / BLE network interface) coupled to the antenna 350 by a connector (e.g., an SMA connector). The host controller 150 or the cloud service 160 provides the power consumption measurements for display on an energy management user interface. The microcontroller unit 410 is further configured to perform PCB functions according to instructions from the host controller 150 or the cloud service 160.

[0024] Also connected to the microcontroller unit 310 is a UI and network module 460. The UI and network module 460 includes a local user interface for displaying at least a portion of the power consumption measurements and / or receiving local control commands, as well as another wireless network interface (e.g., a BLE network interface) for receiving data from and sending control commands to the companion module 132. The UI and network module 460 may include an LCD screen 362 and switches / buttons 364, 366. The UI and network module 460 may further include an accelerometer 368 configured to determine the orientation of the SEM module 134. Depending on the orientation of the SEM module 134, the screen displayed on the LCD may be rotated to ensure that text and / or graphics are properly oriented. Additionally, the UI and network module 460 may include a network system-on-chip (SOC) (e.g., a Bluetooth SOC) adapted to communicate with the companion module 132 as part of the PBC functionality. Components of the SEM module 134, such as the microcontroller unit 310 and the UI and network module 460, may be powered from an AC-to-DC power supply 370 that converts power from the hot bus bars 220, 230 of the load center or panel board 110. A power management integrated circuit (IC) 380 and a voltage converter 382 can be used to condition and convert such power.

[0025] FIG. 5 illustrates an example of a configuration screen 500 that may be displayed by the control app 172 on the mobile device 170 to configure the SEM module 134. At least a portion of the configuration information may be stored in a home database. A user can select or deselect an enable field 510 for each circuit to specify whether that circuit is displayed within the energy management user interface provided by the control app 172. A user can enter a category describing the physical wiring to which the current sensors 250, 260 are connected in the circuit description field 515 and a classification (e.g., consumption, production, supply) in the classification field 520. A user can customize the display of power consumption information within the energy management user interface using the image field 525, group image field 530, and group name field 535. A user can enter identification information for the SEM module 134 in the monitoring device field 540 and identification information for the current sensor connector 320 monitoring the circuit in the channel field 545. A size field 550 can enter the size of the circuit, and a voltage source field 555 can enter identification information for the voltage measurement source for power calculations. The user may further enter detailed information describing the configuration and characteristics of the monitored circuit and its relationship to the larger home automation system in the parent circuit field 560, control field 565, home automation zone field 570, and production type field 575.

[0026] It should be understood that various adaptations and modifications may be made to the SEM module 134 described above. It should be understood that at least a portion of the functionality proposed above as being implemented in hardware may also be implemented in software, and vice versa. In general, functionality may be implemented in hardware, software, or various combinations thereof. Hardware embodiments may include logic circuits, application-specific integrated circuits, and / or other types of hardware components. Software embodiments may include electronic-executable instructions (e.g., computer-executable instructions) stored on a non-transitory electronic-readable medium (e.g., a non-transitory computer-readable medium), such as volatile or persistent memory, a hard disk, a compact disc (CD), or other tangible media. Furthermore, a combined software / hardware embodiment may include both electronic-executable instructions stored on a non-transitory electronic-readable medium and one or more hardware components, such as a processor, memory, etc. Above all, it should be understood that the above-described embodiments are intended to be merely exemplary.

Claims

1. an energy management module having a form factor adapted to fit within one or more slots in a load center or panel board of a structure, a housing configured to fit within the one or more slots of the load center or panel board; a plurality of current sensor connectors configured to connect to current sensors that measure current flowing through breakers at the load center or panel board to circuits within the structure; one or more power measurement digital signal processors (DSPs) configured to measure the power consumption of the circuit; a microcontroller unit having a wireless network interface configured to communicate the power consumption measurements to a host controller or a cloud service, the host controller or the cloud service providing the power consumption measurements for display on an energy management user interface; and Energy management module, including:

2. one or more clips each configured to engage and electrically connect with a hot bus bar of the load center or panel board; a terminal electrically connected to the neutral bus bar of said load center or panel board; The energy management module of claim 1 further comprising:

3. 3. The energy management module of claim 2, wherein the one or more power measurement DSPs are configured to measure power consumption of the circuit using a voltage supplied through the one or more clips.

