Dynamic thermal mapping

Abstract

A load calculation device for determining the maximum electrical load that can be applied to an electrical circuit includes determines the temperature differential (ΔT) between a section of the electrical circuit and the ambient air temperature in which the section of the electrical circuit resides. The actual electrical load applied to the electrical circuit is also determined as is the design load of the electrical circuit. The maximum electrical load that can be applied to the electrical circuit is then determined based on the temperature differential and the electrical load applied to the electrical circuit and the circuit designed load. The load calculation device may be applied to an electrical joint and may be used to calculate the maximum temperature differential allowed for a given current to be applied at the electrical joint. This is particularly beneficial in connection with detecting and preventing electrical joint failure.

Claims

1. A dynamic thermal mapping system, comprising: a temperature sensor to continuously output in real time a temperature differential (ΔT) between a section of an electrical circuit and an ambient air temperature in which the section of the electrical circuit resides; a current measuring device to continuously output in real time an actual electrical load applied to the electrical circuit; a processor that continuously receives in real time, as inputs, the output of the temperature sensor and the output of the current measuring device; wherein the processor is configured to continuously calculate in real time a percentage electrical load applied to the electrical circuit based on the actual electrical load applied to the electrical circuit and a design load of the electrical circuit; wherein when the section of the electrical circuit comprises an electrical joint, the processor further is configured to continuously determine in real time a maximum temperature differential allowed between the electrical joint and the ambient air temperature in which the electrical joint resides, and when the section of the electrical circuit comprises a conductor remote from an electrical joint the processor further is configured to continuously determine in real time a maximum conductor temperature allowed for the electrical circuit; wherein the processor is configured to continuously calculate in real time a maximum electrical load that can be applied to the electrical joint by the following calculations: $a.\left(\frac{\mathrm{actual}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}\right)\times 100=\%\mathrm{load}\left(\mathrm{applied}\mathrm{to}\mathrm{electrical}\mathrm{joint}\right)$ $b.\frac{{100}^2}{\%{\mathrm{load}}^2}=\mathrm{temperature}\mathrm{ratio}$ $c.\mathrm{temperature}\mathrm{ratio}\times \mathrm{actual}\Delta T\mathrm{value}=\mathrm{\Delta T}\mathrm{value}\mathrm{at}\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}$ $d.\sqrt{\frac{\mathrm{\Delta T}\mathrm{value}\mathrm{at}\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{maximum}\mathrm{\Delta T}\mathrm{value}\mathrm{allowed}}}=\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}$ $e.\frac{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}}=\mathrm{maximum}\mathrm{electrical}\mathrm{load}.$ wherein the processor is further configured to continuously determine in real time if the electrical joint is compromised by comparing the maximum electrical load with the design load of the electrical joint, wherein an electrical joint is compromised if the maximum electrical load is less than the design load of the electrical joint; wherein the system further comprises an alarm wherein the alarm is activated when the maximum electrical load is greater than the design load of the electrical joint to notify that a compromised electrical joint has been located; and wherein the system further comprises a switch which communicates with a control device for supplying electrical load to the electrical circuit, such that the switch prevents the control device from increasing the electrical load beyond the safe maximum electrical load of the compromised electrical joint when the alarm has been activated.

2. The dynamic thermal mapping system of claim 1, wherein the switch prevents the control device from supplying an electrical load to the electrical circuit when the alarm has been activated.

3. The dynamic thermal mapping system of claim 1, wherein the temperature sensor comprises a first sensing element for receiving the temperature of the section of the electrical circuit and a second sensing element for receiving the temperature of the ambient air in which the electrical circuit resides, wherein the second sensing element may be separate from the first sensing element or combined with the first sensing element.

4. A dynamic thermal mapping system, comprising: a temperature sensor to continuously output in real time a temperature differential (ΔT) between a section of an electrical circuit and an ambient air temperature in which the section of the electrical circuit resides; a current measuring device to continuously output in real time an actual electrical load applied to the electrical circuit; a processor that continuously receives in real time, as inputs, the output of the temperature sensor and the output of the current measuring device; wherein the processor is configured to continuously calculate in real time a percentage electrical load applied to the electrical circuit based on the actual electrical load applied to the electrical circuit and a design load of the electrical circuit; wherein when the section of the electrical circuit comprises an electrical joint, the processor further is configured to continuously determine in real time a maximum temperature differential allowed between the electrical joint and the ambient air temperature in which the electrical joint resides, and when the section of the electrical circuit comprises a conductor remote from an electrical joint the processor further is configured to continuously determine in real time a maximum conductor temperature allowed for the electrical circuit; wherein the processor is configured to continuously calculate in real time a maximum electrical load that can be applied to the electrical circuit when the electrical circuit is at a particular ambient temperature by the following calculations: $a.\left(\frac{\mathrm{electrical}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{circuit}}{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{circuit}}\right)\times 100=\%\mathrm{load}\left(\mathrm{applied}\mathrm{to}\mathrm{electrical}\mathrm{circuit}\right)$ $b.\frac{{100}^2}{\%{\mathrm{load}}^2}=\mathrm{temperature}\mathrm{ratio}$ $c.\mathrm{temperature}\mathrm{ratio}\times \mathrm{actual}\Delta T\mathrm{value}=\mathrm{\Delta T}\mathrm{value}\mathrm{at}100\%\mathrm{load}$ $d.\mathrm{\Delta T}\mathrm{value}\mathrm{at}100\%\mathrm{load}+\mathrm{ambient}\mathrm{temperature}=\mathrm{conductor}\mathrm{temperature}\mathrm{at}\mathrm{design}\mathrm{load}$ $e.\sqrt{\frac{\mathrm{conductor}\mathrm{temperature}\mathrm{at}\mathrm{design}\mathrm{load}}{\mathrm{maximum}\mathrm{conductor}\mathrm{temperature}\mathrm{allowed}\mathrm{for}\mathrm{the}\mathrm{circuit}}}=\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}$ $f.\frac{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{circuit}}{\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}}=\mathrm{maximum}\mathrm{load}.$ wherein the processor continuously outputs in real time a signal indicating an ambient temperature reduction requirement indicative of a temperature reduction needed to control the ambient air temperature in which the section of the circuit resides such that the maximum load equals or can be increased beyond the design load of the electrical circuit; and wherein the system further comprises a fan, air conditioning system or liquid cooling system to control the air ambient temperature in which the section of the circuit resides; and wherein the fan, air conditioning system or liquid cooling system controls the ambient temperature such that the maximum load equals at least the design load of the electrical circuit.

