Circuit breaker, circuit breaker device and method and system thereof

Abstract

A circuit breaker includes an electromechanical switch, a current sensor, a voltage sensor, and a processor. The electromechanical switch is connected in series between a line input terminal and a load output terminal of the circuit breaker and is configured to be placed in a closed state or an open state. The current sensor is configured to sense a magnitude of current flowing in a path between the line input terminal and the load output terminal and generate a current sense signal. The voltage sensor is configured to sense a magnitude of voltage at a point on the path between the line input terminal and the load output terminal and generate a voltage sense signal. The processor is configured to receive and process the current sense signal and the voltage sense signal to determine operational state information of the circuit breaker and to determine power usage information of a load connected to the load output terminal.

Description

[0001] This application is a divisional application of the patent application with application number 202080051430.X, whose application date is May 18, 2020 and invention name is “Smart Circuit Breaker”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims priority to each of the following applications: (i) U.S. Provisional Application No. 62 / 849,847, filed on May 18, 2019; (ii) U.S. Patent Application No. 16 / 720,446, filed on December 19, 2019, and entitled Intelligent Circuit Breakers; (iii) U.S. Patent Application No. 16 / 720,506, filed on December 19, 2019, and entitled Intelligent Circuit Breakers with Solid-State Bidirectional Switches; (iv) U.S. Patent Application No. 16 / 720,506, filed on December 19, 2019, and entitled Intelligent Circuit Breakers with Air-Gap and Solid-State No. 16 / 720,485, filed on December 19, 2019, entitled "Intelligent Circuit Breakers with Detection Circuitry Configured to Detect Fault Conditions," and (vi) No. 16 / 720,583, filed on December 19, 2019, entitled "Intelligent Circuit Breakers with Visual Indicators to Provide Operational Status," the disclosures of which are hereby incorporated by reference in their entirety. Technical Field

[0004] The present disclosure relates generally to power control systems and devices, and more particularly to circuit breaker devices and systems for protecting branch circuits from damage due to fault conditions. Background Art

[0005] Circuit breakers are essential components in power distribution systems. Generally, circuit breakers are housed in a distribution panel (e.g., a circuit breaker panel) that divides the high current power feed of the utility power system into multiple downstream branch circuits within a given building or home structure. Each circuit breaker is connected between the incoming high current power feed and a corresponding one of the branch circuits to protect the branch circuit conductors and the electrical loads on the branch circuit from exposure to overcurrent conditions. There are several types of overcurrent conditions, including overload conditions and fault conditions. An overload condition is defined as the operation of a device exceeding its normal full load rating, or a branch circuit exceeding the current carrying capacity of the device, which will cause damage or dangerous overheating when the overload lasts for a sufficient period of time. Fault conditions include unexpected or accidental load conditions that typically produce an overcurrent condition much higher than the overload, depending on the impedance of the fault. Faults that produce the largest overcurrent conditions are called short circuits or "bolted faults."

[0006] Conventional circuit breakers are electromechanical in nature and have electrical contacts that physically separate by manual intervention of an operator pulling a lever or automatically separate upon the occurrence of a fault condition or prolonged overcurrent condition, in which case the circuit breaker is considered to be "tripped." Separation of the circuit breaker's electrical contacts may be performed electromagnetically or electromechanically or by a combination of both.

[0007] A significant problem with conventional circuit breakers is that they react slowly to fault conditions due to their electromechanical construction. Conventional circuit breakers typically require at least several milliseconds to isolate a fault condition. The slow reaction time is undesirable because it increases the risk of dangerous fires, damage to electrical equipment, and arc flashes that may occur at the short circuit location when a bolted fault is not isolated quickly enough. An arc flash is an electrical explosion of an electrical conductor that creates a short circuit condition. The energy release in an arc flash can produce temperatures in excess of 35,000°F at the terminals, resulting in rapid vaporization of metal conductors, ejection of molten metal, and expansion of plasma that is ejected outward with great force. As a result, arc flashes are extremely dangerous to life, property, and electrical equipment, particularly in industrial and residential environments where the risk of gas leaks is considerable.

[0008] In addition to being slower in isolating faults, conventional circuit breakers also exhibit large variations in both trip times and current trip limits in response to faults or prolonged overcurrent conditions. This variation is primarily due to limitations in the electromechanical design of the circuit breaker devices and physical factors such as mounting stress and temperature variations. The variations in trip times and current trip limits themselves can vary from device to device, even if the devices are of the same type, have the same rating, and come from the same manufacturer.

[0009] Conventional circuit breakers provide high isolation capabilities once they have tripped. However, their slow reaction time, lack of precision, and high variability are all highly undesirable characteristics. Not only does the slow reaction time result in inadequate protection against the possibility of an arc flash, but the high variability and lack of precision make coordination between multiple circuit breakers in a complex system nearly impossible.

[0010] As a protective device, a circuit breaker must be able to isolate faults from a utility power circuit, even when the fault current greatly exceeds the circuit breaker trip current rating, and thereby prevent internal single-point failures from occurring. The ampere interrupting capacity (AIC) rating of a circuit breaker indicates the maximum fault current (in amperes) that the circuit breaker device will safely clear when a fault occurs at the load side of the circuit breaker device. The AIC rating of a circuit breaker device represents the maximum fault current that can be interrupted by the circuit breaker device without the circuit breaker device failing. The AIC rating requires an extremely high level of short-circuit protection, and the AIC rating of a household circuit breaker is typically 10,000 amperes or higher.

[0011] Conventional circuit breakers do not implement functionality based on intelligent decisions made for disconnecting or isolating the utility power supply from the load, or otherwise monitoring or measuring power components such as voltage and / or current, and making intelligent decisions based on the measurement and calculation of voltage and / or current. In contrast, conventional circuit breakers operate to prevent excessive load power demands (e.g., current overloads, short circuits) based on electromechanical components in which the circuit breaker trips by magnetic or mechanical forces generated by the expansion of bimetallic elements of metals with different thermal expansion parameters. The lack of intelligent tripping operation and the reliance on violent forces generated in the power distribution environment can lead to excessive power conditions such as excessive arcing, slow trip response times, and dangerously high internal operating temperatures. The reliance of conventional circuit breakers on mechanical components such as hooks, springs, etc. to achieve tripping increases the likelihood of disasters regarding fire hazards, device unreliability, and possible loss of human life and property. It is well known that common causes of electrical fires in homes or buildings are unreliable and faulty electromechanical protection devices and circuit breakers. Therefore, there is a desire and need in the circuit breaker and protection device industry to eliminate the use of conventional electromechanical / thermal-magnetic circuit breakers / protectors and implement more reliable and efficient solutions for protection devices. Summary of the invention

[0012] Embodiments of the present disclosure include intelligent circuit breakers and systems and methods for implementing intelligent circuit breakers. For example, one embodiment includes a circuit breaker. The circuit breaker includes an electromechanical switch, a current sensor, a voltage sensor, and a processor. The electromechanical switch is connected in series between the line input terminal and the load output terminal of the circuit breaker and is configured to be placed in one of (i) a closed state and (ii) an open state. The current sensor is configured to sense the magnitude of the current flowing in the electrical path between the line input terminal and the load output terminal and generate a current sensing signal. The voltage sensor is configured to sense the magnitude of the voltage at a point on the electrical path between the line input terminal and the load output terminal and generate a voltage sensing signal. The processor is configured to receive and process the current sensing signal and the voltage sensing signal to determine the operating state information of the circuit breaker and determine the power usage information of the load connected to the load output terminal.

[0013] Another embodiment includes a method comprising: connecting a circuit breaker between a utility power source and a branch circuit including a load, wherein the circuit breaker includes an electromechanical switch configured to be placed in one of the following states: (i) a closed state to connect the utility power source to the branch circuit, and (ii) an open state to disconnect the utility power source from the branch circuit; sensing current through the circuit breaker and generating a current sensing signal indicating the magnitude of the sensed current through the circuit breaker; sensing a voltage at a point on an electrical path through the circuit breaker and generating a voltage sensing signal indicating the magnitude of the sensed voltage; and processing the current sensing signal and the voltage sensing signal to determine operating state information of the circuit breaker and determine power usage information of the load.

[0014] Another embodiment includes a system comprising a circuit breaker distribution panel and a circuit breaker disposed within the circuit breaker distribution panel. The circuit breaker distribution panel includes a busbar coupled to a utility power source. The circuit breaker includes a line input terminal coupled to the busbar, a load output terminal connected to a branch circuit, an electromechanical switch, a current sensor, a voltage sensor, and a processor. The electromechanical switch is configured to be placed in one of the following states: (i) a closed state to connect the utility power source to the branch circuit, and (ii) an open state to disconnect the utility power source from the branch circuit. The current sensor is configured to sense the magnitude of a current flowing in an electrical path between the line input terminal and the load output terminal and generate a current sensing signal. The voltage sensor is configured to sense the magnitude of a voltage at a point on the electrical path between the line input terminal and the load output terminal and generate a voltage sensing signal. The processor is configured to receive and process the current sensing signal and the voltage sensing signal to determine operating state information of the circuit breaker and determine power usage information of a load connected to the load output terminal.

[0015] Another embodiment includes a circuit breaker, comprising a solid-state bidirectional switch, a first switch control circuit, a current sensor, a voltage sensor, and a processor. The solid-state bidirectional switch is connected in series between a line input terminal and a load output terminal of the circuit breaker and is configured to be placed in one of (i) an on state and (ii) an off state. The first switch control circuit is configured to generate a control signal to control the operation of the solid-state bidirectional switch. The current sensor is configured to sense the magnitude of a current flowing in an electrical path between the line input terminal and the load output terminal and generate a current sensing signal. The voltage sensor is configured to sense the magnitude of a voltage at a point on the electrical path between the line input terminal and the load output terminal and generate a voltage sensing signal. The processor is configured to receive and process the current sensing signal and the voltage sensing signal to determine operating state information of the circuit breaker, determine a fault event, and determine power usage information of a load connected to the load output terminal.

[0016] Another embodiment includes a method comprising: connecting a circuit breaker between a utility power source and a branch circuit including a load, wherein the circuit breaker includes a solid-state bidirectional switch configured to be placed in one of the following states: (i) an on state to connect the utility power source to the branch circuit, and (ii) an off state to disconnect the utility power source from the branch circuit; sensing current through the circuit breaker and generating a current sensing signal indicating the magnitude of the sensed current through the circuit breaker; sensing a voltage at a point on an electrical path through the circuit breaker and generating a voltage sensing signal indicating the magnitude of the sensed voltage; generating a control signal to place the solid-state bidirectional switch in an off state in response to detection of a fault event based on at least one of the current sensing signal and the voltage sensing signal; and processing the current sensing signal and the voltage sensing signal to determine operating state information of the circuit breaker and determine power usage information of the load.

[0017] Another embodiment includes a system including a circuit breaker distribution panel and a circuit breaker disposed within the circuit breaker distribution panel. The circuit breaker distribution panel includes a bus coupled to a utility power source. The circuit breaker includes a line input terminal coupled to the bus, a load output terminal connected to a branch circuit, a solid-state bidirectional switch, a first switch control circuit, a current sensor, a voltage sensor, and a processor. The solid-state bidirectional switch is connected in series between the line input terminal and the load output terminal of the circuit breaker and is configured to be placed in one of (i) an on state and (ii) an off state. The first switch control circuit is configured to generate a control signal to control the operation of the solid-state bidirectional switch. The current sensor is configured to sense the magnitude of a current flowing in an electrical path between the line input terminal and the load output terminal and generate a current sensing signal. The voltage sensor is configured to sense the magnitude of a voltage at a point on the electrical path between the line input terminal and the load output terminal and generate a voltage sensing signal. The processor is configured to receive and process the current sensing signal and the voltage sensing signal to determine operating state information of the circuit breaker, determine a fault event, and determine power usage information of a load connected to the load output terminal.

[0018] Another embodiment includes a circuit breaker, which includes a solid-state switch, an air-gap electromagnetic switch, a switch control circuit system, a zero-crossing detection circuit, and a current sensor. The solid-state switch and the air-gap electromagnetic switch are connected in series in an electrical path between a line input terminal and a load output terminal of the circuit breaker. The switch control circuit system is configured to control the operation of the solid-state switch and the air-gap electromagnetic switch. The zero-crossing detection circuit is configured to detect a zero-crossing of an AC power waveform on an electrical path between a line input terminal and a load output terminal of the circuit breaker. The current sensor is configured to sense a current flowing in an electrical path between the line input terminal and the load output terminal, and detect a fault condition based on the sensed current. In response to detecting a fault condition by the current sensor, the switch control circuit system is configured to generate a switch control signal to (i) place the solid-state switch in an off state and (ii) place the air-gap electromagnetic switch in an off state after the solid-state switch is placed in the off state. The switch control circuit system uses the zero-crossing detection signal output from the zero-crossing detection circuit to determine when to place the air-gap electromagnetic switch in an off state.

[0019] Another embodiment includes a method comprising: sensing current flowing in an electrical path between a line input terminal and a load output terminal of a circuit breaker, the circuit breaker comprising a solid-state switch and an air-gap electromagnetic switch connected in series in the electrical path between the line input terminal and the load output terminal of the circuit breaker; detecting a fault condition based on the sensed current; and in response to detecting the fault condition, generating a first switch control signal to place the solid-state switch in an off state; detecting a zero-crossing event of an AC waveform at a point on the electrical path and a polarity of the AC waveform after the zero-crossing event; and in response to detecting that the polarity of the AC waveform after the zero-crossing event causes a body diode of the solid-state switch to be reverse biased, generating a second control signal to place the air-gap electromagnetic switch in an off state.

[0020] Another embodiment includes a system comprising a circuit breaker distribution panel and a circuit breaker disposed within the circuit breaker distribution panel. The circuit breaker distribution panel includes a busbar coupled to a utility power source. The circuit breaker includes a line input terminal coupled to the busbar, a load output terminal connected to a branch circuit, a solid-state switch, an air-gap electromagnetic switch, a switch control circuit system, a zero-crossing detection circuit, and a current sensor. The solid-state switch and the air-gap electromagnetic switch are connected in series in an electrical path between the line input terminal and the load output terminal of the circuit breaker. The switch control circuit system is configured to control the operation of the solid-state switch and the air-gap electromagnetic switch. The zero-crossing detection circuit is configured to detect a zero crossing of an AC power waveform on an electrical path between the line input terminal and the load output terminal of the circuit breaker. The current sensor is configured to sense a current flowing in the electrical path between the line input terminal and the load output terminal, and detect a fault condition based on the sensed current. In response to detecting a fault condition by the current sensor, the switch control circuit system is configured to generate a switch control signal to (i) place the solid-state switch in an OFF state and (ii) place the air-gap electromagnetic switch in an OFF state after the solid-state switch is placed in the OFF state. The switch control circuit system uses a zero-crossing detection signal output from the zero-crossing detection circuit to determine when to place the air-gap electromagnetic switch in the OFF state.

[0021] Another embodiment includes a circuit breaker including a solid-state switch, a sense resistor, a current detection circuit, and a switch control circuit. The solid-state switch and the sense resistor are connected in series in an electrical path between a line input terminal and a load output terminal of the circuit breaker. The current detection circuit is configured to (i) sample a sense voltage generated across the sense resistor in response to a load current flowing through the sense resistor, (ii) detect an overcurrent fault condition based on the sampled sense voltage, and (iii) output a fault detection signal in response to detecting the overcurrent fault condition. The switch control circuit is configured to control the solid-state switch, wherein the switch control circuit is configured to turn off the solid-state switch in response to the fault detection signal output from the current detection circuit.

[0022] Another embodiment includes a circuit breaker including a switch, a sense resistor, a zero crossing detection circuit, and a switch control circuit. The switch and the sense resistor are connected in series in an electrical path between a line input terminal and a load output terminal of the circuit breaker. The zero crossing detection circuit is configured to (i) sample a sense voltage generated across the sense resistor in response to a load current flowing through the sense resistor, (ii) detect a zero crossing of the load current based on the sampled sense voltage, and (iii) output a zero crossing detection signal in response to detecting a zero crossing of the load current. The switch control circuit is configured to control the operation of the switch based on the output of the zero crossing detection circuit.

[0023] Another embodiment includes a circuit breaker, comprising a circuit breaker housing, an air-gap switch disposed within the circuit breaker housing, and a first visual indicator configured to provide an indication of an open state and a closed state of the air-gap switch. The first visual indicator comprises: (i) a first window formed as part of the circuit breaker housing; (ii) a first indicator element disposed within the circuit breaker housing; and (iii) a second indicator element disposed within the circuit breaker housing. The first indicator element is configured to move to a position behind the first window when the air-gap switch is placed in the open state, so that the first indicator element can be viewed through the first window to provide an indication of the open state of the air-gap switch. The second indicator element is configured to move to a position behind the first window when the air-gap switch is placed in the closed state, so that the second indicator element can be viewed through the first window to provide an indication of the closed state of the air-gap switch.

[0024] Another embodiment includes a circuit breaker including a circuit breaker housing, an air gap switch disposed within the circuit breaker housing, an actuator mechanism disposed within the circuit breaker housing, and a first visual indicator configured to provide an indication of a state of the air gap switch. The air gap switch includes a first contact and a second contact disposed in an electrical path between a line input terminal and a load output terminal of the circuit breaker. The air gap switch is coupled to the actuator mechanism, and the actuator mechanism is operatively configured to (i) mechanically force the first contact and the second contact apart to place the air gap switch in an open state and create an air gap in the electrical path, and (ii) mechanically force the first contact and the second contact together to place the air gap switch in a closed state. The first visual indicator includes: (i) a first window formed as part of the circuit breaker housing; (ii) a first indicator element coupled to the actuator mechanism; and (iii) a second indicator element coupled to the actuator mechanism. The actuator mechanism is configured to move the first indicator element into a position behind the first window when the actuator mechanism places the air-gap switch in an open state, so that the first indicator element is viewable through the first window to provide an indication of the open state of the air-gap switch. The actuator mechanism is configured to move the second indicator element into a position behind the first window when the actuator mechanism places the air-gap switch in a closed state, so that the second indicator element is viewable through the first window to provide an indication of the closed state of the air-gap switch.

[0025] Another embodiment includes a circuit breaker, comprising a solid-state switch, an air gap switch, an actuator mechanism, a manual control switch, an electromechanical actuator, a control circuit system, and a sensor switch. The solid-state switch and the air gap switch are connected in series in an electrical path between a line input terminal and a load output terminal of the circuit breaker. The air gap switch comprises a first contact and a second contact. The actuator mechanism is operatively configured to (i) mechanically force the first contact and the second contact to separate to place the air gap switch in an open state and create an air gap in the electrical path, and (ii) mechanically force the first contact and the second contact together to place the air gap switch in a closed state. The manual control switch is operatively coupled to the actuator mechanism and is configured to switch between a first position and a second position, wherein switching the manual control switch to the first position causes the actuator mechanism to place the air gap switch in an open state. The electromechanical actuator is operatively coupled to the actuator mechanism, wherein actuation of the electromechanical actuator causes the actuator mechanism to place the air gap switch in an open state. The control circuit system is configured to control the operation of the solid-state switch and the electromechanical actuator, wherein the control circuit system is configured to generate: (i) a first control signal configured to place the solid-state switch in one of an on state and an off state, and (ii) a second control signal configured to control actuation of the electromechanical actuator. The sensor switch is operatively coupled to the manual control switch and electrically connected to the control circuit system, wherein the sensor switch is configured to (i) detect a switching of the manual control switch from a second position to a first position, the switching causing the actuator mechanism to place the air gap switch in an off state, and (ii) in response to detecting the switching of the manual control switch from the second position to the first position, output a third control signal to the control circuit system. In response to the third control signal, the control circuit system is configured to generate the first control signal to place the solid-state switch in an off state before the air gap switch is placed in an off state to create an air gap in the electrical path.

[0026] Another embodiment includes a circuit breaker device, which includes a line live terminal, a line neutral terminal, a load live terminal and a load neutral terminal, a solid-state switch, an air gap electromagnetic switch, an internal switch and a shunt resistor, a switch control circuit system, and a fault detection circuit system. The solid-state switch and the air gap electromagnetic switch are connected in series between the line live terminal and the load live terminal. The internal switch and the shunt resistor are connected in series between a first node and a second node, wherein the first node includes a point along an electrical path between the line live terminal and the load live terminal, and wherein the second node includes a point along an electrical path between the line neutral terminal and the load neutral terminal. The switch control circuit system is configured to control the operation of the solid-state switch and the internal switch. The fault detection circuit system is configured to detect a fault condition and generate a fault detection control signal in response to the detection of the fault condition. The switch control circuit system is configured to place the solid-state switch in an off state in response to the fault detection control signal. The switch control circuit system is further configured to activate the internal switch and thereby generate an internal short circuit path in response to the fault detection control signal, wherein the shunt resistor is connected between the first node and the second node, and causes the internal short circuit current to flow through the air gap electromagnetic switch. The internal short circuit current is sufficient to trip the air gap electromagnetic switch and thereby generate an air gap in the electrical path between the line live terminal and the load live terminal.

[0027] Another embodiment includes a method comprising: sensing a current flowing in an electrical path between a line hot terminal and a load hot terminal of a circuit breaker device, wherein the circuit breaker device includes a solid-state switch and an air-gap electromagnetic switch connected in series in the electrical path between the line hot terminal and the load hot terminal of the circuit breaker device; detecting a fault condition based on the sensed current; and in response to detecting the fault condition, (i) applying a first switch control signal to the solid-state switch to place the solid-state switch in an off state; and (ii) applying a second switch control signal to an internal switch to activate the internal switch and thereby generate an internal short-circuit path within the circuit breaker device and generate an internal short-circuit current flowing through the air-gap electromagnetic switch. The flow of the internal short-circuit current causes the air-gap electromagnetic switch to trip and thereby generate an air gap in the electrical path between the line hot terminal and the load hot terminal of the circuit breaker device.

[0028] Another embodiment includes a system including a circuit breaker panel including a line hot bus and a line neutral bus coupled to a utility power source, and a circuit breaker device disposed within the circuit breaker panel. The circuit breaker device includes a line hot terminal coupled to the line hot bus, a line neutral terminal coupled to the line neutral bus, and a load hot terminal and a load neutral terminal connected to a branch circuit. The circuit breaker device further includes: a solid-state switch and an air-gap electromagnetic switch, the solid-state switch and the air-gap electromagnetic switch are connected in series between the line live terminal and the load live terminal; an internal switch and a shunt resistor, the internal switch and the shunt resistor are connected in series between a first node and a second node, wherein the first node includes a point along the electrical path between the line live terminal and the load live terminal, and wherein the second node includes a point along the electrical path between the line neutral terminal and the load neutral terminal; a switch control circuit system, which is configured to control the operation of (i) the solid-state switch and (ii) the internal switch; and a fault detection circuit system, which is configured to detect a fault condition and generate a fault detection control signal in response to the detection of the fault condition. The switch control circuit system is configured to place the solid-state switch in an off state in response to the fault detection control signal. The switch control circuit system is configured to activate the internal switch in response to the fault detection control signal and thereby generate an internal short circuit path, wherein the shunt resistor is connected between the first node and the second node, and causes the internal short circuit current to flow through the air-gap electromagnetic switch. The internal short circuit current is sufficient to trip the air gap electromagnetic switch and thereby create an air gap in the electrical path between the line hot terminal and the load hot terminal.

[0029] Other embodiments will be described in the following detailed description of the embodiments, which is to be read in conjunction with the accompanying figures. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1A A schematic circuit diagram of a conventional thermal-magnetic circuit breaker.

[0031] Figure 1B for Figure 1A A perspective view of a housing of a conventional circuit breaker.

[0032] Figure 2A is a schematic block diagram of an intelligent circuit breaker including an electromechanical switch according to an embodiment of the present disclosure.

[0033] Figure 2B is a schematic block diagram of an intelligent circuit breaker including an electromechanical switch according to another embodiment of the present disclosure.

[0034] Figure 3A is a schematic block diagram of an intelligent circuit breaker including a solid-state bidirectional switch according to an embodiment of the present disclosure.

[0035] Figure 3Bis a schematic block diagram of an intelligent circuit breaker including a solid-state bidirectional switch according to another embodiment of the present disclosure.

[0036] Figure 4A is a schematic block diagram of an alternating current to direct current (AC to DC) converter circuit that may be implemented in a smart circuit breaker according to an embodiment of the present disclosure.

[0037] Figure 4B According to the embodiment of the present disclosure Figure 4A A schematic circuit diagram of an AC to DC converter circuit.

[0038] Figure 5 FIG. 4 is a schematic circuit diagram of an AC to DC circuit that can be implemented in a smart circuit breaker according to another embodiment of the present disclosure.

[0039] Fig. 6A is a schematic circuit diagram of a solid-state bidirectional switch that can be implemented in a smart circuit breaker according to an embodiment of the present disclosure.

[0040] Figure 6B During the positive half cycle of the AC mains voltage applied to the solid state bidirectional switch Fig. 6A The active element of a solid-state bidirectional switch.

[0041] Figure 6C FIG. 4 is a schematic circuit diagram of a solid-state bidirectional switch that can be implemented in a smart circuit breaker according to another embodiment of the present disclosure.

[0042] Fig.6D FIG. 4 is a schematic circuit diagram of a solid-state bidirectional switch that can be implemented in a smart circuit breaker according to another embodiment of the present disclosure.

[0043] Fig. 6E FIG. 4 is a schematic circuit diagram of a solid-state bidirectional switch that can be implemented in a smart circuit breaker according to another embodiment of the present disclosure.

[0044] Fig. 6F FIG. 4 is a schematic circuit diagram of a solid-state bidirectional switch that can be implemented in a smart circuit breaker according to another embodiment of the present disclosure.

[0045] Figure 6G FIG. 4 is a schematic circuit diagram of a solid-state bidirectional switch that can be implemented in a smart circuit breaker according to another embodiment of the present disclosure.

[0046] Figure 6H FIG. 4 is a schematic circuit diagram of a solid-state bidirectional switch that can be implemented in a smart circuit breaker according to another embodiment of the present disclosure.

[0047] Fig. 7A and 7B A switch control circuit system for controlling a solid-state bidirectional switch according to an embodiment of the present disclosure is schematically illustrated, wherein:

[0048] Fig. 7A is a schematic block diagram of a control circuit system for controlling a solid-state bidirectional switch that can be implemented in an intelligent circuit breaker according to an embodiment of the present disclosure; and

[0049] Figure 7B According to the embodiment of the present disclosure Fig. 7A Schematic circuit diagram of the control circuit system.

[0050] Fig. 8A FIG. 4 is a greatly simplified schematic diagram of an intelligent circuit breaker according to another embodiment of the present disclosure.

[0051] Figure 8B is a greatly simplified schematic illustration of a smart circuit breaker including an isolation circuit system configured to electrically isolate the smart circuit breaker from a load according to an embodiment of the present disclosure,

[0052] Fig. 9A , 9B 9C schematically illustrate an integrated current sensor and energy metering circuit that may be implemented in a smart circuit breaker according to an embodiment of the present disclosure, wherein:

[0053] Fig. 9A A schematic diagram of a power supply block and a current sensor block of a current sensor and energy metering circuit;

[0054] Fig. 9B A schematic diagram of an overcurrent detection block for a current sensor and energy metering circuit; and

[0055] Fig. 9C Schematic diagram of the energy metering block of the current sensor and energy metering circuit.

[0056] Fig.10 The present invention is a flowchart of a method for controlling switches of an intelligent circuit breaker in response to detection of a fault condition according to an embodiment of the present disclosure.

[0057] Fig.11 A state diagram illustrating a control process implemented by a smart circuit breaker to detect and prevent a fault condition according to an embodiment of the present disclosure.

[0058] Fig.12 An intelligent power distribution and monitoring system using an intelligent circuit breaker according to an embodiment of the present disclosure is schematically illustrated.

[0059] Fig.13 FIG. 4 is an exploded view of a housing structure that can be used to accommodate a switch and an intelligent circuit system of an intelligent circuit breaker according to an embodiment of the present disclosure.

[0060] Fig.14Flowchart of a process implemented by a smart circuit breaker to monitor energy usage on a branch circuit and prevent fault conditions from occurring on the branch circuit according to an embodiment of the present disclosure.

[0061] Fig.15 Flowchart of a process implemented by a smart circuit breaker to monitor energy usage on a branch circuit and prevent fault conditions from occurring on the branch circuit according to an embodiment of the present disclosure.

[0062] Fig.16 The present invention is a schematic block diagram of an intelligent circuit breaker configured to identify the type of load connected to the circuit breaker and control the load based on the identified load type according to an embodiment of the present disclosure.

[0063] Fig.17 The present invention is a flowchart of a method for load identification and control process implemented by an intelligent circuit breaker according to an embodiment of the present disclosure.

[0064] Fig.18A A schematic block diagram of an intelligent circuit breaker configured to monitor ground fault and arc fault conditions and provide circuit interruption in response to detected fault conditions according to an embodiment of the present disclosure.

[0065] Fig.18B According to the embodiment of the present disclosure Fig.18A Schematic circuit diagram of an intelligent circuit breaker.

[0066] Fig.19 According to the embodiment of the present disclosure, Fig.18B A schematic block diagram of a fault detection processor implemented in an intelligent circuit breaker.

[0067] Fig. 20 A current zero-crossing detector circuit according to an embodiment of the present disclosure is schematically illustrated.

[0068] Fig.21A and 21B Description of the embodiment according to the present disclosure Fig. 20 Various waveforms of the operating modes of the current zero-crossing detection circuit, where:

[0069] Fig.21A Description Fig. 20 A waveform of an operating mode of an edge detection stage; and

[0070] Fig.21B Description of the embodiments according to the present disclosure Fig. 20 The simulated signal waveform of the operation mode of the current zero-crossing detection circuit.

[0071] Fig. 22 A short circuit detection circuit according to an embodiment of the present disclosure is schematically illustrated.

[0072] Fig.23 Description of the embodiments according to the present disclosure Fig. 22 The simulated signal waveform of the operation mode of the short-circuit detection circuit.

[0073] Fig.24 An intelligent circuit breaker according to another embodiment of the present disclosure is schematically illustrated.

[0074] Fig.25A Description Input Fig.24 The power supply voltage waveform on the line side of the intelligent circuit breaker.

[0075] Fig.25B Description: When the solid-state switch of the intelligent circuit breaker is in the off state and the air gap electromagnetic switch of the intelligent circuit breaker is in the closed state Fig.24 Output voltage waveform on the load side of the smart circuit breaker.

[0076] Fig.26 According to the embodiment of the present disclosure, Fig.24 Flow chart of the switch control process implemented by the switch controller of the intelligent circuit breaker.

[0077] Fig. 27 An intelligent circuit breaker according to another embodiment of the present disclosure is schematically illustrated.

[0078] Fig.28A , 28B , 28C, 28D and 28E are perspective views and schematic diagrams of an intelligent circuit breaker including a plurality of visual indicators configured to indicate an operating status of the intelligent circuit breaker according to another embodiment of the present disclosure.

[0079] Fig.29 An intelligent circuit breaker according to another embodiment of the present disclosure is schematically illustrated. DETAILED DESCRIPTION

[0080] Embodiments of the present disclosure will now be described in more detail with respect to smart circuit breakers and systems and methods for implementing smart circuit breakers. It should be understood that the same or similar reference numerals are used throughout the drawings to represent the same or similar features, elements, or structures, and therefore, the detailed explanation of the same or similar features, elements, or structures will not be repeated for each of the drawings. In addition, the terms "about" or "substantially" as used herein with respect to percentages, ranges, etc., are meant to represent close or approximate, but not completely. For example, the terms "about" or "substantially" as used herein imply that there is a small error tolerance, such as 1% or less than the stated amount. The term "exemplary" as used herein means "serving as an example, example, or illustration". Any embodiment or design described herein as "exemplary" should not be interpreted as being more preferred or advantageous than other embodiments or designs.

[0081] Figure 1A and 1B A conventional thermal-magnetic circuit breaker 100 is schematically illustrated, wherein Figure 1A is a schematic circuit diagram of a thermal-magnetic circuit breaker 100, and Figure 1B FIG. 1 is a perspective view of the housing 101 of the thermal-magnetic circuit breaker 100. Specifically, Figure 1A A thermal-magnetic circuit breaker 100 is illustrated as being connected between a utility power source 110 (referred to herein as AC mains 110) and a load 120 connected to a branch circuit protected by the circuit breaker 100. Figure 1A It is further described in that the circuit breaker 100 is typically connected between the hot phase 111 (called the “line live wire”) of the AC mains 110 and the load live wire 121 of the load 120, while the middle phase 112 (called the “line neutral wire”) of the AC mains 110 is directly connected to the load neutral wire 122 of the load 120.

[0082] The circuit breaker 100 includes an electromechanical switch 102 that is manually opened and closed by means of a manual switch mechanism (not shown). The electromechanical switch 102 is mechanically coupled 104 to a thermomagnetic actuator that includes a solenoid 106 connected in series with the switch 102 and a bimetallic element 108 (which is heated by a resistive element) also connected in series with the switch 102. The mechanical coupling 104 is configured so that a transient current flowing from a hot phase 111 exceeding a first threshold (e.g., exceeding the current rating of the circuit breaker 100) causes the solenoid 106 to separate the contacts of the switch 102, thereby breaking the circuit and "tripping" the circuit breaker 100. The solenoid 106 (e.g., an electromagnet) asserts a pulling force that increases with current. The circuit breaker contacts are held closed by a latch. When the current in the solenoid 106 increases beyond the rating of the circuit breaker, the pulling force of the solenoid releases the latch, which causes the contacts to open by spring action.

[0083] In addition, the mechanical coupling 104 is configured so that a long-term overcurrent at a second lower threshold causes the bimetallic element 108 to separate the contacts of the switch 102 and thereby trip the circuit breaker 100. The bimetallic element 108 responds to less extreme but long-term overcurrent conditions. The thermal mechanism of the circuit breaker 100 provides a time response feature that trips the circuit breaker 100 earlier in the case of a larger overcurrent, but allows a smaller overload to last longer. This allows for short current spikes, such as those generated when a motor or other non-resistive load is turned on. In this regard, the solenoid 106 (electromagnet mechanism) responds instantaneously to large surges in current (short circuits), and the bimetallic element 108 responds to less extreme but long-term overcurrent conditions. Once tripped, the circuit breaker 100 must be manually reset using a manual switch mechanism.

