Intelligent circuit breaker

Abstract

To provide highly reliable circuit breakers. [Solution] The circuit breaker includes an electromechanical switch, a current sensor, a voltage sensor, and a processor. The electromechanical switch is connected in series between the line input terminal and the load output terminal of the circuit breaker and is configured to be in a closed or open state. The current sensor is configured to detect the magnitude of the current flowing in the circuit between the line input terminal and the load output terminal and to generate a current detection signal. The voltage sensor is configured to detect the magnitude of the voltage at a point on the circuit between the line input terminal and the load output terminal and to generate a voltage detection signal. The processor is configured to receive and process the current detection signal and the voltage detection signal to determine the operating status information of the circuit breaker and to determine the power usage information of the load connected to the load output terminal.

Description

[Technical Field]

[0001] Cross-reference of related applications This application relates to the following applications: (i) U.S. Patent Provisional Application No. 62 / 849,847 filed on 18 May 2019; (ii) U.S. Patent Application No. 16 / 720,446 titled "Intelligent Circuit Breakers" filed on 19 December 2019; (iii) U.S. Patent Application No. 16 / 720,506 titled "Intelligent Circuit Breakers with Solid-State Bidirectional Switches" filed on 19 December 2019; (iv) U.S. Patent Application No. 16 / 720,485 titled "Intelligent Circuit Breakers with Air-Gap and Solid-State Switches" filed on 19 December 2019; and (v) "Intelligent Circuit Breakers with Detection Circuitry Configured to Detect Fault" filed on 19 December 2019. We claim priority to U.S. Patent Application No. 16 / 720,533 entitled "Conditions" and (vi) U.S. Patent Application No. 16 / 720,583 entitled "Intelligent Circuit Breakers with Visual Indicators to Provide Operational Status," filed on 19 December 2019, all of which disclosures are fully incorporated herein by reference.

[0002] This disclosure relates, in general, to power control systems and devices, and more particularly to circuit breaker devices and systems for protecting branch circuits from damage resulting from fault conditions. [Background technology]

[0003] Circuit breakers are essential components in power distribution systems. Generally, circuit breakers are installed in power distribution panels (e.g., circuit breaker panels) that divide the high-current power supply lines of an external power system into multiple downstream branch circuits within a given building or residential structure. Each circuit breaker is connected between the incoming high-current power supply line and the corresponding branch circuit to protect the branch circuit conductors and the electrical load on the branch circuit from being exposed to overcurrent conditions. There are several types of overcurrent conditions, including overload conditions and fault conditions. An overload condition is defined as equipment exceeding its normal full load rating or a branch circuit exceeding its current capacity, which, if the overload persists for a sufficient period, will cause damage or dangerous overheating. Fault conditions include unintended or accidental load conditions that, depending on the impedance of the fault, typically result in overcurrent conditions far higher than those of an overload. Faults that result in maximum overcurrent conditions are called short circuits or "bolted faults."

[0004] Conventional circuit breakers are inherently electromechanical and have electrical contacts that are physically isolated by manual intervention of an operator lever, or automatically isolated in the event of a fault or prolonged overcurrent condition. When automatically isolated, the circuit breaker is considered "tripped." The isolation of the circuit breaker's electrical contacts can be achieved electromagnetically, electromechanically, or a combination of both.

[0005] A significant problem with conventional circuit breakers is their slow response to fault conditions, stemming from their electromechanical structure. Conventional circuit breakers typically require at least several milliseconds to isolate a fault. This slow response time is undesirable because it increases the risk of harmful fires, damage to electrical equipment, and arc flashes that can occur at the short-circuit location if a voltageted fault is not isolated quickly enough. An arc flash is an electrical explosion of a conductor resulting from a short-circuit condition. The energy release in an arc flash generates temperatures exceeding 35,000°F at the terminals, which can rapidly vaporize the metal conductor, blast the molten metal, and expand the plasma, expelling it outward with extreme force. Therefore, arc flashes are extremely hazardous to life, property, and electrical equipment, especially in industrial and residential environments where the risk of gas leaks is significant.