5. The dynamic thermal mapping system of claim 4, wherein the fan, air conditioning system or liquid cooling system controls the ambient temperature such that the maximum load can be increased beyond the design load of the electrical circuit.

6. The dynamic thermal mapping system of claim 4, wherein the temperature sensor comprises a first sensing element for receiving the temperature of the section of the electrical circuit and a second sensing element for receiving the temperature of the ambient air in which the electrical circuit resides, wherein the second sensing element may be separate from the first sensing element or combined with the first sensing element.

7. A dynamic thermal mapping system, comprising: a temperature sensor to continuously output in real time a temperature differential (ΔT) between a section of an electrical circuit and an ambient air temperature in which the section of the electrical circuit resides; a current measuring device to continuously output in real time an actual electrical load applied to the electrical circuit; a processor that continuously receives in real time, as inputs, the output of the temperature sensor and the output of the current measuring device; wherein the processor is configured to continuously calculate in real time a percentage electrical load applied to the electrical circuit based on the actual electrical load applied to the electrical circuit and a design load of the electrical circuit; wherein when the section of the electrical circuit comprises an electrical joint, the processor further is configured to continuously determine in real time a maximum temperature differential allowed between the electrical joint and the ambient air temperature in which the electrical joint resides, and when the section of the electrical circuit comprises a conductor remote from an electrical joint the processor further is configured to continuously determine in real time a maximum conductor temperature allowed for the electrical circuit; wherein the processor is configured to continuously calculate in real time a maximum electrical load that can be applied to the electrical circuit based on the temperature differential, the percentage electrical load applied to the electrical circuit, and either the maximum temperature differential or maximum conductor temperature by the following calculations: $a.\left(\frac{\mathrm{electrical}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{circuit}}{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{circuit}}\right)\times 100=\%\mathrm{load}\left(\mathrm{applied}\mathrm{to}\mathrm{electrical}\mathrm{circuit}\right)$ $b.\frac{{100}^2}{\%{\mathrm{load}}^2}=\mathrm{temperature}\mathrm{ratio}$ $c.\mathrm{temperature}\mathrm{ratio}\times \mathrm{actual}\Delta T\mathrm{value}=\Delta T\mathrm{value}\mathrm{at}100\%\mathrm{load}$ $d.\Delta T\mathrm{value}\mathrm{at}100\%\mathrm{load}+\mathrm{ambient}\mathrm{temperature}=\mathrm{conductor}\mathrm{temperature}\mathrm{at}\mathrm{design}\mathrm{load}$ $e.\sqrt{\frac{\mathrm{conductor}\mathrm{temperature}\mathrm{at}\mathrm{design}\mathrm{load}}{\mathrm{maximum}\mathrm{conductor}\mathrm{temperature}\mathrm{allowed}\mathrm{for}\mathrm{the}\mathrm{circuit}}}=\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}$ $f.\frac{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{circuit}}{\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}}=\mathrm{maximum}\mathrm{load}$ wherein the processor is further configured to continuously calculate in real time the electrical load remaining that can be applied to the electrical joint without exceeding the maximum electrical load; and wherein the system further comprises a switch which communicates with a control device for supplying electrical load to the electrical circuit, such that the switch prevents the control device from supplying an electrical load to the electrical circuit that would exceed the maximum electrical load.

8. The dynamic thermal mapping system of claim 7, wherein the temperature sensor comprises a first sensing element for receiving the temperature of the section of the electrical circuit and a second sensing element for receiving the temperature of the ambient air in which the electrical circuit resides, wherein the second sensing element may be separate from the first sensing element or combined with the first sensing element.

