AU2019268162A1

AU2019268162A1 - A power management system and device for flameproof alternators

Info

Publication number: AU2019268162A1
Application number: AU2019268162A
Authority: AU
Inventors: Giuliano Res
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-11-21
Filing date: 2019-11-21
Publication date: 2020-06-04
Anticipated expiration: 2039-11-21
Also published as: AU2019268162B2

Abstract

A power management system including a power management device for managing fault activity of a flameproof alternator. The alternator includes at least two pairs of output power terminals each pair comprising a positive terminal and a negative terminal; the system including a fault detector capable of detecting electrical faults on any pair of the at least two pairs of output power terminals and of identifying a pair of the at least two pairs of output power terminals on which the fault or faults is/are detected. The power management system further includes a power management device including: a power control for each pair of said at least two pairs of output power terminals for shutting down or limiting the output power on the pair of output power terminals on which the fault has been detected. Power is automatically shut down when an electrical fault is detected on a pair of output power terminals. The presence of a battery is automatically detected and, if present, the over-current fault detection threshold is reduced as the battery charging load drops. 5 717 21 15 23 21 1 FIGURE 1

Description

21 15

5 717

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FIGURE 1

A POWER MANAGEMENT SYSTEM AND DEVICE FOR FLAMEPROOF ALTERNATORS BACKGROUND & FIELD

[0001] The technical field of the present invention is flameproof alternators. The present invention relates to electrical machinery including flame proof alternators and more particularly relates to improvements in the control, monitoring and management of alternators used with such machinery and to data communications which provide real-time information for control of the alternator. The present invention also relates to a communications path which is interfaced to a controller and which allows command input. More particularly, the present invention relates to a control system which is used with a flame proof alternator for detecting alternator faults such as, but not limited to earth leakage and for and management of such faults including remote management.

[0002] The invention further relates to a management control system including a communications interface which allows real time monitoring of alternator parameters and particularly faults. The present invention further relates to such integrated communications and control systems for alternators including flame proof alternators which are used in particular though not exclusively, in dangerous environments such as occurs in underground mining. The present invention is capable of use by maintenance personnel when maintaining machinery which incorporates the communications system.

PRIOR ART

[0003] Hazardous environments are commonly found in, for example, the mining and petrochemical industries. In mines, for example, a spark can result in a mine explosion. Industry standards generally require that machines and machine components used in such hazardous environments are flameproof and/or intrinsically safe. A flameproof device must be able to withstand an internal explosion and any air passages between the internal space and the outside must meet specific flame-path requirements such as a maximum 0.3 mm gap over a minimum 12.5 mm distance. Intrinsically safe devices ensure internal temperatures remain low, even in fault conditions, and so do not pose an ignition hazard.

[0004] The electrical systems on the various types of automotive machines used in hazardous environments are typically powered using a flameproof alternator. A battery may or may not be used as the use of a battery introduces certain types of risks. Electrical power is delivered from a positive and a negative terminal on the alternator through cabling to the battery, if present, and to each electrically operated piece of equipment such as lights and pneumatic control valves.

[0005] Safety standards generally require the flameproof alternator to detect certain types of faults and to automatically shut down. Mining equipment downtime is costly so alternators generally have integrated control systems that can communicate operational information to an external reader used by a technician to determine the cause of the shutdown so appropriate corrective action can be taken.

[0006] Often the piece of faulty equipment responsible for the alternator shutdown is not obvious. Different companies may be responsible for different pieces of equipment and so several repair technicians may need to inspect their particular piece of equipment until the cause of the fault is identified and subsequently rectified. Organizing the various repair technicians to inspect the machine in the mine can also prove quite difficult. The repair technicians can have a difference of opinion on where the fault lies and this can take considerable time to then resolve the issue and rectify the fault. These delays all add to machine downtime and associated costs.

[0007] Flameproof alternators typically include circuitry to monitor the load and detect fault conditions then, when a fault is detected, to automatically shut off their output until they are manually reset by an operator. Circuitry may also record and report via a communications channel operational history including any detected faults.

[0008] The types of faults detected by flameproof alternators include over-voltage, under voltage, over-current, earth leakage from the positive terminal and earth leakage from the negative terminal. Brief transient faults may be acceptable and not result in the power being shut down.

