Circuit Breaker PLC Module for Open-Contact Communication
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Solution Overview
Problem
Existing circuit breakers disrupt communication when tripped, preventing remote control and data collection from the load side, and existing load management systems lack flexibility in adapting to varying power sources and consumption patterns, leading to inefficiencies and inconveniences during peak times or emergencies.
Innovation Solution
An intelligent power load management system with a circuit breaker featuring a communications interface that maintains connectivity even when tripped, a motorized mechanism for remote opening and closing of contacts, and an adaptive load management algorithm using a neural network predictor to manage loads dynamically across various power sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a circuit breaker trips to disconnect a circuit during fault or overload conditions, then safety and protection of loads are improved, but communication capability and remote control functionality are lost
Solution Approach 1:
The circuit breaker is divided into separate functional components: the tripping mechanism that opens contacts for circuit protection, and the communication module that maintains independent communication capability. This segmentation allows the communication function to remain operational even when the circuit is tripped and contacts are open.
Solution Approach 2:
A communication module acts as an intermediary between the tripped circuit and the external monitoring system. This intermediary maintains the communication link across the open contacts, allowing data transmission and remote control instructions to pass through even when the electrical circuit is disconnected.
2Device complexity
If traditional circuit breakers are used that require manual resetting, then device complexity is reduced, but operational convenience and response time are worsened
Solution Approach 1:
The circuit breaker incorporates automatic resetting capability through communication with external control systems. The breaker can self-reset based on pre-programmed conditions, sensor data, or remote commands, eliminating the need for manual intervention while maintaining relatively simple internal structure.
Solution Approach 2:
The communication module provides continuous feedback about the circuit breaker's state (tripped, closed, fault conditions) to external monitoring systems. This feedback enables automated decision-making for resetting operations, improving operational convenience without significantly increasing device complexity.
3Ease of operation
If power line communication is used for remote control, then ease of operation is improved, but communication reliability deteriorates when circuit breaker contacts are open
Solution Approach 1:
The communication module serves as an intermediary that bridges the gap between the line side and load side of the circuit breaker. It maintains a dedicated communication path that is independent of the electrical contacts, ensuring continuous communication even when the breaker is tripped and contacts are open.
Solution Approach 2:
The communication module is designed to handle multiple functions: normal operational communication when the breaker is closed, and maintained communication when the breaker is tripped. This multi-functionality ensures reliable remote control and monitoring under all operational states without requiring separate systems.
4Loss of energy
If rolling blackouts are implemented to reduce peak power consumption, then energy management is improved, but user convenience and system productivity are worsened
Solution Approach 1:
The system dynamically manages power distribution by selectively controlling individual circuits rather than implementing blanket rolling blackouts. The communication module enables real-time monitoring and dynamic adjustment of power delivery to different loads, optimizing energy usage while maintaining user convenience through targeted, rather than widespread, power management.
Data Source
AI summary
An intelligent power management system that includes a circuit breaker containing a PLC module that spans open contacts of the circuit breaker to provide a communication path for PLC messages between communication paths on each of the line and load sides of the circuit when the contacts are open. The contacts are motorized to permit remote operation through PLC messaging. Coupled to the PLC module is a controller, which controls the opening and closing of the motorized contacts under user control or via an adaptive load management algorithm that reduces peak power consumption and adapts a set of loads to changed power supply conditions. The controller can also dynamically alter operational current and fault threshold levels on a real-time basis based upon circuit requirements or environmental conditions. The algorithm runs a state machine and also manages loads in a limited power source environment such as when loads are powered by a generator.