Circuit breaker

Abstract

The invention provides a circuit breaker which at least comprises an insulating shell and elements arranged in the insulating shell, the insulating shell is at least formed by combining a middle seat, a base and a cover, the middle seat and the base form a shell of an L-pole module, the middle seat and the cover form a shell of an N-pole module, and a residual current controller is arranged on the left side of the L-pole module and the left side of the N-pole module. The arc extinguish chamber is arranged at the lower part of the insulating shell, the moving contact device, the static contact and the magnetic release unit are arranged above the arc extinguish chamber, the residual current protection release is arranged between the magnetic release and the operating mechanism, and the rotating centers of the magnetic release unit, the residual current protection release and the moving contact unit are distributed in a triangular shape. The N-pole moving contact is arranged in front of or behind the moving contact unit in the Z-axis direction in an insulated mode and is in linkage with the moving contact unit, and the residual current circuit breaker is more compact in structure and simpler in assembly process by conducting modularized regional layout on internal elements.

Description

Technical Field

[0001] This invention relates to the field of low-voltage electrical appliances, and more specifically to a circuit breaker. Background Technology

[0002] Currently, there are many types of circuit breakers, especially those with residual current protection. Their overall layout is complex and their structure is not compact. The residual current detection circuit, residual current protection trip unit, and residual current testing circuit are interconnected by wires, resulting in complex internal wiring, unreasonable placement of internal components, and low utilization of internal space. This affects the overall performance stability of the circuit breaker. Furthermore, assembly requires welding and riveting processes, making assembly cumbersome and inefficient, which is detrimental to product modularization and industrial automation. In addition, the integrated design of the residual current protection trip unit and the circuit breaker's magnetic trip unit not only significantly impacts the reliability and immediacy of residual current operation but also lacks a residual current operation indication reset button, affecting the safety and reliability of the residual current protection circuit breaker. Moreover, the unreasonable layout of the arc-extinguishing chamber leads to poor short-circuit breaking capacity. Summary of the Invention

[0003] Based on the above background, the present invention provides a circuit breaker with a simple structure, modular structure, high degree of automation in assembly, safety and reliability, and stable performance.

[0004] This invention provides a circuit breaker, comprising at least an insulating housing and components disposed within the insulating housing. The insulating housing is at least composed of a center base, a base, and a cover. The components include an L-pole module, an N-pole module, and a residual current controller. The center base and the base form the housing of the L-pole module, and the center base and the cover form the housing of the N-pole module. The residual current controller is disposed on the left side of the L-pole module and the N-pole module. The L-pole module includes at least a handle, an operating mechanism, a contact indicator, a tripping mechanism, a magnetic tripping unit, a stationary contact, a thermal tripping unit, a moving contact unit, and an arc-extinguishing chamber. The N-pole module includes at least an N-pole moving contact and an N-pole stationary contact. The residual current controller includes at least a residual current detection unit, a residual current protection trip unit, a test button, and / or a reset button. The insulating housing... Terminals are provided on both ends of the housing. The residual current detection unit, magnetic trip unit, stationary contact, and arc-extinguishing chamber are located between the terminals on both ends. The arc-extinguishing chamber is provided with N metal arc-extinguishing grids, which are arranged in an air-insulated manner along the X-axis between the terminals on both ends. The operating mechanism is located on the upper part of the insulating housing, and the arc-extinguishing chamber is located on the lower part. The moving contact device, stationary contact, and magnetic trip unit are located above the arc-extinguishing chamber. The residual current protection trip unit is located between the magnetic trip unit and the operating mechanism. The rotation centers of the magnetic trip unit, residual current protection trip unit, and moving contact unit are triangularly distributed. The N-pole moving contact is insulatedly located in front of or behind the moving contact unit along the Z-axis and is linked with the moving contact unit.

[0005] In this manner, the insulating housing is stacked with a base, a middle seat, and a cover. The internal components of the circuit breaker are divided into three main modules, each housed in its respective area within the insulating housing. The L-pole module is placed in the cavity formed between the middle seat and the base, and the N-pole module is placed in the cavity formed between the middle seat and the cover. A residual current controller is located on the left side of both the N-pole and L-pole modules. The N-pole and L-pole modules are stacked together. The N-pole moving contact is insulated and positioned in front of or behind the moving contact along the Z-axis. This placement depends on the relative positions of the N-pole and L-pole modules and can be flexibly adjusted as needed. The N-pole moving contact is also insulated and positioned in front of or behind the moving contact along the Z-axis and is linked to the moving contact unit. It rotates with the moving contact unit to achieve closing and opening, sharing a single operating mechanism. This significantly reduces the thickness and saves space. A residual current protection trip unit is located between the magnetic trip unit and the operating mechanism. The magnetic trip unit and the residual current protection trip unit are positioned at an angle to the rotation center of the moving contact. The residual current protection trip unit is arranged in a triangular configuration, independent of the magnetic trip unit, resulting in strong anti-interference capabilities and reliable operation. The arc-extinguishing chamber contains N metal arc-extinguishing plates, arranged sequentially with air insulation between the terminals at both ends. By arranging the plates along the length of the circuit breaker, more metal arc-extinguishing plates can be placed within a limited space, effectively improving the circuit breaker's breaking capacity. The reset button, located on the left side of the residual current protection trip unit, serves as an indication of residual current faults and a reminder during closing. It is directly interlocked with the moving iron core of the residual current protection trip unit, offering a simple and reliable structure. The terminals are arranged on both sides of the insulating shell, with two terminals on each side arranged in two layers for wiring. The overlapping terminals partially or completely overlap in the Z-axis direction. For higher voltage levels, the terminals can be staggered to increase electrical clearance and creepage distance after wiring, enhancing the circuit breaker's safety.

[0006] In some embodiments, the residual current controller further includes a controller unit and a power supply unit. The power supply unit supplies power to the controller unit. The controller unit is electrically connected to the residual current protection trip unit. After the residual current is detected by the residual current detection unit, it feeds back to the controller unit. The controller unit outputs an action signal to the residual current protection trip unit. The residual current protection trip unit drives the tripping mechanism to turn off the circuit breaker and realize residual current protection.

