CN121498902A

CN121498902A - Busbar trunking connector connection monitoring system and its assembly method

Info

Publication number: CN121498902A
Application number: CN202511716561.6A
Authority: CN
Inventors: J·R·帕特尔; G·D·基尔克帕特里克; S·G·小科特维茨; R·J·戴维斯
Original assignee: Kangyue Technology Co Ltd
Current assignee: Kangyue Technology Co Ltd
Priority date: 2017-10-20
Filing date: 2018-10-22
Publication date: 2026-02-10
Also published as: DE102018126006A1

Abstract

The application relates to a bus duct joint connection monitoring system and an assembly method thereof. An electrical power distribution busway joint monitoring sensor assembly is provided. The first sensor is configured to measure a first location temperature and generate a first signal indicative of the first location temperature, wherein the first location is proximate to the busway joint. A second sensor is configured to measure a second location temperature and generate a second signal indicative of the second location temperature. The sensor controller is configured to i) receive the first signal and the second signal, ii) process the first signal and the second signal, and iii) generate a processed first signal and a processed second signal. A system controller is configured to receive the processed first signal and the processed second signal and generate an alarm when a temperature difference between the first location temperature and the second location temperature is greater than a predetermined threshold temperature.

Description

Bus duct joint connection monitoring system and assembly method thereof

Information about the divisional application

The invention is a divisional application of an invention patent application of which the application date is 2018, 10, 22, 201811232187.2 and the invention name is bus duct joint connection monitoring system and an assembly method thereof.

Technical Field

Embodiments described herein relate generally to busway joint connection monitoring systems, and more particularly, to temperature measurement and fault detection sensor assemblies for power distribution busway joints and methods of assembling the same.

Background

In commercial and industrial systems, several methods are used to transmit power. One of these approaches includes distributing electricity using bus bars that are generally easier to install and modify than cable duct assemblies. The busbar used in the enclosed area is referred to as a busway. Bus ducts are modular conductors that serve as a common connection for two or more circuits and are typically composed of aluminum or copper. Busways are easily connected together to quickly supply power to a desired location, and are often used to supply power to high-rise buildings, data centers, and heavy equipment and ventilation equipment serving industrial applications. Busways are typically joined together using a bolted connection to form a busway joint. The busway joints must be properly connected to ensure efficient transfer of electricity through the joints and to prevent excessive heat build-up within the busway joints. However, loose busway joints may be difficult to detect because the joints are still able to carry current and may not fail during initial testing or during a startup phase of the system.

At least some known busway joint systems incorporate a mounting torque requirement for the assembly of the busway joint. At least some other known busway joint systems utilize torque-to-yield bolts (torque-to-yield bolts) to facilitate subjecting the busway joint to the proper torque during assembly. However, such systems may not result in properly assembled busway joints due to a number of factors, such as improper lubrication of the busway joint assembly or inadequate preventative maintenance. Further, at least some known busway joint systems use an Infrared (IR) system designed to detect loose and failed joints by identifying abnormal temperatures present in the busway joint. Detecting abnormal busway joint conditions using IR analysis typically requires that the busway joint being inspected be exposed to high current loads and that it may be difficult to identify a failed joint if the ambient temperature is already relatively high. Accordingly, there is a need for an efficient and effective method for detecting bus duct joint anomalies.

Disclosure of Invention

In one aspect, a power distribution busway joint monitoring sensor assembly is provided. The power distribution busway joint monitoring sensor assembly includes a busway joint cover, a first sensor, a second sensor, a sensor mount, a sensor controller, and a system controller. The first sensor is configured to measure a first location temperature at a first location and generate a first signal indicative of the first location temperature, wherein the first location is proximate to a busway joint. The sensor mount is coupled to the first sensor and the busway joint cover and is configured to retain the first sensor in the first position. The second sensor is configured to measure a second location temperature at a second location and generate a second signal indicative of the second location temperature, wherein the second location is different from the first location. The sensor controller is in communication with the first sensor and the second sensor and is configured to i) receive the first signal and the second signal, ii) process the first signal and the second signal, and iii) generate a processed first signal and a processed second signal. The system controller is in communication with the sensor controller and is configured to i) receive the processed first signal and the processed second signal, ii) determine a temperature difference between the first location temperature and the second location temperature based on a comparison between the processed first signal and the processed second signal, and iii) generate an alert when the temperature difference between the first location temperature and the second location temperature is greater than a predetermined threshold temperature.

