Multi-stage feedback actuator assembly for solid-state circuit breakers

Abstract

A multi-stage feedback actuator assembly for a circuit breaker assembly includes a rotary solenoid, an electric actuator assembly, and a manual actuator assembly. The electric actuator assembly includes a switch assembly having an actuator. The manual actuator assembly includes a plurality of primary actuators, a linkage assembly, and a cam assembly. The plurality of primary actuators include a first actuator having a body. The first actuator body is configured to move over a path having at least a first portion and a second portion. The rotary solenoid is operatively coupled to the linkage assembly. The linkage assembly is further operatively coupled to an operating mechanism crossbar. In this configuration, the linkage assembly is configured to apply at least a first bias and a second bias to the first actuator body. In addition, the first bias is significantly different from the second bias.

Description

Background Art Technical Field

[0002] The disclosed and claimed concept relates to a circuit breaker and, more particularly, to a circuit breaker operating mechanism including a multi-stage feedback actuator assembly.

[0003] Background Information

[0004] A circuit breaker is used to protect a circuit from damage due to an overcurrent condition, such as an overload condition or a relatively high level short circuit or fault condition. That is, the circuit breaker is usually arranged between the line (i.e., the power source) and the load (i.e., the device or structure using the power). A mechanical circuit breaker usually includes a plurality of pairs of separable contacts, an operating mechanism, and a trip unit. Each pair of separable contacts is coupled to a line or a load and is electrically connected to the line or the load. Separable contacts usually include a movable contact and a fixed / stationary contact. It should be understood that the circuit breaker includes one or more pairs of separable contacts. However, in the following, a single pair of separable contacts is discussed.

[0005] The movable contact moves between a first position of disconnection and a second position of closing. When the movable contact is in the first position, the separable contact is not in electrical communication, and no current passes through the circuit breaker. When the movable contact is in the second position, the separable contact is in electrical communication, and current passes through the circuit breaker. These separable contacts can be manually operated by an actuator disposed on the outside of the housing assembly, or automatically operated in response to an overcurrent condition. That is, the trip unit is configured to detect an overcurrent condition. When the overcurrent condition is detected, the trip unit actuates an operating mechanism, thereby causing the movable contact to quickly move to an open configuration. The operating mechanism is further configured to move the movable contact from the first position of disconnection to the second position of closing, and thereafter maintain the contact in the second position of closing. A problem with mechanical circuit breakers is that the separation of the separable contacts (i.e., the interruption of the current) is slower than is usually expected.

[0006] Solid-state circuit breakers interrupt current at a greater rate. Solid-state circuit breakers utilize solid-state components to interrupt current and separable contacts for current isolation. That is, the solid-state components interrupt current, and the separable contacts separate to prevent any trace current or (electrical) leakage that the solid-state components cannot interrupt. Solid-state circuit breakers include, but are not limited to, solid-state switching circuits having solid-state switching elements (e.g., non-limitingly, insulated gate bipolar transistors (IGBTs)) configured to switch between an on configuration and an off configuration (i.e., a closed configuration and an open configuration), a trip unit circuit, and an electric actuator assembly for separable contacts. When the trip unit circuit detects an impending fault or an extremely high and unacceptable overvoltage condition in the circuit breaker, the trip unit circuit generates a signal that quickly switches the solid-state switching element to the off / open configuration. Therefore, the trip unit circuit serves as an operating mechanism for the solid-state switching element. In the following, the term "trip unit circuit" will be used for this component to distinguish it from the "operating mechanism" associated with the separable contacts. At the same time, the electric actuator assembly generates a disconnect command for the separable contacts, thereby moving the separable contacts to the open first position. In summary, switching the "off" solid-state device and the open separable contacts protects the load and associated load circuits from damage and electrically and physically isolates the source of the fault or overload condition from the rest of the power distribution system.

[0007] In addition, some solid-state circuit breakers include an indicator (sometimes identified as a "tag") that is mechanically coupled to the separable contacts. That is, the tag has a visual representation, for example, a red portion and a green portion, or the words "open" and "closed." The tag appears in a window in the circuit breaker housing. Thus, for example, when the separable contacts are in a first position, the tag displays the word "open." When the tag is mechanically coupled to the separable contacts and prevents breakdown in the mechanical linkage, the tag always displays the state of the contacts. However, the tag does not display whether the solid-state switching element has been "closed." Therefore, some solid-state circuit breakers also include an indicator, such as, but not limited to, a light coupled to the solid-state switching element. That is, for example, when the solid-state switching element is in an on / closed configuration, an indicator light is illuminated.

[0008] One advantage of using a solid-state device is that an impending fault can be reacted to within microseconds. That is, the solid-state device interrupts the current flow before the contacts separate. Thus, when the separable contacts move to the first position after the solid-state device is in the off / open configuration, the chance of arcing between the separable contacts is minimized.

[0009] Closing the solid-state circuit breaker is accomplished by a trip unit circuit, which, as described above, acts as an operating mechanism for the solid-state switching element. That is, closing the solid-state circuit breaker requires energy, typically energy drawn from the line. That is, the trip unit circuit and / or the solid-state switching element requires power to switch between the on configuration and the off configuration. Power is typically drawn from the line. However, drawing power from the line requires current to pass through the solid-state circuit breaker. That is, the movable contact must be in the second position, i.e., the separable contact needs to be closed, and power must be present in the line. In order for the movable contact to move to the second position, power must be supplied to the operating mechanism.

[0010] For example, one type of operating mechanism for a solid-state circuit breaker separable contact utilizes a rotary solenoid to move the movable contact between a first position and a second position. Although two rotary solenoids may be used (a first rotary solenoid for moving the movable contact from the first position to the second position, and a second rotary solenoid for moving the movable contact from the second position to the first position), in an exemplary embodiment, a single rotary solenoid is bidirectional and moves the movable contact between the first position and the second position.

[0011] In an exemplary embodiment, the bi-directional rotary solenoid is actuated by an electric actuator assembly. That is, the electric actuator assembly includes: an external actuator, such as a button; and a switch assembly that holds an electric charge, such as a switch assembly having a capacitor or being electrically connected to the above capacitor. When the external actuator is actuated by a user, the switch assembly releases the charge, which actuates the bi-directional rotary solenoid, thereby causing the operating mechanism to move the movable contact between the first position and the second position. Typically, the degree to which the actuator / button needs to be pressed in order to actuate the operating mechanism is slight, that is, a small movement requiring less force.

[0012] Furthermore, because the bidirectional rotary solenoid does not utilize an energy separation contact passing therethrough, the bidirectional rotary solenoid generally operates at a lower speed than a bidirectional rotary solenoid that utilizes an energy separation contact passing therethrough. Generally speaking, a rotary solenoid that moves slower operates more quietly than a faster rotary solenoid. Furthermore, the moving element of the rotary solenoid is disposed within a rotary solenoid housing, which in turn is disposed within a circuit breaker housing. Therefore, it is difficult for a user to detect the operation of the rotary solenoid.

[0013] With the solid-state circuit breaker in this configuration, there are different scenarios that can occur following an overcurrent event. For example:

[0014] 1) There is no power on the line side of the solid-state circuit breaker, there is no charge in the switch assembly capacitor, and the label indicates that the movable contact is in the disconnected first position, that is, the separable contact is disconnected. The user viewing the solid-state circuit breaker does not know that the line side power is off or that the capacitor has no power, they only know that the separable contact is disconnected. If the user assumes that the line is energized, then they try to close the separable contact, and they press the button with a light force for a short distance to press the switch and nothing happens. That is, in the absence of energy from the switch assembly capacitor, there is no energy to cause the operating mechanism to move the movable contact to the second position. In this case, the label does not indicate that the separable contact is closed. In addition, if the separable contact is not closed, the trip unit circuit cannot change the solid-state switching element to an on / closed configuration.

[0015] 2) There is power on the line side of the solid state circuit breaker, but there is no charge in / to the capacitors and the label states that the circuit breaker is open. The user looks at the circuit breaker and does not know that the line side power is on or that the capacitors have no power, they only know that the separable contacts are open. They try to close the circuit breaker and they push the actuator / button a short distance with light force and nothing happens. Again, the label does not indicate that the separable contacts are closed.

[0016] 3) The line side of the solid-state circuit breaker has no power, but the capacitor still has a charge. The user presses the close button with light force for a short distance; this causes the capacitor to actuate the solenoid, and the separable contacts close. However, there is no power from the line to allow the trip unit to switch the configuration of the solid-state switching element from the off / open configuration to the on / closed configuration. The label (which is mechanically coupled to the separable contacts) indicates that the solid-state circuit breaker is closed, but the trip unit circuit cannot change the solid-state switching element to the on / closed configuration because there is no power from the line.

[0017] 4) There is power to the line side of the solid state circuit breaker and the capacitor is charged. The user presses the close button with light force for a short distance. This causes the capacitor to actuate the solenoid and the separable contacts to close, the trip unit powers up and the semiconductor connects the line to the load power. This is the expected operation of a solid state circuit breaker.

[0018] As described above, there are several problems associated with an operating mechanism having a bi-directional rotation solenoid as described above. First, as described above, when a user presses the external actuator, the switch assembly capacitor may not have a charge. Without the switch assembly capacitor charge, the bi-directional rotation solenoid cannot be electrically actuated. In addition, the external actuator, which serves as an interface between the user and the operating mechanism, does not provide feedback to the user indicating the status of the switch assembly and / or the bi-directional rotation solenoid. That is, when the user actuates the external actuator, there is no feedback indicating that the switch assembly and / or the bi-directional rotation solenoid has been operated as described above. This is a problem.

[0019] In addition, in some embodiments, in addition to the electric switch assembly, the operating mechanism also includes a manual actuator assembly. The actuator / switch assembly utilizes the same external actuator (button). However, the external actuator does not provide feedback indicating to the user whether the electric actuator assembly has been actuated and / or the manual actuator assembly needs to be actuated. That is, as described above, the operation of the rotary solenoid is silenced by multiple housings. Therefore, in the case where the switch assembly does not have an electric charge, the user can actuate the external actuator and think that the electric actuator assembly has been operated. Such a user will not attempt to utilize the manual actuator assembly. Alternatively, in the case where the switch assembly has an electric charge, the user can actuate the external actuator and think that the electric actuator assembly has not yet been operated. Therefore, the user will attempt to utilize the manual actuator assembly after the movable contact has moved between the first position and the second position. This is a problem.

[0020] In addition, some circuit breaker assemblies include an undervoltage regulating assembly that is configured to move the movable contact from the second position to the first position when the voltage drops below a selected limit. The undervoltage regulating assembly is a separate assembly, that is, the undervoltage regulating assembly is not part of the operating mechanism. Therefore, adding the undervoltage regulating assembly increases the cost of the circuit breaker. This is a problem.

[0021] In addition, it is known that users prefer symmetry with respect to the characteristics of the circuit breaker and / or operating mechanism. That is, for example, if the circuit breaker / operating mechanism includes two separate user interfaces (e.g., buttons), then the user expects / prefers that the tactile feedback from the buttons is substantially similar. That is, if one button is easy to press and the other button is difficult to press, then the user will assume that one of the buttons is not operating correctly. Therefore, it is expected that actuator assemblies that perform similar or complementary actions provide similar tactile feedback. For example, it is expected that an actuator assembly that opens and closes the contacts of a circuit breaker assembly provides similar tactile feedback. If such actuator assemblies provide different tactile feedback, then this is a problem.

[0022] Therefore, there is a need for a multi-level feedback actuator assembly for a circuit breaker assembly, the multi-level feedback actuator assembly being configured to provide distinct feedback to a user, wherein the distinct feedback informs the user that an operating mechanism is or has utilized an electric actuator assembly to move a movable contact from a first position to a second position, or that the electric actuator assembly has failed to move the movable contact from the first position to the second position and the user must utilize a manual actuator assembly to move the movable contact from the first position to the second position. There is also a need for a multi-level feedback actuator assembly to provide an indication to the user that the movable contact has moved from the first position to the second position. There is also a need for an undervoltage regulation assembly incorporated into an operating mechanism. There is also a need for a multi-level feedback actuator assembly that provides substantially the same tactile feedback for both an open actuator and a close actuator. Summary of the invention

[0023] These needs and others are met by at least one embodiment of the present invention, which provides a multi-stage feedback actuator assembly for a circuit breaker assembly, the multi-stage feedback actuator assembly comprising: a rotary solenoid including a rotary output shaft; an electric actuator assembly; and a manual actuator assembly. The electric actuator assembly includes a switch assembly having an actuator. The switch assembly is operatively coupled to the rotary solenoid and is configured to actuate the rotary solenoid. The manual actuator assembly includes a plurality of primary actuators, a linkage assembly, and a cam assembly. The plurality of primary actuators include a first actuator having a body. The first actuator body is configured to move over a path having at least a first portion and a second portion. The rotary solenoid is operatively coupled to the linkage assembly. The linkage assembly is operatively coupled to the rotary solenoid and the first actuator body. The linkage assembly is further configured to be operatively coupled to an operating mechanism crossbar. In this configuration, the linkage assembly is configured to apply at least a first bias and a second bias to the first actuator body. Furthermore, the first bias is significantly different from the second bias. Thus, the linkage assembly is configured to apply the first bias to the first actuator body when the first actuator body is disposed in a first portion of the first actuator body path, and to apply the second bias to the first actuator body when the first actuator body is disposed in a second portion of the first actuator body path.

[0024] It should be understood that the first actuator is configured to and does actuate the electric actuator assembly when it moves over the first actuator body path first portion, and actuate the manual actuator assembly when it moves over the first actuator body path second portion. In addition, because the bias applied to the first actuator body (i.e., the feedback bias felt by the user) is significantly different when the first actuator body moves between the first actuator body path first portion and the first actuator body path second portion, the user is informed as to which actuator assembly is being utilized.