[0007] In the above embodiments, the residual current controller is a module that realizes the residual current protection function. It is generally divided into electronic and electromagnetic types. The electronic type mainly uses a residual current detection unit to detect the residual current signal. The controller unit controls the residual current protection trip device to trip the circuit breaker and disconnect the power. The power supply unit transmits the power of the main circuit of the circuit breaker to the residual current controller unit to provide it with working power. The controller is composed of several electronic devices and several circuits. It monitors the residual current signal from the residual current detection unit at all times and sends a signal to the residual current protection trip device in a timely manner to disconnect the circuit breaker and ensure personal safety.

[0008] In some embodiments, the output terminal of the residual current detection unit is electrically connected to the residual current protection trip unit, which is a flux trip unit. After detecting the residual current, the residual current detection unit directly outputs the residual current to the residual current protection trip unit, which drives the tripping mechanism to turn off the circuit breaker to achieve leakage protection.

[0009] In the above embodiments, when the residual current controller is electromagnetic, the detection unit is a magnetic ring structure. The main circuit wire passes through the magnetic ring at least one turn, and the secondary circuit output terminal passes through the magnetic ring several turns in the form of a wire and is connected to the residual current protection trip unit. The residual current protection trip unit is a current-type flux trip unit. The flux trip unit can operate directly under a small residual current without the cooperation of electronic circuits, thyristor power supply devices, and other components. Moreover, the residual current operation is independent of the power supply voltage, and has higher reliability and anti-interference ability.

[0010] In some embodiments, the middle seat and the base cooperate to form a first cavity and a second cavity, the middle seat and the cover cooperate to form a third cavity, a residual current controller is provided in the first cavity, the L-pole module is provided in the second cavity, and the N-pole module is provided in the third cavity.

[0011] In the above embodiment, the insulating shell is divided into a base, a middle base, and a cover, which are stacked in the middle and lower directions in the thickness direction to form three internal cavities. The third cavity is located above the second cavity. The internal components are divided into three modules through the stacked layout: the L-pole module, the N-pole module, and the residual current controller. The modular layout makes the layout more compact and reasonable, and the circuit breaker more compact.

[0012] In some embodiments, the handle drives the operating mechanism to move, thereby driving electrical contact and separation between the moving contact unit and the stationary contact, and between the N-pole moving contact and the N-pole stationary contact. The contact between the N-pole moving contact and the N-pole stationary contact occurs earlier than the contact between the moving contact unit and the stationary contact; the separation between the N-pole moving contact and the N-pole stationary contact occurs later than the separation between the moving contact unit and the stationary contact.

[0013] In the above embodiments, the N-pole moving contact is located above or below the L-pole and moves together with the moving contact in the L-pole to open and close. Both are driven by the same handle and operating mechanism, which makes the circuit breaker structure simple and compact. Since the N-pole contact occupies less space, no arc extinguishing device is set. In order to prevent the N-pole from being eroded by electric arc, the contact time between the N-pole moving contact and the N-pole stationary contact is set to close first and then open, so as to prevent the phenomenon of electric arc erosion during the breaking process. This simplifies the circuit breaker structure and reduces costs.

[0014] In some embodiments, the tripping mechanism is driven by the magnetic tripping unit, the thermal tripping unit, and the residual current protection trip unit to unlock the operating mechanism, thereby electrically separating the moving contact unit from the stationary contact, and the N-pole moving contact from the N-pole stationary contact. The separation time of the N-pole moving contact from the N-pole stationary contact is later than the separation time of the moving contact unit from the stationary contact.

[0015] In the above embodiments, the tripping mechanism is a component of the operating mechanism in the circuit breaker unlocked and closed state. The tripping mechanism releases the locking link in the operating mechanism, causing the mechanism to lose balance and automatically open. The magnetic tripping unit, thermal tripping unit, and residual current protection trip unit are all execution components. When a corresponding fault occurs, they execute the command to unlock the tripping mechanism, causing the circuit breaker to open and disconnect the power. In order to protect the N-pole moving contact and N-pole stationary contact from arc erosion during the power disconnection process, they are set to disconnect after the arc disappears and then separate to reduce arc erosion.

[0016] In some embodiments, the residual current detection unit includes at least a zero-sequence current transformer, a first through-conductor, and a second through-conductor. The output terminal of the zero-sequence current transformer is electrically connected to the controller unit. One end of the first through-conductor is electrically connected to a stationary contact or a moving contact unit. One end of the second through-conductor is electrically connected to an N-pole stationary contact or an N-pole moving contact. After the first through-conductor and the second through-conductor pass through the zero-sequence current transformer, they are each electrically connected to their corresponding terminals.

[0017] In the above embodiment, to detect the residual current flow, a zero-sequence current transformer is required, in which conductors of the L-pole circuit and N-pole circuit are inserted. When a residual current fault occurs, the current vector sum between the two conductors will be non-zero. The zero-sequence current transformer senses the residual current flow and transmits the residual current flow signal to the controller unit.

[0018] In some embodiments, the residual current protection trip unit includes at least a coil winding, a stationary iron core, a moving iron core, and an iron core spring. The moving iron core has protrusions extending from both ends, and the protrusions reciprocate linearly within the coil winding along with the moving iron core.

[0019] In the above embodiment, the residual current protection trip unit is a voltage-type trip unit. The output voltage signal of the residual current protection trip unit is controlled by the residual current control unit, which causes the moving iron core and the stationary iron core inside the coil winding to generate a magnetic field and attract each other, causing the moving iron core to move towards the stationary iron core. Both ends of the moving iron core are provided with bosses. One end is used to trigger the circuit breaker tripping device, and the other end is used to cooperate with the residual current reset button to realize the residual current tripping indication and the closing prompt after the residual current fault.

[0020] In some embodiments, the reset button has a hook at one end, which is attached to the boss on the left side of the moving iron core. The hook and the boss are interlocked by a spring. When the residual current protection trip device is activated, the moving iron core moves to the right, and the boss on the left side of the moving iron core moves into the coil winding. The residual current reset button is driven by the spring force to pop out towards the insulating shell. One side of the hook is pressed against the moving iron core and cannot be reset. The button can be reset by pressing it.

