A compact intelligent overload protection circuit breaker

Abstract

The application discloses a compact intelligent overload protection circuit breaker and relates to the technical field of circuit breakers.The compact intelligent overload protection circuit breaker comprises a rear shell, a solenoid and a conductive row arranged in the rear shell, a front shell buckled to the front end of the rear shell, a static contact fixedly connected to one end of the solenoid, an arc guide plate fixedly connected to the left inner wall of the rear shell, and a movable contact rotatably connected to the inner side of the arc guide plate.The power module, the first electromagnet, the second electromagnet, the sliding block, the wireless communication module and the MCU controller are cooperated and work together to build a complete remote control system.When the main circuit is powered off, the power module can independently provide temporary power supply for the two electromagnets, the wireless communication module and the MCU controller.In special scenes such as when the circuit breaker is installed at a high place or at a long distance, a user can send a closing instruction through a terminal to perform a closing operation without manually going to the scene to perform the closing operation, thereby improving the convenience of the closing operation and reducing the operation risk of climbing.

Description

Technical Field

[0001] This invention relates to the field of circuit breaker technology, specifically to a compact intelligent overload protection circuit breaker. Background Technology

[0002] A circuit breaker is a switching device that can close, carry, and interrupt current under normal circuit conditions and can close, carry, and interrupt current under abnormal circuit conditions within a specified time.

[0003] Most existing circuit breaker closing operations rely on manual operation. For applications where the circuit breaker is installed at high altitudes, in confined spaces, or far from the operator, manual on-site closing is not only cumbersome but also poses safety risks due to working at heights, causing considerable inconvenience to users and failing to meet the demand for convenient operation. The few products with remote closing capabilities mostly rely on the main circuit for power supply. In the event of a fault trip and the main circuit being de-energized, the remote closing function is often difficult to execute. Furthermore, traditional circuit breakers primarily rely on electromagnetic short-circuit protection and metal strip deformation overload protection. While these two protection methods are simple in structure, when a slight overload occurs in the circuit for an extended period, the metal strip deformation is insufficient to trigger tripping, and the electromagnetic mechanism fails to reach its operating threshold. This can easily lead to damage to circuit components due to prolonged overheating, posing a safety hazard. Therefore, a compact intelligent overload protection circuit breaker is proposed to address the aforementioned problems. Summary of the Invention

[0004] To address the aforementioned technical problems, a compact intelligent overload protection circuit breaker is provided. This technical solution solves the problem mentioned in the background that the closing operation of existing circuit breakers mostly relies on manual operation. For applications installed at high altitudes, in narrow spaces, or far from operators, manual on-site closing is not only cumbersome but also poses safety risks due to working at heights, causing numerous inconveniences for users and failing to meet the demand for convenient operation. The few products with remote closing functions mostly rely on the main circuit for power supply. When the main circuit is de-energized after a fault trip, the remote closing function is often difficult to execute. At the same time, traditional circuit breakers mainly rely on electromagnetic drive-type short-circuit protection and metal strip deformation-type overload protection. Although these two protection methods are simple in structure, when the circuit experiences a slight overload for a long period of time, the deformation of the metal strip is insufficient to trigger tripping, and the electromagnetic mechanism does not reach the action threshold. In this case, the circuit components are prone to damage due to long-term overheating, posing a safety hazard.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A compact intelligent overload protection circuit breaker includes a rear housing, a solenoid and a conductive busbar disposed inside the rear housing. A front housing is fastened to the front end of the rear housing. A stationary contact is fixedly connected to one end of the solenoid. An arc-starting plate is fixedly connected to the inner left side of the rear housing. A moving contact is rotatably connected to the inner side of the arc-starting plate. A conductive strip is fixedly connected to the lower end of the moving contact. A bimetallic strip is disposed at the upper end of the conductive busbar. A lower fixed cylinder and an upper fixed cylinder are disposed inside the solenoid. An operating rod and a lever are rotatably connected inside the rear housing. A PCB board and a power module are snapped into the interior of the rear housing. An MCU controller and a wireless communication module are integrated on the PCB board. The outer surface of the conductive busbar... A Hall current sensor is installed, and a temperature sensor is installed on the inner rear wall of the rear shell. A fixed frame is fixedly connected inside the rear shell. The left and right ends of the fixed frame are respectively provided with a first slide groove and a second slide groove. The bottom and top inner ends of the second slide groove are respectively embedded with a first electromagnet and a second electromagnet. A slider is slidably connected inside the second slide groove. A permanent magnet and a magnetic block are respectively embedded at the top and bottom ends of the slider. A rack is fixedly connected to the end of the slider near the operating rod. The outer surface of the operating rod is provided with a toothed groove that meshes with the rack. A fixed electrode is fixedly connected to the top inner end of the first slide groove, and a sliding electrode is slidably connected inside the first slide groove.

[0006] Preferably, the Hall current sensor is fixedly installed on the rear inner wall of the rear housing, the measuring end of the temperature sensor extends to the connection between the stationary contact and the moving contact, the fixed electrode is electrically connected to the first electromagnet, the Hall current sensor, the temperature sensor, the first electromagnet and the sliding electrode are all electrically connected to the MCU controller, and the power supply module is electrically connected to the PCB board to supply power to the MCU controller, the wireless communication module, the Hall current sensor, the temperature sensor, the first electromagnet and the sliding electrode.

[0007] Preferably, the magnetic block has the opposite magnetism to the first electromagnet. When energized, the first electromagnet generates an attractive force on the magnetic block. The second electromagnet has the same magnetism as the permanent magnet. When energized, the second electromagnet generates a repulsive force on the permanent magnet. The second slide groove is T-shaped, and the shape of the slider is adapted to the second slide groove.

