An automatic configurable relay

TECHNICAL FIELD

The present invention relates broadly to an automatic configurable relay and to a method for automatic configuration of a relay.

BACKGROUND

In the electronics industry, devices such as relays are typically used to operate machinery and circuits. Such devices typically rely on energisation or switching on/off for operations.

For monitoring or control operations using a control relay, typically, a user manually sets parameters to be monitored by the relay. Parameters may include nominal operating voltage range, over voltage limit, under voltage limit, time delay, phase asymmetry threshold etc. The parameters are calculated from a desired working/operating condition which the user also manually programs into the relay. For example, if a user sets the working condition of a power supply as 240V, an overvoltage tolerance of 5%, that has also been set, causes the relay to calculate an overvoltage limit of 252V such that the relay switches on/off when the monitored voltage level meets the calculated limit. As a further example, if a user sets a voltage range to 400V, an under-voltage limit to 300V, an over-voltage limit to 440V, an asymmetry limit to 30V and a time-setting to 5 seconds, this would instruct the relay to monitor a physical input parameter of a source on whether the parameter is less than 300V or more than 440V, or the difference of voltage between 3-phase leads is more than 30V. If any condition is met, the relay de-energizes after delaying for a time-delay of 5 seconds. Thus, in order to ensure that the relay is properly set, the user is expected to have knowledge on the relay, working condition or possible behaviours of the parameter etc. This typically requires the user to constantly refer to manuals or specifications, e.g. for setting the desired working condition. Furthermore, a wrong setting of the working condition has been found to result in numerous erroneous malfunction reports. There have also been instances of erroneous reports in scenarios whereby the parameter is already not fulfilling the conditions set by the user due to wrong user knowledge.

Hence, in view of the above, there exists a need for an automatic configurable relay and a method for automatic configuration of a relay that seek to address at least one of the above problems.

SUMMARY

In accordance with a first aspect of the present invention, there is provided a relay comprising an input sampling module for coupling to a source to be monitored, the sampling module configured to detect a first value of a parameter of the source to be monitored; and a processing module configured to set a working condition based on the detected first value.

The relay may further comprise the processing module configured to monitor a working range, the working range being generated based on applying a threshold level to the set working condition; and wherein the processing module is capable of instructing a trigger module for transmitting a trigger signal from the relay if a detected second value of the parameter is outside the working range.

The parameter may comprise one or more selected from a group consisting three phase voltage, single phase voltage, single phase current, phase angle, phase frequency, power, temperature, resistance, digital signals.

The relay may further comprise a switch element and wherein the transmitting the trigger signal may comprise switching on/off the switch element of the relay.

The threshold level may be capable of being set by a user.

The threshold level may be based on a predetermined value.

The processing module may set the working condition based on an instructional input.

The instructional input may be based on a user activation.

The instructional input may be based on a powering up of the relay.

The relay may further comprise a toggle configured to allow a user to adjust the working condition.

The relay may further comprise a display configured to display a fault based on transmission of the trigger signal.

The relay may further comprise a storage module for storing the set working condition.

In accordance with a second aspect of the present invention, there is provided a method for automatic configuration of a relay, the method comprising coupling the relay to a source to be monitored; automatically detecting a first value of a parameter of the source; and setting a working condition based on the detected first value.

The method may further comprise monitoring a working range, the working range being generated based on applying a threshold level to the set working condition; and transmitting a trigger signal from the relay if a detected second value of the parameter is outside the working range.

The parameter may comprise one or more selected from a group consisting three phase voltage, single phase voltage, single phase current, phase angle, phase frequency, power, temperature, resistance, digital signals.

The transmitting the trigger signal may comprise switching on/off a switch element of the relay.

The threshold level may be set by a user.

The threshold level may be based on a predetermined value.

The setting of the working condition may be based on an instructional input.

The instructional input may be based on a user activation.

The instructional input may be based on a powering up of the relay.

The method may further comprise displaying a fault based on transmission of the trigger signal.

The method may further comprise storing the set working condition.