[0084] like Figure 1AAs further described in , the line neutral 112 is typically joined to a ground 114 (GND) in the circuit breaker distribution panel, and a ground connection 116 is formed by the ground bar in the circuit breaker distribution panel to the load 120. The ground connection 116 provides an alternative low resistance path for the ground fault return current to flow in the event of a ground fault event at the load 120. The ground connection 116 can be used in other circuit breaker or outlet designs that provide protection, such as arc fault sensing and arc fault circuit interruption (AFCI), and ground fault sensing and ground fault circuit interruption (GFCI). In addition, the line neutral ( Figure 1A or Figure 1B ) will be included in a circuit breaker 100 designed to provide AFCI and GFCI protection.

[0085] Figure 1B A conventional housing 101 for residential circuit breakers, typically manufactured using molded plastic components, is illustrated. In some embodiments, the smart circuit breaker is implemented using a standard housing for residential and / or commercial applications to allow the smart circuit breaker to be backward compatible with existing housings and retrofit into existing distribution panels. Those skilled in the art will recognize that the circuits, algorithms, heat exchangers, and other aspects of the disclosed technology can be adjusted to various form factors required in other locations or countries. It is contemplated herein that the inventive method does not require the use of conventional style circuit breaker elements, for example, and in particular, does not use conventional circuit breaker housings.

[0086] According to embodiments of the present disclosure, smart circuit breakers are designed to provide high isolation capabilities while having relatively fast reaction times to isolate short circuit conditions, overcurrent conditions, and other types of faults more quickly than conventional circuit breakers. Smart circuit breakers are designed to have real-time programmable time-current characteristics, and are more accurate and less variable than conventional circuit breakers. For example, in some embodiments, smart circuit breakers implement low-power solid-state bidirectional switches that achieve fast reaction times to isolate faults on high-energy branch circuits. Smart circuit breakers are designed to communicate with smart devices that are connected to provide support for multiple failure points, independent of the location where the circuit breaker is installed, thereby allowing the impedance of the short-circuited conductor to be reduced.

[0087] Compared to conventional circuit breakers, the smart circuit breaker according to the embodiment of the present disclosure provides increased safety, extended convenience, increased energy perception, control, energy saving and improved situational awareness. As further explained in detail below, the smart circuit breaker implements various functionalities and control circuits to implement intelligent processing, including AC mains switching technology, AC to DC conversion technology, internal short circuit tripping technology, technology for wirelessly communicating status and sensor data to achieve a variety of innovative use cases, algorithms for detecting faults, technologies for detecting and preventing internal device failures, technologies for handling new types of loads through air protocol updates, technologies for exchanging thermal energy, technologies for cloud services supporting remote notification, control, monitoring and big data collection even during the event of a collapsed utility, circuit technologies for shunt resistor current sensing, energy metering and overcurrent detection, and technologies for avoiding fault conditions. These technologies are novel technologies in themselves, but their real impact in solving challenges such as increased safety, extended convenience, increased control, energy perception, energy saving and improved situational awareness lies in their combination.

[0088] Figure 2A is a schematic block diagram of an intelligent circuit breaker according to an embodiment of the present disclosure. Specifically, Figure 2A The smart circuit breaker 200 connected between the AC mains 110 and the load 120 is schematically illustrated. The smart circuit breaker 200 includes an electromechanical AC switch 202, a current sensor 204, a first voltage sensor 206, a second voltage sensor 208, an AC to DC converter circuit system 210, a processor 220, a processor reset switch 222, and a radio frequency (RF) transceiver 230 with an associated antenna 232. The electromechanical AC switch 202 is connected in series between the line input terminal and the load output terminal of the circuit breaker 200, wherein the line live wire 111 of the AC mains 110 is connected to the line input terminal and the load live wire 121 of the load 120 is connected to the load output terminal. When the electromechanical AC switch 202 is in a closed state, the line live wire 111 of the AC mains 110 is connected to the load live wire 121. In this embodiment, the line neutral 112 (which is, for example, joined to a ground 114 in a circuit breaker distribution panel) serves as a low-side voltage reference (eg, ground) for the electronic circuitry of the smart circuit breaker 200 .

[0089] In some embodiments, the electromechanical AC switch 202 includes a Figure 1AThe thermal-magnetic trip and switch mechanism of the thermal-magnetic circuit breaker 100 discussed above is the same or similar, wherein the electromechanical AC switch 202 includes a thermal switching mechanism (e.g., a bimetallic switch) and an electromagnetic switching mechanism (e.g., a solenoid). The electromechanical AC switch 202 is configured to automatically provide an "open" circuit when an operator manually disables the hot line path using a manual switch (or actuator pull rod) or when a fault condition (e.g., a short circuit condition, an overcurrent condition, etc.) is detected by the electromechanical AC switch 202.

[0090] The processor 220 operates in conjunction with the current sensor 204 and the first and second voltage sensors 206 and 208 to perform functions such as monitoring energy utilization and detecting fault conditions. For example, in some embodiments, the processor 220 is configured to detect (via software and / or hardware) the presence of a fault condition (e.g., a short circuit condition, an overcurrent condition, an overvoltage condition, etc.) in the load 120 or an internal fault condition within the smart circuit breaker 200, and generate a control signal on the control line 202-1 to cause the electrical contacts of the electromagnetic assembly (e.g., a solenoid) to open and thereby disconnect the line hot wire 111 from the load hot wire 121. In other embodiments, the smart circuit breaker 200 includes additional sensor circuitry and / or processing functionality to support arc fault circuit interruption and / or ground fault circuit interruption functions using, for example, the techniques discussed herein.

[0091] The processor 220 may be implemented using one or more processing architectures. For example, the processor 220 may include a central processing unit, a microprocessor, a microcontroller, an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a system on a chip (SOC), and other types of processors, as well as parts or combinations of such processors that may perform processing functions based on software, hardware, firmware, etc. In some embodiments, the solid-state circuit systems of the various components (e.g., 204, 206, 208, 210, 220, and / or 230) of the smart circuit breaker 200 may be implemented on a single die as a system on a chip. In some embodiments, the solid-state circuit systems of the various components (e.g., 204, 206, 208, 210, 220, and / or 230) of the smart circuit breaker 200 may be implemented on one or more separate dies that are integrally packaged as a multi-chip module (e.g., a system package), thereby providing a high-density heterogeneous integration solution.

[0092] The processor 220 utilizes the RF transceiver 230 to wirelessly communicate with remote nodes, devices, systems, etc. to support remote monitoring of energy utilization and detection of fault conditions. The processor reset switch 222 is used to reset the state of the processor 220 in certain circumstances, such as when the DC power supply of the processor 220 is powered off, etc. In some embodiments, the processor reset switch 222 includes a manual result switch that is mechanically coupled to a manual switch lever mechanism (e.g., an actuator lever) of the electromechanical AC switch 202, so that manual resetting of the switch lever after a trip event also causes mechanical activation of the processor reset switch 222.

[0093] The current sensor 204 and the voltage sensors 206 and 208 are configured to sense and detect conditions indicating an open circuit or damaged or failed internal components of the smart circuit breaker 200, and to provide a timing sequence for safe opening and closing of the circuit. Specifically, the current sensor 204 is configured to detect the magnitude of the current drawn by the load 120 in the live line path through the smart circuit breaker 200. The current sensor 204 can be implemented using any suitable type of current sensing circuit, including but not limited to a current sensing resistor, a current amplifier, a Hall effect current sensor, etc. The current sensor 204 is coupled to the processor 220 via one or more data acquisition and control lines 204-1.

[0094] The first voltage sensor 206 and the second voltage sensor 208 are configured to monitor voltage at different points along the live line path through the circuit breaker 200. For example, Figure 2A As shown in FIG. 1 , a first voltage sensor 206 is coupled to the live line path upstream of the electromechanical AC switch 202 to monitor the AC power voltage of the AC mains 110, and a second voltage sensor 208 is coupled to the live line path downstream of the electromechanical AC switch 202 to monitor the load voltage on the branch circuit connected to and protected by the smart circuit breaker 200. The voltage sensors 206 and 208 are coupled to the processor 220 via one or more data acquisition and control lines 206-1 and 208-1, respectively.

[0095] Voltage sensors 206 and 208 may be implemented using any suitable type of voltage sensing circuitry, including but not limited to zero crossing detector circuitry. The zero crossing detector is configured to receive an AC waveform as an input, compare the input AC waveform to a zero reference voltage (e.g., line neutral voltage), and detect transitions of the AC waveform from positive and negative that coincide when the AC waveform crosses the zero reference voltage. In some embodiments, the zero crossing detector circuitry is configured to generate a square wave output that transitions between a logic "1" and a logic "0" output upon each zero crossing detection of the AC voltage waveform. In other embodiments, the zero crossing detector circuitry is configured to generate a short pulse (~3us) with an RC adjustable duration.

[0096] The AC to DC converter circuitry 210 is configured to provide DC power to various circuitry and elements of the smart circuit breaker 200, including the current sensor 204, the voltage sensors 206 and 208, the processor 220, and the RF transceiver 230. The AC to DC converter circuitry 210 maintains power during a fault when the electromechanical AC switch 202 is in an open state. In some embodiments, the AC to DC converter circuitry 210 includes sufficient storage capacitance to power the DC subsystem immediately after a utility outage, so that relevant power outage or short circuit information can be obtained and stored by the processor 220 when the utility power collapses and then wirelessly transmitted to a remote node, device or system using the RF transceiver 230. The AC to DC converter circuitry 210 may also include sufficient capacitance to power the DC subsystem during a load short circuit event without being pulled down by the collapse voltage of the live line and the load, so that the load can be intentionally disconnected to prevent damage during an out-of-range voltage event.

[0097] Figure 2B is a schematic block diagram of an intelligent circuit breaker according to another embodiment of the present disclosure. Specifically, Figure 2B The intelligent circuit breaker 201 connected between the AC mains 110 and the load 120 is schematically illustrated. The intelligent circuit breaker 201 is similar to Figure 2A The difference is that the smart circuit breaker 201 includes a current sensor and energy metering circuit system 240, a fuse 250, and an internal shorting switch 260. The current sensor and energy metering circuit system 240 is configured to detect the magnitude of the current drawn by the load 120 in the live line path through the circuit breaker 201, and implement a programmable overcurrent detection system and a smart energy metering circuit system. Fig. 9A , 9B 9C discuss an exemplary embodiment of the current sensor and energy metering circuit system 240.

[0098] Fuse 250 is implemented to protect circuit breaker 201 from internal failure or to provide a simple end-of-life deactivation mechanism, for example, in the event of a device failure. Figure 2B , an internal shorting switch 260 is connected between the AC hot line path of the circuit breaker 201 and the line neutral 112, wherein the internal shorting switch 260 is connected to the AC hot line path at a point between the fuse 250 and the electromechanical AC switch 202. The internal shorting switch 260 is responsive to a control signal generated by the processor 220 and applied to the shorting switch 260 via a switch control line 220-1. In this configuration, the processor 220 may implement an end-of-life disabling mechanism, for example, in the event of a device failure, wherein the processor 220 outputs a control signal on the control line 220-1 to activate the internal shorting switch 260 and blow the fuse 250 to disable the smart circuit breaker 201. In other embodiments, the end-of-life deactivation mechanism may be implemented by configuring the processor 220 to generate a control signal that, for example, maintains the electromechanical AC switch 202 in a closed state at any time after a device failure has been detected, or that immediately causes the electromechanical AC switch 202 to trip (and be placed in an open state) any time an individual attempts to close the circuit breaker (via activation of a manual switch) after a device failure has been detected.

[0099] In other embodiments, an internal shorting switch may be implemented in a smart circuit breaker as a mechanism to internally trigger a fault to trip the electromechanical AC switch 202. Figure 2A and 2B In an exemplary embodiment of the present invention, an internal shorting switch may be connected between the AC hot line path and the line neutral 112 on the load side of the electromechanical AC switch 202. The processor 220 may be configured to generate a switch control signal to activate the internal shorting switch and generate a short circuit fault condition at the load side of the electromechanical AC switch 202, and thereby trip the electromechanical AC switch 202. In this configuration, the processor 220 may detect the presence of an unsafe condition or an internal circuit breaker failure based on sensor data generated by the current and / or voltage sensors 240, 206, and 208, and then generate a control signal to activate the internal shorting switch 260 and thereby trip the electromechanical AC switch 202. In addition, the internal shorting trigger event may be triggered in response to the processor 220 receiving a remote command to disconnect or in response to detecting an unsafe local condition such as overheating, excessive moisture, or device failure.

[0100] Figure 3A is a schematic block diagram of an intelligent circuit breaker according to another embodiment of the present disclosure. Specifically, Figure 3AThe intelligent circuit breaker 300 connected between the AC mains 110 and the load 120 is schematically illustrated. The intelligent circuit breaker 300 includes an air gap electromagnetic switch 302, a solid-state bidirectional switch 304, a switch control circuit system 306 configured to control the operation of the air gap electromagnetic switch 302, a manual switch 307 allowing a user to manually open and close the air gap electromagnetic switch 302, and a switch control circuit system 308 configured to control the operation of the solid-state bidirectional switch 304. In addition, similar to Figure 2A An exemplary embodiment of Figure 3A The smart circuit breaker 300 includes a current sensor 204, a first voltage sensor 206, a second voltage sensor 208, an AC to DC converter circuit system 210, a processor 220, a processor reset switch 222, and an RF transceiver 230 and an associated antenna 232, which are configured to perform the same or similar functions as discussed above. In other embodiments, as mentioned above, an external DC power supply can be implemented to provide DC power to the solid-state circuit system and components of the smart circuit breaker 300.

[0101] In some embodiments, the air gap electromagnetic switch 302 includes any suitable type of electromagnetic trip and mechanical switch mechanism configured to physically open and close a set of electrical contacts, wherein an air gap is created between the electrical contacts when the air gap electromagnetic switch 302 is in an open state. For example, the air gap electromagnetic switch 302 may include a latching solenoid or a relay element that responds to a control signal from the switch control circuit system 306 to automatically open or close the electrical contacts of the air gap electromagnetic switch 302. In some embodiments, the switch control circuit system 306 and the air gap electromagnetic switch 302 are configured so that the electrical contacts of the air gap electromagnetic switch 302 can be automatically opened by the switch control circuit system 306, but not automatically closed by the operation of the switch control circuit system 306. In this example, the electrical contacts of the air gap electromagnetic switch 302 are manually closed by the operation of the manual switch 307.

[0102] In some embodiments, the switch control circuit system 308 is responsive to control signals from one or more of the sensors (e.g., current sensor 204, voltage sensors 206 and 208, etc.) to determine when to open the air gap electromagnetic switch 302 in response to a fault condition detected by the sensors. In some embodiments, the switch control circuit system 306 is responsive to control signals received from the processor 220 (on control line 306-1) to control the opening of the air gap electromagnetic switch 302 in response to a fault condition, such as a short circuit fault, an overcurrent fault, and other faults detected by the processor 220 as a result of the processor 220 analyzing sensor data obtained from the current sensor 204 and the voltage sensors 206 and 208, etc.

[0103] In addition, the air gap electromagnetic switch 302 includes a manual switch 307 that enables an individual to manually open or close the electrical contacts of the air gap electromagnetic switch 302 and thereby manually place the air gap electromagnetic switch 302 in an open or closed state. The state (activation or deactivation) of the manual switch 307 can be detected by the processor 220 based on an electrical signal present on a sensing line 307-1 connected between the manual switch 307 and the processor 220. The creation of an air gap in the line path between the line hot wire 111 and the load hot wire 121 provides complete isolation of the AC mains 110 from the load 120 and prevents the flow of current from the line hot wire 111 to the load 120 (and also prevents the flow of leakage current that may be generated by the solid-state bidirectional switch 304 when the solid-state bidirectional switch 304 is in the off state).

[0104] like Figure 3A As shown in FIG. 1 , the air gap electromagnetic switch 302 is connected in series with the solid state bidirectional switch 304 between the line input terminal and the load output terminal of the intelligent circuit breaker 300. The air gap electromagnetic switch 302 can be disposed on the line side of the solid state bidirectional switch 304 (e.g. Figure 3A ) or on the load side of the solid-state bidirectional switch 304. The solid-state bidirectional switch 304 includes an electrically controlled solid-state switching device such as a power metal oxide semiconductor field effect transistor (MOSFET) device and associated bias circuitry. Figures 6A to 6H Exemplary embodiments of the solid state bidirectional switch 304 are discussed in further detail. The semiconductor MOSFET device may be a silicon based solid state device or a silicon carbide (SiC) or gallium arsenide (GaN) based solid state device.

[0105] The solid-state bidirectional switch 304 is controlled by the switch control circuitry 308 to place the solid-state bidirectional switch 304 in an on state or an off state in response to a gate control signal generated by the switch control circuitry 308. In some embodiments, the switch control circuitry 308 is responsive to a control signal received from the processor 220 (on the control line 308-1) to turn off the solid-state bidirectional switch 304 in response to a fault condition, such as a short circuit fault, an overcurrent fault, and other faults detected by the processor 220 as a result of the processor 220 analyzing sensor data obtained from the current sensor 204 and the voltage sensors 206 and 208.

[0106] In other embodiments, the switch control circuit system 308 includes a control circuit system that responds to control signals generated by the current sensor 204 (and other sensors, such as the voltage sensors 206 and 208) in response to the detection of a fault condition and transmitted to the switch control circuit system 308 on the control line 204-1. The switch control circuit system 308 responds to such control signals to generate a gating control signal to control the activation and deactivation of the solid-state bidirectional switch 304. In other embodiments, the switch control circuit system 308 includes a short circuit detection circuit system that is configured to detect a load-side short circuit fault and automatically deactivate the solid-state bidirectional switch 304 in response to the detected short circuit fault. Fig. 7A and 7B An exemplary embodiment of switch control circuitry 308 including short circuit detection circuitry is discussed in further detail. Additionally, switch control circuitry 308 is configured to control a drive voltage of solid-state bidirectional switch 304 for the purpose of controlling and minimizing leakage of solid-state bidirectional switch 304 when switch 304 is in an off state.

[0107] It should be appreciated that the implementation of the solid-state bidirectional switch 304 allows the smart circuit breaker 300 to quickly respond to impending fault conditions, such as overcurrent fault conditions, load-side short circuit fault conditions, internal fault conditions, overvoltage conditions, etc., through rapid deactivation of the solid-state bidirectional switch 304. In fact, the response time for deactivating the solid-state bidirectional switch 304 to isolate the fault condition can be about 1000 times faster than the response time associated with the automatic tripping of the electromechanical AC switch to isolate the fault condition (e.g., about a few milliseconds) because the solid-state bidirectional switch 304 can transition from the on state to the off state in about microseconds or nanoseconds. As another advantage, the solid-state bidirectional switch 304 has a more accurate and repeatable time-current characteristic curve compared to conventional electromechanical circuit breakers. This allows for more precise control of the current conducted by the solid-state bidirectional switch 304 compared to conventional electromechanical circuit breakers that have time-current characteristics that vary over their lifetime.

[0108] In some embodiments, the control logic implemented by the processor 220 of the smart circuit breaker 300 is configured to issue a switch control signal to the switch control circuit system 306 so that the air gap electromagnetic switch 302 is placed in the open state in response to the solid-state bidirectional switch 304 being placed in the off state. In some embodiments, the control logic implemented by the processor 220 is configured to issue a switch control signal to the switch control circuit system 306 so that the air gap electromagnetic switch 302 is placed in the closed state before the solid-state bidirectional switch 304 is placed in the on state. In addition, the processor 220 is configured to monitor and detect a manual switch disconnection event, wherein the manual switch 307 of the air gap electromagnetic switch 302 is actuated to manually disconnect the electrical contacts of the air gap electromagnetic switch 302. In response to the manual switch disconnection event, the processor 220 will generate a control signal and output it to the switch control circuit system 308 to place the solid-state bidirectional switch 304 in the off state.

[0109] The switch timing control scheme as outlined above prevents or minimizes the generation of arcs between the electrical contacts of the air-gap electromagnetic switch 302 by ensuring that: (i) the air-gap electromagnetic switch 302 is placed in the closed state before placing the solid-state bidirectional switch 304 in the on state, and (ii) the solid-state bidirectional switch 304 is automatically placed in the off state prior to the opening of the electrical contacts of the air-gap electromagnetic switch 302 in response to detection of a manual operator disconnecting the air-gap electromagnetic switch 302 and thereby deactivating the solid-state bidirectional switch 304. In another embodiment, the switch control scheme is configured to operate the intelligent circuit breaker 300 in a "standby" state, wherein the solid-state bidirectional switch 304 is in the off state, and the air-gap electromagnetic switch 304 is in the closed state.

[0110] With such a switch control configuration, the electrical contacts of the air gap electromagnetic switch 302 are configured to support high energy flow in the closed state, but can be designed to move only during low current conditions to prevent or minimize arcing between the electrical contacts. For example, a switch control scheme can be implemented in which the air gap electromagnetic switch 302 is actuated when the magnitude of the current on the live line path is less than a preselected value. Preventing arcing within the air gap electromagnetic switch 302 enables miniaturization of the air gap electromagnetic switch 302.

[0111] The implementation of the air gap electromagnetic switch 302 provides additional safety features for the smart circuit breaker 301. For example, the air gap electromagnetic switch 302 provides a fault protection mechanism for fault isolation in the event of a fault in the solid-state bidirectional switch 304. By analyzing the real-time sensor data obtained from the various sensors 204, 206, and 208, the processor 220 can be configured to detect a failure state of the solid-state bidirectional switch 304 or otherwise detect a potential overcurrent or short circuit fault condition. In such an example, the processor 220 can generate a control signal and output it to the switch control circuit system 306 to place the air gap electromagnetic switch 302 in an open state.

[0112] In some embodiments, the current sensor 204 includes a sense resistor connected in series in the live line path. As explained in further detail below, the sense resistor is configured to generate a load voltage or sense voltage due to the load current flowing through the sense resistor, wherein the load voltage or sense voltage is measured and processed by one or more detection circuits (e.g., current sensor circuit, short circuit detection circuit, energy metering circuit, etc.) to detect fault conditions and directly control the solid-state switch without the assistance of a processor. This allows faster reaction time by avoiding the uncertain time of the processor or CPU response.

[0113] Additionally, when the air gap switch 302 is placed in the open state, the air gap switch 302 provides galvanic isolation between the AC mains 110 and the load 120. With the air gap formed, no current can flow from the AC mains 110 to the load 120. Such galvanic isolation prevents unwanted current flow due to leakage current of the solid-state bidirectional switch 304 when the solid-state bidirectional switch 304 is in the off state.

[0114] As with other embodiments discussed herein, the processor 220 may be implemented using one or more processing architectures (e.g., CPU, microprocessor, microcontroller, ASIC, etc.). In some embodiments, the solid-state circuitry of the various components (e.g., 204, 206, 208, 210, 220, 230, 306, and / or 308) of the smart circuit breaker 300 may be implemented on a single die as a system on a chip. In some embodiments, the solid-state circuitry of the various components (e.g., 204, 206, 208, 210, 220, 230, 306, and / or 308) of the smart circuit breaker 230 may be implemented on one or more separate dies that are integrally packaged as a multi-chip module (e.g., a system in package), thereby providing a high-density heterogeneous integration solution.

[0115] Figure 3B is a schematic block diagram of an intelligent circuit breaker according to another embodiment of the present disclosure. Specifically, Figure 3BThe intelligent circuit breaker 301 connected between the AC mains 110 and the load 120 is schematically illustrated. The intelligent circuit breaker 301 includes intelligent circuit breakers 201 and 300 ( Figure 2B and 3A ), and therefore a detailed description of the various components and associated functionality will not be repeated. The intelligent circuit breaker 301 includes a snubber 310, which is connected between the live path and the neutral path to protect the internal components from damage due to energy kickback from the inductive load. The snubber 310 can be placed on the line and / or load side of the switches 302 and 304. The snubber located on the line side of the switches 302 and 304 allows the snubber to protect the internal circuit only when the switches 302 and 304 are in the off state and the on state, respectively. However, as Figure 3B The snubber 310 shown in FIG. 1 on the load side of switches 302 and 304 helps eliminate the possibility of arcing within the air gap electromagnetic switch 302 during an inductive load kickback event. Figure 2A , 2B and 3A smart circuit breaker embodiments implementing the buffer.

[0116] In other embodiments, an external DC power supply may be implemented to provide DC power to the Figure 2A , 2B , 3A and 3B (as well as other embodiments of the circuit breakers discussed below). For example, a distribution panel in which the smart circuit breakers are installed may have a DC battery and a DC power bus configured to distribute DC power to the smart circuit breakers within the distribution panel. In this example, the DC battery may be coupled to an AC to DC converter that is configured to convert AC power from the AC mains 110 into DC power for charging the DC battery.

[0117] Although Figure 2A , 2B, 3A and 3B illustrate a processor reset switch 222 for resetting the processor 220, but it should be understood that the processor reset switch 222 is an optional feature and other mechanisms may be implemented for achieving a processor reset. In some embodiments, the processor 220 includes an internal reset circuit that is configured to reset the processor 220 in certain situations, such as when there is a DC power outage to the processor 220 or when there is an internal fault condition of the processor 200. In some embodiments, the processor is configured to generate a "CPU_OK" signal output on the control lines 306-1 and 308-1 to the switch control circuit systems 306 and 308. The CPU_OK signal provides an indication of whether the processor 220 and associated software are operating normally. When the CPU_OK signal indicates that the processor 200 and / or associated software are not operating normally, the switch control circuit systems 306 and 308 will automatically place the solid-state bidirectional switch 304 in the off state and then place the air gap electromagnetic switch 302 in the open state (to create an air gap for galvanic isolation). This provides a hardware fault protection mechanism to ensure that the smart circuit breaker does not service the load if the processor 220 or its subsystems are not operating properly.

[0118] For example, in some embodiments, the internal reset circuitry of the processor 220 includes a watchdog timer and appropriate architectural software configured to service the watchdog timer (e.g., reset the watchdog timer) when all subsystems within the firmware of the processor 220 are determined to be operating correctly. In some embodiments, the watchdog timer includes a resistor / capacitor network that implements a unique clock. When the watchdog timer is enabled, the timer counts from an initial value to a final count value. If the watchdog timer is not initialized to the initial count value before reaching the final count value, the processor 220 will be reset. The processor 220 will be reset due to an AC (and therefore DC) power outage or an internal fault condition that causes the watchdog timer to reach the final count value, in which case a control signal is generated that causes the processor 220 to reset.

[0119] More specifically, in some embodiments, the internal reset circuit of the processor 220 operates as follows. When DC power is first applied to the processor 220, the processor will perform a self-test and initialization routine. If the self-test and initialization routine is successfully completed, the processor 220 will output a logic "1" CPU_OK control signal to indicate that the processor 220 and the embedded software are operating correctly. The logic "1" CPU_OK control signal is input to the switch control circuit system 306 and 308 to indicate that the switches 302 and 304 can be safely activated to serve the load 120. On the other hand, the logic "0" CPU_OK control signal indicates to the switch control circuit system 306 and 308 that the switches 320 and 304 should be deactivated or should not be activated (if deactivated when CPU_OK is confirmed to be a logic "0" level). After a reset of the processor 220 (e.g., a power-on reset or a forced reset due to a determined internal processor fault), the control signal CPU_OK remains at a logic "0" level until the processor 220 is reset and determined to be fully functional and operating as expected.

[0120] The software of the processor 220, as part of its normal operation, continuously monitors several points in the firmware to ensure that all subsystems of the processor 220 are operating properly as expected. If all monitored points are determined to be operating correctly, the watchdog timer is serviced (e.g., the counter is reset to an initial value). If any of the monitored points is determined to be non-functional or operating incorrectly, the watchdog timer will not be serviced, and the watchdog timer will eventually reach its maximum count value. In some embodiments, the watchdog timer has a count sequence that defines a time of approximately 1 second. If the watchdog timer is not serviced by the reset control software of the processor 220, the watchdog timer will "trigger" and reset the processor 220 after 1 second, which causes the CPU_OK control signal to transition to a logic "0" level. The transition of the CPU_OK signal from logic "1" to logic "0" triggers the switch control circuit system 306 and 308 to place the solid-state bidirectional switch 304 in the off state and the air gap electromagnetic switch 302 in the open state.

[0121] Additionally, in some embodiments, as part of the reset sequence of the processor 220, there is a hardware indication (designed into the processor 220) that indicates whether the processor reset was caused by a watchdog timer reset or a power-on reset. If the processor reset was caused by a power-on reset, the firmware of the processor 220 will continue with the normal boot initialization process. On the other hand, if the processor reset was triggered by the watchdog timer, the firmware of the processor 220 will continue with the "recovery from watchdog timer reset" initialization path instead of normal boot initialization. To the user, the watchdog timer reset appears like a normal over-current "trip" condition (communicating to the cloud or remote computing device that the processor reset was caused by an internal watchdog timer reset).

[0122] Through this reset sequence, the firmware will determine whether the number of consecutive watchdog timer resets has exceeded a predefined threshold number (e.g., 5). If the number of consecutive watchdog timer resets is determined to exceed the predefined threshold number, an internal failure or internal fault condition will be declared, and the smart circuit breaker will be disabled until it is serviced and the counter is reset. In this example, the processor firmware will declare an internal failure and report the error via cloud notification, status LED, and other available user interfaces, and will not allow the smart circuit breaker to be manually turned on until it is serviced. On the other hand, if the number of consecutive watchdog timer resets has not exceeded the predetermined threshold number, the smart circuit breaker can be manually reset after the watchdog timer reset.

[0123] In other words, the watchdog timer reset event appears like a "normal overcurrent trip" by design, and is the result of the processor firmware executing immediately after the reset. The processor firmware will determine whether the processor reset was caused by the watchdog timer, and if so, perform recovery by simulating a "trip" event, communicating to the cloud to indicate the watchdog timer reset event, and allowing normal operation to continue once the air gap switch 302 is manually or automatically placed in a closed state via a control signal, if so specified. If the processor 220 is no longer functional once the watchdog timer triggers (or when power is (re)applied), the unit will be completely non-functional, with AC shutoff to the load guaranteed by design. In the rare case where the processor 220 becomes non-functional immediately after the watchdog timer reset, there will be no communication of the event to the cloud, so the communication to the cloud is part of the "recovery" path during initialization.

[0124] Figure 2A , 2BThe exemplary embodiments of the smart circuit breakers of 3A and 3B provide various advantages over conventional circuit breaker designs. For example, the implementation of voltage and current sensors, processors, wireless communication subsystems enables the smart circuit breaker to sense the operating conditions of the circuit breakers and loads and wirelessly communicate which circuit breaker has tripped, making it easier to identify within the circuit breaker panel. This can be expanded by adding LED signals at the front panel controlled by the processor. Features are achieved by adding an AC to DC converter circuit that maintains power during a fault event.

[0125] In addition, smart circuit breakers can save time in life safety applications, such as when circuits are overloaded or nearly overloaded in hospitals and similar applications such as military command and control facilities. The available information wirelessly notifies maintenance technicians or electricians in such environments of impending or existing faults to direct them to the problematic load, without the need for local affected personnel to contact maintenance personnel for support. The speed with which the load is analyzed and cleared, and the circuit breaker is re-energized or prevented from opening, can be critical to the successful treatment of a patient or the continuation of a critical job function. In some embodiments, wireless communication with the smart circuit breaker allows a technician or electrician to remotely re-energize the load using predetermined commands to remotely control the smart circuit breaker.

[0126] As a third example, in Figure 3A and 3B Solid-state switch technology implemented in smart circuit breakers can, for example, Figure 1A The solid-state switch disconnects the fault approximately 1000 times faster than the electromechanical equivalent in the embodiment of the present invention, and has increased reliability due to the arc-free, non-moving nature of solid-state electronics. The increased speed further reduces the possibility of damage to circuits, electrical devices, loads, fire, and personal injury. In some embodiments, during the collapse of AC power that occurs during a short circuit current at the load, the solid-state switch disconnects in less than one cycle.

[0127] Figure 4A 4 is a schematic block diagram of an AC to DC converter circuit 400 that can be implemented in a smart circuit breaker according to an embodiment of the present disclosure. The AC to DC converter circuit 400 includes an architecture that does not require a rectifier to generate a DC voltage. The AC to DC converter circuit 400 includes a surge protection circuit 410, a sampling circuit 420, a switch driver circuit 430, a control switch and clamp circuit 440, a storage circuit 450, a voltage regulator circuit 460, and a galvanic isolation circuit 470. The AC to DC converter circuit 400 generates a DC supply voltage that is applied to a load circuit system 402.

[0128] The surge protection circuit 410 is configured to limit the magnitude of the input current to the AC to DC converter circuit 400. The sampling circuit 420 is configured to sample the AC power voltage waveform of the AC mains 110. The sampling circuit 420 outputs the sampled voltage to the switch driver circuit 430. The switch driver circuit 430 is configured to apply a control voltage to the control switch of the control switch and clamp circuit 440. The control switch and clamp circuit 440 are configured to supply power to the storage circuit 450 in response to the control voltage applied by the switch driver circuit 430. The storage circuit 450 includes a voltage storage element (e.g., a capacitor) configured to store a DC voltage applied to the voltage regulator circuit 460. The voltage regulator circuit 460 is configured to generate a regulated DC power voltage to the load circuit system 402.

[0129] In some embodiments, switch driver circuit 430 receives feedback voltage 480 from storage circuit 450 and generates a control voltage applied to control switch and clamp circuit 440 based at least in part on feedback voltage 480. In some embodiments, feedback voltage 480 can be eliminated and AC to DC converter circuit 400 operates as a feed-forward converter in which the storage element of storage circuit 450 is controlled from front-side elements 420, 430, and 440.

[0130] In some embodiments, the AC to DC converter circuit system 400 implements a feedback control circuit 490 from the load circuit system 402 to the switch driver circuit 430 to support both feedforward and feedback control. In some embodiments, the balance of feedforward and feedback control is determined by the selection of the feedback voltage 480 and the components in the sampling circuit system 420. In some embodiments, the balance between feedforward and feedback control is configured according to the resistor element and the feedback voltage 480 in the sampling circuit system 420. In other embodiments, variable elements are utilized to achieve adjustment of the feedforward and feedback control. In such embodiments, the feedback circuit 490 will include galvanic isolation between the switch driver circuit 430 and the load circuit system 402.