9. A non-transitory tangible computer readable storage medium having stored thereon a computer program for implementing a method for continuously determining in real time a maximum electrical load that can be applied to an electrical circuit, the computer program comprising a set of instructions which, when executed by a computer, cause the computer to perform a method comprising the steps of: a. continuously determining in real time a temperature differential (ΔT) between a section of the electrical circuit and an ambient air temperature in which the section of the electrical circuit resides; b. continuously determining in real time an actual electrical load applied to the electrical circuit; c. continuously determining in real time a percentage electrical load applied to the electrical circuit based on the actual electrical load applied to the electrical circuit and a design load of the electrical circuit; wherein when the section of the electrical circuit comprises an electrical joint, the method further comprises continuously determining in real time a maximum temperature differential allowed of the electrical joint, and when the section of the electrical circuit comprises a conductor remote from an electrical joint the method further comprises continuously determining in real time a maximum conductor temperature allowed for the electrical circuit; d. continuously determining in real time and continuously outputting in real time a signal indicative of a maximum electrical load that can be applied to the electrical circuit based on the determined temperature differential, the percentage electrical load applied to the electrical circuit and either the maximum temperature differential or maximum conductor temperature; wherein the maximum electrical load that can be applied to the electrical joint is continuously determined in real time by the following calculations: $i.\left(\frac{\mathrm{actual}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}\right)\times 100=\%\mathrm{load}\left(\mathrm{applied}\mathrm{to}\mathrm{electrical}\mathrm{joint}\right)$ $\mathrm{ii}.\frac{{100}^2}{\%{\mathrm{load}}^2}=\mathrm{temperature}\mathrm{ratio}$ $\mathrm{iii}.\mathrm{temperature}\mathrm{ratio}\times \mathrm{actual}\Delta T\mathrm{value}=\mathrm{\Delta T}\mathrm{value}\mathrm{at}\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}$ $\mathrm{iv}.\sqrt{\frac{\mathrm{\Delta T}\mathrm{value}\mathrm{at}\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{maximum}\mathrm{\Delta T}\mathrm{value}\mathrm{allowed}}}=\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}$ $v.\frac{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}}=\mathrm{maximum}\mathrm{temperature}\mathrm{load}$ e. continuously determining in real time if the electrical joint is compromised by comparing the maximum electrical load with the design load of the electrical joint, wherein an electrical joint is compromised if the maximum electrical load is less than the design load of the electrical joint; f. activating an alarm when the maximum electrical load is greater than the design load to notify that a compromised electrical joint has been located; g. activating a switch which communicates with a control device for supplying electrical load to the electrical circuit, such that the switch prevents the control device from increasing the electrical load beyond the safe maximum electrical load of the compromised electrical joint when the alarm has been activated.

10. The non-transitory tangible computer readable storage medium of claim 9, wherein the switch prevents the control device from supplying an electrical load to the electrical circuit when the alarm has been activated.

11. A non-transitory tangible computer readable storage medium having stored thereon a computer program for implementing a method for continuously determining in real time a maximum electrical load that can be applied to an electrical circuit, the computer program comprising a set of instructions which, when executed by a computer, cause the computer to perform a method comprising the steps of: a. continuously determining in real time a temperature differential (ΔT) between a section of the electrical circuit and an ambient air temperature in which the section of the electrical circuit resides; b. continuously determining in real time an actual electrical load applied to the electrical circuit; c. continuously determining in real time a percentage electrical load applied to the electrical circuit based on the actual electrical load applied to the electrical circuit and a design load of the electrical circuit; wherein when the section of the electrical circuit comprises an electrical joint the method further comprises continuously determining in real time a maximum temperature differential allowed of the electrical joint, and when the section of the electrical circuit comprises a conductor remote from an electrical joint the method further comprises continuously determining in real time a maximum conductor temperature allowed for the electrical circuit; d. continuously determining in real time and continuously outputting in real time a signal indicative of a maximum electrical load that can be applied to the electrical circuit based on the determined temperature differential, the percentage electrical load applied to the electrical circuit and either the maximum temperature differential or maximum conductor temperature; wherein the maximum electrical load that can be applied to the electrical joint is continuously determined in real time by the following calculations: $i.\left(\frac{\mathrm{actual}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}\right)\times 100=\%\mathrm{load}\left(\mathrm{applied}\mathrm{to}\mathrm{electrical}\mathrm{joint}\right)$ $\mathrm{ii}.\frac{{100}^2}{\%{\mathrm{load}}^2}=\mathrm{temperature}\mathrm{ratio}$ $\mathrm{iii}.\mathrm{temperature}\mathrm{ratio}\times \mathrm{actual}\Delta T\mathrm{value}=\mathrm{\Delta T}\mathrm{value}\mathrm{at}\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}$ $\mathrm{iv}.\sqrt{\frac{\mathrm{\Delta T}\mathrm{value}\mathrm{at}\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{maximum}\mathrm{\Delta T}\mathrm{value}\mathrm{allowed}}}=\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}$ $v.\frac{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}}=\mathrm{maximum}\mathrm{temperature}\mathrm{load}$ e. continuously calculating in real time the electrical load remaining that can be applied to the electrical joint without exceeding the maximum electrical load; and f. preventing the electrical load that can be applied to the electrical joint from exceeding the maximum electrical load by communicating with a switch which communicates with a control device for supplying electrical load to the electrical circuit, such that the switch prevents the control device from supplying an electrical load to the electrical circuit that would exceed the maximum electrical load.