[0008] Preferably, the lower end of the fixed electrode is fixedly connected to two fixed contacts, the upper end of the sliding electrode is fixedly connected to two moving contacts, the upper fixed cylinder is fixedly connected to the upper end of the lower fixed cylinder, an L-shaped fixed plate is fixedly connected inside the rear shell, the lower fixed cylinder is fixedly connected to the inner bottom end of the L-shaped fixed plate, a first metal column is slidably connected inside the lower fixed cylinder, a push rod is fixedly connected to the lower end of the first metal column, the lower end of the push rod passes through the bottom end of the lower fixed cylinder and the inner bottom end of the L-shaped fixed plate and extends to the lower side of the lower fixed cylinder, and a third spring is sleeved on the outer surface of the push rod.

[0009] Preferably, a fourth spring is fixedly connected inside the upper fixed cylinder, and a second metal column is fixedly connected to the upper end of the fourth spring. The second metal column is slidably connected inside the upper fixed cylinder, and a push rod is fixedly connected to the upper end of the second metal column. The upper end of the push rod passes through the inner top of the upper fixed cylinder and is fixedly connected to a connecting plate. The right end of the connecting plate is fixedly connected to the left end of the sliding electrode, and the connecting plate is slidably connected inside the first sliding groove.

[0010] Preferably, the inner side of the rear shell is fitted with two wiring terminals, and the ends of the two wiring terminals that are far apart from each other are provided with wiring grooves. The right end of the wiring terminal is threaded with a fixing bolt, one end of the fixing bolt extends to the inner side of the wiring groove. The upper and lower ends of the rear shell and the front shell are provided with wiring ports at the corresponding positions of the wiring grooves, and the right ends of the rear shell and the front shell are provided with through grooves at the corresponding positions of the fixing bolts.

[0011] Preferably, each of the two terminals is fixedly connected to a conductive block at one end. The lower end of the upper conductive block is fixedly connected to the end of the solenoid away from the stationary contact. The upper end of the bimetallic strip abuts against the lower end of the conductive strip. The conductive busbar is fixedly connected to the upper end of the lower conductive block. Two symmetrically distributed first springs are fixedly connected between the moving contact and the lever. A second spring is fixedly connected between the lever and the fixed frame. An arc-extinguishing grid is provided inside the rear shell on the left side of the upper fixed cylinder.

[0012] Preferably, the arc-extinguishing grid is composed of multiple metal grid plates arranged in parallel, with one side of the arc-extinguishing grid aligned with the end of the arc-initiating plate, for receiving the electric arc guided by the arc-initiating plate.

[0013] Preferably, the front ends of the operating rod and the lever are respectively provided with a first mounting groove and a second mounting groove. A connector is fixedly connected inside the first mounting groove and the second mounting groove. A fixing hole is provided through the outer surface of the connector. A connecting rod is inserted into the two fixing holes. Both ends of the connecting rod are bent after passing through the two fixing holes to prevent the connecting rod from falling off.

[0014] Preferably, a support frame is fixedly connected to the rear inner wall of the rear shell, a stationary contact is disposed on the outer surface of the support frame, a positioning groove is provided at the front end of the support frame, a positioning block with the same size as the positioning groove is fixedly connected to the front inner wall of the front shell, the positioning groove and the positioning block are inserted and matched to assist the installation of the front shell, four connecting holes are provided through the rear end of the rear shell, four connecting posts are fixedly connected to the rear inner wall of the front shell, and a mating hole with the same diameter as the connecting hole is provided at the rear end of the connecting post, and connecting bolts are connected to the internal threads of the connecting hole and the mating hole.

[0015] The beneficial effects of this invention compared to the prior art are: This solution proposes a compact intelligent overload protection circuit breaker. Through the cooperation and coordinated operation of the power supply module, the first electromagnet, the second electromagnet, the slider, the wireless communication module, and the MCU controller, a complete remote control system is constructed. When the main circuit is de-energized, the power supply module can independently provide temporary power to the first electromagnet, the second electromagnet, the wireless communication module, and the MCU controller. In special scenarios such as when the circuit breaker is installed at a high place or at a long distance, the user can send a closing command through the terminal to perform the closing operation, without the need for manual on-site operation, which improves the convenience of closing operation and reduces the operational risks of working at height.

[0016] This solution achieves intelligent protection through Hall current sensors, temperature sensors, MCU controllers, sliding electrodes, bimetallic strips, and solenoids. Current and temperature parameters are monitored collaboratively. The Hall current sensor collects the main circuit current signal in real time, and the temperature sensor accurately captures temperature changes in the contact area, covering various fault scenarios such as current overload, local high temperature, and poor contact. This avoids the protection blind spots of traditional single-parameter monitoring. At the same time, intelligent protection and mechanical backup are mutually redundant. After the MCU controller determines the fault by combining the signals from the two sensors, it triggers overload tripping by controlling the on / off state of the sliding electrode. When the MCU controller or sensor fails, the bimetallic strip can independently trigger mechanical overload protection due to thermal expansion differences. In the event of a short circuit, the solenoid quickly generates a strong electromagnetic force to push the tripping. An abnormality in one protection path does not affect the normal operation of other paths. Attached Figure Description

[0017] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is an exploded view of the present invention; Figure 3 This is a schematic diagram of the front shell structure in this invention; Figure 4 This is a schematic diagram of the rear shell structure in this invention; Figure 5 This is a schematic diagram of the fixing frame in this invention; Figure 6 This is a schematic diagram of the structure of the first groove in this invention; Figure 7 This is a schematic diagram of the terminal block structure in this invention.

