Compact Load Panel Modules for Dynamic Circuit Shedding

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Solution Overview

Problem

Existing load management systems for distributed energy generation and storage are expensive, complex, and require significant disruption to electrical infrastructure, offering limited flexibility and priority adjustments, with most providing only two priority levels and requiring special inverters and circuit re-routing.

Innovation Solution

A modular load management system comprising compact modules that fit within standard AC distribution panels, featuring input and output terminals, disconnect switches, current sensors, and microprocessors for remote or local control, allowing for flexible configuration and monitoring of power and energy flow on a per-circuit basis, with the ability to connect end-to-end or via jumper cables to manage all circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If commercialized load management products are used, then load management capabilities are provided, but the system becomes expensive and complex with significant infrastructure disruption

Engineering Contradiction:
Improveload management capabilityVSAvoidsystem complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The load management system is divided into multiple modular units, each capable of independently managing specific circuits. These modular units can be installed in standard electrical panels without requiring complete system replacement, thereby reducing complexity while maintaining adaptability.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The modular load management units are designed to perform multiple functions including load prioritization, circuit monitoring, and dynamic load shedding. This multi-functionality is achieved within a standardized module that can be universally applied across different electrical panel configurations.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If special inverters and circuit re-routing are implemented, then priority control is achieved, but installation disruption and complexity increase

Engineering Contradiction:
Improvepriority control flexibilityVSAvoidinstallation ease
Core Design Contradiction:
Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The system provides dynamic priority control through software configuration rather than fixed hardware wiring. Users can dynamically adjust circuit priorities and load management parameters through a user interface, eliminating the need for physical circuit re-routing while maintaining flexibility.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The modular load management unit acts as an intermediary device installed within the existing electrical panel. It interfaces with standard breakers and circuits without requiring special inverters or complex re-wiring, thereby achieving priority control through a simplified installation process.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Device complexity

If only two priority levels are provided, then system simplicity is maintained, but flexibility to adjust circuit priorities is limited

Engineering Contradiction:
Improvesystem simplicityVSAvoidpriority adjustment flexibility
Core Design Contradiction:
Device complexityVSAdaptability or versatility

Solution Approach 1:

The system transitions from static priority levels to dynamic, user-configurable priorities. Each circuit can be assigned different priority levels that can be adjusted in real-time through software, providing flexibility while maintaining a simple modular hardware architecture.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The priority control parameter is made changeable through software configuration rather than being fixed in hardware. This allows users to modify priority assignments and load management parameters without changing the physical system, balancing simplicity with flexibility.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS12062905B2Compact modular electrical load management system
Publication Date: 2024.08.13 GENERAC POWER SYSTEMS INC
  • US12062905B2 patent drawing
  • US12062905B2 patent drawing
  • US12062905B2 patent drawing

AI summary

A modular load management system comprises one or more compact modules designed to fit in the wiring troughs of a standard AC distribution panel of a building. The modules include one or more input terminals to receive electrical power from one or more circuit breakers in the panel and deliver power to load circuits of the building via one or more output terminals. The modules contain at least one disconnect switch for disconnecting circuits from breakers in response to a remote or locally-generated control signal. The modules may also include current sensors on some or all terminals, such that power and energy flow may be monitored on a per-circuit basis.