In another aspect, a power distribution busway assembly is provided. The power distribution busway assembly includes a first busway including a first busway row and a second busway including a second busway row. The power distribution busway assembly also includes a busway joint including a joint stack coupled between the first busway and the second busway. The power distribution busway assembly includes a power distribution busway joint monitoring sensor assembly coupled to the busway joint near the joint stack. The power distribution busway joint monitoring sensor assembly includes a busway joint cover, a first sensor, a second sensor, a sensor mount, a sensor controller, and a system controller. The first sensor is configured to measure a first location temperature at a first location and generate a first signal indicative of the first location temperature, wherein the first location is proximate to a busway joint. The sensor mount is coupled to the first sensor and the busway joint cover and is configured to retain the first sensor in the first position. The second sensor is configured to measure a second location temperature at a second location and generate a second signal indicative of the second location temperature, wherein the second location is different from the first location. The sensor controller is in communication with the first sensor and the second sensor and is configured to i) receive the first signal and the second signal, ii) process the first signal and the second signal, and iii) generate a processed first signal and a processed second signal. The system controller is in communication with the sensor controller and is configured to i) receive the processed first signal and the processed second signal, ii) determine a temperature difference between the first location temperature and the second location temperature based on a comparison between the processed first signal and the processed second signal, and iii) generate an alert when the temperature difference between the first location temperature and the second location temperature is greater than a predetermined threshold temperature.

In yet another aspect, a method of assembling a busway joint monitoring sensor assembly is provided. The method includes coupling a sensor mount to a busway joint cover. The method also includes coupling a first sensor to the sensor mount such that the first sensor is positioned at a first location, wherein the first sensor is configured to measure a temperature at the first location and generate a first signal indicative of the first location temperature. The method further includes positioning a second sensor at a second location different from the first location, wherein the second sensor is configured to measure a temperature at the second location and generate a second signal indicative of the temperature of the second location. The method includes coupling the first sensor and the second sensor to a sensor controller, wherein the sensor controller is configured to i) receive the first signal and the second signal, ii) process the first signal and the second signal, and iii) generate a processed first signal and a processed second signal. The method also includes coupling the sensor controller to a system controller, wherein the system controller is configured to i) receive the processed first signal and the processed second signal, ii) determine a temperature difference between the first location temperature and the second location temperature based on a comparison between the processed first signal and the processed second signal, and iii) generate an alarm when the temperature difference between the first location temperature and the second location temperature is greater than a predetermined threshold temperature.

Drawings

FIG. 1 is an exploded perspective view of an exemplary embodiment of a power distribution busway assembly illustrating an exemplary busway joint and an exemplary power distribution busway joint monitoring sensor assembly;

FIG. 2 is a block diagram of a controller for operating the power distribution busway joint monitoring sensor assembly shown in FIG. 1;

FIG. 3 is a top view of the busway joint shown in FIG. 1 illustrating an exemplary joint stack;

FIG. 4 is an exploded perspective view of the power distribution busway joint monitoring sensor assembly shown in FIG. 1 illustrating an exemplary first sensor assembly;

FIG. 5 is a perspective view of the first sensor assembly shown in FIG. 4;

FIG. 6 is a perspective view of an exemplary busway joint cover sensor mounting template, and

Fig. 7 is a flowchart illustrating a method for assembling a power distribution busway joint monitoring sensor.

Detailed Description

In the following description and claims, reference will be made to a number of terms, which shall be defined to have the following meanings.

The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

"Optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.

Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by one or more terms, such as "about," "approximately," and "substantially," are not to be limited to the exact value specified. As used herein throughout this specification and claims, values modified by the term "substantially similar" may be applied to modify any quantitative representation that is within 5% of the quantitative representation referred to, and more specifically, within 1% of the quantitative representation referred to. In at least some cases, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

As used herein, the terms "processor" and "computer" and related terms (e.g., "processing device," "computing device," and "controller") are not limited to just those integrated circuits referred to in the art as computers, but broadly refer to microcontrollers, microcomputers, programmable Logic Controllers (PLCs), and application specific integrated circuits, as well as other programmable circuits, and these terms are used interchangeably herein. In the embodiments described herein, memory may include, but is not limited to, computer-readable media such as Random Access Memory (RAM) and computer-readable non-volatile media such as flash memory. Or a floppy disk, a compact disc read only memory (CD-ROM), a magneto-optical disk (MOD), and/or a Digital Versatile Disc (DVD) may also be used. Also, in the embodiments described herein, the additional input channel may be, but is not limited to, a computer peripheral associated with an operator interface such as a mouse and keyboard. Or other computer peripheral devices may also be used, which may include, for example, but are not limited to, scanners. Moreover, in the exemplary embodiment, additional output channels may include, but are not limited to, an operator interface monitor.

