Easy to expand the distribution plane and the extension method using the same

Abstract

The present invention relates to an easily expandable distribution board and an expansion method using the same, and more specifically, to an easily expandable distribution board and an expansion method using the same that provides flexible expandability of a distribution board system in response to changes in power demand.

Description

Technology Field

[0001] The present invention relates to an easily expandable distribution board and an expansion method using the same, and more specifically, to an easily expandable distribution board and an expansion method using the same that provides flexible expandability of a distribution board system in response to changes in power demand. Background Technology

[0002] As the demand for electrical energy continues to increase, the importance of distribution panel systems for stable and efficient power supply is growing day by day. However, existing distribution panel systems suffer from the following serious problems, and consequently, they face significant limitations in meeting the demands of the modern industrial environment.

[0003] First, existing distribution panel systems are designed with fixed capacities, making it difficult to respond flexibly to changes in power demand. If the initially installed capacity becomes insufficient, the entire system must be replaced; this not only incurs massive costs and time but also leads to power outages, causing serious disruptions to production activities. Conversely, if the initial capacity is designed to be excessive, it results in unnecessary initial investment costs and leads to lower energy efficiency in the long run.

[0004] Second, in existing systems, the electrical connections inside the distribution panel are complex and difficult to maintain. With numerous cables and busbars entangled, it is difficult to pinpoint the location of a fault, and there is a high risk of safety accidents, such as electric shock, during maintenance work. Furthermore, there is a constant risk of overheating and fire due to errors at connection points or poor contact. This significantly reduces system reliability and is a major cause of increased maintenance costs.

[0005] Third, existing systems have very limited scalability. When additional distribution panels need to be added due to increased load, integration with existing facilities is difficult and space constraints are significant. There is insufficient workspace for cable connections, and the risk of accidents caused by operator error increases. Furthermore, prolonged equipment downtime due to expansion work leads to decreased productivity. This acts as a fundamental limitation that makes it difficult to respond quickly to corporate growth and change.

[0006] Fourth, existing distribution panels lack effective monitoring and control functions. It is difficult to monitor the status of each panel in real time and detect abnormal signs early, making accident prevention challenging. Furthermore, the lack of control functions for optimizing load distribution or saving energy leads to energy waste and increased costs resulting from inefficient operation. This acts as a major obstacle hindering the implementation of smart factories required in the modern industrial environment.

[0007] Fifth, existing systems have very limited data collection and utilization. Due to a lack of infrastructure capable of systematically collecting and analyzing the vast amount of operational data generated from each distribution panel, it is difficult to utilize this data for equipment preventive maintenance or performance improvement. This leads to reduced equipment reliability and frequent breakdowns, resulting in increased maintenance costs. Furthermore, the difficulty in supporting decision-making based on collected data leads to the loss of opportunities for efficient equipment operation and energy savings.

[0008] Sixth, existing distribution panels significantly lack safety and convenience. Their complex and cramped internal structures hinder worker accessibility, posing a constant risk of safety accidents such as electric shock and fire. Furthermore, the inconvenient door opening and closing mechanisms and low durability of the panels lead to frequent breakdowns and increased maintenance costs. In addition, inadequate internal environmental control functions result in frequent equipment damage caused by temperature rises or humidity.

[0009] Seventh, existing systems are vulnerable to electromagnetic interference. Although strong electromagnetic fields are generated due to the dense concentration of high-voltage equipment and cables, adequate shielding measures are lacking. Consequently, electronic equipment inside distribution panels frequently malfunctions or fails. Furthermore, electromagnetic noise disrupts communication and control signals, posing a problem that significantly degrades the overall stability and reliability of the system.

[0010] Eighth, the installation and maintenance of existing distribution panels are complex and inefficient. Since numerous parts and cables must be assembled and connected manually, they consume a significant amount of time and manpower. The complexity of the wiring process increases the likelihood of worker errors, leading to frequent rework. Furthermore, repairs require the individual replacement of related parts, which prolongs work time and increases costs.

[0011] Ninth, existing systems have very low interoperability. Since specifications and standards vary by manufacturer, it is difficult to link heterogeneous equipment. This leads to difficulties in procuring parts and limits the range of options when expanding the system. Furthermore, additional costs and effort are required to manage heterogeneous equipment in an integrated manner, and trial and error frequently occurs due to compatibility issues.

