AU2019268162B2

AU2019268162B2 - A power management system and device for flameproof alternators

Info

Publication number: AU2019268162B2
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: 2025-07-10
Anticipated expiration: 2039-11-21
Also published as: AU2019268162A1

Abstract

#$%^&*AU2019268162B220250710.pdf##### 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. 2019268162 21 Nov 2019 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. FIGURE 1 3 + — + — A B C 1 5 7 + — Earth 9 11 15 17 19 13 21 23 20 19 26 81 62 2 1 N ov 2 01 92019268162 21 Nov 2019 5 71 9 15 + + 3 A C B - + 11 Earth 17 23 19 21 13 FIGURE 1

Description

2019268162 21 Nov 2019 2019268162

1 1 5 5 7 7 9 9 15 15

+ A A C B

+ + + — B — 3 3 C - + + —

11 11 Earth Earth

17 17 23 19 19 23 21 21 13 13

FIGURE FIGURE 11

A POWER POWER MANAGEMENT SYSTEM AND DEVICEFOR FORFLAMEPROOF FLAMEPROOF 20 Jun 2025 2019268162 20 Jun 2025

A MANAGEMENT SYSTEM AND DEVICE ALTERNATORS ALTERNATORS BACKGROUND BACKGROUND & &FIELD FIELD

[0001] Thetechnical

[0001] The technicalfield fieldofofthe thepresent presentinvention invention is is flameproof flameproof alternators. alternators. TheThe present present

invention relates totoelectrical invention relates electricalmachinery machinery including including flameflame proof alternators proof alternators and moreand more

particularly relates relatestotoimprovements in the the control, control,monitoring monitoring and and management management ofof alternators 2019268162

particularly improvements in alternators

used with used with such suchmachinery machineryandand to to data data communications communications whichwhich provide provide real-time real-time information information

for for control ofthe control of thealternator. alternator.The The present present invention invention also also relates relates to a to a communications communications path which path which

is is interfaced interfaced to toa acontroller controllerand andwhich which allows allows command input.More command input. More particularly,thethepresent particularly, present invention relatestotoa acontrol invention relates control system system whichwhich iswith is used useda with flame a flame proof proof alternator alternator for detecting for detecting

alternator faults such alternator faults suchas, as,but butnot notlimited limitedto to earth earth leakage leakage and and for management for and and management of such faults of such faults

including including remote management. remote management.

[0002]

[0002] The invention further The invention further relates relates to to aa management management control control system system including including a a communications communications interface interface which which allows allows real real timetime monitoring monitoring of alternator of alternator parameters parameters and and particularly faults. The present invention further relates to such integrated communications and particularly faults. The present invention further relates to such integrated communications and

control systems control systems forfor alternators alternators including including flame flame proof alternators proof alternators which arewhich used inare used in particular particular

thoughnot though not exclusively, exclusively, in in dangerous environmentssuch dangerous environments suchasasoccurs occursininunderground underground mining. mining. TheThe

present invention present invention is is capable capable of of use use by bymaintenance maintenance personnel personnel whenwhen maintaining maintaining machinery machinery

whichincorporates which incorporatesthe the communications communications system. system.

PRIOR ART PRIOR ART

[0003] Hazardous environments

[0003] Hazardous environments are are commonly commonly found found in, in, forfor example, example, thethe mining mining and and

petrochemicalindustries. petrochemical industries. InIn mines, mines,forforexample, example, a spark a spark can can result result in a in a mine mine explosion. explosion.

Industry standards Industry standards generally generallyrequire requirethat thatmachines machinesandand machine machine components components used inused such in such hazardousenvironments hazardous environments areflameproof are flameproof and/or and/or intrinsicallysafe. intrinsically safe. A flameproofdevice A flameproof devicemust mustbebe able to withstand an internal explosion and any air passages between the internal space and the able to withstand an internal explosion and any air passages between the internal space and the

outside outside must meetspecific must meet specificflame-path flame-pathrequirements requirements such such as as a maximum a maximum 0.3 mm0.3 gapmm overgap a over a

minimum minimum 12.5 12.5 mm mm distance. distance. Intrinsicallysafe Intrinsically safedevices devicesensure ensureinternal internal temperatures remainlow, temperatures remain low, even infault even in faultconditions, conditions,andand so not so do do not pose pose an ignition an ignition hazard.hazard.

1

2019268162 20 Jun 2025

[0004] Theelectrical

[0004] The electrical systems on the systems on the various various types types of of automotive machinesused automotive machines used in in hazardous hazardous

environments aretypically environments are typically powered poweredusing using a flameproof a flameproof alternator.A A alternator. batterymaymay battery or or maymay not not

be used as the use of a battery introduces certain types of risks. Electrical power is delivered be used as the use of a battery introduces certain types of risks. Electrical power is delivered

from from aa positive positive and anda anegative negativeterminal terminalonon thethe alternatorthrough alternator through cabling cabling to to thethe battery, battery, if if

present, and present, to each and to each electrically electrically operated piece of operated piece of equipment equipmentsuch such as as lightsandand lights pneumatic pneumatic

control valves. 2019268162

control valves.