[0009] When an electrical fault occurs on a machine powered by a flameproof alternator the built-in safety mechanism shuts down all power output. All electrical equipment powered by the alternator immediately loses power. A manual reset is required to restore power. Although the type of fault can generally be read from the electrical fault log of the flameproof alternator it can still prove difficult to identify the piece of equipment that caused or is causing the fault. Where a battery is used the over-current threshold may need to be set quite high to deliver the high power that a battery can require. This threshold may then mask over current faults that may occur when the battery is not drawing high power.

SUMMARY OF INVENTION

[0010] The present invention provides improvements in the control, monitoring and management of alternators used with machinery and also provides data communications which provide real-time information for control of the alternator. The present invention also provides a power management system which includes a power management device and a communications path which is interfaced to a controller and which allows command input. More particularly, the present invention provides a control system which is used with a flame proof alternator for detecting alternator faults such as, but not limited to earth leakage and for remote management of such faults.

[0011] The invention further provides a management control system including a communications interface which allows real time monitoring of alternator parameters and particularly faults. The present invention further provides integrated communications and control systems for alternators including flame proof alternators which are used in particular though not exclusively, in dangerous environments such as occurs in underground mining.

[0012] The present invention provides an enhanced flameproof alternator employing multiple output power terminals, each pair of power terminals being monitored for electrical faults. When a fault occurs only the equipment powered by the pair of power terminals on which the fault occurred loses power. Other equipment continues to be powered where it is not the cause of the electrical fault. When an electrical fault occurs on a machine powered by a flameproof alternator the built-in safety mechanism according to conventional technology shuts down all power output. At present, all electrical equipment powered by the alternator immediately loses power, requiring a manual reset to restore power. A fault will be stored in the electrical log, but it can still prove difficult to identify the piece of equipment that caused or is causing the fault. The present invention provides a solution to that problem by providing a power management system including a power control for each pair of output power terminals for shutting down or limiting the output power on the pair of output power terminals on which the fault has been detected.

[0013] More broadly, the present invention provides an alternative to the known prior art and the shortcomings identified. The foregoing and other objects and advantages will appear from the description to follow. In the description reference is made to the accompanying representations, which forms a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying illustrations, like reference characters designate the same or similar parts throughout the views. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims.

[0014] One advantage of the present invention is that machine downtime and associated costs can be dramatically reduced as the faulty piece of equipment is more readily identified.

[0015] Where a battery is present the over-current fault threshold needs to be high enough to allow for the battery's occasional high power consumption. This high threshold may be too high to effectively protect over-current faults on equipment powered by the alternator.

[0016] Providing multiple pairs of output power terminals, each with its own over-current threshold, allows better over-current protection on the pairs of output power terminals that do not charge the battery. Further, over-current protection on the battery charging pair of power terminals can be made more effective by automatically reducing the over-current threshold as the battery charges. It is advantageous to provide automatic detection of a battery to simplify installation and configuration.

[0017] The advantageous effects of automatically reducing the over-current threshold as the battery charges can also be used on flameproof alternators with a single pair of output power terminals.

[0018] In one broad form the present invention comprises: a power management system including a power management device for a flameproof alternator including: at least two pairs of output power terminals each pair comprising a positive terminal and a negative terminal, a fault detector capable of detecting electrical faults on any pair of the at least two pairs of output power terminals and of identifying a pair of the at least two pairs of output power terminals on which the fault or faults is detected; the power management device including: a power control for each pair of said at least two pairs of output power terminals for shutting down or limiting the output power on the pair of output power terminals on which the fault has been detected, a recorder for recording power management device activity including fault detection; the power management system further comprising; a communications channel enabling communications between the power management device and an external controller which controls fault detection, power control , the recorder and said communications.

[0019] In a broad form of a method aspect the present invention comprises;

a method for monitoring and management of electrical performance of an alternator using a management system including a power management device to limit output power upon detection of a fault, the system including a recorder, a communications channel and an external controller; the method comprising the steps of: a) providing an alternator associated with a machine and having at least two pairs of power output terminals; b) providing a fault detector capable of detecting electrical faults on any pair of the at least two pairs of output power terminals; c) identifying a pair of the at least two pairs of output power terminals on which the fault or faults is detected; d) providing a communications channel enabling communications between the power management device and an external controller; e) using the power management device to shut down or limit output power on the pair of output power terminals on which the fault has been detected, f) using the controller to control the shut down or power limitation and using the recorder to record the power management device activity including fault detection;

[0020] According to a preferred embodiment method relies on the alternator a software module, firmware and a micro controller. According to a preferred embodiment, there is provided a two way communications link between the micro controller and an operator.