[0013] As discussed above, existing distribution panel systems are currently unable to meet the demands of modern industrial sites due to various problems and limitations. Accordingly, there is an urgent need for the development of next-generation distribution panel systems that significantly improve scalability, flexibility, safety, efficiency, and eco-friendliness. To address these technical challenges, this invention proposes a high-efficiency distribution panel system equipped with an innovative modular structure and intelligent management functions. The problem to be solved

[0015] The present invention has been devised to improve upon the aforementioned problems. The purpose of the present invention is to provide an easily expandable distribution panel and an expansion method using the same, which include flexible scalability of the distribution panel system in response to changes in power demand, stability and efficiency of electrical connections between distribution panel modules, simplification and time saving of the system configuration and reconfiguration process, and real-time monitoring and efficient operation management functions of the distribution panel system. means of solving the problem

[0016] To achieve the above objectives, one embodiment of the present invention relates to an expandable modular distribution board system, wherein each distribution board module, which includes a plurality of distribution board modules and accommodates electrical components inside, comprises: a door formed on each of the upper, lower, left, and right sides of the distribution board module; a clamp installed on the inner side of each door; and a busbar jack detachably coupled to the clamp; wherein the door is configured to be pushed inward to open and has a structure that separates and opens to both sides when opened, and the busbar jack has a structure in which identical shapes are attached to both sides and includes a clamp portion formed within the coupling portion and coupled to the clamp; and the clamp includes a connecting portion that electrically connects to the coupling portion; and the electrical bar made of a conductive material within the connecting portion and the clamp portion made of a conductive material in the coupling portion are coupled.

[0017] The present invention relates to a method for configuring and operating an expandable modular distribution system, comprising: a) preparing a plurality of distribution modules; wherein each distribution module includes a main body, opening / closing doors on the top, bottom, left, and right sides, a busbar jack, and a clamp; b) analyzing system requirements to determine the quantity and arrangement of necessary distribution modules; c) physically arranging the distribution modules according to the determined arrangement; d) opening the opening / closing doors of adjacent distribution modules; e) exposing the clamps on the inside of the opened opening / closing doors; and f) inserting a busbar jack between the exposed clamps to electrically connect them. Effects of the invention

[0019] The present invention provides the following effects:

[0020] 1. Through a modular structure, the system can be easily expanded or contracted according to changes in power demand, minimizing initial investment costs and allowing for flexible response to future demand changes.

[0021] 2. The specially designed busbar jack and clamp system significantly improve the stability and reliability of electrical connections between modules and minimize human error during the connection process.

[0022] 3. System configuration and reconfiguration time is significantly reduced through standardized modules and simple connection methods, thereby increasing work efficiency and minimizing downtime.

[0023] 4. By continuously observing and analyzing the status and performance of each module through a real-time monitoring system, potential problems can be detected in advance, enabling preventive maintenance.

[0024] 5. In the event of a failure, the module is quickly isolated and its function is automatically switched, thereby maximizing system availability and ensuring the continuity of power supply.

[0025] 6. Increase energy efficiency and reduce operating costs through AI-based load analysis and power distribution optimization.

[0026] 7. Through a systematic data collection and analysis system, long-term operational patterns can be identified, and based on this, plans for system improvement and expansion can be established.

[0027] 8. The use of standardized modules makes maintenance and parts replacement easier, which leads to reduced maintenance costs in the long run.

[0028] When these effects are combined, the present invention significantly improves the efficiency, reliability, and flexibility of the power distribution system, and enables environmentally friendly power management along with reduced operating costs. Brief explanation of the drawing

[0029] FIG. 1 is a perspective view showing the overall configuration of an expandable modular distribution board system according to the present invention. FIG. 2 is a front view of a distribution board module according to the present invention. FIG. 3 is an exploded perspective view showing the combined structure of a clamp and a busbar jack according to the present invention. FIG. 4 is a side view showing the combined state of the clamp and the busbar jack according to the present invention. FIG. 5 is a plan view showing the connection structure between adjacent distribution board modules according to the present invention. FIG. 6 is a perspective view showing the detailed structure of a busbar jack according to the present invention. FIG. 7 is a perspective view showing the detailed structure of a clamp according to the present invention. FIG. 8 is a perspective view showing the combined structure of a clamp and a busbar jack according to the present invention. FIG. 9 is a drawing showing a front view of a busbar jack according to the present invention. Specific details for implementing the invention

[0030] The present invention as described above will be explained in detail through the attached drawings and embodiments.