[0005] Safety standards

[0005] Safety standards generally generallyrequire require the the flameproof flameproofalternator alternatorto to detect detect certain certain types types of of

faults faults and and to to automatically shut down. automatically shut down.Mining Mining equipment equipment downtime downtime is costly is costly so alternators so alternators

generally generally have integrated control have integrated control systems that can systems that can communicate operationalinformation communicate operational information toto anan

external external reader reader used by aa technician used by techniciantoto determine determinethe thecause causeofofthetheshutdown shutdown so appropriate so appropriate

corrective action can be taken. corrective action can be taken.

[0006] Oftenthe

[0006] Often thepiece pieceofoffaulty faultyequipment equipment responsible responsible for for the the alternator alternator shutdown shutdown is not is not

obvious. Different companies obvious. Different companiesmaymay be responsible be responsible for different for different pieces pieces of equipment of equipment and soand so

several several repair repair technicians technicians may needtotoinspect may need inspecttheir theirparticular particular piece pieceofofequipment equipment untilthethe until

cause of cause of the thefault fault isis identified identified and andsubsequently subsequently rectified.Organizing rectified. Organizing the the various various repair repair

technicians to technicians to inspect inspect the the machine machinein in thethe mine mine can can also also proveprove quite quite difficult. difficult. The repair The repair

technicians can technicians canhave havea difference a difference of of opinion opinion on where on where the lies the fault faultand liesthis andcanthis can take take considerable time to then resolve the issue and rectify the fault. These delays all add to machine considerable time to then resolve the issue and rectify the fault. These delays all add to machine

downtime andassociated downtime and associatedcosts. costs.

[0007] Flameproof

[0007] Flameproof alternators alternators typically typically includeinclude circuitry circuitry to the to monitor monitor thedetect load and load fault and detect fault conditions then, when a fault is detected, to automatically shut off their output until they are conditions then, when a fault is detected, to automatically shut off their output until they are

manuallyreset manually resetbybyananoperator. operator.Circuitry Circuitrymay may also also record record andand report report via via a communications a communications

channel operational channel operational history history including including any detected any detected faults. faults.

[0008] Thetypes

[0008] The typesofoffaults faultsdetected detectedbybyflameproof flameproof alternators alternators include include over-voltage, over-voltage, under- under-

voltage, over-current, voltage, earth leakage over-current, earth fromthe leakage from thepositive positiveterminal terminalandand earth earth leakage leakage from from the the negative terminal. negative terminal. Brief Brief transient transient faults faultsmay may be be acceptable and not acceptable and not result result in in the the power being power being

shut shut down. down.

2

2019268162 20 Jun 2025

[0009] When

[0009] When an an electricalfault electrical fault occurs occursononaamachine machine powered powered by aby a flameproof flameproof alternator alternator the the

built-in safety built-in safetymechanism shutsdown mechanism shuts down allpower all power output. output. Allelectrical All electricalequipment equipment powered powered by by the alternator the alternatorimmediately immediately loses loses power. A manual power. A manualreset resetisis required required to to restore restorepower. power. Although Although

the type of fault can generally be read from the electrical fault log of the flameproof alternator the type of fault can generally be read from the electrical fault log of the flameproof alternator

it it can can still stillprove difficult to prove difficult to identify identifythe thepiece pieceofofequipment equipment that that caused caused or is or is causing causing the fault. the fault.

Where a battery is is used the the over-current threshold may need set to be high set quite high the to deliver the 2019268162

Where a battery used over-current threshold may need to be quite to deliver

high power high powerthat thataa battery battery can can require. require. This This threshold threshold may maythen thenmask mask over-current over-current faults faults that that

mayoccur may occurwhen whenthethe batteryisisnot battery not drawing drawinghigh highpower. power.

SUMMARY OFINVENTION SUMMARY OF INVENTION

[0010] The present

[0010] The present invention invention provides provides improvements improvements in in thethe control,monitoring control, monitoringandand management management of of alternatorsused alternators usedwith withmachinery machineryandand also also provides provides datacommunications data communications which which

provide real-time information for control of the alternator. The present invention also provides provide real-time information for control of the alternator. The present invention also provides

aa power power management managementsystem systemwhich whichincludes includes a apower powermanagement management device device andand a a communications communications path path which which is interfaced is interfaced tocontroller to a a controller andand which which allows allows command command input. input. Moreparticularly, More particularly, the the present present invention invention provides provides a a control control system whichisis used system which used with with aa flame flame proof alternator for detecting alternator faults such as, but not limited to earth leakage and for proof alternator for detecting alternator faults such as, but not limited to earth leakage and for

remote management remote managementof of such such faults. faults.