12. A non-transitory tangible computer readable storage medium having stored thereon a computer program for implementing a method for continuously determining in real time a maximum electrical load that can be applied to an electrical circuit, the computer program comprising a set of instructions which, when executed by a computer, cause the computer to perform a method comprising the steps of: a. continuously determining in real time a temperature differential (ΔT) between a section of the electrical circuit and an ambient air temperature in which the section of the electrical circuit resides; b. continuously determining in real time an actual electrical load applied to the electrical circuit; c. continuously determining in real time a percentage electrical load applied to the electrical circuit based on the actual electrical load applied to the electrical circuit and a design load of the electrical circuit; wherein when the section of the electrical circuit comprises an electrical joint the method further comprises continuously determining in real time a maximum temperature differential allowed of the electrical joint, and when the section of the electrical circuit comprises a conductor remote from an electrical joint the method further comprises continuously determining in real time a maximum conductor temperature allowed for the electrical circuit; d. continuously determining in real time and continuously outputting in real time a signal indicative of a maximum electrical load that can be applied to the electrical circuit based on the determined temperature differential, the percentage electrical load applied to the electrical circuit and either the maximum temperature differential or maximum conductor temperature; wherein the maximum electrical load that can be applied to the electrical circuit when the electrical circuit is at a particular ambient temperature is continuously determined in real time by the following calculations: $i.\left(\frac{\mathrm{electrical}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{circuit}}{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{circuit}}\right)\times 100=\%\mathrm{load}\left(\mathrm{applied}\mathrm{to}\mathrm{electrical}\mathrm{circuit}\right)$ $\mathrm{ii}.\frac{{100}^2}{\%{\mathrm{load}}^2}=\mathrm{temperature}\mathrm{ratio}$ $\mathrm{iii}.\mathrm{temperature}\mathrm{ratio}\times \mathrm{actual}\Delta T\mathrm{value}=\mathrm{\Delta T}\mathrm{value}\mathrm{at}100\%\mathrm{load}$ $\mathrm{iv}.\mathrm{\Delta T}\mathrm{value}\mathrm{at}100\%\mathrm{load}+\mathrm{ambient}\mathrm{temperature}=\mathrm{conductor}\mathrm{temperature}\mathrm{at}\mathrm{design}\mathrm{load}$ $v.\sqrt{\frac{\mathrm{conductor}\mathrm{temperature}\mathrm{at}\mathrm{design}\mathrm{load}}{\mathrm{maximum}\mathrm{conductor}\mathrm{temperature}\mathrm{allowed}\mathrm{for}\mathrm{the}\mathrm{circuit}}}=\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}$ $\mathrm{vi}.\frac{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{circuit}}{\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}}=\mathrm{maximum}\mathrm{load}$ e. communicating with a fan, air conditioning system or liquid cooling system to control the air ambient temperature in which the section of the circuit resides such that the maximum load equals or can be increased beyond the design load of the electrical circuit.

13. The non-transitory tangible computer readable storage medium of claim 12, wherein the method further comprises communicating with the fan, air conditioning system or liquid cooling system to control the air ambient temperature in which the section of the circuit resides such that the maximum load equals the design load of the electrical circuit.

14. The non-transitory tangible computer readable storage medium of claim 12, wherein the method further comprises communicating with the fan, air conditioning system or liquid cooling system to control the air ambient temperature in which the section of the circuit resides such that the maximum load can be increased beyond the design load of the electrical circuit.

15. A dynamic thermal monitoring system, comprising: an electrical joint temperature sensor to continuously output in real time an electrical joint temperature of an electrical joint; an ambient air temperature sensor to continuously output in real time an ambient air temperature of air surrounding the electrical joint; a current measuring device to continuously output in real time an actual electrical load applied to the electrical joint; a processor that continuously receives in real time, as inputs, the actual electrical load applied to the electrical joint and either: (1) the electrical joint temperature from the electrical joint temperature sensor and the ambient air temperature from the ambient air temperature sensor; or (2) a difference between the electrical joint temperature and the ambient air temperature (actual ΔT value), and using the inputs continuously calculates, in real time, a maximum electrical load that may be applied to the electrical joint by: (1) determining a percentage electrical load applied to the electrical joint based on the actual electrical load applied to the electrical joint and a design load of the electrical joint using equation (a): $a.\left(\frac{\mathrm{actual}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}\right)\times 100=\%\mathrm{load}\left(\mathrm{applied}\mathrm{to}\mathrm{the}\mathrm{electrical}\mathrm{joint}\right)$ (2) determining a temperature ratio for the electrical joint using equation (b): $b.\frac{{100}^2}{\%{\mathrm{load}}^2}=\mathrm{temperature}\mathrm{ratio}$ (3) determining an expected temperature differential (ΔT at design load of electrical joint) between the joint temperature and ambient air temperature that would be expected to be experienced by the electrical joint if the electrical joint were to be operated at the design load using equation (c):
temperature ratio*actual ΔT value=ΔT value at design load of electrical joint  c. (4) determining an equivalent temperature load ratio for the electrical joint based on the expected temperature differential (ΔT value at the design load of the electrical joint) and the maximum temperature differential for the electrical joint (maximum ΔT value allowed) using equation (d): $d.\sqrt{\frac{\mathrm{\Delta T}\mathrm{value}\mathrm{at}\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{maximum}\mathrm{\Delta T}\mathrm{value}\mathrm{allowed}}}=\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}$ (5) determining the maximum electrical load that may be applied to the electrical joint under current operating conditions using equation (e): $e.\frac{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}}=\mathrm{maximum}\mathrm{electrical}\mathrm{load}$ (6) outputting an indication of the maximum electrical load that may be applied to the electrical joint under the current operating conditions; the method further comprising: iterating the steps of calculating and outputting the maximum electrical load, by the processor; and dynamically adjusting the actual electrical load applied to the electrical joint based on the calculated maximum electrical load output by the processor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will now be described by way of example only, with reference to the accompanying drawing in which:

(2) FIG. 1 illustrates an exemplary electrical circuit.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(3) Embodiments of the present invention are described below by way of example only. These embodiments represent the best ways of putting the invention into practice that are currently known to the Applicant, although they are not the only ways in which this could be achieved.

(4) FIG. 1 shows an exemplary electrical circuit 10 illustrating two types of electrical joints 12, 14 between different types of conductor 14, 16. 18. The electrical joint 14 may be for example a joint between metal connectors 16, 18, which are typically formed from copper or aluminium, or the joint 12 may be at the termination of an electric cable 20 to a metal connector 16, or any other joint in an electrical circuit between two or more components.

(5) The electrical joint 12, 14 is provided with a first sensing element 22, 24 which measures the temperature of the electrical joint 12, 14. The first sensing element 22, 24 is located within the electrical enclosure in which the electrical circuit 10 is located so that the temperature of the electrical joint is obtained accurately and without any need for correlation. The first sensing element 22 is an example of a non contact temperature sensor. The first sensing element 22 may either measure the temperature of the electrical joint 14 or the temperature of the electrical conductor 16 adjacent the electrical joint 14 as this will be at around the same temperature. The first sensing element 24 is an example of a cable mounted contact temperature sensor. The first sensing element 24 may measures the temperature of the electrical cable 24 adjacent the electrical joint 12 as this will be at around the same temperature as that of the electrical joint 12 itself.

(6) A second sensing element 26, 28 is also provided within the electrical enclosure in which the electrical circuit 10 is located which measures the ambient temperature of the air within the electrical enclosure. The second sensing element 26 is an example where the local ambient temperature sensor is remote from the first sensing element and not directly connected thereto. The second sensing element 28 is an example of where the local ambient temperature sensor is connected to the first sensing element 24.

(7) The second sensing element may be separate from the first sensing element or combined with the first sensing element.

(8) The temperature differential or ΔT value of the electrical joint is the difference between the temperature of the electrical joint (or the electrical conductor adjacent thereto) and the ambient temperature.

(9) The sensing elements may be for example: A combined sensing element located close to the electrical joint which has a first sensing element which measures the temperature of the electrical joint or the temperature of the electrical conductor adjacent the electrical joint using non contact infrared for example, or a contact device such as a thermocouple or a fibre optic sensing device, and a second sensing element which measures the ambient air temperature within the enclosure. In one alternative such a combined sensing element sends each measurement separately to the local calculation device. In an alternative such a combined sensing element is provided with a device adapted to determine the ΔT value of the electrical joint or of the conductor adjacent the electrical joint which is effectively the ΔT value of the joint and the combined sensing element sends the ΔT value to the local calculation device. Separate contact or non contact sensing elements, the first sensing element located above the electrical joint which measures the temperature of the electrical joint or the temperature of the electrical conductor adjacent the electrical joint using infrared for example, and the second sensing element located remote from the first sensing element but still within the enclosure which measures the ambient air temperature within the enclosure. The load calculation device would then determine the ΔT value based on the individual temperature values. Separate linked elements, the first sensing element is located near or on the external insulating layer of an electrical conductor, in the case of an electrical cable, adjacent to the electrical joint which measures the temperature of the electrical conductor adjacent to the electrical joint which is connected to the second sensing element located remote from the first sensing element but still within the enclosure which measures the ambient air temperature within the enclosure wherein the second sensing element is provided with a device adapted to determine the ΔT value of the electrical conductor adjacent to the electrical joint which is effectively the ΔT value of the electrical joint which then sends the ΔT value to the load calculation device.

(10) In the instances where the local calculation device is provided with the ΔT value directly it may be necessary to provide a secondary ambient temperature sensing element where it is necessary to know the ambient temperature separately from the ΔT value. In these instances though it is only necessary to provide one such additional sensing element per enclosure.

(11) Furthermore, when it is known that none of the electrical joints are compromised and one desires to run an electrical circuit either at elevated electrical loads or elevated ambient temperatures, as discussed in detail later, it is only necessary to provide a single first sensing element which either measures the temperature of the conductor or joint and a second sensing element which measures the ambient air temperature per enclosure.

(12) The first and second sensing elements 22, 24, 26, 28 are either directly or indirectly connected to a load calculation device 30 which continuously receives and may additionally log the temperature values which have been continuously measured by each of the first and second sensing elements 22, 24, 26, 28, to provide the load calculation device 30 with real time data. The load calculation device 30 may receive the temperature values via a cable or via wireless means.

(13) The electrical circuit is also provided with a metering device 32, 34, 36, 38 which continuously monitors the electrical load being put through the electrical circuit (i.e. the electrical current). In FIG. 1 the metering devices 32, 34, 36 are integrated energy meters located within the electrical circuit and metering device 38 is a third party energy meter located externally to the electrical circuit.

