Claims:1. A motor protection relay(MPR) comprising:
a humidity/temperature sensor 102 configured to transmit sensor output to a signal conditioning circuit 108 having an in-built ADC for processing before further transmission to CPU 114 of the MPR;
a pressure sensor 104 and a motor speed/load current sensor 106 configured to transmit respective sensor outputs to respective receivers 110, 112 for processing before further transmission to the CPU 114 of the MPR; and
a memory card 116 configured to log sensor outputs.

2. The MPR of claim 1, wherein the receivers 110, 112 are RS-485 receivers, and wherein the receivers 110, 112 transmit respective outputs to the CPU 114 through COM ports.

3. The MPR of claim 1, wherein the MPR further comprises an Ethernet port 122 for transmission of at least one sensor output to a remote client.

4. The MPR of claim 1, wherein the MPR further comprises a display unit 124 configured to display at least one sensor output.

5. The MPR of claim 1, wherein the memory card 116 is a micro SD card.

6. The MPR of claim 1, wherein the sensor outputs are logged along with respective timestamps into the memory card 116 using SPI communication protocol.
7. The MPR of claim 1, wherein the CPU 114 is configured to transmit at least one sensor output over a COM port to RS3232 118 for further transmission to a remote client.

8. The MPR of claim 1, wherein the memory card 116 is further configured to store any or a combination of sensor output, metering data, event data, and protection data.

9. The MPR of claim 8, wherein data stored in the memory card 116 is sent over Ethernet 122 or over a serial port to a remote client.

10. The MPR of claim 8, wherein the data is serially sent over a COM UART port for serial communication to the remote client.
, Description:TECHNICAL FIELD
[0001] The present disclosure generally relates to a motor protection relay (MPR) with multiple sensors, more particularly it discloses MPR with in-built data logging of event data, metering data, protection data, and sensor data.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] An electric motor may be protected from overload or excessive temperatures that may damage it. This protection is usually performed by a motor protection relay (MPR) configured with appropriate setting values. Motor protection relay is used to detect overload, short-circuits, and other faults and may be based on electromechanical or numerical techniques. However, most of these motor protection relays need to be manually parameterized by the installer before being put into service, and cannot adapt themselves to each application of the electric motor.
[0004] MPR (also interchangeably referred to as Motor protection and control relay/unit) is designed as a reliable building block for Motor Control Centers (MCCs), and is configured to provide complete motor protection. MPR’s cover conventional and advanced motor protection, metering, and annunciation in MCC feeders into a single, easy to configure, compact communicating module with a powerful long-lasting display. Such protection and control relays/units are used as protection controllers for Low-voltage Contactor Controlled Motor Starter Feeders.
[0005] Existing MPR’s are not able to measure real-time values of current, voltage, power, analog output, temperature, and monitor motor specific data such as phase sequence, motor status, among others. Such relay also store only last few (such as five) event records in their non-volatile memory, and therefore there is a need in the art to increase the number of events that can be recorded. Existing Motor Protection Relays (MPRs) are also not capable of logging all the data related to events, metering, protection etc. Furthermore, existing MPRs also do not have a provision of sensor interface such as temperature, pressure, and humidity.
[0006] There is therefore a need in the art for an improved MPR that can log multiple events and trip records, alarm, and pickups. There is further a need in the art to log metering data, protection data, and sensor data such as temperature, relative humidity, and pressure. There is also a need in the art to monitor real time parameters such as pressure, temperature, and humidity, motor load current and motor speed in order to increase relays reliability.There is further a need in the art to have a data format that is user configurable, and helps user to decide the data format to save data on say a Micro SD card as per requirement.
[0007] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0008] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0009] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0010] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0011] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

OBJECTS OF THE INVENTION
[0012] A general object of the present disclosure is to provide a MPR with multiple sensor interfaces.
[0013] Another object of the present disclosure is to provide a MPR that enables loggingof multiple events and trip records, alarm and pickups.
[0014] An object of the present disclosure is to provide a provision of sensor interface such as temperature, pressure, humidity for use with MPR.
[0015] Another object of the present disclosure is to provide output data log sentences to the operator.
[0016] Yet another object of the present disclosure is to provide a user configurable data format to record/log data for Micro SD card.