[0011]

[0011] The invention further The invention further provides provides a amanagement management control control system system including including a a communications communications interface interface which which allows allows real real timetime monitoring monitoring of alternator of alternator parameters parameters and and particularly faults. particularly faults.The The present invention further present invention further provides providesintegrated integratedcommunications communications and and control systems control systems forfor alternators alternators including including flame flame proof alternators proof alternators which arewhich used inare used in particular particular

thoughnot though not exclusively, exclusively, in in dangerous environmentssuch dangerous environments such asas occursininunderground occurs underground mining. mining.

[0012] Thepresent

[0012] The presentinvention inventionprovides providesananenhanced enhanced flameproof flameproof alternator alternator employing employing multiple multiple

output powerterminals, output power terminals,each eachpair pairofofpower power terminals terminals being being monitored monitored for electrical for electrical faults. faults.

Whena afault When faultoccurs occursonly onlythe the equipment equipmentpowered powered by the by the pair pair of of power power terminals terminals on which on which the the fault fault occurred occurred loses loses power. power. Other Other equipment continuestotobebepowered equipment continues powered where where it it isisnot notthe the cause cause of of the the electrical electricalfault. When fault. Whenan anelectrical electricalfault occurs fault on on occurs a machine a machinepowered powered by by a a flameproof flameproof

3 alternator alternator the thebuilt-in safety mechanism mechanism according to conventional technologyshuts shutsdown downallall 20 Jun 2025 2019268162 20 Jun 2025 built-in safety according to conventional technology poweroutput. power output. At Atpresent, present, all allelectrical electricalequipment equipmentpowered by the powered by the alternator alternatorimmediately loses immediately loses power, requiring a manual reset to restore power. A fault will be stored in the electrical log, 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 but it can still prove difficult to identify the piece of equipment that caused or is causing the fault. fault. The present invention The present inventionprovides provides a solution a solution to that to that problem problem by providing by providing a power a power management management system system including including a power a power control control for pair for each each of pair of output output power power terminals terminals for for shutting shutting down or limiting limiting the the output output power onthe the pair pair of of output output power terminals on on which whichthe the 2019268162 down or power on power terminals fault fault has beendetected. has been detected.

[0013] Morebroadly,

[0013] More broadly,the thepresent presentinvention inventionprovides providesananalternative alternative to to the the known prior art known prior art and and

the shortcomings the identified. The shortcomings identified. foregoing and The foregoing andother other objects objects and and advantages advantageswill willappear appearfrom from the description the description toto follow. follow. In In the the description descriptionreference referenceis ismade made to to the the accompanying accompanying

representations, which forms a part hereof, and in which is shown by way of illustration specific representations, which forms a part hereof, and in which is shown by way of illustration specific

embodiments embodiments in in which which thethe invention invention maymay be practiced. be practiced. These These embodiments embodiments will will be be described described

in sufficientdetail in sufficient detailtotoenable enable those those skilled skilled in art in the thetoartpractice to practice the invention, the invention, and and it is it is to be to be

understoodthat understood that other other embodiments embodiments maymay be utilized be utilized andand that that structuralchanges structural changes maymay be made be made

without departing without departingfrom fromthethescope scope of of thethe invention. invention. In the In the accompanying accompanying illustrations, illustrations, like like

reference characters reference characters designate the same designate the or similar same or similar parts parts throughout the views. throughout the views. The Thefollowing following detailed descriptionis,is,therefore, detailed description therefore,notnottotobebetaken taken in in a limiting a limiting sense, sense, and and the scope the scope ofpresent of the the present invention is best invention is bestdefined defined by by the theappended claims. appended claims.

[0014] Oneadvantage

[0014] One advantageofofthe thepresent presentinvention inventionisis that that machine downtime machine downtime andand associated associated costs costs

can bedramatically can be dramatically reduced reduced asfaulty as the the faulty piece piece of equipment of equipment is more is more readily readily identified. identified.

[0015] Where

[0015] Where a battery a battery is present, is present, the over-current the over-current fault threshold fault threshold needs to needs be hightoenough be high to enough to

allow for allow for the the battery's battery’s occasional occasional high powerconsumption. high power consumption. This This high high threshold threshold may may be be too too high to effectively protect over-current faults on equipment powered by the alternator. high to effectively protect over-current faults on equipment powered by the alternator.

[0016] Providingmultiple

[0016] Providing multiplepairs pairsofofoutput outputpower power terminals, terminals, each each withwith its its own own over-current over-current

threshold, allows better over-current protection on the pairs of output power terminals that do threshold, allows better over-current protection on the pairs of output power terminals that do

not charge not the battery. charge the battery. Further, Further, over-current over-current protection protection on on the the battery batterycharging charging pair pairof ofpower power

terminals can terminals be made can be mademore more effectivebybyautomatically effective automaticallyreducing reducing thethe over-current over-current threshold threshold asas

4 the battery charges. It is advantageous to provide automatic detection of a battery to simplify 20 Jun 2025 2019268162 20 Jun 2025 the battery charges. It is advantageous to provide automatic detection of a battery to simplify installation andconfiguration. installation and configuration.