(14) The metering device 32, 34, 36, 38 may be directly connected to the load calculation device 30 or in the alternative the metering device 32, 34, 36, 38 may be indirectly connected to the load calculation device 30 via a secondary system to which the metering device 32, 34, 36, 38 is connected to such as a building management system, electrical monitoring system, power management system or the like.

(15) The load calculation device 30 continuously receives and may additionally log the electrical load values which have been continuously provided by the metering device 32, 34, 36, 38, to provide the software with real time data. The load calculation device 30 may receive the electrical load values via cable or via wireless means.

(16) The load calculation device 30 may be located remote from the electrical circuit 10 and thus the electrical joint 12, 14.

(17) The load calculation device 30 may be for example a computer provided with computer software, in the alternative the load calculation device may be PLCs (process logic controllers), process control devices, automation control devices, processors for process control devices or the like.

(18) Method of Determining the Electrical Load that can be Applied to a Compromised Electrical Joint

(19) The load calculation device, using the maximum electrical load the electrical circuit and thus the electrical joint is designed to operate at, the ΔT value of the electrical joint and actual electrical load, continuously calculates the maximum electrical load that the electrical joint can safely handle in real time. The load calculation device also continuously calculates the remaining electrical load that the electrical joint can safely handle and the ΔT value that the electrical joint will reach if operated at the maximum electrical load that the electrical circuit and thus the electrical joint is designed to operate at.

(20) The load calculation device uses the following calculations to continuously calculate in real time the maximum safe operating electrical load for the electrical joint and the remaining electrical load that can be placed on the electrical joint before the maximum electrical load that the electrical joint can safely operate at is exceeded. It should be noted that the electrical load that the electrical circuit is designed to operate at is the same as the electrical load that the electrical joint is designed to operate at.

(21) $\begin{array}{cc}\left(\frac{\mathrm{actual}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}\right)\times 100=\%\mathrm{load}\left(\mathrm{applied}\mathrm{to}\mathrm{the}\mathrm{electrical}\mathrm{joint}\right)\text{.Math.}\frac{{100}^2}{\%{\mathrm{load}}^2}=\mathrm{temperature}\mathrm{ratio}\mathrm{temperature}\mathrm{ratio}\times \mathrm{actual}\Delta T\mathrm{value}=\mathrm{\Delta T}\mathrm{value}\mathrm{at}\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}\text{.Math.}\sqrt{\frac{\mathrm{\Delta T}\mathrm{value}\mathrm{at}\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{maximum}\mathrm{\Delta T}\mathrm{value}\mathrm{allowed}}}=\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}\text{.Math.}\frac{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}}=\mathrm{maximum}\mathrm{electrical}\mathrm{load}\mathrm{maximum}\mathrm{load}-\mathrm{actual}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}=\mathrm{load}\mathrm{remaining}& \mathrm{Equation}\mathrm{Set}1\end{array}$

(22) The load remaining value is provided with a cap to stop this value from exceeding [design load of electrical joint−actual load of electrical joint], should the ambient temperature of the air within the enclosure be below 40° C. at full electrical load values for example.

Example 1

(23) Actual electrical joint load=201 Amps

(24) Design electrical joint load=619 Amps

(25) Actual ΔT=4.5° C.

(26) Maximum ΔT=40° C.

(27) $\left(\frac{201}{619}\right)\times 100=32.47\%$$\frac{{100}^2}{{32.47}^2}=\frac{10000}{1054.30}=9.48$$9.48\times 4.5°C.=42.66°C.\sqrt{\frac{42.66}{40.00}}=1.03$$\frac{619}{1.03}=600.97\mathrm{Amps}\mathrm{maximum}\mathrm{load}$$600.97-201=399.97\mathrm{Amps}\mathrm{remaining}\mathrm{before}\mathrm{the}\mathrm{electrical}\mathrm{joint}\mathrm{and}\mathrm{thus}\mathrm{the}\mathrm{electrical}\mathrm{circuit}\mathrm{exceeds}\mathrm{maximum}\mathrm{allowed}\mathrm{\Delta T}\mathrm{value}\mathrm{of}40°C.$

(28) The load calculation device would therefore calculate in real time: maximum electrical load of 600.97 Amps that the electrical joint and thus the electrical circuit can safely handle; remaining load of 399.97 Amps that we can expect the electrical joint and thus the electrical circuit to safely handle; ΔT value of 42.66° C. that the electrical joint will reach if allowed to run at the design load of the electrical circuit, and thus the design load of the electrical joint.

(29) The load calculation device provides to the operator in real time; current ΔT value that the electrical joint is operating at in ° C. or ° F.; design load of the electrical circuit and thus the design load of the electrical joint in Amps; actual electrical load applied to the electrical joint in Amps; ΔT value of the electrical joint if 100% electrical joint design load is applied to the electrical joint in ° C.; maximum electrical load, that can be applied to the electrical joint so that it still operates safely and below a given actual temperature threshold, in Amps;
along with other interactive capabilities.