In accordance with a third aspect of the present invention, there is provided a computer readable data storage medium having stored thereon computer code means for instructing a processing module of a relay to execute a method for automatic configuration, the method comprising automatically detecting a first value of a parameter of a source to be monitored; and setting a working condition based on the detected first value.

The computer readable data storage medium may have the method further comprising monitoring a working range, the working range being generated based on applying a threshold level to the set working condition; and transmitting a trigger signal from the relay if a detected second value of the parameter is outside the working range.

BRIEF DESCRIPTION OF THE DRAWINGS

Example embodiments of the invention will be better understood and readily apparent to one of ordinary skill in the art from the following written description, by way of example only, and in conjunction with the drawings, in which:

• Figure 1(a) is a schematic diagram illustrating a relay in an example embodiment.
• Figure 1(b) is a schematic circuit diagram illustrating the relay in the example embodiment.
• Figure 2 is a schematic diagram illustrating an interface allowing a user to set threshold levels in an example embodiment.
• Figure 3 is a schematic diagram illustrating a relay in an example embodiment.
• Figure 4 is a schematic flowchart illustrating a method for automatic configuration of a relay in an example embodiment.
• Figure 5 is a schematic flow diagram for broadly illustrating an algorithm of an exemplary firmware for the processing module of Figures 1(a) and 1(b) in an example embodiment.

DETAILED DESCRIPTION

Example embodiments described below can provide an automatic configurable relay and a method for automatic configuration of a relay.

In example embodiments, a relay can be provided to detect a parameter value of a source to be monitored and to automatically set the detected value as a working condition for the relay. The relay can access pre-set or user-set one or more threshold levels and apply the threshold levels to the working condition to obtain a working range. The relay monitors parameter values of the source to be monitored against the working range and if the value is outside the working range, a trigger signal is transmitted. In one example embodiment, the trigger signal comprises energising or de-energising (e.g. switching on or switching off) a switch element of the relay. In one example embodiment, a toggle, e.g. in the form of a slidable door, is provided to a user to toggle between an "auto-setting configuration mode" or a conventional "manual-setting configuration mode". In the example embodiment, when the user slides to the "auto-setting configuration mode", settings of e.g. a voltage range, an over-voltage limit, an under-voltage limit, an asymmetry limit and/or a time setting can be automatically configured for the relay. In the example embodiment, this is carried out by the relay self detecting at least a value of one or more input parameters through an input module and processing the detected values to self-recognize settings of a voltage range, pre-set over-voltage limit, under-voltage limit, asymmetry limit and time setting. After the working range is set, the relay can monitor the parameter values.

In the description herein, a relay can be an energisable coil device that can include, but is not limited to, any device that can be switched/powered on and off such as an electrical relay or other electromechanical switching devices, components or parts. An energisation event of an energisable coil device can include, but is not limited to, an electrical powering on/off of the element and/or a mechanical switching on/off of the element.

The terms "coupled" or "connected" as used in this description are intended to cover both directly connected or connected through one or more intermediate means, unless otherwise stated.

The description herein may be, in certain portions, explicitly or implicitly described as algorithms and/or functional operations that operate on data within a computer memory or an electronic circuit. These algorithmic descriptions and/or functional operations are usually used by those skilled in the information/data processing arts for efficient description. An algorithm is generally relating to a self-consistent sequence of steps leading to a desired result. The algorithmic steps can include physical manipulations of physical quantities, such as electrical, magnetic or optical signals capable of being stored, transmitted, transferred, combined, compared, and otherwise manipulated.

Further, unless specifically stated otherwise, and would ordinarily be apparent from the following, a person skilled in the art will appreciate that throughout the present specification, discussions utilizing terms such as "scanning", "calculating", "determining", "replacing", "generating", "initializing", "outputting", and the like, refer to action and processes of a instructing processor/computer system, or similar electronic circuit/device/component, that manipulates/processes and transforms data represented as physical quantities within the described system into other data similarly represented as physical quantities within the system or other information storage, transmission or display devices etc.

The description also discloses relevant device/apparatus for performing the steps of the described methods. Such apparatus may be specifically constructed for the purposes of the methods, or may comprise a general purpose computer/processor or other device selectively activated or reconfigured by a computer program stored in a storage member. The algorithms and displays described herein are not inherently related to any particular computer or other apparatus. It is understood that general purpose devices/machines may be used in accordance with the teachings herein. Alternatively, the construction of a specialized device/apparatus to perform the method steps may be desired.