In addition, as used herein, the terms "software" and "firmware" are interchangeable, and include any computer program stored in memory for execution by a personal computer, workstation, client, and server.

As used herein, the term "non-transitory computer-readable medium" is intended to mean any tangible computer-based device implemented in any technical method for short-term and long-term storage of information, such as computer-readable instructions, data structures, program modules and sub-modules, or other data in any device. Thus, the methods described herein may be encoded as executable instructions embedded within a tangible, non-transitory computer-readable medium including, but not limited to, a storage device and/or memory device. Such instructions, when executed by a processor, cause the processor to perform at least a portion of the methods described herein. Furthermore, as used herein, the term "non-transitory computer-readable medium" includes all tangible computer-readable media, including but not limited to non-transitory computer storage devices, including but not limited to volatile and non-volatile media, and removable and non-removable media, such as firmware, physical and virtual storage devices, CD-ROMs, DVDs, and any other digital source such as a network or the internet, as well as digital means yet to be developed, the only exception being a transitory propagating signal.

Further, as used herein, the term "real-time" refers to at least one of the time of occurrence of an associated event, the time of measurement and collection of predetermined data, the time of processing data, and the time of system response to the event and environment. In the embodiments described herein, these activities and events occur substantially instantaneously.

Embodiments described herein facilitate detection of loose and/or faulty busway joints using busway joint monitoring sensor assemblies. In particular, the busway joint monitoring sensor assembly includes a busway joint cover, a first sensor positioned in contact with and/or proximate to a busway joint and within a sensor mount coupled to the joint cover, a second sensor positioned at a different location than the first sensor, a sensor controller in communication with the first sensor and the second sensor, and a system controller in communication with the sensor controller. The system controller is configured to compare signals received from the first sensor and the second sensor, determine a temperature difference between temperatures present at the first sensor and the second sensor, and generate an alarm or notification if the temperature difference exceeds a predetermined threshold based on test characterization data for the power distribution busway. The temperature profile and trend may be analyzed using data obtained from the first sensor and the second sensor. A temperature difference exceeding a predetermined threshold is indicative of loose and/or faulty connections within the busway joint. This configuration facilitates efficient and quick detection of loose, highly resistive, and/or faulty connections within the busway assembly prior to significant energy loss to generate heat or complete failure of the joint, thereby facilitating superior performance, reduced cost, and more efficient maintenance of the busway system. The remote monitoring and management capability of the busway joint monitoring sensor assembly facilitates reducing the need for personnel to physically inspect the busway joint, such as with an infrared scanner, and facilitates improving the safety of the overall power distribution system.

Fig. 1 is an exploded perspective view of an exemplary embodiment of a power distribution busway assembly 100 illustrating busway joint 116 and busway joint monitoring sensor assembly 132. In the exemplary embodiment, power distribution busway assembly 100 includes a first busway 102 that includes a first busway 108 and a second busway 104 that includes a second busway 110. The first busbar 108 has a first end 111 and a second end 112. The second busbar 110 has a first end 114 and a second end 113. The first bus bar 108 and the second bus bar 110 are configured to carry current via the first bus bar slot 102 and the second bus bar slot 104, respectively. In alternative embodiments, the first and second busways 102, 104 may contain any type and number of busway rows to enable the power distribution busway assembly 100 to function as described herein.