[0018] The numbers on the map are: 1. Rear shell; 101. L-shaped fixing plate; 2. Front shell; 3. Terminal block; 4. Conductive block; 5. Solenoid; 6. Stationary contact; 7. Arc-starting plate; 8. Moving contact; 9. Conductive strip; 10. Bimetallic strip; 11. Conductive busbar; 12. Lower fixing cylinder; 13. Upper fixing cylinder; 14. Operating lever; 15. Lever; 16. Arc-extinguishing grid; 17. PCB board; 18. MCU controller; 19. Wireless communication module; 20. Hall current sensor; 21. Temperature sensor; 22. Fixing bracket; 23. First mounting slot; 24. Second mounting slot; 25. Connector; 26. Connecting rod; 27. First spring; 2701. Second spring; 28. Power module; 29. First metal column; 30. Push rod; 31. Third spring; 32. Fourth spring; 33. Second metal column; 34. Top rod; 35. Connecting plate; 36. First slide groove; 37. Second slide groove; 38. First electromagnet; 39. Second electromagnet; 40. Slider; 41. Permanent magnet; 42. Magnetic block; 43. Rack; 44. Gear groove; 45. Sliding electrode; 46. Moving contact; 47. Fixed electrode; 48. Fixed contact; 49. Wiring groove; 50. Fixing bolt; 51. Through groove; 52. Wiring port; 53. Connecting hole; 54. Connecting column; 55. Butt hole; 56. Connecting bolt; 57. Support frame; 58. Positioning groove; 59. Positioning block. Detailed Implementation

[0019] The following description is intended to disclose the invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art.

[0020] Reference Figure 1 , Figure 2 , Figure 4 , Figure 5 and Figure 6As shown, a compact intelligent overload protection circuit breaker includes a rear housing 1, a solenoid 5 and a conductive busbar 11 disposed inside the rear housing 1. A front housing 2 is fastened to the front end of the rear housing 1. A stationary contact 6 is fixedly connected to one end of the solenoid 5. An arc-starting plate 7 is fixedly connected to the inner left side of the rear housing 1. A moving contact 8 is rotatably connected to the inner side of the arc-starting plate 7. A conductive strip 9 is fixedly connected to the lower end of the moving contact 8. A bimetallic strip 10 is provided at the upper end of the conductive busbar 11. A lower fixed cylinder 12 and an upper fixed cylinder 13 are provided inside the solenoid 5. An operating rod 14 and a lever 15 are rotatably connected inside the rear housing 1. A PCB board 17 and a power module 28 are snapped into the interior of the rear housing 1. An MCU controller 18 and a wireless communication module 19 are integrated on the PCB board 17. A protective sleeve is fitted on the outer surface of the conductive busbar 11. The device includes a Hall current sensor 20, a temperature sensor 21 on the inner rear wall of the rear shell 1, a fixed bracket 22 fixedly connected inside the rear shell 1, a first slide groove 36 and a second slide groove 37 respectively opened at the left and right ends of the fixed bracket 22, a first electromagnet 38 and a second electromagnet 39 respectively embedded at the bottom and top inner sides of the second slide groove 37, a slider 40 slidably connected inside the second slide groove 37, a permanent magnet 41 and a magnetic block 42 respectively embedded at the top and bottom ends of the slider 40, a rack 43 fixedly connected at the end of the slider 40 near the operating rod 14, a toothed groove 44 that meshes with the rack 43 opened on the outer surface of the operating rod 14, a fixed electrode 47 fixedly connected at the top inner side of the first slide groove 36, and a sliding electrode 45 slidably connected inside the first slide groove 36.

[0021] Specifically, the rear shell 1 serves as the mounting reference carrier for internal components. Its inner wall is integrally formed with multiple partition ribs, which divide the internal space of the rear shell 1 into multiple areas for snapping together components, achieving physical isolation of different functional modules, and avoiding circuit interference and arc propagation. The front shell 2 has reserved space for the operation rod 14 and lever 15 to move. After the front shell 2 is fastened to the front end of the rear shell 1, it forms an outer protective shell with the rear shell 1, which can protect the internal components of the circuit breaker from external interference.

[0022] Furthermore, two wiring terminals 3 are snapped onto the inner side of the rear shell 1. Each of the two wiring terminals 3 has a wiring groove 49 at the ends that are far apart from each other. A fixing bolt 50 is threaded onto the right end of the wiring terminal 3. One end of the fixing bolt 50 extends into the inner side of the wiring groove 49. Wiring ports 52 are provided through the upper and lower ends of the rear shell 1 and the front shell 2 at the corresponding positions of the wiring groove 49. Through grooves 51 are provided through the right ends of the rear shell 1 and the front shell 2 at the corresponding positions of the fixing bolt 50.

[0023] Specifically, the wiring slot 49 is used to connect the circuit breaker to the external conductor, and the fixing bolt 50 is used to fix the external conductor after connection. In actual operation, the external conductor is first inserted into the wiring slot 49, and then the fixing bolt 50 is rotated so that the end of the bolt gradually abuts against the outer surface of the external conductor and applies pressure, which can form a stable clamping and fixing of the external conductor, avoiding the external conductor from falling off due to vibration or pulling during daily use, and ensuring the stability of the conductor connection. The wiring port 52 provides a path for the external conductor to pass into the housing, making the conductor installation process more convenient, while the through slot 51 provides operating space for rotating the fixing bolt 50, making it convenient for tools such as screwdrivers to reach into the housing to complete the tightening or loosening of the bolt.

[0024] Furthermore, conductive blocks 4 are fixedly connected to opposite ends of the two terminals 3. The lower end of the upper conductive block 4 is fixedly connected to the end of the solenoid 5 away from the stationary contact 6. The upper end of the bimetallic strip 10 abuts against the lower end of the conductive strip 9. The conductive busbar 11 is fixedly connected to the upper end of the lower conductive block 4. Two symmetrically distributed first springs 27 are fixedly connected between the moving contact 8 and the lever 15. A second spring 2701 is fixedly connected between the lever 15 and the fixing frame 22. An arc-extinguishing grid 16 is provided inside the rear shell 1 on the left side of the upper fixing cylinder 13.