[0021] In the above embodiment, a hook is provided at one end of the reset button. A spring locks the hook to the protrusion on the left side of the moving iron core. Even with the spring force, the reset button cannot pop out of the insulating housing. Only after the moving iron core moves to the right and disengages from the lock between the button and the hook can the reset button be popped out of the insulating housing by the spring force. The reset button popping out of the insulating housing provides a clear indication to the operator that a residual current fault has occurred. Since the side of the hook will press against the moving iron core after the reset button pops out and cannot be reset, the tripping mechanism of the residual current circuit breaker is always in the triggered state and cannot perform the closing operation. Therefore, it is necessary to press the reset button first to return the hook and the protrusion to the locked state. Only after the moving iron core is reset can the residual current circuit breaker be closed again. This reminds the operator that the reset button needs to be pressed before closing the circuit. This action alerts the operator whether the residual current fault has been eliminated or whether the danger to the person who was electrocuted has been eliminated, thus improving safety.

[0022] In some embodiments, the power supply unit includes at least an L-pole power supply element and an N-pole power supply element. The L-pole power supply element is an elastic conductor and is laid in the base and extends from the first cavity to the second cavity. The N-pole power supply unit is an elastic conductor, a flexible conductor, or a rigid conductor and is laid in the middle seat and extends from the first cavity to the third cavity.

[0023] In the above embodiments, the power supply unit is a component that supplies power to the electronic residual current controller. The main principle is to use a conductor to lead the power of the main circuit to the residual current controller, providing the residual current controller with a power supply that enables it to work normally. The L-pole power supply element is fixed and limited by an elastic conductor laid on the base. The N-pole power supply element is positioned on the middle seat by an elastic conductor, flexible conductor, or hard conductor, which can better fix it and improve the convenience and reliability of installation.

[0024] In some embodiments, the controller unit is welded with at least two metal tubular rivets for power supply.

[0025] In the above embodiments, the metal tubular rivets welded on the controller unit for power extraction are designed to facilitate easier insertion and connection with the L-pole and N-pole power extraction components. The elastic conductor head is provided with a bend and a protrusion, so that the elastic conductor inserted into the metal tubular rivet is squeezed to achieve good electrical contact. This design facilitates easy installation and modular operation.

[0026] In some embodiments, the L-pole power-taking element and the N-pole power-taking element are elastic conductors, one end of which is provided with a bent protrusion or arc-shaped structure and is inserted into a metal tubular rivet. The other end of the L-pole power-taking element is arranged on the moving trajectory of the moving contact unit, and the other end of the N-pole power-taking element is arranged on the moving trajectory of the N-pole moving contact. The moving contact unit and the N-pole moving contact make electrical contact with the stationary contact and the N-pole stationary contact when the closing movement is about to make contact with them.

[0027] In the above embodiments, the L-pole power-taking element and the N-pole power-taking element are elastic conductors. One end is provided with a bent protrusion or arc-shaped structure, which can be inserted into the hole of the metal tubular rivet for elastic engagement, achieving good electrical contact. During the assembly process, vertical insertion can be achieved, which is more conducive to automated assembly production and improves efficiency. The power-taking element is set on the moving contact unit's moving trajectory, making contact with it when closing and disconnecting it after opening, which can promptly cut off the power to the residual current controller, solving the problem of burning out the residual current protection trip unit due to reverse power supply connection. It can realize arbitrary wiring between the power supply end and the load end during installation and wiring, improving convenience.

[0028] In some embodiments, the test button has an inverted buckle on one side. The test button is inserted from the outside of the base into the insulating shell while overcoming the spring force of the inverted buckle. The pressing direction of the test button is provided with a resistor and a compression spring. One end of the resistor is directly or indirectly electrically connected to the N-pole module, and the other end is electrically connected to the compression spring. The other end of the compression spring abuts against the test button and is also provided with a conductive extension. When the test button is pressed, the conductive extension makes electrical contact with the L-pole power-taking element.

[0029] In the above embodiment, the test button is used to connect a new circuit to simulate a residual current signal to the residual current detection unit, causing the residual current controller to send an execution signal to the residual current protection trip unit, and the circuit breaker to complete the tripping and opening. The main function of the test button is to confirm the integrity of the residual current function in daily use. To facilitate assembly, the button is set upside down and snapped into the outside of the insulating shell, making assembly simpler and positioning more reliable. A resistor and a compression spring are set in the pressing direction of the test button. The compression spring supports and holds the test button. An extension is also provided at the end of the compression spring. The extension moves back and forth with the test button. When pressed all the way down, it will contact the L-pole power supply device. The other end of the compression spring presses the resistor. The other end of the resistor is in electrical contact with the N-pole unit, forming a new circuit to simulate the residual current flow and to detect the integrity of the residual current control device. By setting the test button, compression spring and resistor in this way, the assembly is convenient, efficient and has no flying wires, and the structure is simpler.

[0030] In some embodiments, the two terminals on each side are respectively arranged in a first groove between the base and the middle seat and in a second groove between the middle seat and the cover. The terminals in the first groove and the terminals in the second groove are staggered vertically along the Y-axis. A mounting boss is provided behind the first groove. The mounting boss is used to pre-install the terminals that are electrically connected to the second through conductor. During pre-installation, the mounting boss is in an upright state, the middle seat is fastened to the base, and the terminals that are electrically connected to the second through conductor pass through the through hole on the middle seat and can be rotated 90° to enter the second groove.

[0031] In the above embodiment, the residual current detection unit needs to have a through conductor of the L pole and a through conductor of the N pole so that the current of the two conductors can pass through the zero-sequence current transformer of the residual current detection unit. During assembly, the two through conductors need to be assembled separately, one above the other. By setting a mounting boss behind the base where the terminal block is placed to temporarily store the terminal block connected to the N pole through conductor, the terminal block is first placed upright on the mounting boss. After the middle seat is fastened, it is then rotated forward 90° to enter the second groove. Compared with the traditional left and right through wire assembly method, this method is simpler, more efficient and more conducive to automated assembly.

[0032] In some embodiments, the terminal block includes a terminal block, a terminal socket, and a terminal screw, wherein the terminal socket is sleeved on the terminal block and rotatably disposed relative to the terminal block, and the terminal screw is inserted into the terminal socket.

[0033] In the above embodiments, the base is provided with a mounting boss and the terminal block of the wiring terminal is configured to be rotatable, which eliminates the need to fold and unfold the second through conductor in the existing operation, making the assembly of the wiring terminal more convenient and efficient.