[0017] Theadvantageous

[0017] The advantageous effectsofofautomatically effects automatically reducing reducing thethe over-current over-current threshold threshold as as thethe

battery charges battery can also charges can also be used on be used on flameproof flameproofalternators alternators with withaa single single pair pair of of output output power power

terminals. terminals. 2019268162

[0018] In one

[0018] In broad form one broad formthe thepresent present invention invention comprises: comprises: aa power management power management system system including including a power a power management management devicedevice for a for a flameproof flameproof alternator alternator

including: including:

at at least least two two pairs pairs of of output output power terminalseach power terminals eachpair paircomprising comprising a positiveterminal a positive terminal andand a a

negative terminal, negative terminal,

aa fault fault detector detectorcapable capable of detecting of detecting electrical electrical faultsfaults on anyon any pair of pair ofleast the at the at twoleast pairs two of pairs of

output powerterminals output power terminalsandand of of identifying identifying a pair a pair of of thethe at at leasttwo least two pairs pairs of of output output power power

terminals on which the fault or faults is detected; 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 the power management device including: a power control for each pair of said at least two pairs

of outputpower of output power terminals terminals for shutting for shutting down down or or limiting limiting thepower the output output power on the pair on of the pair of output output

powerterminals power terminalsononwhich whichthe thefault fault has has been beendetected, detected, aa recorder recorder for for recording recording power management power management device device activity activity including including faultdetection; fault detection; the power the managementsystem power management system furthercomprising; further comprising;a acommunications communications channel channel enabling enabling

communications between communications betweenthe the power powermanagement management device device andand an an externalcontroller external controller which which controls controls fault faultdetection, detection,power power control , the control, therecorder recorderand andsaid saidcommunications. communications.

[0019] In aa broad

[0019] In broad form of aa method form of aspectthe method aspect thepresent present invention invention comprises; comprises;

aa method for monitoring method for monitoringand andmanagement management of electrical of electrical performance performance of an of an alternatorusing alternator using aa management system management system including including a power a power management management device device to limit to limit outputoutput power power upon upon

detection detection of of a a fault, fault,the thesystem system including including a a recorder, recorder, aa communications channel communications channel andand an an

external controller;the external controller; themethod method comprising comprising theof: the steps steps of:

5 a) providing providing an alternator associated with a machine and and having at least twotwo pairs of of 20 Jun 2025 2019268162 20 Jun 2025 a) an alternator associated with a machine having at least pairs poweroutput power outputterminals; terminals; b) providing a fault detector capable of detecting electrical faults on any pair of the at least b) providing a fault detector capable of detecting electrical faults on any pair of the at least two pairs two pairs of of output output power terminals; power terminals; c) identifying c) identifying a pairofofthe a pair theatat least least two two pairs pairs of of output output power terminals on power terminals whichthe on which the fault fault or faults is or faults is detected; detected; 2019268162 d) d) providinga acommunications providing communications channel channel enablingcommunications enabling communications between between thethe power power management management device device andand an an external external controller; controller; e) e) using the using the power management power management device device to shut to shut down down or limit or limit output output power power on the on the pairpair of of output output power terminalsononwhich power terminals whichthe thefault fault has has been beendetected, detected, f) f) using the controller to control the shut down or power limitation and using the recorder using the controller to control the shut down or power limitation and using the recorder to record to record the the power management power management device device activityincluding activity includingfault faultdetection; detection;

[0020] Accordingtotoa apreferred

[0020] According preferredembodiment embodiment method method relies relies on alternator on the the alternator a software a software

module,firmware module, firmwareand and a micro a micro controller.According controller. Accordingto to a preferred a preferred embodiment, embodiment, there there is is provided aa two provided twoway waycommunications communicationslinklink between between the micro the micro controller controller and and an operator. an operator.

[0021] Accordingtotothe

[0021] According themethod methodaspect, aspect,the theinvention inventioncomprises comprisesthe thefurther furthersteps steps of: of:

a) allowing the operator to receive and transmit data to and from the microprocessor; 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 b) assessing the performance of the alternator to determine if its performance lies within

normaloperating normal operatingparameters. parameters.

c) adjusting c) adjusting the the microprocessor data to microprocessor data to alter alter the the performance ofthe performance of thealternator alternator to to within within

normaloperating normal operatingparameters. parameters.

[0022] Thealternator

[0022] The alternatorincludes includesa amicro micro controllerhaving controller having a software a software module module integrated integrated

into into control control firmware of the firmware of the alternator's alternator’s microcontroller. Thecontrol microcontroller. The controlsystem systemenables enablesa a machineoperator machine operatortotomonitor, monitor,detect detectandand communicate communicate withalternator with the the alternator so data so that that data

6 available in the the microcontroller microcontrollerisisobtained obtainedby by thethe software module andvia sent a via a 20 Jun 2025 2019268162 20 Jun 2025 available in software module and sent communications path communications path toto thecontrol the controlsystem systemassociated associatedwith withthe themachine. machine.