[0131] Figure 4B According to the embodiment of the present disclosure Figure 4A A schematic circuit diagram of an AC to DC converter circuit. Figure 4BIn an exemplary embodiment of the present invention, the surge protection circuit system 410 includes a first input resistor 411 connected to the line hot line 111 of the AC mains 110 and a second input resistor 412 connected to the line neutral line 112 of the AC mains 110. In other embodiments, for high power and high efficiency applications, the surge protection circuit system 410 includes a switching element that is configured to allow current to flow through the resistors 411 and 412 at startup, and then bypass the resistors 411 and 412 once steady-state operation is reached. In other embodiments, the surge protection circuit system 410 includes a first inductor element and a second inductor element instead of the first resistor 411 and the second resistor 412.

[0132] The sampling circuit system 420 includes a plurality of resistors 421, 422, 423, and 424 connected to various nodes N1, N2, N3, and N4 as shown. The resistors 421, 422, and 423 form a voltage divider network for sampling an input AC waveform, wherein the voltage divider network includes a feedback node N2 and an output node N3. The resistor 424 is connected between the feedback node N2 and the output node N4 of the storage circuit system 450 to provide a feedback voltage from a storage capacitor 452. The switch driver circuit system 430 includes a resistor 431 connected between nodes N1 and N5, and a switch element 432. The control switch and clamp circuit system 440 includes a control switch element 441, a resistor 442, and a Zener diode 443. The storage circuit system 450 includes a diode 451 and a storage capacitor 452. The voltage regulator circuit system 460 includes a switch element 461, a resistor 462, a Zener diode 463, and a capacitor 464.

[0133] In some embodiments, the switch elements 432, 441, and 461 include Figure 4B 4. In other embodiments, the switch elements 432, 441 and 461 may be implemented using bipolar transistors or micro-electromechanical switches. Figure 4B , the switch element 443 includes a gate terminal G connected to the output node N3 of the voltage divider network of the sampling circuitry 420, a drain terminal D connected to the output node N5 of the switch driver circuitry 430, and a source terminal S connected to the output node N3 of the surge protection circuitry 410. The drain terminal D of the switch element 432 is coupled to the output node N1 of the surge protection circuitry 410 through the resistor 431.

[0134] The control switch 441 includes a drain terminal D connected to the output node N1 of the surge circuit system 410, a gate terminal G connected to the output node N5 of the switch driver circuit system, and a source terminal S connected to the input of the storage circuit system 450 (i.e., the anode of the diode 451). The Zener diode 443 is connected between the gate terminal G and the source terminal S of the control switch 441, wherein the cathode of the Zener diode 443 is connected to the gate terminal G of the control switch 441 and the anode of the Zener diode 443 is connected to the source terminal S of the control switch 441.

[0135] The switch element 461 of the voltage regulator circuit system 460 includes a drain terminal D connected to the output node N4 of the storage circuit system 450, a gate terminal G connected to the node N7 between the resistor 462 and the Zener diode 463, and a source terminal S connected to the output node N8 of the voltage regulator circuit system 460. The capacitor 464 is connected between the output node N8 of the voltage regulator circuit system 460 and the output node N6 of the surge protection circuit system 410.

[0136] Resistor 424 (or sense resistor) is connected between output node N4 of storage circuitry 450 to provide a feedback voltage that is applied to feedback node N2 of sampling circuitry 420 through resistor 424. The feedback path provided by the connection of resistor 424 between nodes N4 and N2 provides a feedback path such as Figure 4A An exemplary embodiment of a feedback voltage 480 is shown in which the charge of a storage capacitor 452 is partially utilized to generate a control voltage at an output node N3 of the sampling circuitry 420 connected to a gate terminal G of a switching element 432 of the switch driver circuitry 430 .

[0137] The switch element 432 is driven by a gate control voltage generated at the output node N3 of the voltage divider network of the sampling circuit system 420. The gating of the switch element 432 controls the operation of the control switch 441 of the switch driver circuit system 430. The resistance values ​​of the resistors 421, 422, 423 and 424 are selected so that the voltage on the node N3 of the voltage divider network applied to the gate terminal G of the switch element 432 in the switch driver circuit system 430 will turn the switch element 432 on and off and thereby synchronously turn on and off the control switch element 441. The control switch element 441 is thereby driven to output a preselected timed output pulse to charge the storage capacitor 452.

[0138] The peak output current of the control switch 441 is clamped to a preselected value based on a preselected value of the Zener voltage (ie, reverse breakdown voltage) of the Zener diode 443, where the maximum gate-source voltage (V GS) is limited by the Zener voltage of Zener diode 443. The pulse output from control switch 441 operates to turn on diode 451 and supply charge to node N4 to charge storage capacitor 452. Feedback provided by resistor 424 connected between output node N4 of storage circuitry 450 and feedback node N2 of sampling circuitry 420 is used to drive switch driver circuit 430 to maintain storage capacitor 452 at a constant charge.

[0139] Switching element 432 and control switch 441 are activated (opened or closed) when synchronized with the AC voltage input. AC to DC converter circuit 400 provides a low voltage output with pulse modulation at the frequency of the incoming AC power supply. Switches 432 and 441 are activated (opened or closed) at a voltage close to the zero crossing of the AC power supply within the threshold voltage of switches 432 and 441. The output node N4 of storage circuit system 450 is applied to the input of voltage regulator circuit system 460 and then applied to load circuit 402. Capacitor 464 provides storage capacity to buffer and thereby smooth the output from AC to DC converter 400 to load circuit system 402.

[0140] In summary, if Figure 4A and 4B The exemplary AC to DC converter circuit 400 shown in FIG. 4 includes a surge protection circuit 410, a voltage sampling circuit 420, a switch driver circuit 430, a control switch and clamp circuit 440, a storage circuit 450, and a voltage regulator circuit 460. The selection of components in the voltage sampling circuit 420 determines the timing of the switch driver 430. The selection of components of the control switch and clamp circuit 440 determines the peak voltage and current of the output pulse. The power output is controlled by selecting both the peak current and the pulse timing. The pulse timing is selected using feedback from the storage element 452 through the voltage sampling circuit 420. The AC to DC converter circuit 400 operates synchronously with the AC voltage waveform of the AC mains 110.

[0141] In other embodiments, Figure 2A , 2B, 3A and 3B (and other embodiments of the smart circuit breaker as discussed below) can be implemented using DC power conversion technology that is the same or similar to the technology disclosed in the following co-pending applications: (1) U.S. patent application No. 16 / 092,263, entitled High-Efficiency AC to DC Converter and Methods, filed on October 9, 2018 (Publication No.: US 2019 / 0165691); and (2) U.S. patent application No. 16 / 340,672, entitled High-Efficiency AC Direct to DC Extraction Converter and Methods, filed on April 9, 2019 (Publication No.: US2019 / 0238060), the disclosures of which are all fully incorporated herein by reference.

[0142] Figure 5 FIG. 5 is a schematic circuit diagram of an AC to DC converter circuit 500 that can be implemented in a smart circuit breaker according to another embodiment of the present disclosure. Specifically, Figure 5 An exemplary embodiment of a sample and hold AC to DC converter circuit 500 that can be implemented using techniques as disclosed in U.S. patent application Ser. No. 16 / 029,546, filed on July 7, 2018, and entitled Method and Apparatus for Signal Extraction with Sample and Hold and Release, the disclosure of which is incorporated herein by reference in its entirety, is schematically illustrated. The AC to DC converter circuit 500 is configured to generate a DC supply voltage from an AC voltage waveform of an AC mains 110. The AC to DC converter circuit 500 includes a first resistor 501 and a second resistor 502, a first switch 510, a second switch 512, a controller 520, a diode 530, a storage capacitor 540, a voltage regulator 550, and an output capacitor 560. In Figure 5 In the exemplary embodiment of , the first switch 510 and the second switch 512 include N-type enhancement MOSFETs having a gate terminal G, a drain terminal D, and a source terminal S as illustrated.

[0143] Resistors 501 and 502 form a voltage divider circuit with an output node N1 driving a gate terminal G of a first switch 510. A source terminal S of the first switch 510 is connected to neutral / ground 114, and a drain terminal D of the first switch 510 is connected to a gate terminal G of a second switch 512 and to a controller 520. A drain terminal D of the second switch 512 is connected to line hot 111, and a source terminal S of the second switch 512 is connected to an input of the controller 520. The controller 520 has an output connected to an anode of a diode 530. The diode 530 and the storage capacitor 540 form a similar Figure 4B In addition, the voltage regulator 550 and the output capacitor 560 form a storage circuit similar to Figure 4B A voltage regulator circuit of the voltage regulator circuit shown in .

[0144] Now combine Figures 6A to 6H In more detail, Figure 3A and 3B 0044] An exemplary embodiment of a solid-state bidirectional switch 304 as shown in (and as implemented in other exemplary embodiments discussed below). For example, Fig. 6A is a schematic circuit diagram of a solid-state bidirectional switch 600 - 1 that can be implemented in a smart circuit breaker according to an embodiment of the present disclosure. Specifically, Fig. 6A A method for controlling the AC power delivered from the AC mains 110 to the load 120 is described. Figure 3A and 3B . The solid-state bidirectional switch 600-1 is configured to allow bidirectional flow of current between the AC mains 110 and the load 120 (i.e., conduct positive current or negative current) when the solid-state bidirectional switch 600-1 is in the on state, and to block positive or negative current between the AC mains 110 and the load 120 when the solid-state bidirectional switch 600-1 is in the off state.

[0145] The solid-state bidirectional switch 600-1 includes a first MOSFET switch 601 and a second MOSFET switch 602, which are connected in series back-to-back along a live line path between the line live line 111 and the load live line 121. In some embodiments, the first MOSFET switch 601 and the second MOSFET switch 602 include power MOSFET devices having a gate terminal (G), a drain terminal (D), and a source terminal (S) as shown, and specifically, N-type enhancement MOSFET devices. Fig. 6A In the exemplary embodiment of (and other embodiments discussed herein), the solid-state bidirectional switch 600 - 1 is implemented using two N-channel MOSFET switches 601 and 602 having commonly connected source terminals.

[0146] The first MOSFET switch 601 and the second MOSFET switch 602 include intrinsic body diodes 601-1 and 602-1, respectively, which represent the PN junction between the P-type substrate body and the N-doped drain region of the MOSFET device. The body diodes 601-1 and 602-1 are intrinsic elements (i.e., non-discrete elements) of the MOSFET switches 601 and 602, and are therefore shown with a dashed connection. It should be noted that the intrinsic body-source diodes of the MOSFET switches 601 and 602 are not shown because they are shorted by the connection between the source region and the substrate body (e.g., the N+ source and P body junctions are shorted by the source metallization).

[0147] The solid-state bidirectional switch 600-1 further includes a first resistor 603 and a second resistor 604, a first rectifier diode 605 and a second rectifier diode 606, a Zener diode 608, and a single-pole single-throw (SPST) switch element 607. The first resistor 603 and the first rectifier diode 605 are connected in series between the drain terminal (D) and the gate terminal (G) of the first MOSFET switch 601. The second resistor 604 and the second rectifier diode 606 are connected in series between the drain terminal (D) and the gate terminal (G) of the second MOSFET switch 602. The switch 607 and the Zener diode 608 are connected in parallel between the commonly connected source terminal (S) and the commonly connected gate terminal (G) of the first MOSFET switch 601 and the second MOSFET switch 602, wherein the anode of the Zener diode 608 is connected to the source terminal, and the cathode of the Zener diode 608 is connected to the gate terminal.

[0148] Zener diode 608 includes a threshold voltage V greater than the threshold voltage V of power MOSFET switches 601 and 602. T The reverse breakdown voltage (called the "Zener voltage" V Z ). During the on-state of the solid-state bidirectional switch 600-1, the Zener diode 608 is "reversely" biased by a first bias branch circuit including a first resistor 603 and a first rectifier diode 605 connected in series or by a second bias branch circuit including a second resistor 604 and a second rectifier diode 606 connected in series. The first rectifier diode 605 and the second rectifier diode 606 are coupled to the drain terminals D of the power MOSFET switches 601 and 602, respectively, and are protected by the first resistor 603 and the second resistor 604, respectively, to limit the amount of current flowing through the first rectifier diode 605 and the second rectifier diode 606.

[0149] The solid-state bidirectional switch 600-1 generally operates as follows. Fig. 6A, the first bias branch (603-605) and the second bias branch (604-606) provide a "reverse bias" to the Zener diode 608 when the drain terminal D exceeds the Zener voltage, thereby placing the power MOSFET switches 601 and 602 in the "on" state. When the switch 607 is in the "closed" state, the switch 607 shunts the bias current from the first bias branch (603-605) and the second bias branch 604-608 to the source S terminal of the power MOSFET switches 601 and 602, which causes the MOSFET switches 601 and 602 to be placed in the "off" state. In this circuit configuration, the "on" time constant is determined by the value of the current limiting resistors 603 and 604 and the gate-source capacitance of the power MOSFET switches 601 and 602, while the "off" time constant is determined by the intrinsic capacitance of the MOSFET switches 601 and 602 and the on-resistance of the switch 607. The "on" and "off" time constants can be designed to be much shorter than the period of the AC mains 110, which allows the solid-state bidirectional switch 600-1 to operate in both on-off and phase control modes. However, in practice, the Zener diode 608 may never reach its Zener voltage, and the gate-source voltage of the MOSFET switches 601 and 602 will rarely exceed the threshold voltage V T Therefore, neither MOSFET switch 601 nor 602 may be fully “ON”, resulting in excessive power dissipation in the cell and reduced current supplied to load 120 .

[0150] Figure 6B The following illustrates the positive half cycle of the AC mains 110 power supply voltage waveform applied to the solid-state bidirectional switch 600-1. Fig. 6A The active element of the solid-state bidirectional switch 600-1. When the switch 607 is in the off state to allow the first MOSFET switch 601 to turn on, the gate voltage of the first MOSFET switch 601 begins to follow the positive offset of the power supply voltage waveform of the AC mains 110 when the power supply voltage increases from zero volts. When the gate voltage reaches the threshold voltage of the first MOSFET switch 601, current begins to flow to the load 120, and the body diode 602-1 of the second MOSFET switch 602 is forward biased. The source voltage of the first MOSFET switch 601 "follows" the increased gate voltage, but lags behind the value of the threshold voltage plus the additional bias to take into account the current supplied to the load 120. This situation is maintained until the voltage waveform of the AC mains 110 becomes negative. Therefore, the drain-source-source voltage of the first MOSFET switch 601 is never lower than the threshold voltage, regardless of the drain-source resistance of the first MOSFET switch 601, so that the power dissipated in the first MOSFET switch 601 is (I D ×V T ), where ID is the drain current. If the gate voltage rises well above the threshold voltage, the power dissipated is given by (I D 2 × ds ) is given by, where r ds is the “on” resistance of the first MOSFET switch 601, where (I D 2 × ds ) can be significantly smaller than (I D ×V T ) value.

[0151] On the other hand, during the negative half cycle of the power supply voltage waveform of the AC mains 110 applied to the solid-state bidirectional switch 600-1, the active components of the solid-state bidirectional switch 600-1 include the body diode 601-1 of the first MOSFET switch 601, the Zener diode 608, the second MOSFET switch 602, and the second branch elements 604 and 606. The gate voltage of the second MOSFET switch 602 starts at 0V and decreases to a negative threshold voltage (-V T ) begins to follow the negative source voltage, where current begins to flow through the load 120 and the body diode 601-1 of the first MOSFET switch 601 is forward biased. The drain voltage of the second MOSFET switch 602 is effectively clamped to the gate voltage, so that the drain-source voltage V DS Keep at -V T , until the power voltage waveform of the AC mains 110 becomes positive. Therefore, V DS never falls below the threshold voltage except around the zero crossing of the supply voltage waveform of the AC mains 110, regardless of the drain-source resistance of the second MOSFET switch 602, and the power dissipated in the negative half cycle is (I D ×V T ).

[0152] Figure 6C FIG. 6 is a schematic circuit diagram of a solid-state bidirectional switch 600-2 that can be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. The solid-state bidirectional switch 600-2 is similar in circuit configuration to FIG. Fig. 6A The solid-state bidirectional switch 600-2 is similar to the solid-state bidirectional switch 600-1, except that the solid-state bidirectional switch 600-2 implements a single-pole double-throw (SPDT) switch element 612 instead of the SPST switch 607, and further includes a capacitor 613 connected in parallel with the Zener diode 608. The bipolar switch 612 is controlled by a switch control circuit 610 coupled to the bipolar switch 612 via a control line 610-1. In some embodiments, the switch control circuit 610 includes Figure 3A and 3B. The switch control circuit 610 operates the bipolar switch 612 to selectively connect the gate G terminals of the first MOSFET switch 601 and the second MOSFET switch 602 to (i) the source S terminals of the first MOSFET switch 601 and the second MOSFET switch 602 (“position 1”) or to (ii) the bias circuit system including the first resistor 603 and the second resistor 604, the first rectifier diode 605 and the second rectifier diode 606, and the capacitor 613 (“position 2”).

[0153] When the switch 612 is set to position 1, the first MOSFET switch 601 and the second MOSFET switch 602 are maintained in the "off" state. The switch control circuit 610 is configured to maintain the switch 612 in position 1 until the power voltage waveform of the AC mains 110 exceeds the pre-established trigger level V TRIG , then switch 612 is set to position 2. In this example, during the positive half cycle of AC mains 110, switch control circuit 610 operates switch 612 to maintain first MOSFET switch 601 and second MOSFET switch 602 in the "off" state until the AC mains voltage waveform reaches V TRIG This allows the bias circuitry 603, 605, 613 to charge to V TRIG , while the source S terminal of the first MOSFET switch 601 remains at 0 volts.

[0154] When switch 612 is placed in position 2, the bias voltage V TRIG Applied to the gate terminal of the first MOSFET switch 601, whereby the bias voltage value is comparable to the threshold voltage V T The source terminal of the first MOSFET switch 601 starts to move toward V TRIG -V T The voltage is charged, and part of this voltage step is coupled to the gate terminal of the first MOSFET switch 601 through capacitor 613. This increases the gate bias to well beyond V TRIG , so that it exceeds the voltage value of the AC power supply 601. Therefore, the first MOSFET switch 601 reaches a state where the drain-source voltage is almost zero and the gate-source voltage is greater than V TRIG In this state, the first MOSFET switch 601 exhibits its minimum channel resistance R DS , and the maximum voltage is presented across the load 120.

[0155] Fig.6D FIG. 6 is a schematic circuit diagram of a solid-state bidirectional switch 600-3 that can be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. The solid-state bidirectional switch 600-3 is similar in circuit configuration to FIG. Figure 6C The invention provides a solid-state bidirectional switch 600-2, wherein the bipolar switch 612 is implemented using a first control switch 621 and a second control switch 622 controlled by a switch control circuit 620. The switch control circuit 620 includes a first control line 620-1 coupled to the first control switch 621, and a second control line 620-2 coupled to the second control switch 622. In some embodiments, the first control switch 621 and the second control switch 622 include optical transistors (e.g., optical bipolar junction transistors).

[0156] The switch control circuit 620 monitors the voltage level of the power supply voltage waveform on the line hot path 111. When the voltage level remains below a predetermined trigger level V TRIG , the switch control circuit 620 outputs an optical control signal on the control line 620-1 to drive the first control switch 621 (i.e., maintain the switch 621 in the "on" state), while the second control switch 622 is maintained in the off state. On the other hand, when the voltage level exceeds the predetermined trigger level trigger level V TRIG , the switch control circuit 620 outputs the optical control signal on the control line 620-2 to drive the second control switch 622 (i.e., maintain the second control switch 622 in the "on" state), while the first control switch 621 is maintained in the off state. In some embodiments, the switch control circuit 620 is configured so that the optical driver control signal outputs 620-1 and 620-2 do not overlap, thereby providing a "break before make" switching characteristic, which avoids discharging the capacitor 613 prematurely.

[0157] Fig. 6E FIG. 6 is a schematic circuit diagram of a solid-state bidirectional switch 600-4 that can be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. The solid-state bidirectional switch 600-4 is similar in circuit configuration to FIG. Fig. 6A The solid-state bidirectional switch 600-1 is different in that the solid-state bidirectional switch 600-4 includes a capacitor 613 connected in parallel with the Zener diode 608, and the second bias branch including the second resistor 604 and the second rectifier diode 606 is connected to the line nerve 112 of the AC mains 110 instead of being connected to the drain terminal D of the second MOSFET switch 602.

[0158] The configuration of the solid-state bidirectional switch 600-4 avoids Fig. 6A The clamping action occurs and allows the source terminal S of the second MOSFET switch 602 to drop to -V Z When the Zener diode 608 reaches its Zener voltage V Z This allows the gate-source voltage of the second MOSFET switch 602 to be significantly greater than V T V Z, which results in a relatively small drain-source resistance (R DS ) and reduce power dissipation. In addition, the increased gate-source bias is stored on the intrinsic gate-source capacitance of the MOSFET switches 601 and 602 and the capacitor 613 and is maintained during the subsequent positive half cycle of the supply voltage waveform of the AC mains 110. Therefore, both MOSFET switches 601 and 602 maintain minimum R DS Configuration until switch 607 is closed.

[0159] The first resistor 603 and the first rectifier diode 605 (bias branch element) are maintained to improve the initial turn-on characteristics during the positive half cycle, and the additional capacitor 613 in parallel with the intrinsic gate-source capacitance of the MOSFET switches 601 and 602 allows the storage of the increased gate-source bias voltage to be more stable. When the solid-state bidirectional switch 600-4 is utilized in the phase control mode, the switch 607 is closed for a predetermined period during each cycle of the power supply voltage waveform of the AC mains 110. Since the capacitor 613 is discharged through the switch 607 when the switch 607 is closed, the gate-source bias required to turn on the MOSFET switches 601 and 602 must be reestablished during each cycle. This results in the first MOSFET switch 601 operating in a suboptimal mode when the switch 607 is disconnected during the positive half cycle of the voltage waveform of the AC mains 110, because the boost provided during the negative half cycle is reset when the switch 607 is closed.

[0160] Fig. 6F FIG. 6 is a schematic circuit diagram of a solid-state bidirectional switch 600-5 that can be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. The solid-state bidirectional switch 600-5 is similar in circuit configuration to FIG. Fig. 6E The solid-state bidirectional switch 600-4 is different in that the solid-state bidirectional switch 600-5 implements a SPDT switch 632 instead of the SPST switch 607, and wherein the gate terminals of the first MOSFET switch 601 and the second MOSFET switch 602 are directly connected to the input of the SPDT switch 632. The SPDT switch 632 is controlled by a switch control circuit 630 coupled to the SPDT switch 632 via a control line 630-1. In some embodiments, the switch control circuit 630 includes Figure 3A and 3B. The switch control circuit 630 operates the SPDT switch 632 to selectively connect the gate terminals of the MOSFET switches 601 and 602 to (i) the commonly connected source terminal S of the MOSFET switches 601 and 602 (“position 1”) or to (ii) the Zener diode bias circuit including resistors 603 and 604, rectifier diodes 605 and 606, and capacitor 613 (“position 2”).

[0161] More specifically, in this circuit configuration, activating switch 632 into position 1 causes MOSFET switches 601 and 602 to be coupled to each other by disconnecting the gate terminals of MOSFET switches 601 and 602 from the Zener diode bias circuit and making V GS 603 and 604 and capacitor 613 are shorted to "turn off". This allows capacitor 613 to charge to the Zener voltage of Zener diode 608 until capacitor 613 is discharged through external circuitry or until switch 632 is placed in position 2, causing the stored Zener voltage to be reapplied to the gate terminal and subsequently refreshing the gate-source bias voltage during the negative half cycle. In some embodiments, once charged, as long as the values ​​of resistors 603 and 604 and capacitor 613 are selected appropriately, capacitor 613 will never fully discharge, regardless of the phase or position of switch 632, until AC power is removed.

[0162] Figure 6G FIG. 6 is a schematic circuit diagram of a solid-state bidirectional switch 600-6 that can be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. The solid-state bidirectional switch 600-6 is similar in circuit configuration to FIG. Fig. 6F Solid-state bidirectional switch 600-5, wherein the SPDT switch 632 (in Fig. 6F ) is implemented using a first control switch 641 and a second control switch 642 controlled by a switch control circuit 640. The switch control circuit 640 includes a first control line 640-1 coupled to the first control switch 641, and a second control line 640-2 coupled to the second control switch 642. In some embodiments, the first control switch 641 and the second control switch 642 include phototransistors (e.g., optical bipolar junction transistors).

[0163] The switch control circuit 640 is configured to synchronize the optical control signal outputs 640-1 and 640-2 with the power supply voltage waveform of the AC mains 110. The switch control circuit 640 monitors the voltage level of the power supply voltage waveform on the line hot path 111. When the voltage level remains below a predetermined trigger level V TRIG, the switch control circuit 640 outputs an optical control signal on the control line 640-1 to drive the first control switch 641 (i.e., maintain the switch 641 in the "on" state), while the second control switch 642 is maintained in the off state. On the other hand, when the voltage level exceeds the predetermined trigger level trigger level V TRIG , the switch control circuit 640 outputs an optical control signal on the control line 640-2 to drive the second control switch 642 (i.e., maintain the second control switch 642 in the "on" state), while the first control switch 641 is maintained in the off state. In some embodiments, the switch control circuit 640 is configured so that the optical driver control signal outputs 640-1 and 640-2 do not overlap, thereby providing a "break before make" switching characteristic, which avoids prematurely discharging the capacitor 613. The time constant of the switch control allows fast switching of the optical drive signal outputs 640-1 and 640-2 synchronized with the supply voltage waveform of the AC mains 110 by an external control circuit system (not shown) to provide phase control of the applied AC waveform, such as for use in dimmer applications.

[0164] Figure 6H FIG. 6 is a schematic circuit diagram of a solid-state bidirectional switch 600-7 that can be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. The solid-state bidirectional switch 600-7 is similar in circuit configuration to FIG. Figure 6G The solid-state bidirectional switch 600-6 is different in that the solid-state bidirectional switch 600-7 includes a current sensor circuit 650 and a current sensing element 652. The current sensor circuit 650 uses the current sensing element 652 to sense the AC current delivered from the AC mains 110 to the load 120. Figure 6H In an exemplary embodiment of the present invention, the current sensing element 652 is coupled to a node between the first MOSFET switch 601 and the second MOSFET switch 602 connected in series (e.g., a node coupled to the commonly connected source terminals S of the MOSFET switches 601 and 602). In some embodiments, the current sensing element 652 includes a current transformer or a Hall effect sensing element.

[0165] The current sensor circuit 650 is configured to generate a control signal and output it to the switch control circuit 640 to selectively control the activation and deactivation of the control switches 641 and 642. For example, when the current sensor circuit 650 determines that there is no current or excessive current in the live path between the line live wire 111 and the load live wire 121, the current sensor circuit 650 will output a control signal to the switch control circuit 640, which causes the switch control circuit 640 to (i) turn off the control switch 642 to thereby disconnect the first MOSFET switch 601 and the second MOSFET switch 602 from the bias circuit system, and (ii) turn on the control switch 641 to thereby deactivate the first MOSFET switch 601 and the second MOSFET switch 602 and place the solid-state bidirectional switch 600-7 in an off state.

[0166] In other exemplary embodiments, the smart circuit breaker may implement the same or similar solid-state AC switching circuit systems and techniques as disclosed in any of the following co-pending applications and issued patents: (1) U.S. Patent Application No. 16 / 093,044, filed on October 11, 2018 (Publication No.: US2019 / 0207375), entitled Solid-State Line Disturbance Circuit Interrupter; (2) U.S. Patent No. 10,469,077, issued on November 5, 2019, entitled Electronic Switch and Dimmer; (3) U.S. Patent No. 10,469,077, filed on November 7, 2018 (WO 2019 / 133110), entitled Electronic Switch and Dimmer. and (6) U.S. patent application Ser. No. 16 / 589,999, filed on October 1, 2019, entitled Solid-State Circuit Interrupters, the disclosures of which are hereby incorporated by reference in their entirety.

[0167] Fig. 7A and 7BThe switch control circuit for controlling a solid-state bidirectional switch according to an embodiment of the present disclosure is schematically illustrated. Specifically, Fig. 7A is a schematic block diagram of a switch control circuit that can be implemented in an intelligent circuit breaker and is used to control a solid-state bidirectional switch according to an embodiment of the present disclosure, and Figure 7B According to the embodiment of the present disclosure Fig. 7A Schematic circuit diagram of a switch control circuit. Fig. 7A and 7B Description for control Figure 3A and 3B An exemplary embodiment of a switch control circuit system 308 for a solid-state bidirectional switch 304 in an exemplary embodiment of FIG.

[0168] Fig. 7A A solid-state bidirectional switch 700 is illustrated that includes a first MOSFET switch 601 and a second MOSFET switch 602 and respective body diodes 601-1 and 602-1. The solid-state bidirectional switch is coupled to a control circuit 710 that includes a sense resistor 716, a short circuit detection and protection circuit 712, and a switch VGS controller 714. The sense resistor 716 is connected between source terminals S (e.g., nodes N1 and N2) of the first MOSFET switch 601 and the second MOSFET switch 602. The short circuit detection and protection circuit 712 is configured to detect a load-side short circuit fault condition and operates in conjunction with the switch VGS controller 714 to provide a fast disconnection of the solid-state bidirectional switch in response to the detection of the short circuit fault condition.

[0169] Specifically, the short circuit detection and protection circuit 712 is coupled to nodes N1 and N2 and is configured to measure the load voltage across the sensor resistor 716 and determine when the load voltage exceeds a default value indicating a short circuit fault condition. The short circuit detection and protection circuit 712 cooperates with the switch VGS controller 714 to quickly disconnect the first MOSFET switch 601 and the second MOSFET switch 602 when the load voltage across the sense resistor 716 exceeds the default value. In some embodiments, the short circuit detection and protection circuit 712 is configured to provide a notification of the fault to a processor (e.g., processor 220, Figure 3A and 3B ).

[0170] like Fig. 7A, the switch VGS controller 714 is coupled to the gate terminals (e.g., node N3) of the first MOSFET switch 601 and the second MOSFET switch 602. The switch VGS controller 714 is configured to control activation and deactivation of the first MOSFET switch 601 and the second MOSFET switch 602 during normal operation (e.g., on-state) of the bidirectional switch, and to deactivate both the MOSFET switches 601 and 602 in response to a fault condition. In addition, the switch VGS controller 714 is configured to minimize leakage of the first MOSFET device 601 and the second MOSFET device 602 during the off-state of the solid-state bidirectional switch. In some embodiments, the switch VGS controller 714 is configured to be received from a control processor (e.g., processor 220, Figure 3A and 3B ) receives a control signal (e.g., a switch control signal, a leakage control signal) to implement switch VGS control functionality.

[0171] Although Fig. 7A An exemplary embodiment is described in which the sensing resistor 716 is connected between the source terminals S of the first MOSFET switch 601 and the second MOSFET switch 602, but it should be understood that the sensing resistor 716 can be connected at other locations along the hot line path between the line hot line 111 and the load hot line 121. In addition, the sensing resistor 716 can also be used as Figure 3B The current sensor and the energy sensing element of the energy metering circuit system 240 enable different sensing and control circuit systems to utilize the load voltage across the sense resistor 716 to implement corresponding functions.

[0172] Figure 7B A circuit diagram of a short circuit detection and protection circuit 712 according to an embodiment of the present disclosure is schematically illustrated. A sensing resistor 716 is connected between nodes N1 and N2, wherein node N1 is coupled to a source terminal of a first MOSFET switch 601 (denoted as a high-side switch) and wherein node N2 is coupled to a source terminal of a second MOSFET switch 602 (denoted as a low-side switch), e.g. Fig. 7A The switch VGS controller 714 is connected to the node N4 of the short circuit detection and protection circuit 712.

[0173] The short circuit detection and protection circuit 712 includes a plurality of bipolar junction transistors 720, 721 and 722, an N-type MOSFET 724, a plurality of resistors 730, 731, 732, 733, 734, 735 and 736, and a capacitor 740, all of which are as shown in FIG. Figure 7B. Transistors 720, 721, and 722 are arranged to include a phase discriminator characterized by substantially bidirectional support of AC current. Short circuit detection circuit 712 monitors the load voltage across sense resistor 716 (i.e., across nodes N1 and N2) and cuts off VGS control of switches 601 and 602 when the load voltage exceeds 0.7 volts. More specifically, in this embodiment, the resistance value of sense resistor 716 is selected to produce a base-emitter (VGS) sufficient to turn on bipolar junction transistors 720 and 722 when the current through sense resistor 716 reaches or exceeds a predetermined maximum current value (e.g., a trip current threshold). BE ). For higher trip currents, the resistance value of the sense resistor 716 decreases, while for lower trip currents, the resistance value of the sense resistor 716 increases. For example, for a trip current of approximately 200 amperes, the sense resistor 716 will have a resistance value of approximately 30 milliohms.

[0174] Those skilled in the art will appreciate that a ground reference sensing circuit may be utilized, but such circuits provide a poor, expensive, and complex solution requiring additional components including an isolator. Also, the short circuit trip current may be adjusted by changing the resistance value of the sensor resistor 716 or by adjusting its ability to affect the 0.7 volt bias point with a voltage divider. In other embodiments, additional mechanisms such as a digital-to-analog converter (DAC) may be utilized to affect and adjust the short circuit current threshold in real time, thereby allowing the system to be programmable with respect to the short circuit current level. This programmability is particularly useful for expanding the performance of the system to improve reaction time and reduce nuisance tripping. As an example, when both circuit breakers experience a short circuit load, the circuit breaker operating under a large load may be closer to the short circuit trip threshold than the unloaded circuit breaker.

[0175] Fig. 8A FIG. 1 is a simplified schematic diagram of an intelligent circuit breaker according to another embodiment of the present disclosure. Specifically, Fig. 8A The intelligent circuit breaker 800 including a solid-state bidirectional switch 801 and a load isolation switch 802 is described. The solid-state bidirectional switch 801 is connected in series in an electrical path between the line input terminal (connected to the line live wire 111) and the loud output terminal (connected to the load live wire 121) of the intelligent circuit breaker 800. The load isolation switch 802 is connected across the load live wire 121 and the load neutral wire 122. It should be understood that for ease of illustration and discussion, Fig. 8A Various components of the smart circuit breaker 800 (eg, processor, switch controller, current sensor, voltage sensor, AC to DC converter circuitry, etc.) are not illustrated.