SUMMARY
[0017] Aspects of the present disclosure pertain to a motor protection relay (MPR) with multiple sensor interfaces and in-built data logger.
[0018] MPR with inbuilt Data Logger is designed to display & record data logs of all events, protection, and metering parameters with sensor inputs. Sensor data in general can include, but is not limited to, temperature, humidity, pressure, motor speed and load current. In an embodiment, the proposed MPR can include a microcontroller, a plurality of sensors operatively coupled with the microcontroller, and a Micro SD card.
[0019] In an aspect, a signal conditioning circuit converts Temperature/Humidity sensor output to a required/desired range by Analog to Digital Converter (ADC) before passing it to MPR’s CPU. In another exemplary aspect, for Pressure sensor and Motor Speed/Load Current sensor, the output passes through RS-485 receiver to reach MPR CPU.
[0020] In an aspect, the data can be logged with a timestamp onto say an on-board external Micro SD card (up to 4GB), wherein output data logged sentences are available through Ethernet Port as well as COM Port to the client, and wherein the logged data can be displayed on a display (say an OLED LCD display) on the front panel.
[0021] In an exemplary aspect, the proposed disclosure provides for counting of the number of starts that have happened with MPR. This information is retrievable as the MPR logs the number of starts along with the range and the increment of each start to an external memory, which feature adds further intelligence.
[0022] In an embodiment of the present disclosure, data format for Micro SD card to record/log data can be user configurable.
[0023] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0025] FIG. 1 shows an exemplary block diagram of motor protection relay in accordance to an embodiment of the present disclosure.
[0026] FIG. 2 shows an exemplary block diagram of proposed motor protection relay having an inbuilt data logger in accordance to an embodiment of the present disclosure.
[0027] FIG. 3 shows an exemplary Micro SD card interface in accordance to an embodiment of the present disclosure.
[0028] FIG. 4 shows an exemplary block diagram of communication interface in accordance to an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0029] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0030] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0031] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0032] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0033] Various terms as used herein. To the extent a term used in a claim is not defined, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0034] Aspects of the present disclosure pertain to a motor protection relay (MPR) with multiple sensor interfaces and in-built data logger.
[0035] MPR with inbuilt Data Logger is designed to display & record data logs of all events, protection, and metering parameters with sensor inputs. Sensor data in general can include, but is not limited to, temperature, humidity, pressure, motor speed and load current. In an embodiment, the proposed MPR can include a microcontroller, a plurality of sensors operatively coupled with the microcontroller, and a Micro SD card.
[0036] In an aspect, a signal conditioning circuit converts Temperature/Humidity sensor output to a required/desired range by Analog to Digital Converter (ADC) before passing it to MPR’s CPU. In another exemplary aspect, for Pressure sensor and Motor Speed/Load Current sensor, the output passes through RS-485 receiver to reach MPR CPU.
[0037] In an aspect, the data can be logged with a timestamp onto say an on-board external Micro SD card (up to 4GB), wherein output data logged sentences are available through Ethernet Port as well as COM Port to the client, and wherein the logged data can be displayed on a display (say an OLED LCD display) on the front panel.
[0038] In an exemplary aspect, the proposed disclosure provides for counting of the number of starts/events/processes that have happened with MPR. This information can be retrievable as the MPR logs the number of starts/events along with the range and the increment of each start/event to an external memory, which feature adds further intelligence.
[0039] In an embodiment of the present disclosure, data format for Micro SD card to record/log data can be user configurable.
[0040] FIG. 1 illustrates view 100 of motor protection relay (MPR) with sensor interface and in-built data logger. In an aspect, power supply 120 delivers appropriate power to Humidity/Temperature sensor 102, pressure sensor 104, motor speed/load current sensor 106, Ethernet 122, OLED Display 124, Micro SD card 116. Signal conditioning circuit 108 can be configured to convert Humidity/Temperature sensor 102 output to a required range by ADC before passing it to MPR CPU 114. For Pressure sensor 104 and Motor Speed/Load Current Sensor 106, the output passes through RS-485 receiver 110 and RS-485 receiver 112 respectively to reach MPR CPU 114 over COM0 and COM1 respectively. In an aspect, the data can be logged with timestamp into on-board external Micro SD card 116 over SPI0, wherein output data logged sentences can be available through Ethernet 122 Port as well as COM Port to the client. The logged data received from MPR CPU 114 over SPI1 can be displayed on a display such as OLED LCD 124 display on front panel. MPR CPU 114 can be configured to output over COM2 to RS3232 118 for the Remote Client 404 (shown in FIG. 4) COM port.
[0041] In an aspect, as mentioned above, the proposed MPR 100 can include a Temperature/Humidity sensor output (0-5V range) that can be first given to a signal conditioning circuit 108 that converts it into a desired range that is required by ADC (0-3.3V Range).In an exemplary embodiment, CPU 114 or signal conditioning circuit 108 can have an on-chip ADC with resolution of 12-Bit.
[0042] In another embodiment, pressure sensor 104 can be configured to output 4-20mA over RS-485, wherein theRS-485 receiver 110 receives it and sends data to CPU unit 114 over COM0.
[0043] In another embodiment, motor speed sensor/load current sensor 106, on the other hand, outputs 4-20mA over RS485, wherein theRS-485 receiver 112 receives the data, and send sit to the CPU unit 114 over COM1.
[0044] The proposed MPR 100 can further include a motor protection relay CPU 114 that starts and initializes any or a combination of the UARTs, TIMERs, ADC, SPI, OLED Display and SD card. The numbers of UARTs used can be COM0, COM1, COM2, and COM3, among others. Pressure sensor output and Motor speed sensor/Load current sensor output can be given to CPU unit over COM0 & COM1 respectively.
[0045] In an aspect, Serial Peripheral Interface (SPI) communication protocol can be used for interfacing of MicroSD 116 and OLED display 124 with the CPU 114.MicroSD card 116 can be interfaced with CPU unit 114 by SPI-0 (Serial peripheral interface 0), whereas OLED display can be interfaced through SPI-1 (Serial peripheral interface 1).Therefore, protection relay CPU 114 can be configured to read sensors data from UARTs & ADC, along with reading metering and protection data.
[0046] In an exemplary aspect, power supply unit 120 can include an SMPS with outputs 3.3V, 5V, 24V etc. Overall circuitry can be powered by these isolated voltages. Different types of sensors used are given below along with their specifications to highlight their range and other important parameters:
Sr. No. Sensor Range Output Resolution Accuracy
1 Barometric Pressure Sensor 500 to 1100 hPa 4-20 mA, RS232 Serial 0.01 hPa
Analog 0.025% 0.2 hPa (25°C) 0.3 hPa (-40 to +60°C)
2 Temperature (RTD/PTC) -50 to +50 °C 4-20 mA _ ±0.3°C at 0°C
3 Humidity (Capacitive Polymer) 0 to 100 % RH 4-20 mA _ ± 2% RH