In addition, it is submitted that the description also implicitly covers a computer program, in that it would be clear that the steps of the methods described herein may be put into effect by computer code. It will be appreciated that a large variety of programming languages and coding can be used to implement the teachings of the description herein. Moreover, the computer program if applicable is not limited to any particular control flow and can use different control flows without departing from the scope of the invention.

Furthermore, one or more of the steps of the computer program if applicable may be performed in parallel and/or sequentially. Such a computer program if applicable may be stored on any computer readable medium. The computer readable medium may include storage devices such as magnetic or optical disks, memory chips, or other storage devices suitable for interfacing with a suitable reader/general purpose computer. The computer readable medium may even include a wired medium such as exemplified in the Internet system, or wireless medium such as exemplified in bluetooth technology. The computer program when loaded and executed on a suitable reader effectively results in an apparatus that can implement the steps of the described methods.

The example embodiments may also be implemented as hardware modules. A module is a functional hardware unit designed for use with other components or modules. For example, a module may be implemented using digital or discrete electronic components, or it can form a portion of an entire electronic circuit such as an Application Specific Integrated Circuit (ASIC). A person skilled in the art will understand that the example embodiments can also be implemented as a combination of hardware and software modules.

Figure 1(a) is a schematic diagram illustrating a relay in an example embodiment. In the example embodiment, the relay is a control relay 100. The relay 100 is configured to be coupled to a source to be monitored such as a three-phase power supply line voltage source 110. The relay 100 can detect values of one or more parameters of the source to be monitored.

Figure 1(b) is a schematic circuit diagram illustrating the relay 100 in the example embodiment.

In the example embodiment, the relay 100 comprises an input sampling module 104 coupled to a processing module 101. The processing module 101 is coupled to a setting module 103 that is in turn coupled to a user interface 108. The processing module 101 is further coupled to a trigger module 105 that can control a switch element 208 of the relay 100. The input sampling module 104 can couple to the source 110 using e.g. leads L1, L2, L3. A power supply module 102 is provided to supply power to the various components of the relay 100. The relay 100 may optionally comprise a teach module 113 coupled to the processing module 101 for instructing the processing module 101 to obtain a present sensed parameter as a working condition. The relay 100 may also be coupled to a programmable logic controller (not shown) for feedback.

In the example embodiment, the source indicated at numeral 110 is not limited to a three-phase voltage and can include various parameters for sources to be monitored such as single phase voltage, single phase current, temperature (from e.g. temperature sensors such as PT100, PTC, thermocouplers etc.), electrical signals associated with frequency characteristics, resistance (from e.g. resistor probes for liquid level sensing), and digital signals (from e.g. digital output sensors such as ultrasonic sensors, photo sensors, inductive sensors, pressure sensors etc.). Other parameters such as phase angle or power of a three-phase power supply may also be monitored. Accordingly, the relay 100 is not limited to monitoring power source parameters but may be adapted to monitor temperature, liquid level, speed, pressure, light, and other parameters that are suitable to be monitored.

The input sampling module 104 comprises a plurality of resistors e.g. R2, R3, R4, R5, R7, R8, R9, R10 and a linear voltage regulator REG3 which regulates voltage at about 1.8V. REG3 can be implemented using e.g. TPS72118DBVR from Texas Instruments. Capacitors e.g. C6, C7, C10 are included for noise filtering purposes. The input sampling module 104 steps down and shifts a voltage level of the 3 phase voltage from numeral 110 to a voltage level suitable to be processed by the processing module 101. It will be appreciated that the sampling module 104 can have different circuit arrangements in order to adapt to various kinds of physical input parameters from different sources for monitoring at numeral 110.