[0031] Furthermore, in describing the present invention, detailed descriptions of related prior art are omitted if it is determined that such descriptions could obscure the essence of the invention. Additionally, it should be noted that the attached drawings are intended only to facilitate an understanding of the concept of the present invention and should not be interpreted as limiting the concept of the present invention.

[0032] In this case, each functional description divided by a distinguishing number describing each embodiment implies that it includes a function or module according to such description. Furthermore, these functions or modules are organically connected to the present invention via a network.

[0033] Hereinafter, preferred embodiments according to the present invention will be described in detail with reference to the attached drawings. Identical or similar components are given the same reference number regardless of the drawing symbols, and redundant descriptions thereof will be omitted.

[0035] FIG. 1 is a perspective view showing the overall configuration of an expandable modular distribution board system according to the present invention.

[0036] As illustrated in FIGS. 1 to 5, the distribution board system (100) of the present invention is composed of a plurality of distribution board modules (110). Each distribution board module (110) includes a main body that accommodates electrical components inside, an opening / closing door (10) formed on each of the upper, lower, left, and right sides of the main body, a clamp (21, 23) fixedly installed on one side of the main body frame of the distribution board module (110) so as to be exposed to the outside when the opening / closing door (10) is opened, and a busbar jack (22) detachably coupled to the clamp (21, 23).

[0037] That is, a busbar jack (22) can be inserted between the exposed clamps (21, 23) to make an electrical connection.

[0038] The above-mentioned opening / closing door (10) is configured to be pushed inward to open and has a structure that separates and opens to both sides when opened. This allows the user to easily access the interior of each module and secure sufficient space when connecting modules.

[0039] Specifically, each distribution panel module (110) has a main body that accommodates electrical components inside. A door (10) is formed on each of the upper, lower, left, and right sides of the distribution panel module (110). The door (10) is configured to be pushed inward to open and has a structure that separates and opens to both sides when opened.

[0040] A pair of clamps (21, 23) are installed on one side of the main body frame of the distribution board module (110) so as to be exposed to the outside when the opening / closing door (10) is opened. A busbar jack (22) is detachably connected between the clamps (21, 23).

[0041] The above busbar jack (22) has a structure in which identical shapes are joined on both sides, and the coupling part (221) includes a clamp part (223) that is coupled to the clamp (21, 23), and the clamp (21, 23) is electrically connected to the coupling part.

[0042] Meanwhile, the clamp (21, 23) has a connecting part (211, 231) that is electrically connected to the coupling part (221). At this time, an electric bar (213, 233) made of a conductive material is provided inside the connecting part (211, 231), and the electric bar (213, 233) is physically and electrically connected to the clamp part (223) of the busbar jack (22) coupling part (221).

[0043] The distribution board modules (110) of the present invention configured in this manner can freely expand capacity and function according to the user's needs. That is, as shown in FIG. 1, the system can be expanded simply and quickly by opening the doors (10) of a plurality of distribution board modules (110) and implementing electrical connection by simply inserting a busbar jack (22) between the clamps (21, 23) of adjacent modules.

[0044] As illustrated in FIGS. 6 to 9, the distribution board modules (110) of the present invention are configured to flexibly expand the capacity and functions of the distribution board system according to the user's needs.

[0045] Specifically, when the opening / closing door (10) of each distribution panel module (110) is opened, the clamps (21, 23) installed inside are exposed, and when expanded, an electrical connection is made by simply inserting a busbar jack (22) between the exposed clamps (21, 23) of adjacent modules.

[0046] Due to these structural features, the distribution panel system of the present invention can initially install only the necessary number of modules and expand capacity by adding modules as power demand increases. This provides the effect of actively responding to future load increases while minimizing initial investment costs. Furthermore, maintainability is significantly improved because only the relevant module can be easily detached for replacement or upgrade of a faulty module.

[0047] Meanwhile, the clamp portion (223) of the busbar jack (22) according to one embodiment of the present invention further includes a coupling projection (224) to improve coupling with the electric bar (213, 233). The coupling projection (224) is formed to protrude from the inner surface of the clamp portion (223) as shown in FIG. 3.

[0048] When the clamp portion (223) is inserted into the connecting portion (211, 231) of the clamp (21, 23) and comes into contact with the electric bar (213, 233), the coupling projection (224) presses the surface of the electric bar (213, 233) to increase the contact area and minimize contact resistance.

[0049] In addition, the coupling projection (224) also serves as a stopper to prevent the busbar jack (22) from detaching due to external force applied to the clamp (21, 23). Thus, a stable and highly reliable electrical connection can be achieved.