[0006] Conventional circuit breakers exhibit significant variations in both trip time and current trip limit in response to faults or prolonged overcurrent conditions, in addition to slow fault isolation. These variations are primarily due to limitations in the electromechanical design of the circuit breaker device and the influence of physical factors such as mounting stress and temperature fluctuations. The variations in trip time and current trip limit themselves can differ between devices, even if they are of the same type, have the same ratings, and are manufactured by the same company.

[0007] Conventional circuit breakers offer high isolation capabilities when they trip. However, their slow response time, lack of precision, and high-order variability are all highly undesirable characteristics. The slow response time not only provides insufficient protection against the possibility of arc flash, but the high-order variability and lack of precision make coordination between multiple circuit breakers in a complex system virtually impossible.

[0008] As a protective device, a circuit breaker must be able to isolate a fault from the external supply circuit even when the fault current significantly exceeds the circuit breaker trip current rating, thereby protecting against a single internal point of fault. The ampere interrupting capacity (AIC) rating of a circuit breaker indicates the maximum fault current (in amperes) that the circuit breaker device will safely clear when a fault is applied to the load side of the circuit breaker device. The AIC rating of a circuit breaker device represents the maximum fault current that can be interrupted by the circuit breaker device without a fault in the circuit breaker device itself. The AIC rating requires an extremely high level of short-circuit protection, and circuit breakers in the country are often rated at 10,000 amperes or more.

[0009] Conventional circuit breakers either do not implement functionality based on smart decision-making to interrupt or isolate external power from the load, or they monitor or measure power components such as voltage and / or current and make intelligent decisions based on the measurement and calculation of voltage and / or current. In contrast, conventional circuit breakers operate to protect against excessive load power demands (e.g., current overload, short circuit) based on electromechanical components that trip the circuit breaker by a mechanical force generated by magnetism or the expansion of a bimetallic element with metals having different thermal expansion parameters. The lack of intelligent tripping operation and reliance on crude forces created in the power distribution environment can result in excessive power conditions such as excessive arcing, slow trip response times, and dangerously high internal operating temperatures. The reliance of conventional circuit breakers on mechanical components that cause tripping, such as hooks and springs, increases the potential for disaster in terms of fire risk, device unreliability, and potential loss of life and property. It is known that a common cause of electrical fires in homes or buildings is the result of unreliable, faulty electromechanical protection devices and circuit breakers. Therefore, eliminating the use of conventional electromechanical / thermomagnetic circuit breakers / protection devices and implementing more reliable and efficient solutions for protection devices is desired and needed in the circuit breaker and protection device industry. [Overview of the project]

[0010] Embodiments of the present disclosure include intelligent circuit breakers, as well as systems and methods for implementing intelligent circuit breakers. For example, one embodiment includes a circuit breaker comprising an electromechanical switch, a current sensor, a voltage sensor, and a processor. The electromechanical switch is connected in series between the line input terminal and the load output terminal of the circuit breaker and is configured to be in one of two states: (i) a closed switch state and (ii) an open switch state. The current sensor is configured to detect the magnitude of the current flowing in the circuit between the line input terminal and the load output terminal and to generate a current detection signal. The voltage sensor is configured to detect the magnitude of the voltage at a point on the path between the line input terminal and the load output terminal and to generate a voltage detection signal. The processor is configured to receive and process the current detection signal and the voltage detection signal to determine the operating status information of the circuit breaker and to determine the power usage information of a load connected to the load output terminal.

[0011] Another embodiment includes a method for connecting a circuit breaker between an external power source and a branch circuit including a load, wherein the circuit breaker includes an electromechanical switch configured to be in one of the following states: (i) a closed switch state for connecting the external power source to the branch circuit, and (ii) an open switch state for disconnecting the external power source from the branch circuit; detecting the flow of current through the circuit breaker and generating a current detection signal indicating the magnitude of the detected current flow through the circuit breaker; detecting a voltage at a point on the circuit through the circuit breaker and generating a voltage detection signal indicating the magnitude of the detected voltage; and processing the current detection signal and the voltage detection signal to determine the operating status information of the circuit breaker and to determine the power usage information of the load.

