Control panel assembly methods and techniques

Patent metadata

Field	Value
Publication number	US-11219147-B2
Application number	US-202117185936-A
Country	US
Kind code	B2
Filing date	Feb 25, 2021
Priority date	Feb 26, 2020
Publication date	Jan 4, 2022
Grant date	Jan 4, 2022

Abstract

Systems, apparatus, methods, and techniques of assembly of discrete modules of a control panel are disclosed. The modules can be independently wired, tested, and installed into a control panel. Module definitions are defined specifying components to perform the electrical function, a mechanical arrangement of the components, electrical connections, and logical interactions of the module. A bill of materials can be generated based on a designation of a set of modules for a control panel and the module definitions. Modularly assembled control panels are disclosed. An assembly frame is described herein for temporarily mounting components of a module for independent assembly of a control module and for eventual removal and installation into a control panel frame. The assembly frame may include a faceplate frame and side frames and temporary mounting features.

First claim

The invention claimed is:

1. A method of modular control panel assembly comprising:
receiving, at a computing system, a designation of a set of modules to be included in a control panel to be assembled to address an application in operating an electrical power system, each module of the set of modules selected from a plurality of modules, each module of the plurality of modules to be a self-contained solution that performs an electrical function pertaining to operation of the electrical power system, the each module of the plurality of modules defined by a module definition that includes data specifying:
components to perform the electrical function;
a mechanical arrangement of the components to facilitate human interaction, use, and independent manufacture and testing of the each module of the plurality of modules;
electrical connections; and
logical interactions, including logical connections between the components and logical interfaces with another module of the plurality of modules or electrical power system equipment,
wherein the each module of the plurality of modules is designed to be discretely functional and independently wired to be and installed in the control panel;

generating, by the computing system, a bill of materials for the components of the set of modules, the bill of materials specifying a parts list that includes a part listing for each of the components of the set of modules designated, wherein the bill of materials is to be used to order the components according to each part listing in the parts list;
assembling the each module from the set of modules from the components of the component order, wherein the assembling the module of the set of modules includes arranging the components according to a corresponding module definition and the data therein specifying the mechanical interaction, and wherein the assembling the module of the plurality of modules includes wiring the each module according to the corresponding module definition, the data therein specifying electrical connections between the components;
independently testing the each module of the set of modules; and
assembling the control panel from the set of modules, the assembling including mounting the set of modules to a control panel rack.

2. The method of claim 1 , further comprising:
defining the plurality of modules with a corresponding module definition, including determining the components, the mechanical arrangement, the electrical connections, and the logical interactions of the each module of the plurality of modules.

3. The method of claim 1 , further comprising presenting, on a computing device, a selection interface providing a listing of modules from which the set of modules is to be selected for assembly.

4. The method of claim 1 , wherein the designation of the set of modules is received at the computing system over a communication network.

5. The method of claim 1 , further comprising engineering a forthcoming installation of the control panel at an installation site.

6. The method of claim 1 , wherein the components include an interface device for communication between modules of the plurality of modules.

7. The method of claim 1 , further comprising configuring the logical interaction of the one or more components by:
generating one or more settings for the set of modules to configure the one or more of the components and the logical interactions of the module, based on the defined electrical connections and specified function requirements; and
loading settings into components of the set of modules via the one or more settings load files.

8. The method of claim 1 , wherein independently testing each module includes one or more of:
testing to verify settings of each module; and
current injection testing.

9. The method of claim 1 , further comprising testing that the control panel correctly addresses the application in operating the electrical power system.

10. The method of claim 1 , further comprising installing the control panel at an installation site.

11. A method of modular control panel assembly comprising:
defining, on a computing system, a plurality of modules with a module definition, each module to be a self-contained solution to an electrical function pertaining to operation of an electrical power system, the each module definition to include data specifying:
components to perform the electrical function;
mechanical arrangement of the components;
electrical connections, including connections between the components and points of interface with other modules and other equipment of the power system; and
logical interaction, including logical connections between the components and logical interfaces with another module of the plurality of modules or electrical power system equipment,
wherein the each module is designed to be compatible with a plurality of electrical power system configurations, independently wired, tested, and installed in a control panel;

receiving, at the computing system, a designation of a set of modules to be included in the control panel to be assembled for an application in operating the electrical power system, wherein each module of the set of modules is selected from the plurality of modules defined;
preparing a bill of materials for all components of every module of the set of modules, the bill of materials specifying a parts list that includes a part listing for each of the one or more components of all the modules in the set of modules designated;
engineering a forthcoming installation of the control panel;
assembling the each module from the set of modules from the components of the component order, wherein the assembling the each module of the set of modules includes wiring according to a corresponding module definition and the data therein specifying the mechanical arrangement and the electrical connections between the one or more components;
independently testing the each module of the set of modules;
assembling the control panel from the set of modules and according to each module definition; and
installing the control panel at the site.

12. The method of claim 11 , further comprising testing the control panel.

13. The method of claim 11 , wherein the designation of the set of modules is received from one of a customer, an operator of the electrical power system, and an engineer of an engineering services team.

14. The method of claim 11 , wherein engineering the forthcoming installation of the control panel comprises:
obtaining one or more of a module input data list, outage planning list, and commissioning plan and checklist;
performing safety checks;
obtaining drawings of one or more of: the installation site, an anticipated final rendering of the installation, and an interconnection of the control panel with other site hardware;
developing an outage and commissioning plan; and
generating an engineering drawings package for approval using a design automation tool.

15. The method of claim 1 , further comprising configuring the logical interaction of the one or more components by:
generating one or more settings for the set of modules to configure the one or more of the components and the logical interactions of the module, based on the defined electrical connections and specified function requirements; and
loading settings into components of the set of modules via the one or more settings load files.

16. The method of claim 11 , wherein independently testing the each module of the set of modules includes one or more of:
testing to verify settings of the each module of the set of modules; and
current inj

Assignees

• Schweitzer Engineering Lab Inc

Inventors

• Barber Michael
• Alzate Julian M
• Jayne Robert I

Classifications

• H05K7/16

  on hinges or pivots · CPC title

• B25H1/14

  with provision for adjusting the bench top · CPC title

• H02B3/00 Primary

  Apparatus specially adapted for the manufacture, assembly, or maintenance of boards or switchgear · CPC title

• H02B1/32

  Mounting of devices therein · CPC title

• H05K13/0069 Primary

  Holders for printed circuit boards · CPC title