In the exemplary embodiment, first end 111 of first bus bar 108 is coupled to second end 113 of second bus bar 110 using a tab stack 130 to form bus bar tab 116, thereby enabling current to be transferred from first bus bar 108 to second bus bar 110. The plurality of busway contact covers 134 substantially surround the busway contacts 116 to shield the busway contacts 116, the first end 111 of the first busway 108, and the second end 113 of the second busway 110 from unintended electrical delivery. The busway joint monitoring sensor assembly 132 includes one busway joint cover 134, a first sensor assembly 137 including a first sensor 136 and a sensor mount 138 coupled to the busway joint cover 134, a second sensor 140 located remotely from the busway joint 116, a sensor controller 107 communicatively coupled to the first sensor 136 and the second sensor 140, and a system controller 106 communicatively coupled to the sensor controller 107. The sensor controller 107 includes a memory coupled to the processor and is configured to monitor the temperatures measured by the first sensor 136 in the first location 146 and the second sensor 140 in the second location 148 for purposes of clarity (seal) and processing information from the first sensor 136 and the second sensor 140. More specifically, in the exemplary embodiment, sensor controller 107 performs digital signal processing on information received from first sensor 136 and second sensor 140 to normalize the level and/or state of digital signals contained within the information. The system controller 106 is configured to receive explicit and processed information from the sensor controller 107 for the purpose of detecting faulty and/or improperly assembled busway joints and alerting the user of these conditions. In alternative embodiments, the busway joint monitoring sensor assembly 132 may contain any type and number of assemblies to enable the busway joint monitoring sensor assembly 132 to function as described herein.

Fig. 2 is a block diagram of the system controller 106 used to operate the bus duct joint monitoring sensor assembly 132 (shown in fig. 1). In the exemplary embodiment, system controller 106 is in communication with a sensor controller 107 that is in communication with a first sensor 136 and a second sensor 140. The system controller 106 performs operations to control operation of the busway joint monitoring sensor assembly 132 based at least in part on instructions from a human operator. The system controller 106 is programmed to generate an alarm, for example, when a temperature difference between the temperature measured at the first sensor 136 and the temperature measured at the second sensor 140 exceeds a user-defined temperature difference stored in the system controller 106. For example, in one embodiment, the system controller 106 generates an audible alert. In another embodiment, the system controller 106 vibrates. In yet another embodiment, the system controller 106 transmits an alarm signal. Or the system controller 106 may generate any suitable alert. In an exemplary embodiment, the user-defined temperature difference is 50 degrees celsius. In alternative embodiments, the system controller 106 and the sensor controller 107 may be any type of controller that enables the busway joint monitoring sensor assembly 132 to operate as described herein. In other alternative embodiments, the system controller 106 may perform any operation and be set to generate an alarm for any temperature differential that enables the busway joint monitoring sensor assembly 132 to function as described herein.

In the exemplary embodiment, system controller 106 includes a memory device 118 and a processor 120 coupled to memory device 118. The processor 120 may include one or more processing units, such as, but not limited to, a multi-core configuration. Processor 120 is any type of processor that allows system controller 106 to operate as described herein. In some embodiments, the executable instructions are stored in memory device 118. The system controller 106 may be configured to perform one or more operations described herein by programming the processor 120. For example, the processor 120 may be programmed by encoding operations into one or more executable instructions and providing the executable instructions within the memory device 118. In an exemplary embodiment, the memory device 118 is one or more devices that enable storage and retrieval of information, such as executable instructions or other data. Memory device 118 may include one or more computer-readable media such as, without limitation, random Access Memory (RAM), dynamic RAM, static RAM, solid state disk, hard disk, read-only memory (ROM), erasable programmable ROM, electrically erasable programmable ROM, or non-volatile RAM memory. With respect to the types of memory usable for storage of a computer program, the above memory types are exemplary only, and are thus not limiting.

The memory device 118 may be configured to store any type of data, including but not limited to the temperature differential that the busway joint monitoring sensor assembly 132 may permit. In some embodiments, the processor 120 removes or "clears" data from the memory device 118 based on the age (age) of the data. For example, the processor 120 may overwrite previously recorded and stored data associated with a subsequent time or event. Additionally or alternatively, the processor 120 may remove data that exceeds a predetermined time interval. Further, the memory device 118 includes, but is not limited to, sufficient data, algorithms, and commands to facilitate monitoring temperatures at the first sensor 136 and the second sensor 140 with the system controller 106 and generating an alarm.

In some embodiments, the system controller 106 includes a presentation interface 122 coupled to the processor 120. The presentation interface 122 presents information to the user 124, such as the current temperatures measured at the first sensor 136 and the second sensor 140. In one embodiment, presentation interface 122 includes a display adapter coupled to a display device (not shown), such as a Cathode Ray Tube (CRT), liquid Crystal Display (LCD), organic LED (OLED) display, or "electronic ink" display. In some embodiments, presentation interface 122 includes one or more display devices. Additionally or alternatively, presentation interface 122 includes an audio output device (not shown), such as, but not limited to, an audio adapter or speaker (not shown).