[0025] Specifically, the conductive block 4 is used to achieve conductive transition between the terminal 3 and the internal components. The upper conductive block 4 is used to transmit the current from the terminal 3 to the solenoid 5, and the lower conductive block 4 is used to transmit the current from the conductive busbar 11 back to the terminal 3, ensuring the continuity of current transmission. When the operating lever 14 is in the open state, the first spring 27 and the second spring 2701 are both in a balanced state. When the operating lever 14 is closed, the first spring 27 is compressed and the second spring 2701 is stretched. The force of the two is related to the subsequent first electromagnetic... After the attraction forces of iron 38 and magnetic block 42 are superimposed, the whole remains in balance, keeping the operating lever 14 stable and stationary, avoiding accidental shaking. After the operating lever 14 is closed, the elastic force of the first spring 27 can provide closing pressure to push the moving contact 8 to contact the stationary contact 6, so that the moving contact 8 and the stationary contact 6 are tightly fitted, avoiding poor contact and heat generation. At the same time, after the circuit is opened, it can pull the moving contact 8 to reset, preparing for the next closing. The arc extinguishing grid 16 is used to quickly extinguish the arc generated by the contact breaking, preventing the arc from burning the components or causing a short circuit.

[0026] Furthermore, the arc-extinguishing grid 16 is composed of multiple metal grid plates arranged in parallel, with one side of the arc-extinguishing grid 16 aligned with the end of the arc-initiating plate 7, for receiving the electric arc guided by the arc-initiating plate 7.

[0027] Specifically, multiple metal grids are arranged in parallel to form multiple independent arc-extinguishing spaces. The metal grids of the arc-extinguishing grid 16 are fixed to the arc-extinguishing cavity inside the rear shell 1 by an insulating high-temperature resistant bracket. The bracket is bonded to the inner wall of the rear shell 1 with thermally conductive silicone. When the moving contact 8 and the stationary contact 6 break and generate an arc, the arc-initiating plate 7 guides the arc to the arc-extinguishing grid 16 through its own conductivity and magnetic field. At this time, the metal grids divide the arc into multiple short arcs. Since the voltage of each short arc is lower than the arc-ignition voltage required for the arc to continue burning, the arc... The arc can no longer maintain its burning state. At the same time, the metal grid can quickly absorb the heat generated by the arc, further accelerating the extinction of the arc. After the metal grid absorbs the heat of the arc, the heat is first evenly distributed among multiple grids through the thermal conductivity of the grid itself, avoiding local overheating. Subsequently, the heat is transferred to the back shell 1 through the bracket and thermally conductive silicone. Finally, the heat is transferred to the outside air through the back shell 1. The design of aligning the ends of the arc extinguishing grid 16 and the arc ignition plate 7 ensures that the arc is accurately guided to the grid area, preventing the arc from spreading to other parts of the shell.

[0028] Furthermore, the front ends of the operating lever 14 and the lever 15 are respectively provided with a first mounting groove 23 and a second mounting groove 24. The first mounting groove 23 and the second mounting groove 24 are both fixedly connected to the interior of the connector 25. The outer surface of the connector 25 is provided with a fixing hole. The connector 26 is inserted into the two fixing holes. Both ends of the connector 26 are bent after passing through the two fixing holes to prevent the connector 26 from falling off.

[0029] Specifically, the first mounting slot 23 and the second mounting slot 24 are used to accommodate the connector 25, ensuring that the connector 25 does not protrude from the surface of the operating rod 14 and the lever 15 after installation, thus avoiding interference with other components. The fixing hole of the connector 25 is used to accurately position the connecting rod 26, ensuring that the connecting rod 26 can transmit power along the axis of the fixing hole. After the two ends of the connecting rod 26 are bent, they will form an anti-disengagement hook, which will be stuck on the outside of the connector 25 to prevent the connecting rod 26 from falling off when the operating rod 14 and the lever 15 are linked, thus ensuring the reliability of the power transmission between the two.

[0030] Reference Figures 1-7 As shown, the upper fixed cylinder 13 is fixedly connected to the upper end of the lower fixed cylinder 12. An L-shaped fixed plate 101 is fixedly connected inside the rear shell 1. The lower fixed cylinder 12 is fixedly connected to the inner bottom end of the L-shaped fixed plate 101. A first metal column 29 is slidably connected inside the lower fixed cylinder 12. A push rod 30 is fixedly connected to the lower end of the first metal column 29. The lower end of the push rod 30 passes through the bottom end of the lower fixed cylinder 12 and the inner bottom end of the L-shaped fixed plate 101 and extends to the lower side of the lower fixed cylinder 12. A third spring 31 is sleeved on the outer surface of the push rod 30.

[0031] Specifically, the L-shaped fixing plate 101 provides stable installation support for the lower fixing cylinder 12, ensuring that the lower fixing cylinder 12 and the upper fixing cylinder 13 remain stable. When the circuit is short-circuited, the current in the main circuit will increase sharply and instantaneously. The solenoid 5 is made of a multi-turn coil. According to the principle of electromagnetic induction, when the current passes through the coil, it will generate a magnetic field around it. The strength of the magnetic field is proportional to the magnitude of the current. The large current during the short circuit will cause the solenoid 5 to generate an extremely strong magnetic field. The electromagnetic force generated by the magnetic field will quickly attract the first metal column 29 inside to slide downward against the elastic force of the third spring 31, push the push rod 30 to move down and compress the third spring 31. The downward push rod 30 will abut the emergency trip end of the lever 15, causing the lever 15 to rotate to achieve rapid circuit breaking. After the circuit is broken, the electromagnetic force generated by the magnetic field disappears. At this time, the third spring 31 pushes the first metal column 29 and the push rod 30 to automatically reset, preparing for the next short circuit protection.