[0021] According to the method aspect, the invention comprises the further steps of:

a) allowing the operator to receive and transmit data to and from the microprocessor;

b) assessing the performance of the alternator to determine if its performance lies within normal operating parameters.

c) adjusting the microprocessor data to alter the performance of the alternator to within normal operating parameters.

[0022] The alternator includes a micro controller having a software module integrated into control firmware of the alternator's microcontroller. The control system enables a machine operator to monitor, detect and communicate with the alternator so that data available in the microcontroller is obtained by the software module and sent via a communications path to the control system associated with the machine.

[0023] In another broad form the present invention comprises:

an interactive control system which enables an operator to monitor and control performance parameters of a machine which includes an alternator, the control system comprising a machine controller, a software module, associated firmware and a microcontroller; a communications interface which connects the microcontroller to the machine controller which includes an operator console; wherein the software module communicates with the machine controller and provides a visual output at the operator console reporting on the status and history of the machine's power system as detected by the alternator and also allows command data input from an operator.

[0024] In another broad form the present invention comprises: a power management device for automatically reducing the over-current threshold electrical fault detection on a pair of output power terminals on a flameproof alternator which are connected to a battery as the battery reduces its power consumption; the flameproof alternator including a stator, a diode bridge, a field coil, at least two pairs of positive and negative power terminals, fault detection circuitry and power shutdown circuitry for each pair of power terminals; control circuitry for monitoring the fault detection circuitry and for operating the power shutdown circuitry; the power management device including: a power controller for each pair of said at least two pairs of output power terminals for shutting down or limiting the output power on at least one of said at least two pairs of output power terminals on which a fault has been detected.

[0025] According to a preferred embodiment the management device includes an earth leakage detection circuit for detecting earth leakage on a machine or equipment frame associated with the alternator. Preferably each terminal or each set of terminals are powered sequentially to determine which power terminal or positive/negative pair of power terminals has an earth leakage fault. The alternator also includes at least two pairs of output power terminals each pair comprising a positive terminal and a negative terminal The system also includes, a fault detector capable of detecting electrical faults on any pair of output power terminals and of identifying the pair of output power terminals on which the fault or faults were detected. A power controller for each pair of output power terminals shuts down or limits the output power on the pair of output power terminals;

[0026] Preferably a recorder records operational faults. A communications channel is provided for interacting with an external control unit. A control system is provided for operating the fault detector, the power controller, the recorder and for communicating with the external control unit over the communications channel. According to a preferred embodiment a battery detector is provided. An over-current threshold is automatically reduced for the pair of output power terminals connected to the battery as the battery reduces its power consumption.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The present invention will now be described in broad detail according to preferred but non limiting embodiments wherein;

Figure 1 shows a block diagram of a preferred embodiment of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

[0025] Referring to figure 1 there is shown a flameproof alternator 1 having a stator 3, a diode bridge 5, a field coil 11, at least two pairs of positive and negative power terminals 15, fault detection circuitry 9 and power shutdown circuitry 7 for each set of power terminals, control circuitry 13 for monitoring the fault detection circuitry and for operating the power shutdown circuitry, recording circuitry 21 for recording fault and operational history, a communications channel 19 for providing data to and receiving commands from an external control unit and software or firmware to receive input from input signals, to generate control signals to operate the circuitry and for communicating over the communications channel 19.

[0026] Earth leakage circuitry detects any leakage current occurring on the Earth terminal 17 and may be implemented in several forms. In one embodiment each power terminal has its own earth leakage detection circuitry.

[0027] In another embodiment a single earth leakage detection circuit is multiplexed to a single power terminal whereby each power terminal is then tested sequentially. In another embodiment a single earth leakage detection circuit detects earth leakage on any positive and/or negative terminal 15 and the individual terminals or each set of terminals are then powered sequentially to determine which power terminal or positive/negative pair of power terminals has an earth leakage fault. Combinations of the above embodiments are also contemplated.