[0047] In another aspect, the proposed MPR can include the CPU 114 that is further configured to record and save sensors data, metering data, and protection data onto an SD card 116, for instance. In an aspect, use of Micro SD card offers large space (up to 4GB) to log all events, metering data, protection data, sensors data etc. The string or data format for events, metering data, and protection data can be identified by respective header of the string. Therefore, data format to save data to SD card is user configurable.
[0048] In an aspect, all data can be sent over Ethernet 122 or over a serial port to a remote client. The ease of sending data over Ethernet or over serial port to remote client adds reliability in communication interface. In an instance, COM3 UART can be used for serial communication to remote client and Serial to Ethernet module converts serial data to Ethernet packets.
[0049] FIG. 2 illustrates view 200 that shows the proposed MPR that has an in-built data logger that logs sensor, metering and protection data. Micro SD card is also configured to store processed/output data, which can also be displayed on a suitable display.
[0050] FIG. 3 illustrates an exemplary Micro SD card 300 having connections as shown, wherein the proposed MPR can use an onboard external Micro SD card.
[0051] In an embodiment of the present disclosure, data format for SD card to record/log data can be user configurable. SD cards offer large memory space to log events, metering data, protection data, and sensors data. The string or data format for the said events and data can be identified by respective header of the string. The header for each string or set of data can be decided as per requirement, which makes the data format to save data to Micro SD card user configurable.
[0052] FIG. 4 illustrates view 400 that shows communication interface in accordance to an embodiment of the present disclosure. COM Port can be used for communication to remote client 404, wherein a Serial to Ethernet module converts serial data to Ethernet packets. Serial to Ethernet Port connects Motor Protection Inbuilt Data Logger 402 with Ethernet Switch 406.
[0053] In an aspect, the proposed invention also provides/storesa count of the number of starts/events that have happened with the proposed motor protection relay, which can be done by logging earlier number of starts/events to an external memory provided. Along with this, multiple sensor interface outputs such as of temperature, pressure, humidity etc. are also possible.
[0054] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0055] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0056] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
[0057] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0058] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0059] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0060] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.
ADVANTAGES OF THE INVENTION
[0061] The present disclosure provides a system that monitors real time parameters in order to increase relay reliability.
[0062] The present disclosure provides a system that is cost effective because of less hardware requirements.
[0063] The present disclosure provides a system that is designed to record and display the data logs of all events.
[0064] The present disclosure provides a system which time stamps the logged data.
[0065] The present disclosure provides a system that provides client with output data logged sentences through Ethernet as well as COM port.
[0066] The present disclosure provides a system with user configurable data format for Micro SD card.