[0032] Furthermore, a fourth spring 32 is fixedly connected inside the upper fixed cylinder 13. A second metal column 33 is fixedly connected to the upper end of the fourth spring 32. The second metal column 33 is slidably connected inside the upper fixed cylinder 13. A top rod 34 is fixedly connected to the upper end of the second metal column 33. The upper end of the top rod 34 passes through the inner top of the upper fixed cylinder 13 and is fixedly connected to a connecting plate 35. The right end of the connecting plate 35 is fixedly connected to the left end of the sliding electrode 45. The connecting plate 35 is slidably connected inside the first slide groove 36. Two fixed contacts 48 are fixedly connected to the lower end of the fixed electrode 47. Two moving contacts 46 are fixedly connected to the upper end of the sliding electrode 45. The magnetic block 42 has the opposite magnetic properties to the first electromagnet 38. When energized, the first electromagnet 38 generates an attraction force on the magnetic block 42. The second electromagnet 39 has the same magnetic properties as the permanent magnet 41. When energized, the second electromagnet 39 generates a repulsive force on the permanent magnet 41. The second slide groove 37 is T-shaped, and the shape of the slider 40 is adapted to the second slide groove 37.

[0033] Specifically, when the circuit is normally conducting, the fourth spring 32 is in a naturally extended state. Its elastic force pushes the second metal column 33 upwards, thereby causing the top rod 34 and connecting plate 35 to move upwards synchronously. This causes the sliding electrode 45 to move upwards along the first sliding groove 36 with the connecting plate 35, ensuring stable contact between the moving contact 46 and the fixed contact 48, thus completing the circuit of the first electromagnet 38. At this time, the first electromagnet 38 magnetically attracts the magnetic block 42. The attraction force of the first electromagnet 38, combined with the elastic force of the first spring 27 when compressed and the elastic force of the second spring 2701 when stretched, causes the operating rod 1 to... When the circuit is in equilibrium, the magnetic force generated by the solenoid 5 will cause the second metal column 33 to slide downward and compress the fourth spring 32. At this time, the push rod 34 moves down with the second metal column 33, pulling the connecting plate 35 and the sliding electrode 45 down along the first slide groove 36, causing the moving contact 46 to separate from the fixed contact 48, cutting off the circuit of the first electromagnet 38. The equilibrium state of the operating rod 14 is broken. At this time, the operating rod 14 rotates under the action of the elastic force of the first spring 27 and the second spring 2701, thereby driving the lever 15 to rotate and perform the release action.

[0034] It should be noted that the permanent magnet 41 and the second electromagnet 39 are mainly used to assist in remote control closing operations. When remote closing is required, the circuit is in an open state. At this time, the fixed contact 48 and the moving contact 46 remain closed under the elastic force of the fourth spring 32. When the first electromagnet 38 and the second electromagnet 39 are energized simultaneously, the first electromagnet 38 generates a magnetic field after being energized. Since its magnetism is opposite to that of the magnetic block 42, it will generate a downward attraction force. The magnetic field generated by the second electromagnet 39 after being energized is the same as that of the permanent magnet 41, and it will generate a downward repulsive force. The two forces are in opposite directions. The two forces overlap and work together to push the slider 40 smoothly downward along the second T-shaped groove 37. The T-shaped structure can effectively limit the movement direction of the slider 40 and avoid lateral deviation. During the downward movement of the slider 40, the rack 43 at one end precisely meshes with the tooth groove 44 of the operating rod 14. The linear motion of the rack 43 is converted into the rotational motion of the tooth groove 44, which drives the operating rod 14 to rotate to achieve closing. After closing, the first electromagnet 38 is de-energized. The operating rod 14 remains stationary only by the balance of the forces of the first spring 27 and the second spring 2701, ensuring stable circuit conduction.

[0035] Furthermore, the Hall current sensor 20 is fixedly installed on the rear inner wall of the rear housing 1, the measuring end of the temperature sensor 21 extends to the connection between the stationary contact 6 and the moving contact 8, the fixed electrode 47 is electrically connected to the first electromagnet 38, the Hall current sensor 20, the temperature sensor 21, the first electromagnet 38 and the sliding electrode 45 are all electrically connected to the MCU controller 18, and the power module 28 is electrically connected to the PCB board 17 to supply power to the MCU controller 18, the wireless communication module 19, the Hall current sensor 20, the temperature sensor 21, the first electromagnet 38 and the sliding electrode 45.

[0036] Specifically, the power module 28 integrates a charging management unit and an energy storage battery. Its input terminal is connected to the main circuit's busbar 11 via a wire. When the circuit is closed and operating normally, the main circuit supplies power to the power module 28. The charging management unit automatically adjusts the charging parameters to prevent overcharging, over-discharging, or overcurrent of the energy storage battery, ensuring that the energy storage battery is always kept at full or near full charge, thus reserving reliable power for subsequent remote operation or momentary power outages of the main circuit. Simultaneously, the output terminal of the power module 28 is connected to the power supply interface of the PCB board 17 via a wire, distributing power to various intelligent components. The Hall current sensor 20 is based on... The Hall effect operates by generating a Hall voltage related to the current in a magnetic field through the Hall element inside the Hall current sensor 20. By covering the outer surface of the conductive bus 11, the current flowing through the bus 11 generates a magnetic field inside the Hall current sensor 20. The Hall element converts the magnetic field change into a corresponding electrical signal, acquiring the current information of the main circuit in real time and transmitting it to the MCU controller 18. The temperature sensor 21 is made of a thermistor, and its resistance changes with temperature. Extending its measuring end to the contact connection, it can directly sense temperature fluctuations in that area, converting temperature changes into resistance changes, which are then converted into electrical signals by the signal conditioning circuit and transmitted to the MCU controller 18. Since the contact connection is a critical point of circuit contact, poor contact can easily generate localized high temperatures. The temperature data here can directly reflect abnormal circuit conditions. The MCU controller 18, as the core control component, has a built-in preset safety threshold and receives and analyzes the electrical signals from both sensors in real time. If the circuit parameters are within the normal range, the sliding electrode 45 is kept energized to ensure the control loop is open. If an overload or fault is detected in the circuit, the power supply to the sliding electrode 45 and the related electromagnet is immediately cut off, triggering a tripping action. Simultaneously, the MCU controller 1... 8 can also establish a connection with the user terminal through the wireless communication module 19, receive remote closing and opening control commands, and accurately control the on / off of the first electromagnet 38 and the second electromagnet 39 according to the commands to realize remote operation. The power module 28 provides a stable and suitable working voltage for all intelligent components through the circuit distribution of the PCB board 17. When closing remotely, since the main circuit is not powered, the energy storage battery of the power module 28 will directly power the MCU controller 18, the wireless communication module 19 and the two electromagnets to ensure the reception and execution of remote commands and avoid the failure of remote operation due to the lack of power in the main circuit.