[0034] In some embodiments, when the residual current controller detects that the vector sum of the currents between the first and second conductors is not zero and reaches a certain threshold, it drives the tripping mechanism through the residual current protection tripping unit to turn off the residual current circuit breaker to achieve residual current protection.

[0035] In the above embodiment, the residual current detection unit monitors the current vector sum of the first and second through conductors of the L and N poles in real time. When residual current phenomenon caused by electric shock or other faults occurs, the current vector sum between the first and second through conductors in the residual current detection unit is not zero, and the residual current detection unit detects the residual current flow. When the residual current flow reaches the set value, the residual current control unit will send a trip signal to the residual current protection trip device to make the trip mechanism complete the tripping of the circuit breaker and quickly disconnect the power supply to ensure that the person is not injured.

[0036] The beneficial effects of this invention are as follows:

[0037] 1. This application divides the internal space into three cavities by using an insulating shell with a base, middle seat, and cover, and combines the internal components into multiple modules, which refer to the L-pole module, N-pole module, and residual current controller. The multiple modules are placed into their respective cavities, which makes the insulation between the modules high, the performance safe and reliable, simplifies the production assembly, enables fully automated assembly, and effectively improves production efficiency.

[0038] 2. This application arranges the magnetic trip unit, residual current protection trip unit, and moving contact unit in a triangular layout. The residual current protection trip unit is tilted, which is more conducive to triggering the tripping mechanism. The arc-extinguishing chamber is located at the bottom and arranged sequentially in the X-axis direction, which can accommodate more metal arc-extinguishing grids in a limited space, resulting in higher performance in the same space.

[0039] 3. This application directly drives the residual current reset button and the tripping mechanism by tilting the residual current protection trip unit, without the need to add conversion parts. The residual current tripping accuracy is high and the response speed is fast. At the same time, it makes the structure of the residual current reset button simpler and more conducive to automated assembly.

[0040] 4. This application uses an elastic conductor as the power supply unit, is assembled in a plug-in manner, and achieves connection and disconnection with the action of the contact device. It eliminates the need for flying wires and soldering processes, making assembly more convenient while providing reliable electrical isolation, thus improving production efficiency and safety.

[0041] 5. This application uses an operating mechanism to drive the moving contact device of the L pole while simultaneously driving the moving contact of the N pole, and realizes that the moving contact of the N pole closes first and then opens. Only an arc extinguishing device needs to be set for the L pole, which simplifies the circuit breaker structure and reduces its size, making the circuit breaker more compact. Attached Figure Description

[0042] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0043] Figure 1 This is a structural diagram of the circuit breaker concealed by the cover in the first embodiment;

[0044] Figure 2 This is an exploded view of the circuit breaker structure according to the first embodiment;

[0045] Figure 3 This is a structural diagram of the residual current controller in the first embodiment;

[0046] Figure 4 This is a structural diagram of the circuit breaker in the first embodiment with the center seat and cover concealed.

[0047] Figure 5 This is a partial structural diagram of the circuit breaker in the first embodiment when the intermediate seat and base are separated;

[0048] Figure 6 This is a schematic diagram of the structure of the circuit breaker in the first embodiment after the middle seat and base are fastened together.

[0049] Figure 7 This is a cross-sectional view of the residual current protection trip unit of the first embodiment;

[0050] Figure 8 This is a structural diagram of the test button in the first embodiment;

[0051] Figure 9 This is an overall structural diagram of the second embodiment with the middle seat and cover hidden. Detailed Implementation

[0052] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of the embodiments of this invention will be described in more detail below with reference to the accompanying drawings. In the drawings, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The described embodiments are some, but not all, embodiments of this invention. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this invention, and should not be construed as limiting the invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0053] In the description of embodiments of this disclosure, the term "comprising" and similar terms should be understood as open-ended inclusion, i.e., "including but not limited to". The term "one embodiment" or "the embodiment" should be understood as "at least one embodiment". The terms "first", "second", etc., may refer to different or the same objects. Other explicit and implicit definitions may also be included below.

[0054] First Embodiment

[0055] Please refer to Figures 1 to 8 This embodiment provides a circuit breaker, including at least an insulating shell and components disposed within the insulating shell. The insulating shell is composed of at least a middle base 2000, a base 1000, and a cover 3000. The components include an L-pole module 10, an N-pole module 40, and a residual current controller. The middle base 2000 and the base 1000 form the shell of the L-pole module 10, and the middle base 2000 and the cover 3000 form the shell of the N-pole module 40. A residual current controller 20 is disposed on the left side of the L-pole module 10 and the N-pole module 40. The L-pole module includes at least a handle 101, an operating mechanism 102, a contact indicator 103, a tripping mechanism 104, a magnetic tripping unit 105, a stationary contact 106, a thermal tripping unit 107, a moving contact unit 108, and an arc-extinguishing chamber 109. The N-pole module 40 includes at least an N-pole moving contact 401 and an N-pole stationary contact 402. Terminal blocks 50 are disposed on each of the two ends of the insulating shell. The residual current detection unit 201, magnetic trip unit 105, stationary contact 106, and arc-extinguishing chamber 109 are disposed between the terminals 50 on both ends. The arc-extinguishing chamber 109 is provided with N metal arc-extinguishing grids, which are arranged in an air-insulated manner along the X-axis between the terminals 50 on both ends. The operating mechanism 102 is disposed on the upper part of the insulating shell, and the arc-extinguishing chamber 109 is disposed on the lower part of the insulating shell. The moving contact unit 108, stationary contact 106, and magnetic trip unit 105 are disposed above the arc-extinguishing chamber 109. A residual current protection trip unit 30 is disposed between the magnetic trip unit 105 and the operating mechanism 102. The rotation centers of the magnetic trip unit 105, the residual current protection trip unit 30, and the moving contact unit 108 are triangularly distributed. The N-pole moving contact 401 is insulatedly disposed in front of or behind the moving contact unit 108 along the Z-axis and is linked with the moving contact unit 108.