In some embodiments, the system controller 106 includes a user input interface 126. In the exemplary embodiment, user input interface 126 is coupled to processor 120 and receives input from user 124. The user input interface 126 may include, for example, but is not limited to, a keyboard, a pointing device, a mouse, a stylus, a touch sensitive panel (e.g., but not limited to, a touchpad or a touch screen), and/or an audio input interface (e.g., but not limited to, a microphone). A single component, such as a touch screen, may serve as both a display device presenting interface 122 and user input interface 126.

In an exemplary embodiment, the communication interface 128 is coupled to the processor 120 and is configured to be coupled to communicate with one or more other devices (e.g., the first sensor 136 and the second sensor 140), and to perform input and output operations for such devices while performing as an input channel. For example, the communication interface 128 may include, but is not limited to, a wired network adapter, a wireless network adapter, a mobile telecommunications adapter, a serial communication adapter, or a parallel communication adapter. The communication interface 128 may receive data signals from or transmit data signals to one or more remote devices.

Both presentation interface 122 and communication interface 128 are capable of providing information suitable for use with the methods described herein, e.g., providing information to user 124 or processor 120. Thus, the presentation interface 122 and the communication interface 128 may be referred to as output devices. Similarly, the user input interface 126 and the communication interface 128 are capable of receiving information suitable for use with the methods described herein, and may be referred to as input devices. Information related to the operation of the power distribution busway assembly 100 may be used on a standard network manager using TCP/IP protocols such as SNMPV < 2 > C, SNMPV < 3 >, modbus TCP and TL 1. Further, the sensor controller 107 and the system controller 106 may have their own built-in internet-enabled servers that facilitate allowing users to utilize an internet browser to retrieve information via a network connection.

Fig. 3 is a top view of busway joint 116 (shown in fig. 1), illustrating an exemplary joint stack 130. Fig. 4 is an exploded perspective view of an exemplary bus duct joint monitoring sensor assembly 132 (shown in fig. 1) illustrating an exemplary first sensor assembly 137. Fig. 5 is a perspective view of the first sensor assembly 137 (shown in fig. 4). In an exemplary embodiment, the joint stack 130 is a connector configured to receive the first busbar first end 111 and the second busbar second end 113. The joint stack fasteners 152 are threaded into and through the threaded portions of the joint stack 130 until a certain amount of torque is reached by the fasteners 152, compressing portions of the joint stack 130 and fastening the first busbar 108 to the second busbar 110. In an alternative embodiment, fastener 152 is a torque yield fastener. In other alternative embodiments, the joint stack 130 may secure the first busbar 108 to the second busbar 110 in any manner that enables the power distribution busbar assembly 100 to operate as described herein.

In the exemplary embodiment, busway joint monitoring sensor assembly 132 is coupled to first busway 102 and second busway 104 near joint stack 130. The sensor mount 138 includes a threaded portion 158 having a length 160 that extends through the busway joint cover opening 154 of the busway joint cover 134. The threaded portion 158 is threaded to receive the first nut 139 and the second nut 141. To secure the sensor mount 138 to the busway joint cover 134, a first nut 139 is threaded onto the threaded portion 158 and positioned against the outer face 135 of the busway joint cover 134, and a second nut 141 is threaded onto the threaded portion 158 and positioned against the inner face 133 of the busway joint cover 134. Indicia 156 is adhered to the surface of the busway joint cover 134 and contains information regarding the type of cover and sensor used as part of the busway joint monitoring sensor assembly 132. In alternative embodiments, the busway joint cover 134 may include any number and type of openings and identifying indicia to enable the busway joint monitoring sensor assembly 132 to operate as described herein.