(30) The load calculation device continuously monitors the values and makes the calculations to enable the user to locate compromised electrical joints at any operating electrical loads in real time. The load calculation device also calculates in real time the additional electrical load that can be safely handled by the electrical joint and thus the electrical circuit. This means that any such compromised joints do not have additional electrical load applied to them which otherwise result in failure of the compromised joint along with associated safety issues and economic loss. In addition the load calculation device can be used to identify the degeneration of an electrical joint in an electrical circuit over the lifetime of the electrical circuit to enable for accurate determination of when the electrical circuit and/or joint should be replaced or its electrical load capacity reduced.

(31) The load calculation device may additionally be provided with a stop mechanism that prevents the electrical load being applied to the electrical joint from being increased beyond the safe maximum electrical load in the event that a compromised electrical joint has been located by the load calculation device, i.e. when safe maximum electrical load is less than the design load of the electrical joint and thus the electrical circuit.

(32) Method of Determining the Electrical Load that can be Applied to an Electrical Circuit at a Given Ambient Temperature

(33) The load calculation device, using the maximum electrical load the circuit is designed to operate at, the ΔT value of the electrical conductor, which may be the ΔT value of an electrical joint or the ΔT value of the conductor remote from an electrical joint, actual circuit load and ambient temperature, continuously calculates in real time the maximum electrical load that the electrical circuit can safely handle. The load calculation device also continuously calculates in real time the remaining electrical load that the electrical circuit can safely handle and the actual conductor temperature that the conductor will reach if operated at the maximum electrical load that the electrical circuit is designed to operate at and thus the amount that the ambient temperature would need to be reduced by to allow the electrical circuit to be operated at maximum load without exceeding the maximum allowed temperature for the electrical circuit.

(34) In the case where the ΔT value of the electrical conductor is taken at a point remote from an electrical joint the load calculation device will assume that none of the electrical joints in the electrical circuit have been compromised and furthermore will not be able to detect if any of the electrical joints have been compromised. In the case where the ΔT value of the electrical conductor is taken at or adjacent to an electrical joint the load calculation device will, in addition to calculating the correct safe electrical load for a given ambient temperature, be able to detect if such an electrical joint has been compromised and factor this into the calculations to calculate the correct safe electrical load for a given ambient temperature.

(35) The load calculating device uses the following calculations to continuously calculate in real time the maximum safe operating electrical load for the electrical circuit and the remaining electrical load that can be placed on the electrical circuit before the maximum electrical load that the electrical circuit can safely be operated at is exceeded for the ambient temperature. The following calculations assume that the ΔT value is taken on a conductor at a point remote from any electrical joints. However, if it also desired to detect any compromised joints and adjust the electrical load to take into account any such compromised joints as well as the ambient temperature such calculations are combined with those provided in Equation Set 1 that are used to determine the electrical load that can be applied to a compromised electrical joint as set out in Equation Set 3 and Example 3 further below.

(36) $\left(\frac{\mathrm{electrical}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{circuit}}{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{circuit}}\right)\times 100=\%\mathrm{load}\left(\mathrm{applied}\mathrm{to}\mathrm{electrical}\mathrm{circuit}\right)$$\frac{{100}^2}{\%{\mathrm{load}}^2}=\mathrm{temperature}\mathrm{ratio}$$\mathrm{temperature}\mathrm{ratio}\times \mathrm{actual}\Delta T\mathrm{value}=\mathrm{\Delta T}\mathrm{value}\mathrm{at}100\%\mathrm{load}$$\mathrm{\Delta T}\mathrm{value}\mathrm{at}100\%\mathrm{load}+\mathrm{ambient}\mathrm{temperature}=\mathrm{conductor}\mathrm{temperature}\mathrm{at}\mathrm{design}\mathrm{load}$$\sqrt{\frac{\mathrm{conductor}\mathrm{temperature}\mathrm{at}\mathrm{design}\mathrm{load}}{\mathrm{maximum}\mathrm{conductor}\mathrm{temperature}\mathrm{allowed}\mathrm{for}\mathrm{the}\mathrm{circuit}}}=\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}$$\frac{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{circuit}}{\mathrm{equivalent}\mathrm{temperature}\mathrm{load}\mathrm{ratio}}=\mathrm{maximum}\mathrm{load}$$\mathrm{maximum}\mathrm{load}-\mathrm{actual}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{circuit}=\mathrm{load}\mathrm{remaining}$

(37) The load remaining value is provided with a cap to stop this value from exceeding [design load of electrical circuit−actual load of electrical circuit], should the conductor temperature be below 85° C. at full load values for example, or other standard as required.

(38) Using the above equations the load calculation device continuously calculates in real time the value of the maximum electrical load a given electrical circuit can safely operate at before exceeding the given threshold for temperature rise on the conductors in the electrical circuit which is for example 85° C. as set out in BS159, and the value of the remaining electrical load that can be placed on the circuit before the maximum electrical load for the given circuit is exceeded. ANSI, IEC and UL have similar standards and the actual threshold for temperature rise will depend on the particular standard that is in force and recommended by each manufacturer.

Example 2

(39) Actual circuit load=201 Amps

(40) Design circuit load=619 Amps

(41) Actual ΔT=6.0° C.

(42) Ambient temperature=35° C.