[0012] Another embodiment includes a system comprising a circuit breaker distribution board and circuit breakers disposed within the circuit breaker distribution board. The circuit breaker distribution board includes a busbar coupled to an external power supply. The circuit breakers include a line input terminal coupled to the busbar, a load output terminal connected to a branch circuit, an electromechanical switch, a current sensor, a voltage sensor, and a processor. The electromechanical switch is configured to be in one of two states: (i) a closed state for connecting an external power supply to a branch circuit, and (ii) an open state for disconnecting an external power supply from a branch circuit. The current sensor is configured to detect the magnitude of the current flowing in the circuit between the line input terminal and the load output terminal and to generate a current detection signal. The voltage sensor is configured to detect the magnitude of the voltage at a point on the path between the line input terminal and the load output terminal and to generate a voltage detection signal. The processor is configured to receive and process the current detection signal and the voltage detection signal to determine the operating status information of the circuit breaker and the power usage information of the load connected to the load output terminal.

[0013] Another embodiment includes a circuit breaker comprising a solid bidirectional switch, a first switch control circuit, a current sensor, a voltage sensor, and a processor. The solid bidirectional switch is connected in series between the line input terminal and the load output terminal of the circuit breaker and is configured to be (i) switched on and (ii) switched off. The first switch control circuit is configured to generate a control signal for controlling the operation of the solid bidirectional switch. The current sensor is configured to detect the magnitude of the current flowing in the circuit between the line input terminal and the load output terminal and to generate a current detection signal. The voltage sensor is configured to detect the magnitude of the voltage at a point on the path between the line input terminal and the load output terminal and to generate a voltage detection signal. The processor receives and processes the current detection signal and the voltage detection signal and is configured to determine the operating status information of the circuit breaker, to determine fault events, and to determine power usage information of a load connected to the load output terminal.

[0014] Another embodiment includes a method for connecting a circuit breaker between an external power source and a branch circuit including a load, wherein the circuit breaker comprises a solid bidirectional switch configured to be in one of the following states: (i) an ON state for connecting the external power source to the branch circuit, and (ii) an OFF state for disconnecting the external power source from the branch circuit; detecting a current through the circuit breaker and generating a current sensing signal indicating the magnitude of the detected current flow through the circuit breaker; detecting a voltage at a point on the circuit through the circuit breaker and generating a voltage sensing signal indicating the magnitude of the detected voltage; generating a control signal to switch the solid bidirectional switch to an OFF state in response to the detection of a fault event based on at least one of the current sensing signal and the voltage sensing signal; and processing the current sensing signal and the voltage sensing signal to determine the operating status of the circuit breaker and to determine the power usage of the load.

[0015] Another embodiment includes a system comprising a circuit breaker distribution board and circuit breakers disposed within the circuit breaker distribution board. The circuit breaker distribution board includes a busbar coupled to an external power supply. The circuit breaker comprises a line input terminal coupled to the busbar, a load output terminal connected to a branch circuit, a solid bidirectional switch, a first switch control circuit, a current sensor, a voltage sensor, and a processor. The solid bidirectional switch is connected in series between the line input terminal and the load output terminal of the circuit breaker and is configured to be in one of two states: (i) switched on and (ii) switched off. The first switch control circuit is configured to generate a control signal for controlling the operation of the solid bidirectional switch. The current sensor is configured to detect the magnitude of the current flowing in the circuit between the line input terminal and the load output terminal and to generate a current detection signal. The voltage sensor is configured to detect the magnitude of the voltage at a point on the path between the line input terminal and the load output terminal and to generate a voltage detection signal. The processor is configured to receive and process current detection signals and voltage detection signals to determine the operating status information of a circuit breaker, to determine fault events, and to determine the power usage information of a load connected to the load output terminal.

[0016] Another embodiment includes a circuit breaker comprising a solid switch, an air gap electromagnetic switch, a switch control circuit mechanism, a zero-crossing detection circuit, and a current sensor. The solid switch and the air gap electromagnetic switch are connected in series in a circuit between the line input terminal and the load output terminal of the circuit breaker. The switch control circuit is configured to control the operation of the solid switch and the air gap electromagnetic switch. The zero-crossing detection circuit is configured to detect zero crossings in the AC power waveform on the circuit between the line input terminal and the load output terminal of the circuit breaker. The current sensor is configured to detect the current flowing in the circuit between the line input terminal and the load output terminal and to detect a fault condition based on the detected current flow. The switch control circuit mechanism is configured to, in response to the detection of a fault condition by the current sensor, generate a switch control signal to (i) switch the solid switch off and (ii) switch the air gap electromagnetic switch open after the solid switch has been switched off. The switch control circuit mechanism uses the zero-crossing detection signal output from the zero-crossing detection circuit to determine when to switch the air gap electromagnetic switch open.