[0037] Furthermore, a support frame 57 is fixedly connected to the rear inner wall of the rear shell 1, and a stationary contact 6 is disposed on the outer surface of the support frame 57. A positioning groove 58 is provided at the front end of the support frame 57. A positioning block 59 with the same size as the positioning groove 58 is fixedly connected to the front inner wall of the front shell 2. The positioning groove 58 and the positioning block 59 are inserted and engaged to assist in the installation of the front shell 2. Four connecting holes 53 are provided through the rear end of the rear shell 1. Four connecting posts 54 are fixedly connected to the rear inner wall of the front shell 2. A mating hole 55 with the same diameter as the connecting hole 53 is provided at the rear end of the connecting post 54. Connecting bolts 56 are threadedly connected to the internal threads of the connecting hole 53 and the mating hole 55.

[0038] Specifically, the support frame 57 is used to fix the stationary contact 6, providing a flat and stable mounting surface for the stationary contact 6, ensuring accurate contact between the stationary contact 6 and the moving contact 8, and avoiding poor contact or abnormal arcing due to the offset of the stationary contact 6. When installing the front shell 2, first align the positioning block 59 of the front shell 2 with the positioning groove 58 of the support frame 57 and insert it. Through the plugging and matching of the two, the installation position of the front shell 2 is quickly positioned, ensuring that the wiring port 52 of the front shell 2 is accurately aligned with the wiring groove 49, through groove 51 and fixing bolt 50 of the rear shell 1, reducing installation deviation and facilitating subsequent wiring operations. The four connecting holes 53 correspond one-to-one with the mating holes 55 of the connecting post 54. Through the threaded connection of the connecting bolt 56, a fixing force can be evenly applied from the four corners of the rear shell 1, so that the front shell 2 and the rear shell 1 are tightly fastened, avoiding gaps at the edge of the shell, improving the dustproof and splashproof capabilities of the shell, providing a good protective environment for internal components, and extending the service life of the equipment.