The processing module 101 accepts inputs from the input sampling module 104 and conducts processing. In the example embodiment, the processing module 101 can accept a sampled parameter value (e.g. the voltage level) sampled at the input sampling module 104 as a working condition for the relay 100. For example, the sampled parameter value may be a voltage of 240V. In the example embodiment, the processing module 101 may set the working condition as 240V automatically. The processing module 101 can also compare a sampled parameter value (e.g. the voltage level) sampled at the input sampling module 104 against a working range for the relay 100.

The processing module 101 can comprise a microcontroller U1. U1 can be implemented using e.g. STM32F100C from STMicroelectronics or LPC1114 from NXP. Other components may be provided connected to the microcontroller as a supporting circuit to enable the microcontroller to function. It will be appreciated that the supporting circuit can vary depending on the type of microcontroller selected for implementation. In the example embodiment, the processing module 101 functions as an intelligent process element that interacts with the components within the relay 100. Processing in the processing module 101 is dependent on the firmware written.

The user interface 108 can comprise external manipulated elements to be accessed by a user of the relay 100. The manipulation or setting set by the user on the user interface 108 is sensed by the setting module 103 and is translated into an electrical signal at the setting module 103. The signal is transmitted to the processing module 101 for processing at the processing module 101.

There are various types of manipulation or settings depending on the type of relay 100. In this example, possible manipulation or setting can include voltage range selection setting, under-voltage setting, over-voltage setting etc. Asymmetry setting can be included as well. In an alternative example embodiment, for a relay 100 that is meant for monitoring frequency as a physical input type, possible manipulation or setting to be done by a user can include under-temperature setting, over-temperature setting etc. The settings set via the user interface 108 provide one or more threshold levels or "sets of conditions" that the relay 100 uses at the processing module 101 in order to determine whether the parameter values sampled at the source at numeral 110 fall within a working range based on these "sets of conditions".

In the example embodiment, the setting module 103 comprises a plurality of potentiometers P1, P2, P3 meant for converting the setting set by the user at the user interface 108 to an electrical signal that can be transmitted and recognized by the processing module 101. For example, P1 can translate a selection of nominal voltage range selected by the user (e.g. 200V, 220V, 380V, 400V, 440V, 480V); P2 can translate an over-voltage user setting; and P3 can translate an under-voltage user setting. It will be appreciated that the setting module 103 is not limited as such and can be expanded to more settings such as asymmetry, time setting etc.

Therefore, in the example embodiment, the processing module 101 can set a working condition based on input from the input sampling module 104 and the processing module 101 can set a working range based on applying the one or more threshold levels to the working condition, the threshold levels supplied via the setting module 103. If a monitored value of the parameter of the source to be monitored falls outside the working range, a trigger signal is transmitted. The trigger signal can be transmitted by the processing module 101 instructing the trigger module 105 to control the switch element 108.

The trigger module 105 comprises a transistor T1 for driving or controlling the switch element 208. In the example embodiment, when T1 is turned ON, the switch element 208 is energized or switched on. When T1 is turned OFF, the switch element 208 is de-energized or switched off. It will be appreciated that there are various possibilities to modify the design and/or to reverse the above logic depending on designer preference. The trigger signal can be a feedback signal to a programmable logic controller (not shown) for alerting the user.

In the example embodiment, the switch element 208 can be constructed as an electro-mechanical relay switch. The switch element 208 comprises a coil portion 204 and a contact portion 206. The coil portion 204 can be energized or de-energized by the trigger module 105 in order to switch the position or logic of the contact portion 206. It will be appreciated that the switch element can be any of electro-mechanical relay or solid-state switch.

In the example embodiment, the power supply module 102 functions as a power supply circuit of the relay 100. The power supply module 102 steps down and regulates an external power supply (see numeral 109) provided to the relay 100 to a voltage supply level that is suitable for the components in the relay 100. In the example embodiment, the power supply module 102 comprises a switching regulator integrated circuit REG1. REG1 can be implemented using e.g. NCP1052ST44T3G from ON Semi. Diodes D3, D6, an inductor L1, zener diode Z1, and capacitors C5, C1, C2 provide a construction of a buck-converter. Diodes D4, D5, resistor R6, and capacitor C4 function as a feedback circuit for REG1, and functions to sample a regulated output voltage at about +5.6V in order to be able to achieve a voltage regulation purpose. A capacitor C3 is provided as a start-up element for REG1 when the power supply is initially provided to the relay 100. A resistor R1 and diodes D1, D2 function as a circuit for transient voltage protection. The power supply module 102 also comprises a linear voltage regulator REG2 which regulates voltage at about 3.6V. REG2 may be implemented as e.g. 3.6V voltage regulator LD2981ABM36TR from STMicroelectronics.