[0056] The base 1000 is oriented downwards, and the cover 3000 is oriented upwards, meaning the base, middle seat, and cover are arranged sequentially from bottom to top. The left side of the middle seat 2000 forms a first through cavity with a partition wall, and the middle part is enclosed by a partition wall to form a second through cavity. The middle seat 2000 is fastened to the base 1000. A first cavity 1 for accommodating the residual current control module 20 is formed between the first through cavity and the base 1000. A second cavity 2 for accommodating the L-pole module 10 is formed between the second through cavity and the base 1000. The first cavity 1 is located to the left of the second cavity 2, and both are located in the same plane along the X-axis. An upper concave cavity is provided on the right front of the middle seat, facing the cover 3000. The middle seat 2000 is fastened to the cover 3000, and the upper concave cavity and the cover form a third cavity for accommodating the N-pole module 40. The insulating shell has a snap-fit ​​structure at both ends to fix the base, middle seat and cover after they are snapped together, which facilitates production turnover. The base, middle seat and cover are all provided with circular through holes in the Z-axis direction. Rivets are placed in the circular through holes to fasten the base, middle seat and cover after they are snapped together.

[0057] The base 1000 is divided into two parts by a partition wall along the Y-axis on the left side: a first recess on the left and a second recess on the right. The middle seat has a first through cavity corresponding to the first recess, a second through cavity above the second recess, and a partition plate. The partition plate is located to the right of the second through cavity. A fence extends around the partition plate towards the cover, forming a third recess. The cover has a fence that mates with the first through cavity, the second through cavity, and the third recess. When the base, the middle seat, and the cover are fastened together, the first recess, the first through cavity, and the corresponding fence on the cover together form a first cavity; the second recess, the second through cavity, and the corresponding fence on the cover form a second cavity; and the third recess and the corresponding fence on the cover form a third cavity. Dividing the internal cavity composed of the insulating shell into three chambers allows for modular arrangement of internal components, simplifying the assembly process and improving safety.

[0058] This embodiment divides the internal space into three cavities by using an insulating shell with a base, a middle seat, and a cover to accommodate different modules of internal components. Multiple modules are placed into their respective cavities, ensuring high insulation between modules and reliable performance. This simplifies production and assembly, enables fully automated assembly, and effectively improves production efficiency.

[0059] The residual current protection trip unit 30 is arranged obliquely at the junction of the first cavity 1 and the second cavity 2. In this embodiment, the left side of the residual current protection trip unit 30 is disposed in the first cavity, and the right side is disposed in the second cavity. The test button 60 and the reset button 70 are disposed on the left side of the residual current protection trip unit 30, penetrate through the first cavity 1 and extend out of the outer surface of the insulating shell.

[0060] Please refer to Figure 7 The residual current protection trip unit 30 includes at least a coil winding 301, a stationary iron core 302, a moving iron core 303, and an iron core spring 304. Both ends of the moving iron core 303 have protrusions 3031. One end of the reset button 70 is provided with a hook 701, which is hooked to the left side of the protrusion 3031. The hook 701 can interlock with the left-side protrusion 3031. The spring 71 is a compression spring, with one end abutting against the central base 2000 and the other end abutting against the reset button 70. The spring 71 provides the reset button 70 with the spring force to move outward from the base 1000. The moving iron core 303 has a boss 3031 on its right side fitted with a core spring 304 that passes through the stationary iron core 302. The coil winding 301 is wound around the moving iron core 303 and the stationary iron core 302. The boss 3031 moves linearly back and forth within the coil winding 301 with the moving iron core. The boss 3031 on the right side moves to the right to push the tripping mechanism 104 to unlock. When the residual current protection trip device 30 is activated, the moving iron core 303 moves to the right, and the boss 3031 on the right side strikes the tripping mechanism to unlock it. The left-side boss 3031 enters the coil winding 301, the hook 71 unlocks from the left-side boss 3031, and the reset button 70 is pushed out of the insulating shell by the spring force of the spring 71. One side of the hook 701 abuts against the moving iron core 303, preventing the moving iron core 303 from resetting. Pressing the reset button 70 moves the hook 71, thus removing the restriction on the moving iron core 303. The moving iron core 303 resets under the action of the iron core spring 304. When a residual current fault occurs, the residual current protection trip unit 30 activates, causing the... When the reset button 70 pops up, the side of the hook 701 abuts against the protrusion 3031 on the left side, preventing the moving iron core 303 from resetting. At this time, the tripping mechanism 104 is in the unlocked state and cannot reset into engagement, causing the operating mechanism 1102 to be unable to cooperate. This setting serves as a dedicated indicator for residual current fault tripping and also serves as a reminder to press the reset button 70 before closing the circuit. Before resetting, the circuit with residual current fault can be checked to see if the residual current fault has been cleared and if the person who was electrocuted is out of danger, thus serving as a warning and improving safety.

[0061] In this embodiment, the N-pole moving contact is disposed above the Z-axis direction of the moving contact unit 108. The moving contact unit 108 is provided with an insulating post extending into the third cavity 3 and into which the N-pole moving contact 401 is inserted. The N-pole moving contact 401 is linked with the moving contact unit 108, that is, the rotation of the moving contact unit 108 can drive the N-pole moving contact 401 to rotate synchronously.

[0062] The handle 101 is connected to the operating mechanism 102 and drives the operating mechanism 102 to rotate, thereby driving the moving contact unit 108 to make contact with or separate from the stationary contact 106. The rotation of the moving contact unit 108 synchronously drives the N-pole moving contact 401 to rotate, making contact with or separate from the N-pole stationary contact 402. The contact between the N-pole moving contact 401 and the N-pole stationary contact 402 is earlier than the contact between the moving contact unit 108 and the stationary contact 106, and the separation between the N-pole moving contact 401 and the N-pole stationary contact 402 is later than the separation between the moving contact unit 108 and the stationary contact 106. This ensures that no arc is generated when the N-pole moving contact 401 and the N-pole stationary contact 402 separate, eliminating the need for an arc-extinguishing chamber and a corresponding arc-initiating device. This reduces the volume and space occupied by the N-pole module, and greatly reduces the volume of the circuit breaker of this application.

[0063] The operating mechanism 102 is a multi-link operating mechanism. The handle 101 drives the operating mechanism 102 to rotate, allowing the moving contact unit to contact or separate from the stationary contact 106 located on the rotation trajectory. The N-pole moving contact 401 is located above the moving contact unit 108. An insulating post extends from the moving contact unit 108 to drive the N-pole moving contact 401. The moving contact unit 108 and the N-pole moving contact 401 are separated by a center seat 2000 in the Z-axis direction, making them insulated from each other. This allows two sets of contact systems to be driven by one operating mechanism.

