Dynamic Thermal Mapping for Electrical Joint Safety
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for monitoring and controlling electrical joints in circuits are inadequate for real-time detection of compromised joints, especially at low electrical loads, leading to potential arc flashes and equipment failures, with no effective system to determine the maximum safe operating load or ambient temperature.
Innovation Solution
A load calculation device that continuously determines the temperature differential and actual electrical load, allowing real-time calculation of the maximum safe operating load and ambient temperature, using sensing elements to measure joint and ambient temperatures, and communicating with temperature control systems to prevent overload.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If periodic inspection using thermal imaging camera is carried out annually, then inspection coverage is provided, but detection reliability is insufficient because inspections occur less than 1% of operating time
Solution Approach 1:
The patent implements continuous thermal monitoring of electrical joints using internal sensors that operate 100% of the time, eliminating the gaps between periodic inspections. This continuous measurement approach ensures compromised joints are detected regardless of when they fail, resolving the contradiction between detection reliability and inspection frequency.
2Ease of operation
If external thermal inspection is performed, then inspection can be conducted without exposing joints, but measurement precision deteriorates due to correlation errors between external and internal temperatures
Solution Approach 1:
The patent introduces internal thermal sensors as intermediaries that are placed in direct thermal contact with electrical joints inside enclosures. These sensors measure joint temperature directly at the source, eliminating the need for external thermal imaging and the associated correlation errors, thus resolving the contradiction between ease of operation and measurement precision.
3Productivity
If thermal inspection is performed at low electrical load (50% or less), then inspection can be conducted during normal operation, but detection capability is insufficient because compromised joints may not exhibit excess heat at low load
Solution Approach 1:
The patent implements continuous thermal monitoring with real-time feedback that tracks temperature trends over time. By comparing current temperature readings against historical data and calculating temperature differentials, the system can detect compromised joints even at low electrical loads, resolving the contradiction between operational continuity and defect detection capability.
4Ease of operation
If manual correlation of external temperature to internal joint temperature is performed, then inspection can be conducted externally, but measurement precision deteriorates due to multiple variables at each location
Solution Approach 1:
The patent places internal thermal sensors directly on or near electrical joints inside enclosures, serving as intermediaries that measure joint temperature directly. This eliminates the complex correlation process between external and internal temperatures by providing direct measurement, thus resolving the contradiction between ease of operation and measurement precision.
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
Enables continuous, real-time detection of compromised joints and calculation of maximum safe loads, reducing downtime and preventing catastrophic failures by ensuring electrical joints operate within safe limits.
Implementation Method 1
a first sensing element which measures the temperature of the electrical joint or the temperature of the electrical conductor adjacent the electrical joint
Implementation Method 2
a cable sensor which is mounted directly onto cable conductors adjacent the electrical joint
Implementation Method 3
a second sensing element which measures the ambient temperature within the enclosure
Implementation Method 4
a load calculation device which receives the temperature values from the first and second sensing elements and which calculates the temperature differential, ΔT, of the electrical joint or electrical conductor
Data Source
AI summary
A load calculation device for determining the maximum electrical load that can be applied to an electrical circuit includes determines the temperature differential (ΔT) between a section of the electrical circuit and the ambient air temperature in which the section of the electrical circuit resides. The actual electrical load applied to the electrical circuit is also determined as is the design load of the electrical circuit. The maximum electrical load that can be applied to the electrical circuit is then determined based on the temperature differential and the electrical load applied to the electrical circuit and the circuit designed load. The load calculation device may be applied to an electrical joint and may be used to calculate the maximum temperature differential allowed for a given current to be applied at the electrical joint. This is particularly beneficial in connection with detecting and preventing electrical joint failure.