[0025] That is, when the user actuates the first actuator, the bias applied to the first actuator is further transmitted / transmitted to the user. That is, the user feels the bias on the first actuator body. In an exemplary embodiment, the user has been informed, for example, in the user manual that significantly different bias indications are actuating different actuator assemblies. For example, the user is informed that the light bias indication is actuating the electric actuator assembly, while the stronger bias indication is actuating the manual actuator assembly. Therefore, when the user initially actuates the first actuator, the first actuator moves above the first part of the first actuator body path, and the first bias is transmitted / transmitted to the user by the first actuator. During this movement, the user feels the light bias and is informed by this tactile feedback that the first actuator is actuating the electric actuator assembly. If the electric actuator assembly is in a non-operating state, the user will not receive an indication that the movable contact has moved between positions. For example, the label will not change position. Therefore, the user is informed that additional action is required to change the position of the movable contact. Therefore, the user continues to press on the first actuator, causing the first actuator to move into and over the first actuator body path second portion. When the first actuator moves into and over the first actuator body path second portion, the second bias is applied to the first actuator, and the user feels this stronger bias. Therefore, the user is informed that the first actuator is actuating the manual actuator assembly.

[0026] Furthermore, the elements of the multi-stage feedback actuator assembly as part of the operating mechanism are also configured as an undervoltage regulating assembly. As described in detail below, the multi-stage feedback actuator assembly in this configuration solves the above-mentioned problems. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] A complete understanding of the present invention can be obtained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings, in which:

[0028] Figure 1 is a partially schematic, partially cross-sectional side view of a circuit breaker assembly.

[0029] Figure 2is an isometric view of a multi-stage feedback actuator assembly.

[0030] Figure 3 is another isometric view of the multi-stage feedback actuator assembly.

[0031] Figure 4A and Figure 4B is an exploded isometric view of a multi-stage feedback actuator assembly. Figure 4A and Figure 4B are identical and are provided with relative reference numerals for clarity.

[0032] Figure 5 is a side view of the switch assembly.

[0033] Figures 6 to 10 is a partial side view of a multi-stage feedback closing actuator assembly with a limited number of components identified. Figures 6 to 10 The elements identified and the locations of the force lines are shown sequentially as the multi-stage feedback closing actuator assembly is actuated.

[0034] Fig.11 is a diagram illustrating the terms "first side" and "second side" to demonstrate the definition of the rotation axis and the "position" of the force lines relative to the rotation axis.

[0035] Figure 12 to Figure 14 is a partial side view of a multi-stage feedback disconnect actuator assembly with a limited number of components identified. Figure 12 to Figure 14 The elements identified and the locations of the force lines are sequentially shown when the multi-stage feedback disconnect actuator assembly is actuated. DETAILED DESCRIPTION

[0036] It will be understood that the specific elements depicted herein in the drawings and described in the following specification are merely exemplary embodiments of the disclosed concepts, which are provided as non-limiting examples for illustrative purposes only. Therefore, specific dimensions, orientations, components, number of parts used, embodiment configurations, and other physical characteristics related to the embodiments disclosed herein should not be considered to limit the scope of the disclosed concepts.

[0037] Directional phrases used herein, such as clockwise, counterclockwise, left, right, top, bottom, upward, downward and their derivatives, refer to the orientation of elements shown in the drawings and do not limit the claims unless explicitly recited therein.

[0038] As used herein, the singular form "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0039] As used herein, "configured to [verb]" means that the identified element or assembly has a structure that is shaped, sized, arranged, connected, and / or configured to perform the identified verb. For example, a member that is "configured to move" is movably connected to another element and includes an element that moves the member, or the member is additionally configured to move in response to other elements or assemblies. Therefore, as used herein, "configured to [verb]" describes structure rather than function. In addition, as used herein, "configured to [verb]" means that the identified element or assembly is intended and designed to perform the identified verb. Therefore, an element that is only capable of performing the identified verb but is not intended to be designed to perform the identified verb is not "configured to [verb]".

[0040] As used herein, "associated" means that the elements are part of the same assembly and / or operate together, or interact / act with each other in some way. For example, a car has four tires and four hub caps. Although all elements are connected as part of the car, it is understood that each hub cap is "associated" with a specific tire.

[0041] As used herein, a "coupling assembly" includes two or more couplings or coupling components. A coupling or a component of a coupling assembly is generally not part of the same element or other component. Therefore, the components of a "coupling assembly" may not be described together in the following description.

[0042] As used herein, a "coupler" or "coupling component" is one or more components of a coupling assembly. That is, a coupling assembly includes at least two components that are configured to be coupled together. It should be understood that the components of a coupling assembly are compatible with each other. For example, in a coupling assembly, if one coupling component is a snap-on socket, then the other coupling component is a snap-on plug, or if one coupling component is a bolt, then the other coupling component is a nut or a threaded hole.

[0043] As used herein, "rotational coupling" means a coupling that rotatably couples two or more elements. "Rotational coupling" includes, but is not limited to, an opening (or similar structure) in an element, through which a pin, shaft or similar structure is inserted or can be inserted. In other words, "rotational coupling" includes openings (i.e., at least two openings or similar structures) and pins, shafts or similar structures on different elements, or an opening on an element and a pin, shaft or similar structure on another element. Therefore, as used herein, the "opening" described as a "rotational coupling" is also correctly identified as a "coupling" or "rotational coupling". In addition, in the case where the following description fails to mention or identify a pin, shaft or similar structure associated with a "rotational coupling", it should be understood that such a pin, shaft or similar structure exists, and such a pin, shaft or similar structure extends through the opening identified as a "rotational coupling". In addition, as used herein, all elements described as "rotatably coupled" have a "rotational coupling" as defined herein.

[0044] As used herein, a "fastener" is a separate component that is configured to connect two or more elements. Thus, for example, a bolt is a "fastener," but a tongue-and-groove joint is not a "fastener." That is, the tongue-and-groove element is part of the elements being connected, not a separate component.

[0045] As used herein, the statement that two or more parts or components are "coupled" will mean that the parts are directly or indirectly connected or operated together, that is, connected or operated together through one or more intermediate parts or components, as long as the connection occurs. As used herein, "directly connected" means that two elements are directly in contact with each other. As used herein, "fixedly connected" or "fixed" means that two components are connected so as to move as a whole while maintaining a constant orientation relative to each other. Therefore, when two elements are connected, all parts of those elements are connected. However, describing that a specific part of a first element is connected to a second element, for example, the first end of an axle is connected to a first wheel, means that a specific part of the first element is arranged closer to the second element than other parts of the first element. In addition, an object resting on another object that is held in place only by gravity is not "coupled" to the lower object unless the upper object is otherwise substantially held in place. That is, for example, a book on a table is not connected to it, but a book glued to the table is connected to it.

[0046] As used herein, the phrases "removably coupled" or "temporarily coupled" mean that one component is coupled to another component in an essentially temporary manner. That is, the two components are coupled in such a manner that joining or separation of the components is easy and does not damage the components. For example, two components that are secured to one another with a limited number of fasteners that are easily accessible (i.e., fasteners that are not difficult to access) are "removably coupled," whereas two components that are welded together or joined by inaccessible fasteners are not "removably coupled." An "inaccessible fastener" is a fastener that requires removal of one or more other components prior to accessing the fastener, where the "other components" are not access devices, such as, but not limited to, doors.

[0047] As used herein, "operably coupled" means coupling a plurality of elements or components (each of which is capable of moving between a first position and a second position or between a first configuration and a second configuration) such that when a first element moves from one position / configuration to another, the second element also moves between positions / configurations. It should be noted that a first element may be "operably coupled" to another element, but not vice versa. With respect to electronic devices, a first electronic device is "operably coupled" to a second electronic device when the first electronic device is configured to and does send a signal or current to the second electronic device such that the second electronic device actuates or otherwise becomes powered or active.

[0048] As used herein, "temporarily disposed" means that one or more first elements or components are resting on one or more second elements or components in a manner that allows the first elements / components to be moved without having to uncouple or otherwise manipulate the first elements. For example, a book merely resting on a table (i.e., the book is not glued or otherwise secured to the table) is "temporarily disposed" on the table.

[0049] As used herein, the statement that two or more parts or components "engage" one another means that the elements apply a force or bias against one another, either directly or through one or more intermediate elements or components. In addition, as used herein with respect to a moving part, a moving part may "engage" another element during movement from one position to another and / or may "engage" another element once in the described position. Therefore, it should be understood that the statements "when element A moves to the element A first position, element A engages element B" and "when element A is in the element A first position, element A engages element B" are equivalent statements and mean that element A engages element B when moving to the element A first position and / or element A engages element B when it is in the element A first position.

[0050] As used herein, "operatively engaged" means "engage and move." That is, "operatively engaged," when used with respect to a first component that is configured to move a movable or rotatable second component, means that the first component applies a force sufficient to cause the second component to move. For example, a screwdriver may be placed in contact with a screw. When no force is applied to the screwdriver, the screwdriver is only "temporarily coupled" to the screw. If an axial force is applied to the screwdriver, the screwdriver is pressed against the screw and "engages" the screw. However, when a rotational force is applied to the screwdriver, the screwdriver "operatively engages" the screw and causes the screw to rotate. Further, in the case of electronic components, "operatively engaged" means that one component controls (e.g., actuates) another component by a control signal or current.

[0051] As used herein, in the phrases “[x] moves between its first position and its second position” or “[y] is configured to move [x] between its first position and its second position”, “[x]” is the name of an element or component. Furthermore, when [x] is an element or component that moves between multiple positions, the pronoun “its” means “[x]”, that is, the element or component mentioned before the pronoun “its”.

[0052] As used herein, "corresponding" indicates that the size and shape of two structural components are set to be similar to each other and can be connected with the minimum amount of friction. Therefore, the size of the opening "corresponding" to the member is slightly larger than the member so that the member can pass through the opening with the minimum amount of friction. If the two components are to be "tightly" matched together, then modify this definition. In that case, the difference between the sizes of the components is even smaller, thereby increasing the amount of friction. If the element defining the opening and / or the component inserted into the opening is made of a deformable or compressible material, then the opening can even be slightly smaller than the component inserted into the opening. With respect to surfaces, shapes and lines, two or more "corresponding" surfaces, shapes or lines generally have the same size, shape and profile. With respect to movable or configurable elements / components, "corresponding" means that when the elements / components are related and when one element / component is moved / reconfigured, then the other element / component is also moved / reconfigured in a predetermined manner. For example, a rod comprising a central fulcrum and an elongated plate (i.e., a "teeter-totter" or "balance bar") having a first end and a second end. When the first end of the plate is in an elevated position, the second end of the plate is in a lowered position. When the plate first end moves to the lowered position, the plate second end moves to a "corresponding" raised position. Alternatively, a camshaft in the engine has a first lobe operably coupled to the first piston. When the first lobe moves to its upper position, the first piston moves to a "corresponding" upper position, and when the first lobe moves to the lower position, the first piston moves to a "corresponding" lower position.

[0053] As used herein, when used in association with a moving element, a "path of travel" or "path" includes the space through which the element moves when in motion. Therefore, and as used herein, any element that inherently moves has a "path of travel" or "path". In addition, a "path of travel" or "path" involves the movement of an identifiable structure as a whole relative to another object. For example, assuming that the road is very flat, the rotating wheel on a car (an identifiable structure) will not generally move relative to the body of the car (another object). That is, the wheel as a whole will not change its position relative to, for example, an adjacent fender. Therefore, the rotating wheel does not have a "path of travel" or "path" relative to the body of the car. In contrast, the intake valve on that wheel (an identifiable structure) has a "path of travel" or "path" relative to the body of the car. That is, when the wheel rotates and moves, the intake valve moves relative to the body of the car as a whole.

[0054] As used herein, a "planar body" or "planar member" is a generally thin element that includes opposing, broad, generally parallel surfaces, i.e., the planar surfaces of the planar member, and a thinner edge surface extending between the broad parallel surfaces. That is, as used herein, a "planar" element inherently has two opposing planar surfaces with an edge surface extending between them. The perimeter, and therefore the edge surface, may include a generally straight portion, for example, as on a rectangular planar member (such as a credit card), or be curved, as on a disk (such as a coin), or have any other shape.

[0055] As used herein, the term "monolithic" refers to a component that is created as a single piece or unit. That is, a component that includes parts that are created separately and then coupled together as a unit is not a "monolithic" component or body.

[0056] As used herein, "unitary" means that all elements of an assembly are disposed in a single location and / or within a single housing, frame, or similar structure.

[0057] As used herein, the term "number" shall mean one or an integer greater than one (ie, a plurality). That is, for example, the phrase "a plurality of elements" shall mean one element or a plurality of elements. It should be specifically noted that the term "a plurality of" [X] includes a single [X].

[0058] As used herein, the "radial side / surface" of a circular or cylindrical body is a side / surface extending around or around its center or through a height line extending through its center. As used herein, the "axial side / surface" of a circular or cylindrical body is a side extending on a plane extending substantially perpendicular to a height line extending through the center. That is, generally speaking, for a cylindrical soup can, the "radial side / surface" is a substantially circular sidewall, and the "one or more axial side / surfaces" are the top and bottom of the soup can. In addition, as used herein, "radially extending" means extending in a radial direction or along a radial line. That is, for example, a "radially extending" line extends from the center of a circle or cylinder toward a radial side / surface. In addition, as used herein, "axially extending" means extending in an axial direction or along an axis. That is, for example, an "axially extending" line extends from the bottom of the cylinder toward the top of the cylinder and extends substantially parallel to or along the central longitudinal axis of the cylinder.

[0059] As used herein, "substantially curvilinear" includes elements having multiple curved portions, combinations of curved portions and planar portions, and multiple planar portions or segments disposed at angles relative to each other to form a curve.

[0060] As used herein, an "elongated" element inherently includes a longitudinal axis and / or longitudinal line extending in the direction of elongation.