[0176] The smart circuit breaker 800 implements a control scheme to activate the load isolation switch 802 to bypass the load 120 and thereby isolate (e.g., electrically isolate) the load 120 from the smart circuit breaker 800 when the solid-state bidirectional switch 801 is in the off state. This allows any leakage current from the deactivated solid-state bidirectional switch 801 to flow through the isolation switch 802 to ground and prevents such leakage current from flowing to the load 120. When the solid-state bidirectional switch 801 is in the on state, the load isolation switch 802 is deactivated, wherein the smart circuit breaker 800 supplies power to the load 120.

[0177] Figure 8B 1 is a simplified schematic diagram of an intelligent circuit breaker including an isolation circuit system configured to isolate the intelligent circuit breaker from a load according to an embodiment of the present disclosure. More specifically, Figure 8B illustrate Fig. 8A An exemplary embodiment of a smart circuit breaker 800 of FIG. 800 is shown, wherein the isolation switch 802 is implemented as part of an isolation circuit 810 configured to isolate the smart circuit breaker 800 from the load 120 (e.g., dielectric isolation) when the solid-state bidirectional switch 801 is in the off state. As mentioned above, when the solid-state bidirectional switch 801 is in the off state, the solid-state bidirectional switch may generate a small amount of leakage current. For example, even when the solid-state bidirectional switch 801 is biased to be in a fully off state, a small amount of leakage current (e.g., 200uA) may flow through the solid-state switch 801 and generate a considerable voltage drop across the load 120 when the load 120 includes a high impedance load. When the solid-state bidirectional switch 801 is deactivated, the isolation circuit 810 is used to shunt the undesired leakage current from the load 120.

[0178] Isolation circuit 810 includes controller 820, MOSFET devices 830 and 840, and associated body diodes 830-1 and 840-1. In this exemplary embodiment, Fig. 8A The isolation switch 802 of the embodiment is implemented as a solid-state bidirectional switch including MOSFET devices 830 and 840. When the solid-state bidirectional switch 801 is placed in the off state, the controller 820 commands the MOSFET switches 830 and 840 to turn on, which prevents any leakage current from the deactivated solid-state bidirectional switch 801 from flowing to the load 120. The effect of bypassing or shunting the leakage current from the load 120 acts as a galvanic isolation technique that can be implemented with an air gap switch between the AC mains 110 and the load 120. In this configuration, the isolation circuit 810 provides dielectric isolation and acts as a pseudo air gap. It should be understood that the isolation circuit 810 can be implemented in other exemplary embodiments of the smart circuit breaker as discussed herein.

[0179] Fig. 9A , 9B9C schematically illustrate an integrated current sensor and energy metering circuit 900 that can be implemented in a smart circuit breaker according to an embodiment of the present disclosure. In some embodiments, Fig. 9A , 9B and 9C instructions Figure 2B and 3B An exemplary embodiment of a current sensor and energy metering circuit 240 is shown in FIG. Fig. 9A , 9B 9C illustrate different circuit blocks of the energy metering circuit 900 and the current sensor, wherein Fig. 9A is a schematic diagram of a power supply block 910 and a current sensor block 920, Fig. 9B is a schematic diagram of the overcurrent detection block 930, and Fig. 9C Schematic diagram of energy metering block 980.

[0180] refer to Fig. 9A , power block 910 includes an isolation DC to DC converter 911, a ferrite bead 912, capacitors 914 and 916, and a virtual ground (HGND) 918, all of which are arranged and connected as shown. The isolation DC to DC converter 911 is configured to convert a first DC power supply voltage VDC-A into a second DC power supply voltage VDC-on-Hot, and to provide isolation between the first DC power supply voltage and the second DC power supply voltage. The ferrite bead 912 is connected between the line hot line 111 and the virtual ground (HGND) 918. The capacitor 914 acts as a bypass capacitor connected across the input terminal of the isolation DC to DC converter 911 and thus connected between the VDC-A voltage rail and the neutral ground (GND) 114. Similarly, the capacitor 916 acts as a bypass capacitor connected across the output terminal of the isolation DC to DC converter 911 and thus across the VDC-on-Hot voltage rail and the virtual ground HGND 918 connection. Ferrite bead 912 and capacitors 914 and 916 are used to filter high frequency noise from the power supply voltage rail.

[0181] In some embodiments, the first DC supply voltage VDC-A on the VDC-A voltage rail includes a first DC supply voltage VDC-A provided by the AC to DC converter circuitry 210 (see Figure 2B and 3B) and the isolated DC to DC converter 911 provides a 1:1 conversion to generate a second VDC-on-Hot supply voltage (e.g., 5V) which is applied to the VDC-on-Hot voltage rail connected to the line hot line 111. In this regard, the isolated DC to DC converter 911 generates a second VDC-on-Hot voltage (e.g., 5V) which is applied to the hot line path to provide a 5V DC offset on the hot line path, which is measured relative to the virtual ground HGND 918, while the first DC supply voltage VDC-A is measured relative to the neutral ground GND 114.

[0182] The current sensor block 920 includes an isolation amplifier 921, which includes a first block 921-1 and a second block 921-2 that are galvanically isolated from each other using, for example, optical coupling technology, capacitive coupling technology, etc. The first block 921-1 is powered by the VDC-on-Hot power supply voltage generated by the power supply block 910, and the second block 921-2 is powered by the VDC-A power supply voltage. The current sensor block 920 further includes a current sensing resistor 922 and a low pass filter formed by resistors 923 and 924 and a capacitor 925 at the input of the isolation amplifier 921. A bypass capacitor 926 is connected between the power rail VDC-A and the ground 114.

[0183] like Fig. 9A As shown in FIG. 1 , in some embodiments, a sensing resistor 922 is connected in series in an electrical path between the line hot wire 111 and the AC switch. The sensing resistor 922 generates an AC voltage (referred to herein as a load voltage (V )) across a first node N1 (referred to as a line-side node) and a second node N2 (referred to as a load-side node) based on the AC load current flowing through the sensing resistor 922 in the hot wire path. B ) or sense voltage (V Sense ). In some embodiments, the sensing resistor 922 comprises a high power resistor with a relatively low resistance value that can generate a sufficient sensing voltage across the sensing resistor 922 for measurement purposes without consuming a large amount of energy. For example, in some embodiments, the sensing resistor 922 comprises a resistance value of approximately 1 milliohm.

[0184] In operation, the current sensing resistor 922 generates a load voltage V that is proportional to the load current flowing in the hot path. B . Load voltage V B Determined as: V B =I L ×R S , where I L represents the load current and R Srepresents the resistance value of the sensing resistor 922. The first block 921-1 of the isolation amplifier 921 amplifies and converts the load voltage V across the sensing resistor 922 into B The voltage level of the first block 921-1 of the isolation amplifier 921 is sampled, and the sampled voltage information is transmitted (e.g., optically, capacitively, etc.) to the second block 921-2 through the isolation barrier. In this circuit configuration, the biasing of the first block 921-1 of the isolation amplifier 921 using VDC-on-Hot and the virtual HGND 918 allows the first block 921-1 of the isolation amplifier 921 to measure the voltage across the sense resistor 922 (which is connected in series in the hot line path) relative to the virtual ground HGND 918. The isolation between the first block 921-1 and the second block 921-2 of the isolation amplifier 921 allows the second block 921-2 and downstream circuit components to be biased using VDC-A and the neutral ground GND 114.

[0185] The second block 921-2 of the isolation amplifier 921 generates and outputs a differential signal including first and second current sensing control signals (denoted as Current_Sense(+) and Current_Sense(-)) relative to the neutral ground GND 114 using the sampled voltage information provided from the first block 921-1. In some embodiments, the differential output of the isolation amplifier 921 is implemented as a differential signal with a DC offset (e.g., 1.3V offset) and a desired gain (e.g., a gain of 8). The first and second current sensing control signals (Current_Sense(+) and Current_Sense(-)) are input to the overcurrent detection block 930 ( Fig. 9B ) and energy metering block 980( Fig. 9C ).

[0186] In some embodiments, Fig. 9A As shown in , the isolation amplifier 921 is configured to have an adjustable gain that can be controlled by a processor or controller of the smart circuit breaker. Specifically, as Fig. 9A, the second block 921-2 of the isolation amplifier 921 includes a Gain_Adjust control input that allows the processor or controller to adjust the gain of the isolation amplifier 921 and thereby adjust the level of the overcurrent condition in which the smart circuit breaker will trip. In this configuration, the isolation amplifier 921 provides a gain element to amplify the relatively small sense voltage generated across the sense resistor 922 (i.e., across nodes N1 and N2) due to the current on the hot line path between the line hot line 111 and the load hot line 121. Thus, the sense resistor 922 can have a relatively small resistance value (e.g., 1 milliohm), which produces a relatively small sense voltage and minimizes power dissipation for normal circuit operation, but it is amplified by the isolation amplifier 921 to achieve overcurrent detection using a small sense voltage. In addition, the resistance value of the sense resistor 922 can remain fixed (e.g., 1 milliohm), while the gain of the isolation amplifier 921 is adjusted as needed to adjust the level of overcurrent detection.

[0187] In some embodiments, the processor or controller may be configured to adjust the gain of amplifier 912 based on the temperature of the smart circuit breaker, as determined by a temperature sensor integrated with or otherwise coupled to the smart circuit breaker. For example, in an example where the temperature of the smart circuit breaker increases to a relatively high level (e.g., 115 degrees Celsius and above), the gain of isolation amplifier 921 may be adjusted (e.g., increased) to reduce the level of overcurrent that trips the smart circuit breaker.

[0188] refer to Fig. 9B , the overcurrent detection block 930 includes a unit gain amplifier 931, and a two-stage detection circuit 935 including an RMS stage 935-1 and a comparator stage 935-2. The unit gain amplifier 931 has a non-inverting input connected to a node N3 between resistors 932 and 933. Resistors 932 and 933 are connected in series between the current sensor block 920 ( Fig. 9A ) between the differential outputs of the isolation amplifier 921. The unity gain amplifier 931 and resistors 932 and 933 act as a level shift input stage for the overcurrent detection block 930, where the resistors 932 and 933 are selected to have the same resistance value to account for the DC offset (e.g., 1.3V offset) of the differential output of the isolation amplifier 921. In this regard, the overcurrent detection block 930 utilizes only one side of the current sensing differential output of the isolation amplifier 921, so the input to the overcurrent detection block 930 is effectively given by: Vin_OCD = 1.3V + Aa / 2 × I L ×R S , where A is 8, where “a” represents the peak amplitude of the AC waveform amplified by the isolation amplifier 921 of the current sensor block 920.

[0189] The output of the unity gain amplifier 931 is input to the RMS stage 935-1. The RMS stage 935-1 includes an active peak detection circuit configured to generate an output signal representing a root mean square (RMS) value of Vin_OCD. The RMS stage 935-1 includes a first amplifier 940 and a second amplifier 950. The first amplifier 940 and the second amplifier 950 include respective non-inverting inputs coupled to the output of the unity gain amplifier 931 through resistors 941 and 951, respectively. The first amplifier 940 and the second amplifier 950 include respective inverting inputs coupled to the Current_Sense (-) output of the current sensor block 920 through resistors 942 and 943, respectively. The output of the first amplifier 940 is coupled to the inverting input of the second amplifier 950 through a rectifying diode 946 and a resistor 952. The first amplifier 940 includes a first negative feedback loop including a rectifying diode 945 and a second negative feedback loop including a resistor 944. The second amplifier 950 includes a negative feedback configuration including a resistor 953 and a capacitor 954 connected in parallel.

[0190] RMS stage 935-1 is configured to produce an RMS voltage given by: V RMS =1.3V-RMS(Aa / 2×I L ×R S ) or 1.3V-(.707)×Aa / 2×I L ×R S , assuming a sine wave. An RMS voltage is generated at the output of a second amplifier 950 coupled to the input of a second (comparator) stage 935-2. Comparator stage 935-2 includes a comparator 960 having an output coupled to amplifier 950 to receive the RMS voltage V RMS In some embodiments, the Current_Threshold control signal includes an inverting input of the control processor (e.g., processor 220, Figure 2B and 3B ) in the current digital-to-analog converter (DAC). The Current_Threshold control signal generates a current threshold voltage V across a resistor 961 connected to the non-inverting input of the comparator 960. CT In some embodiments, the resolution of the DAC is 2.4 μA / bit, and resistor 961 has a resistance value of 4320Ω. This results in a current threshold voltage V CT There is a resolution of 10.368 mV / bit at the non-inverting input of comparator 960. The relationship between the DAC code and Current_Threshold (CT) is given by: D = (1.3 V - (Aa / 2 × CT × RS ) / (10.368mV / bit)or D=(1.3V-16mΩ×Ct) / (10.368mV / bit), where CT is in amperes RMS.

[0191] Since the RMS voltage V generated by the RMS stage 935-1 RMS V may have a certain voltage fluctuation, so the comparator stage 935-2 is implemented as a two-stage comparator including a first comparator 960 and a second comparator 970. The comparator 960 converts V CT With V RMS If V CT Signal and V RMS signals are close to each other, the output of the first comparator 960 will increase with respect to V RMS The first comparator 960 has an output coupled to a non-inverting input of a second comparator 960 through a low pass filter formed by a resistor 962 and a capacitor 963. The second comparator 970 includes an inverting input connected to a voltage divider network including a first resistor 971 and a second resistor 972 connected in series between a power supply voltage VDC-A and a ground GND 114. The voltage divider network generates a reference voltage V applied to the inverting input of the second comparator 970. REF When the duty cycle of the first comparator 960 is greater than 50%, the second comparator 970 generates an Over_Current_Detection signal.

[0192] The Over_Current_Detection signal is input to the control circuit system to deactivate the AC switch of the circuit breaker to prevent an over-current fault condition. Fig.11 The following further details the processor of the intelligent circuit breaker Fig. 9A and 9B The current sensor circuit system 900 implements an exemplary control process for monitoring and detecting an overcurrent fault condition.

[0193] Reference Fig. 9C , the energy metering block 980 includes an energy metering circuit 981 and a passive bandpass filter including resistors 982, 983 and 984 and capacitors 985, 986 and 987. The energy metering circuit 981 includes a current sensor block 920 ( Fig. 9A ) is connected to the differential input of the isolation amplifier 921 of the current metering circuit system 981. Effectively, the input voltage V CM By V CM =(Aa×IL ×R S ) / A N (A N = represents the attenuation of the bandpass filter) because the bandpass filter removes the DC offset (e.g., 1.3V offset), attenuates the Current_Sense (+) and Current_Sense (-) signals, and highly attenuates unwanted high frequencies. From the perspective of the energy metering software, the effective constant is the current-to-voltage ratio, Ks = Aa × R S =0.032Ω (assuming Aa=8 and Rs=0.004Ω), where 1 / Ks=A N / (Aa*R S ) = 656.25 amperes / volt.

[0194] It should be understood that Fig. 9A , 9B The various resistor and capacitor values ​​of the circuit components in 9C may vary depending on the application. To provide some context, Fig. 9A , 9B The following non-limiting examples of resistor and capacitor values ​​are implemented in the circuit system of 9C. For example, in Fig. 9A , the values ​​of resistors 922, 923 and 924 and capacitor 925 are selected to provide the desired input signal filtering.

[0195] Furthermore, in some embodiments, Fig. 9B The resistance values ​​and capacitor values ​​in are as follows. Resistors 932 and 933 have a resistance value of 5.9K. Resistor 941 has a resistance value of 4.7K. Resistors 942, 943, and 944 have a resistance value of 10K. Resistor 951 has a resistance value of 2.7K. Resistor 952 has a resistance value of 4.99K. Resistor 953 has a resistance value of 11K. Capacitor 954 has a capacitance value of 2.2uF. Resistor 961 has a resistance value of 4.3K. Resistor 962 has a resistance value of 22K. Capacitor 963 has a capacitance value of 0.47uF. Resistors 971 and 972 have a resistance value of 22K.

[0196] Furthermore, in some embodiments, Fig. 9CThe resistor values ​​and capacitor values ​​in are as follows. Resistors 982 and 983 have a resistance value of 4.7K. Resistor 984 has a resistance value of 470 ohms. Capacitors 985 and 986 have a capacitance value of 10uF. Capacitor 987 has a capacitance value of 10nF. In some embodiments, energy metering circuit 981 includes an application specific integrated circuit (ASIC) that is specifically designed to measure power and energy in a power line system and process instantaneous voltage and current waveforms to calculate RMS values ​​of voltage and current, active, reactive and apparent power and energy. In other embodiments, energy metering circuit 981 includes an "off-the-shelf" application specific standard product (ASSP) chip that implements the desired energy metering functionality.

[0197] The energy metering circuit 981 generates energy metering data and outputs it to the processor 220 (eg, Figure 2B and 3B ), and the processor 220 stores and analyzes energy metering data to determine energy usage of loads on branch circuits protected by the smart circuit breaker. The processor 220 can provide energy usage information to a remote computing node or device via a wireless or wired network connection. This configuration allows remote energy monitoring and notification of energy usage and thereby improves energy awareness for various applications.

[0198] By way of example, multiple energy-aware smart circuit breakers may be configured to report real-time and cumulative energy usage from multiple branch circuits within a given residence or building. Energy-aware smart circuit breakers within a given residence or building may provide cumulative energy usage information that an asset owner may utilize to verify or otherwise correlate energy usage of a given residence or building as reported by a utility company. Additionally, in a multi-dwelling or multi-unit asset such as a strip mall, smart energy metering using energy-aware smart circuit breakers allows asset owners to bill tenants individually without the need for multiple utility meters. As another example, smart energy metering by smart circuit breakers may also be applicable to tenants or Airbnb renters to prevent or report unnecessary energy waste, such as a tenant sleeping with windows open on a cold night and an electric heater continuously operating at full power, or an AC unit on a maximum cooling setting when a tenant sleeps under a thick blanket on a warm night.

[0199] As another example, smart energy metering performed by smart circuit breakers provides a way to determine possible energy theft or unusual and unexpected energy consumption, and can also reveal defective or malfunctioning utility meters. In other applications, smart energy-aware circuit breakers are also capable of sending warnings / notifications when electrical usage exceeds a settable "normal level" for a device on a branch or a collection of devices and branches. In addition, smart energy-aware circuit breakers are also suitable for utility companies because they search for loads that can be disabled or power reduced during peak load cycles. For example, in some embodiments, smart circuit breakers may implement load profiling techniques as disclosed in U.S. Patent Application No. 16 / 682,627, entitled Managing Power for Residential and Commercial Networks, filed on November 13, 2019, the disclosure of which is incorporated herein by reference in its entirety. As disclosed, these same smart devices are capable of providing valuable outage information during the collapse of utility power and in moments during the restoration of the circuit. The timing of power outages can help pinpoint the location of faulty or damaged power lines, assist in estimating the number of damaged points, and help generate more accurate utility restoration times. In other applications, smart energy-aware circuit breakers can also measure, diagnose and control the increasingly improperly synchronized bidirectional energy that is prevalent in renewable energy sources and electric vehicles connected to building infrastructure and utility energy suppliers.

[0200] Fig.10 1 is a flow chart of a method for controlling a switch of an intelligent circuit breaker in response to detection of a fault condition according to an embodiment of the present disclosure. Fig.10 The exemplary process flow of will be discussed in the context of controlling a solid-state bidirectional switch of a smart circuit breaker, but the same or similar process flow may be implemented to control an electromagnetic switch (e.g., switch 302, Figure 3A and 3B ). After utility power is applied, the control logic of the smart circuit breaker assumes control of the solid-state bidirectional switch (block 1000). Initially, the control logic will place the solid-state bidirectional switch in an open state (or off state) (block 1001), and proceed to determine when it is appropriate to place the solid-state bidirectional switch in a closed state (or on state) (block 1002).

[0201] For example, the control logic may determine that it is appropriate to close the solid-state bidirectional switch based on (i) manual circuit breaker switch position (e.g., manual switch closed), (ii) switch condition when a utility power outage occurs (e.g., switch closed when an outage occurs), (iii) a command received from a local processor or wirelessly received from a remote node, (iv) an end-of-life outage condition, etc. Once the solid-state bidirectional switch is in the closed state (block 1003), the control logic will continue to monitor for the occurrence of an event that is considered to require placing the solid-state bidirectional switch in an open state, i.e., an off state (block 1004).

[0202] For example, the occurrence of a fault event such as a current overload event (block 1005) or a short circuit event (block 1006) will trigger the deactivation (i.e., the off state) of the solid-state bidirectional switch. For example, as mentioned above, in some embodiments, the current overload event may be determined by the processor analyzing real-time current sensor data obtained using a current sensor configured to detect line current. In other embodiments, the smart circuit breaker includes a current sensor that includes a current overload detection circuit system (e.g., Fig. 9A and 9B ), which is configured to detect a current overload event and generate a current overload detection signal that triggers the opening of the solid-state bidirectional switch.

[0203] In other embodiments, detection of the opening of a manual circuit breaker switch is considered an event that will trigger the opening of a solid-state bidirectional switch (block 1007). As mentioned above, in this example, the opening of the solid-state bidirectional switch prior to or concurrent with the manual switch opening event will serve to eliminate or minimize the occurrence of arcs between the contacts of the electromechanical or electromagnetic switches of the smart circuit breaker. The occurrence of arcs causes degradation of the metal contacts of the circuit breaker and is a safety hazard in situations where flammable gases may be present. In this regard, the ability to eliminate arcs during a fault event or manual lever action is an example of how the smart circuit breakers disclosed herein extend the safety of the circuit breaker rather than just protecting downstream circuit wiring from thermal damage. In addition, as mentioned above, the implementation of a solid-state bidirectional switch with a fast disconnect response time prevents the flow of dangerous current levels that can cause arcs in downstream wiring and loads.

[0204] In other embodiments, the remote switch open command event will trigger the opening of the solid-state bidirectional switch (block 1008). As mentioned above, the implementation of the wireless transceiver within the smart circuit breaker enables wireless communication to remotely disconnect branch circuits and loads protected by the smart circuit breaker. For example, the remote switch open command capability allows emergency services personnel to power down part or all of a structure during a reported gas leak or flooding event. The implementation of the wireless transceiver over a secure Internet Protocol (IP) address and IP network allows a remote command to be issued to the control logic of the smart circuit breaker to turn off the solid-state bidirectional switch and actually trip the smart circuit breaker.

[0205] In other embodiments, the sensor data trip event will trigger the opening of the solid-state bidirectional switch (block 1009). As mentioned above, various sensors and implementations of a processor with control logic enable the tripping of the smart circuit breaker in response to various sensed conditions. For example, in addition to current and voltage sensors, the smart circuit breaker may also include other types of sensors, such as temperature sensors, humidity sensors, etc. The ability to acquire sensor data combined with implementations of control algorithms capable of processing the acquired sensor data and predicting dangerous and problematic events and issuing wireless warnings / notifications expands the safety capabilities of the smart circuit breakers as disclosed herein.

[0206] For example, by acquiring and processing sensor data, the smart circuit breaker can be configured to initiate the opening of the solid-state switch just before a potential fault condition of the load by predicting the impending failure of the load, such as a spa pump, a heater, or a compressor of a central air conditioning system. In some embodiments, the smart circuit breaker can implement predictive analytics techniques as disclosed in U.S. Patent Application No. 15 / 980,311, filed on May 15, 2018, and entitled Predictive Analytics System, the disclosure of which is incorporated herein by reference in its entirety. In addition, the ability of the smart circuit breaker to identify the type of load (e.g., a spa pump) can be very helpful in analyzing potentially unsafe conditions. In some embodiments, the smart circuit breaker may implement circuit load characterization techniques as disclosed in U.S. Patent Application No. 16 / 340,474, entitled Load Identifying AC Power Supply with Controls and Methods, filed on April 9, 2019 (Publication No.: US2019 / 0245457), the disclosure of which is incorporated herein by reference in its entirety. In addition, the wireless communication capabilities of the smart circuit breaker allow for enhanced support for new types of load patterns, such as new types of refrigeration motors, and abnormal alternative energy feeds, through automatic software, firmware, and algorithm updates from a remote site.

[0207] As another example, sensors can detect unsafe conditions at a specific outlet or load when intelligently connected to downstream electrical devices. A 20 amp circuit breaker typically feeds many downstream outlets. Assuming that the 20 amp load is shared between multiple outlets, each of these outlets may be a 15 amp rated device. Sensors in the circuit breaker can alert specific smart outlets, smart loads, or asset owners of unsafe conditions, such as overloads and daisy-chained power strips, or too many strings of holiday lights on a single outlet. As described below in conjunction with Fig.15 Discussing further in detail, a smart circuit breaker may issue a wireless warning / notification, or direct the outlet to disconnect, or simply trip the circuit breaker itself until the situation is corrected and reset.

[0208] In another embodiment, the ability of a smart circuit breaker to characterize a load type (whether through an algorithm or through data provided by the asset owner) allows the smart circuit breaker to detect or otherwise monitor a possible degradation in performance of a given load type. This is particularly useful, for example, in providing information for preventative maintenance of refrigeration units prior to failure and any resulting damage and many other types of appliances or loads. In this regard, a smart circuit breaker may be configured to recognize and analyze many types of loads and compare the real-time operating curve of a given load to the nominal operating curve of the given load. Appliance manufacturers will greatly benefit from the collection of big data associated with energy usage analysis, communication, and analytics.

[0209] In other embodiments, a smart circuit breaker may be paired with a smart socket to detect an overload condition of the smart socket, which has the ability to wirelessly communicate before resupplying power to its loads, may trip the branch circuit under the condition of a dangerous fault condition, and automatically reapply power by wirelessly directing the problematic smart socket to remain in a load disconnected state after the smart circuit breaker reapplies power to the branch circuit. This enables the smart circuit breaker to re-function and continue to supply power to all other loads on a given branch, details of which will be discussed below in conjunction with Fig.15 In addition, the smart circuit breaker, when paired with a smart outlet having more than one separate branch feed or phase and a mechanism to switch between them, can direct the smart outlet to switch branch circuits in an effort to balance the load and more economically utilize phase balancing.

[0210] In other embodiments, the smart circuit breaker may include or otherwise be connected to remote sensors, such as temperature, humidity, gas, smoke / fire, and water sensors. Smart circuit breakers may use such sensors to monitor environmental conditions and react to unsafe conditions by disconnecting the power supply from the branch circuit in situations where unsafe water levels may cause electrocution or fire or unsafe temperatures may cause device failures in the circuit breaker panel. By way of specific examples, a humidity sensor may be placed in a smart circuit breaker, or in a circuit breaker distribution panel, or in a wall, and used to detect roof or pipe leaks that may adversely affect the safety of the entire electrical system. Smart circuit breakers are also capable of issuing wireless warnings / notifications before or immediately after a fault event. Each of these instances may also include wireless notifications to local emergency services and / or local utility companies.

[0211] In other embodiments, smart circuit breakers including arc fault and / or ground fault sensors can also safely shut down branch circuits in unsafe situations. Smart circuit breakers can issue wireless warnings / notifications immediately before, immediately after, and immediately after such arc fault or ground fault events. Each of these examples can also include wireless notifications to local emergency services and / or local utility companies.

[0212] In other embodiments, additional information derived from external sensors or data available via wireless communications may also be used to generate notification / warning or trip events.

[0213] Fig.11 1 is a state diagram of a control process implemented by an intelligent circuit breaker to detect and prevent a fault condition according to an embodiment of the present disclosure. Specifically, Fig.11 A fault detection state diagram is described that illustrates a state machine implemented by a processor of a smart circuit breaker (e.g., processor 220 of smart circuit breakers 2B and 3B) to detect an overcurrent fault condition. In some embodiments, processor 220 includes a current digital-to-analog converter (current DAC) to generate a programmable reference current (e.g., a current threshold, Fig. 9B ) and a general purpose input / output (GPIO) digital signal pin to receive an over-current detection signal generated by the current sensor (e.g., an Over_Current_Detection signal generated by an over-voltage comparator 935-2 of an over-current detection block 930 of the current sensor 900, Fig. 9B ).

[0214] In some embodiments, the processor 220 implements a 1 KHz state machine to detect an overcurrent fault condition, wherein the state machine includes the following states: (i) Stop; (ii) Reset; (iii) Overcurrent Detection (S0); (iv) Slow Blow Ramp (S1); (v) Tail Detection (S2); and (vi) Trip. In addition, in some embodiments, the state machine implements the following programmable parameters: (i) OCT, which represents the overcurrent threshold (output during S0 and S2); (ii) ITT, which represents the instantaneous trip threshold (the beginning of the S1 ramp); (iii) SBRT, which represents the slow blow ramp time (the duration of S2); and (iv) TT, which represents the tail time (the duration of S2).

[0215] The states are defined as follows. The Stop state is used when a trip or fault condition has been detected to stop current sensing until it is set to the Reset state by a command. The Reset state is the initial state for starting the state machine, which initializes the DAC output to the overcurrent threshold detection circuitry and sets the state machine to the S0 state. In the S0 state, the current DAC is programmed to output a current that represents the current input to the Fig. 9B The voltage of the desired over-current threshold (OCT) in the comparator stage of the over-current detection block 930 of the current sensor 900 is set to the desired over-current threshold (OCT). This is the stable state until the current rises above the output threshold as measured at the comparator circuit, at which time the comparator will output a logic level "1" as the Over_Current_Detection signal, which will be detected by the over-current state machine. At this point, the DAC is programmed to the instantaneous trip threshold and will set the ramp duration and the length and duration of each step required for state S1, and the state machine transitions to the S1 state.

[0216] During the S1 state, any time the comparator output transitions to a logic "1" it is considered a trip condition and the state machine will immediately move to the Tripped state. During the S1 state, a slow blow ramp will be executed where the DAC is gradually adjusted as time passes from the instantaneous trip threshold back to the overcurrent threshold. If the ramp is completed without the comparator indicating a trip condition, the state machine will move to the S2 state. Although the ramp does not have to be as Fig.11 , but the slopes may be weighted or nonlinear in any desired manner to achieve desired effects, such as the varying heating characteristics of the protected wiring. In some embodiments, the S1 slope may be perturbed (via software control) to compensate for the increased temperature of the smart circuit breaker.

[0217] During the S2 state, any time the comparator output transitions to a logic "1" it will be considered a trip condition and the state machine will immediately move to the Trip state. During the S2 state, the DAC will output the overcurrent threshold for a programmed time period (same as in state S0), giving the state machine a chance to detect a condition where the current is stable and just at the overcurrent threshold reference level, rather than continuously cycling through the overcurrent state without actually declaring a trip condition. At the end of the S2 period, the state machine is set to the Reset state (which sets the DAC output to the overcurrent threshold and sets the state to S0).

[0218] Upon entering the trip state, due to overcurrent detection in the S1 or S2 state, the AC switch off action is initiated, which will cause the AC switch control line to switch to the off state at or before the next zero crossing function is executed.

[0219] In another embodiment, a "wire heating" process is implemented by changing the S0 output current based on how many high current trips have occurred without exceeding overcurrent detection. The process may implement a secondary state machine configured to change (in durations in seconds or minutes) the S0 level, the instantaneous trip level, and therefore the slope of the slow blow ramp accordingly.

[0220] Fig.12 An intelligent power distribution and monitoring system 1200 utilizing intelligent circuit breakers according to an embodiment of the present disclosure is schematically illustrated. The system 1200 includes a circuit breaker distribution panel 1210, a wired and / or wireless communication network 1220, one or more intelligent load devices 1230, one or more user computing devices 1240, and an Internet of Things (IoT) computing platform 1250. The circuit breaker distribution panel 1210 includes a front panel 1211 and a cover 1212, which is opened to access a main circuit breaker 1213 and a plurality of branch circuit breakers 1214 protecting branch circuits in a given residence or building, as well as a circuit breaker and load status display module 1215.

[0221] The configuration of the circuit breaker distribution panel 1210 will vary depending on the type of electrical service provided. For example, residential electrical service (120 / 240VAC) in the United States includes a single-phase service that includes two hot voltage lines and one neutral line, where both line voltages are derived from a single phase of a distribution transformer with a central tapped neutral line and are 180° out of phase with each other. In this type of electrical service, the two hot service conductors that feed the circuit breaker panel 1210 are connected to the main circuit breaker 1213, and the main circuit breaker 1213 is connected to two hot busbars within the circuit breaker panel 1210. In addition, the incoming neutral service conductor is connected to the neutral busbar in the circuit breaker panel 1210, and the neutral busbar is coupled to a separate ground busbar in the circuit breaker panel 1210.

[0222] The two live service conductors feeding the main circuit breaker 1213 each provide 120V from, for example, an electric meter, and feed the two live busbars in the circuit breaker panel 1210 through the main circuit breaker 1213 (when the main circuit breaker 1213 is turned on). The branch circuit breakers 1214 have line input terminals connected to one or both of the live busbars to provide power to the circuit (for example, a single-pole circuit breaker has one input line terminal connected to one live busbar to provide 120V to the branch circuit, while a double-pole circuit breaker includes two input line terminals connected to two live busbars to provide 240V to the branch circuit). According to an embodiment of the present disclosure, some or all of the main circuit breaker 1213 and the branch circuit breakers 1214 include smart circuit breakers implemented using smart circuit systems and functionality as discussed herein. In this example, smart circuit breakers 1213 and 1214 would have a connection to neutral, for example, a conductor connecting a ground plane for solid-state circuitry to the neutral bus in circuit breaker panel 1210 .

[0223] The smart load device 1230 may include various types of smart devices, such as smart electrical sockets or smart energy consumption devices, including but not limited to switches, power outlets, light bulbs, appliances, heating systems, ventilation systems, air conditioning systems, appliances, communication systems, entertainment systems, home security devices, etc., as well as other types of smart electrical and electronic devices and systems used in residential, commercial or industrial buildings.

[0224] In the context of IoT computing, smart circuit breakers 1213 and 1214 and smart load devices 1230 include smart IoT devices that operate and communicate within an IoT device network and are configured to support IoT applications for a given application domain. IoT devices (e.g., 1213, 1214, and 1230) generate data that is uploaded to an IoT cloud computing platform 1250 on a communication network 1220 for data processing, data storage, and data management by the cloud computing platform 1220. In addition, the IoT device can access and download data from the IoT cloud computing platform 1250 on the communication network 1220. In addition, depending on the type of device and network configuration, some or all of the IoT devices (e.g., 1213, 1214, and 1230) are configured for peer-to-peer communication within an IoT device network. The IoT devices are configured to form a network (e.g., a mesh network) by self-organization using known methods.