With reference to Figure 1(a), numeral 109 at leads L2, L3 denotes an external source of supply voltage for the relay 100. In this example, the source of supply voltage is the same physical input of the relay 100 (i.e. at leads L2, L3). However, it will be appreciated that it is not necessary that the source of supply voltage to be the same as the input to the relay 100.

As described, a teach module 113 can be optionally included in the relay 100. The teach module 113 can be provided for instructing the processing module 101 to obtain a present sensed parameter value as a working condition. In such a scenario, the processing module 101 ignores previously sensed values and sets a new working condition. Additionally, the teach module 113 can function to inform the processing module 101 on whether to enter into an auto-detection mode or into a manual setting mode. It will be appreciated that the teach module 113 can be any electronics or electro-mechanical switch that functions to e.g. reset the processing module 101 and/or to inform the processing module 101 on a selected mode.

In the example embodiment, optionally, a storage element or memory (not shown) may be provided. The memory can store all the information related to the parameters detected at the input sampling module 104. For example, the memory can store all instantaneous information of a 3 phase voltage, the information including instantaneous voltage level, historical voltage level, frequency, historical faults that had happened etc. The memory can be, but not limited to, an external memory module such as EEPROM, FLASH, PROM etc., or an integrated memory circuit embedded into the processing module 101.

In the example embodiment, optionally, a transceiver integrated circuit (not shown) can be provided. The transceiver integrated circuit can transmit and receive information wirelessly or through a wired-medium to and from the relay 100, in communication with external devices such as a mobile phone, a computer, and/or a programmable logic controller. The transceiver integrated circuit can be, but not limited to, a Bluetooth transceiver, a Wifi transceiver, a Zigbee transceiver, a universal serial bus (USB) transceiver, a Serial Port transceiver etc.

Therefore, in the example embodiment, the relay 100 can function as a control & monitoring device for monitoring physical input parameters and to automatically determine the condition of the physical input parameters, i.e. whether the parameters are meeting one or more threshold levels set by a user. The relay 100 can reflect that status in terms of a digital form/feedback. This may be a trigger signal in terms of "closing a contact" or "opening a contact" if the switch element 208 is an electro-mechanical relay or in terms of "ON" or "OFF" if the switch element 208 is a solid-state switch. The relay 100 can be powered by a separate source of supply voltage or share the same source of supply voltage as the physical input parameters of the source to be monitored. In the example embodiment, the power source is preferably a three phase power source, although other kinds of power sources may also be used. It will be appreciated that the power source may be either an alternating current (AC) or direct current (DC) power.

Figure 2 is a schematic diagram illustrating an interface allowing a user to set threshold levels in an example embodiment. The interface 210 comprises one or more potentiometers e.g. 212. The user can manipulate a potentiometer e.g. 212 for overvoltage to reflect 5%. Thus, if the monitored voltage at numeral 110 exceeds 5% of the normal working condition, a fault is detected.

In an example embodiment, if a storage module is provided, the working condition information can be stored for future use. Further, an actuator such as a button and/or a sliding door can be provided to a teach module (compare numeral 113) so that a user can manipulate the actuator to send an instructional input for instructing the relay to access a present detected parameter value for determining/setting the working condition, and to disregard any previous stored working condition information. As yet another alternative, the relay can be instructed to determine/set the working condition at each powering-up of the relay, that is, each initial detection of a power supply to the relay acts as an instructional input.

In an example embodiment, the trigger signal can also function to send a visual indication/display to a user. For example, the trigger signal can be transmitted to a light emitting diode (LED) circuit that instructs an LED to be lit when a corresponding parameter is detected to have a value outside its determined working range. For example, an overvoltage LED may be lit if a detected voltage level is determined to be outside e.g. a 5% tolerance from a working condition for the voltage and an overcurrent LED may be lit if a detect current level is determined to be outside e.g. 2% tolerance from a working condition for the current.