[0061] As used herein, "about" in phrases such as "disposed around [element, point, or axis]" or "extending around [element, point, or axis]" or "[x] degrees around [element, point, or axis" means around, extending around, or measured around. When used in reference to a measurement or in a similar manner, "about" means "approximately," i.e., within an approximate range associated with the measurement, as would be understood by one of ordinary skill in the art.

[0062] As used herein, "substantially" means "in a general manner" in relation to the term being modified, as would be understood by one of ordinary skill in the art.

[0063] As used herein, "substantially" means "to a large extent" in relation to the term being modified, as would be understood by one of ordinary skill in the art.

[0064] As used herein, "at" means "on" and / or "near" in relation to the term to be modified, as would be understood by one of ordinary skill in the art.

[0065] As used herein, "in electronic communication" is used with reference to conveying signals via electromagnetic waves or signals. "In electronic communication" includes both hardwired and wireless communication forms; thus, for example, "data transmission" or "communication method" via a component "in electronic communication" with another component means that data is transmitted from one computer to another computer (or from one processing component to another processing component) via a physical connection (such as USB, Ethernet connection) or a remote connection (such as NFC, Bluetooth, etc.), and should not be limited to any particular device.

[0066] As used herein, "electrical communication" means that electrical current passes or can pass between identified elements. "In electrical communication" also depends on the position or configuration of the elements. For example, in a circuit breaker, a movable contact is "in electrical communication" with a fixed contact when the contact is in a closed position. The same movable contact is not "in electrical communication" with the fixed contact when the contact is in an open position.

[0067] As used herein, when used with respect to comparing two or more biases (including counter / feedback forces), "significantly different" means that the biases are human detectable. That is, a "significantly different" bias relative to a bias that is less than 1.0 lbf or where one of the biases is less than 1.0 lbf means that the difference between the biases is more than 25%. Additionally, a "significantly different" bias relative to a bias where both biases are greater than 1.0 lbf means that the difference between the biases is at least 1.0 lbf.

[0068] As used herein, "significant feedback" when used with respect to a solenoid means that the solenoid is constructed to generate sound and / or vibration that can be detected by a human. That is, certain solenoids are constructed to reduce sound and / or vibration and do not generate "significant feedback" as used herein. For example, a solenoid that includes a damper and / or muffler (such as, but not limited to, a housing disposed within another housing) does not generate "significant feedback" as used herein. In addition to other configurations not specifically identified, a solenoid that includes a stop pin that is located outside the housing and is affected by an element moved by the solenoid is constructed to and does provide "significant feedback" as used herein.

[0069] As used herein, "service current" is the current that a circuit breaker assembly is configured to pass when the circuit breaker assembly contacts are in the closed position.

[0070] As used herein, and when used in connection with a solenoid that draws current from the service current passing through a circuit breaker, "proportional current" means that the current drawn by the solenoid is a fixed proportion of the service current. For example, a current drawn by a solenoid that fluctuates with the service current but is always a set percentage of the service current is "proportional current."

[0071] As used herein, a "multi-level feedback" actuator means an actuator that moves over a path and is constructed to and does provide tactile feedback to a user. As used herein, "tactile feedback" means a bias transmitted to a user by an actuator that the user has actuated. Furthermore, in order to be a "multi-level feedback" actuator, as used herein, the tactile feedback is significantly different when the actuator moves over / through different portions of the actuator's path of travel.

[0072] A solid-state circuit breaker assembly 10 (hereinafter, and as used herein, "circuit breaker assembly" 10) is Figure 1 1 and 2 (some elements are shown schematically). The circuit breaker assembly 10 includes a housing assembly 12, a conductor assembly 14, an operating mechanism 16, a trip assembly 18, and a solid-state interrupter assembly 40. The circuit breaker assembly housing assembly 12 defines an enclosed space 13 in which most of the other elements of the circuit breaker assembly 10 are disposed or substantially disposed. In an exemplary embodiment, the circuit breaker assembly housing assembly 12 is elongated. In an exemplary embodiment, the circuit breaker assembly housing assembly 12 includes an elongated, generally circular shaft 15 that is configured to be and is a rotating mount for selected elements, as discussed below. In an exemplary embodiment, the circuit breaker assembly housing assembly shaft 15 extends generally transversely relative to the longitudinal axis of the circuit breaker assembly housing assembly 12.

[0073] The schematically illustrated solid-state interrupter assembly 40 includes a solid-state switching circuit having a solid-state switching element (e.g., without limitation, an insulated gate bipolar transistor (IGBT)) configured to switch between an on configuration and an off configuration (i.e., a closed configuration and an open configuration) and a trip unit circuit (not numbered) that operates as discussed above. It should be understood that the solid-state interrupter assembly 40 is coupled to the conductor assembly 14 and the line and load (not shown) and selectively communicates with them. In an exemplary embodiment, the trip unit circuit includes a trip assembly 18, included in the assembly, or operatively coupled to the assembly. That is, when the trip unit circuit is actuated, the trip assembly 18 is also actuated. As described above, the trip unit circuit is effectively an operating mechanism for the solid-state interrupter assembly 40, and the "operating mechanism 16" identified above is associated with the contact assembly 19 discussed below.

[0074] The conductor assembly 14 includes a plurality of elongated conductive members (not numbered) that are in electrical communication with a line and a load (not shown). In an exemplary embodiment, any "conductive" element is made of a conductive metal such as, but not limited to, copper, aluminum, gold, silver, or platinum. The conductor assembly 14 also includes a contact assembly 19 having a plurality of movable contacts 20 and a corresponding number of fixed contacts 22 (one of each is shown). Hereinafter, this description will refer to a single pair of contacts 20, 22; however, it should be understood that in an exemplary embodiment, the circuit breaker assembly 10 includes multiple pairs of contacts 20, 22.

[0075] The operating mechanism 16 is operatively coupled to the movable contacts 20 and is configured to move each movable contact 20 between a first, open configuration in which the movable contact 20 is spaced apart from and not electrically connected to the fixed contact 22 and a second, closed configuration in which the movable contact 20 is coupled to or directly coupled to and electrically connected to the fixed contact 22. When the movable contact 20 is in the second position, current is "used" to pass through the circuit breaker assembly 10. Furthermore, in an exemplary embodiment, the movable contact 20 is configured as a "sweeping contact." As used herein, a "sweeping contact" means a movable contact that slides over the surface of a fixed contact as the movable contact moves into the second position. Thus, as Fig. 9 As shown, when the movable contact 20 moves to the second position, the movable contact 20 initially touches the fixed contact 22 at the initial interface 23. When the movable contact 20 is completely in the second position, as shown in FIG. Fig.10 As shown, the point of initial interface 23 is moved (upwardly as shown, also shown enlarged for clarity). It should be understood that the sweeping motion of the movable contact 20 relative to the fixed contact 22 is configured to and does remove debris such as, but not limited to, carbon deposits on the pair of contacts 20, 22.

[0076] The operating mechanism 16 includes a plurality of elements, such as, but not limited to, a crossbar 30 and a multi-stage feedback actuator assembly 50 discussed below. The elements of the operating mechanism 16 (including the crossbar 30) move between a plurality of configurations / positions, including configurations / positions corresponding to the positions of the movable contact 20. For example, the crossbar 30 moves between at least a first position and a second position; when the crossbar 30 is in its first position, the movable contact 20 is in its first position (or is moving toward its first position). Similarly, when the crossbar 30 is in its second position, the movable contact 20 is in its second position (or is moving toward its second position). In an exemplary embodiment, the crossbar 30 is rotatably coupled to the circuit breaker assembly housing assembly 12 and extends generally transversely across the circuit breaker assembly housing assembly 12. The crossbar 30 includes an elongated body 32. The crossbar body 32 is configured to and is rotatably coupled to the circuit breaker assembly housing assembly 12. In addition, the crossbar body 32 includes at least one radial extension 34, i.e., an extension that extends generally radially relative to the crossbar body 32 rotational axis. At least one rotational coupling 36, shown as an axis 38, is disposed on the crossbar body radial extension 34. In addition, the movable contact 20 is coupled to, directly coupled to, or fixed to the crossbar body 32 and is disposed on the radial extension 34 as shown. In the exemplary embodiment, the fixed contact 22 is coupled to the housing assembly 12 adjacent to / within the travel path of the movable contact 20. The rotational axis of the crossbar body radial extension rotational coupling 36 (i.e., the crossbar body axis 38) extends generally parallel to the crossbar body 32 rotational axis.

[0077] As is known and discussed above, when an overcurrent event is detected, the solid-state interrupter assembly 40 interrupts the current. Once the current is interrupted within the solid-state interrupter assembly 40, the trip assembly 18 is configured to move the operating mechanism 16 from the second configuration / position to the first configuration / position in the event of an overcurrent condition. That is, the trip assembly 18 is configured to cause the operating mechanism 16 to open the contacts 20, 22 in the event of an overcurrent condition. In other words, the trip assembly 18 is configured to cause the operating mechanism 16 to move the movable contact 20 from the second position to the first position in the event of an overcurrent condition. This is typically achieved by a biasing device (such as, but not limited to, a rotary solenoid 60 (discussed below)), which causes the elements of the operating mechanism 16 to move from the second configuration to the first configuration.

[0078] In an exemplary embodiment, the operating mechanism 16 includes a multi-stage feedback actuator assembly 50, such as Figure 24. The multi-stage feedback actuator assembly 50 is configured to and does move the operating mechanism 16 and thus the movable contact 20 between the first configuration / position and the second configuration / position. In one embodiment, the multi-stage feedback actuator 50 is a multi-stage feedback closing actuator assembly 52, which is configured to and does move the operating mechanism 16 and thus the movable contact 20 from the first configuration / position to the second configuration / position. That is, in one embodiment, the multi-stage feedback actuator 50 is configured to and does close the contacts 20, 22.

[0079] In another embodiment, the multi-step feedback actuator 50 is a multi-step feedback disconnect actuator assembly 54 that is configured to and does move the operating mechanism 16 and, therefore, the movable contact 20 from the second configuration / position to the first configuration / position. That is, in one embodiment, the multi-step feedback actuator 50 is configured to and does disconnect the contacts 20, 22.

[0080] In another embodiment, the multi-stage feedback actuator 50 includes: a multi-stage feedback closing actuator assembly 52 (hereinafter, and as used herein, the "closing actuator assembly" 52), which is constructed to and does move the movable contact 20 from the first position to the second position; and a multi-stage feedback opening actuator assembly 54 (hereinafter, and as used herein, the "opening actuator assembly" 54), which is constructed to and does move the movable contact 20 from the second position to the first position.

[0081] In the embodiment discussed below, the multi-stage feedback actuator 50 includes a closing actuator assembly 52 and an opening actuator assembly 54. In this embodiment, the multi-stage feedback closing actuator assembly 52 and the multi-stage feedback opening actuator assembly 54 share several components that operate in a generally similar manner. The following description first presents the closing actuator assembly 52, but it should be understood that several elements thereof are also identified as part of the opening actuator assembly 54, which is further discussed below. In addition, the following description describes the "first" primary actuators 90, 92 (discussed below); because the following discussion initially presents the closing actuator assembly 52, the initial "first" primary actuator 90 identified is the actuator for the closing actuator assembly 52. ​​Subsequently, the description describes the "second" primary actuator 92 as the actuator for the opening actuator assembly 54. However, it should be understood that in embodiments having only the closing actuator assembly 52 or only the opening actuator assembly 54, the "first" primary actuators 90, 92 are the actuators for the disclosed assemblies. That is, as used herein, the “first” primary actuator 90 , 92 is not limited to actuators used to close the actuator assembly 52 .

[0082] In the exemplary embodiment, the multi-step feedback actuator assembly 50 or closing actuator assembly 52 includes a rotary solenoid 60, an electric actuator assembly 70, and a manual actuator assembly 80. It should be appreciated that both the electric actuator assembly 70 and the manual actuator assembly 80 share / utilize the same components, such as but not limited to the linkage assembly 150 (described below), even though those components are initially identified as being part of only one actuator assembly.

[0083] The rotary solenoid 60 includes a housing assembly 62, a coil (not shown), and a rotary output shaft 64. In an exemplary embodiment, the rotary solenoid housing assembly 62 is generally cylindrical and / or disc-shaped. That is, the rotary solenoid housing assembly 62 includes a generally radial surface and two generally planar axial surfaces, which are not numbered. In this exemplary embodiment, the rotary solenoid output shaft 64 includes a first end 66 and a second end 68. The rotary solenoid output shaft first end 66 and the rotary solenoid output shaft second end 68 each extend from opposite axial surfaces of the rotary solenoid housing assembly 62. In addition, each of the rotary solenoid output shaft first end 66 and the rotary solenoid output shaft second end 68 is non-circular.

[0084] As is known, the rotary solenoid output shaft 64 responds to the current applied to the rotary solenoid coil. That is, the rotary solenoid output shaft 64 is constructed to and does rotate between a first position and a second position. In one embodiment, the application of a current having a first characteristic applied to the rotary solenoid coil causes the rotary solenoid output shaft 64 to rotate from the second position to the first position, and the application of a current having a second characteristic applied to the rotary solenoid coil causes the rotary solenoid output shaft 64 to rotate from the first position to the second position. In another embodiment, the rotary solenoid 60 includes a biasing device, such as but not limited to a spring (not shown), which biases the rotary solenoid output shaft 64 to one of the first position or the second position. In this embodiment, the rotary solenoid output shaft 64 is maintained in a selected position by a biasing device and moves to another position when a current is applied to the rotary solenoid coil.

[0085] The rotary solenoid 60 is constructed to and does provide noticeable feedback when actuated. In an exemplary embodiment, the rotary solenoid 60 rotary solenoid housing assembly 62 includes stops 61, 63, which are disposed in the path of travel of at least one element of the connecting rod assembly 150 and the shaft coupling 160 as shown (discussed below). Therefore, when the rotary solenoid output shaft 64 moves between the first position and the second position, the connecting rod assembly 150 strikes the rotary solenoid housing assembly stops 61, 63. Since the stops are disposed outside the rotary solenoid housing assembly 62, the sound of the strike is not muffled and is therefore "noticeable feedback" as defined above. That is, the rotary solenoid 60 is constructed to and does generate a sound that a human can hear through the circuit breaker assembly housing assembly 12 and / or generates a vibration that can be detected by a human through the multi-stage feedback actuator assembly 50. This solves the above-mentioned problem.