[0050] The electric bar (213, 233) and the clamp part (223) are made of a copper alloy with excellent electrical conductivity. Specifically, copper alloys such as brass, bronze, and beryllium copper may be used.

[0051] These alloys have excellent mechanical strength and wear resistance compared to pure copper, and also have high electrical conductivity, making them suitable for electrical contact applications where frequent contact and disconnection occur, such as in the present invention.

[0052] In addition, plating treatment is additionally performed on the surfaces of the electric bar (213, 233) and the clamp part (223) made of the copper alloy to improve corrosion resistance.

[0053] Plating materials mainly include tin (Sn), nickel (Ni), gold (Au), and silver (Ag), and one or more of these can be plated in a single-layer or multi-layer structure. By suppressing oxidation and corrosion of the electrical contact parts through appropriate plating treatment, contact failures due to long-term use can be prevented and the reliability of the electrical connection can be further enhanced.

[0054] Therefore, according to the technical features of the present invention, the expandability, maintainability, and electrical stability of the modular distribution panel system can be comprehensively improved.

[0055] In particular, the ability to easily and quickly expand and replace modules to meet user requirements enables proactive responses to rapidly changing power demands. Furthermore, by securing long-term reliability through the design optimization and material selection of electrical contacts, it contributes to improving the overall availability of the system.

[0057] Meanwhile, the following describes in detail the expansion method using an easily expandable distribution panel.

[0058] The expandable modular distribution board system according to the present invention can be implemented through the following configuration and expansion method.

[0059] First, a plurality of distribution board modules (110) are prepared (step a). Referring to FIGS. 1 to 3, each distribution board module (110) includes a rectangular main body containing electrical components. Opening and closing doors (10) are installed on the upper, lower, left, and right sides of the main body. Clamps (21, 23) are installed on the inside of the opening and closing doors (10), and a busbar jack (22) is detachably connected between adjacent clamps (21, 23).

[0060] Next, the specifications required by the system are analyzed to determine the quantity and arrangement of the necessary distribution panel modules (110) (step b). To do this, a power system diagram and a single-line diagram are first created, and a load list is prepared to calculate the total capacity and safety margin.

[0061] In addition, the module layout is designed by comprehensively considering physical space constraints and ease of maintenance.

[0062] Once the layout design is complete, each distribution panel module (110) is physically arranged in the actual installation space (step c).

[0063] When the arrangement of the modules is complete, the doors (10) of adjacent distribution board modules (110) are opened (step d). The doors (10) are connected to the module body by a hinge structure, so they can be easily opened by holding the handle and pulling it forward.

[0064] At this time, for safety, before opening the door (110), the live wire status inside the module must be checked, and if necessary, insulation measures must be taken to prevent electric shock.

[0065] When the door (10) is opened, the clamps (21, 23) installed on the inside are exposed (step e).

[0066] As shown in FIG. 7, each clamp (21, 23) is spaced apart at a predetermined interval in the horizontal direction so that a busbar jack (22) can be easily inserted between them.

[0067] Next, a busbar jack (22) is inserted between the exposed clamps (21, 23) to electrically connect them (step f). Referring to FIG. 3, a coupling portion (221) that is coupled with the clamps (21, 23) is formed at both ends of the busbar jack (22).

[0068] A clamp part (223) is provided inside the above-mentioned coupling part (221) to physically and electrically connect the electric bar (213, 233) formed on the connecting part (211, 231) of the clamp (21, 23).

[0069] Meanwhile, the above step f) may further include the following detailed steps.

[0070] First, the connecting portion (211, 231) of the exposed clamp (21, 23) and the joining portion (221) of the busbar jack (22) are positioned to correspond to each other. To do this, the operator checks the position of the clamp (21, 23) and rotates both ends of the busbar jack (22) appropriately to adjust the direction of the joining portion (221). It is important to align the positions so that the joining surfaces of the two members face each other precisely.

[0071] When the position alignment is complete, the electric bar (213, 233) embedded in the connecting part (211, 231) and the clamp part (223) embedded in the coupling part (221) are pushed together to join them. At this time, the electric bar (213, 233) is strongly compressed by the elasticity of the clamp part (223), thereby making a solid contact. In addition, the electric bar (213, 233) is more securely fixed by the protrusion (224) formed on the inner side of the clamp part (223), thereby increasing the reliability of the contact.