[0225] The user computing device 1240 includes one of various types of computing devices, such as a desktop computer, a laptop computer, a server, a smart phone, an electronic tablet, etc., which allows a user or administrator to access the IoT cloud computing platform 1250 and the smart devices 1213, 1214, and 1230 over the communication network 1220. The user computing device 1240 can host a client IoT application for configuring and managing the network smart devices 1213, 1214, and 1230 directly or through the IoT cloud computing platform 1250.

[0226] Although the communication network 1220 is generally depicted in FIG. 1 , it should be understood that the communication network 1220 may include any combination of known wired and / or wireless communication networks, such as a global computer network (e.g., the Internet), a wide area network (WAN), a local area network (LAN), a satellite network, a telephone or cable network, a cellular network, a wireless network such as Wi-Fi or WiMAX, Bluetooth, or various portions or combinations of these and other types of networks. The term "communication network" is understood in a broad sense to cover a wide variety of different network arrangements, including combinations of multiple networks that may have different types. In this regard, in some embodiments, the communication network 1220 includes a combination of multiple different types of communication networks, each of which includes a network device configured to communicate using an Internet Protocol (IP) or other related communication protocol. The communication network 1120 includes intermediate points (e.g., routers, switches, etc.) and other elements (e.g., gateways) that form a network backbone to establish a communication path and enable communication between network endpoints.

[0227] In the context of IoT computing, the communication network 1220 includes an IoT device network, wherein smart circuit breakers 1213 and 1214 and smart load devices 1230 (as well as other wireless / wired sensors such as humidity sensors, temperature sensors, etc.) include smart IoT devices that operate and communicate within the IoT device network and are configured to support IoT applications for a given application domain (e.g., controlling and managing smart circuit breakers and smart electrical devices within a given residence or building, collecting and analyzing energy usage information for a given residence or building, etc.).

[0228] The IoT devices (e.g., 1213, 1214, and 1230) generate data that is uploaded to the IoT cloud computing platform 1250 over the communication network 1220 for data processing, data storage, and data management by the cloud computing platform 1220. In addition, the IoT devices can access and download data from the IoT cloud computing platform 1250 over the communication network 1220. The IoT cloud computing platform 1250 manages and processes the IoT data received from the various IoT devices 1213, 1214, and 1230. In some embodiments, the IoT cloud computing platform 1250 performs data processing, data storage, and data management functions, and supports one or more IoT network applications and / or other types of high-performance computing applications, such as deep learning applications, machine learning, big data analytics, or other types of high-performance computing applications suitable for supporting a home or building automation system that includes a network of smart electrical devices that can be monitored and controlled using the techniques disclosed herein.

[0229] In addition, depending on the type of device and network configuration, some or all of the IoT devices (e.g., 1213, 1214, and 1230) are configured for peer-to-peer communication within the IoT device network. The IoT devices are configured to form a network (e.g., a mesh network) through self-organization using known methods. In some embodiments, wireless communication between IoT devices (e.g., 1213, 1214, and 1230) and wireless communication between user computing device 1240 and IoT devices (e.g., 1213, 1214, and 1230) can be performed via radio frequency communication protocols and systems, such as Near field communication, Wi-Fi devices, and other proprietary and non-proprietary protocol implementations. Additionally, various sensors such as temperature, humidity, motion, and sound sensors may be included as part of the IoT device network to provide environmental information used by the smart circuit breakers 1213 and 1214 to prevent potential electrical hazards that may be caused by adverse environmental conditions.

[0230] In some embodiments, the circuit breaker and load status display module 1215 includes a main processor that communicates with the processors of the smart circuit breakers 1213 and 1214 and the smart load devices 1230 to obtain, process and display operational status data of such devices. The main processor is configured to display analog or digital data received from various smart devices and sensors, and provide the status of the circuit breaker (e.g., tripped, overloaded, etc.), and activate alarms / notifications when sensor readings exceed pre-selected limits. Alarms include visual displays on the user interface of the panel, audible sounds from an audio output device, communication signals sent through an electronic communication module, and signals sent to lights or audio alarms. In some embodiments, the user computing device 1240 can access the circuit breaker / load status display module 1215 to obtain status information about IoT devices and issue commands to perform specific functions (e.g., tripping, resetting and resetting smart circuit breakers, etc.). In some embodiments, Fig.12 The system 1200 implements the home / building automation and control system and method as disclosed in International Application No. PCT / US2017 / 057309, entitled Building Automation System, filed on October 19, 2017 (published as WO 2018 / 075726), the disclosure of which is fully incorporated herein by reference. The present application discloses technology for implementing smart electrical outlets that can be augmented with smart circuit breakers as discussed herein for enhanced safety and security, power metering, power control, and home diagnostics.

[0231] In some embodiments, the main processor is configured to control and manage IoT communications for all smart circuit breakers and components within a distribution panel, and to communicate with individual smart circuit breakers within the distribution panel using wired communications (e.g., a controller area network (CAN) bus) or bus) or using wireless communications to individual smart circuit breakers within the distribution panel using a local Bluetooth Low Energy (BLE) mesh network, wherein the main processor implements or otherwise utilizes any suitable broadband communication technology to communicate with remote IoT devices, systems, etc.

[0232] Fig.131 is an exploded view of a circuit breaker housing structure 1300 that can be used to house switches, circuit systems, sensors, and other components of an intelligent circuit breaker according to an embodiment of the present disclosure. The housing structure 1300 includes a first housing component 1301, a heat sink element 1302, and a second housing component 1303. The heat sink element 1302 is disposed within the housing structure 1300 formed by the coupling of the first housing component 1301 and the second housing component 1303. The first housing component 1301 and the second housing component 1303 include molded plastic covers for the heat sink element 1302 and other components of the circuit breaker. The heat sink element 1302 is formed of a metal material such as aluminum or other suitable materials or alloys that will have sufficient thermal conductivity for a given application.

[0233] The first housing member 1301 includes a plurality of open slots 1301-1, and the heat sink element 1302 includes a plurality of cooling fins 1302-1. When the housing structure 1300 is assembled, the cooling fins 1302-1 of the heat sink element 1302 are aligned with the corresponding slots 1301-1 of the first housing member 1301 to achieve an air-cooled heat sink mechanism. Various integrated circuit chip components (e.g., processors, solid-state bidirectional switches, etc.) are thermally coupled to the heat sink element 1302, which acts as a cooling plate for the integrated circuit chip. Integrated heat sink cooling allows for enhanced heat exchange and reduced total on-resistance of the solid-state bidirectional switch during heavy circuit breaker load conditions. The line neutral (not shown) is added in the traditional industry standard method for AFCI and GFCI products and for smart circuit breakers. Those skilled in the art will recognize that the various circuits, algorithms, heat exchangers, and other aspects of the disclosed configuration of the smart circuit breaker can be adjusted to various form factors required in other locations or countries.

[0234] Fig.14 1 is a flow chart of a process implemented by a smart circuit breaker to monitor energy usage on a branch circuit and prevent a fault condition from occurring on the branch circuit according to an embodiment of the present disclosure. Fig.14 Description When the utility power is in a normal state (e.g., no power outage) (block 1400), Fig.12The automated process implemented by the intelligent power distribution and monitoring system 1200 of the present invention. The intelligent circuit breaker will monitor the energy usage profile of the circuit breaker and the smart socket or electrical device using the intelligent energy metering method as discussed herein (box 1401). Based on the monitored energy usage, if the intelligent circuit breaker determines that a given load has an impending fault condition (affirmative determination in box 1402), the intelligent circuit breaker will communicate with the smart socket or device to automatically disable power delivery to the given load (box 1403). In some embodiments, the "imminent fault" includes a user / machine programmable threshold (e.g., determined based on historical information using artificial intelligence techniques). In this example, the intelligent circuit breaker will compare the monitored energy usage with the programmed threshold setting (or "imminent fault threshold") maintained in the device being monitored. The intelligent circuit breaker (or main processor) will send a warning signal or notification of the automated action to one or more user computing devices to notify the user of the action taken (box 1404).

[0235] For example, assume that a smart circuit breaker or sensor intelligently connected to a downstream electrical device detects an unsafe condition at a specific outlet or load. By way of specific example, a 20 amp circuit breaker typically feeds many downstream outlets. Assuming that a 20 amp load is shared between multiple outlets, each of these outlets may be a 15 amp rated device. Sensors in the smart circuit breaker may alert a specific smart outlet, smart load, or asset owner of an unsafe condition, such as an overload and daisy chained power strip, or too many strings of holiday lights on a single outlet. In this example, the smart circuit breaker may issue a wireless warning / notification, or direct the outlet to disconnect, or simply trip the circuit breaker itself until the situation is corrected and reset.

[0236] Fig.15 Flowchart of a process implemented by a smart circuit breaker to monitor energy usage on a branch circuit and prevent fault conditions from occurring on the branch circuit according to an embodiment of the present disclosure. Fig.15 Description When the utility power is in a normal state (e.g., no power outage) (block 1500), Fig.12 The invention relates to an automated process implemented by the intelligent power distribution and monitoring system 1200 of the present invention. The intelligent circuit breaker will monitor the energy usage curve of the circuit breaker and the intelligent socket or electrical device using the intelligent energy metering method as discussed herein (block 1501). When a circuit breaker trip or fault event occurs on a given branch circuit that causes the branch circuit to be de-energized, the intelligent circuit breaker protecting the given branch circuit will communicate with the intelligent devices (e.g., intelligent sockets and load devices) on the given branch circuit and command such intelligent devices to disable power to the load devices (block 1502).

[0237] The smart circuit breaker will wait a predetermined amount of time after the fault event (block 1503) and then automatically re-energize the branch circuit (block 1504). After the branch circuit is energized, the smart circuit breaker will proceed to determine or otherwise identify which outlet or load was the source of the fault event (block 1505). The smart circuit breaker will communicate with other outlets or loads that do not have a problem to re-apply power (block 1506).

[0238] Through this control process, when paired with an overloaded smart socket that has the ability to wirelessly communicate before resupplying power to its load, the smart circuit breaker can trip the branch circuit under the condition of a dangerous fault condition, and automatically reapply power after powering on by wirelessly directing the problematic smart socket to remain in a load disconnected state. This enables the smart circuit breaker to re-energize to continue powering all other loads on the branch while still isolating the fault. As another example, when the smart circuit breaker is paired with a smart socket that has more than one separate branch feed or phase and a mechanism to switch between them, the smart circuit breaker can direct the smart socket to switch branch circuits in an effort to balance the load and more economically utilize phase balancing.

[0239] In other embodiments, the smart circuit breaker may be configured to identify the type of load connected to the circuit breaker and control the identified load using a control circuit system and a control process as disclosed in U.S. Patent Application No. 16 / 340,474, entitled “Load Identifying AC Power Supply With Control and Methods” filed on April 9, 2019, the disclosure of which is fully incorporated herein by reference. For example, Fig.16 1 is a schematic block diagram of an intelligent circuit breaker 1600 configured to identify the type of load connected to the circuit breaker and control the load based on the identified load type according to an embodiment of the present disclosure. Specifically, Fig.16 Schematically illustrates an intelligent circuit breaker 1600 connected between an AC mains 110 and a load 120. The intelligent circuit breaker 1600 includes a processor 1602, a first switch 1604, a second switch 1606, a switch control circuit system 1608, an AC to DC converter circuit system 1610, a first voltage sensor 1620, a second voltage sensor 1622, a first current sensor 1630, a second current sensor 1632, a third current sensor 1634, and a fourth current sensor 1636.

[0240] The first switch 1604 is connected in series in the live line path between the line input terminal and the load output terminal of the circuit breaker 1600, wherein the line live line 111 of the AC mains 110 is connected to the line input terminal and the load live line 121 of the load 120 is connected to the load output terminal. The second switch 1606 is connected in series in the neutral line path between the line neutral line 112 and the load neutral line 122. When the first switch 1604 is in the on state, the line live line 111 of the AC mains 110 is connected to the load live line 121, and when the second switch 1606 is in the on state, the line neutral line 112 is connected to the load neutral line 122. As in other embodiments of the smart discussed above, the line neutral line 112 (which is, for example, joined to the ground line 114 in the circuit breaker distribution panel) serves as a low-side voltage reference (e.g., ground) for the electronic circuit system of the smart circuit breaker 1600.

[0241] In some embodiments, the first switch 1604 and the second switch 1606 include solid-state bidirectional switches, which can be configured to use the above-described combination of Figures 6A-6H One of the exemplary switch circuits discussed herein. Switch control circuit system 1608 is configured to control the operation of first switch 1604 and second switch 1606 using switch control circuit systems and techniques as discussed herein. Load identification AC power supply includes AC to DC converter 1610, which supplies power to current sensors 1630, 1632, 1634 and 1636 and voltage sensors 1620 and 1622, which acquire AC mains data and load data. AC to DC converter circuit system 1610 is configured to provide DC power to various circuit systems and elements of smart circuit breaker 1600, including processor 1602, voltage sensors 1620 and 1622, current sensors 1630, 1632, 1634 and 1636, and switch control circuit system 1608. The above-mentioned combination can be used Figure 4A , 4B 5 to implement the AC to DC converter circuit system 1610.

[0242] The first voltage sensor 1620 and the second voltage sensor 1622 are configured to monitor the voltage at different points along the live line path through the circuit breaker 1600. For example, Fig.16, a first voltage sensor 1620 is coupled to a live line path upstream of a first switch 1604 to monitor the AC power voltage of the AC mains 110, and a second voltage sensor 1622 is coupled to a live line path downstream of the first switch 1604 to monitor the load voltage on a branch circuit connected to and protected by the smart circuit breaker 1600. The voltage sensors 1620 and 1622 are each coupled to the processor 1602 via one or more data acquisition and control lines 1620-1 and 1622-1, respectively. The voltage sensors 1620 and 1622 can be implemented using any suitable type of voltage sensing circuit system, including but not limited to a zero crossing detector circuit, a resistor divider, and the like.

[0243] Current sensors 1630, 1632, 1634, and 1636 are configured to monitor current at different points along the hot and neutral paths through circuit breaker 1600. For example, Fig.16 , a first current sensor 1630 is coupled to a hot line path upstream of a first switch 1604 to monitor a line side supply current, and a second current sensor 1632 is coupled to a hot line path downstream of the first switch 1604 to monitor a load side supply current. A third current sensor 1634 is coupled to a neutral line path upstream of a second switch 1606 to monitor a line side return current, and a fourth current sensor 1636 is coupled to a neutral line path downstream of the second switch 1606 to monitor a load side return current. The current sensors 1630, 1632, 1634, and 1636 are each coupled to the processor 1602 via one or more data acquisition and control lines 1630-1, 1632-1, 1634-1, and 1636-1, respectively. The current sensors 1630, 1632, 1634, and 1636 may be implemented using any suitable type of current sensing circuit, including but not limited to a current sensing resistor, a current amplifier, a Hall effect current sensor, and the like.

[0244] The processor 1602 operates in conjunction with voltage sensors 1620 and 1622 and current sensors 1630, 1632, 1634 and 1636 to sample the analog power supply voltage and current waveform of the AC mains 110 and the voltage and current waveform across and through the load 120. The processor 1602 is configured to sample the sensed current and voltage waveform at a sampling frequency significantly greater than the cycle time of a single cycle of the power supply voltage of the AC mains 110. The sampling frequency of the voltage and current waveforms is selected as needed to distinguish the load type. In some embodiments, the sampling frequency is in the kilohertz range. In other embodiments, the sampling frequency is in the megahertz range. In some embodiments, a programmed change of power (or power modulation) is applied to the load 120 to optimize the distinction of the acquired waveforms between the expected load types.

[0245] In some embodiments, processor 1602 includes circuitry to capture, process, and record current and voltage samples, wherein the circuitry includes comparators, analog-to-digital converters, etc., and data storage elements, such as random access memory (RAM), read-only memory (ROM), and other types of solid-state memory and non-solid-state memory devices, as known in the art. In some embodiments, processor 1602 includes control logic and associated computing resources to analyze the recorded current and voltage samples (e.g., neural network analysis and classification of load data) to identify the load type of load 120.

[0246] For example, analysis of the sampled current and voltage waveforms includes matching patterns in high frequency components of the voltage and current waveforms from the load 120. In other embodiments, analysis of the waveforms includes determining a delay in the timing of the load drawing power after power is first applied to the load. In other embodiments, analysis includes classifying the acquired waveforms including their high frequency components into groups indicative of different load types. Non-limiting examples of groups include waveforms indicative of primarily resistive loads, capacitive loads, inductive loads, loads that include power factor correction, and loads that include power control such that there is a delay in power to the load when power from the power source is initially applied.

[0247] In other embodiments, the processor 1602 may access and utilize a remote server to analyze the recorded current and voltage waveform samples. In this example, the processor 1602 will transmit the recorded samples (via a wired or wireless communication link over an Internet Protocol (IP) network) to the remote server for processing, and then receive the process results from the remote server. In some embodiments, the processor 1602 is configured to perform the following steps: Fig.17 The process flow described in .

[0248] To be precise, Fig.17 1700 is a flowchart of a method for a load identification and control process implemented by an intelligent circuit breaker according to an embodiment of the present disclosure. An intelligent circuit breaker with load type identification and load control capabilities is installed at a target location between the AC mains and the load (block 1700). For illustrative purposes, Fig.16 The context of the intelligent circuit breaker 1600 is described Fig.17 In some embodiments, the smart circuit breaker 1600 is installed in a circuit breaker distribution panel. In some embodiments, the smart circuit breaker 1600 comprises a device installed in a separate junction box between the AC mains and the load. In other embodiments, the smart circuit breaker 1600 is a component of an electrical outlet. In some embodiments, the smart circuit breaker 1600 is a component of an electronic power strip or a smart extension cord.

[0249] Once power is installed and applied, the smart circuit breaker 1600 will continue to monitor the connection of the load (block 1701). In response to detecting the load (affirmative determination in block 1701), the smart circuit breaker 1600 will activate switches 1604 and 1606 to connect the power voltage of the AC mains to the load (block 1702). The smart circuit breaker 1600 then continues to acquire and store various types of data for subsequent analysis (block 1703). The acquired data is stored in the data storage device 1710.

[0250] For example, data acquisition includes recording timing information about the time when the load is connected to the AC mains power supply, the time when power is applied to the load, and the time when the power is used by the load. In addition, data acquisition includes acquiring waveform data. Any data acquired after the load is detected is referred to as "load data". The load data includes the on timing of the load and the waveform data. The waveform data includes acquiring the values ​​of the AC main voltage, the load voltage, the load current, and the power consumed by the load over time.

[0251] The data is acquired at a frequency optimized for detection of the load type. In some embodiments, the data is acquired at a frequency several times higher than the frequency of the AC mains power. For example, in one embodiment, data is acquired at a kilohertz rate for 50 to 60 cycles of AC mains power data. In other embodiments where high frequency components of the voltage and current waveforms are needed to properly identify a given load type, the data is acquired at a megahertz rate.

[0252] In some embodiments, the acquired data is stored in the RAM of the processor 1602 for real-time or near real-time processing. In other embodiments, the acquired data is stored in a permanent memory or storage device for subsequent access and analysis, for example, pattern matching to identify the same or similar loads based on matching of a waveform pattern obtained at a first connection of the load with a waveform pattern at a later connection of the same or different load (block 1701). In some embodiments, the data storage device 1710 can be accessed by a plurality of smart circuit breaker devices having load identification and load control capabilities. Such storage devices can be accessed by a device connected to the smart circuit breaker 1600 by wire or wireless or by transmitting the stored load data from the smart circuit breaker 1600 to another device such as a smart circuit breaker device.

[0253] After the initial data acquisition (block 1703), the smart circuit breaker 1600 can modulate the power supplied to the load (block 1704). Specifically, in some embodiments, the power modulation includes controlling one or more of switches 1604 and 1606 to change the power delivered to the load. Additional load data is acquired and stored both during and after the power modulation (block 1705). The smart circuit breaker 1600 continues to perform a load identification process to identify the load type of the connected load based on the acquired load data captured before, during, and after the power modulation (block 1706).

[0254] In some embodiments, the load identification process is performed by comparing the waveform of the load data with a previously acquired waveform in the load data of a known load device. In other embodiments, the load identification process is based on the timing before and after power is turned on to the load, as discussed, and the matching of the waveform data. In other embodiments, neural network analysis is used to classify the load data into categories of load types by comparing with a library of previous load data. In other embodiments, the load identification process can use a trained model to implement any suitable classification process to classify the connected load into a specific category of load based on the phase relationship between the load voltage and current waveform and the AC mains voltage waveform before, during, and after modulating the power to the connected load using switches 1604 and / or 1606.

[0255] For example, the load type of a given load may be classified as one of the following:

[0256] (1) Purely resistive load: The voltage and current zero crossings and peaks are synchronized before, during and after the modulation of the supply voltage. The power decreases when the voltage decreases, and returns to the pre-modulation level when the modulation of the supply voltage stops and the supply voltage returns to full voltage.

[0257] (2) Constant power resistive load with power correction. Voltage and current peaks are synchronized before modulation, and power is constant before, during, and after modulation;

[0258] (3) Purely reactive (capacitive or inductive) loads. The voltage and current are out of phase before, during and after modulation, the power is reduced during the modulation of the supply voltage, and the power returns to the pre-modulation level when the modulation of the supply voltage is terminated and returns to full voltage.

[0259] (4) Constant power reactive load. The voltage and current are out of phase before, during and after modulation, and the power is constant before, during and after modulation of the supply voltage.

[0260] In some embodiments, the modulation of the supply voltage causes the RMS supply voltage to decrease by an amount between 1% and 20%. In some embodiments, the load identification process (block 1706) further includes determining a confidence level for the identification. In one embodiment, the confidence level is determined by the goodness of fit of a match between the load data obtained during the data acquisition steps 1703 and 1705 and data previously obtained on a known load and stored in the data storage device 1701. Once the identification process (block 1706) is completed, it is determined whether the load type of the connected load has been properly identified with a given confidence level and whether there are control rules associated with the identified load type (block 1707). In some embodiments, such a determination is made by comparing the confidence level in the identification with a pre-selected confidence level defined as a positive identification (block 1707).

[0261] If the load is positively identified and there is a pre-selected control rule associated with the identified load (positive determination in block 1707), the smart circuit breaker 1600 may control power to the connected load according to one or more of the associated control rules (block 1708). For example, power to the connected load is controlled by controlling switches 1604 and / or 1606 in series with the load. Non-limiting examples of pre-selected control rules include:

[0262] (1) During the day, purely resistive loads such as light bulbs are dimmed to reduce power usage, especially during peak demand periods;

[0263] (2) In constant power loads, when the load demand decreases, the input power will decrease accordingly to minimize the power consumption at no load / minimum load demand;

[0264] (3) In remote areas (no human presence), pure resistance loads and constant power resistance loads will automatically disconnect and reconnect based on the load demand; and

[0265] (4) Devices that produce arcs during normal operation (eg, electric motors having brush connections to the rotor) are ignored by arc fault circuit interrupters to prevent unintended disconnection.

[0266] In other embodiments, there is a set of preselection rules based on whether the load type is one of: a pure resistive load; a constant power resistive load, a pure reactive load, and a constant power reactive load. In one non-limiting example of a preselection rule, a load identified as having included power factor correction (i.e., a constant power load) is not turned off by the controller, and the pure resistive load is turned off during a preselected time period, and power is reduced to a pure reactive load during a preselected time period. On the other hand, if the load type is not identified or there is no predefined control rule associated with the identified load type (negative determination in block 1707), the smart circuit breaker will simply maintain the connection of the power source and the load (block 1709), and disconnect in response to a fault condition as discussed herein.

[0267] In other embodiments, the smart circuit breaker may be configured to include fault detection sensors and circuit systems to support arc fault circuit interruption (AFCI) and / or ground fault circuit interruption (GFCI) functions using control circuit systems and methods as disclosed in U.S. patent application Ser. No. 16 / 093,044, entitled “Solid-State Line Disturbance Circuit Interrupter,” filed on Oct. 11, 2018, the disclosure of which is incorporated herein by reference in its entirety. Smart AFCI circuit breakers according to embodiments of the present disclosure are configured to provide protection against parallel arcs (line to neutral), series arcs (loose, broken, or otherwise high resistance segments in a given line, and ground arcs (from line or neutral to ground). Smart GFCI circuit breakers according to embodiments of the present disclosure are configured to provide protection against ground faults where current in a given device or appliance leaks from the normal path from the line to the neutral appliance. The GFCI circuit breaker monitors the current difference between the hot and neutral wires, and when the current input to a given load on the hot wire is greater than the return current from the load on the neutral wire by a predefined amount (e.g., 5 mA), the GFCI circuit breaker will trip to stop the flow of current. Fig.18AA schematic block diagram of an intelligent circuit breaker 1800 configured to monitor ground fault and arc fault conditions and provide circuit interruption in response to detected fault conditions according to an embodiment of the present disclosure. The intelligent circuit breaker 1800 includes a low voltage DC power supply 1804, a voltage and current sensing circuit system 1820, a control processor 1830, and an electronic switch and switch control circuit system 1840. The low voltage DC power supply 1810 efficiently provides DC power to the voltage and current sensing circuit system 1820 and the control processor 1830. Sensing inputs 1820-1 and 1820-2 are provided to the control processor 1830 from the voltage and current sensing circuit system 1820. The voltage and current sensing circuit system 1820 includes a sensor that senses the waveform of the voltage and current applied to the load circuit and generates a proportional analog waveform. The control processor 1830 processes the proportional analog waveform and generates a fault output on a control line 1840-1 coupled to the switch control circuit system 1840 after detecting a ground fault or an arc fault. After a fault is detected, the fault output signal applied to the control line 1840-1 is latched and fed to the control input of the switch control circuit system, and causes the electronic switch to disconnect the load 120 from the AC mains 110 until a reset 1850 is applied to the fault detection control processor 1830.

[0268] In other embodiments, the output voltage of the electronic switch 1840 can be varied by the switch control circuit system. For example, after an arc fault is detected, the output voltage can be reduced to a value less than the threshold of the arc but greater than zero. Such embodiments allow the load circuit to continue to operate at a reduced voltage while reducing the possibility of damaging the arc. Operation at a reduced voltage also allows continued characterization of the load and mains power supply circuit to determine the location of the arc fault for subsequent replacement or repair.

[0269] Fig.18B According to the embodiment of the present disclosure Fig.18A A schematic circuit diagram of the intelligent circuit breaker 1800 is shown in FIG. Fig.18B In an exemplary embodiment of the present invention, the voltage and current sensing circuit system (1820, Fig.18A ) includes a first current sensor 1821, a second current sensor 1822, a full-wave rectifier 1823, and sensing resistors 1824 and 1825. The electronic switch and control circuit system (1840, Fig.18A) includes a solid-state switch circuit system 1842 (e.g., a solid-state bidirectional switch) to connect the AC mains 110 to the load 120, and a switch control circuit 1844 that controls the solid-state switch circuit system 1842 via an optical signal interface 1844-1. The low voltage AC to DC power supply 1810 provides a DC power supply for the current sensors 1821 and 1822, the fault detection processor 1830, and the switch control circuit system 1844. The fault detection processor 1830 includes a current sensing input for each of the current sensors 1821 and 1822 and a voltage sensing input for sensing the voltage across the sense resistors 1824 and 1825.

[0270] In some embodiments, Fig.18B As shown in , the first current sensor 1821 and the second current sensor 1822 include solid-state Hall effect sensors that generate an output voltage proportional to the current flowing in the line live wire 111 and the line neutral wire 112 paths. The voltage generated by the Hall effect sensor output is fed to the current sensing input of the fault detection processor 1830. In addition, in some embodiments, the voltage sensor includes a full-wave rectifier bridge 1823, which is configured to convert two half cycles of the AC power supply voltage waveform of the AC mains 110 into a pulsating DC voltage. A resistor divider network including resistors 1824 and 1825 is used to attenuate the full-wave rectified waveform and apply it to the voltage sensing input of the fault detection processor 1830. In some embodiments, the full-wave rectifier bridge 1823 can be eliminated, and the full-wave rectified waveform can be obtained directly from the output of the AC-DC converter circuit 1810.

[0271] After the fault is detected by the fault detection processor 1830, the fault output of the fault detection processor 1830 is latched and fed to the control input of the switch control circuit system 1844, which then generates an optical control signal 1844-1 to the solid-state bidirectional switch circuit system 1842 to disconnect the load 120 from the AC mains 110 until the reset switch 1850 is activated to reset the fault detection processor 1830. As mentioned above, in other embodiments, the output voltage of the solid-state switch circuit system 1842 is changed by the switch control circuit system 1844 so that after the arc fault is detected, the output voltage is reduced to a value less than the threshold value of the arc but greater than zero. This allows the load 120 to continue to operate at a reduced voltage while reducing the possibility of damaging the arc. Operation at a reduced voltage also allows continued characterization of the load and the mains power supply circuit to determine the location of the arc fault for subsequent replacement or repair.

[0272] Fig.19 According to the embodiment of the present disclosure, Fig.18BSchematic block diagram of a fault detection processor 1900 implemented in an intelligent circuit breaker of FIG. The fault detection processor 1900 includes input resistors 1902 and 1904, amplifiers 1910, 1912 and 1914, A / D converters 1920, 1922 and 1924, a voltage anomaly detection module 1930, a current anomaly detection module 1932, and a threshold detection module 1934, an AND gate 1940, and an OR gate 1950, and a latch circuit 1960. The voltage sensing signal is applied to the inverting and non-inverting input terminals of the amplifier 1910. The amplifier 1910 is configured as a differential amplifier that generates a difference signal ΔV input to the A / D converter 1920. The current sensing input is applied to the non-inverting input of the amplifier 1912 through resistors 1902 and 1904. The sense inputs are summed by the input circuits (1902, 1904), and the operational amplifier 1912 outputs a signal proportional to the sum ∑I of the currents in the line and neutral branches of the AC mains 110. The ∑I signal is also applied to the input of the A / D converter 1922. The digitized ΔV signal is processed by a voltage anomaly detection module 1930 (e.g., a subroutine), which is executed by the fault detection processor 1900 to detect anomalies in the voltage waveform within a number of cycles indicating the presence of an arc fault. A non-limiting example of such a voltage anomaly is the presence of excessive high frequency energy imposed on the normally low frequency AC mains voltage waveform.

[0273] The digitized ΣI signal is processed by a current anomaly detection module 1932 (subroutine) which is executed by the fault detection processor 1900 to detect anomalies in the current waveform within a number of cycles indicating the presence of an arc fault. A non-limiting example of such a current anomaly is the appearance of a "shoulder" (flat spot) in the current waveform that occurs near the zero crossing of the current waveform. The outputs of the detection modules 1930 and 1932 are input to an AND gate 1940 where the combined appearance of the voltage waveform anomaly and the current waveform anomaly is an indicator of an arc fault.

[0274] The current sense signal is also applied to the input of amplifier 1914, which forms a difference signal ΔI proportional to the difference between the currents in the line and neutral branches. The ΔI signal is digitized by A / D converter 1924 and processed by threshold detection module 1934, which generates a threshold detection signal indicating a ground fault. The arc fault signal at the output of AND gate 1940 and the ground fault signal at the output of threshold detection module 1934 are logically ORed via OR gate 1950, and the output of OR gate 1950 is input to latch circuit 1960. Latch circuit 1960 outputs a fault detection signal and stores the fault condition until it is cleared by an external reset signal.

[0275] Fig. 20A current zero-crossing detector circuit according to an embodiment of the present disclosure is schematically illustrated. Specifically, Fig. 20 The current zero crossing detector circuit 2000 is schematically illustrated and includes a polarity change detection stage 2010, an edge detection stage 2020, an output stage 2030, and a sense resistor 2040. In some embodiments, the sense resistor 2040 is connected in series in an electrical path between the line hot wire 111 and the load hot wire 121. The polarity change detection stage 2010 includes a first comparator 2011 and a second comparator 2012. The edge detection stage 2020 includes a first edge detection circuit 2020-1 connected to the output of the first comparator 2011, and a second edge detection circuit 2020-2 connected to the output of the second comparator 2012. The first edge detection circuit 2020-1 and the second edge detection circuit 2020-2 include respective inverters 2021 and 2022, respective resistors 2023 and 2034, respective capacitors 2025 and 2026, and respective exclusive OR (XOR) gates 2027 and 2028. Output stage 2030 includes an AND gate 2032 having inputs connected to the outputs of XOR gates 2027 and 2028 of edge detection stage 2020 .

[0276] The sensing resistor 2040 generates an AC voltage (referred to as a sensing voltage V) across a first node N1 (a line side node) and a second node N2 (a load side node) based on an AC load current flowing through the sensing resistor 2040 in an electrical path between the line hot wire 111 and the load hot wire 121. Sense As mentioned above, in some embodiments, the sensing resistor 2040 comprises a high power resistor having a relatively low resistance value, which can generate a sufficient sensing voltage across the sensing resistor 2040 for measurement purposes without consuming a large amount of energy. For example, in some embodiments, the sensing resistor 2040 comprises a resistance value of approximately 1 milliohm. In some embodiments, Fig. 20 The sensing resistor 2040 shown in FIG. Fig. 9A The same sense resistor 922 shown in FIG. 1 is used, where multiple detection circuits of the smart circuit breaker tap the same sense resistor to provide various functionalities.

[0277] The polarity change detection stage 2010 is configured to detect a sense voltage V across the sense resistor 2040 due to the AC current passing through the sense resistor 2040. Sense The first comparator 2011 and the second comparator 2012 are each configured as a voltage comparator, which compares a reference voltage applied to the inverting input (-) of the comparator with an input voltage applied to the non-inverting input (+) of the comparator, and generates a logic "1" output when the input voltage is greater than the reference voltage, and generates a logic "0" output when the input voltage is less than the reference voltage. More specifically, Fig. 20 In an exemplary embodiment of the present invention, the first comparator 2011 includes a non-inverting input (+) connected to the load side (node ​​N2) of the sense resistor 2040 and an inverting input (-) connected to the line side (node ​​N1) of the sense resistor 2040. The second comparator 2012 includes a non-inverting input (+) connected to the line side (node ​​N1) of the sense resistor 2040 and an inverting input (-) connected to the load side (node ​​N2) of the sense resistor 2040.