[0086] In an exemplary embodiment, the rotary solenoid 60 is part of, i.e., utilized by, the electric actuator assembly 70 and the manual actuator assembly 80. The electric actuator assembly 70 includes a first switch assembly 72 and a plurality of conductors, such as, but not limited to, wires (shown schematically, not numbered). As for the primary actuators 90, 92 and in the embodiment of the multi-stage feedback actuator 50 including both the closing actuator assembly 52 and the opening actuator assembly 54, the switch assembly 72 is described as a "first" switch assembly 72 because there is a "second" switch assembly 1072, as discussed below. It should be understood that in embodiments having only the closing actuator assembly 52 or only the opening actuator assembly 54, the switch assembly 72, 1072 will not be identified by the terms "first" and "second" because there will be a single switch assembly 72, 1072. As is known, the switch assembly conductors are coupled to the rotary solenoid coil and are in electrical communication with the rotary solenoid coil. Thus, when the switch assembly 72, 1072 is actuated, a charge / current is applied to the rotary solenoid coil, and the rotary solenoid output shaft 64 moves between positions. That is, the switch assembly 72, 1072 is constructed to and does maintain a charge (or otherwise selectively allows current to pass therethrough) sufficient to cause the rotary solenoid output shaft 64 to move between positions. In an exemplary embodiment, the switch assembly 72, 1072 includes a plurality of capacitors (not shown). Regardless of the configuration of the switch assembly 72, 1072, the switch assembly 72, 1072 includes (or transmits) a charge / current sufficient to cause the rotary solenoid output shaft 64 to rotate between the first / second position. In another exemplary embodiment, the switch assembly 72, 1072 or a configuration electrically connected to the switch assembly 72, 1072 includes an electrical connector configured to be connected to a power source. Therefore, if the switch assembly 72, 1072 is not charged, the user is able to charge the switch assembly 72, 1072.

[0087] In an exemplary embodiment, and as Figure 5 As shown, the first switch assembly 72 includes a housing assembly 74 and an actuator 76. As shown, the first switch assembly actuator 76 includes a lever 77 / button 78 combination. The first switch assembly actuator 76 is configured to and does move between an unactuated first position and an actuated second position. When the first switch assembly actuator 76 moves into the actuated second position, the first switch assembly 72 transfers a charge / current to the rotary solenoid coil. Therefore, the first switch assembly 72 is operatively coupled to the rotary solenoid 60, and the first switch assembly 72 is configured to and does actuate the rotary solenoid 60.

[0088] like Figure 2 As shown in FIG. 4 , the manual actuator assembly 80 includes a plurality of primary actuators 90, a tag 130, a linkage assembly 150, and a cam assembly 200. In the embodiment where the multi-stage feedback actuator assembly 50 includes both a closing (or first) actuator assembly 52 and a disconnecting (or second) actuator assembly 54, the plurality of primary actuators 90 include at least a first actuator 94 and a second actuator 96. As discussed above, in this embodiment, the first actuator 94 is associated with the closing actuator assembly 52 and is configured to actuate the closing actuator assembly. The second actuator 96 is associated with the disconnecting actuator assembly 54 and is configured to actuate the disconnecting actuator assembly.

[0089] The first actuator 94 includes a body 100. As shown in FIG. 4, the first actuator body 100 is elongated and includes a first end 102, a middle portion 104, and a second end 106. The first actuator body first end 102 is configured to be and is rotatably coupled to the circuit breaker housing assembly 12. The first actuator body 100 is configured to move between an unactuated first position and an actuated second position. As the name indicates, when the first actuator body 100 is not actuated, the first actuator body 100 is in the first position. When the first actuator body 100 is fully actuated, the first actuator body is in the second position. In an exemplary embodiment, the first actuator body first end 102 includes a rotational coupling 108, such as but not limited to a shaft 109, which is configured to be and is coupled to the circuit breaker housing assembly 12. That is, in an exemplary embodiment, the circuit breaker housing assembly 12 includes a circular channel (not numbered) corresponding to the first actuator body first end shaft 109. It should be noted that in this configuration, the first actuator body 100 moves (i.e., rotates) generally in a single plane. That is, the longitudinal axis of the first actuator body 100 moves (i.e., rotates) generally in a plane extending generally perpendicular to the first actuator body first end rotational coupling 108 rotational axis. The first actuator body middle portion 104 defines a user interface, such as but not limited to a button 103. In an exemplary embodiment, the first actuator body middle portion 104 also includes a switch assembly interface 107, which is shown as an extension 105 extending generally opposite to the button 103. The first actuator body second end 106 is configured to and does operatively couple to the linkage assembly 150. Therefore, the first actuator body second end 106 is configured to and does operatively engage the linkage assembly 150. That is, the first actuator body 100 is operatively coupled to the linkage assembly 150 and is configured to and does move at least one of the links 160 , 170 , 180 , 190 discussed below.

[0090] In addition, as discussed below, the linkage assembly 150 includes elements that move over a generally circular path. The first actuator body 100 also moves over a generally arcuate path (the arcuate path is also the first actuator 94 "path" as used herein), but in the illustrated embodiment, the first actuator body 100 path has a different radius than the path of the linkage assembly 150 element. In this configuration, the first actuator body second end 106 does not move over the path corresponding to the linkage assembly 150 element. Therefore, in this embodiment, the first actuator body second end 106 includes a rotational coupling 111 and a rotational extension assembly 110. The rotational extension assembly 110 includes a rotational coupling 112, an extension body 114, and a biasing device (such as but not limited to a return spring 116). The rotational extension assembly extension body 114 is elongated and includes a first end 120 and a second end 122. The rotational extension assembly extension body first end 120 includes a rotational coupling 124. The swivel extension assembly extension body second end 122 is configured to and does operatively engage the linkage assembly 150. Additionally, the swivel extension assembly extension body second end 122 is configured to and does operatively engage the linkage assembly 150.

[0091] The rotational extension assembly 110 is assembled as follows. The rotational extension assembly extension body first end rotational coupling 124 is movably coupled to the first actuator body second end rotational coupling 111. In addition, the rotational couplings 108, 111, 124 are oriented so that the longitudinal axis of the rotational extension assembly extension body 114 moves in a plane that is substantially the same as or substantially parallel to the plane of motion of the first actuator body 100. The rotational extension assembly return spring 116 is operatively coupled to both the first actuator body 100 and the rotational extension assembly extension body 114. The rotational extension assembly return spring 116 is configured to and does bias the rotational extension assembly extension body 114 toward the linkage assembly 150.

[0092] When the rotational extension assembly 110 acts as an extension of the first actuator body 100 hereinafter and as used herein with respect to elements / assemblies other than the first actuator 94, the rotational extension assembly extension body second end 122 is considered to be the equivalent of the first actuator body second end 106. That is, as used herein, a statement such as "the first actuator body second end 106 operatively engages the linkage assembly 150" means that the rotational extension assembly extension body second end 122 operatively engages the linkage assembly 150.

[0093] The second actuator 96 will be discussed below in conjunction with the disconnect actuator assembly 54 .

[0094] Before discussing the linkage assembly 150 in detail, it should be noted that the circuit breaker assembly 10 is well known to include a single "link" or "link member" that includes a plurality of generally planar laminates. That is, the laminates have substantially the same size, shape, and other properties (or are coupled to each other so as to form a separate laminate assembly having substantially the same size, shape, and other properties), and are coupled to other elements at substantially the same locations in the exemplary embodiment. Thus, for example, two laminates coupled to a single "link" of a rotating element (such as, but not limited to, the crossbar 30) appear as a single element when viewed along the axis of rotation of the crossbar 30. Even when the laminates are spaced apart from each other, the laminates are part of the same "link." As used herein, such laminates are the same "link" or "link member." Therefore, it should be understood that although the drawings may show a "link" having two or more separate laminates, the following description will identify those laminates by a single name and reference number (i.e., the "link" name and reference number). 4 , the shaft coupling 160 discussed below includes a plurality of laminates 160A, 160B, 160C, 160D, 160E, 160F forming a single shaft coupling 160. That is, even though the various laminates 160A, 160B, 160C, 160D, 160E, 160F have different shapes, the laminates 160A, 160B, 160C, 160D, 160E, 160F are coupled to one another to form a laminate assembly (i.e., a “coupling”) wherein the laminate assembly has substantially the same size, shape, and other characteristics. That is, as used herein and as shown, the laminates 160A, 160B, 160C and 160D, 160E, 160F or the assembly of laminates 160A, 160B, 160C and 160D, 160E, 160F in the coupling have "substantially the same size, shape and other characteristics". It should be noted that the selected laminates 160A, 160B, 160C and 160D, 160E, 160F are disposed on opposite sides of the rotary solenoid 60, but are a single "coupling" as used herein. That is, as described above, in some embodiments, the laminates of a single "coupling" are spaced apart from each other.

[0095] The connecting rod assembly 150 is configured and does operatively couple to the cross bar 30, the rotary solenoid 60, and the first actuator body 100. Therefore, the connecting rod assembly 150 is configured and does operatively engage the cross bar 30, the rotary solenoid 60, and the first actuator body 100. In addition, the cross bar 30 is configured and does operatively couple to the connecting rod assembly 150, and thus is configured and does operatively engage the connecting rod assembly 150. Similarly, the rotary solenoid 60 is configured and does operatively couple to the connecting rod assembly 150, and thus is configured and does operatively engage the connecting rod assembly 150. Similarly, the first actuator body 100 is configured and does operatively couple to the connecting rod assembly 150, and thus is configured and does operatively engage the connecting rod assembly 150. That is, generally speaking, a force / bias applied to any of the crossbar 30, the rotary solenoid 60, the first actuator body 100, and the linkage assembly 150 is transmitted to the elements operatively coupled thereto. Furthermore, as described in detail below, the linkage assembly 150 is configured to apply at least a first bias to the first actuator body 100 and a second bias to the first actuator body 100. The first bias is significantly different from the second bias.

[0096] In this configuration, the multi-level feedback actuator assembly 50 is constructed to and does provide "indicative feedback". As used herein, "indicative feedback" means applying significantly different forces / biases to a user interface (such as, but not limited to, the first actuator 94) so ​​that when the user actuates the user interface, the user is able to sense and distinguish the significantly different forces / biases applied to the user interface through the user interface. Prior to use, the user is informed of the content of the indicative feedback indication. For example, the user is informed of one type of bias / feedback indication, such as through a user manual: a smaller bias / feedback indicates that the first actuator 94 is actuating the electric actuator assembly 70, and a larger bias / feedback indicates that the first actuator 94 is actuating the manual actuator assembly 80.

[0097] In an exemplary embodiment, the connecting rod assembly 150 includes a shaft coupling 160, an upper coupling 170, an intermediate coupling 180, and a lower coupling 190. The shaft coupling 160 includes an elongated body 162 having a first end 164, a middle portion 165, and a second end 166. Each of the shaft coupling body first end 164, the shaft coupling body middle portion 165, and the shaft coupling body second end 166 includes a coupling. In an exemplary embodiment, the shaft coupling 160 includes at least two laminates (not numbered) spaced apart from each other and thereby defining a bracket (not numbered). In an exemplary embodiment, the shaft coupling body first end 164 defines a rotation coupling 161. In an exemplary embodiment, the bracket at the shaft coupling body first end 164 includes two openings (not numbered), which are the shaft coupling body first end coupling 161. In addition, a wheel 163 having an axle (not numbered) is rotatably coupled to the bracket opening of the first end 164 of the shaft coupling body. As discussed below, the wheel 163 is also identified as the second cam member 204 of the cam assembly (discussed below). The wheel 163 and therefore the first end 164 of the shaft coupling body are constructed to and do operatively engage the first cam member 202 of the cam assembly discussed below. Similarly, the first cam member 202 of the cam assembly is constructed to and does operatively engage the wheel 163 and therefore the first end 164 of the shaft coupling body. In an alternative embodiment, the first end 164 of the shaft coupling body defines a cam surface (not shown), which is a second cam member that is constructed to and does operatively engage the first cam member 202 of the cam assembly.

[0098] The shaft coupling body intermediate portion 165 coupling includes an opening 167 that is shaped to substantially correspond to the longitudinal cross-sectional shape of the rotary solenoid output shaft 64. In this configuration, the shaft coupling body intermediate portion 165 is configured to and is indeed fixed to the rotary solenoid output shaft 64. Therefore, the shaft coupling 160 rotates with the rotary solenoid output shaft 64. That is, the rotary solenoid output shaft 64 is operatively coupled to and thus operatively engages the shaft coupling 160. Similarly, the shaft coupling 160 is operatively coupled to and thus operatively engages the rotary solenoid output shaft 64.

[0099] The shaft coupling body second end 166 coupling is a rotational coupling, such as a substantially circular opening 168. The shaft coupling body second end 166 coupling is configured to and is rotationally coupled to the intermediate coupling 180. In addition, the edge surface of the shaft coupling body second end 166 is configured to and is a first actuator interface 169. In an exemplary embodiment, the shaft coupling body second end first actuator interface 169 is disposed between the shaft coupling body middle portion opening 167 and the shaft coupling body second end opening 168.

[0100] The upper coupling 170 includes a body 172. The upper coupling body 172 is elongated and, as shown, is generally curvilinear. The upper coupling body 172 includes a first end 174 and a second end 176. Each of the upper coupling body first end 174 and the second end 176 includes a coupling, such as, but not limited to, a swivel coupling. As shown, each of the upper coupling body first end 174 and the second end 176 includes a substantially circular opening 175, 177.