[0028] In one embodiment each pair of output power terminals 15 has over-current, over voltage and/or under-voltage detection circuitry. In another embodiment a single set of over current, over-voltage and/or under-voltage detection circuitry is sequentially used with each pair of output power terminals 15 to detect the respective faults. It will be appreciated by persons skilled in the art that different combinations of the above embodiments are also contemplated.

[0029] In addition to the circuitry mentioned above, i. e. the control circuitry 13 for monitoring the fault detection circuitry 9 and the recording circuitry 21, the control circuitry 23 includes other circuitry commonly employed in flameproof alternators. The power management system according to the present invention is advantageous for use with any machinery powered by a flameproof alternator.

[0030] The power management device for the flameproof alternator 1 comprises: at least two pairs of output power terminals 15 each pair comprising a positive terminal and a negative terminal. The device also includes a fault detection circuit 9 capable of detecting electrical faults on any pair of output power terminals 15 and of identifying the specific pair of output power terminals on which the fault or faults were detected.

[0031] A remote power controller is provided for each pair of output power terminals 15 for shutting down or limiting the output power on the pair of output power terminals. In operation, the device records operational faults which are stored in recording circuitry 21. Communications channel 19 allows interaction with an external control unit which operates fault detection circuitry 9 the remote power controller, the recording circuitry 21 and the communications with the external control unit over the communications channel 19. Alternator 1 includes a battery detector. An over-current threshold is automatically reduced for the pair of output power terminals connected to the battery as the battery reduces its power consumption.