[0039] Working principle: When using this compact intelligent overload protection circuit breaker, firstly, perform external wiring installation. Pass the external wires through the wiring ports 52 at the upper and lower ends of the front shell 2 and the rear shell 1, and insert them into the wiring grooves 49 at opposite ends of the two terminals 3 inside the rear shell 1. Then, use a tool to rotate the fixing bolt 50 at the right end of the terminal 3 through the through groove 51 at the right end of the front shell 2 and the rear shell 1, so that the end of the fixing bolt 50 extending to the inside of the wiring groove 49 is pressed against the outer surface of the external wire, thus fixing the external wire. At this time, the conductive blocks 4 fixed at opposite ends of the two terminals 3 respectively establish the connection between the external circuit and the internal components. The upper conductive block 4 transmits the current of the terminal 3 to the end of the solenoid 5 away from the stationary contact 6, and the lower conductive block 4 transmits the current of the conductive busbar 11 back to the other terminal 3, forming the basic path of the main circuit. Then, perform the closing operation. When manually closing the circuit breaker, the operating rod 14, which is rotatably connected inside the rear housing 1, can be rotated. The connector 25 in the first mounting groove 23 at the front end of the operating rod 14 pulls the connector 25 in the second mounting groove 24 at the front end of the lever 15 through the connecting rod 26, causing the lever 15 to rotate synchronously. During the rotation of the lever 15, the second spring 2701 between the lever 15 and the fixed frame 22 is stretched, and the two symmetrical first springs 27 between the lever 15 and the moving contact 8 are compressed, pushing the moving contact 8, which is rotatably connected to the inner side of the arc-inducing plate 7, to rotate around the rotation point until the moving contact 8 and the spiral... The stationary contact 6 fixed at one end of tube 5 fits tightly. During this process, the toothed groove 44 on the outer surface of the operating rod 14 meshes with the rack 43, causing the slider 40 to move down along the second slide groove 37 at the right end of the fixed frame 22. At this time, the MCU controller 18 controls the first electromagnet 38 at the bottom of the inner side of the second slide groove 37 to be energized. The first electromagnet 38 generates an attraction force on the magnetic block 42 embedded at the bottom of the slider 40. Combined with the elastic force of the first spring 27 after compression and the elastic force of the second spring 2701 after stretching, the operating rod 14 remains in a stable and stationary state. When using remote closing, the MCU controller 18 receives the remote command through the wireless communication module 19 on the PCB board 17, and simultaneously controls the first electromagnet 38 and the second electromagnet 39 at the top of the inner side of the second slide 37 to be energized. The first electromagnet 38 attracts the magnetic block 42 and generates a downward pulling force, while the second electromagnet 39 generates a repulsive force on the permanent magnet 41 embedded at the top of the slider 40. The two forces together push the slider 40 down along the second slide 37. The operation rod 14 is rotated through the meshing of the rack 43 and the toothed groove 44 to achieve closing. After closing, the first electromagnet 38 is de-energized, and the closing state is maintained by the balance of the forces of the first spring 27 and the second spring 2701. After the circuit is closed, it enters the normal operation stage. The power module 28 inside the rear shell 1 supplies power to the MCU controller 18, wireless communication module 19, Hall current sensor 20, temperature sensor 21, first electromagnet 38 and sliding electrode 45 through PCB board 17. The Hall current sensor 20 on the outer surface of the conductive busbar 11 collects the main circuit current signal based on the Hall effect and transmits it to the MCU controller 18. The temperature sensor 21 set on the inner wall of the rear side of the rear shell 1 extends its measuring end to the connection between the stationary contact 6 and the moving contact 8, collects the temperature signal in this area and transmits it to the MCU controller 18. The MCU controller 18 analyzes the two signals in real time. If the parameters are both within the safe range, it keeps the sliding electrode 45 slidably connected inside the first slide groove 36 energized to ensure the stable closed state. When a short circuit fault occurs in the circuit, the main circuit current surges instantaneously. The solenoid 5, due to the large current flowing through its multi-turn coil, generates a strong electromagnetic force. According to the principle of electromagnetic induction, the magnetic field strength increases with the increase of current. This strong electromagnetic force attracts the first metal post 29, which is slidably connected inside the lower fixed cylinder 12, to overcome the elastic force of the third spring 31 on its outer surface and slide downwards. The push rod 30 at the lower end of the first metal post 29 passes through the bottom end of the lower fixed cylinder 12 and abuts against the emergency release end of the lever 15, pushing the lever 15 to rotate rapidly, causing the moving contact 8 to separate instantly from the stationary contact 6. Simultaneously, the short circuit... The impact force generated by the circuit current causes the second metal column 33 to slide downwards and compress the fourth spring 32. The sliding electrode 45 moves down with the connecting plate 35 to cut off the circuit of the first electromagnet 38, assisting in the tripping process. The electric arc generated during the disconnection process is guided to the arc extinguishing grid 16 located on the left side of the upper fixed cylinder 13 inside the rear shell 1 by the conductivity and magnetic field of the arc ignition plate 7. The arc extinguishing grid 16 is composed of multiple parallel metal grid plates, which can divide the electric arc into multiple short electric arcs. The short electric arcs are extinguished because the voltage is lower than the arc ignition voltage and the heat is quickly absorbed by the metal grid plates. When an overload fault occurs in the circuit, the MCU controller 18 detects that the signal of the Hall current sensor 20 or the temperature sensor 21 exceeds the preset threshold. It first sends an overload warning message through the wireless communication module 19. If the overload condition continues and the bimetallic strip 10 and the push rod 30 do not trigger the trip, the MCU controller 18 will cut off the power supply to the sliding electrode 45. At this time, the power supply circuit of the first electromagnet 38 is disconnected, the attraction force of the first electromagnet 38 on the magnetic block 42 disappears, the balance state of the operating lever 14 is broken, and it rotates in the opposite direction under the action of the first spring 27 and the second spring 2701, which drives the lever 15 to separate the moving contact 8 from the stationary contact 6. The arc is also guided to the arc extinguishing grid 16 through the arc ignition plate 7 to be extinguished. After troubleshooting, if manual reset is required, the operating lever 14 can be rotated to the closed position, which will drive the lever 15 to make the moving contact 8 re-engage with the stationary contact 6. The third spring 31 will push the first metal column 29 and the push rod 30 to reset, and the fourth spring 32 will push the second metal column 33, the push rod 34, the connecting plate 35 and the sliding electrode 45 to reset. The moving contact 46 will re-engage with the stationary contact 48, and the first electromagnet 38 will be energized to attract the magnetic block 42, and the circuit will return to normal. If remote reset is required, a reset command can be sent to the MCU controller 18 via the wireless communication module 19. The MCU controller 18 controls the relevant components to complete the closing reset. Afterward, the MCU controller 18 continues to monitor the circuit parameters through the Hall current sensor 20 and the temperature sensor 21 to ensure the circuit breaker continues to work stably. Throughout the process, the partition ribs on the inner wall of the rear shell 1 achieve physical isolation of each functional module. The support frame 57 fixes the stationary contact 6 and cooperates with the positioning block 59 of the front shell 2 through the positioning groove 58 to ensure accurate shell fastening. The connecting bolt 56 passes through the connecting hole 53 and the mating hole 55 to make the rear shell 1 and the front shell 2 tightly fastened together to form a stable protective shell.

[0040] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention. The scope of protection claimed by the appended claims and their equivalents is defined.

Claims

1. A compact intelligent overload protection circuit breaker, characterized in that, The device includes a rear shell (1), a solenoid (5) and a conductive busbar (11) disposed inside the rear shell (1). The front shell (2) is fastened to the front end of the rear shell (1). A stationary contact (6) is fixedly connected to one end of the solenoid (5). An arc-starting plate (7) is fixedly connected to the inner wall of the left side of the rear shell (1). A moving contact (8) is rotatably connected to the inner side of the arc-starting plate (7). A conductive strip (9) is fixedly connected to the lower end of the moving contact (8). A bimetallic strip (10) is provided at the upper end of the conductive busbar (11). A lower fixed cylinder (12) and an upper fixed cylinder (13) are provided on the inner side of the solenoid (5). An operating rod (14) and a lever (15) are rotatably connected inside the rear shell (1). A PCB board (17) and a power module (28) are snapped into the interior of the rear shell (1). An MCU controller (18) and a wireless communication module (19) are integrated on the PCB board (17). A Hall current sensor is sleeved on the outer surface of the conductive busbar (11). A temperature sensor (21) is provided on the inner wall of the rear side of the back shell (1). A fixed frame (22) is fixedly connected inside the back shell (1). A first slide groove (36) and a second slide groove (37) are respectively opened at the left and right ends of the fixed frame (22). A first electromagnet (38) and a second electromagnet (39) are respectively embedded at the bottom and top of the inner side of the second slide groove (37). A slider (40) is slidably connected inside the second slide groove (37). A permanent magnet (41) and a magnetic block (42) are respectively embedded at the top and bottom of the slider (40). A rack (43) is fixedly connected to one end of the slider (40) near the operating rod (14). A toothed groove (44) that meshes with the rack (43) is opened on the outer surface of the operating rod (14). A fixed electrode (47) is fixedly connected to the top of the inner side of the first slide groove (36). A sliding electrode (45) is slidably connected inside the first slide groove (36).