[0101] The intermediate coupling 180 includes a body 182. The intermediate coupling body 182 is elongated and is substantially straight as shown. The intermediate coupling body 182 includes a first end 184 and a second end 188. Each of the intermediate coupling body first end 184 and the second end 188 includes a coupling, such as but not limited to a rotating coupling. In an exemplary embodiment, each of the intermediate coupling body first end 184 and the second end 188 includes a substantially circular opening 185, 189, respectively. However, in another exemplary embodiment, the intermediate coupling body first end opening 185 is an elongated slot 185A having a longitudinal axis extending along or substantially parallel to the longitudinal axis of the intermediate coupling body 182. It should be noted that when the intermediate coupling body first end opening 185 is an elongated slot 185A, the element connected thereto can move in the slot without causing the intermediate coupling body 182 to move. That is, for example and as discussed below, the shaft coupling body 162 is coupled to the intermediate coupling body first end 184 by a pin (not numbered). Thus, as the shaft coupling body 162 moves, the pin moves in the intermediate coupling body first end slot 185A until the pin abuts the end of the slot 185A. Only when the pin abuts the end of the slot 185A is the motion of the shaft coupling body 162 transmitted to the intermediate coupling body 182.

[0102] The lower link 190 includes a body 192. The lower link body 192 is elongated and is generally straight as shown. The lower link body 192 includes a first end 194, a middle portion 196, and a second end 198. Each of the lower link body first end 194, the middle portion 196, and the second end 198 includes a coupling, such as but not limited to a swivel coupling. As shown, each of the lower link body first end 194, the middle portion 196, and the second end 198 includes a substantially circular opening 195, 197, 199.

[0103] The cam assembly 200 includes a first cam member 202, a second cam member 204, and a biasing device 206. In an exemplary embodiment, the cam assembly first cam member 202 includes a generally planar body 210 defining a rotational coupling and a cam surface 212. That is, the cam assembly first cam member body 210 defines a substantially circular opening 214. The circuit breaker assembly housing assembly shaft 15 is configured as and is a rotational mounting for the cam assembly first cam member body 210. That is, the circuit breaker assembly housing assembly shaft 15 extends through the cam assembly first cam member body opening 214. The circuit breaker assembly housing assembly shaft 15 is disposed adjacent to or proximate to the path of travel of the shaft coupling body first end 164, as discussed below. In an exemplary embodiment, an edge surface of the cam assembly first cam member body 210 disposed adjacent to the path of travel of the shaft coupling body first end 164 defines the cam assembly first cam member body cam surface 212. Further, in an exemplary embodiment, the cam assembly first cam member body cam surface 212 is generally curvilinear. As discussed above, in the exemplary embodiment, the cam assembly second cam member 204 is the wheel 163. That is, the cam assembly second cam member 204 includes a generally circular (ie, disc-shaped) body 216, wherein the radial surface is a generally circular cam surface 218.

[0104] In an exemplary embodiment, the cam assembly biasing device 206 is a spring 220 that is configured to and does engage / apply a bias to at least one of the cam assembly first cam member 202 or the cam assembly second cam member 204. The cam assembly biasing device 206 is configured to and does generate a force line 230 discussed below that extends from a contact point between the cam assembly first cam member 202 and the second cam member 204 through the shaft coupling body first end coupling 161. In an exemplary embodiment, the circuit breaker assembly housing assembly 12 includes a spring mount 222 that is disposed adjacent to the circuit breaker assembly housing assembly shaft 15. The cam assembly biasing device 206 (i.e., spring 220) is coupled to, directly coupled to, or fixed to the circuit breaker assembly housing assembly spring mount 222.

[0105] The multi-stage feedback actuator assembly 50 is assembled as follows. The rotary solenoid 60 is disposed in the circuit breaker assembly housing assembly enclosure 13. As is known, the circuit breaker assembly housing assembly 12 includes a mounting member (not numbered) configured to support the rotary solenoid 60. Thus, the rotary solenoid 60 is coupled to, directly coupled to, or fixed to the circuit breaker assembly housing assembly 12. As shown, and in an exemplary embodiment, the rotation axis 65 of the rotary solenoid output shaft 64 extends substantially parallel to the rotation axis of the crossbar 30.

[0106] The shaft coupling 160 is coupled to, directly coupled to, or fixed to the rotary solenoid output shaft 64. In an exemplary embodiment, the shaft coupling body middle portion opening 167 is directly coupled to the rotary solenoid output shaft 64. In addition, since the rotary solenoid output shaft 64 and the shaft coupling body middle portion opening 167 are both non-circular (and have corresponding shapes), the shaft coupling 160 is fixed to the rotary solenoid output shaft 64 and rotates with it. In addition, in this configuration, the force and bias applied by either the shaft coupling 160 or the rotary solenoid output shaft 64 are transmitted to the other. In addition, when the rotary solenoid output shaft 64 rotates and when the shaft coupling 160 moves with it, the shaft coupling 160 and its subcomponents each have a travel path. As described above, the wheel 163 (i.e., the cam assembly second cam member 204) is rotatably coupled to the shaft coupling body first end 164. The shaft link body second end 166 is rotatably coupled to the intermediate link body first end 184 .

[0107] In the exemplary embodiment, the upper link body first end 174 is rotatably coupled to the circuit breaker assembly housing assembly shaft 15. That is, the circuit breaker assembly housing assembly shaft 15 extends through the upper link body first end opening 175. The upper link body second end 176 is rotatably coupled to the lower link body first end 194. That is, in the exemplary embodiment, a shaft or pin (not numbered) extends through both the upper link body second end opening 177 and the lower link body first end opening 195.

[0108] The intermediate link body second end 188 is rotatably coupled to the lower link body 192. In an exemplary embodiment, a shaft or pin (not numbered) extends through both the intermediate link body second end opening 189 and the lower link body middle portion opening 197. Thus, the intermediate link 180 (i.e., the intermediate link body 182) extends between and is rotatably coupled to the shaft link 160 (i.e., the shaft link body 162) and the lower link 190 (i.e., the lower link body 192). The lower link body 192 is further rotatably coupled to the crossbar 30. In an exemplary embodiment, the lower link body second end opening 199 is rotatably coupled to the crossbar body radial extension rotation coupling 36 (i.e., the crossbar body shaft 38).

[0109] As shown, the axis of rotation of each rotating coupling in the linkage assembly 150 extends generally or substantially parallel to the axis of rotation of the crossbar body 32. In addition, although not discussed in detail, as is known in the art, in an exemplary embodiment, the movement of the various couplings in the linkage assembly 150 is stopped or limited by a stop pin (not numbered). It should be understood that the stop pin is positioned to stop / limit the movement of the linkage assembly 150 to the first position and the second position of the movable contact 20. That is, for example, if the coupling of the linkage assembly 150 is moving in the first direction when the movable contact 20 moves into the first position, then the stop pin is positioned so as to stop the movement of the coupling of the linkage assembly 150 in the first direction once the movable contact 20 is in the first position.

[0110] The cam assembly first cam member 202 is rotatably coupled to the circuit breaker assembly housing assembly shaft 15 and is disposed adjacent to or proximate to the travel path of the shaft coupling body first end 164. In addition, the cam assembly biasing device 206 (i.e., spring 220) is disposed adjacent to the cam assembly first cam member 202 and is configured to and does bias the cam assembly first cam member 202 toward the cam assembly second cam member 204 (i.e., wheel 163). In other words, the cam assembly biasing device 206 causes the cam assembly first cam member 202 to operatively engage the cam assembly second cam member 204.

[0111] The first actuator body 100 is rotatably coupled to the circuit breaker housing assembly 12. That is, the first actuator body first end 102 is rotatably coupled to the circuit breaker housing assembly 12. In this configuration, the first actuator body 100 has a travel path. In addition, the first actuator body middle portion user interface (i.e., button 103) is disposed on the exterior of the circuit breaker housing assembly 12. The first actuator body second end 106 is operatively coupled to the linkage assembly 150. That is, the first actuator body second end 106 is operatively coupled to the shaft coupling body second end first actuator interface 169. As shown in FIG. Figure 6 As shown, the first actuator body second end 106 abuts the shaft coupling body second end first actuator interface 169, and when the first actuator body 100 moves over the first actuator body 100 path second portion (as discussed below), the first actuator body second end 106 engages the shaft coupling body second end first actuator interface 169. In addition, the multi-stage feedback actuator assembly 50 includes an actuator spring 101. The multi-stage feedback actuator assembly actuator spring 101 is disposed between the first actuator body 100 and the circuit breaker housing assembly 12. The multi-stage feedback actuator assembly actuator spring 101 is configured to and does bias the first actuator body 100 to the first position, as described below.

[0112] The first switch assembly 72 is disposed adjacent to the travel path of the first actuator body 100. That is, the first switch assembly 72 is positioned so that the first switch assembly actuator 76 is disposed in the travel path of the first actuator body mid-portion switch assembly interface 107. As described above, the first switch assembly 72 is further operatively coupled to the rotary solenoid 60, and actuation of the first switch assembly actuator 76 causes the rotary solenoid 60 to actuate.

[0113] The label 130 includes a body 132 having two markings (unnumbered) thereon. The markings are different and are associated with the position of the movable contact 22. As shown, the markings are the words "open" and "closed". The label 130 (i.e., the label body 132) is operatively connected to the crossbar 30 and moves into a corresponding position therewith. That is, when the crossbar 30 is in the first position, the label 130 is in the first position, and when the crossbar 30 is in the second position, the label 130 is in the second position. As described above, the circuit breaker assembly housing assembly 12 includes an opening or "window" through which only one of the markings is visible. When the crossbar 30 is in the first position, the "open" marking is visible. When the crossbar 30 is in the second position, the "closed" marking is visible.

[0114] In this configuration, the first actuator body 100 is operatively coupled to the connecting rod assembly 150 and is configured to and does move at least one connecting rod member (e.g., the shaft coupling 160). In addition, the connecting rod assembly 150 is operatively coupled to the first actuator body 100, the rotary solenoid output shaft 64, and the cam assembly 200. In addition, the cam assembly 200 is operatively coupled to the connecting rod assembly 150. In addition, the cam assembly biasing device 206 is configured to and does apply a bias to at least one of the first cam member 202 and / or the second cam member 204. In addition, the cam assembly 200 is configured to and does apply a bias to the connecting rod assembly 150.

[0115] In this configuration, the first actuator body 100 is configured to and does move over a path having at least a first portion and a second portion when the first actuator body moves between its first position and its second position. As described below, and as used herein, the first actuator body 100 path "first portion" and "second portion" are those portions of the first actuator body 100 path where the first actuator body 100 operatively engages a different set of elements of the multi-stage feedback actuator assembly 50. That is, as used herein, the first actuator body 100 path "first portion" is the portion of the first actuator body 100 path where the first actuator body 100 operatively engages the first switch assembly 72 (i.e., the first switch assembly actuator 76). The first actuator body 100 path "second portion" is the portion of the first actuator body 100 path where the first actuator body 100 operatively engages the linkage assembly 150 and the first switch assembly 72. The first actuator body 100 is in the second position when the first actuator body 100 is at the end of a "second portion" of the first actuator body 100 path. It should be noted that in some configurations, the first actuator body 100 moves over a path in which the first actuator body 100 does not operatively engage another element of the multi-stage feedback actuator assembly 50. As used herein, such a portion of the first actuator body 100 path is a "zero portion" of the first actuator body 100 path, i.e., an embodiment in which the intermediate link body first end opening 185 is an elongated slot 185A.

[0116] In addition, the connecting rod assembly 150 is configured to and does apply at least a first bias to the first actuator body 100 and a second bias to the first actuator body 100. In addition, the first bias is significantly different from the second bias. That is, the connecting rod assembly 100 is configured to apply the first bias to the first actuator body 100 when the first actuator body 100 is disposed in a first portion of the first actuator body 100 path, and the connecting rod assembly 150 is configured to and does apply the second bias to the first actuator body 100 when the first actuator body 100 is disposed in a second portion of the first actuator body 100 path.

[0117] That is, the multi-stage feedback actuator assembly 50 operates as follows. Initially, for the sake of this example using the closing actuator assembly 52, it is assumed that the movable contact 20 is in the open first position and the operating mechanism 16 is in the corresponding first configuration, that is, the crossbar 30 is in the first position. In addition, the first actuator body 100 is in the unactuated first position.

[0118] When the user actuates the first actuator body mid-section user interface, i.e., when the user presses the button 103, the first actuator body 100 moves over the first portion of the path of the first actuator body 100. When the first actuator body 100 moves over the first portion of the path of the first actuator body 100, the first actuator body 100 and, as shown, the first actuator body mid-section switch assembly interface 107 engage and actuate the first switch assembly actuator 76. Thus, the first actuator body 100 is configured to and does operatively engage the first switch assembly actuator 76 when the first actuator body 100 is disposed in the first portion of the path of the first actuator body 100. As discussed above, after actuating the first switch assembly actuator 76, the rotary solenoid 60 is actuated and causes the rotary solenoid output shaft 64 to move from the first position to the second position. Rotation of the rotary solenoid output shaft 64 causes the linkage assembly 150 to move from the first configuration to the second configuration, which in turn causes the crossbar 30 (and other elements of the operating mechanism 16) to move from the first position / configuration to the second position / configuration. As discussed above, when the operating mechanism 16 moves from the first configuration to the second configuration, the movable contact 20 moves from the first position to the second position. That is, the movable contact 20 is closed.

[0119] This is normal operation of the electric actuator assembly 70. That is, the electric actuator assembly 70 includes the first actuator 94, the rotary solenoid 60 and the first switch assembly 72. In addition, as discussed below, actuating the electric actuator assembly 70 requires a minimum force on the first actuator 94. That is, the reaction force or feedback force applied by the electric actuator assembly 70 is relatively low when compared to the feedback force generated by the manual actuator assembly 80, as discussed below. Therefore, when the first actuator 94 moves over the first portion of the path of the first actuator body 100, there is a first bias applied to the first actuator 94. In addition, if the electric actuator assembly 70 actuates the rotary solenoid 60, there is a significant feedback, as described above. In addition, the label 130 moves from its first position to its second position, thereby indicating that the movable contact 20 is in the second position. Thus, the user is notified that the electric actuator assembly 70 has moved the movable contact 20 from the first position to the second position, and the user stops pressing the first actuator body middle portion user interface (ie, button 103).