[0072] When the connection is complete, the door (10) is closed and the outer handle is turned to the locked position to engage the locking device. A locking mechanism is installed in the locking device to prevent unauthorized opening. Additionally, when the door (10) is closed, a dustproof and waterproof gasket is in close contact between the door (10) and the front of the module to block the entry of foreign substances or moisture.

[0073] An expandable modular distribution board system can be effectively implemented through the step-by-step configuration and operation method described above. In particular, by installing opening and closing doors (10) on the top, bottom, left, and right sides of the module body and adopting a structure that connects the exposed clamps (21, 23) of adjacent modules with a busbar jack (22), the capacity and functions of the system can be easily and quickly expanded according to the user's requirements.

[0074] In addition, the safety and reliability of the electrical connection can be maximized by precisely aligning the coupling part (221) of the busbar jack (22) and the connecting part (211, 231) of the clamp (21, 23), and by ensuring secure contact between the electric bar (213, 233) embedded in both members and the clamp part (223). Furthermore, the risk of electric shock to the operator and damage to internal parts can be prevented by various safety devices applied to the enclosure and the opening / closing door (10).

[0075] Consequently, the modular distribution panel system of the present invention can be easily configured and expanded to meet required power capacity, allowing it to flexibly respond to various on-site environmental conditions. Furthermore, since it possesses both structural safety and electrical reliability, it is expected to enable stable operation over a long period.

[0076] The method for configuring and operating a modular distribution board system of the present invention includes step b) of determining the quantity and arrangement of necessary distribution board modules (110) by analyzing system requirements. This step may consist of the following detailed steps.

[0077] First, power demand is forecasted (step b1). To do this, historical power usage data is collected, and based on this, short-term and medium-to-long-term demand is forecasted using time series analysis techniques. When forecasting, various variables such as seasonal factors, business plans, and facility expansion plans are considered to improve the accuracy of the forecast.

[0078] Next, the total required capacity is calculated based on the predicted power demand (step b2). The total capacity is calculated by adding an appropriate margin to the predicted maximum load. The margin is generally set to 20–30% to account for prediction errors and emergency situations.

[0079] Next, the number of required distribution panel modules (110) is determined based on the calculated total capacity (step b3). The number of modules is determined by comprehensively considering the capacity of the unit modules, the distribution of the expected load, and the constraints of the installation space. At this time, it is desirable to secure a sufficient number of modules by considering the uniformity and scalability of load distribution among the modules.

[0080] Based on the calculated number of modules, the optimal arrangement of the distribution panel modules (110) is designed considering the efficiency of power distribution (step b4). When designing the arrangement, a structure that minimizes power loss is derived by considering the distance between modules, cable length, heat dissipation, etc. In addition, the convenience and safety of maintenance are also considered to secure an easy and safe path for movement.

[0081] Finally, a cable wiring plan is established based on the designed layout (step b5). The wiring plan includes the type and specifications of the cable, installation route, support structure, and termination treatment. In particular, the cable thickness and material are selected carefully, as they are directly related to the allowable current and system lifespan. In addition, shielding and grounding designs are also included to minimize noise interference.

[0082] Meanwhile, in step i) above, a real-time current value is measured through a current sensor installed in each distribution panel module (110) (step i1). It is preferable to use a CT (Current Transformer) type current sensor that has minimal zero point fluctuation and excellent temperature characteristics. The CT consists of an iron core and a secondary coil, and measures the current value by inducing a secondary current that is proportional to the primary current.

[0083] The analog signal measured by the current sensor is converted into a digital value through a signal converter and then transmitted to a control unit inside the module. The control unit calculates the load rate of each branch circuit in real time based on the received current value (step i2). The load rate is defined as the ratio of the actual load to the design capacity, and by monitoring this, it is possible to determine whether there is an overload.

[0084] Load rate data calculated by each module is transmitted to the upper-level control system for integrated management. The control system statistically processes the collected load rate data by time of day, day, week, and month (Step i3). This allows for the identification of load rate trends and the detection of seasonal patterns or anomalies.

[0085] Next, load patterns are analyzed in depth based on statistically processed load rate data (step i4). During the analysis, machine learning algorithms are utilized beyond simple statistical analysis to extract complex and diverse patterns. This can be used to predict future load fluctuations and to formulate strategies for facility expansion and energy efficiency.

[0086] In step j), the previously analyzed load pattern is received as input (step j1), and the expected load for each branch circuit is calculated (step j2). The expected load is the result of predicting short-term and medium-to-long-term loads based on past patterns, and is automatically calculated without user intervention.