[0064] To make the circuit breaker of this application compact, the N-pole module 40 of this embodiment does not have an arc-extinguishing chamber and an arc-initiating device. Without an arc-extinguishing device to protect the contact system, an arc will be generated during the energized closing or opening process. In order to prevent the arc from burning the N-pole moving contact 401 and the N-pole stationary contact 402, the contact between the N-pole moving contact 401 and the N-pole stationary contact 402 is set to be earlier than the contact between the moving contact unit 108 and the stationary contact 106, and the separation between the N-pole moving contact 401 and the N-pole stationary contact 402 is set to be later than the separation between the moving contact unit 108 and the stationary contact 106, so that the arc generated during the entire current circuit connection and disconnection process occurs in the L-pole module 10 with arc-extinguishing chamber protection.

[0065] The residual current protection trip unit 30 is located adjacent to the tripping mechanism 104 on its right side. The tripping mechanism 104 is driven by the magnetic tripping unit 105, the thermal tripping unit 107, and the residual current protection trip unit 30, causing the operating mechanism 102 to unlock. This allows for electrical separation between the moving contact unit 108 and the N-pole moving contact 401, and between the stationary contact 106 and the N-pole stationary contact 402. The separation of the N-pole moving contact 401 and the N-pole stationary contact 402 occurs later than the separation of the moving contact unit 108 and the stationary contact 106. During the high-current interruption process, a large electric arc is generated between the contacts. This arc is generated between the moving contact unit 108 and the stationary contact 106 and is then extinguished by the arc-extinguishing chamber 109. Subsequently, the N-pole moving contact 401 separates from the N-pole stationary contact 402, which reduces the erosion of the N-pole module 40 by the arc. Compared to the N-pole stationary contact, the N-pole moving contact 401 contacts first and then separates later than the moving contact unit 108 contacts the stationary contact 106. This is achieved by adjusting the position of the stationary contact on their respective rotation trajectories, so that the opening distance between the first contacting N-pole moving contact 401 and the N-pole stationary contact 402 is smaller than the opening distance between the moving contact unit 108 and the stationary contact 106. This setting also achieves the later disconnection. In order to solve the problem of excessive overtravel of the first contacting contact group generating excessive reaction force on the operating mechanism, the N-pole stationary contact 402 is an elastic movable structure. After the N-pole moving contact 401 contacts the N-pole stationary contact 402, the N-pole stationary contact 402 will move together with the N-pole moving contact 401 to reduce the reaction force on the operating mechanism. At the same time, the time difference between closing and opening can be made longer to protect the N-pole 40 module from arc erosion.

[0066] Please continue to refer to this. Figure 3 The residual current controller 20 includes at least a residual current protection trip unit 30, a residual current detection unit 201, a controller unit 202, a power supply unit 203, a test button 60, and a reset button 70. The power supply unit 203 is electrically connected to the controller unit 202 and supplies power to the controller unit 202. The controller unit 202 is electrically connected to the residual current protection trip unit 30. The residual current detection unit 201 is signal-connected to the controller unit 202. After detecting the residual current flow, the residual current detection unit 201 feeds back to the controller unit 202. The controller unit 202 outputs an action signal to the residual current protection trip unit 30. The residual current protection trip unit 30 drives the tripping mechanism 104 to turn off the circuit breaker and achieve residual current protection.

[0067] Please continue to refer to this. Figure 4The residual current detection unit 201 includes at least a zero-sequence current transformer 2013, a first through-core conductor 2011, and a second through-core conductor 2012. The output terminal of the zero-sequence current transformer 2013 is electrically connected to the controller unit 202. One end of the first through-core conductor 2011 is indirectly electrically connected to the stationary contact 106, and one end of the second through-core conductor 2012 is electrically connected to the N-pole moving contact 402. After passing through the zero-sequence current transformer 2013, the first through-core conductor 2011 and the second through-core conductor 2012 are respectively electrically connected to their corresponding terminals 50. The terminals 50 electrically connected to the first through-core conductor 2011 are arranged in a first groove formed between the base 1000 and the middle seat 2000. The terminals 50 connected to the second through-core conductor 2012 are arranged in a second groove formed between the middle seat 2000 and the cover 3000. The terminals in the first groove and the terminals in the second groove are arranged along the Y-axis direction and are also staggered vertically along the Z-axis direction.

[0068] Please refer to Figure 5 and Figure 6 A mounting boss is provided behind the first groove. The mounting boss is used to pre-install the terminal 50, which is electrically connected to the second through conductor 2012. The terminal 50 includes a terminal plate 501, a terminal block 502, and a terminal screw 503. The terminal screw 503 is screwed into the threaded hole of the terminal block 502. The terminal block 502 is sleeved on the terminal plate 501 and can be rotatably set relative to the terminal plate 501. The terminal plate 501 is mounted on the mounting boss. A through hole is provided behind the second groove of the middle seat. During pre-installation, the terminal is in an upright state. The middle seat 2000 is fastened to the base. The terminal passes through the through hole on the middle seat. After fastening, the mounting boss on the base 1000 is flush with the bottom surface of the second groove on the middle seat. The terminal screw 503 and the terminal block 502 are rotated upwards by 90° to tilt them. The wire screw 503 and the terminal block 502 enter the second groove. Since the terminal block 50 installed in the second groove is connected to the second through conductor, and the second through conductor is inserted into the zero-sequence current transformer together with the first through conductor, the terminal block connected to the first through conductor and the terminal block connected to the second through conductor must be insulated from each other, and cannot be directly fastened during assembly. Compared with the conventional operation of folding the second through conductor and passing it through the middle seat 2000, which requires a large through hole to be set on the middle seat, and then fastening the middle seat 2000 and the base 1000 before inserting the terminal block 50 into the second groove and then unfolding the second through conductor, in this application, the mounting boss is set on the base and the terminal block of the terminal block is set to be rotatable, which eliminates the need to fold and unfold the second through conductor, making the assembly of the terminal block more convenient and efficient.