[0120] If the electric actuator assembly 70 is unable to move the movable contact 20 from the first position to the second position, for example, if the first switch assembly 72 is unable to provide a charge to the rotary solenoid 60, then the user must utilize the manual actuator assembly 80 to move the movable contact 20 from the first position to the second position. This is accomplished by continuously pressing on the first actuator body middle portion user interface (i.e., button 103).

[0121] That is, when the user continues to press on the first actuator body middle portion user interface (i.e., button 103), the first actuator body 100 moves into the second portion of the first actuator body 100 path. When the first actuator body 100 moves into the second portion of the first actuator body 100 path, the first actuator body 100 engages the connecting rod assembly 150. That is, the first actuator body second end 106 engages the shaft coupling body second end first actuator interface 169. This bias causes the shaft coupling 160 to rotate. Therefore, the first actuator body 100 is configured to and does operatively engage the connecting rod assembly 150 when the first actuator body 100 is disposed in the second portion of the first actuator body 100 path. As described above, the shaft coupling 160 is operatively coupled to the rotary solenoid output shaft 64, so that rotation of the shaft coupling 160 causes the rotary solenoid output shaft 64 to rotate from the first position to the second position and generate noticeable feedback. Furthermore, as described above, rotation of the rotary solenoid output shaft 64 causes the operating mechanism 16 and, therefore, the movable contacts 20 to move into their second position / configuration.

[0122] Generally speaking, the linkage assembly 150 provides a reaction or feedback bias / force to the first actuator body 100. In an exemplary embodiment, the bias provided by the linkage assembly 150 to the first actuator body 100 when the first actuator body 100 is in a first portion of the first actuator body 100 path is less than the bias provided by the linkage assembly 150 to the first actuator body 100 when the first actuator body 100 is in a second portion of the first actuator body 100 path. This is achieved at least in part by the forces generated in the cam assembly 200.

[0123] That is, as mentioned above and as Figures 6 to 10As shown, the cam assembly biasing device 206 generates a force line 230 extending from the contact point between the cam assembly first cam member 202 and the second cam member 204 through the shaft coupling body first end coupling 161. Initially, i.e., when the first actuator body 100 is disposed in the first portion of the first actuator body 100 path, the force line 230 extends to the "first side" of the solenoid output shaft rotation axis 65. When the rotary solenoid output shaft 64 and the shaft coupling 160 are moved / rotated from the first position to the second position, and when the first actuator body 100 is disposed in the second portion of the first actuator body 100 path, the force line 230 extends to the "second side" of the solenoid output shaft rotation axis 65. In this configuration, when the first actuator body 100 is disposed in the first portion of the first actuator body 100 path, the reaction force or feedback force exerted on the first actuator body 100 by the linkage assembly 150 is initially low (when compared to the higher forces discussed below). As the first actuator body 100 moves into the second portion of the first actuator body 100 path, the reaction or feedback force applied by the linkage assembly 150 on the first actuator body 100 increases until the force line 230 crosses the solenoid output shaft rotation axis 65. After the force line 230 crosses the solenoid output shaft rotation axis 65, the reaction or feedback force applied by the linkage assembly 150 on the first actuator body 100 quickly decreases to zero or a negligible amount. Thus, the combination of the linkage assembly 150 and the cam assembly 200 produces a feedback or response similar to a toggle device. Specific examples of reaction or feedback forces are shown below.

[0124] Before discussing specific examples of reaction forces or feedback forces, the "first side" and "second side" of the solenoid output shaft rotational axis 65 are defined as follows. As used herein, the "side" of the rotational axis on which the force line is disposed is determined as follows. Fig.11 As shown in the figure, the "side" is determined when looking along the axis of rotation. That is, as shown in the figure, the axis of rotation is Fig.11 , because the images are shown "along the axis of rotation". In addition, all force lines and any other lines discussed herein are constrained to be as seen when viewed "along the axis of rotation" (i.e., as Fig.11 That is, all lines are limited to the following two-dimensional representations: Fig.11The plane shown is a view along the axis of rotation. When the force line does not pass through the axis of rotation and when the movable contact is in the first position or the second position, the "side" of the axis of rotation is determined. That is, the "side" of the axis of rotation relative to the closing actuator assembly 52 is determined when the movable contact 20 is in the first position, and the "side" of the axis of rotation relative to the disconnecting actuator assembly 54 is determined when the movable contact 20 is in the second position. In order to identify the "side" of the axis of rotation, the "dividing line" parallel to the initial position and direction of the force line and passing through the axis of rotation is identified. It should be understood that the "initial position and direction of the force line" for the closing actuator assembly 52 means the position and direction of the force line when the closing operation begins. Conversely, the "initial position and direction of the force line" for the disconnecting actuator assembly 54 means the position and direction of the force line when the disconnecting operation begins. The side of the "dividing line" that initially includes the force line is the "first side" of the axis of rotation. The opposite side of the "dividing line" is the "second side" of the axis of rotation. That is, the side of the "dividing line" without the initial force line is the "second side" of the axis of rotation. In addition, the position of a "line" (other than a "dividing line" or any other line passing through the axis of rotation) is determined at a position "radial to" the axis of rotation, and where the radial line intersects the other line substantially perpendicularly. That is, the radial lines from the axis of rotation extend to and are substantially perpendicular to the lines of force. The position where the radial lines intersect the lines of force determines which side of the "dividing line", i.e., which side of the axis of rotation, the lines of force are located. That is, as used herein, the "position" of the lines of force relative to the axis of rotation is identified at the intersection point of the radial lines from the axis of rotation that are substantially perpendicular to the lines of force. In addition, if the intersection point of the radial lines from the axis of rotation and the lines of force is on the "dividing line", then the lines of force are located on the "first side" of the axis of rotation as used herein.

[0125] Considering these definitions, and if Figures 6 to 10 As shown, during use of the closing actuator assembly 52, the first actuator 94 is in its first position and the force line 230 is disposed on a first side of the solenoid output shaft rotation axis 65. When a user actuates the first actuator 94 (which in this example is the actuator associated with the closing actuator assembly 52), the linkage assembly 150 causes the force line 230 to move. In other words, the movement of the first actuator 94 causes the linkage assembly 150 elements to move. The movement of the linkage assembly 150 causes the position of the force line 230 to move.

[0126] As the first actuator 94 moves over the first portion of the path of the first actuator body 100, the line of force 230 remains on the first side of the solenoid output shaft rotation axis 65. In addition, the force applied to the first actuator body middle portion user interface (i.e., button 103) is relatively low compared to the latter force applied as discussed below. Similarly, the force applied by the linkage assembly 150 to rotate the solenoid output shaft 64 is relatively low compared to the latter force applied to rotate the solenoid output shaft 64. In addition, and in the exemplary embodiment, as the first actuator 94 moves over the first portion of the path of the first actuator body 100, the movement of the linkage assembly 150 has a negligible effect on the crossbar 30. That is, in the exemplary embodiment in which the intermediate link body first end opening 185 is an elongated slot 185A, the initial movement of the first actuator 94 is not transmitted to the crossbar 30 through the linkage assembly 150 because the movement of the shaft link 160 is not transmitted to the intermediate link 180 until the pin-jointed links 160, 180 move to the end of the elongated slot 185A. In addition, it should be noted that when the pin-jointed links 160, 180 move to the end of the elongated slot 185A, the first actuator body 100 and the rotation extension assembly 110 as shown are operatively coupled to and operatively engage both the shaft link 160 and the intermediate link 180.

[0127] As the user continues to press the first actuator 94, the reaction force generated by the multi-stage feedback actuator assembly 50 continues to increase. That is, when the first actuator 94 moves into and over the second portion of the path of the first actuator body 100, the reaction force increases and is significantly different from the reaction force generated by the multi-stage feedback actuator assembly 50 when the first actuator body 100 is in the first portion of the path of the first actuator body 100. In addition, the movement of the linkage assembly 150 begins to significantly affect the crossbar 30. That is, the crossbar 30 rotates and moves the movable contact 20 toward the second position. As shown in the following graph, the feedback force generated by the linkage assembly 150 on the first actuator 94 is the largest when the crossbar 30 rotates and moves the movable contact 20 toward the second position. Just before the movable contact 20 engages the fixed contact 22, the feedback force generated by the linkage assembly 150 on the first actuator 94 begins to decrease. When the movable contact 20 engages the fixed contact 22, the feedback force generated by the linkage assembly 150 on the first actuator 94 is reduced by a significantly different amount. In addition, when the first actuator 94 moves into and over the second portion of the path of the first actuator body 100, the force line 230 remains on the first side of the solenoid output shaft rotation axis 65. When the movable contact 20 engages the fixed contact 22, the force line 230 crosses to the second side of the solenoid output shaft rotation axis 65. The configuration of the linkage assembly 150 when the force line 230 crosses the solenoid output shaft rotation axis 65 is identified herein as a "toggle device." Therefore, as shown in the following chart, when the linkage assembly 150 crosses the toggle configuration, the feedback force generated by the linkage assembly 150 on the first actuator 94 is reduced by a significantly different amount when compared to the feedback force generated by the linkage assembly 150 on the first actuator 94 when the force line 230 is on the first side of the solenoid output shaft rotation axis 65. In addition, when the force line 230 crosses the solenoid output shaft rotation axis 65, the movable contact 20 moves quickly from the first position to the second position. That is, the movable contact 20 snaps closed. The rapid movement of the movable contact 20 from the first position to the second position reduces the chance of arcing and / or reduces the duration of the arc in the event of an arc. At this moment, the first actuator body 100 has moved into the third portion of the first actuator body 100 travel path. In addition, at this moment in the actuation process, the movable contact 20 has moved into the second position. That is, the contacts 20, 22 are closed.

[0128] In an exemplary embodiment, the multi-stage feedback actuator assembly 50 has the characteristics shown in the following graph.

[0129]

[0130] Thus, generally speaking, when the user begins to actuate the first actuator body mid-portion user interface (i.e., button 103), there is initially minimal feedback when the first actuator body 100 is moving over the zero portion of the path (if there is a zero portion due to the elongated slot 185A as described above) and the first actuator body 100 path first portion. During this time, the linkage assembly 150 applies a first bias to the first actuator body 100 that can be detected by the user. When the first actuator body 100 moves over the first actuator body 100 path first portion, the first actuator body 100 actuates the first switch assembly 72. That is, the first actuator body 100 actuates the first switch assembly actuator 76. When the first switch assembly 72 is actuated, and if the first switch assembly 72 is capable of applying a charge to the rotary solenoid 60, the first switch assembly 72 actuates the rotary solenoid 60, thereby causing the movable contact 20 to move into the second position and generating noticeable feedback. If the user detects significant feedback, the user is notified that the movable contact 20 is in the second position and the user stops actuating the first actuator 94. Additionally, the rotational extension assembly return spring 116 returns the first actuator 94 to its first position.

[0131] However, if the first switch assembly 72 is unable to apply charge to the rotary solenoid 60, the first switch assembly 72 will not actuate the rotary solenoid 60 and there is no obvious feedback. Therefore, the user is notified that the first actuator 94 needs to be further actuated. Therefore, the user continues to press the first actuator body middle part user interface (i.e., button 103), thereby causing the first actuator body 100 to move above the first actuator body 100 path second part. As described in detail above, the connecting rod assembly 150 generates a second bias applied to the first actuator body 100 and is a user-detectable increase. As described above, the second bias is greater than the first bias, and the first bias is significantly different from the second bias. In addition, as also described above, the continuous movement of the first actuator body 100 above the first actuator body 100 path second part manually moves the movable contact 20 to the second position. When the movable contact 20 moves to the second position, the feedback force generated by the connecting rod assembly 150 and applied to the first actuator body 100 is reduced by an amount significantly different from the second bias. Thus, due to the change in feedback force, the user is notified that the movable contact 20 has moved into the second position. The user stops actuating the first actuator 94, and the rotation extension assembly return spring 116 returns the first actuator 94 to its first position. Thus, the multi-stage feedback closing actuator assembly 52 is configured to and does move the movable contact 20 from the first position to the second position while providing different tactile feedback, i.e., feedback forces that can be detected by the user through the button 103.

[0132] In embodiments of the multi-stage feedback actuator 50 that include both a closing actuator assembly 52 and an opening actuator assembly 54, the opening actuator assembly 54 includes a second actuator 96 as discussed above. The following description will use the term "second actuator" 94, but it should be understood that in embodiments having only an opening actuator assembly 54, this actuator will be identified as the "first" actuator.

[0133] In this embodiment, and in addition to the above-mentioned elements, the multi-stage feedback actuator 50 includes the second actuator 96 mentioned above and the second switch assembly 1072. The second actuator 96 includes an elongated body 1100 having a first end 1102, a middle portion 1104, and a second end 1106. As shown, the second actuator body 1100 is an assembly including bodies 1100A and 1100B, but is identified as a single element as used herein. In addition, although shown as having an elongated axis 1109 discussed below, the second actuator body 1100 is "elongated" as used herein in the same direction as the first actuator body 100 discussed above. Therefore, the second actuator body 1100 rotates in a plane that is generally parallel to the rotation plane of the first actuator body 100, as discussed above.