[0087] When the expected load is calculated, the load distribution between each distribution panel module (110) is optimized based on this (step j3). During optimization, the capacity and switching settings of the circuit breakers are automatically adjusted by taking into account the expected load, with the goal of leveling the load rate between modules. This prevents local overloads and extends the lifespan of the equipment.

[0088] The optimized load distribution result is transmitted to each distribution panel module (110) through the control system, and the module control device controls the circuit breaker according to the transmitted setting value (step j4). The control command is converted into a digital signal and applied to the trip coil of the circuit breaker, and accordingly, the open / closed state of the circuit breaker is changed.

[0089] Through the steps described above, the load on the entire system can be monitored in real time and actively controlled. This serves as the foundation for evolving beyond a mere scalable hardware platform into an intelligent solution that maximizes energy efficiency and ensures stability.

[0090] The method of the present invention also includes a real-time monitoring and abnormality diagnosis function for a distribution board module (110). Specifically, sensors that measure various status information, such as temperature, humidity, vibration, and noise, in addition to voltage and current, are installed in each module (step o). These sensors are installed on the front or inside of the module and transmit analog output signals to a control device.

[0091] The control unit monitors the received status information in real time and compares it with a preset threshold (step p). If any measured value exceeds the threshold, the control unit generates an alarm signal to notify the upper system and the operator.

[0092] When an alarm occurs, a precise diagnosis of the relevant module is performed (step q). During the diagnosis, the trend of sensor values ​​showing abnormal signs is analyzed, and the degree of deterioration and aging of related components is comprehensively evaluated. Recently, artificial intelligence technology has been incorporated into this process to significantly improve the accuracy of fault prediction.

[0093] If a serious abnormality or sign of failure is detected as a result of diagnosis, the module is isolated from the system (step r). When isolating, the circuit breaker is controlled via the PLC to bypass the problematic module, and the tie breaker is closed to receive power from another module.

[0094] To replace the function of the isolated module, a backup module is automatically deployed (step s). The backup module is normally kept in a standby state and is activated immediately when needed, and is equipped with the same capacity and control logic as the isolated module. This allows the facility to continue operating without interruption even in an emergency.

[0095] Subsequently, a maintenance plan for the isolated module is established (step t). When establishing the plan, the cause of failure, repairability, estimated cost, available parts, and work schedule are comprehensively considered. In particular, the key is to derive an optimal maintenance scenario that ensures safety and quality while minimizing the impact on the production schedule.

[0096] As described above, the method of the present invention provides a comprehensive solution that goes beyond mere physical scalability to encompass system operation optimization, reliability improvement, and even the implementation of a smart factory. A modular distribution board system capable of real-time monitoring, data analysis, and intelligent control is expected to enable stable and efficient power supply, as well as directly contribute to enhancing corporate competitiveness through energy cost reduction and equipment operation optimization.

[0097] In detail, the method for configuring and operating a modular distribution board system of the present invention includes step b) of analyzing system requirements to determine the quantity and arrangement of necessary distribution board modules (110). This step may consist of the following detailed steps.

[0098] First, power demand is forecasted (step b1). To do this, historical power usage data is collected, and based on this, short-term and medium-to-long-term demand is forecasted using time series analysis techniques. When forecasting, various variables such as seasonal factors, business plans, and facility expansion plans are considered to improve the accuracy of the forecast.

[0099] Next, calculate the total capacity required based on the predicted power demand (step b2).

[0100] The total capacity is calculated by adding an appropriate margin to the predicted maximum load. The margin is generally set at a level of 20–30% to prepare for prediction errors and emergency situations.

[0101] Next, the number of required distribution panel modules (110) is determined based on the calculated total capacity (step b3). The number of modules is determined by comprehensively considering the capacity of the unit modules, the distribution of the expected load, and the constraints of the installation space. At this time, it is desirable to secure a sufficient number of modules by considering the uniformity and scalability of load distribution among the modules.

[0102] Based on the calculated number of modules, the optimal arrangement of the distribution panel modules (110) is designed considering the efficiency of power distribution (step b4). When designing the arrangement, a structure that minimizes power loss is derived by considering the distance between modules, cable length, heat dissipation, etc. In addition, the convenience and safety of maintenance are also considered to secure an easy and safe path for movement.

[0103] Finally, a cable wiring plan is established based on the designed layout (step b5). The wiring plan includes the type and specifications of the cable, installation route, support structure, and termination treatment. In particular, the cable thickness and material are selected carefully, as they are directly related to the allowable current and system lifespan. In addition, shielding and grounding designs are also included to minimize noise interference.

