Retrofit Fuse Monitoring for Compact Predictive Maintenance
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Solution Overview
Problem
Existing fuse monitoring systems for high voltage electrical power systems are complex, costly, and large, making them unsuitable for retrofitting in industrial settings, particularly in hazardous environments where they are prone to fatigue due to temperature fluctuations, humidity, and other environmental factors, leading to increased maintenance costs and unplanned downtime.
Innovation Solution
A compact, affordable, and reliable fuse monitoring system that can be easily attached to pre-existing fuse blocks without tools, using sensors to measure real-time parameters such as temperature, humidity, vibrations, and current to assess fuse performance and remaining service life, and communicate alerts and recommendations for maintenance and inventory management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If known fuse monitoring systems are used, then fuse performance can be monitored, but the systems are complex, costly, and large
Solution Approach 1:
The patent extracts the monitoring functionality from complex existing systems and implements it through a simple attachment mechanism that connects to the fuse block without requiring integration into the entire electrical system. This extraction approach reduces device complexity while maintaining monitoring capability.
Solution Approach 2:
The patent uses sensors to create measurements of electrical parameters (current, temperature, humidity) that copy the state of the fuse environment, enabling monitoring without direct interference with the fuse operation. This allows reliable monitoring while keeping the system simple.
2Reliability
If known fuse monitoring systems are used, then fuse performance can be monitored, but they are large in size
Solution Approach 1:
The monitoring function is extracted from large existing systems and implemented through a compact attachment device that interfaces with the fuse block externally, significantly reducing the volume required for monitoring while maintaining full monitoring capability.
3Adaptability or versatility
If retrofitting is performed in hazardous environments, then existing fuse blocks can be monitored, but temperature fluctuations and humidity cause fuse fatigue
Solution Approach 1:
The system performs preliminary monitoring of environmental conditions (temperature, humidity) and electrical parameters to detect early signs of fuse fatigue caused by hazardous environment exposure. This allows proactive identification of fuses at risk before actual failure occurs.
Solution Approach 2:
The system continuously monitors environmental conditions and fuse performance parameters, providing feedback that enables assessment of fuse health and prediction of remaining service life. This feedback mechanism helps manage the reliability issues caused by temperature fluctuations and humidity in hazardous environments.
4Ease of operation
If simple attachment is used, then installation is easy without tools, but monitoring accuracy may be compromised
Solution Approach 1:
The attachment mechanism is designed to self-align and self-secure to the fuse block without requiring external tools or complex installation procedures. The sensors automatically establish electrical and environmental contact when the attachment is placed on the fuse block, maintaining measurement accuracy while ensuring ease of installation.
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
The system enables proactive replacement of fuses, reduces downtime, and optimizes inventory management by providing real-time monitoring and predictive analytics, while being modular and scalable to fit various fuse types and applications, thus improving overall electrical system reliability and reducing labor and maintenance costs.
Implementation Method 1
using sensors to measure real-time parameters such as temperature
Implementation Method 2
using sensors to measure real-time parameters such as temperature, humidity
Implementation Method 3
using sensors to measure real-time parameters such as temperature, humidity, vibrations
Implementation Method 4
using sensors to measure real-time parameters such as temperature, humidity, vibrations, and current
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A fuse monitoring device for monitoring a fuse supported by a fuse block, the fuse monitoring device including a housing. The housing includes a holder attachment mechanism configured to connect the fuse monitoring device to a fuse block. The housing also includes a mounting attachment mechanism configured to connect the fuse monitoring device to a mounting structure and at least one sensor configured to be operably connected to a fuse and configured to measure fuse data associated with the fuse. The monitoring device further includes at least one processor communicatively coupled to the at least one sensor.