Direct-Apply Thermal Sensor Assembly for Branch Circuit Monitoring

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Solution Overview

Problem

Existing thermal monitoring systems for electrical power distribution systems are costly, require additional mounting assemblies, and can lead to downtime and hazardous conditions due to battery replacement needs, while they often fail to provide continuous and reliable temperature monitoring of connection elements like joints, lugs, and cables.

Innovation Solution

A branch circuit thermal monitoring system with modular thermal modules and sensor assemblies directly applied to connection points, communicating through a main controller that is expandable and powered by DC or AC, allowing continuous temperature monitoring without additional mounting and reducing system interruptions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If battery-powered wireless temperature sensors are used, then temperature monitoring is achieved, but battery replacement causes downtime and hazardous conditions

Engineering Contradiction:

Improvetemperature monitoring reliabilityVSAvoidsystem downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The thermal sensor assembly is powered directly by the electrical connection element itself through the electrical conductor, eliminating the need for external batteries. The sensor serves itself by drawing power from the monitored component, ensuring continuous operation without maintenance interruptions for battery replacement.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If infra-red view ports are installed, then thermal imaging capability is provided, but the cost is expensive and continuous monitoring is not achieved

Engineering Contradiction:

Improvethermal condition assessmentVSAvoidinstallation cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent replaces expensive mechanical infra-red view ports and hand-held scanning devices with an electrical sensing system. The thermal sensor assembly uses electrical conductors and circuitry to measure temperature directly, substituting complex optical-mechanical systems with simpler electrical measurement techniques.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Duration of action of moving object

If surface acoustic wave sensors are used, then battery-free operation is achieved, but the technology is expensive for installation

Engineering Contradiction:

Improvesensor operation durationVSAvoidinstallation cost

Core Design Contradiction:

Duration of action of moving objectVSEase of manufacture

Solution Approach 1:

The patent uses a simplified version of the surface acoustic wave concept by implementing a temperature sensor that leverages the existing electrical infrastructure. Instead of deploying expensive specialized acoustic wave transducers, the system uses standard electrical conductors and simple temperature-sensitive electrical components to achieve the same battery-free, continuous monitoring goal.

Inventive Principle:

Principle #26Copying

4Device complexity

If thermal sensor assembly is directly applied to connection point, then additional mounting assembly is avoided, but precise application to electrical connections is required

Engineering Contradiction:

Improvemounting assembly complexityVSAvoidsensor application precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The thermal sensor assembly is merged with the electrical connection element itself. The temperature sensor, electrical conductor, and mounting structure are combined into a single integrated component that is installed as one unit, eliminating separate mounting steps and reducing the need for precise separate positioning of sensor and mounting hardware.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution provides cost-effective, continuous temperature monitoring that notifies users of temperature variations, preventing overheating and reducing downtime, while being adaptable to existing systems and avoiding hazardous conditions.

Implementation Method 1

a plurality of thermal modules (7(1-n)) connected with a thermal sensor assembly (25(1-n))

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10866144B2Branch circuit thermal monitoring system for continuous temperature monitoring by directly applied sensors

Publication Date: 2020.12.15 SIEMENS INDUSTRY INC

AI summary

A branch circuit thermal monitoring system comprises a housing and an electrical power distribution sub-system. The housing includes a plurality of thermal modules each connected with a thermal sensor assembly of a plurality of thermal sensor assemblies. The housing further includes a module rack wherein each of the thermal modules is installed on the module rack. The housing further includes a main controller configured to communicate with the thermal modules. The thermal modules are configured for individually monitoring corresponding identified connection points of interest with the attached thermal sensor assemblies such that the thermal modules and the thermal sensor assemblies provide continuous temperature monitoring of the corresponding identified connection points of interest. The thermal sensor assembly is configured to be directly applied to a connection point of interest thus avoiding any additional mounting assembly. The electrical power distribution sub-system is coupled to the thermal modules.