Thus, in the described example embodiments, the relay is capable of setting a working condition based on a detected value of a parameter of a source to be monitored. A working range can then be set based on applying a threshold level to the set working condition. If another detected value of the parameter is outside the working range, a trigger signal can be sent from the relay. This may include a visual indication to the user.

Figure 3 is a schematic diagram illustrating a relay 302 in an example embodiment. The relay 302 functions substantially identical to the relay 100 in Figures 1(a) and 1(b). The relay 302 additionally comprises a toggle 304 in the form of a sliding door. The toggle 304 can allow a user to toggle to using a set of manual controls 306 for manually adjusting/fine-tuning the working condition and/or threshold levels. It will be appreciated that the toggle is not limited to a sliding door but can include various other forms such as switches, buttons, sliding members and even finger swipe gestures on a touchscreen surface. The toggle 304 is coupled to a teaching module (compare numeral 113) of the relay 302.

In another example embodiment, a relay can be provided that functions substantially identical to the relay 100 in Figures 1(a) and 1(b). However, in this example embodiment, the threshold levels are set automatically and stored in a storage module, i.e. predetermined threshold levels. The stored values may be in the form of a lookup table. In this example embodiment, a pre-set tolerance may be provided for each expected value of a parameter of the source to be monitored. For example, it may be stored that for a detected 240V to be set as a working condition, the pre-set tolerance for overvoltage may be 5% and for a detected 300V to be set as a working condition, the pre-set tolerance for overvoltage may be 10% etc.

Figure 5 is a schematic flow diagram 500 for broadly illustrating an algorithm of an exemplary firmware for the processing module of Figures 1(a) and 1(b) in an example embodiment. It is noted that step 512 may be the first step depending on implementation of how the working condition is obtained by the processing module.

At step 502, when a power supply (at numeral 109) is available to the relay 100, the processing module 101 reads the threshold settings (e.g. +10% for over-voltage; -10% for under-voltage). At step 504, the threshold settings are translated to root mean square values and stored. At step 506, the processing module 101 samples the analog to digital conversion (ADC) value of the detected parameter value at numeral 110 (L1,L2) in 200us intervals. At step 508, the ADC sample values are processed, in true root mean square calculations. At step 510, the parameter value at numeral 110 (L1,L2) is translated in equivalent root mean square value as well for comparison with the settings later.

At step 512, when it is detected that the teach module 113 is activated, the processing module 101 recognizes the activation as a "learn signal" from a user to instruct the relay 100 to store the instantaneous root means square value of the parameter value at numeral 110 (L1,L2) as a nominal value working condition (e.g. the processing module 101 reads nominal value as 300V) and a Nom LED (a LED signaling normal operations) is turned ON by the processing module 101. At step 514, the processing module 101 compares the threshold settings (e.g. of the user interface 108) against the detected parameter value (root mean square value) to determine if the reading of the parameter meets the conditions of the settings: If a condition of step 514 is met, the switch element 208 is triggered through the trigger module 105 and a fault signal is issued/transmitted, and can be stored.

Figure 4 is a schematic flowchart 400 illustrating a method for automatic configuration of a relay in an example embodiment. At step 402, the relay is coupled to a source to be monitored. At step 404, a first value of a parameter of the source is automatically detected. At step 406, a working condition is set based on the detected first value.

In the above described example embodiments, an automatic setting mode can be provided to a user in that the user is not required to set a working condition for a relay. This can advantageously reduce problems associated with manual setting of e.g. working conditions. This can also provide a plug-n-play device for novice users. Such a device can enhance user-friendliness and have simplified user interfaces. Furthermore, a toggle can be provided to allow the user to carry out some manual adjustment/fine-tuning. Thus, optimisation can be carried out if needed by the user. The inventors have recognised that the described example embodiments can be applied to control relays and timer relay products such that a larger number of users can be attracted to using such devices.

It will be appreciated by a person skilled in the art that other variations and/or modifications may be made to the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects to be illustrative and not restrictive.