In the exemplary embodiment, sensor mount 138 is configured to retain first sensor 136 in a first position 146, wherein first position 146 is near busway joint 116. The first position 146 may be altered by modifying the position of the first nut 139 and/or the second nut 141 on the threaded portion 158 relative to the busway joint cover 134 and/or by replacing the sensor mount 138 with a different length 160. In alternative embodiments, the distance of the first sensor 136 from the busway joint 116 when in the first position 146 may be any distance that enables the busway joint monitoring sensor assembly 132 to operate as described herein, including touching at least a portion of the busway joint 116. The first sensor 136 includes a probe 162 and is configured to measure a first location temperature at the first location 146 and generate a first signal. In an exemplary embodiment, the first sensor 136 is a 100 kiloohm thermistor configured to generate a signal related to the temperature at the first location 146. In the exemplary embodiment, sensor mount 138 includes a non-conductive plastic material rated 94 for Underwriter Laboratories (UL) vertical burn test (V). In alternative embodiments, the first sensor 136 may be maintained in the first position 146 in any manner that enables the busway joint monitoring sensor assembly 132 to operate as described herein. In other alternative embodiments, probe 162 may be any type of sensor probe and may include any material that facilitates operation of first sensor 136 as described herein.

The second sensor 140 includes a probe 162 and is located remotely from the second location 148 (both shown in fig. 1). That is, the second location 148 is located remotely from the busway joint 116 such that the second sensor 140 is able to measure ambient air temperature that is not affected by heat generated by current carried via the busway joint 116. In an exemplary embodiment, the second sensor 140 is a 100 kiloohm thermistor and is configured to generate a second signal related to the temperature at the second location 148. In alternative embodiments, probe 162 may be any type of sensor probe, and may include any material that facilitates operation of second sensor 140 as described herein. In other alternative embodiments, first sensor 136 and second sensor 140 are any type of sensor that enables busway joint monitoring sensor assembly 132 to function as described herein.

In the exemplary embodiment, first sensor 136 and second sensor 140 are in direct communication with system controller 106. In an alternative embodiment, the first sensor 136 is coupled to a Remote Peripheral Measurement (RPM) device positioned near the busway joint cover 134. In an alternative embodiment, the RPM device includes a second sensor 140 and communicates with the system controller 106 to facilitate the modular implementation of the busway joint monitoring sensor assembly 132 as part of the power distribution busway assembly 100. In other alternative embodiments, the first sensor 136 and the second sensor 140 may be coupled to the system controller 106 in any manner that facilitates the bus duct joint monitoring sensor assembly 132 to operate as described herein.

FIG. 6 is a perspective view of an exemplary busway joint cover sensor mounting template 200. In an exemplary embodiment, the busway joint cover 134 that does not include the busway joint cover openings 154 may be modified to include at least one busway joint cover opening 154 by using the busway joint cover sensor mounting template 200. The busway joint cover sensor mounting template 200 includes a plurality of template positioning openings 202 and at least one probe base positioning opening 204. To modify the busway joint cover 134 that does not include the busway joint cover opening 154, the busway joint cover sensor mounting template 200 is positioned against the busway joint cover outer face 135. The template positioning openings 202 are aligned with the corresponding busway joint cover mounting openings 150 and the busway joint cover sensor mounting template 200 is secured to the busway joint cover 134. Using the probe base positioning opening 204 as a guide, material is removed from the busway joint cover 134 to form the busway joint cover opening 154. In the exemplary embodiment, when busway joint cover 134 is uncoupled from busway joint assembly 100, a drill bit is used to remove material from busway joint cover 134 to form busway joint cover opening 154. In alternative embodiments, the busway joint cover opening 154 may be formed in any manner that facilitates the operation of the busway joint monitoring sensor assembly 132 as described herein.

FIG. 7 is a flow chart illustrating a method 300 for assembling the busway joint monitoring sensor assembly 132. Referring to fig. 1-5, the method 300 includes coupling 302 the sensor mount 138 to the busway joint cover 134. The method 300 also includes coupling 304 the first sensor 136 to the sensor mount 138 such that the first sensor 136 is positioned at the first location 146, wherein the first sensor 136 is configured to measure a temperature at the first location 146 and generate a first signal indicative of the first location temperature. The method 300 further includes positioning 306 the second sensor 140 at a second location 148 different from the first location 146, wherein the second sensor 140 is configured to measure a temperature at the second location 148 and generate a second signal indicative of the second location temperature. The method 300 includes coupling 308 the first sensor 136 and the second sensor 140 to the sensor controller 107, wherein the sensor controller 107 is configured to i) receive the first signal and the second signal, ii) process the first signal and the second signal, and iii) generate a processed first signal and a processed second signal. The method 300 also includes coupling 310 the sensor controller 107 to the system controller 106, wherein the system controller 106 is configured to i) receive the processed first signal and the processed second signal, ii) determine a temperature difference between the first location temperature and the second location temperature based on a comparison between the processed first signal and the processed second signal, and iii) generate an alarm when the temperature difference between the first location temperature and the second location temperature is greater than a predetermined threshold temperature.