[0104] Meanwhile, in step i) above, a real-time current value is measured through a current sensor installed in each distribution panel module (110) (step i1). It is preferable to use a CT (Current Transformer) type current sensor that has minimal zero point fluctuation and excellent temperature characteristics. The CT consists of an iron core and a secondary coil, and measures the current value by inducing a secondary current that is proportional to the primary current.

[0105] The analog signal measured by the current sensor is converted into a digital value through a signal converter and then transmitted to a control unit inside the module. The control unit calculates the load rate of each branch circuit in real time based on the received current value (step i2). The load rate is defined as the ratio of the actual load to the design capacity, and by monitoring this, it is possible to determine whether there is an overload.

[0106] Load rate data calculated by each module is transmitted to the upper-level control system for integrated management. The control system statistically processes the collected load rate data by time of day, day, week, and month (Step i3). This allows for the identification of load rate trends and the detection of seasonal patterns or anomalies.

[0107] Next, load patterns are analyzed in depth based on statistically processed load rate data (step i4). During the analysis, machine learning algorithms are utilized beyond simple statistical analysis to extract complex and diverse patterns. This can be used to predict future load fluctuations and to formulate strategies for facility expansion and energy efficiency.

[0108] In step j), the previously analyzed load pattern is received as input (step j1), and the expected load for each branch circuit is calculated (step j2). The expected load is the result of predicting short-term and medium-to-long-term loads based on past patterns, and is automatically calculated without user intervention.

[0109] When the expected load is calculated, the load distribution between each distribution panel module (110) is optimized based on this (step j3). During optimization, the capacity and switching settings of the circuit breakers are automatically adjusted by taking into account the expected load, with the goal of leveling the load rate between modules. This prevents local overloads and extends the lifespan of the equipment.

[0110] The optimized load distribution result is transmitted to each distribution panel module (110) through the control system, and the module control device controls the circuit breaker according to the transmitted setting value (step j4). The control command is converted into a digital signal and applied to the trip coil of the circuit breaker, and accordingly, the open / closed state of the circuit breaker is changed.

[0111] Through the steps described above, the load on the entire system can be monitored in real time and actively controlled. This serves as the foundation for evolving beyond a mere scalable hardware platform into an intelligent solution that maximizes energy efficiency and ensures stability.

[0112] The method of the present invention also includes a real-time monitoring and abnormality diagnosis function for a distribution board module (110). Specifically, sensors that measure various status information, such as temperature, humidity, vibration, and noise, in addition to voltage and current, are installed in each module (step o). These sensors are installed on the front or inside of the module and transmit analog output signals to a control device.

[0113] The control unit monitors the received status information in real time and compares it with a preset threshold (step p). If any measured value exceeds the threshold, the control unit generates an alarm signal to notify the upper system and the operator.

[0114] When an alarm occurs, a precise diagnosis of the relevant module is performed (step q). During the diagnosis, the trend of sensor values ​​showing abnormal signs is analyzed, and the degree of deterioration and aging of related components is comprehensively evaluated. Recently, artificial intelligence technology has been incorporated into this process to significantly improve the accuracy of fault prediction.

[0115] If a serious abnormality or sign of failure is detected as a result of diagnosis, the module is isolated from the system (step r). When isolating, the circuit breaker is controlled via the PLC to bypass the problematic module, and the tie breaker is closed to receive power from another module.

[0116] To replace the function of the isolated module, a backup module is automatically deployed (step s). The backup module is normally kept in a standby state and is activated immediately when needed, and is equipped with the same capacity and control logic as the isolated module. This allows the facility to continue operating without interruption even in an emergency.

[0117] Subsequently, a maintenance plan for the isolated module is established (step t). When establishing the plan, the cause of failure, repairability, estimated cost, available parts, and work schedule are comprehensively considered. In particular, the key is to derive an optimal maintenance scenario that ensures safety and quality while minimizing the impact on the production schedule.