[0278] During the positive half cycle of the voltage waveform of the AC mains 110, a positive current flows through the sense resistor 2040 from node N1 to node N2, which generates a positive sense voltage (+V Sense ) drops (i.e., VN1-VN2>0). At the positive sensing voltage (+V Sense ), the output comparison signal C1 of the first comparator 2011 will be logic "0", and the output comparison signal C2 of the second comparator 2012 will be logic "1". On the other hand, during the negative half cycle of the voltage waveform of the AC mains 110, a negative current flows through the sensing resistor 2040 from the node N2 to the node N1, which generates a negative sensing voltage (-V Sense ) drops (i.e., VN1-VN2<0). At the negative sensing voltage (-V Sense ), the output comparison signal C1 of the first comparator 2011 will be logic "1", and the output comparison signal C2 of the second comparator 2012 will be logic "0".

[0279] The sensing voltage V Sense From positive (+V Sense ) changes to negative (-V Sense ), the output comparison signal C1 of the first comparator 2011 changes from logic 0 to logic 1, and the output comparison signal C2 of the second comparator 2012 changes from logic 1 to logic 0. On the other hand, when the sensing voltage V Sense From negative (-V Sense ) turns to positive (+V Sense ), the output comparison signal C1 of the first comparator 2011 changes from logic 1 to logic 0, and the output comparison signal C2 of the second comparator 2012 changes from logic 0 to logic 1.

[0280] The transitions (or edges) of the comparison signals C1 and C2 are detected by the corresponding edge detection circuits 2020-1 and 2020-2 of the edge detection stage 2020. More specifically, in the first edge detection circuit 2020-1, the XOR gate 2027 has a first input terminal receiving the comparison signal C1 and a second input terminal receiving the delayed complementary comparison signal The second input terminal of the delayed complementary comparison signal Generated by an inverter 2021 and a delay circuit implemented by a resistor 2023 and a capacitor 2025, wherein the inverter 2021 is configured to generate and output an inverted (complementary) comparison signal and wherein resistor 2023 and capacitor 2025 are configured to apply an RC delay to the complementary comparison signal And thus generate a delayed complementary comparison signal In an exemplary embodiment, resistor 2023 has a resistance of 1 kilo-ohm, and capacitor 2025 has a capacitance of 3.3 nano-farads. XOR gate 2027 generates a gate voltage between input signals C1 and A short logic-0 edge pulse signal E1 is generated during a time period when the two signals have the same logic level (eg, both are logic 0 or both are logic 1).

[0281] Similarly, in the second edge detection circuit 2020-2, the XOR gate 2028 has a first input terminal receiving the comparison signal C2 and a second input terminal receiving the delayed complementary comparison signal The second input terminal of the delayed complementary comparison signal Generated by an inverter 2022 and a delay circuit implemented by a resistor 2024 and a capacitor 2026, wherein the inverter 2022 is configured to generate and output an inverted (complementary) comparison signal and wherein resistor 2024 and capacitor 2026 are configured to apply an RC delay to the complementary comparison signal And thus generate a delayed complementary comparison signal In an exemplary embodiment, resistor 2024 has a resistance of 1 kilo-ohm and capacitor 2026 has a capacitance of 3.3 nano-farads. XOR gate 2028 generates a gate voltage between input signals C2 and A short logic-0 edge pulse signal E2 is generated during a time period when the two signals have the same logic level (eg, both are logic 0 or both are logic 1).

[0282] In operation, the XOR gates 2027 and 2028 generate corresponding edge pulse signals E1 and E2 just before the current zero crossing and just after the zero current crossing. The AND gate 2032 has a first input terminal and a second input terminal connected to the corresponding outputs of the XOR gates 2027 and 2028. The AND gate 2032 generates and outputs the current zero crossing detection signal Zi based on the logical AND of the output signals E1 and E2. The current zero crossing detection signal Zi is applied to the switch control circuit system, which controls one or more switches of the intelligent circuit breaker (e.g., a solid-state bidirectional switch and / or a solenoid of an electromechanical switch). Fig. 20In the exemplary circuit configuration of , AND gate 2032 outputs two zeroing pulses, one before the current zero crossing and one after the current zero crossing. As the sense current increases, the two pulses get closer together. At high currents (e.g., 100 amps), the two pulses are essentially one pulse. Under the condition that the outputs of edge detection circuits 2020-1 and 2020-2 are "ground true", in this configuration, AND gate 2032 acts as a "ground true" OR gate because any time a logical "0" is on one of the inputs of AND gate 2032, the output of AND gate 2032 will be a logical "0".

[0283] Fig.21A and 21B Description of the embodiment according to the present disclosure Fig. 20 Various waveforms of the current zero-crossing detection circuit's operating modes. For example, Fig.21A Description Fig. 20 The operation mode of the edge detection stage 2020, more specifically, the waveform of the operation mode of the first edge detection circuit 2020-1. More specifically, Fig.21A A timing diagram illustrating a plurality of signal waveforms 2100, 2110, 2120, and 2130, wherein waveform 2100 represents an exemplary comparison signal C1 generated by first comparator 2011, wherein waveform 2110 represents an exemplary complementary comparison signal output from inverter 2021 Wherein waveform 2120 represents an exemplary delayed complementary comparison signal generated due to the RC delay circuit at the output of inverter 2021 And wherein waveform 2130 represents an exemplary edge detection signal E1 generated by XOR gate 2027 in response to waveforms 2100 and 2120 applied to inputs of XOR gate 2027 .

[0284] like Fig.21A As shown in FIG. 2 , the waveform 2130 of the edge detection signal E1 generates a zeroing pulse in response to each logic transition of the waveform 2100 of the comparison signal C1 output from the first comparator 2011. The edge detection circuit 2020-2 operates in a similar manner to the edge detection circuit 2020-1, such as Fig.21A Specifically, waveforms 2100, 2110, 2120, and 2130 may represent the comparison signal C2 generated by the second comparator 2012, the complementary comparison signal C3 generated by the inverter 2022, and the comparison signal C4 generated by the inverter 2022, respectively. The delayed complementary comparison signal generated by the RC delay circuit (resistor 2024 and capacitor 2026) and in response to waveform C2 applied to the input of XOR gate 2028 and The edge detection signal E2 is output from the XOR gate 2028. Fig.21AThe waveforms 2100, 2110, 2120, and 2130 are generally depicted in FIG. 2 and do not take into account, for example, the slew rate (of rising and falling edges) of the signals, propagation delays through logic gates, etc.

[0285] Fig.21B Description of the embodiments according to the present disclosure Fig. 20 The analog signal waveform of the operation mode of the current zero-crossing detection circuit 2000. Specifically, Fig.21B A timing diagram illustrating multiple analog signal waveforms 2140, 2150, 2160, 2170, 2180, and 2190. Waveform 2140 represents an exemplary current waveform of a load current flowing through a sense resistor 2040. Waveform 2150 represents an exemplary comparison signal C1 generated by a first comparator 2011. Waveform 2160 represents an exemplary comparison signal C2 generated by a second comparator 2012. Waveform 2170 represents an exemplary edge detection signal E1 generated by a first edge detection circuit 2020-1. Waveform 2180 represents an exemplary edge detection signal E2 generated by a second edge detection circuit 2020-2. Waveform 2190 represents a current zero crossing detection signal Zi generated by an AND gate 2032 in response to waveforms (D) and (E). In addition, Fig.21B A dashed line Z-REF is depicted representing the time of current zero crossings of the current waveform 2140 .

[0286] exist Fig.21B , the waveform 2140 of the load current is shown as rising from negative to positive, which indicates the transition of the AC current waveform through the sense resistor 2040 from the negative half cycle to the positive half cycle. In this example, the sense voltage V Sense From negative (-V Sense ) turns to positive (+V Sense In practice, the zero crossing of the load current through the sense resistor 2040 does not necessarily coincide with the zero crossing of the voltage, because there may be a phase difference between the voltage and current due to, for example, an inductive load (the current phase tracks the voltage phase) or other examples when the power factor is less than 1, resulting in a phase difference between the load current and voltage waveforms.

[0287] like Fig.21B As shown in FIG. 21, waveform 2150 illustrates the response of the sensing voltage V Sense The first comparison signal C1 changes from logic "1" to logic "0" due to the transition from negative to positive, and the waveform 2160 illustrates the response of the sensing voltage V SenseThe waveform 2170 illustrates that the first edge detection signal E1 output from the XOR gate 2027 includes a short zeroing edge detection pulse 2171 corresponding to the edge transition of the first comparison signal C1 of the waveform 2150. Similarly, the waveform 2180 illustrates that the second edge detection signal E2 output from the XOR gate 2028 includes a short zeroing edge detection pulse 2182 corresponding to the edge transition of the second comparison signal C2 of the waveform 2160.

[0288] It should be noted that Fig.21B , the falling edge of the first comparison signal C1 waveform 2150 precedes the zero current crossing Z-REF, and the rising edge of the second comparison signal C2 waveform 2160 follows the zero current crossing Z-REF. On a negative going cycle of the load current 2140 (not specifically shown), the roles are reversed. Specifically, the falling edge of the second comparison signal C2 will precede the zero crossing of the load current, and the rising edge of the first comparison signal C1 will follow the zero crossing of the load current. This is due to the asymmetry in the rising and falling edge propagation delays of the comparator circuitry in the polarity change detection stage 2010, and for the dual circuit configuration.

[0289] In addition, the waveform 2190 of the zero-crossing detection signal Zi includes a first zero-crossing detection pulse 2191 (zero-setting pulse) and a second zero-crossing detection pulse 2192 (zero-setting pulse) generated just before and just after the actual zero-crossing of the load current waveform 2140. As mentioned above, the waveform 2190 of the zero-crossing detection signal Zi is generated by logically ANDing the waveforms 2170 and 2180 of the edge detection signals E1 and E2, wherein the first zero-crossing detection pulse 2191 corresponds to the first edge detection pulse 2171 in the E1 waveform 2170, and wherein the second zero-crossing detection pulse 2192 corresponds to the second edge detection pulse 2182 in the E2 waveform 2180. In this regard, as mentioned above, in Fig. 20 In the exemplary circuit configuration of , AND gate 2032 outputs two zeroing pulses 2191 and 2192 , one before the current zero crossing and one after the current zero crossing.

[0290] Additional simulations show that the zero crossing detection pulses move closer together as the load current through the sense resistor 2040 increases. At large currents (e.g., 100 amps), the two zero crossing detection pulses are essentially one pulse and are generated at essentially the same time as the actual current zero crossing, where the load current through the sense resistor 2040 is substantially or effectively zero. Specifically, as the load current increases, the slope (dv / dt) of the load current increases. Fig. 20A benefit of the current zero crossing detector circuit 2000 is that as the load current increases, the dual negative-going pulses of Zi move closer in time to each other and toward the point in time of the current zero crossing. Given that the goal of the smart circuit breaker (in which the current zero crossing detector circuit 2000 is integrated) is to disconnect the AC switch as close to the time of the zero crossing as possible, it is beneficial to utilize the first of the dual pulses of Zi (because it precedes the zero current crossing) to invoke the action and "lead" the disconnection of the AC switch, given the unavoidable delays in the switch control circuitry that invoke such an action. Additionally, as mentioned above, another benefit is that the pulses of Zi are closest to the current zero crossing when it is most important under high current loads. At the highest loads (e.g., greater than 100A), the dual pulses of Zi move so close together that they are essentially merged into one pulse that is almost consistent with the current zero crossing.

[0291] Fig. 22 The short circuit detection circuit according to the embodiment of the present disclosure is schematically illustrated. Specifically, Fig. 22 The short circuit detection circuit 2200 is schematically illustrated, which includes a first comparator 2202, a second comparator 2204, a NOR gate 2210, a plurality of resistors 2212, 2213, 2213 and 2215, and a sensing resistor 2040. The sensing resistor 2040 is connected in series between nodes N1 and N2 in the electrical path between the line hot wire 111 and the load hot wire 121. In some embodiments, the sensing resistor 2040 is used to Fig. 20 The same sense resistor 2040 of the current zero crossing detector circuit 2000.

[0292] The first comparator 2202 includes a non-inverting input (+) connected to the load side (node ​​N2) of the sense resistor 2040 and an inverting input (-) connected to a node N3 between resistors 2212 and 2213. The second comparator 2204 includes a non-inverting input (+) connected to the line side (node ​​N1) of the sense resistor 2040 and an inverting input (-) connected to a node N4 between resistors 2214 and 2215. Resistors 2212 and 2213 implement a first voltage divider circuit (connected across VDC on Hot and node N1) configured to generate a first reference voltage VREF1 at node N3 that is applied to the inverting input (-) of the first comparator 2202. Resistors 2214 and 2215 implement a second voltage divider network (connected across VDC on the hot line and node N2) configured to generate a second reference voltage VREF2 at node N4 that is applied to the inverting input (-) of the second comparator 2204. The first comparator 2202 and the second comparator 2204 have output terminals connected to the input terminals of the NOR gate 2210.

[0293] In operation, the first comparator 2202 senses the voltage V at the node N2. Sense The second comparator 2204 compares the sensing voltage V at the node N1 with the first reference voltage VREF1 and generates and outputs a first comparison signal HC1. Sense The NOR gate 2210 logically NORs the first comparison signal HC1 and the second comparison signal HC2 to generate and output a high current detection signal HC applied to a switch control circuit system that controls one or more switches (e.g., a solid-state bidirectional switch and / or a solenoid of an electromechanical switch) of the smart circuit breaker.

[0294] More specifically, the sensed voltage V at node N2 Sense When the first reference voltage VREF1 is exceeded, the first comparator 2202 generates and outputs a logic “1” signal (HC1), and the sensing voltage V at the node N1 is Sense When the second reference voltage VREF2 is exceeded, the second comparator 2204 generates and outputs a logic 1 signal (HC2). Fig. 22 In an exemplary embodiment of the present invention, the first comparator 2202 is configured to detect an extreme over-current condition (i.e., a short circuit) of the load during the negative half-cycle of the AC power voltage waveform, and the second comparator 2204 is configured to detect an extreme over-current condition (i.e., a short circuit) of the load during the positive half-cycle of the AC power voltage waveform. When any of the half-cycles is detected to have an extreme over-current condition (e.g., when HC1 or HC2 is logic "1"), the NOR gate 2210 will output a logic "0" signal (HC).

[0295] The resistance values ​​of resistors 2212, 2213, 2214, and 2215 are selected to generate reference voltages VREF1 and VREF2 that allow the short circuit detection circuit 2200 to detect overcurrent conditions that exceed a target overcurrent threshold level. For example, for a 20A circuit breaker, the short circuit detection circuit 2220 can be configured to detect a short circuit condition where the load current is 200A or more. The ratio of the resistance values ​​of resistors 2212 and 2213 is selected to achieve a desired value for the first reference voltage VREF1, and the ratio of the resistance values ​​of resistors 2214 and 2215 is selected to achieve a desired value for the second reference voltage VREF2. In some embodiments, the resistance value of resistor 2215 is selected to be substantially equal to the resistance value of resistors 2212 and 2213 in parallel, which effectively compensates for the voltage drop across the sense resistor 2040.

[0296] Fig.23 Description of the embodiments according to the present disclosure Fig. 22The analog signal waveform of the operation mode of the short circuit detection circuit 2200. Specifically, Fig.23 A timing diagram illustrating a plurality of signal waveforms 2300, 2310, 2320, and 2330. Waveform 2300 represents an exemplary first comparison signal HC1 generated by the first comparator 2202. Waveform 2310 represents an exemplary second comparison signal HC2 generated by the second comparator 2204. Waveform 2320 represents an exemplary high current detection signal HC generated by the NOR gate 2210. Waveform 2330 represents a simulated AC current waveform of a load current flowing through the sense resistor 2040.

[0297] exist Fig.23 In an exemplary embodiment, it is assumed that the short circuit detection circuit 2200 is configured to detect an overcurrent condition when the load current waveform 2330 reaches or exceeds 200A or more in any half cycle. Fig.23 , waveform 2300 illustrates that the first comparison signal HC1 is set to a logic "1" level during a time period in each negative half cycle in which the load current waveform 2330 reaches or exceeds 200A. Waveform 2310 illustrates that the second comparison signal HC2 is set to a logic "1" during a time period in each positive half cycle in which the load current waveform 2330 reaches or exceeds 200A. Waveform 2320 illustrates the high current detection signal HC generated by logically NORing the waveforms 2300 and 2310. In this exemplary embodiment, waveform 2320 illustrates that the NOR gate 2210 generates a logic "0" pulse in each time period in which the load current waveform 2330 reaches and exceeds 200A in either half cycle of the load current.

[0298] It should be understood that Fig. 20 and 22 The hardware detection circuitry of the MCU allows for fast and efficient detection of current zero-crossing events, as well as fast and efficient detection and response to extreme over-current and short-circuit conditions. Although such detection can be implemented using software executed by a processor, the use of hardware detection enables fast detection and response times compared to the detection and response delays that may occur due to the non-deterministic processing time that the processor may impose by using software to analyze sensor data. In addition, Fig. 20 The current zero crossing detection circuit 2000 allows the smart circuit breaker to place the solid-state switch in an off state when the load current is near zero. In this example, the solid-state switch can be turned off when the load current is near zero to avoid kickback from the inductive load, where the high voltage kickback spike can damage the MOSFET or leakage clamp (e.g., isolation circuit system 810, Figure 8B ) of the MOSFET. Fig. 20 and 22The hardware detection circuits are powered by a DC supply (e.g., VDC-on-Hot) referenced from line hot 110. This provides the advantage of avoiding delays introduced by optoisolators or other circuits that would be required if these circuits were powered by a DC supply referenced to neutral.

[0299] Fig.24 The intelligent circuit breaker according to another embodiment of the present disclosure is schematically illustrated. Specifically, Fig.24 The smart circuit breaker 2400 connected between the AC mains 110 and the load 120 is schematically illustrated, wherein the smart circuit breaker 2400 includes a single-pole hybrid solid-state and mechanical circuit breaker architecture. The smart circuit breaker 2400 includes a solid-state switch 2410 and an air-gap electromagnetic switch 2420 connected in series in an electrical path between the line live wire 111 of the AC mains 110 and the load live wire 121 of the load 120 (for example, the air-gap electromagnetic switch 2420 and the solid-state switch 2410 are connected in series between the line input terminal and the load output terminal of the smart circuit breaker 2400). The smart circuit breaker 2400 further includes an AC to DC converter circuit 2430, a zero-crossing detection circuit system 2440, a sensing resistor 2442, a current sensor 2450, other types of sensors 2460 (for example, an environmental sensor, a light sensor, etc.), and a switch controller 2470.

[0300] In such Fig.24 In some embodiments shown in , the solid-state switch 2410 includes a power MOSFET switch 2410 (e.g., an N-type enhancement MOSFET device) having a gate terminal (G), a drain terminal (D), and a source terminal (S) as shown, and an intrinsic body diode 2410-1. The air gap electromagnetic switch 2420 includes any suitable type of electromagnetic switch mechanism configured to physically open and close a set of electrical contacts, wherein an air gap is created between the electrical contacts when the air gap electromagnetic switch 2420 is in an open state. For example, the air gap electromagnetic switch 2420 may include a latching solenoid or a relay contact element that responds to a control signal from the switch controller 2470 to automatically open or close the electrical contacts of the air gap electromagnetic switch 2420.

[0301] The creation of an air gap in the line path between the line hot wire 111 and the load hot wire 121 provides complete isolation of the AC mains 110 from the load 120 because the air gap prevents current from flowing from the line hot wire 111 to the load hot wire 121. The air gap electromagnetic switch 2420 can be placed on the line side of the solid-state switch 2410 (e.g., Fig.24) or on the load side of the solid-state switch 2410. The smart circuit breaker 2400 provides a cost-effective solution that allows one solid-state switch to be utilized (compared to several solid-state switches in the exemplary embodiment described above) in instances where electrical codes require implementation of an air gap in the circuit breaker for complete isolation.

[0302] The AC to DC converter circuitry 2430 is configured to provide DC power to various circuitry and elements of the smart circuit breaker 2400, including the zero crossing detection circuitry 2440, the switch controller 2470, and optional current sensors 2450 and other sensors 2460 (depending on the configuration of such sensors 2450 and 2460). The AC to DC converter circuitry 2430 is configured to maintain power during a fault when the solid-state switch 2410 is in an off state or when the electromagnetic switch 2420 is in an open state. In some embodiments, the AC to DC converter circuitry 2430 includes sufficient storage capacitance to power the DC subsystem immediately after a utility outage, so that relevant power outage or short circuit information can be obtained and stored by the switch controller 2470 as a utility power collapse, and then wirelessly transmitted to a remote node, device, or system using a radio frequency transceiver (not shown) coupled to or integrated with the switch controller 2470.

[0303] In some embodiments, the zero crossing detection circuit system 2440 is configured to monitor the voltage and / or current at a target point along the hot line electrical path of the smart circuit breaker 2400 and detect zero current and / or zero voltage crossings of the AC waveform on the hot line electrical path. Fig.24 , an example of a zero crossing detection circuit system 2440 coupled to the hot line electrical path upstream of switches 2420 and 2410 to detect zero current and / or zero voltage crossings of an AC power waveform on the line side of smart circuit breaker 2400. Zero crossing detection circuit system 2440 is coupled to switch controller 2470 via one or more data acquisition and control lines 2440-1.

[0304] The zero crossing detection circuit system 2440 may be implemented using any suitable type of voltage zero crossing and / or current zero crossing detection circuit system configured to sense zero crossings of current and / or voltage of an AC power waveform and generate a detection signal indicating the zero crossing event and the associated transition direction of the zero crossing event of the current or voltage waveform (e.g., the AC waveform transitions from negative to positive (referred to as a “positive transition direction”), or the AC waveform transitions from positive to negative (referred to as a “negative transition direction”)).

[0305] In some embodiments, the zero crossing detection circuit system 2440 is configured to receive as input a sample of the AC waveform on the hot path (on the line side of switches 2420 and 2410), compare the AC waveform sample to a zero reference voltage (e.g., the line neutral voltage) to determine the polarity of the AC waveform on the hot path, and detect zero crossing events and the associated transition direction of the zero crossing of the AC waveform. In some embodiments, the comparison is performed using a voltage comparator having a non-inverting input connected to the hot path and an inverting input receiving a reference voltage. The output of the voltage comparator (i) switches from a logic 1 to a logic 0 when the input voltage transitions from positive to negative and (ii) switches from a logic 0 to a logic 1 when the input voltage transitions from negative to positive. In this example, the output of the zero crossing detection circuit system 2440 will transition between a logic "1" output and a logic "0" output at each detected zero crossing of the AC voltage waveform.

[0306] In some embodiments, the zero crossing detection circuitry 2420 implements Fig. 20 Current zero crossing detection circuit 2000. In this example, Fig.24 The sense resistor 2442 in the Fig. 20 Instead of or in addition to the voltage zero crossing detection circuitry, current zero crossing detection circuitry is utilized to determine when the AC current waveform (i.e., AC load current) on the hot line is zero and the direction of transition of the AC current waveform. In an example, this is required, for example, when there is an inductive load that causes the voltage and current waveforms on the hot line path to be out of phase.

[0307] In some embodiments, the current sensor 2450 is configured to detect the magnitude of the current drawn by the load 120 in the hot line path through the smart circuit breaker 2400. The current sensor 2450 can be implemented using any suitable type of current sensing circuit, including but not limited to a current sensing resistor, a current amplifier, a Hall effect current sensor, etc. The current sensor 2450 is coupled to the switch controller 2470 via one or more data acquisition and control lines 2450-1. In some embodiments, the current sensor 2450 implements Fig. 22 The short circuit detection circuit 2200 of the embodiment of the present invention is shown in FIG. 2 , wherein the current sensor 2450 includes a sense resistor connected in series between the load side of the solid-state switch 2410 and the load live wire 121. In some embodiments, the current sensor 2450 utilizes the same sense resistor 2442 as the zero crossing detection circuit system 2440, wherein the current sensor 2450 will have a sense resistor connected to nodes N1 and N2 to sense the voltage V Sense Input to be sampled.

[0308] Sensor 2460 includes one or more optional sensors configured to sense environmental conditions (e.g., chemicals, gases, humidity, water, temperature, light, etc.) and generate sensor data indicative of potentially hazardous environmental conditions. Sensor 2460 is coupled to switch controller 2470 via one or more data acquisition and control lines 2460-1. By way of example, sensor 2460 may include one or more of the following: (i) a chemical sensitive detector configured to detect the presence of hazardous chemicals; (ii) a gas sensitive detector configured to detect the presence of hazardous gases; (iii) a temperature sensor configured to detect high temperatures indicative of, for example, a fire; (iv) a piezoelectric detector configured to detect large vibrations associated with, for example, an explosion, an earthquake, etc.; (v) a humidity sensor or water sensor configured to detect flooding or wet conditions; and other types of sensors configured to detect the presence or occurrence of hazardous environmental conditions that would warrant circuit interruption.

[0309] The switch controller 2470 operates in conjunction with the zero-crossing detection circuit system 2440, the current sensor 2450, and the sensor 2460 to perform functions such as detecting a fault condition (e.g., a short circuit fault, an overcurrent fault, an arc fault, a ground fault, etc.), detecting a hazardous environmental condition (e.g., a gas leak, a chemical spill, a fire, a flood, etc.), and providing timing control for the opening and closing of the switches 2410 and 2420 in response to detecting a fault condition or a hazardous environmental condition to thereby avoid arcing in the air-gap electromagnetic switch 2420. The switch controller 2470 generates a gate control signal that is applied to the gate terminal (G) of the solid-state switch 2410 to place the solid-state switch 2410 in an on or off state. In some embodiments, the switch controller 2470 generates a gate control signal to place the solid-state switch 2410 in an off state in response to a fault condition, such as a short circuit fault, an overcurrent fault, an overvoltage condition, and other faults or hazards detected by the switch controller 2470 due to analysis of sensor data obtained from the current sensor 2450 and / or other sensors 2460.

[0310] The switch controller 2470 may be implemented using a processor configured to process sensor data and implement a switch control timing protocol as discussed herein for controlling switches 2410 and 2420. Additionally, the switch controller 2470 may implement circuitry for converting the sensor data into an appropriate format suitable for processing by the processor. In other embodiments, the switch control 2470 implements hardware-based switch control circuitry (as in the exemplary embodiments discussed above) to achieve hardware-based control rather than software-based control.

[0311] The switch controller 2470 may include an RF transceiver to wirelessly communicate with remote nodes, devices, systems, etc. to support remote monitoring and detection of fault conditions and to receive remote commands for controlling the smart circuit breaker 2400. Processors may include central processing units, microprocessors, microcontrollers, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), and other types of processors, as well as portions or combinations of such processors that may perform processing functions based on software, hardware, firmware, etc. In other embodiments, the solid-state circuitry of the various components of the smart circuit breaker 2400 (e.g., 2430, 2440, and 2470) may be implemented on a single die as a system on a chip.

[0312] To prevent arcing between the electrical contacts of the electromagnetic switch 2420, the switch controller 2470 is configured to place the solid-state switch 2410 in an off state before placing the air gap electromagnetic switch 2420 in an open or closed state. Fig.24 In the configuration, even when the solid-state switch 2410 is in the off state, and assuming that the air gap electromagnetic switch 2420 is in the closed state, the body diode 2410-1 of the solid-state switch 2410 will allow negative current to be conducted from the load 120 to the AC mains 110 when the AC power waveform of the AC mains 110 is in the negative half cycle.

[0313] In this example, if the air gap electromagnetic switch 2420 is opened during the negative half cycle of the AC power waveform, the flow of negative current will create an arc between the electrical contacts of the air gap electromagnetic switch 2420. In addition to the creation of an arc, it may be difficult or impossible to open the air gap electromagnetic switch 2420 due to the relatively strong electromagnetic forces that will be generated due to the short circuit current condition and the negative current at a given time.

[0314] In order to avoid the generation of such arcs and to be able to easily disconnect the air gap electromagnetic switch 2420, the switch controller 2470 is configured to place the solid-state switch 2410 in an off state in response to detecting a fault or dangerous condition, and to process the sensor data obtained from the zero-crossing detection circuit system 2440 to determine the zero-crossing event and the associated transition direction of the zero-crossing event of the AC voltage and / or current on the line side (e.g., the line live wire 111) of the smart circuit breaker 2400, and then disconnect the air gap electromagnetic switch 2420 in response to the detected zero-crossing event when the polarity of the AC voltage and / or current on the line side is determined to have transitioned to a positive half-cycle.

[0315] On the other hand, when the switch controller 2470 determines at a given time that the associated transition direction of the zero crossing event is a positive transition to a negative transition of the polarity of the AC voltage and / or current on its zero line side, the switch controller 2470 will not open the air gap electromagnetic switch 2420, but will delay opening the air gap electromagnetic switch 2420 until the next instance of a zero crossing event with a positive transition as detected by the zero crossing detection circuitry 2440. In this instance, the air gap electromagnetic switch 2420 will open during the half cycle in which the solid state switch 2410 is blocking all current (less any leakage). This switch control protocol achieves a significant reduction in the size and strength requirements of the electromagnetic mechanism that opens the air gap electromagnetic switch 2420.

[0316] Now refer to Fig.25A , 25B 26 discusses the switch timing control implemented by the switch controller 2470 in more detail. For example, Fig.25A Description Input Fig.24 The power supply voltage waveform on the line side of the intelligent circuit breaker 2400. Specifically, Fig.25A An input voltage waveform 2500 representing the power supply voltage waveform of the AC mains 110 is illustrated. The input voltage waveform 2500 includes a positive half cycle 2502, a negative half cycle 2504, and a zero voltage crossing 2510 at times T0, T1, T2, T3, and T4. When the solid-state switch 2410 is in the on state and the air-gap electromagnetic switch 2420 is in the closed state, the input voltage waveform 2500 is applied to the load live wire 121 of the load 120. When the switch controller 2470 determines that the power supply should be disconnected from the load 120, the switch controller 2470 will generate a gate control signal, which is applied to the gate terminal G of the solid-state switch 2410 to place the solid-state switch 2410 in the off state.

[0317] Fig.25B Description: When the solid-state switch 2410 is in the off state and the air gap electromagnetic switch 2420 is in the closed state Fig.24 The output voltage waveform 2520 on the load side of the smart circuit breaker 2400. In this state, the body diode 2410-1 of the solid-state switch 2410 is forward biased during the negative half cycle 2504 of the input voltage waveform 2500, which rectifies the input voltage waveform 2500 and produces Fig.25B , where a portion 2522 of the output voltage waveform 2520 corresponding to the positive half cycle 2502 of the input waveform 2500 is at 0V, and where a portion 2524 of the output voltage waveform 2520 tracks the voltage of the negative half cycle 2504 of the input waveform 2500. In this example, a negative current will flow from the load 120 to the AC mains 110 during each negative half cycle 2524 until the air gap electromagnetic switch 2420 opens.

[0318] As mentioned above, after the solid-state switch 2410 is turned off, the switch controller 2470 will process the sensor data obtained from the zero-crossing detection circuit system 2440 to determine the zero-crossing event and the transition direction of the zero-crossing event of the AC voltage waveform (and / or AC current waveform) on the live path of the smart circuit breaker 2400. The switch controller 2470 will generate a control signal to open the air-gap electromagnetic switch 2420 in response to the detected zero-crossing event if the AC voltage waveform is transitioning to the positive half cycle. For example, while Fig.25A The zero crossing events 2510 of the AC waveform 2500 at times T0, T1, T2, T3, and T4 are shown, but only the zero crossing events 2510 at times T0, T2, and T4 have a positive transition direction where the AC waveform 2500 transitions to a positive half cycle.

[0319] In this example, the switch controller 2470 will generate a control signal in response to a zero-crossing event at T0, T2, or T4 to open the air-gap electromagnetic switch 2420 to completely disconnect the power supply from the load 120. Specifically, if Fig.25A As shown in FIG. 2 , in some embodiments, in response to detecting a positive transition zero crossing event (e.g., at time T0 or T2), the switch controller 2470 will wait for a short delay T before generating a switch control signal to open the air gap electromagnetic switch 2420. S (For example, about 10 μs). This short delay time T S It is ensured that the AC waveform is slightly positive and no current is flowing in the live path, thereby preventing possible arc formation in the air gap electromagnetic switch 2420 and allowing the air gap electromagnetic switch 2420 to open easily without jitter due to the small current.

[0320] On the other hand, suppose a fault condition occurs and solid-state switch 2410 is in Fig.25A and 25B In this example, the switch controller 2470 will determine that the next zero crossing event 2510 of the AC waveform 2500 at time T1 is a negative transition zero crossing event. In this example, the switch controller 2470 will wait for the next positive transition zero crossing event 2510 at time T2 and then generate a control signal (delay time T after the zero crossing event is detected at time T2). S 2420 to open the air gap electromagnetic switch 2420. Again, this ensures that the AC waveform 2500 is slightly positive and no current is flowing in the hot line path, thereby preventing possible arc formation in the air gap electromagnetic switch 2420 and allowing the air gap electromagnetic switch 2420 to open easily without jitter due to small currents.

[0321] It should be understood that the exemplary voltage waveforms 25A and 25B represent a load 120 having a power factor of approximately one (1), wherein it is assumed that the AC voltage waveform and the current drawn by the load 120 are in phase. In such examples, the zero voltage crossing is assumed to be a zero current crossing. However, in examples where the load 120 has a power factor less than one (e.g., a capacitive or inductive load), the voltage waveform and the current drawn by the load 120 will be out of phase. In this regard, the zero crossing detection circuitry 2440 may include a current zero crossing detector to determine a zero current crossing or a positive transition zero current crossing of the current waveform on the line side of the switches 2420 and 2410 to ensure that no positive current is flowing on the line hot path prior to opening the air gap electromagnetic switch 2420. For example, as mentioned above, in some embodiments, the zero crossing detection circuitry 2420 implements Fig. 20 Current zero-crossing detection circuit 2000.

[0322] Fig.26 According to the embodiment of the present disclosure, Fig.24 Flow chart of the switch control process implemented by the switch controller 2470 of the intelligent circuit breaker 2400. Fig.26 The switch control process of represents a non-limiting exemplary embodiment for restoring utility power or manual, automatic or remote activation control to activate the smart circuit breaker 2400 (block 2600). In this example, it is assumed that the solid-state switch 2410 is in the off state and the air gap electromagnetic switch 2420 is in the closed state.