(43) 0$\left(\frac{201}{619}\right)\times 100=32.47\%$$\frac{{100}^2}{{32.47}^2}=\frac{10000}{1054.30}=9.48$$9.48\times 6.0°C.=56.88°C.56.88°C.+35.00°C.=91.88°C.\left(\mathrm{actual}\mathrm{joint}\mathrm{temperature}\right)$$\sqrt{\frac{91.88}{85.00}=}1.04$$\frac{619}{1.04}=595.19\mathrm{Amps}\mathrm{maximum}\mathrm{electrical}\mathrm{load}$$595.19-201=394.19\mathrm{Amps}\mathrm{remaining}\mathrm{before}\mathrm{circuit}\mathrm{exceeds}\mathrm{maximum}\mathrm{allowed}\mathrm{conductor}\mathrm{temperature}\mathrm{of}85°C.$

(44) The load calculation device would therefore calculate in real time: maximum electrical load of 595.19 Amps that the circuit can safely handle; remaining load of 394.19 Amps that we can expect the circuit to safely handle; an actual temperature of the electrical joint of 91.88° C. that the electrical joint will reach if allowed to run at the design circuit load.

(45) The load calculation device then subtracts the maximum allowed electrical conductor temperature from the actual conductor temperature, i.e. 85.0° C.-91.88° C., to provide the value that the ambient temperature needs to be reduced by to bring the conductor temperature in line with the acceptable standards i.e. 6.88° C.

(46) The load calculation device provides to the operator continuously in real time; current ΔT that the electrical conductor is operating at in ° C. or ° F.; design load of the electrical circuit and thus the electrical conductor in Amps; actual electrical load applied to the electrical circuit and thus the electrical conductor in Amps; local ambient temperature in ° C. or ° F.; the temperature that the electrical conductor will reach if 100% electrical load is applied to the electrical conductor in ° C. or ° F.; the maximum electrical load that can be applied to the electrical conductor and thus the electrical circuit to stay below the defined threshold in Amps; the remaining electrical load that can be safely applied to the electrical circuit in Amps; the reduction in ambient temperature required to bring the electrical conductor in line with the applicable standard, or other threshold in ° C. or ° F.;
along with other interactive capabilities.

(47) The temperature reduction can be achieved manually or may be automatically provided by the load calculation device which may for example automatically start cooling fans or liquid cooling systems such as water cooling devices located close to the electrical circuit within the enclosure for example or lower the temperature of the room or other enclosure in which the electrical circuit is located. In addition the load calculation device may communicate with a BMS/SCADA system to facilitate such changes in room or enclosure temperature.

(48) This means that the operator would know in real time the maximum electrical load that could be applied to an electrical circuit based on the real time ambient temperature. This also means that the ambient temperature could be cooled by the required amounts to safely allow the electrical circuit to operate at 100% electrical load in elevated ambient temperatures. Similarly the load calculation device allows for safe operation of the electrical circuit at levels above 100% electrical load by reducing the ambient temperature to compensate. In addition the load calculation device can be used to identify the degeneration of an electrical joint in an electrical circuit over the lifetime of the electrical circuit to enable for accurate determination of when the electrical circuit and/or joint should be replaced or its electrical load capacity reduced.

(49) In the case where it is also desired to detect any compromised electrical joints and adjust the electrical load to take into account any such compromised electrical joints as well as the ambient temperature the load calculation devices uses both of the calculations detailed above wherein the ΔT values are taken at or adjacent to such electrical joints. Once the load calculation device has made the two sets of calculations, the lowest maximum electrical load calculated is taken to be the maximum electrical load for the electrical joint taking into account both the ambient temperature and integrity of the electrical joint.

(50) Method of Determining the ΔT Value Threshold an Electrical Joint at any Electrical Load

(51) The load calculation device also provides for a dynamic ΔT value threshold. This allows for an alarm or other signal to be set off when a compromised electrical joint is identified irrespective of the electrical load being applied to the electrical joint.

(52) The load calculation device uses the maximum allowed ΔT value of the electrical joint and the % electrical load to calculate the ΔT value alarm threshold using the following calculations.

(53) Equation Set 3

(54) $\left(\frac{\mathrm{actual}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}{\mathrm{design}\mathrm{load}\mathrm{of}\mathrm{electrical}\mathrm{joint}}\right)\times 100=\%\mathrm{load}\left(\mathrm{applied}\mathrm{to}\mathrm{the}\mathrm{electrical}\mathrm{joint}\right)$$\mathrm{Maximum}\mathrm{allowed}\mathrm{\Delta T}\mathrm{value}\times {\left(\frac{\%\mathrm{load}}{100}\right)}^2=\mathrm{\Delta T}\mathrm{value}\mathrm{threshold}$

Example 3

(55) For a maximum allowed ΔT value of 40° the ΔT value threshold at 40% electrical load is calculated as follows:

(56) $40\times {\left(\frac{40}{100}\right)}^2=6.4°C.\mathrm{\Delta T}\mathrm{value}\mathrm{threshold}$

(57) The load calculation device provides to the operator continuously in real time; current ΔT value that the electrical joint is operating at in ° C. or ° F.; design load of the electrical circuit and thus the electrical joint in Amps; actual electrical load applied to the electrical circuit and thus the electrical joint in Amps; ΔT value alarm threshold for the % electrical load utilized on the circuit in ° C. or ° F., equivalent to that which would apply at 100% electrical load.
along with other interactive capabilities.