The above-described sensor assemblies herein facilitate detection of loose and/or faulty busway joints using busway joint monitoring sensor assemblies. In particular, a busway joint monitoring sensor assembly includes a busway joint cover, a first sensor positioned proximate to a busway joint and within a sensor mount coupled to the joint cover, a second sensor positioned at a different location than the first sensor, and a controller in communication with the first sensor and the second sensor. The controller is configured to compare signals received from the first sensor and the second sensor and determine a temperature difference between temperatures present at the first sensor and the second sensor and generate an alarm or notification if the temperature difference exceeds a predetermined threshold. The presence of a temperature differential exceeding a predetermined threshold is indicative of loose and/or faulty connections within the busway joint. This configuration facilitates efficient and quick detection of loose and/or faulty connections within the busway assembly prior to significant energy loss to heat or complete failure of the joint, thereby contributing to superior performance, reduced cost, and more efficient maintenance of the busway system.

Exemplary technical effects of the methods, systems, and apparatus described herein include at least one of (a) facilitating detection of loose and/or faulty busway joints in a busway system, (b) reducing an operating cost of the busway system, (c) reducing energy loss caused by loose and/or faulty busway joints, and (d) reducing unplanned service outages caused by busway joint failure.

Exemplary embodiments of busway joint monitoring sensor assemblies are described above in detail. The busway joint monitoring sensor assembly and method of assembly thereof are not limited to the specific embodiments described herein, but rather, components of the system and/or steps of the method may be utilized independently and separately from other components and/or steps described herein. For example, the methods may also be used in combination with other components of a busway or busbar system, and are not limited to practice with only the systems and methods as described herein. Indeed, the exemplary embodiment may be implemented and utilized in connection with many other power transmission applications that require the attachment of a monitoring sensor assembly.

Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. Any feature of the drawings may be referenced and/or claimed in combination with any feature of any other drawings in accordance with the principles of the invention.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A power distribution busbar joint monitoring sensor assembly, comprising:

A busbar connector cover configured to surround a busbar connector, wherein the inner surface of the busbar connector cover defines a substantially enclosed volume between the inner surface of the busbar connector cover and the busbar connector, the busbar connector including connector stack fasteners.

A first sensor is configured to measure the temperature at a first location via a probe portion of the first sensor at a first location and generate a first signal indicating the temperature at the first location, wherein the first location is adjacent to the busbar joint and within the generally enclosed volume.

A sensor base, which is coupled to the first sensor and the busbar connector cover and configured to hold the probe portion of the first sensor in the first position, the sensor base extending through the busbar connector cover into the generally enclosed volume, wherein the probe portion of the first sensor partially protrudes from the sensor base at the first position.

A second sensor is configured to measure the temperature at a second location and generate a second signal indicating the temperature at the second location, wherein the second location is at ambient temperature.

A sensor controller, communicating with the first sensor and the second sensor, is configured to: i) receive the first signal and the second signal; ii) process the first signal and the second signal; and iii) generate the processed first signal and the processed second signal; and

A system controller, which communicates with the sensor controller, is configured to: i) receive the processed first signal and the processed second signal; ii) determine the temperature difference between the first location temperature and the second location temperature based on a comparison between the processed first signal and the processed second signal; and iii) generate an alarm when the temperature difference between the first location temperature and the second location temperature is greater than a predetermined threshold temperature.

2. The power distribution busbar joint monitoring sensor assembly of claim 1, wherein the probe portion of the first sensor in the first position is configured to measure the temperature of the busbar joint, and wherein the first portion of the first sensor is positioned outside the generally enclosed volume.

3. The power distribution busbar joint monitoring sensor assembly according to claim 1, wherein the first sensor and the second sensor are each 100 kΩ thermistors.

4. The power distribution busbar joint monitoring sensor assembly according to claim 1, wherein the second sensor is located outside the generally enclosed volume.

5. The power distribution busbar connector monitoring sensor assembly of claim 1, wherein the sensor base comprises a non-conductive plastic material with an Underwriters Laboratories UL Flammability Test V rating of 94.