[0323] The switch controller 2470 waits to detect the proper zero crossing (block 2602) before closing the air gap electromagnetic switch 2420 (block 2604). Although it is ideal to wait for a voltage and / or current zero crossing condition before closing the air gap electromagnetic switch 2420, those skilled in the art will appreciate that this is not a required condition for closing. The zero crossing event may be a positive transition zero crossing event or a negative transition zero crossing event. As mentioned above, in some embodiments, it is preferred to close the air gap electromagnetic switch 2420 at the zero crossing of the upcoming half cycle in which the body diode (e.g., diode 2410-1) of the solid state switch (e.g., switch 2410) is not forward biased and conducting. For example, at Fig.24 In an exemplary embodiment of the present invention, the body diode 2410-1 of the solid-state switch 2410 is reverse biased and non-conductive during the positive half cycle of the supply voltage waveform of the AC mains 110. In such an embodiment, it is desirable to place the air-gap electromagnetic switch in a closed state upon detection of a positive transition (current or voltage) zero crossing event (block 2604).

[0324] In other embodiments, depending on the type of MOSFET used to implement the solid-state switch 2410, it may be desirable to close the air gap electromagnetic switch 2420 upon detecting a negative transition (current or voltage) zero crossing event. Fig.24 In an exemplary embodiment where the solid-state switch 2410 in is implemented as a P-type enhancement MOSFET having a drain terminal coupled (line side) to the air-gap switch 2420 and a source terminal coupled (load side), the body diode of the P-type MOSFET will have its anode connected to the line side and its cathode disposed on the load side. In such an example, the body diode of the P-type solid-state switch will be reverse biased and non-conductive during the negative half-cycle of the supply voltage waveform of the AC mains 110. Thus, it would be ideal to close the air-gap electromagnetic switch 2420 upon detection of a negative transition (current or voltage) zero crossing event when the P-type solid-state switch is in the off state. The same applies to Fig.24 The N-type solid-state switch 2410 shown in FIG. 1 has a circuit configuration in which the line side is connected with the source terminal and the load side is connected with the drain terminal in reverse.

[0325] When the air gap electromagnetic switch 2420 is closed, the switch controller 2470 will continue to generate a gate control signal to place the solid state switch 2410 in the on state (block 2606). The solid state switch 2410 may be turned on at any time after the air gap electromagnetic switch 2420 is closed. For example, the smart circuit breaker 2400 may operate in a "standby" mode, in which the air gap electromagnetic switch 2420 is maintained in a closed state, and the switch controller 2470 waits for the occurrence of a certain triggering event (e.g., a remote command) to continue to activate the solid state switch 2410.

[0326] When both switches 2410 and 2420 are activated, the switch controller 2470 will enter a wait state (block 2608) waiting for some event or command to interrupt the circuit connection between the power supply and the load. During the wait period, the solid-state switch 2410 and the air-gap electromagnetic switch 2420 will remain in an activated state (block 2610). The event may be the detection of a given fault condition or hazardous condition as determined by the switch controller 2470 processing sensor data received from the various sensors 2450 and 2460. The command may be a manual command or an automatic command to interrupt the circuit connection.

[0327] Upon detection of a fault or hazardous condition (affirmative determination in block 2608) or in response to a manual or automatic command to trip the circuit breaker, the switch controller 2470 will generate a gate control signal to place the solid-state switch 2410 in the OFF state (block 2612). The switch controller 2470 will then continue to process data from the zero-crossing detection circuitry 2440 to detect a target zero-crossing event (e.g., a positive transition zero-crossing event) on the line hot path (block 2614), and in response to detecting the target zero-crossing event (affirmative determination in block 2614), the switch controller 2470 will generate a switch control signal to place the air-gap electromagnetic switch 2420 in the OFF state (block 2616).

[0328] The switch controller 2470 will enter a wait state waiting for the fault event or hazardous condition to clear (block 2618) and maintain the solid-state and air-gap electromagnetic switches in a deactivated state (block 2620). When the fault event or hazardous condition is cleared (affirmative determination in block 2618), or when the switch controller 2470 otherwise receives a manual or remote command instructing to reconnect power to the load, control returns to block 2600, where the switch controller 2470 continues to reactivate the air-gap and solid-state switches and thereby reconnect power to the load. It should be understood that although Fig.26 The process flow does not explicitly include a process step for performing zero crossing detection prior to opening and closing the solid-state switch 2410, but technicians in the field will recognize and understand that for certain applications, the opening and closing of the solid-state switch 2410 can be timed by voltage or current zero crossing events as needed.

[0329] Fig. 27 The intelligent circuit breaker according to another embodiment of the present disclosure is schematically illustrated. Specifically, Fig. 27 The intelligent circuit breaker 2700 connected between the AC mains 110 and the load 120 is schematically illustrated. The intelligent circuit breaker 2700 is similar to Fig.24 The difference of the intelligent circuit breaker 2400 is Fig. 27 The intelligent circuit breaker 2700 implements a thermal electromechanical circuit breaker switch 2710 (instead of Fig.24 In some embodiments, the thermomechanical circuit breaker switch 2710 includes a conventional circuit breaker architecture, such as the above combined with the air gap electromagnetic switch 2420, the internal switch 2720 and the shunt resistor 2730. Figure 1A Discussed.

[0330] The internal switch 2720 and the shunt resistor 2730 are connected in series between a node N3 and the ground (neutral) 114, wherein the node N3 comprises a connection point between the thermal electromechanical circuit breaker switch 2710 and the solid-state switch 2410. In some embodiments, as Fig. 27As shown in FIG. 2 , the internal switch 2720 comprises a solid-state bidirectional switch including a first MOSFET switch 2721 and a second MOSFET switch 2722 (e.g., N-channel MOSFET switches) connected in series back-to-back with a commonly connected source terminal and a commonly connected gate terminal. The commonly connected gate terminals of the first MOSFET switch 2721 and the second MOSFET switch 2722 are connected to the control output port of the switch controller 2470. The first MOSFET switch 2721 and the second MOSFET switch 2722 have intrinsic body diodes ( Fig. 27 (not shown in detail).

[0331] As in Fig.24 In an exemplary embodiment of the present invention, the switch controller 2470 operates in conjunction with the zero-crossing detection circuit system 2440, the current sensor 2450, and the other sensors 2460 to perform functions such as detecting fault conditions (e.g., short circuit conditions, overcurrent conditions, overvoltage conditions, arc faults, ground faults, etc.), and detecting hazardous environmental conditions (e.g., gas leaks, chemical spills, fires, floods, etc.). The switch controller 2470 is configured to apply a control signal to the gate terminal (G) of the solid-state switch 2410 to control the activation (on) and deactivation (off) of the solid-state switch 2410. In addition, the switch controller 2470 is configured to generate a control signal to control the activation and deactivation of the internal switch 2720. The switch controller 2470 implements a timing control protocol that is configured to control the timing of activation / deactivation of the solid-state switch 2410 and the internal switch 2720 under different operating conditions of the smart circuit breaker 2700.

[0332] For example, the switch controller 2470 generates a gate control signal to place the solid-state switch 2410 in an off state in response to a detected fault condition, such as a short circuit fault, an overcurrent fault, an overvoltage condition, and other faults or hazards detected by the switch controller 2470 as a result of analyzing sensor data obtained from the current sensor 2450 and / or other sensors 2460. In addition, after the solid-state switch 2410 is turned off, the switch controller 2470 generates a control signal to activate the internal switch 2720 and thereby generate an internal short circuit between the node N3 and the ground 114. The internal short circuit between the node N3 and the ground 114 causes an overcurrent to flow through the thermo-mechanical circuit breaker switch 2710 and thereby trips the thermo-mechanical circuit breaker switch 2710 and generates an air gap in the electrical path between the line hot wire 110 and the load hot wire 121.

[0333] In other words, in this embodiment, the switch controller 2470 does not generate a control signal that is directly applied to the thermo-electromechanical circuit breaker switch 2710 to trip the thermo-electromechanical circuit breaker switch 2710. Instead, the switch controller 2470 applies a gate control signal to the commonly connected gate terminals of the first MOSFET switch 2721 and the second MOSFET switch 2722 to turn on the first MOSFET switch 2721 and the second MOSFET switch 2722. This creates an internal short circuit between the node N3 and the ground 114, where current flows through the shunt resistor 2730, which trips the thermo-electromechanical circuit breaker switch 2710. The internal switch 2720 is deactivated (e.g., the first MOSFET switch 2721 and the second MOSFET switch 2722 are turned off) at a certain point in time after the thermo-electromechanical circuit breaker switch 2710 is tripped and before the smart circuit breaker 2700 is reset for normal operation.

[0334] In some embodiments, the resistance of the shunt resistor 2730 is selected so that the short circuit current from the node N3 to the ground 114 is in the range of about 2 to 3 times the current rating of the thermo-electromechanical circuit breaker switch 2710. For example, if the thermo-electromechanical circuit breaker switch 2710 has a current rating of 20 amperes, the resistance 2730 of the shunt resistor is selected so that a current of approximately 40 to 60 amperes maximum flows through the thermo-electromechanical circuit breaker switch 2710 and through the short circuit branch between the node N3 and the ground 114 so that the thermo-electromechanical circuit breaker switch 2710 trips and creates an air gap in the electrical path between the line hot wire 110 and the load hot wire 121.

[0335] In some embodiments, the switch controller 2470 is configured to utilize the zero-crossing detection signal output from the zero-crossing detection circuit 2440 to determine when to activate the internal switch 2720 and thereby create a short circuit between the node N3 and the ground 114, which causes the thermal electromechanical circuit breaker switch 2710 to trip. Figure 24-26 In the exemplary embodiment discussed, when the zero crossing detection circuit 2440 is configured to detect the direction of the polarity transition between opposite half-cycles of the AC voltage waveform or the AC current waveform on the line side of the thermal electromechanical circuit breaker switch 2710, the switch controller 2470 is configured to activate the internal switch 2720 when the polarity transition causes the body diode 2410-1 of the deactivated solid-state switch 2410 to be reverse biased.

[0336] exist Fig. 27In an exemplary embodiment of the present invention, the body diode 2410-1 of the solid-state switch 2410 is reverse biased during the positive half-cycle of the AC voltage waveform or the AC current waveform on the line side of the thermo-mechanical circuit breaker switch 2710. However, when the AC power waveform, such as the AC mains 110, is in the negative half-cycle, the body diode 2410-1 of the solid-state switch 2410 will be forward biased and allow negative current to be conducted from the load 120 to the AC mains 110 through the thermo-mechanical circuit breaker switch 2710.

[0337] In this example, if the internal switch 2720 is activated during the negative half cycle of the AC power waveform, the current through the thermo-electromechanical circuit breaker switch 2710 will be a combination of (i) the negative current from the load 120 to the AC mains 110 and (ii) the current generated in the short circuit path from the ground 114 to the node N3, thereby providing an increased current through the thermo-electromechanical circuit breaker switch 2710 to trip the thermo-electromechanical circuit breaker switch 2710. This may result in a high energy arc being generated between the electrical contacts of the thermo-electromechanical circuit breaker switch 2710 upon tripping.

[0338] In contrast, by ensuring that the internal switch 2720 is activated when the polarity transition causes the body diode 2410-1 of the solid-state switch 2410 to be reverse biased, the amount of current through the thermo-electromechanical circuit breaker switch 2710 is at least initially limited to the current generated in the short-circuit path between the node N3 and the ground 114 based on the resistance value of the shunt resistor 2730. In this example, the amount of short-circuit current generated to trip the thermo-electromechanical circuit breaker switch 2710 can be controlled / limited by the shunt resistor 2730, and thus limit the amount of arcing generated between the electrical contacts of the thermo-electromechanical circuit breaker switch 2710 when tripping. In other words, by timing the activation of the internal switch 2720 to the time when the body diode 2410-1 of the deactivated solid-state switch 2140 is reverse biased, the smart circuit breaker 2700 avoids using the actual short-circuit load current to trip the conventional thermomechanical circuit breaker switch 2710, and instead utilizes a limited / controlled internal short-circuit current (which is generated by the activation of the internal switch 2720) to trip the circuit breaker switch 2710.

[0339] In other embodiments, the smart circuit breaker is designed to include one or more visual indicators that allow an individual to determine the operating status of the smart circuit breaker. Fig.28A , 28B , 28C, 28D and 28E are perspective views and schematic diagrams of a smart circuit breaker 2800 including a plurality of visual indicators configured to indicate the operating status of the smart circuit breaker 2800. Specifically, Fig.28A and 28B2800 includes a circuit breaker housing 2810 (or cover), a manual toggle switch 2820, a first visual indicator 2830, and a second visual indicator 2840. The manual toggle switch 2820 includes an off position and an on position that allow a person to manually trip and reset the smart circuit breaker 2800. As explained in further detail below, the first visual indicator 2830 and the second visual indicator 2840 are configured to provide a visual status of the operating status of the smart circuit breaker 2800. Fig.28C , 28D 28E schematically illustrate various components within the circuit breaker housing 2810 of the smart circuit breaker 2800. For example, Figures 28C-28E As shown in , the assembly includes an actuator mechanism 2850, a solenoid 2860, and an air gap switch 2870. The air gap switch 2870 includes a first fixed contact 2871 and a second movable contact 2872 connected to the actuator mechanism 2850. The manual toggle switch 2820 and the solenoid 2860 are connected to the actuator mechanism 2850. The actuator mechanism 2850 is configured to control the position of the movable contact 2872 relative to the fixed contact 2871 in response to (i) manual actuation of the toggle switch 2820 and (ii) magnetic actuation of the solenoid 2860. In this configuration, the solenoid 2850 is configured to be magnetically actuated in response to a high overcurrent, wherein the magnetic actuation of the solenoid 2860 causes mechanical actuation of the actuator mechanism 2850 to separate the movable contact 2872 from the fixed contact 2871 of the air gap switch 2870. For ease of illustration and explanation, Fig.28C , 28D 28E do not illustrate circuit boards and associated solid-state circuitry for implementing the various intelligent functionalities of the smart circuit breaker 2800 as discussed above.

[0340] Fig.28C , 28D 28E illustrate different operating states of the intelligent circuit breaker 2800. Specifically, Fig.28C An operating state is described in which the air gap switch 2870 is “off” and the first contact 2871 and the second contact 2872 are separated to form an air gap 2873. Fig.28C , the manual toggle switch 2820 is in the "off" position. In this example, the air gap switch 2870 is manually opened by moving the toggle switch 2820 from the on position to the off position, wherein actuation of the toggle switch 2820 in this example causes the actuator mechanism 2850 to move the movable contact 2872 away from the fixed contact 2871.

[0341] Next, Fig.28DAn operating state is described in which the air gap switch 2870 is "closed" and the first contact 2871 and the second contact 2872 make electrical contact and the air gap 2873 is closed. Fig.28D , the manual toggle switch 2820 is in the "on" position and the solenoid 2860 is in the closed position. In this example, the air gap switch 2870 is manually closed by moving the toggle switch 2820 from the off position to the on position, wherein actuation of the toggle switch 2820 in this example causes the actuator mechanism 2850 to move the movable contact 2872 against the fixed contact 2871. Fig.28D The normal operation status of the intelligent circuit breaker 2800 is described.

[0342] Next, Fig.28E An operating state is described in which the air gap switch 2870 is “off” and the first contact 2871 and the second contact 2872 are separated to form an air gap 2873. Fig.28E , it is assumed that the manual toggle switch 2820 is in the “on” position, and due to the magnetic actuation of the solenoid 2860 (e.g., the solenoid 2860 is in the off position), the smart circuit breaker 2800 is in the “tripped” state, so that the actuator mechanism 2850 moves the movable contact 2872 away from the fixed contact 2871, and thereby opens the air gap switch 2870 to form the air gap 2873. In this example, the smart circuit breaker 2800 is electromechanically tripped, and the smart circuit breaker 2800 is reset by moving the manual toggle switch 2820 from the on position to the off position and then back to the on position.

[0343] like Figures 28A-28E , the first visual indicator 2830 includes a window 2832 (e.g., a glass or plastic window) formed as part of the circuit breaker housing 2810, and a status LED 2834 disposed behind the window 2832 within the circuit breaker housing 2810. The status LED 2834 is illuminated to indicate the state of the smart circuit breaker 2800 (e.g., on, off, standby, wireless state, supply, etc.). The status LED 2834 may emit different colors (e.g., red, green, etc.) and / or have different illumination patterns (e.g., continuous, flashing, etc.) to indicate different operating states. In some embodiments, the status LED 2834 is only operable when utility power is present.

[0344] Fig.28AAn exemplary embodiment is described in which the status LED 2834 of the first visual indicator 2830 is illuminated in a first color (e.g., red) when the smart circuit breaker 2800 is in a "tripped" state in which the manual toggle switch 2820 is in the on position but the air gap switch is in the off state. In other embodiments, when the smart circuit breaker 2800 is operating normally (e.g., non-tripped state) with the manual toggle switch 2820 in the on position, the status LED 2834 of the first visual indicator 2830 may be illuminated in another color (e.g., green).

[0345] Fig.28B An exemplary embodiment is described in which the status LED 2834 of the first visual indicator 2830 does not illuminate when the smart circuit breaker 2800 is in the off state (e.g., not connected to utility power, or connected to utility power but the manual toggle switch 2820 is in the off position). In this example, when the status LED 2834 is not illuminated, the viewing window 2832 can have a coating with a translucent color that is the same or similar to the color of the circuit breaker housing 2810.

[0346] In addition, if Figures 28A-28E 2832, the second visual indicator 2840 includes a window 2842 (e.g., a glass or plastic window) formed as part of the circuit breaker housing 2810, and a first colored element 2844 (or more generally, a first indicator element) and a second colored element 2846 (or more generally, a second indicator element) disposed within the circuit breaker housing 2810 and selectively positioned behind the window 2832 to display different operating states of the smart circuit breaker. More specifically, in some embodiments, the second visual indicator 2840 is configured to provide the state of the air gap switch 2870 (open or closed).

[0347] For example, the first colored element 2844 and the second colored element 2846 include colored plastic sheets bonded to a portion of the actuator mechanism 2850 or otherwise include a painted surface on a portion of the actuator mechanism 2850. The first colored element 2844 and the second colored element 2846 are selectively disposed behind the viewing window 2842 to allow an individual to view the colors and thereby determine the state of the air gap switch 2870 based on the colors visible through the viewing window 2842. For example, the second colored element 2846 may be a red color indicating that the air gap is in an "open" state, while the first colored element 2844 may be a non-red color (e.g., black) indicating that the air gap is in a "closed" state. In other embodiments, the first indicator element 2844 and the second indicator element 2846 may implement other means of indicating the state of the air gap switch 2870, such as words, patterns, etc., in addition to and / or in lieu of different colors.

[0348] For example, Fig.28C and 28E Schematically illustrating that the air gap switch 2870 is in the "off" state ( Fig.28C In this state, the second colored element 2846 is positioned behind the viewing window 2842 by the movement of the actuator mechanism 2850 to open the air gap switch 2870, while the first colored element 2844 is positioned away from the viewing window 2842.

[0349] on the other hand, Fig.28D Schematically illustrated is a state in which the air gap switch 2870 is in a "closed" state by manual actuation of the toggle switch 2820 which causes the air gap switch 2870 to close. In this state, the first colored element 2844 is positioned behind the viewing window 2842 by movement of the actuator mechanism 2850 to close the air gap switch 2870, while the second colored element 2846 is positioned away from the viewing window 2842. In this regard, the second visual indicator 2840 functions as such even when utility power is not present and safely provides an "air gap open" indicator.

[0350] Fig.29 Schematically illustrates an intelligent circuit breaker 2900 according to another embodiment of the present disclosure. The intelligent circuit breaker 2900 is similar to Figures 28A-28E The invention relates to a smart circuit breaker 2800 of the present invention, except that the smart circuit breaker 2900 includes a secondary internal sensing switch 2910 (e.g., an electromechanical detector) coupled to the manual toggle switch 2820. The sensing switch 2910 is configured to detect an expected manual state change of the toggle switch 2820 from, for example, an on position (the air gap switch 2870 is closed) to an off position (the air gap switch 2870 is open). The sensing switch 2910 triggers the electronics of the smart circuit breaker 2900 (e.g., a solid-state switch control circuit system) to activate or deactivate the solid-state switch (e.g., a bidirectional solid-state switch) before the air gap switch 2870 ends its opening or closing movement, which takes a period of time, for example, one or two orders of magnitude longer than the time required to open / close the solid-state switch. The internal sensing switch 2910 ensures that, for example, the air gap switch 2870 does not open at high load currents, or that the air gap switch 2870 closes before the solid-state switch is activated.

[0351] Although exemplary embodiments have been discussed above in the context of smart circuit breakers used with AC power supplies, it should be appreciated that smart circuit breakers can be configured for use with DC power supplies. There are various systems (e.g., telecommunications systems) that operate using DC power supplies rather than AC power supplies. In these systems, AC power delivered / provided by a utility company can be converted locally to a DC power supply (using an AC to DC power conversion system), where the DC power supply is then fed to one or more DC distribution panels having DC circuit breakers, which feed downstream branch circuits and loads.

[0352] Depending on whether AC power or DC power is applied to the line input terminals of the smart circuit breaker, the exemplary embodiments of the smart circuit breaker as discussed herein can be configured to operate in an "AC protection mode" or a "DC protection mode." For example, when the smart circuit breaker is powered on, the solid-state circuit system (e.g., sensor, processor, etc.) of the smart circuit breaker can be configured to detect whether AC power or DC power is applied to the line input terminals of the smart circuit breaker, and then automatically configure the smart circuit breaker to operate in the AC protection mode or the DC protection mode depending on the detected input power.

[0353] More specifically, in some embodiments, when power is initially applied to the line input terminal of the smart circuit breaker, a voltage sensor or zero-crossing detector coupled to the line side of the switch of the smart circuit breaker may monitor the voltage waveform and send the sensor data to the processor. The processor of the smart circuit breaker may analyze the sensor data to determine whether the input power is AC or DC. For example, when the voltage sensor data indicates that the magnitude of the input voltage remains at a constant level within a predetermined time period, and / or when the zero-crossing detection circuit system does not output a zero-crossing event signal within a predetermined time period, the processor may determine that DC power is applied to the line input terminal. On the other hand, when the voltage sensor data indicates that the magnitude of the input voltage changes and / or when the zero-crossing detection circuit system outputs multiple zero-crossing event signals within a predetermined time period, the processor may determine that AC power is applied to the line input terminal.

[0354] In some embodiments, the processor (e.g., microprocessor, controller, etc.) of the smart circuit breaker can be configured to process different embedded software programs (e.g., different state machines) for different protection modes. The embedded software programs for different protection modes include different program instructions and utilize different predefined parameters or register values ​​to enable the processor to make intelligent control decisions in response to detection and response to fault conditions (e.g., short circuit, overcurrent, overvoltage, etc.) depending on the detected power supply (AC or DC power). For example, different thresholds and timing considerations for identifying overcurrent or overvoltage conditions and protecting against them will vary depending on whether the smart circuit breaker is operating in the DC protection mode of the AC protection mode.

[0355] In addition, the switch control protocol for controlling the activation and deactivation of the switch (e.g., solid-state bidirectional switch) of the smart circuit breaker will vary depending on whether the smart circuit breaker is operating in a DC protection mode or an AC protection mode. For example, in the DC protection mode, the gate-source voltages of the two MOSFET devices of the solid-state bidirectional switch are controlled so that both MOSFET devices are turned on during normal operation, and both MOSFET devices are turned off in response to the detection of a fault condition. In addition, in order to save power, some hardware circuit systems of the smart circuit breaker may be disabled depending on whether the smart circuit breaker is operating in a DC protection mode or an AC protection mode. For example, when the smart circuit breaker is operating in a DC protection mode, the zero-crossing detection circuit of the smart circuit breaker may be disabled. In addition, in the DC protection mode, the AC to DC converter of the smart circuit breaker may be disabled, and the DC to DC converter of the smart circuit breaker may be selectively enabled to convert the DC power supply voltage (applied to the line input terminal of the smart circuit breaker) to a lower DC voltage to power the solid-state circuit system of the smart circuit breaker.

[0356] Exemplary embodiments of smart circuit breakers as discussed herein and illustrated by the drawings include various features, functions, components, etc. that can be used to implement different types of smart circuit breakers with various functions for different applications. In this regard, it should be understood that a smart circuit breaker illustrated in one figure may be incorporated with one or more additional features illustrated in one or more other figures to implement another architecture of the smart circuit breaker. For example, all exemplary embodiments of smart circuit breakers as illustrated throughout the figures may be configured to include arc fault and / or ground fault sensing and protection capabilities.

[0357] At this point, it should be understood that exemplary embodiments of the present disclosure encompass various embodiments of circuit breakers, and associated systems and methods as discussed herein, which may be summarized as follows or otherwise expanded upon.

[0358] In some embodiments, a circuit breaker includes: an electromechanical switch connected in series between a line input terminal and a load output terminal of the circuit breaker and configured to be placed in one of (i) a closed state and (ii) an open state; a current sensor configured to sense the magnitude of a current flowing in an electrical path between the line input terminal and the load output terminal and generate a current sensing signal; a voltage sensor configured to sense the magnitude of a voltage at a point on the electrical path between the line input terminal and the load output terminal and generate a voltage sensing signal; and a processor configured to receive and process the current sensing signal and the voltage sensing signal to determine operating status information of the circuit breaker and determine power usage information of a load connected to the load output terminal.

[0359] In some embodiments, the circuit breaker further includes a radio frequency transceiver coupled to the processor, wherein the radio frequency transceiver is configured to transmit the operating status information and the power usage information to the remote computing node, and to receive remote control commands transmitted from the remote computing node for processing by the processor.

[0360] In some embodiments, the voltage sensor includes: a first voltage sensor coupled to an electrical path upstream of the electromechanical switch and configured to sense the magnitude of an AC power voltage applied to a power input terminal; and a second voltage sensor coupled to an electrical path downstream of the electromechanical switch and configured to sense the magnitude of a load voltage of a load connected to a load output terminal.

[0361] In some embodiments, the current sensor includes circuitry configured to detect an overcurrent condition, generate a control signal indicative of the detected overcurrent condition, and output the control signal to a processor to notify the processor of the overcurrent condition. In some embodiments, the current sensor detects the overcurrent condition based on a programmable overcurrent threshold. In some embodiments, the overcurrent threshold comprises a reference threshold current generated by a current digital-to-analog converter and applied to an input of a comparator of the current sensor.

[0362] In some embodiments, the electromechanical switch comprises an air gap electromagnetic switch, wherein in some embodiments, the processor generates a switch control signal to cause the air gap electromagnetic switch to open in response to sensor data indicating an impending fault event.

[0363] In some embodiments, the circuit breaker further includes an internal shorting switch configured to generate an internal short circuit within the circuit breaker in response to a switch control signal output from the processor, wherein generation of the internal short circuit causes the electromechanical switch to trip or melt a fuse of the circuit breaker.

[0364] In some embodiments, the current sensor of the circuit breaker includes energy metering circuitry, wherein the energy metering circuitry is configured to generate energy usage data based on the sensed current flowing through the circuit breaker and output the energy usage data to the processor for analysis.

[0365] In some embodiments, a processor of the circuit breaker is configured to utilize the current and voltage sensor data to identify a type of load connected to the circuit breaker and to control power applied to the load based on the identified load type.

[0366] In some embodiments, the circuit breaker further includes a power converter circuit configured to generate a DC supply voltage from an AC supply voltage applied to the power input terminal, wherein the DC supply voltage is utilized to provide DC power to the processor, the current sensor, and the voltage sensor.

[0367] In another embodiment, a method includes: connecting a circuit breaker between a utility power source and a branch circuit including a load, wherein the circuit breaker includes an electromechanical switch configured to be placed in one of the following states: (i) a closed state to connect the utility power source to the branch circuit, and (ii) an open state to disconnect the utility power source from the branch circuit; sensing current through the circuit breaker and generating a current sensing signal indicating the magnitude of the sensed current through the circuit breaker; sensing a voltage at a point on an electrical path through the circuit breaker and generating a voltage sensing signal indicating the magnitude of the sensed voltage; and processing the current sensing signal and the voltage sensing signal to determine operating status information of the circuit breaker and determine power usage information of the load.

[0368] In some embodiments, the method further includes: transmitting operating status information and power usage information to a remote computing node through a circuit breaker; and receiving a remote control command transmitted from the remote computing node through the circuit breaker, wherein the operating status information is transmitted on a wireless communication channel and / or a wired communication channel; and wherein the remote computing node includes a main controller.

[0369] In some embodiments, the process of sensing current through the circuit breaker includes detecting an overcurrent condition, generating a control signal indicative of the detected overcurrent condition, and outputting the control signal to a processor of the circuit breaker to notify the processor of the overcurrent condition. In some embodiments, the overcurrent condition is detected based on a programmable overcurrent threshold. In some embodiments, the method further includes using a current digital-to-analog converter to generate a reference threshold current, wherein the reference threshold current serves as the programmable overcurrent threshold.

[0370] In some embodiments, the elec...

Claims

1. A circuit breaker, comprising: a solid-state bidirectional switch connected in series between the line input terminals and the load output terminals of the circuit breaker and configured to be placed in one of (i) an on state and (ii) an off state; a first switch control circuit configured to generate a control signal to control the operation of the solid-state bidirectional switch; a current sensor configured to sense a magnitude of a current flowing in an electrical path between the line input terminal and the load output terminal and to generate a current sensing signal; a voltage sensor configured to sense a magnitude of a voltage at a point on the electrical path between the line input terminal and the load output terminal and to generate a voltage sense signal; as well as A processor is configured to receive and process the current sensing signal and the voltage sensing signal to determine operating status information of the circuit breaker, determine a fault event, and determine power usage information of a load connected to the load output terminal.

2. The circuit breaker of claim 1 , further comprising a radio frequency transceiver coupled to the processor, wherein the radio frequency transceiver is configured to transmit the operating status information and the power usage information to a remote computing node, and to receive a remote control command transmitted from the remote computing node for processing by the processor to perform an action indicated by the remote control command.

3. The circuit breaker according to claim 1, wherein the voltage sensor comprises: a first voltage sensor coupled to the electrical path upstream of the electromechanical switch and configured to sense a magnitude of an AC supply voltage applied to a power input terminal; as well as A second voltage sensor is coupled to the electrical path downstream of the electromechanical switch and is configured to sense a magnitude of a load voltage of a load connected to the load output terminal.

4. The circuit breaker of claim 1, wherein the current sensor comprises circuitry configured to detect an overcurrent condition, generate a control signal indicative of the detected overcurrent condition, and output the control signal to the processor to notify the processor of the overcurrent condition.

5. The circuit breaker of claim 4, wherein the current sensor detects the overcurrent condition based on a programmable overcurrent threshold, wherein the overcurrent threshold comprises a reference threshold current generated by a current digital-to-analog converter and applied to an input of a comparator of the current sensor.

6. The circuit breaker according to claim 1, further comprising: an air gap electromagnetic switch connected in series with the solid-state bidirectional switch; as well as a second switch control circuit configured to generate a control signal to control the operation of the air-gap electromagnetic switch; wherein the processor generates a switch control signal to the first switch control circuit and the second switch control circuit such that the air gap electromagnetic switch is (i) placed in a closed state before placing the solid-state bidirectional switch in an on state, and (ii) placed in an off state in response to the solid-state bidirectional switch being placed in an off state.

7. The circuit breaker according to claim 6, further comprising: a manual switch configured to trigger opening of the air-gap electromagnetic switch in response to actuation of the manual switch by an individual; Wherein the processor is configured to monitor and detect actuation of the manual switch and in response to the processor detecting actuation of the manual switch, generate and output a control signal to the first switch control circuit to place the solid-state bidirectional switch in an off state.

8. The circuit breaker of claim 6, wherein the first switch control circuit and the second switch control circuit are configured to operate the circuit breaker in a standby state, wherein the solid-state bidirectional switch is in an off state and the air-gap electromagnetic switch is in a closed state.

9. The circuit breaker of claim 6, wherein the processor is configured to analyze real-time sensor data obtained from the voltage sensor and the current sensor and detect a failure of the solid-state bidirectional switch, and in response to detecting a failure of the solid-state bidirectional switch, generate a control signal and output it to the second switch control circuit to place the air-gap electromagnetic switch in a closed state.

10. The circuit breaker of claim 1, wherein the current sensor comprises energy metering circuitry, wherein the energy metering circuitry is configured to generate energy usage data based on the sensed current flowing through the circuit breaker and output the energy usage data to the processor for analysis.

11. The circuit breaker of claim 1, wherein the processor is configured to utilize current and voltage sensor data to identify a type of load connected to the circuit breaker and to control power applied to the load based on the identified load type.

12. The circuit breaker of claim 1, wherein the current sensor, the voltage sensor, and the processor are configured to support at least one of (i) arc fault circuit interruption and ground fault circuit interruption.

13. The circuit breaker of claim 1 , wherein the first switch control circuit comprises a short circuit detection circuit coupled to the solid-state bidirectional switch, wherein the short circuit detection circuit is configured to detect a current passing through the solid-state bidirectional switch, and generate a gating control signal to place the solid-state bidirectional switch in an off state in response to the detected current indicating a short circuit fault event of a load connected to the load output terminal of the circuit breaker, wherein the short circuit detection circuit is configured to sense a voltage across a sensing resistor disposed between a first solid-state switch and a second solid-state switch of the solid-state bidirectional switch, and utilize the sensed voltage to detect a level of current indicating a short circuit fault event.

14. The circuit breaker of claim 1, further comprising a power converter circuit configured to generate a direct current (DC) supply voltage from an alternating current (AC) supply voltage applied to a power input terminal, wherein the DC supply voltage is utilized to provide DC power to the processor, the first switch control circuit, the current sensor, and the voltage sensor.

15. A method comprising: connecting a circuit breaker between a utility power source and a branch circuit including a load, wherein the circuit breaker includes a solid-state bidirectional switch configured to be placed in one of: (i) an on state to connect the utility power source to the branch circuit, and (ii) an off state to disconnect the utility power source from the branch circuit; sensing current through the circuit breaker and generating a current sensing signal indicative of a magnitude of the sensed current through the circuit breaker; sensing a voltage at a point on an electrical path through the circuit breaker and generating a voltage sensing signal indicative of a magnitude of the sensed voltage; generating a control signal to place the solid-state bidirectional switch in an OFF state in response to detection of a fault event based on at least one of the current sensing signal and the voltage sensing signal; as well as The current sensing signal and the voltage sensing signal are processed to determine operating status information of the circuit breaker and to determine power usage information of the load.