[0032] It will be recognised by persons skilled in the art that numerous variations and modifications may be made to the invention without departing from the overall spirit and scope of the invention.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1 A flameproof alternator including a stator, a diode bridge, a field coil, at least two pairs of positive and negative power terminals, fault detection circuitry and power shutdown circuitry for each pair of power terminals; control circuitry for monitoring the fault detection circuitry and for operating the power shutdown circuitry; the alternator further comprising a power management device including: a power controller for each pair of said at least two pairs of output power terminals for shutting down or limiting the output power on at least one of said at least two pairs of output power terminals on which a fault has been detected.
2 An alternator according to claim 1 further comprising, recording circuitry for recording fault data and operational history of the alternator.
3 An alternator according to claim 2 further comprising, a communications channel for providing data to and receiving commands from an external control unit.
4 An alternator according to claim 3 further comprising, software or firmware to receive input from input signals from said recording circuitry, to generate control signals to operate the fault detection and shutdown circuitry.
An alternator according to claim 4 wherein said software or firmware facilitates communications over the communications channel.
6 An alternator according to claim 5 wherein said fault detection circuitry detects any leakage current occurring on an earth terminal.
7 An alternator according to claim 6 wherein said each pair of output power terminals has over-current, over-voltage and/or under-voltage detection circuitry.
8 An alternator according to claim 7 wherein each said power terminal has its own earth leakage detection circuitry.
9 An alternator according to claim 8 wherein a single earth leakage detection circuit is multiplexed to a single power terminal at any one time.
An alternator according to claim 9 wherein each said power terminal is tested sequentially.
11 An alternator according to claim 10 wherein each said individual terminals or each set of terminals are powered sequentially to determine which power terminal or positive/negative pair of power terminals has an earth leakage fault.
12 An alternator according to claim 11 further comprising a single earth leakage detection circuit which detects earth leakage on any positive and/or negative terminal.
13 An alternator according to claim 12 further comprising a single set of over-current, over-voltage and/or under-voltage detection circuitry, sequentially used with each pair of output power terminals to detect the respective faults.
14 A power management system including a power management device for managing fault activity of a flameproof alternator, the alternator including: at least two pairs of output power terminals each pair comprising a positive terminal and a negative terminal, the system including a fault detection circuitry capable of detecting electrical faults on any pair of the at least two pairs of output power terminals and of identifying a pair of the at least two pairs of output power terminals on which the fault or faults is/are detected; the power management system further including a power management device including: a power control for each pair of said at least two pairs of output power terminals for shutting down or limiting the output power on the pair of output power terminals on which the fault has been detected.
A power management system according to claim 14 further comprising, a communications channel for providing data to and receiving commands from an external control unit.
16 A power management system according to claim 15 further comprising, software or firmware to receive input from input signals from said recording circuitry, to generate control signals to operate fault detection and shutdown circuitry.
17 A power management system according to claim 16 wherein, said software or firmware facilitates communications over the communications channel.
18 A power management system according to claim 17 wherein, said fault detection circuitry detects any leakage current occurring on an earth terminal.
19 A power management system according to claim 18 wherein, said each pair of output power terminals has over-current, over-voltage and/or under-voltage detection circuitry.
A power management system according to claim 19 wherein, each said power terminal has its own earth leakage detection circuitry which detects earth leakage on any positive and/or negative terminal.
21 A power management system according to claim 20 wherein, a single earth leakage detection circuit is multiplexed to a single power terminal at any one time.
22 A power management system according to claim 21 wherein each said power terminal is tested sequentially.
23 A power management system according to claim 22 wherein each said individual terminals or each set of terminals are powered sequentially to determine which power terminal or positive/negative pair of power terminals has an earth leakage fault.
24 A power management system according to claim 23 further comprising a single set of over-current, over-voltage and/or under-voltage detection circuitry, sequentially used with each pair of output power terminals to detect the respective faults.
A power management system according to claim 24 further comprising; a recorder for recording power management device activity including fault detection;.
26 A power management system according to claim 25 wherein the controller is an external controller which controls fault detection, power control , the recorder and said communications.
27 A power management system according to claim 26 further comprising a battery detector.
28 A power management system according to claim 27 wherein an over-current threshold is automatically reduced for a pair of output power terminals connected to the battery as the battery reduces its power consumption.
29 A power management system according to claim 14 or 28 wherein the power management device automatically reduces the over-current threshold electrical fault detection on a pair of the output power terminals of the flameproof alternator that are connected to a battery as the battery reduces its power consumption.
A power management device for automatically reducing the over-current threshold electrical fault detection on a pair of output power terminals on a flameproof alternator which are connected to a battery as the battery reduces its power consumption; the flameproof alternator including a stator, a diode bridge, a field coil, at least two pairs of positive and negative power terminals, fault detection circuitry and power shutdown circuitry for each pair of power terminals; control circuitry for monitoring the fault detection circuitry and for operating the power shutdown circuitry; the power management device including: a power controller for each pair of said at least two pairs of output power terminals for shutting down or limiting the output power on at least one of said at least two pairs of output power terminals on which a fault has been detected.
31 A power management device according to claim 30 further comprising an earth leakage detection circuit detecting earth leakage on a machine or equipment frame associated with the alternator; wherein each terminal or each set of terminals are powered sequentially to determine which power terminal or positive/negative pair of power terminals has an earth leakage fault.
32 A power management device for a flameproof alternator comprising: at least two pairs of output power terminals each pair comprising a positive terminal and a negative terminal, a fault detection circuitry capable of detecting electrical faults on any pair of output power terminals and of identifying the pair of output power terminals on which the fault or faults were detected; a power controller for each pair of output power terminals for shutting down or limiting the output power on the pair of output power terminals; a recorder for recording operational faults; a communications channel for interacting with an external control unit and a control system for operating the fault detection circuitry, the power controller, the recorder and for communicating with the external control unit over the communications channel.
33 A power management device for a flameproof alternator according to claim 32 further comprising a battery detector.
34 A power management device for a flameproof alternator according to claim 33 whereby an over-current threshold is automatically reduced for the pair of output power terminals connected to the battery as the battery reduces its power consumption.

A method for monitoring and management of electrical performance of an alternator using a management system including a power management device to limit output power upon detection of a fault, the system including a recorder, a communications channel and a controller; the method comprising the steps of:

a) providing an alternator associated with a machine and having at least two pairs of power output terminals;

b) providing a fault detector capable of detecting electrical faults on any pair of the at least two pairs of output power terminals;

c) identifying a pair of the at least two pairs of output power terminals on which the fault or faults is detected; d) providing a communications channel enabling communications between the power management device and an external controller;

e) using the power management device to shut down or limit output power on the pair of output power terminals on which the fault has been detected,

a) using the controller to control the shut down or power limitation and using the recorder to record the power management device activity including fault detection.

1 5 7 9 15

+ A + — B — 3 C + —

11 Earth

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FIGURE 1