[0023] [In another

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

The invention The inventionfurther further provides an interactive provides an interactive control controlsystem system which enables an which enables an operator operator to to 2019268162

monitor and monitor andcontrol controlperformance performance parameters parameters ofmachine of a a machine which which includes includes an alternator, an alternator,

the control the control system systemcomprising comprising a machine a machine controller, controller, a software a software module,module, associated associated

firmware anda amicrocontroller. firmware and microcontroller.The Thesystem system includes includes a communications a communications interface interface which which

connects themicrocontroller connects the microcontroller to the to the machine machine controller controller which includes which includes an console; an operator operator console; whereinthe wherein the software softwaremodule module communicates communicates with with the machine the machine controller controller and provides and provides a a visual output at the operator console reporting on the status and history of the machine’s visual output at the operator console reporting on the status and history of the machine's

powersystem power systemasasdetected detectedbybythe thealternator alternatorand andalso alsoallows allowscommand commanddatadata input input fromfrom an an operator. operator.

[0024]

[0024] In In another another broad formthe broad form the present present invention invention comprises: comprises: aa power power management managementsystem system comprising comprising a power a power management management device device integrated integrated withwith a a

flameproof alternatorthe, the flameproof alternator, alternator alternator including including a stator, a stator, a diodea bridge, diode bridge, a field coil; a field coil;

the power the management power management system system further further comprising: comprising:

negative terminal, negative terminal,

fault detectioncircuitry fault detection circuitrycapable capable of detecting of detecting electrical electrical faults faults on any on pairany pairatofleast of the the two at least two pairs of pairs of output output power terminalsand power terminals andofofidentifying identifyinga apair pairofofthe theatat least least two twopairs pairs of of output output power terminals on which the fault or faults is/are detected; power terminals on which the fault or faults is/are detected;

power shut down circuitry responsive to fault detection circuitry; power shut down circuitry responsive to fault detection circuitry;

control circuitryfor control circuitry formeasuring measuringthe the fault fault detection detection circuitry circuitry for for the power the management power management device device alsoalso including: including: a power a power controller controller forfor each each pair pair of of saidatatleast said least two pairs two pairs of of output output power terminals for power terminals for shutting shutting down or limiting down or limiting the the output output power on the power on the pair pair of of output output power terminals on power terminals onwhich whichthe thefault fault has has been been detected, detected, recording circuitry recording circuitry for forrecording recordingpower power management device management device activityincluding activity includingfault faultdetection; detection;

7 the power managementsystem system furthercomprising; comprising;a acommunications communications channel enabling 20 Jun 2025 2019268162 20 Jun 2025 the power management further channel enabling communications between communications betweenthe the power powermanagement management device device andand an an externalcontroller external controller which which controls controls fault faultdetection, detection,power power control , the control, therecorder recorderand andsaid saidcommunications. communications.

[0025]

[0025] According toaa preferred According to preferred embodiment themanagement embodiment the management device device includes includes an earth an earth

leakage detection detectioncircuit circuit for fordetecting detectingearth earthleakage leakage on on a machine or equipment frame 2019268162

leakage a machine or equipment frame

associated associated with the alternator. with the alternator.Preferably Preferablyeach each terminal terminal or oreach each set setofofterminals terminalsare are powered powered

sequentially sequentially to to determine whichpower determine which power terminal terminal or or positive/negative positive/negative pairofofpower pair power terminals terminals

has an has an earth earth leakage leakagefault. fault. The Thealternator alternatoralso alsoincludes includesatatleast least two twopairs pairsofofoutput outputpower power terminals each terminals each pair pair comprising comprisinga apositive positiveterminal terminaland anda anegative negative terminal terminal TheThe system system alsoalso

includes, includes, a a fault fault detector detector capable capable of of detecting electrical faults detecting electrical faultson onany any pair pair of of output output power power

terminals and of identifying the pair of output power terminals on which the fault or faults were terminals and of identifying the pair of output power terminals on which the fault or faults were

detected. detected. A powercontroller A power controller for for each each pair pair of of output output power terminalsshuts power terminals shuts down downororlimits limitsthe the output output power onthe power on thepair pair of of output output power terminals; power terminals;

[0026]

[0026] Preferably aa recorder Preferably recorder records records operational operational faults. faults. AA communications channel communications channel is is

provided for provided forinteracting interacting with withananexternal external control control unit. unit. A control A control system system is provided is provided for for operating thefault operating the faultdetector, detector,thethe power power controller, controller, the recorder the recorder and and for for communicating communicating with the with the external external control control unit unitover overthe thecommunications channel.According communications channel. Accordingto to a a preferredembodiment preferred embodiment aa battery batterydetector detectorisisprovided. provided. An over-current An over-current threshold threshold is automatically is automatically reduced reduced for the pairfor the pair

of output power of output power terminals terminals connected connected toto the the battery battery as as the the battery battery reduces reduces its its power power

consumption. consumption.