16. The method of claim 15, wherein the circuit breaker comprises an air gap electromagnetic switch connected in series with the solid state bidirectional switch, and wherein the method further comprises: A control signal is generated to synchronize switching operations of the air gap electromagnetic switch and the solid-state bidirectional switch so that the air gap electromagnetic switch is (i) placed in a closed state before placing the solid-state bidirectional switch in an on state, and (ii) placed in an off state in response to the solid-state bidirectional switch being placed in an off state.

17. The method according to claim 16, further comprising: sensing actuation of a manual switch configured to trigger opening of the air-gap electromagnetic switch; as well as A control signal is generated in response to sensing the actuation of the manual switch to place the solid-state bidirectional switch in an OFF state.

18. The method according to claim 16, further comprising: analyzing sensor data obtained from the voltage sensor and the current sensor to detect a failure of the solid-state bidirectional switch; as well as A control signal is generated to place the air-gap electromagnetic switch in a closed state in response to detecting a failure of the solid-state bidirectional switch.

19. A system comprising: a circuit breaker distribution panel including a bus bar coupled to a utility power source; A circuit breaker disposed within the circuit breaker panel, wherein the circuit breaker includes a line input terminal coupled to the busbar and a load output terminal connected to a branch circuit, wherein the circuit breaker includes: a solid-state bidirectional switch connected in series between the line input terminal and the load output terminal of the circuit breaker and configured to be placed in one of (i) an on state and (ii) an off state; a first switch control circuit configured to generate a control signal to control the operation of the solid-state bidirectional switch; a current sensor configured to sense a magnitude of a current flowing in an electrical path between the line input terminal and the load output terminal and to generate a current sensing signal; a voltage sensor configured to sense a magnitude of a voltage at a point on the electrical path between the line input terminal and the load output terminal and to generate a voltage sense signal; and A processor is configured to receive and process the current sensing signal and the voltage sensing signal to determine operating status information of the circuit breaker, determine a fault event, and determine power usage information of a load connected to the load output terminal.

20. The system of claim 19, further comprising: A status display system including a display and a main processor; wherein the main processor is configured to communicate with the processor of the circuit breaker to obtain, process and display the operating status information and the power usage information received from the processor of the circuit breaker, and wherein the main processor is configured to transmit the operating status information and the power usage information to a remote computing node.

21. A circuit breaker comprising: a solid-state switch and an air-gap electromagnetic switch connected in series in an electrical path between a line input terminal and a load output terminal of the circuit breaker; switch control circuitry configured to control operation of the solid-state switch and the air-gap electromagnetic switch; a zero-crossing detection circuit configured to detect a zero-crossing of an alternating current (AC) power waveform on the electrical path between the line input terminal and the load output terminal of the circuit breaker; as well as a current sensor configured to sense current flowing in the electrical path between the line input terminal and the load output terminal and detect a fault condition based on the sensed current; wherein in response to detecting a fault condition by the current sensor, the switch control circuitry is configured to generate a switch control signal to (i) place the solid-state switch in an OFF state and (ii) place the air-gap electromagnetic switch in an OFF state after the solid-state switch is placed in the OFF state; and Wherein the switch control circuitry utilizes a zero-cross detection signal output from the zero-cross detection circuit to determine when to place the air-gap electromagnetic switch in the open state.

22. The circuit breaker of claim 21, wherein the solid state switch comprises a P-type enhancement metal oxide semiconductor field effect transistor device.

23. The circuit breaker of claim 21, wherein the solid state switch comprises an N-type enhancement metal oxide semiconductor field effect transistor device.

24. The circuit breaker of claim 21, wherein the zero-crossing detection circuit is configured to detect a zero-crossing of an AC power voltage waveform applied to the line input terminal of the circuit breaker.

25. The circuit breaker of claim 24, wherein the zero crossing detection circuit is configured to detect an associated direction of a polarity transition between opposite half cycles of the AC supply voltage waveform, and wherein the switch control circuit system places the air gap electromagnetic switch in the open state when the polarity transition causes a body diode of the solid-state switch to be reverse biased.

26. The circuit breaker of claim 21, wherein the zero crossing detection circuit is configured to detect a zero crossing of an AC current waveform.

27. A circuit breaker according to claim 26, wherein the zero crossing detection circuit is configured to detect the associated direction of the polarity transition between opposite half cycles of the AC current waveform, and wherein the switch control circuit system places the air gap electromagnetic switch in the open state when the polarity transition causes the body diode of the solid-state switch to be reverse biased.

28. A circuit breaker according to claim 26, wherein the zero-crossing detection circuit is configured to (i) sample the magnitude and polarity of a sense voltage across a sense resistor connected in series in the electrical path, (ii) detect a zero-crossing event of the AC current waveform in response to determining that the magnitude of the sense voltage is zero, and (iii) determine the polarity of the AC current waveform based on the polarity of the sense voltage.

29. The circuit breaker of claim 21, wherein the current sensor is configured to detect at least one of a short circuit fault condition, an overcurrent fault condition, an arc fault condition, and a ground fault condition.

30. The circuit breaker of claim 21, further comprising an environmental sensor circuit configured to sense an environmental condition and detect whether the sensed environmental condition is dangerous, and wherein in response to detecting a dangerous environmental condition, the switch control circuit system is configured to generate a switch control signal to (i) place the solid-state switch in an OFF state and (ii) place the air-gap electromagnetic switch in an OFF state after the solid-state switch is placed in the OFF state.

31. A circuit breaker according to claim 30, wherein the environmental sensor circuit includes one or more of the following: (i) a chemical sensitive detector configured to detect the presence of hazardous chemicals, (ii) a gas sensitive detector configured to detect the presence of hazardous gases, (iii) a temperature sensor configured to detect temperature, (iv) a piezoelectric detector configured to detect vibration; and (v) a humidity sensor configured to detect a humid environment.

32. A method comprising: sensing a current flowing in an electrical path between a line input terminal and a load output terminal of a circuit breaker, the circuit breaker comprising a solid-state switch and an air-gap electromagnetic switch connected in series in the electrical path between the line input terminal and the load output terminal of the circuit breaker; detecting a fault condition based on the sensed current, and in response to detecting the fault condition; generating a first switch control signal to place the solid-state switch in an off state; detecting a zero crossing event of an alternating current (AC) waveform at a point on the electrical path and a polarity of the AC waveform after the zero crossing event; as well as A second control signal is generated to place the air-gap electromagnetic switch in an open state in response to detecting that the polarity of the AC waveform after the zero-crossing event causes a body diode of the solid-state switch to be reverse biased.

33. The method of claim 32, wherein detecting the zero-crossing event of the AC waveform and the polarity of the AC waveform after the zero-crossing event comprises: detecting a next zero crossing event of the AC waveform occurring at a time after the solid-state switch is placed in an OFF state; as well as in response to detecting that the polarity of the AC waveform after the next zero crossing event causes the body diode of the solid state switch to be forward biased, delaying the generation of the second control signal to place the air gap electromagnetic switch in the open state until after a next subsequent zero crossing event of the AC waveform is detected, wherein The polarity of the AC waveform after the next subsequent zero crossing event causes the body diode of the solid-state switch to be reverse biased.

34. The method of claim 32, wherein the solid-state switch comprises one of a P-type enhancement metal oxide semiconductor field effect transistor device and an N-type enhancement metal oxide semiconductor field effect transistor device.

35. The method of claim 32, wherein detecting the zero-crossing event of the AC waveform comprises detecting a zero-crossing of an AC power voltage waveform applied to the line input terminals of the circuit breaker.

36. The method of claim 32, wherein detecting the zero crossing event of the AC waveform comprises detecting a zero crossing of the AC current waveform at a point on the electrical path.

37. The method of claim 36, wherein detecting the zero crossing of the AC current waveform comprises: sampling a magnitude and polarity of a sense voltage across a sense resistor connected in series in the electrical path; detecting a zero crossing event in response to determining that the magnitude of the sense voltage is zero; as well as A polarity of the AC current waveform is determined based on the polarity of the sense voltage.

38. The method of claim 32, wherein detecting the fault condition comprises detecting at least one of a short circuit fault condition, an overcurrent fault condition, an arc fault condition, and a ground fault condition.

39. The method of claim 32, further comprising detecting an environmental condition, and in response to determining that the environmental condition is hazardous, generating a first control signal to place the solid-state switch in an OFF state and generating a second control signal to place the air-gap electromagnetic switch in an OFF state after the solid-state switch is placed in the OFF state, wherein detecting the environmental condition comprises detecting one of: (i) the presence of a chemical, (ii) the presence of a gas, (iii) temperature, (iv) vibration; and (v) humidity.

40. A system comprising: a circuit breaker distribution panel including a bus bar coupled to a utility power source; A circuit breaker disposed within the circuit breaker panel, wherein the circuit breaker includes a line input terminal coupled to the busbar and a load output terminal connected to a branch circuit, wherein the circuit breaker includes: a solid-state switch and an air-gap electromagnetic switch connected in series in an electrical path between the line input terminal and the load output terminal of the circuit breaker; switch control circuitry configured to control operation of the solid-state switch and the air-gap electromagnetic switch; a zero-crossing detection circuit configured to detect a zero-crossing of an alternating current (AC) power waveform on the electrical path between the line input terminal and the load output terminal of the circuit breaker; and a current sensor configured to sense current flowing in the electrical path between the line input terminal and the load output terminal and detect a fault condition based on the sensed current; wherein in response to detecting a fault condition by the current sensor, the switch control circuitry is configured to generate a switch control signal to (i) place the solid-state switch in an OFF state and (ii) place the air-gap electromagnetic switch in an OFF state after the solid-state switch is placed in the OFF state; and Wherein the switch control circuitry utilizes a zero-cross detection signal output from the zero-cross detection circuit to determine when to place the air-gap electromagnetic switch in the open state.

41. A circuit breaker comprising: a solid-state switch and a sense resistor connected in series in an electrical path between a line input terminal and a load output terminal of the circuit breaker; a current detection circuit configured to (i) sample a sense voltage generated across the sense resistor in response to a load current flowing through the sense resistor, (ii) detect an overcurrent fault condition based on the sampled sense voltage, and (iii) output a fault detection signal in response to detecting the overcurrent fault condition; as well as A switch control circuit is configured to control the solid-state switch, wherein the switch control circuit is configured to turn off the solid-state switch in response to the fault detection signal output from the current detection circuit.

42. The circuit breaker of claim 41, wherein the sensing resistor comprises a power resistor having a resistance value on the order of about one milliohm.

43. The circuit breaker of claim 41, wherein the current sensing circuit comprises: an input stage including a first comparator and a second comparator; wherein the first comparator is configured to (i) compare a first reference voltage with a sense voltage generated across the sense resistor during a positive half cycle of the load current, and (ii) generate a first over-current detection signal when the sense voltage generated during the positive half cycle of the load current exceeds the first reference voltage; and wherein the second comparator is configured to (i) compare a second reference voltage with a sense voltage generated across the sense resistor during a negative half cycle of the load current, and (ii) generate a second over-current detection signal when the sense voltage generated during the negative half cycle of the load current exceeds the second reference voltage; as well as An output stage configured to generate and output the fault detection signal based on the first overcurrent detection signal and the second overcurrent detection signal output from the first comparator and the second comparator.

44. The circuit breaker of claim 43, wherein the output stage of the current detection circuit comprises a logic NOR gate configured to output the fault detection signal as a logic low pulse in response to an output of one of the first overcurrent detection signal and the second overcurrent detection signal from the first comparator and the second comparator.

45. The circuit breaker of claim 43, wherein: the sense resistor having a first terminal connected to a line-side node of the electrical path, and a second terminal connected to a load-side node of the electrical path; The first comparator includes a non-inverting input connected to the first terminal of the sense resistor, and receiving an inverting input of the first reference voltage; and The second comparator includes a non-inverting input connected to the second terminal of the sense resistor, and An inverting input receives the second reference voltage.

46. ​​The circuit breaker of claim 45, wherein: The current detection circuit includes a first voltage divider circuit configured to generate the first reference voltage, and a second voltage divider circuit configured to generate the second reference voltage; the first voltage divider circuit being connected between a DC supply voltage rail and the load-side node of the electrical path; as well as The second voltage divider circuit is connected between the DC supply voltage rail and the line side of the electrical path.

47. The circuit breaker of claim 46, wherein the DC supply voltage rail comprises a live rail having a DC voltage offset.

48. The circuit breaker of claim 41, wherein the solid-state switch comprises a solid-state bidirectional switch including a power metal oxide semiconductor field effect transistor device.

49. The circuit breaker of claim 41, further comprising a zero-crossing detection circuit configured to (i) sample a sensing voltage generated across the sensing resistor in response to the load current flowing through the sensing resistor, (ii) detect a zero-crossing of the load current based on the sampled sensing voltage, and (iii) output a zero-crossing detection signal in response to detecting the zero-crossing of the load current.

50. The circuit breaker of claim 49, wherein the zero crossing detection circuit comprises: a polarity change detection stage configured to detect a polarity change between a positive half cycle and a negative half cycle of the load current; an edge detection stage coupled to an output of the polarity change detection stage, wherein the edge detection stage is configured to generate a control pulse in response to a change in polarity of the load current detected by the polarity change detection stage; as well as An output stage is configured to output the zero-crossing detection signal based on the control pulse generated by the edge detection stage.

51. The circuit breaker of claim 50, wherein: the sense resistor having a first terminal connected to a line-side node of the electrical path, and a second terminal connected to a load-side node of the electrical path; and The polarity change detection stage includes a first comparator and a second comparator, wherein the first comparator includes a non-inverting input connected to the first terminal of the sensing resistor, and an inverting input connected to the second terminal of the sensing resistor, and wherein the second comparator includes a non-inverting input connected to the second terminal of the sensing resistor, and an inverting input connected to the first terminal of the sensing resistor.

52. A circuit breaker according to claim 51, wherein the edge detection stage comprises: a first edge detection circuit configured to generate a first edge detection pulse in response to a transition of a first comparison signal output from the first comparator; as well as The second edge detection circuit is configured to generate a second edge detection pulse in response to a transition of a second comparison signal output from the second comparator.

53. The circuit breaker of claim 52, wherein the output stage comprises a logic AND gate that outputs the zero-crossing detection signal based on the first edge detection pulse and the second edge detection pulse generated by the edge detection stage.

54. The circuit breaker of claim 49, further comprising a processor, wherein the processor is configured to process a zero-crossing detection signal output from the zero-crossing detection circuit and control one or more operations of the circuit breaker based on the zero-crossing detection signal.

55. The circuit breaker of claim 54, wherein the processor configures the circuit breaker to operate in one of a direct current (DC) protection mode and an alternating current (AC) protection mode upon powering up the circuit breaker based on the output of the zero crossing detection circuit.

56. A circuit breaker comprising: a switch and a sense resistor connected in series in an electrical path between a line input terminal and a load output terminal of the circuit breaker; a zero-crossing detection circuit configured to (i) sample a sense voltage generated across the sense resistor in response to a load current flowing through the sense resistor, (ii) detect a zero-crossing of the load current based on the sampled sense voltage, and (iii) output a zero-crossing detection signal in response to detecting the zero-crossing of the load current; as well as A switch control circuit is configured to control operation of the switch based on the output of the zero-crossing detection circuit.

57. The circuit breaker of claim 56, wherein the zero crossing detection circuit comprises: a polarity change detection stage configured to detect a polarity change between a positive half cycle and a negative half cycle of the load current; an edge detection stage coupled to an output of the polarity change detection stage, wherein the edge detection stage is configured to generate a control pulse in response to a change in polarity of the load current detected by the polarity change detection stage; as well as An output stage is configured to output the zero-crossing detection signal based on the control pulse generated by the edge detection stage.

58. The circuit breaker of claim 57, wherein the sense resistor has a first terminal connected to a line-side node of the electrical path, and a second terminal connected to a load-side node of the electrical path; wherein the polarity change detection stage comprises a first comparator and a second comparator, wherein the first comparator comprises a non-inverting input connected to the first terminal of the sense resistor, and an inverting input connected to the second terminal of the sense resistor, and wherein the second comparator comprises a non-inverting input connected to the second terminal of the sense resistor, and an inverting input connected to the first terminal of the sense resistor; wherein the edge detection stage comprises: (i) a first edge detection circuit configured to generate a first edge detection pulse in response to a transition of a first comparison signal output from the first comparator; and (ii) a second edge detection circuit configured to generate a second edge detection pulse in response to a transition of a second comparison signal output from the second comparator; and The output stage includes a logic AND gate that outputs the zero-crossing detection signal based on the first edge detection pulse and the second edge detection pulse generated by the edge detection stage.

59. The circuit breaker of claim 56, wherein the switch control circuit comprises a processor, wherein the processor is configured to process a zero-crossing detection signal output from the zero-crossing detection circuit and control one or more operations of the circuit breaker based on the zero-crossing detection signal.

60. The circuit breaker of claim 59, wherein the processor configures the circuit breaker to operate in one of a DC protection mode and an AC protection mode upon powering up of the circuit breaker based on the output of the zero crossing detection circuit.

61. A circuit breaker comprising: Circuit breaker housing; an air-gap switch disposed within the circuit breaker housing, the air-gap switch comprising a first contact and a second contact disposed in an electrical path between a line input terminal and a load output terminal of the circuit breaker; an actuator mechanism disposed within the circuit breaker housing, wherein the air-gap switch is coupled to the actuator mechanism, and wherein the actuator mechanism is operatively configured to (i) mechanically force the first contact and the second contact apart to place the air-gap switch in an open state and create an air gap in the electrical path, and (ii) mechanically force the first contact and the second contact together to place the air-gap switch in a closed state; as well as a first visual indicator configured to provide an indication of a state of the air-gap switch, wherein the first visual indicator comprises: (i) a first window formed as part of the circuit breaker housing; (ii) a first indicator element coupled to the actuator mechanism; and (iii) a second indicator element coupled to the actuator mechanism; wherein the actuator mechanism is configured to move the first indicator element into a position behind the first window when the actuator mechanism places the air-gap switch in the open state such that the first indicator element is viewable through the first window to provide an indication of the open state of the air-gap switch; and wherein the actuator mechanism is configured to move the second indicator element into a position behind the first window when the actuator mechanism places the air-gap switch in the closed state, such that the second indicator element can be viewed through the first window to provide an indication of the closed state of the air-gap switch.

62. The circuit breaker of claim 61, wherein the first indicator element comprises a colored element having a first color, and wherein the second indicator element comprises a colored element having a second color different from the first color.

63. The circuit breaker of claim 61 , further comprising a second visual indicator configured to provide an indication of an operational status of the circuit breaker, wherein the second visual indicator comprises: (i) a second window formed as part of the circuit breaker housing, and (ii) at least one light emitting element disposed within the circuit breaker housing behind the second window.

64. The circuit breaker of claim 63, wherein the at least one light emitting element comprises a light emitting diode.

65. The circuit breaker of claim 63, wherein the at least one light emitting element is configured to emit light of a first color viewable through the second window to provide an indication of a non-trip operating state of the circuit breaker.

66. The circuit breaker of claim 65, wherein the at least one light emitting element is configured to emit light of a second color viewable through the second window to provide an indication of a tripped state of the circuit breaker.

67. The circuit breaker of claim 63, wherein the at least one light emitting element is deactivated and does not emit light to provide an indication of an OFF state of the circuit breaker.

68. The circuit breaker of claim 61, further comprising a manually controlled switch mechanically coupled to the actuator mechanism, wherein the manually controlled switch is configured to switch between a first position and a second position, wherein switching the manually controlled switch into the first position causes the actuator mechanism to place the air-gap switch in the open state.

69. The circuit breaker of claim 61, further comprising an electromechanical actuator coupled to the actuator mechanism, wherein actuation of the electromechanical actuator causes the actuator mechanism to place the air-gap switch in the open state and trip the circuit breaker.

70. The circuit breaker of claim 69, wherein the electromechanical actuator comprises a solenoid.

71. A circuit breaker comprising: a solid-state switch and an air-gap switch connected in series in an electrical path between a line input terminal and a load output terminal of the circuit breaker, wherein the air-gap switch includes a first contact and a second contact; an actuator mechanism operatively configured to (i) mechanically force the first contact and the second contact apart to place the air-gap switch in an open state and create an air gap in the electrical path, and (ii) mechanically force the first contact and the second contact together to place the air-gap switch in a closed state; a manually controlled switch operatively coupled to the actuator mechanism, wherein the manually controlled switch is configured to switch between a first position and a second position, wherein switching the manually controlled switch into the first position causes the actuator mechanism to place the air-gap switch into the open state; an electromechanical actuator operatively coupled to the actuator mechanism, wherein actuation of the electromechanical actuator causes the actuator mechanism to place the air-gap switch in the open state; a control circuit system configured to control operation of the solid-state switch and the electromechanical actuator, wherein the control circuit system is configured to generate: (i) a first control signal configured to place the solid-state switch in one of an on state and an off state, and (ii) a second control signal configured to control actuation of the electromechanical actuator; as well as a sensor switch operatively coupled to the manual control switch and electrically connected to the control circuitry, wherein the sensor switch is configured to (i) detect a switching of the manual control switch from the second position to the first position, the switching causing the actuator mechanism to place the air-gap switch in the open state, and (ii) output a third control signal to the control circuitry in response to detecting the switching of the manual control switch from the second position to the first position; Wherein in response to the third control signal, the control circuitry is configured to generate the first control signal to place the solid-state switch in the off state before the air-gap switch is placed in the off state to create the air gap in the electrical path.

72. The circuit breaker of claim 71, further comprising: a current sensor configured to sense current flowing in the electrical path between the line input terminal and the load output terminal and detect a fault condition based on the sensed current; wherein in response to detecting a fault condition by the current sensor, the control circuit system is configured to generate the first control signal and the second control signal to (i) place the solid-state switch in an off state and (ii) actuate the electromechanical actuator after the solid-state switch is placed in the off state so that the actuation mechanism places the air-gap electromagnetic switch in the open state.

73. The circuit breaker of claim 71, wherein the electromechanical actuator comprises a solenoid.

74. The circuit breaker of claim 71, further comprising: a first visual indicator configured to provide an indication of the state of the air-gap switch, wherein the first visual indicator comprises: (i) a first window formed as part of a circuit breaker housing of the circuit breaker; (ii) a first indicator element coupled to the actuator mechanism; and (iii) a second indicator element coupled to the actuator mechanism; wherein the actuator mechanism is configured to move the first indicator element into a position behind the first window when the actuator mechanism places the air-gap switch in the open state such that the first indicator element is viewable through the first window to provide an indication of the open state of the air-gap switch; and wherein the actuator mechanism is configured to move the second indicator element into a position behind the first window when the actuator mechanism places the air-gap switch in the closed state, such that the second indicator element can be viewed through the first window to provide an indication of the closed state of the air-gap switch.

75. The circuit breaker of claim 74, wherein the first indicator element comprises a colored element having a first color, and wherein the second indicator element comprises a colored element having a second color different from the first color.

76. The circuit breaker of claim 71, further comprising a second visual indicator configured to provide an indication of an operational status of the circuit breaker, wherein the second visual indicator comprises: (i) a second window formed as part of the circuit breaker housing, and (ii) at least one light emitting element disposed within the circuit breaker housing behind the second window.

77. The circuit breaker of claim 76, wherein the at least one light emitting element comprises a light emitting diode.

78. The circuit breaker of claim 76, wherein the at least one light emitting element is configured to: emitting light of a first color viewable through the second window to provide an indication of a non-tripped operating state of the circuit breaker; emitting light of a second color viewable through the second window to provide an indication of a tripped state of the circuit breaker; and No light is emitted to provide an indication of the OFF state of the circuit breaker.

79. A circuit breaker comprising: Circuit breaker housing; an air-gap switch disposed in the circuit breaker housing; as well as a first visual indicator configured to provide an indication of an open state and a closed state of the air-gap switch, wherein the first visual indicator comprises: (i) a first window formed as part of the circuit breaker housing; (ii) a first indicator element disposed within the circuit breaker housing; and (iii) a second indicator element disposed within the circuit breaker housing; wherein the first indicator element is configured to move into a position behind the first window when the air-gap switch is placed in the open state such that the first indicator element is viewable through the first window to provide an indication of the open state of the air-gap switch; and Wherein the second indicator element is configured to move into a position behind the first window when the air-gap switch is placed in the closed state such that the second indicator element is viewable through the first window to provide an indication of the closed state of the air-gap switch.

80. The circuit breaker of claim 79, further comprising: a second visual indicator configured to provide an indication of an operational status of the circuit breaker, wherein the second visual indicator comprises: (i) a second window formed as part of the circuit breaker housing, and (ii) at least one light emitting element disposed within the circuit breaker housing behind the second window; Wherein the at least one light emitting element is configured to emit light of at least one color through the second window to provide an indication of an operating status of the circuit breaker corresponding to the at least one color.

81. A circuit breaker device, comprising: Line live terminal, line neutral terminal, load live terminal and load neutral terminal; A solid-state switch and an air-gap electromagnetic switch, wherein the solid-state switch and the air-gap electromagnetic switch are connected in series between the line live terminal and the load live terminal; an internal switch and a shunt resistor connected in series between a first node and a second node, wherein the first node comprises a point along an electrical path between the line hot terminal and the load hot terminal, and wherein the second node comprises a point along an electrical path between the line neutral terminal and the load neutral terminal; switch control circuitry configured to control operation of (i) the solid-state switch and (ii) the internal switch; as well as a fault detection circuit system configured to detect a fault condition and generate a fault detection control signal in response to detection of the fault condition; wherein the switch control circuitry is configured to place the solid-state switch in an OFF state in response to the fault detection control signal; and wherein the switch control circuit system is configured to activate the internal switch and thereby generate an internal short circuit path in response to the fault detection control signal, wherein the shunt resistor is connected between the first node and the second node, and causes an internal short circuit current to flow through the air gap electromagnetic switch, wherein the internal short circuit current is sufficient to trip the air gap electromagnetic switch and thereby generate an air gap in the electrical path between the line live terminal and the load live terminal.

82. The circuit breaker device of claim 81, wherein the shunt resistor has a resistance value configured to limit the magnitude of the internal short circuit current to a range of about 2 times to about 3 times a current rating of the air-gap electromagnetic switch.

83. The circuit breaker device of claim 81, wherein the solid-state switch comprises one of a P-type enhancement metal oxide semiconductor field effect transistor (MOSFET) device and an N-type enhancement MOSFET device.

84. A circuit breaker device according to claim 81, wherein the fault detection circuit system includes a current sensor, which is configured to sense the current flowing in the electrical path between the line hot terminal and the load hot terminal, and detect one of an overcurrent fault condition and a short-circuit load current fault condition based on the sensed current.

85. The circuit breaker device of claim 81, wherein the internal switch comprises a solid-state bidirectional switch comprising a first MOSFET device and a second MOSFET device connected in series.

86. A circuit breaker device according to claim 85, wherein the first MOSFET device and the second MOSFET device have a commonly connected gate terminal, wherein the commonly connected gate terminal is coupled to the switch control circuit system, and wherein the switch control circuit system controls activation and deactivation of the internal switch by applying a gate control signal to the commonly connected gate terminal.

87. The circuit breaker device of claim 81, further comprising: a zero crossing detection circuit configured to detect a zero crossing of an alternating current (AC) power waveform on the electrical path between the line hot terminal and the load hot terminal of the circuit breaker device; The switch control circuit system utilizes the zero-crossing detection signal output from the zero-crossing detection circuit to control the timing for activating the internal switch in response to the fault detection control signal, so that after the solid-state switch is placed in the off state in response to the fault detection control signal, a short-circuit current is generated to trip the air-gap electromagnetic switch.

88. The circuit breaker device of claim 87, wherein: The zero crossing detection circuit is configured to detect a zero crossing of an AC supply voltage waveform on the electrical path between the line hot terminal and the load hot terminal circuit breaker; The zero crossing detection circuit is configured to detect an associated direction of polarity transition of the zero crossing between opposing half cycles of the AC supply voltage waveform; and The switch control circuitry activates the internal switch when the polarity transition of the detected zero crossing of the AC supply voltage waveform causes a body diode of the solid-state switch to be in a reverse biased state after placing the solid-state switch in the off state.

89. The circuit breaker device of claim 87, wherein: The zero crossing detection circuit is configured to detect a zero crossing of an AC current waveform on the electrical path between the line hot terminal and the load hot terminal circuit breaker; The zero crossing detection circuit is configured to detect an associated direction of polarity transition of the zero crossing between opposing half cycles of the AC current waveform; and The switch control circuitry activates the internal switch when the polarity transition of the detected zero crossing of the AC current waveform causes a body diode of the solid-state switch to be in a reverse biased state after placing the solid-state switch in the off state.

90. A method comprising: sensing a current flowing in an electrical path between a line hot terminal and a load hot terminal of a circuit breaker device, wherein the circuit breaker device includes a solid state switch and an air gap electromagnetic switch connected in series in the electrical path between the line hot terminal and the load hot terminal of the circuit breaker device; detecting a fault condition based on the sensed current; and in response to detecting the fault condition; applying a first switch control signal to the solid-state switch to place the solid-state switch in an off state; as well as applying a second switch control signal to the internal switch to activate the internal switch and thereby create an internal short circuit path within the circuit breaker device and generate an internal short circuit current flowing through the air-gap electromagnetic switch; wherein the flow of the internal short circuit current causes the air gap electromagnetic switch to trip and thereby create an air gap in the electrical path between the line live terminal and the load live terminal of the circuit breaker device.

91. The method of claim 90, wherein the internal short circuit path comprises a shunt resistor having a resistance value configured to limit the magnitude of the internal short circuit current to a range of about 2 times to about 3 times a current rating of the air gap electromagnetic switch.

92. A method according to claim 91, wherein the internal switching circuit and the shunt resistor are connected in series between a first node and a second node, wherein the first node comprises a point along the electrical path between the line hot terminal and the load hot terminal of the circuit breaker device, and wherein the second node comprises a point along the electrical path between the line neutral terminal and the load neutral terminal of the circuit breaker device.

93. The method of claim 90, wherein applying the second switch control signal to the internal switch comprises applying the second switch control signal to activate the internal switch and generate the internal short circuit path after applying the first switch control signal to the solid-state switch to place the solid-state switch in the off state.

94. The method of claim 90, further comprising: detecting a zero crossing of an alternating current (AC) power waveform on the electrical path between the line hot terminal and the load hot terminal of the circuit breaker device; as well as The timing of the detected zero crossings of the AC power waveform is utilized to control a timing for applying the second switch control signal to activate the internal switch after applying the first switch control signal to place the solid-state switch in the off state.

95. The method of claim 94, wherein utilizing the timing of the detected zero crossings of the AC power waveform to control a timing for applying the second switch control signal to activate the internal switch comprises: detecting a direction of a polarity transition between opposite half cycles of the AC power waveform at a detected zero crossing of the AC power waveform; as well as The second switch control signal is applied to the internal switch to activate the internal switch when the detected direction of the polarity transition of the AC power waveform after the detected zero crossing of the AC power voltage waveform causes the body diode of the solid-state switch to be in a reverse biased state after the solid-state switch is placed in the off state.

96. A system comprising: a circuit breaker distribution panel including a line hot bus and a line neutral bus coupled to a utility power source; a circuit breaker device disposed in the circuit breaker distribution panel; The circuit breaker device comprises: a line hot terminal coupled to the line hot bus, a line neutral terminal coupled to the line neutral bus, and a load hot terminal and a load neutral terminal connected to a branch circuit: A solid-state switch and an air-gap electromagnetic switch, wherein the solid-state switch and the air-gap electromagnetic switch are connected in series between the line live terminal and the load live terminal; an internal switch and a shunt resistor connected in series between a first node and a second node, wherein the first node comprises a point along an electrical path between the line hot terminal and the load hot terminal, and wherein the second node comprises a point along an electrical path between the line neutral terminal and the load neutral terminal; switch control circuitry configured to control operation of (i) the solid-state switch and (ii) the internal switch; and a fault detection circuit system configured to detect a fault condition and generate a fault detection control signal in response to detection of the fault condition; wherein the switch control circuitry is configured to place the solid-state switch in an OFF state in response to the fault detection control signal; and wherein the switch control circuit system is configured to activate the internal switch and thereby generate an internal short circuit path in response to the fault detection control signal, wherein the shunt resistor is connected between the first node and the second node, and causes an internal short circuit current to flow through the air gap electromagnetic switch, wherein the internal short circuit current is sufficient to trip the air gap electromagnetic switch and thereby generate an air gap in the electrical path between the line live terminal and the load live terminal.

97. The system of claim 96, wherein the shunt resistor of the circuit breaker device has a resistance value configured to limit the magnitude of the internal short circuit current to a range of about 2 times to about 3 times the current rating of the air-gap electromagnetic switch.

98. The system of claim 96, wherein the circuit breaker device further comprises: a zero crossing detection circuit configured to detect a zero crossing of an alternating current (AC) power waveform on the electrical path between the line hot terminal and the load hot terminal of the circuit breaker device; The switch control circuit system utilizes the zero-crossing detection signal output from the zero-crossing detection circuit to control the timing for activating the internal switch in response to the fault detection control signal, so that after the solid-state switch is placed in the off state in response to the fault detection control signal, a short-circuit current is generated to trip the air-gap electromagnetic switch.

99. The system of claim 98, wherein: The zero crossing detection circuit is configured to detect a zero crossing of an AC supply voltage waveform on the electrical path between the line hot terminal and the load hot terminal circuit breaker; The zero crossing detection circuit is configured to detect an associated direction of polarity transition of the zero crossing between opposing half cycles of the AC supply voltage waveform; and The switch control circuitry activates the internal switch when the polarity transition of the detected zero crossing of the AC supply voltage waveform causes a body diode of the solid-state switch to be in a reverse biased state after placing the solid-state switch in the off state.

100. The system of claim 98, wherein: The zero crossing detection circuit is configured to detect a zero crossing of an AC current waveform on the electrical path between the line hot terminal and the load hot terminal circuit breaker; The zero crossing detection circuit is configured to detect an associated direction of polarity transition of the zero crossing between opposing half cycles of the AC current waveform; and The switch control circuitry activates the internal switch when the polarity transition of the detected zero crossing of the AC current waveform causes a body diode of the solid-state switch to be in a reverse biased state after placing the solid-state switch in the off state.

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