[0069] Please continue to refer to this. Figure 3The power-gathering unit 203 includes at least an L-pole power-gathering element 2031 and an N-pole power-gathering element 2032. The L-pole power-gathering element 2031 is an elastic conductor and is laid within the base 1000, extending from the first cavity 1 to the second cavity 2. The N-pole power-gathering element 2032 is an elastic conductor and is laid within the middle base 2000, extending from the first cavity 1 to the third cavity 3. The controller unit 202 has at least two metal tubular components welded on it for power extraction. The rivets include an L-pole power-taking tubular rivet 2033 electrically connected to the L-pole power-taking element 2031, and an N-pole power-taking tubular rivet 2034 connected to the N-pole power-taking element 2032. The L-pole power-taking element 2031 and the N-pole power-taking element 2032 are elastic conductors, each with a bent protrusion or arc-shaped structure at one end, which is inserted into the metal tubular rivet. The width of the bent protrusion or arc-shaped structure is greater than the inner hole of the tubular rivet, resulting in an interference fit when inserted into the inner hole of the metal tubular rivet. Both the L-pole power-taking element 2031 and the N-pole power-taking element 2032 are elastic conductors, allowing for elastic pressure contact and good conductivity, reliably forming an electrical connection. This also facilitates assembly, eliminating the need for soldering and enabling easy automated assembly. The other end of the L-pole power-taking element 2031 is positioned on the moving contact unit 108, and the other end of the N-pole power-taking element 2032 is positioned on the moving contact 401. The moving contact unit 108 and the N-pole moving contact 401 make electrical contact with the stationary contact 106 and the N-pole stationary contact 402 respectively during the closing movement. The power-taking unit 203 only provides power to the residual current control module 20 in the closed state and cuts off the power after opening, providing better electrical isolation for the residual current control module 20 and making it safer to use. This effectively avoids the phenomenon of the residual current protection trip unit 30 being continuously energized and burned out after the residual current circuit breaker trips due to incorrect power wiring, improving both assembly efficiency and safety.

[0070] Please continue to refer to this. Figure 4 and Figure 8The test button 60 has an inverted buckle 603 on one side. The test button 60 is inserted into the base 1000 from the outside in, overcoming the elastic force of the inverted buckle 60 to be installed into the base 1000. The test button 60 has a resistor 601 and a compression spring 602 in the pressing direction. The resistor 601 is a columnar chip resistor with no leads at both ends, which are directly conductive electrodes. One end of the resistor 601 is electrically connected to the terminal 50 and the connection point of the second through conductor 2012 through an elastic connecting conductor 604 to achieve electrical connection with the N-pole module 40. The other end of the resistor 601 is electrically connected to the compression spring 602. The other end of the compression spring 602 abuts against the test button 60 and also has a conductive extension 6021. The conductive extension 6021 is an extension end that extends downwards integrally with the compression spring 602. The L-pole power-taking element 2031 is arranged adjacent to the compression spring 602. When the test button is pressed... When the compression spring 602 contracts, the conductive extension 6021 makes electrical contact with the L-pole power-taking element 2031. When the test button 60 is released, the compression spring 602 resets, separating the conductive extension 6021 from the L-pole power-taking element 2031. The conductive extension 6021 makes electrical contact with the L-pole power-taking element 2031 by pressing the test button 60, which is used to pass the conductive circuit across the residual current detection unit 201 to generate a simulated residual current flow, so that the residual current control module 20 performs residual current protection, causing the residual current protection trip unit 30 to operate and thus trip the circuit breaker. The main purpose of pressing the test button is to periodically press and check whether the residual current protection function is normal, so as to prevent the function from failing and failing to protect against electric shock. The test circuit is set in the insulating housing, which simplifies and reduces the size of the residual current control module and reduces costs compared to setting it in the residual current control module.

[0071] In this embodiment, when the residual current detection unit 201 detects that the current vector sum between the first conductor 2011 and the second conductor 2012 is not zero and reaches a certain threshold, the controller unit 202 energizes the residual current protection trip unit 30 to drive the trip mechanism 104 to turn off the circuit breaker and achieve residual current protection. The residual current detection unit 201 detects the residual current flow by relying on the zero-sequence current transformer 2013. After receiving the residual current flow signal from the zero-sequence current transformer 2013, the residual current controller 202 sends an action command to the residual current protection trip unit 30, causing it to drive the trip mechanism 104 to unlock the operating mechanism 102, thereby preventing electric shock hazards to personnel and losses caused by residual current faults in the line.

[0072] Second Embodiment

[0073] Please refer to Figure 9This application provides another specific embodiment of the circuit breaker, which differs from the first embodiment in that the output terminal of the residual current detection unit 201 is electrically connected to the residual current protection trip unit 30. The residual current protection trip unit 30 is a flux trip unit. After detecting the residual current flow, the residual current detection unit 201 directly outputs the residual current to the residual current protection trip unit 30. The residual current protection trip unit 30 drives the tripping mechanism 104 to turn off the circuit breaker, thereby achieving residual current protection. The residual current detection unit 201 is a magnetic ring, and the first through-core conductor 2011 and the second through-core conductor 2012 pass through the magnetic ring at least once simultaneously. The output terminal is a wire that passes through the center of the magnetic ring at least 10 times. The output terminal is electrically connected to the residual current protection trip unit 30. Under normal operating conditions... In the normal state, the vector sum of the currents flowing through the magnetic ring in the first conductor 2011 and the second conductor 2012 is zero, the magnetic ring does not generate a magnetic field, there is no induced current output at the output terminal, and the residual current protection trip 30 will not operate. When residual current or electric shock occurs, current will be conducted to the ground by the human body or the line in the first conductor 2011 or the second conductor 2012, so that the vector sum of the currents in the first conductor 2011 and the second conductor 2012 is not zero, and when it reaches the set value, the magnetic field generated by the magnetic ring causes the induced current generated at the output terminal to reach the starting current of the residual current protection trip 30. The residual current protection trip 30 drives the trip mechanism 104 to unlock the operating mechanism 102, the circuit breaker is de-energized, and the residual current flow is stopped in time to stop the continued harm to the human body and protect people's lives.

[0074] This invention may be implemented in other specific forms without departing from its spirit and essential characteristics. The present embodiments are to be regarded in all respects as exemplary rather than limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description, and all modifications falling within the meaning of the claims and their equivalents are thus included within the scope of the invention.