BRIEF BRIEF DESCRIPTION DESCRIPTION OF OF THE THE DRAWINGS DRAWINGS

[0027] Thepresent

[0027] The presentinvention inventionwill will now nowbebedescribed describedininbroad broaddetail detailaccording accordingtotopreferred preferredbut but non limiting non limiting embodiments wherein; embodiments wherein;

Figure 11 shows Figure shows aablock blockdiagram diagramofofa apreferred preferredembodiment embodiment of the of the invention. invention.

DETAILED DESCRIPTIONOF DETAILED DESCRIPTION OFEMBODIMENTS EMBODIMENTS 8

2019268162 20 Jun 2025

[0025]

[0025] Referring to figure 1 there is shown a flameproof alternator 1 having a stator 3, Referring to figure 1 there is shown a flameproof alternator 1 having a stator 3,

aa diode bridge5,5,a afield diode bridge fieldcoil coil11,11,atatleast leasttwo two pairs pairs of of positive positive and and negative negative power power terminals terminals 15, 15, fault fault detection detection circuitry circuitry99 and and power shutdown power shutdown circuitry7 7forforeach circuitry each setset ofof power power terminals, terminals,

control control circuitry circuitry 13 13 for for monitoring the fault monitoring the fault detection detection circuitry circuitry and and for for operating operating the the power power

shutdown circuitry,recording shutdown circuitry, recordingcircuitry circuitry2121 forfor recording recording fault fault and and operational operational history, history, a a communications channel 19 19 for for providing datadata to and receiving commands from an external 2019268162

communications channel providing to and receiving commands from an external

control unitand control unit andsoftware software or firmware or firmware to receive to receive input input from from input inputtosignals, signals, generateto generate control control

signals signals to to operate operate the thecircuitry circuitryand forfor and communicating communicating over over the the communications channel communications channel 19. 19.

[0026] Earth leakage

[0026] Earth leakagecircuitry circuitry detects detects any any leakage current occurring leakage current occurring on on the the Earth Earth terminal terminal 17 17 and maybebeimplemented and may implementedin in severalforms. several forms.InInone oneembodiment embodimenteacheach power power terminal terminal has has its its ownown

earth leakagedetection earth leakage detection circuitry. circuitry.

[0027]

[0027] InIn another another embodiment embodiment a single a single earth leakage earth leakage detectiondetection circuit iscircuit is multiplexed multiplexed to a singleto a single

power terminal power terminal whereby wherebyeach eachpower power terminal terminal is then is then tested tested sequentially.InInanother sequentially. another embodiment a single earth leakage detection circuit detects earth leakage on any positive and/or embodiment a single earth leakage detection circuit detects earth leakage on any positive and/or

negative terminal negative terminal 15 15and andthe theindividual individualterminals terminalsororeach eachset setofofterminals terminalsare arethen thenpowered powered sequentially sequentially to to determine whichpower determine which power terminal terminal or or positive/negative positive/negative pairofofpower pair power terminals terminals

has an has an earth earth leakage leakage fault. fault.Combinations of the Combinations of the above embodiments above embodiments areare alsocontemplated. also contemplated.

[0028] In one

[0028] In oneembodiment embodimenteacheach pair pair of output of output powerpower terminals terminals 15 has15 has over-current, over-current, over- over-

voltage and/or under-voltage voltage and/or under-voltagedetection detectioncircuitry. circuitry. In In another another embodiment embodiment a a singleset single setofofover- over- current, current, over-voltage over-voltage and/or under-voltagedetection and/or under-voltage detectioncircuitry circuitry is is sequentially sequentially used with each used with each pair of pair of output powerterminals output power terminals1515 to to detectthetherespective detect respective faults.ItItwill faults. will be beappreciated appreciatedbyby persons skilled persons skilled in in the the art art that that different different combinations combinationsofofthetheabove above embodiments embodiments are are also also contemplated. contemplated.

[0029]

[0029] InInaddition additionto to the the circuitry circuitry mentioned mentioned above, above, i. e.control i. e. the the control circuitry circuitry 13 for 13 for monitoring monitoring

the fault detection circuitry 9 and the recording circuitry 21, there is provided control circuitry the fault detection circuitry 9 and the recording circuitry 21, there is provided control circuitry

23 includes 23 includes other other circuitry circuitry commonly employedininflameproof commonly employed flameproofalternators. alternators. The The power power

9 management system according to present the present invention is advantageous for use for withuse anywith any 20 Jun 2025 2019268162 20 Jun 2025 management system according to the invention is advantageous machinerypowered machinery poweredby by a flameproof a flameproof alternator. alternator.