[0134] The second actuator body first end 1102 is configured to and is rotatably coupled to the circuit breaker housing assembly 12. In an exemplary embodiment, the second actuator body first end 1102 includes a rotational coupling 1108, such as but not limited to a shaft 1109, which is configured to and is coupled to the circuit breaker housing assembly 12. That is, in an exemplary embodiment, the circuit breaker housing assembly 12 includes a circular channel (not numbered) corresponding to the second actuator body second end shaft 1109. It should be noted that in this configuration, the second actuator body 1100 moves (i.e., rotates) generally in a single plane. That is, the longitudinal axis of the second actuator body 1100 moves (i.e., rotates) generally in a plane extending generally perpendicular to the second actuator body first end rotational coupling 1108 rotational axis. The second actuator body middle portion 1104 defines a user interface, such as but not limited to a button 1103. In an exemplary embodiment, the second actuator body middle portion 1104 also includes a switch assembly interface 1107, which is shown as an extension 1105 extending generally opposite the button 1103. The second actuator body second end 1106 is configured to and does operatively couple to the linkage assembly 150. Thus, the second actuator body second end 1106 is configured to and does operatively engage the linkage assembly 150. That is, the second actuator body 1100 is operatively coupled to the linkage assembly 150 and is configured to and does move at least one of the linkages 160, 170, 180, 190.

[0135] The second actuator 96 (i.e., the multi-step feedback actuator assembly 50) also includes a plurality of return springs 1101. The multi-step feedback actuator assembly return springs 1101 are disposed between the second actuator body 1100 and the circuit breaker housing assembly 12. The multi-step feedback actuator assembly return springs 1101 are configured to and do bias the second actuator body 1100 to the first position.

[0136] The second switch assembly 1072 is substantially similar to the first switch assembly 72, and therefore will not be described in detail. It should be noted that, as identified in the figure, the elements of the second switch assembly 1072 have the same reference number +1000. Therefore, the second switch assembly 1072 includes a housing assembly 1074 and an actuator 1076, that is, a lever / button combination (both not shown). As is known, the second switch assembly conductor (e.g., wire, not numbered) is connected to the rotary solenoid coil and is electrically connected to the rotary solenoid coil. The second switch assembly 1072 is constructed to and does provide a charge / current that causes the rotary solenoid output shaft 64 to rotate in a direction opposite to the direction in which the rotary solenoid output shaft 64 rotates when the charge / current is applied by the first switch assembly 72. Therefore, when the second switch assembly 1072 is actuated, the charge / current is applied to the rotary solenoid coil, and the rotary solenoid output shaft 64 moves between positions. That is, the second switch assembly 1072 is constructed to and does maintain a charge sufficient to cause the rotary solenoid output shaft 64 to move between positions (or otherwise selectively allow current to pass therethrough). The second switch assembly 1072 is coupled to, directly coupled to, or fixed to the circuit breaker housing assembly 12 in a position such that the second switch assembly actuator 1076 is disposed in the path of the second actuator body mid-portion switch assembly interface 1107.

[0137] The connecting rod assembly 150 is substantially the same as the connecting rod assembly 150 described above, with the following exceptions. For the disconnect actuator assembly 54, the edge surface of the shaft coupling body first end 164 is configured as and is the second actuator interface 1169. In an exemplary embodiment, the shaft coupling body second end first actuator interface 1169 (which is an edge surface) is disposed adjacent to or in close proximity to the cam assembly second cam member 204.

[0138] The second actuator body 1100 is constructed to and is rotatably coupled to the circuit breaker housing assembly 12 and moves between an unactuated first position and an actuated second position and over a path having at least a first portion and a second portion. As the name indicates, when the second actuator body 1100 is unactuated, the second actuator body 1100 is in the first position. When the second actuator body 1100 is fully actuated, the second actuator body is in the second position. As used herein, the second actuator body 1100 path "first portion" and "second portion" are those portions of the second actuator body 1100 path where the second actuator body 1100 operatively engages a different set of elements of the multi-stage feedback actuator assembly 50. That is, as used herein, the "first portion" of the second actuator body 1100 path is the portion of the second actuator body 1100 path where the second actuator body 1100 operatively engages the second switch assembly 1072 (i.e., the switch assembly actuator 1076). The "second portion" of the second actuator body 1100 path is the portion of the second actuator body 1100 path where the second actuator body 1100 operatively engages the linkage assembly 150 and the second switch assembly 1072. When the second actuator body 1100 is at the end of the "second portion" of the second actuator body 1100 path, the second actuator body 1100 is in the second position. As for the first actuator body 100, in some embodiments (i.e., embodiments where the intermediate link body first end opening 185 is an elongated slot 185A), the second actuator body 1100 moves over the "zero" portion of the path.

[0139] As previously described, the linkage assembly 150 is configured to and does apply at least a first bias to the second actuator body 1100 and a second bias to the second actuator body 1100. In addition, the first bias is significantly different from the second bias. That is, the linkage assembly 150 is configured to apply the first bias to the second actuator body 1100 when the second actuator body 1100 is disposed in the first portion of the second actuator body 1100 path, and the linkage assembly 150 is configured to and does apply the second bias to the second actuator body 1100 when the second actuator body 1100 is disposed in the second portion of the second actuator body 1100 path.

[0140] With respect to the disconnect actuator assembly 54, the multi-stage feedback actuator assembly 50 operates as follows. Initially, it should be noted that for the purposes of this example using the disconnect actuator assembly 54, it is assumed that the movable contact 20 is in the closed second position and the operating mechanism 16 is in the corresponding second configuration, i.e., the crossbar 30 is in the second position. In addition, the second actuator body 1100 is in the unactuated first position. In this configuration, the cam assembly biasing device 206 generates a force line 1230 extending from the contact point between the cam assembly first cam member 202 and the second cam member 204 through the shaft coupling body first end connector 161. As shown in FIG. Fig.12 As shown, the force line 1230 is disposed on the "first" side of the solenoid output shaft rotational axis 65. It should be noted that the "first" side of the solenoid output shaft rotational axis 65 for the second actuator 96 is different from the "first" side associated with the first actuator 94, as described above. In addition, in the initial second position, the second actuator body second end 1106 is spaced apart from the linkage assembly 150.

[0141] When the user engages the second actuator body mid-section user interface (i.e., button 1103), the second actuator body 1100 rotates and moves over the first portion of the second actuator body 1100 path. When the second actuator body 1100 moves over the first portion of the second actuator body 1100 path, the second actuator body 1100 and, as shown, the second actuator body mid-section switch assembly interface 1107 engage and actuate the second switch assembly actuator 1076. Thus, when the second actuator body 1100 is disposed in the first portion of the second actuator body 1100 path, the second actuator body 1100 is configured to and does operatively engage the second switch assembly actuator 1076. As discussed above, after actuating the second switch assembly actuator 1076, the rotary solenoid 60 is actuated and causes the rotary solenoid output shaft 64 to move from the second position to the first position. Rotation of the rotary solenoid output shaft 64 causes the linkage assembly 150 to move from the second configuration to the first configuration, which in turn causes the crossbar 30 (and other elements of the operating mechanism 16) to move from the second position / configuration to the first position / configuration. As discussed above, when the operating mechanism 16 moves from the second configuration to the first configuration, the movable contact 20 moves from the second position to the first position. That is, the movable contact 20 opens.

[0142] This is the normal operation of the electric actuator assembly 70. That is, the electric actuator assembly 70 includes the second actuator 96, the rotary solenoid 60 and the second switch assembly 1072. In addition, as discussed below, actuating the electric actuator assembly 70 requires a minimum force on the second actuator 96. That is, when compared with the feedback force generated by the manual actuator assembly 80, the reaction force or feedback force applied by the electric actuator assembly 70 is relatively low, as discussed below. Therefore, when the second actuator 96 moves above the first part of the second actuator body 1100 path, there is a first bias applied to the second actuator 96. In addition, if the electric actuator assembly 70 actuates the rotary solenoid 60, there is a significant feedback, as described above. Therefore, if the user detects a significant feedback of the rotary solenoid 60, the user is notified that the electric actuator assembly 70 has moved the movable contact 20 from the second position to the first position, and the user stops pressing the second actuator body middle part user interface (i.e., button 1103).

[0143] If the electric actuator assembly 70 is unable to move the movable contact 20 from the second position to the first position, for example, if the second switch assembly 1072 is unable to provide a charge to the rotary solenoid 60, the user must utilize the manual actuator assembly 80 to move the movable contact 20 from the second position to the first position. This is accomplished by continuously pressing on the user interface (i.e., button 1103) in the middle portion of the second actuator body.

[0144] That is, when the user continues to press on the second actuator body middle portion user interface (i.e., button 1103), the second actuator body 1100 moves into the second portion of the second actuator body 1100 path. When the second actuator body 1100 moves into the second portion of the second actuator body 1100 path, the second actuator body 1100 engages the connecting rod assembly 150. That is, the second actuator body second end 1106 engages the shaft coupling body first end second actuator interface 1169. This bias causes the shaft coupling 160 to rotate. Therefore, when the second actuator body 1100 is disposed in the second portion of the second actuator body 1100 path, the second actuator body 1100 is configured to and does operatively engage the connecting rod assembly 150. As described above, the shaft coupling 160 is operatively coupled to the rotary solenoid output shaft 64, so that rotation of the shaft coupling 160 causes the rotary solenoid output shaft 64 to rotate from the second position to the first position and generate a noticeable feedback. In addition, as described above, rotation of the rotary solenoid output shaft 64 causes the operating mechanism 16 and thus the movable contact 20 to move into their first position / configuration.

[0145] Generally speaking, the linkage assembly 150 provides a reaction bias / force or feedback bias / force to the second actuator body 1100. In an exemplary embodiment, the bias provided by the linkage assembly 150 to the second actuator body 1100 when the second actuator body 1100 is in a first portion of the second actuator body 1100 path is less than the bias provided by the linkage assembly 150 to the second actuator body 1100 when the second actuator body 1100 is in a second portion of the second actuator body 1100 path. This is achieved at least in part by the forces generated in the cam assembly 200.

[0146] That is, as described above, the cam assembly biasing device 206 generates a force line 1230 extending from the contact point between the cam assembly first cam member 202 and the second cam member 204 through the shaft coupling body first end coupling 161. Initially, that is, when the second actuator body 1100 is disposed in the second actuator body 1100 path first portion, the force line 1230 extends to the "first side" of the solenoid output shaft rotation axis 65. When the rotary solenoid output shaft 64 and the shaft coupling 160 are moved / rotated from the second position to the first position, and when the second actuator body 1100 is disposed in the second actuator body 1100 path second portion, the force line 1230 extends to the "second side" of the solenoid output shaft rotation axis 65. In this configuration, when the second actuator body 1100 is disposed in the first portion of the second actuator body 1100 path, the reaction force or feedback force applied by the linkage assembly 150 on the second actuator body 1100 is initially low (when compared to the higher forces discussed below). As the second actuator body 1100 moves into the second portion of the second actuator body 1100 path, the reaction force or feedback force applied by the linkage assembly 150 on the second actuator body 1100 increases until the line of force 1230 crosses the solenoid output shaft rotation axis 65. After the line of force 1230 crosses the solenoid output shaft rotation axis 65, the reaction force or feedback force applied by the linkage assembly 150 on the second actuator body 1100 quickly decreases to zero or a negligible amount. Thus, the combination of the linkage assembly 150 and the cam assembly 200 produces a feedback or response similar to a toggle device. Specific examples of reaction forces or feedback forces are shown below.

[0147] That is to say, and if Figure 12 to Figure 14 As shown, during use of the disconnect actuator assembly 54, the second actuator 96 is in its first position and the force line 1230 is disposed on a first side of the solenoid output shaft rotational axis 65 ( Fig.12). When the user actuates the second actuator 96 (which in this example is the actuator associated with the disconnect actuator assembly 54), the linkage assembly 150 causes the force line 1230 to move. That is, the movement of the disconnect actuator assembly 54 causes the linkage assembly 150 elements to move. The movement of the linkage assembly 150 causes the position of the force line 1230 to move.

[0148] As the second actuator 96 moves over the first portion of the path of the second actuator body 1100, the line of force 1230 remains on the first side of the solenoid output shaft rotation axis 65. In addition, the force applied to the first actuator body middle portion user interface (i.e., button 103) is relatively low compared to the latter force applied as discussed below. Similarly, the force applied by the linkage assembly 150 to rotate the solenoid output shaft 64 is relatively low compared to the latter force applied to rotate the solenoid output shaft 64. As the second actuator 96 moves over the first portion of the path of the second actuator body 1100, the movement of the linkage assembly 150 has a negligible effect on the crossbar 30. That is, in the exemplary embodiment in which the first end opening 185 of the intermediate link body is an elongated slot 185A, the initial movement of the second actuator 96 is not transmitted to the cross bar 30 through the linkage assembly 150 because the movement of the shaft link 160 is not transmitted to the intermediate link 180 until the pin-connected links 160, 180 move to the end of the elongated slot 185A.

[0149] As the user continues to press the second actuator 96, the reaction force generated by the multi-step feedback actuator assembly 50 continues to increase. That is, as the second actuator 96 moves into and over the second portion of the path of the second actuator body 1100, the reaction force increases and is significantly different from the reaction force generated by the multi-step feedback actuator assembly 50 when the second actuator body 1100 is in the first portion of the path of the second actuator body 1100. In addition, the movement of the linkage assembly 150 begins to significantly affect the crossbar 30. That is, when the crossbar 30 rotates and moves the movable contact 20 toward the first position, the feedback force generated by the linkage assembly 150 on the second actuator 96 is almost twice the feedback force generated on the second actuator 96 when the second actuator body 1100 is in the first portion of the path of the second actuator body 1100.

[0150] In addition, when the second actuator 96 moves into and over the second portion of the path of the second actuator body 1100, the force line 1230 remains on the first side of the solenoid output shaft rotation axis 65. When the crossbar begins to move the movable contact 20, the force line 1230 crosses to the second side of the solenoid output shaft rotation axis 65. The configuration of the connecting rod assembly 150 when the force line 1230 crosses the solenoid output shaft rotation axis 65 is identified as a "toggle device" in this article. Therefore, as shown in the following chart, when the connecting rod assembly 150 crosses the toggle configuration, the feedback force generated by the connecting rod assembly 150 on the second actuator 96 is significantly different when compared to the feedback force generated by the connecting rod assembly 150 on the second actuator 96 when the force line 1230 is on the first side of the solenoid output shaft rotation axis 65. At this moment in the actuation process, the movable contact has moved into the first position. That is, the contacts 20, 22 are disconnected.