Claims

1. A circuit breaker, comprising at least an insulating housing and components disposed within the insulating housing, The insulating housing is composed of at least a middle base, a base, and a cover, and the components include an L-pole module, an N-pole module, and a residual current controller. The middle base and the base together form the housing of the L-pole module, and the middle base and the cover together form the housing of the N-pole module. The residual current controller is located on the left side of both the L-pole module and the N-pole module. The L-pole module includes at least a handle, an operating mechanism, a contact indicator, a tripping mechanism, a magnetic tripping unit, a stationary contact, a thermal tripping unit, a moving contact unit, and an arc-extinguishing chamber; The N-pole module includes at least an N-pole moving contact and an N-pole stationary contact. The residual current controller includes at least a residual current detection unit, a residual current protection trip unit, a test button and / or a reset button. Its features are, The insulating shell has terminals on both ends. The arc-extinguishing chamber has N metal arc-extinguishing grids arranged in an air-insulated manner between the terminals on both ends. The arc-extinguishing chamber is located at the lower part of the insulating shell. The moving contact device, stationary contact, and magnetic trip unit are arranged above the arc-extinguishing chamber. The residual current protection trip unit is arranged between the magnetic trip unit and the operating mechanism. The rotation centers of the magnetic trip unit, residual current protection trip unit, and moving contact unit are triangularly distributed. The N-pole moving contact is insulatedly arranged in front of or behind the moving contact unit along the Z-axis and is linked with the moving contact unit.

2. A circuit breaker according to claim 1, characterized in that... The residual current controller also includes a controller unit and a power supply unit. The power supply unit supplies power to the controller unit. The controller unit is electrically connected to the residual current protection trip unit. After the residual current is detected by the residual current detection unit, it feeds back to the controller unit. The controller unit outputs an action signal to the residual current protection trip unit. The residual current protection trip unit drives the tripping mechanism to turn off the circuit breaker and realize residual current protection.

3. A circuit breaker according to claim 1, characterized in that... The output terminal of the residual current detection unit is electrically connected to the residual current protection trip unit, which is a flux trip unit. After detecting the residual current, the residual current detection unit directly outputs the residual current to the residual current protection trip unit. The residual current protection trip unit drives the tripping mechanism to turn off the circuit breaker and realize residual current protection.

4. A circuit breaker according to claim 1, characterized in that... The middle seat and the base cooperate to form a first cavity and a second cavity, and the middle seat and the cover cooperate to form a third cavity. The residual current controller is disposed in the first cavity, the L pole unit is disposed in the second cavity, and the N pole unit is disposed in the third cavity.

5. A circuit breaker according to claim 2, characterized in that... The residual current detection unit includes at least a zero-sequence current transformer, a first through-conductor, and a second through-conductor. The output terminal of the zero-sequence current transformer is electrically connected to the controller unit. One end of the first through-conductor is electrically connected to a stationary contact or a moving contact unit. One end of the second through-conductor is electrically connected to an N-pole stationary contact or an N-pole moving contact. After the first through-conductor and the second through-conductor pass through the zero-sequence current transformer, they are each electrically connected to their corresponding terminals.

6. A circuit breaker according to claim 1, characterized in that... The residual current protection trip unit includes at least a coil winding, a stationary iron core, a moving iron core, and an iron core spring. The moving iron core has protrusions extending from both ends, and the protrusions reciprocate linearly within the coil winding along with the moving iron core.

7. A circuit breaker according to claim 6, characterized in that... The reset button has a hook at one end, which is attached to the boss on the left side of the moving iron core. The hook and the boss are interlocked by a spring. When the residual current protection trip device is activated, the moving iron core moves to the right, and the boss on the left side of the moving iron core moves into the coil winding. The reset button is driven by the spring force to pop out towards the insulating shell. One side of the hook is pressed against the moving iron core and cannot be reset. The reset button can be reset by pressing it.

8. A circuit breaker according to claim 2, characterized in that... The power supply unit includes at least an L-pole power supply element and an N-pole power supply element. The L-pole power supply element is an elastic conductor and is laid inside the base and extends from the first cavity to the second cavity. The N-pole power supply unit is an elastic conductor, a flexible conductor, or a rigid conductor and is laid inside the middle seat and extends from the first cavity to the third cavity.

9. A circuit breaker according to claim 8, characterized in that... The controller unit is welded with at least two metal tubular rivets for power supply.

10. A circuit breaker according to claim 9, characterized in that... The L-pole power-taking element and the N-pole power-taking element are elastic conductors, with a bent protrusion or arc-shaped structure at one end, each inserted into a metal tubular rivet. The other end of the L-pole power-taking element is set on the moving trajectory of the moving contact unit, and the other end of the N-pole power-taking element is set on the moving trajectory of the N-pole moving contact. The moving contact unit and the N-pole moving contact make electrical contact with the stationary contact and the N-pole stationary contact when the closing movement is about to make contact with them.

11. A circuit breaker according to claim 1, characterized in that... The test button has an inverted buckle on one side. The test button is inserted from the outside of the base into the insulating shell while overcoming the spring force of the inverted buckle. The test button has a resistor and a compression spring in the pressing direction. One end of the resistor is directly or indirectly electrically connected to the N pole module, and the other end is electrically connected to the compression spring. The other end of the compression spring abuts against the test button and also has a conductive extension. When the test button is pressed, the conductive extension makes electrical contact with the L pole power-taking element.

12. A circuit breaker according to claim 5, characterized in that... The two terminals on each side are respectively arranged in the first groove between the base and the middle seat and in the second groove between the middle seat and the cover. The terminals in the first groove and the terminals in the second groove are staggered vertically along the Y-axis. A mounting boss is provided behind the first groove. The mounting boss is used to pre-install the terminals that are electrically connected to the second through conductor. During pre-installation, the mounting boss is in an upright state, the middle seat is fastened to the base, and the terminals that are electrically connected to the second through conductor pass through the through hole on the middle seat and can be rotated 90° to enter the second groove.

13. A circuit breaker according to claim 12, characterized in that, The terminal block includes a terminal board, a terminal block, and a terminal screw. The terminal block is sleeved on the terminal board and is rotatably disposed relative to the terminal board. The terminal screw is inserted into the terminal block.

14. A circuit breaker according to claim 5, characterized in that, When the residual current detection unit detects that the current vector sum between the first and second conductors is not zero and reaches a certain threshold, the controller unit drives the tripping mechanism through the residual current protection trip unit to turn off the circuit breaker and achieve leakage protection.

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