[0030] Thepower

[0030] The power management management device device forflameproof for the the flameproof alternator alternator 1 comprises: 1 comprises:

at at least leasttwo two pairs pairsofofoutput outputpower power terminals terminals 15 15 each each pair pair comprising comprising aa positive positive terminal terminal and and a a

negative terminal. negative terminal. The Thedevice devicealso alsoincludes includesa afault faultdetection detectioncircuit circuit99capable capableofofdetecting detecting electrical faults on onany anypair pairofofoutput output power terminals 15 and15 of and of identifying the specific pair of pair of 2019268162

electrical faults power terminals identifying the specific

output output power terminalsononwhich power terminals whichthe thefault faultor or faults faults were detected. AAremote were detected. remotepower power controller controller

is is provided foreach provided for each pair pair of of output output power power terminals terminals 15 for 15 for shutting shutting down orthe down or limiting limiting output the output

power on the pair of output power terminals. In operation, the device records operational faults power on the pair of output power terminals. In operation, the device records operational faults

whichare which are stored stored in in recording recording circuitry circuitry21. 21.Communications channel1919allows Communications channel allowsinteraction interactionwith with an externalcontrol an external controlunit unitwhich which operates operates fault fault detection detection circuitry circuitry 9 the power 9 the remote remote power controller, controller,

the recording the recording circuitry circuitry 21 21 and andthe thecommunications communicationswithwith the external the external control control unit unit over over the the communications communications channel channel 19.19. Alternator1 1includes Alternator includesa abattery battery detector. detector. An An over-current over-current threshold threshold

is is automatically reduced automatically reduced for for the the pairpair of output of output power power terminals terminals connectedconnected to the to the battery battery as the as the

battery reduces battery reduces its itspower power consumption. consumption.

[0029] It will

[0029] It will be berecognised recognisedby by persons persons skilled skilled in the in the art that art that numerous numerous variations variations and and modifications may be made to the invention without departing from the overall spirit and scope modifications may be made to the invention without departing from the overall spirit and scope

of the invention. of the invention.

10

Claims

2019268162 20 Jun 2025

THE CLAIMS THE DEFINING THE CLAIMS DEFINING THE INVENTION INVENTIONARE AREAS ASFOLLOWS: FOLLOWS:

11 A power A powermanagement management system system comprising comprising a power a power management management device integrated device integrated with with aa flameproof alternatorthe, the flameproof alternator, alternator alternator including including a stator, a stator, a diodea bridge, diode bridge, a field coil; a field coil;

the power the management power management system system further further comprising: comprising:

at at least least two two pairs pairs of of output output power terminalseach eachpair paircomprising comprising a positiveterminal terminal andand a a 2019268162

power terminals a positive

negative terminal, negative terminal, fault detectioncircuitry fault detection circuitrycapable capable of detecting of detecting electrical electrical faults faults on any on pairany pairatofleast of the the two at least two pairs of pairs of output output power terminalsand power terminals andofofidentifying identifyinga apair pairofofthe theatat least least two twopairs pairs of of output output power terminals on which the fault or faults is/are detected; power terminals on which the fault or faults is/are detected;

power shut down circuitry responsive to fault detection circuitry; power shut down circuitry responsive to fault detection circuitry;

control circuitryfor control circuitry formeasuring measuringthe the fault fault detection detection circuitry circuitry for for

the power the management power management device device alsoalso including: including: a power a power controller controller forfor each each pair pair of of saidatatleast said least two pairs two pairs of of output output power terminals for power terminals for shutting shutting down or limiting down or limiting the the output output power on the power on the pair pair of of output output power terminals on power terminals onwhich whichthe thefault fault has has been been detected, detected, recording circuitry recording circuitry for forrecording recordingpower power management device management device activityincluding activity includingfault faultdetection; detection; the power the managementsystem power management system furthercomprising; further comprising;a acommunications communications channel channel enabling enabling

communications between communications betweenthe the power powermanagement management device device and and an an externalcontroller external controller which which controls controls fault faultdetection, detection,power power control , the control, therecorder recorderand andsaid saidcommunications. communications.

2 2 A system A systemaccording accordingtotoclaim claim1,1,wherein whereinthethe recording recording circuitryrecords circuitry recordsfault faultdata dataand and operational historyof of operational history thethe alternator. alternator.

33 A system A systemaccording accordingtotoclaim claim2,2,wherein whereinthethecommunications communications channel channel provides provides data data to to and receives commands and receives from commands from thethe external external controller. controller.

4 4 A system according to claim 3, further comprising software or firmware to receive input A system according to claim 3, further comprising software or firmware to receive input

from inputsignals from input signals from from saidsaid recording recording circuitry, circuitry, to generate to generate controlcontrol signals signals to operate to operate the faultthe fault

detection detection and and shutdown circuitry. shutdown circuitry.

55 A system A systemaccording accordingtotoclaim claim4 wherein 4 wherein saidsaid software software or firmware or firmware facilitates facilitates

communications communications over over thethe communications communications channel. channel.