2. The compact intelligent overload protection circuit breaker according to claim 1, characterized in that: The Hall current sensor (20) is fixedly installed on the rear inner wall of the rear shell (1). The measuring end of the temperature sensor (21) extends to the connection between the stationary contact (6) and the moving contact (8). The fixed electrode (47) is electrically connected to the first electromagnet (38). The Hall current sensor (20), the temperature sensor (21), the first electromagnet (38) and the sliding electrode (45) are all electrically connected to the MCU controller (18). The power module (28) is electrically connected to the PCB board (17) to supply power to the MCU controller (18), the wireless communication module (19), the Hall current sensor (20), the temperature sensor (21), the first electromagnet (38) and the sliding electrode (45).

3. A compact intelligent overload protection circuit breaker according to claim 1, characterized in that: The magnetic block (42) has the opposite magnetism to the first electromagnet (38). When the first electromagnet (38) is energized, it attracts the magnetic block (42). The second electromagnet (39) has the same magnetism as the permanent magnet (41). When the second electromagnet (39) is energized, it repels the permanent magnet (41). The second slide groove (37) is T-shaped, and the shape of the slider (40) is adapted to the second slide groove (37).

4. A compact intelligent overload protection circuit breaker according to claim 1, characterized in that: The lower end of the fixed electrode (47) is fixedly connected to two fixed contacts (48), the upper end of the sliding electrode (45) is fixedly connected to two moving contacts (46), the upper fixed cylinder (13) is fixedly connected to the upper end of the lower fixed cylinder (12), the interior of the rear shell (1) is fixedly connected to an L-shaped fixed plate (101), the lower fixed cylinder (12) is fixedly connected to the inner bottom end of the L-shaped fixed plate (101), the interior of the lower fixed cylinder (12) is slidably connected to a first metal column (29), the lower end of the first metal column (29) is fixedly connected to a push rod (30), the lower end of the push rod (30) passes through the bottom end of the lower fixed cylinder (12) and the inner bottom end of the L-shaped fixed plate (101) and extends to the lower side of the lower fixed cylinder (12), and the outer surface of the push rod (30) is fitted with a third spring (31).

5. A compact intelligent overload protection circuit breaker according to claim 1, characterized in that: The upper fixed cylinder (13) is fixedly connected to a fourth spring (32), and the upper end of the fourth spring (32) is fixedly connected to a second metal column (33). The second metal column (33) is slidably connected to the inside of the upper fixed cylinder (13). The upper end of the second metal column (33) is fixedly connected to a top rod (34). The upper end of the top rod (34) passes through the inner top of the upper fixed cylinder (13) and is fixedly connected to a connecting plate (35). The right end of the connecting plate (35) is fixedly connected to the left end of the sliding electrode (45). The connecting plate (35) is slidably connected to the inside of the first sliding groove (36).

6. A compact intelligent overload protection circuit breaker according to claim 1, characterized in that: The inner side of the rear shell (1) is fitted with two terminals (3). The two terminals (3) are provided with wiring grooves (49) at their ends that are far apart from each other. The right end of the terminals (3) is threaded with a fixing bolt (50). One end of the fixing bolt (50) extends to the inner side of the wiring groove (49). The upper and lower ends of the rear shell (1) and the front shell (2) are provided with wiring ports (52) at the corresponding positions of the wiring grooves (49). The right ends of the rear shell (1) and the front shell (2) are provided with through grooves (51) at the corresponding positions of the fixing bolts (50).

7. A compact intelligent overload protection circuit breaker according to claim 6, characterized in that: A conductive block (4) is fixedly connected to one end of each of the two terminals (3). The lower end of the upper conductive block (4) is fixedly connected to the end of the solenoid (5) away from the stationary contact (6). The upper end of the bimetallic strip (10) abuts against the lower end of the conductive strip (9). The conductive bar (11) is fixedly connected to the upper end of the lower conductive block (4). Two symmetrically distributed first springs (27) are fixedly connected between the moving contact (8) and the lever (15). A second spring (2701) is fixedly connected between the lever (15) and the fixing frame (22). An arc-extinguishing grid (16) is provided inside the rear shell (1) on the left side of the upper fixing cylinder (13).

8. A compact intelligent overload protection circuit breaker according to claim 7, characterized in that: The arc-extinguishing grid (16) is composed of multiple metal grids arranged in parallel. One side of the arc-extinguishing grid (16) is aligned with the end of the arc-initiating plate (7) and is used to receive the electric arc guided by the arc-initiating plate (7).

9. A compact intelligent overload protection circuit breaker according to claim 1, characterized in that: The front ends of the operating rod (14) and the lever (15) are respectively provided with a first mounting groove (23) and a second mounting groove (24). The first mounting groove (23) and the second mounting groove (24) are both fixedly connected to a connector (25). The outer surface of the connector (25) is provided with a fixing hole. A connecting rod (26) is inserted into the two fixing holes. Both ends of the connecting rod (26) are bent after passing through the two fixing holes to prevent the connecting rod (26) from falling off.

10. A compact intelligent overload protection circuit breaker according to claim 1, characterized in that: The rear inner wall of the rear shell (1) is fixedly connected to a support frame (57), and a stationary contact (6) is set on the outer surface of the support frame (57). The front end of the support frame (57) is provided with a positioning groove (58). The front inner wall of the front shell (2) is fixedly connected to a positioning block (59) with the same size as the positioning groove (58). The positioning groove (58) and the positioning block (59) are inserted and matched to assist the installation of the front shell (2). The rear end of the rear shell (1) is provided with four connecting holes (53). The rear inner wall of the front shell (2) is fixedly connected to four connecting posts (54). The rear end of the connecting post (54) is provided with a mating hole (55) with the same diameter as the connecting hole (53). The internal threads of the connecting hole (53) and the mating hole (55) are connected with connecting bolts (56).

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