[0151] In addition, in an exemplary embodiment, the disconnect actuator assembly 54 includes a "force leveling assembly" 1300. As used herein, a "force leveling assembly" is a construction that is constructed to change the characteristics of one actuator assembly to be substantially similar to the similar characteristics of another actuator assembly. With the closing actuator assembly 52 and the disconnect actuator assembly 54 configured as described above, the bias associated with the closing actuator assembly 52 (i.e., both the first bias and the second bias) is different from the bias associated with the disconnect actuator assembly 54 (i.e., both the first bias and the second bias). However, as described above, users prefer complementary actuators (e.g., disconnect and closing actuators) with substantially the same tactile feedback (i.e., the same bias). In addition, and due to the geometry, position, and other aspects of the elements of the closing actuator assembly 52, the closing actuator assembly 52 bias is greater than the bias of the disconnect actuator assembly 54. Therefore, the disconnect actuator assembly 54 includes a "force leveling assembly" 1300.

[0152] In an exemplary embodiment, the multi-step feedback actuator assembly return spring 1101 is configured as and does act as a force leveling assembly 1300. That is, the multi-step feedback actuator assembly return spring 1101 increases the bias on the second actuator body 1100. That is, the multi-step feedback actuator assembly return spring 1101 increases the first bias applied to the second actuator body 1100 by the connecting rod assembly 150 and the second bias applied to the second actuator body 1100. In addition, the multi-step feedback actuator assembly return spring 1101 is configured to increase the bias so that both the first bias and the second bias applied to the second actuator body 1100 by the connecting rod assembly 150 are substantially the same as the first bias and the second bias applied to the first actuator body 100 by the connecting rod assembly 150. In this configuration, the force leveling assembly 1300 solves the above-mentioned problems.

[0153] In an exemplary embodiment, the multi-stage feedback actuator assembly 50 has the characteristics shown in the following graph.

[0154]

[0155] Therefore, generally speaking, when the user begins to actuate the second actuator body middle portion user interface (i.e., button 1103), there is initially minimal feedback when the second actuator body 1100 moves over the zero portion of the path (if there is a zero portion) and the first portion of the second actuator body 1100 path. During this time, the linkage assembly 150 applies a first bias that can be detected by the user to the second actuator body 1100. When the second actuator body 1100 moves over the first portion of the second actuator body 1100 path, the second actuator body 1100 actuates the second switch assembly 1072. That is, the second actuator body 1100 actuates the second switch assembly actuator 1076. When the second switch assembly 1072 is actuated, and if the second switch assembly 1072 is capable of applying a charge to the rotary solenoid 60, the second switch assembly 1072 actuates the rotary solenoid 60, causing the movable contact 20 to move into the first position and generating noticeable feedback. If the user detects significant feedback, the user is informed that the movable contact 20 is in the first position and the user stops actuating the second actuator 96 .

[0156] However, if the second switch assembly 1072 is unable to apply charge to the rotary solenoid 60, the second switch assembly 1072 will not actuate the rotary solenoid 60 and there is no obvious feedback. Therefore, the user is notified that the second actuator 96 needs to be further actuated. Therefore, the user continues to press the second actuator body middle part user interface (i.e., button 1103), thereby causing the second actuator body 1100 to move above the second actuator body 1100 path second part. As described in detail above, the connecting rod assembly 150 generates a second bias that is applied to the second actuator body 1100 and is an increase that can be detected by the user. As described above, the second bias is greater than the first bias, and the first bias is significantly different from the second bias. In addition, as also described above, the continuous movement of the second actuator body 1100 above the second actuator body 1100 path second part manually moves the movable contact 20 to the first position. When the movable contact 20 moves into the first position, the feedback force generated by the linkage assembly 150 and applied to the second actuator body 1100 is reduced by an amount significantly different from the second bias. Therefore, due to the change in feedback force, the user is notified that the movable contact 20 has moved into the first position. The user stops actuating the second actuator 96, and the multi-stage feedback actuator assembly return spring 1101 returns the second actuator 96 to its first position. Therefore, the multi-stage feedback closing actuator assembly 52 is constructed to and does move the movable contact 20 from the second position to the first position while providing different tactile feedback, i.e., feedback forces that can be detected by the user through the button 1103.

[0157] In addition, in the exemplary embodiment, the disconnect actuator assembly 54 is configured as an undervoltage regulator. In this embodiment, the cam assembly 200 (i.e., the cam assembly biasing device 206) generates sufficient bias to move the rotary solenoid output shaft 64 from the second position to the first position. That is, the cam assembly 200 is configured to and does apply the disconnect bias to the operating mechanism crossbar 30 through the linkage assembly 150. When the rotary solenoid 60 is drawing proportional current from the circuit breaker assembly 10 use current, the rotary solenoid 60 generates a bias sufficient to match or slightly overcome the bias generated by the cam assembly 200 in the exemplary embodiment. That is, the cam assembly 200 disconnect bias is substantially equal to or less than the rotary solenoid 60 closed bias. In this configuration, the rotary solenoid 60 is configured to and does apply the closed bias to the operating mechanism crossbar 30 when drawing proportional current from the circuit breaker assembly 10 use current. Thus, when the use current, and therefore the proportional current, drops below the selected minimum current, the rotary solenoid 60 closing bias is reduced, and the cam assembly 200 is configured to and does operatively engage the operating mechanism crossbar 30 and move the operating mechanism crossbar to the first position. This in turn causes the movable contact 20 to move to the open first position. Thus, the open actuator assembly 54 is configured as an undervoltage regulator.

[0158] Although specific embodiments of the present invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details may be formed in light of the overall teachings of this disclosure. Therefore, the specific arrangements disclosed are intended to be illustrative only and not to limit the scope of the present invention, which is given by the full scope of the appended claims and any and all equivalents thereof.

Claims

1. A multi-stage feedback actuator assembly for a circuit breaker assembly, the circuit breaker assembly being configured to have a service current selectively passed therethrough, the circuit breaker assembly comprising a housing assembly, a separable contact assembly, and an operating mechanism, the housing assembly defining an enclosed space, the separable contact assembly comprising a plurality of fixed contacts and a plurality of movable contacts, each of the movable contacts being movable between a first disconnected position and a second position, in which each of the movable contacts is spaced apart from and not electrically connected to an associated fixed contact, and in which each of the movable contacts is coupled to and electrically connected to the associated fixed contact, in which the operating mechanism is configured to move the plurality of movable contacts between the first position and the second position, the operating mechanism comprising an elongated crossbar, the operating mechanism crossbar being rotatably coupled to the housing assembly, the operating mechanism crossbar being configured to move between a first position and a second position corresponding to the first position of the movable contacts and the second position of the movable contacts, the multi-stage feedback actuator assembly comprising: a rotary solenoid, the rotary solenoid comprising a rotary output shaft; Electric actuator assembly; a manual actuator assembly; The electric actuator assembly includes a switch assembly; The switch assembly includes a switch assembly actuator; the switch assembly being operatively coupled to the rotary solenoid, wherein the switch assembly is configured to actuate the rotary solenoid; The manual actuator assembly includes a plurality of primary actuators, a connecting rod assembly and a cam assembly; The plurality of primary actuators include a first actuator; The first actuator includes a body; the first actuator body being configured to move over a path having at least a first portion and a second portion; The rotary solenoid is operatively coupled to the linkage assembly; the linkage assembly being operatively coupled to the rotary solenoid and the first actuator body; The linkage assembly is configured to be operatively coupled to the operating mechanism crossbar; wherein the linkage assembly is configured to apply at least a first bias to the first actuator body and a second bias to the first actuator body; wherein the first bias is significantly different from the second bias; wherein the linkage assembly is configured to apply the first bias to the first actuator body when the first actuator body is disposed in a first portion of the first actuator body path; and Wherein the linkage assembly is configured to apply the second bias to the first actuator body when the first actuator body is disposed in the first actuator body path second portion. 2 . The multi-stage feedback actuator assembly of claim 1 , wherein the second offset is greater than the first offset.

3. The multi-stage feedback actuator assembly of claim 2, wherein: the first actuator body being configured to operatively engage the switch assembly actuator when the first actuator body is disposed in the first actuator body path first portion; and The first actuator body is configured to operatively engage the linkage assembly when the first actuator body is disposed in the first actuator body path second portion.

4. The multi-stage feedback actuator assembly of claim 3, wherein: The connecting rod assembly includes a plurality of connecting members; The cam assembly includes a first cam member, a second cam member and a biasing device; The first actuator body is operatively coupled to the linkage assembly and is configured to move at least one link; the linkage assembly being operatively coupled to the first actuator body, the rotary solenoid output shaft, and the cam assembly; The cam assembly is operatively coupled to the connecting rod assembly; The cam assembly biasing device is configured to apply a bias to at least one of the first cam member or the second cam member; and The cam assembly applies a bias to the connecting rod assembly.

5. The multi-stage feedback actuator assembly of claim 4, wherein: The first actuator body is elongated and includes a first end portion, a middle portion, and a second end portion; The first actuator body first end is configured to be rotatably coupled to the circuit breaker housing assembly; The first actuator body intermediate portion defines a button; The first actuator body second end is configured to be operatively coupled to the linkage assembly; The connecting rod assembly includes a shaft coupling; The shaft coupling includes an elongated body having a first end, a middle portion, and a second end; Each of the shaft coupling body first end portion, the shaft coupling body middle portion, and the shaft coupling body second end portion includes a coupling; The shaft coupling body intermediate portion is fixedly and operatively coupled to the rotary solenoid output shaft; wherein the shaft coupling body rotates together with the solenoid output shaft; The second cam member of the cam assembly is coupled to the first end of the shaft coupling body; The cam assembly first cam member is disposed adjacent the shaft coupling body first end travel path and is configured to engage the cam assembly second cam member; The cam assembly biasing device is configured to engage the cam assembly first cam member; wherein the cam assembly biasing means generates a line of force extending from a point of contact between the first cam members of the cam assembly through the first end coupling of the shaft coupling body; Wherein, when the first actuator body is disposed in a first portion of the first actuator body path, the force line extends to a first side of the rotation axis of the solenoid output shaft, and when the first actuator body is disposed in a second portion of the first actuator body path, the force line extends to a second side of the rotation axis of the solenoid output shaft.

6. The multi-stage feedback actuator assembly of claim 5, wherein: The cam assembly first cam member includes an elongated body having a generally curvilinear cam surface; The cam assembly second cam member includes a body having a generally circular cam surface; The second cam member of the cam assembly is rotatably coupled to the first end of the shaft coupling body; and Wherein the cam assembly first cam member body cam surface engages the cam assembly second cam member body cam surface.

7. The multi-stage feedback actuator assembly of claim 5, wherein: The connecting rod assembly includes an upper connecting member, an intermediate connecting member, a lower connecting member and a shaft connecting member; The upper link includes an elongated body having a first end and a second end; The upper link body first end portion and the upper link body second end portion each include a coupling member; The intermediate coupling member includes an elongated body having a first end and a second end; The first end of the intermediate coupling body and the second end of the intermediate coupling body each include a coupling member; The lower link includes an elongated body having a first end, a middle portion, and a second end; The lower link body first end portion, the lower link body middle portion, and the lower link body second end portion each include a coupling; The cam assembly first cam member is rotatably coupled to the upper link body first end; The upper link body second end portion is rotatably coupled to the lower link body first end portion; The intermediate coupling body first end portion is rotatably coupled to the shaft coupling body first end portion; The intermediate link body second end is rotatably coupled to the lower link body intermediate portion; and The lower link body second end is configured to be rotatably coupled to the operating mechanism crossbar.

8. The multi-stage feedback actuator assembly of claim 7, wherein the first actuator body second end is configured to operatively engage the shaft coupling body second end.

9. The multi-stage feedback actuator assembly of claim 1, wherein the rotary solenoid is configured to provide noticeable feedback when actuated.

10. The multi-stage feedback actuator assembly of claim 1, wherein: The rotary solenoid is configured to draw a proportional current from the circuit breaker assembly use current; the rotary solenoid being configured to apply a closing bias to the operating mechanism crossbar when the proportional current is drawn from the circuit breaker assembly use current; The cam assembly is configured to apply a disconnect bias to the operating mechanism crossbar; wherein the cam assembly opening bias is equal to the rotary solenoid closing bias; and Wherein when the proportional current drops below a selected minimum current, the rotary solenoid closing bias is reduced and the cam assembly is configured to operatively engage the operating mechanism crossbar and move the operating mechanism crossbar to the first position.

11. A circuit breaker assembly, the circuit breaker assembly being configured to have a service current selectively passed therethrough, the circuit breaker assembly comprising: Shell assembly; A separable contact assembly; Operating mechanism; The housing assembly defines an enclosed space; The separable contact assembly includes a plurality of fixed contacts and a plurality of movable contacts, each of the movable contacts being movable between a disconnected first position in which each of the movable contacts is spaced apart from and not in electrical communication with an associated fixed contact, and a second position in which each of the movable contacts is coupled to and in electrical communication with an associated fixed contact; The separable contact component assembly is disposed in the closed space of the housing assembly; The operating mechanism is configured to move the plurality of movable contacts between the first position and the second position, the operating mechanism comprising an elongated crossbar; The operating mechanism is arranged in the closed space of the housing assembly; The operating mechanism crossbar is rotatably coupled to the housing assembly, the operating mechanism crossbar being configured to move between a first position and a second position corresponding to a first position of the movable contact and a second position of the movable contact; A multi-stage feedback actuator assembly according to any one of claims 1 to 10.

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