11

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66 A system A system according according to claim to claim 5 wherein 5 wherein saiddetection said fault fault detection circuitry circuitry detects detects any leakage any leakage

current occurring current occurring on on an an earth earth terminal terminal

77 A systemaccording A system accordingtotoclaim claim 6 wherein 6 wherein said said each each pair pair of of output output power power terminals terminals has has

over-current, over-voltage and/or under-voltage detection circuitrycircuitry 2019268162

over-current, over-voltage and/or under-voltage detection

88 A system A systemaccording accordingtotoclaim claim7 7wherein wherein each each said said pair pair of of power power terminals terminals hashas its its ownown

earth leakagedetection earth leakage detection circuitry. circuitry.

99 A systemaccording A system accordingtotoclaim claim8 8wherein wherein a single a single earth earth leakage leakage detection detection circuitininthe circuit the alternator is multiplexed alternator is multiplexed to to a single a single power power terminal terminal at any at any one one time time

10 10 A system A systemaccording accordingtotoclaim claim99wherein whereineach eachsaid saidpower power terminal terminal is istested testedsequentially. sequentially.

11 11 A system A systemaccording accordingtotoclaim claim1010wherein, wherein,each each said said individual individual terminals terminals oror each each setofof set

terminals are powered sequentially to determine which power terminal or positive/negative pair terminals are powered sequentially to determine which power terminal or positive/negative pair

of powerterminals of power terminals has has an earth an earth leakage leakage fault.fault.

12 12 A system A systemaccording accordingtotoclaim claim1111wherein wherein a singleearth a single earthleakage leakagedetection detectioncircuit circuit which which detects earthleakage detects earth leakageon on anyany positive positive and/or and/or negative negative terminal. terminal.

13 13 A system A system according according to claim to claim 11 wherein 11 wherein the alternator the alternator further comprises further comprises a single seta of single set of over-current, over-current, over-voltage and/orunder-voltage over-voltage and/or under-voltagedetection detection circuitry,sequentially circuitry, sequentiallyused used with with

each pairofofoutput each pair outputpower power terminals terminals to detect to detect the respective the respective faults. faults.

14 14 A A system system according according to claim to claim 13 wherein 13 wherein the controller the controller is an external is an external controller controller whichwhich

controls controls fault faultdetection, detection,power power control , the control, therecorder recorderand andsaid saidcommunications communications

15 15 A system A systemaccording according to to claim claim 14 14 wherein, wherein, an over-current an over-current threshold threshold is automatically is automatically

reduced for a pair of output power terminals connected to the battery as the battery reduces its reduced for a pair of output power terminals connected to the battery as the battery reduces its

power consumption. power consumption. 12

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16[ 16[ A system A system according according to claim to claim 15 wherein 15 wherein the power the power management management device automatically device automatically

reduces the reduces the over-current over-currentthreshold thresholdelectrical electrical fault fault detection detection on onaapair pairofofthe theoutput outputpower power terminals of the flameproof alternator that are connected to a battery as the battery reduces its terminals of the flameproof alternator that are connected to a battery as the battery reduces its

power consumption power consumption

17 A method for monitoring and management of electrical performance of an 2019268162

17 A method for monitoring and management of electrical performance of an

alternator alternator using using a a management system management system including including a power a power management management device device to limit to limit

output output power upondetection power upon detectionofofaa fault, fault, the thesystem systemincluding includingaarecorder, a communications recorder, a communications

channel and channel and a controller; a controller; thethe method method comprising comprising the the steps of:steps of:

a) a) providing an providing an alternator alternator associated associated with with aa machine andhaving machine and havingatat least least two pairs of two pairs of

poweroutput power outputterminals; terminals;

b) b) providing a fault detector capable of detecting electrical faults on any pair of the at least providing a fault detector capable of detecting electrical faults on any pair of the at least

two pairs two pairs of of output output power terminals; power terminals;

c) c) identifying identifying a apair pairofofthe theatatleast leasttwo two pairs pairs of of output output power power terminals terminals onthewhich on which fault the fault

or faults is or faults is detected; detected;

d) d) providing aa communications providing channel enabling communications channel enabling communications between the communications between the power power management management device device andand an an external external controller; controller;

e) e) using the using the power management power management device device to shut to shut down down or limit or limit output output power power on the on the pairpair of of output output power terminalsononwhich power terminals whichthe thefault fault has has been beendetected, detected, f) f) using the controller to control the shut down or power limitation and using the recorder using the controller to control the shut down or power limitation and using the recorder

to record to record the the power management power management device device activityincluding activity includingfault faultdetection. detection.

13

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1 1 5 5 7 7 9 9 15 15

+ A A C B

+ + + — B — 3 3 C - + + —

11 11 Earth Earth

17 17 23 19 19 23 21 21 13 13

FIGURE FIGURE 11