[0118] As described above, the method of the present invention provides a comprehensive solution that goes beyond mere physical scalability to encompass system operation optimization, reliability improvement, and even the implementation of a smart factory. A modular distribution board system capable of real-time monitoring, data analysis, and intelligent control is expected to enable stable and efficient power supply, as well as directly contribute to enhancing corporate competitiveness through energy cost reduction and equipment operation optimization. Explanation of the symbols

[0119] 100: Distribution panel system 110: Distribution panel module 10: Opening and closing gates 21, 23: Clamp 22: Busbarjack 221: Joint 223: Clamp part 224: Connecting protrusion 211, 231: Connection 213, 233: Electric bar

Claims

Claim 1 In an easily expandable distribution board, each distribution board module (110) includes a plurality of distribution board modules (110) and accommodates electrical components inside, and each distribution board module (110) comprises: a door (10) formed on the upper, lower, left, and right sides of the distribution board module (110); and a clamp (21, 23) fixedly installed on one side inside the main body frame of the distribution board module (110) so as to be exposed to the outside when the door (10) is opened. The easily expandable distribution board includes a busbar jack (22) that is detachably coupled to the clamp (21, 23); the opening / closing door (10) is configured to be pushed inward to open and has a structure that separates and opens on both sides when opened; the busbar jack (22) has a structure in which identical shapes are attached to both sides; the coupling part (221) includes a clamp part (223) that is coupled to the clamp (21, 23); the clamp (21, 23) is electrically connected to the coupling part; and the clamp (21, 23) includes a connecting part (211, 231) that is electrically connected to the coupling part (221); and is characterized by coupling an electric bar (213, 233) made of a conductive material within the connecting part (211, 231) with a clamp part (223) made of a conductive material of the coupling part (221). Claim 2 An easily expandable distribution board according to claim 1, wherein the distribution board modules (110) are: electrically connected by opening the opening / closing door (10) of each distribution board module (110) and inserting a busbar jack (22) between the exposed clamps (21, 23) to flexibly expand the capacity and function of the distribution board system. Claim 3 An easily expandable distribution board according to claim 1, wherein the clamp portion (223) further comprises a coupling projection (224) for improving coupling with the electric bar (213, 233). Claim 4 An easily expandable distribution board according to claim 1, wherein the electric bar (213, 233) and the clamp part (223) are made of a copper alloy having electrical conductivity greater than a certain amount, and the surface is plated to improve corrosion resistance, thereby providing stable electrical connection and easy operability. Claim 5 An expansion method using an easily expandable distribution board, characterized by comprising: a) a step of preparing a plurality of distribution board modules (110); b) a step of determining the quantity and arrangement of necessary distribution board modules (110) by analyzing system requirements; c) a step of physically arranging the distribution board modules (110) according to the determined arrangement; d) a step of opening the doors (10) of adjacent distribution board modules (110); e) a step of exposing clamps (21, 23) fixedly installed on one side of the main body frame of the distribution board module (110) so as to be exposed to the outside as the doors (10) are opened; and f) a step of electrically connecting a busbar jack (22) by inserting it between the exposed clamps (21, 23). Claim 6 In claim 5, f) a step of electrically connecting a busbar jack (22) between exposed clamps (21, 23) by inserting them into each other; the step of positioning the connecting portion (211, 231) of the exposed clamps (21, 23) and the coupling portion (221) of the busbar jack (22) at corresponding positions; and the step of coupling an electric bar (213, 233) made of a conductive material within the connecting portion (211, 231) with a clamp portion (223) made of a conductive material of the coupling portion (221); characterized by comprising an expansion method using an easily expandable distribution board. Claim 7 An expansion method using an easily expandable distribution board according to claim 5, further comprising: f) a step of electrically connecting by inserting a busbar jack (22) between exposed clamps (21, 23); subsequently, a step of monitoring status information of temperature, humidity, vibration, and noise in real time through a sensor installed in each distribution board module (110); a step of generating an alarm signal if the measured value of the monitoring result exceeds a preset threshold; a step of diagnosing a fault by analyzing abnormal signs of the corresponding distribution board module (110) according to the generation of the alarm signal; a step of isolating the corresponding module from the system if a serious abnormality or fault is detected as a result of the diagnosis; a step of automatically switching the function of the isolated module to a backup module to continue power supply; and a step of establishing a maintenance plan for the isolated module by considering the cause of the fault, repairability, estimated cost, and work schedule. Claim 8 An expansion method using an easily expandable distribution board according to claim 5, further comprising: f) a step of electrically connecting by inserting a busbar jack (22) between exposed clamps (21, 23); subsequently, a step of measuring a real-time current value through a current sensor installed in each distribution board module (110); a step of calculating the load rate of each branch circuit based on the real-time current value and analyzing the load pattern by calculating statistics by time period, day, week, and month; a step of calculating the expected load of each branch circuit according to the result of the load pattern analysis; and a step of automatically updating the circuit breaker settings of each module according to the result of load distribution between each distribution board module (110) based on the expected load.

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