4. the housing further includes one or more tabs each configured to engage a fastener bar of the load center or panel board; The energy management module of claim 2 , wherein a combination of the one or more tabs and the one or more clips secures the energy management module within the one or more slots of the load center or panel board.

5. The energy management module of claim 1 , wherein the one or more slots are two slots and the form factor is a two-pole breaker.

6. 2. The energy management module of claim 1, wherein the wireless network interface comprises a Wi-Fi interface or a Bluetooth Low Energy (BLE) interface configured to communicate the power consumption measurements to the host controller or the cloud service.

7. a local user interface configured to locally display at least a portion of the power consumption measurements and / or receive local control commands; The energy management module of claim 1 further comprising:

8. 2. The energy management module of claim 1, wherein the breakers include a main breaker at the load center or panel board and a plurality of individual circuit breakers, and the current sensor measures current flowing through the main breaker and current flowing through the plurality of individual circuit breakers to a circuit supplying power to a load.

9. an integrated panel bridge controller (PBC) configured to communicate over the wireless network with one or more companion modules associated with each breaker in the load center or panel board to receive data from and send control commands to the one or more companion modules; The energy management module of claim 1 further comprising:

10. 10. The energy management module of claim 9, wherein the wireless network interface includes a Bluetooth Low Energy (BLE) interface configured to receive data from and send control commands to the one or more companion modules.

11. an energy management module having a form factor adapted to fit within one or more slots in a load center or panel board of a structure, one or more clips each configured to engage and electrically connect with a hot bus bar of the load center or panel board; a terminal electrically connected to the neutral bus bar of the load center or panel board; a plurality of current sensor connectors configured to connect to current sensors that measure current flowing through breakers at the load center or panel board to circuits within the structure; one or more power measurement digital signal processors (DSPs) configured to measure the power consumption of the circuit; a microcontroller unit configured to communicate the power consumption measurements to a host controller or a cloud service; Energy management module, including:

12. 12. The energy management module of claim 11, wherein the one or more power measurement DSPs are configured to measure power consumption of the circuit using a voltage supplied through the one or more clips.

13. 12. The energy management module of claim 11, wherein the wireless network interface comprises a Wi-Fi interface or a Bluetooth Low Energy (BLE) interface configured to communicate the power consumption measurements to the host controller or the cloud service.

14. a local user interface configured to locally display at least a portion of the power consumption measurements and / or receive local control commands to control the local display; The energy management module of claim 11 further comprising:

15. 12. The energy management module of claim 11, wherein the breakers include a main breaker at the load center or panel board and a plurality of individual circuit breakers, and the current sensor measures current flowing through the main breaker and current flowing through the plurality of individual circuit breakers to a circuit supplying power to a load.

16. an integrated panel bridge controller (PBC) configured to communicate over the wireless network with one or more companion modules associated with each breaker in the load center or panel board to receive data from and send control commands to the one or more companion modules; The energy management module of claim 11 further comprising:

17. 17. The energy management module of claim 16, wherein the wireless network interface includes a Bluetooth Low Energy (BLE) interface configured to receive data from and send control commands to the one or more companion modules.

18. 1. A method of using an energy management module having a form factor adapted to fit within one or more slots in a load center or panel board of a structure, comprising: installing the energy management module within the one or more slots of the load center or panel board; connecting a plurality of current sensor connectors of the energy management module to a plurality of current sensors that measure current flowing through the breakers of the load center or panel board to circuits within the structure; configuring the energy management module with information describing the circuits within the structure; configuring the energy management module to communicate power consumption measurements of the circuits within the structure based on the measured current to a host controller or a cloud service; A method comprising:

19. installing the energy management module engaging one or more clips of the energy management module with a hot bus bar of the load center or panel board; Connecting the terminals of the energy management module to the neutral bus bar of the load center or panel board.

20. The method of claim 18, further comprising:

20. Configuring the energy management module to operate as an integrated panel bridge controller (PBC) for the load center or panel board, the integrated panel bridge controller (PBC) communicating with one or more companion modules associated with each breaker in the load center or panel board to receive data from and send control commands to the one or more companion modules.

20. The method of claim 18, further comprising:

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