6. The power distribution busbar connector monitoring sensor assembly according to claim 1, wherein the sensor base is threaded to receive a first nut and a second nut, and wherein the first nut is positioned against the outside of the busbar connector cover, and the second nut is positioned against the inner surface of the busbar connector cover.

7. The power distribution busbar joint monitoring sensor assembly according to claim 6, wherein the predetermined threshold temperature is approximately 50 degrees Celsius.

8. A power distribution busbar assembly, comprising:

The first busbar trunking includes a first busbar row;

The second busbar trunking includes a second busbar row;

Busbar connectors, including:

A connector stack, which connects the first busbar and the second busbar; and

Joint stack fasteners; and

A power distribution busbar joint monitoring sensor assembly, comprising:

A busbar connector cover surrounding the busbar connector, wherein the inner surface of the busbar connector cover defines a substantially enclosed volume between the inner surface of the busbar connector cover and the busbar connector.

A second sensor, configured to measure the temperature at a second location and generate a second signal indicating the temperature at the second location, wherein the second location is at ambient temperature; and

9. The power distribution busbar assembly of claim 8, wherein the probe portion of the first sensor in the first position is configured to measure the temperature of the busbar joint, and a portion of the first sensor is positioned outside the generally enclosed volume.

10. The power distribution busbar assembly according to claim 8, wherein the first sensor and the second sensor are each 100 kΩ thermistors.

11. The power distribution busbar assembly of claim 8, wherein the second sensor is located outside the generally enclosed volume.

12. The power distribution busbar assembly of claim 8, wherein the sensor base comprises a non-conductive plastic material with an Underwriters Laboratories UL Flammability Test V rating of 94.

13. The power distribution busbar assembly according to claim 8, wherein the sensor base is threaded to receive a first nut and a second nut, and wherein the first nut is positioned against the outside of the busbar connector cover, and the second nut is positioned against the inner surface of the busbar connector cover.

14. The power distribution busbar assembly of claim 13, wherein the predetermined threshold temperature is approximately 50 degrees Celsius.

15. A method for assembling a monitoring sensor assembly for a power distribution busbar connector, the method comprising:

The sensor base is coupled to the busbar connector cover by extending the sensor base through the busbar connector cover, wherein the busbar connector cover is configured to surround the busbar connector and define a generally enclosed volume between the inner surface of the busbar connector cover and the busbar connector, the busbar connector including connector stack fasteners, and wherein the sensor base extends into the generally enclosed volume.

A first sensor is coupled to the sensor base such that a probe portion of the first sensor partially protrudes from the sensor base and is positioned at a first location, wherein the first sensor is configured to measure the temperature at the first location via the probe portion and generate a first signal indicating the temperature at the first location, and wherein the first location is adjacent to the busbar connector.

The second sensor is positioned at a second location different from the first location, wherein the second sensor is configured to measure the ambient temperature at the second location and generate a second signal indicating the temperature at the second location;

The first sensor and the second sensor are coupled to a sensor controller, wherein the sensor controller is configured to: i) receive the first signal and the second signal; ii) process the first signal and the second signal; and iii) generate the processed first signal and the processed second signal; and

The sensor controller is coupled to a system controller, wherein the system controller is configured to: i) receive the processed first signal and the processed second signal; ii) determine the temperature difference between the first location temperature and the second location temperature based on a comparison between the processed first signal and the processed second signal; and iii) generate an alarm when the temperature difference between the first location temperature and the second location temperature is greater than a predetermined threshold temperature.

16. The method of claim 15, wherein connecting the sensor base to the busbar connector cover further comprises:

Align the template with the busbar joint cover, such that the multiple template positioning openings are aligned with the corresponding multiple busbar joint cover mounting openings; and

The busbar joint cover opening is formed using the guide hole located in the template.

17. The method of claim 15, wherein connecting the first sensor to the sensor base comprises connecting a 100 kΩ thermistor to the sensor base.

18. The method of claim 15, wherein coupling the first sensor to the sensor base further comprises positioning a portion of the first sensor outside the generally enclosed volume.

19. The method of claim 15, wherein positioning the second sensor at the second location comprises positioning a 100 kΩ thermistor at the second location.

20. The method of claim 15, wherein attaching the sensor base to the busbar connector cover comprises attaching the sensor base to the busbar connector cover using a first nut positioned against the outside of the busbar connector cover and a second nut positioned against the inner surface of the busbar connector cover.