[0017] Another embodiment includes a method for detecting a current flowing in a circuit between a line input terminal and a load output terminal of a circuit breaker, wherein the circuit breaker comprises a solid switch and an air gap electromagnetic switch connected in series in the circuit between the line input terminal and the load output terminal of the circuit breaker, the method comprising: detecting; detecting a fault condition based on the detected current flow; generating a first switch control signal to switch the solid switch to an off state in response to detecting the fault condition; detecting a zero-crossing event of an AC waveform at a point on the circuit, and the polarity of the AC waveform following the zero-crossing event; and generating a second control signal to switch the air gap electromagnetic switch to an open state in response to detecting that the polarity of the AC waveform following the zero-crossing event reverse-biases the body diode of the solid switch.

[0018] Another embodiment includes a system comprising a circuit breaker distribution board and circuit breakers disposed within the circuit breaker distribution board. The circuit breaker distribution board includes a busbar coupled to an external power supply. The circuit breaker comprises a line input terminal coupled to the busbar, a load output terminal connected to a branch circuit, a solid switch, an air-gap electromagnetic switch, a switch control circuit mechanism, a zero-crossing detection circuit, and a current sensor. The solid switch and the air-gap electromagnetic switch are connected in series in the circuit between the line input terminal and the load output terminal of the circuit breaker. The switch control circuit mechanism is configured to control the operation of the solid switch and the air-gap electromagnetic switch. The zero-crossing detection circuit is configured to detect zero crossings in the AC power waveform on the circuit between the line input terminal and the load output terminal of the circuit breaker. A current sensor is configured to detect the current flowing in the circuit between the line input terminal and the load output terminal and to detect a fault condition based on the detected current flow. The switch control circuit mechanism is configured to (i) switch off the solid switch and (ii) after the solid switch has been switched off, generate a switch control signal to open the air gap electromagnetic switch in response to the detection of a fault condition by the current sensor. The switch control circuit mechanism uses the zero-crossing detection signal output from the zero-crossing detection circuit to determine when to open the air gap electromagnetic switch.

[0019] Another embodiment includes a circuit breaker comprising a solid switch, a sensing resistor, a current sensing circuit, and a switch control circuit. The solid switch and the sensing resistor are connected in series in a circuit between the line input terminal and the load output terminal of the circuit breaker. The current sensing circuit is configured to (i) sample a sensing voltage generated in the sensing resistor in response to a load current flowing through the sensing resistor, (ii) detect an overcurrent fault condition based on the sampled sensing voltage, and (iii) output a fault detection signal in response to the detection of the overcurrent fault condition. The switch control circuit is configured to control the solid switch, and the switch control circuit is configured to switch off the solid switch in response to the fault detection signal output from the current sensing circuit.

[0020] Another embodiment includes a circuit breaker comprising a switch, a sensing resistor, a zero-crossing detection circuit, and a switch control circuit. The switch and the sensing resistor are connected in series in a circuit between the line input terminal and the load output terminal of the circuit breaker. The zero-crossing detection circuit is configured to (i) sample a sensing voltage generated across the sensing resistor in response to a load current flowing through the sensing resistor, (ii) detect a zero crossing of the load current based on the sampled sensing voltage, and (iii) output a zero-crossing detection signal in response to the detection of a zero crossing of the load current. The switch control circuit is configured to control the operation of the switch based on the output of the zero-crossing detection circuit.

[0021] Another embodiment includes a circuit breaker comprising a circuit breaker housing, an air gap switch disposed within the circuit breaker housing, and a first visual indicator configured to provide indication of the open and closed states of the air gap switch. The first visual indicator comprises (i) a first window formed as part of the circuit breaker housing, (ii) a first indicator element disposed within the circuit breaker housing, and (iii) a second indicator element disposed within the circuit breaker housing. The first indicator element is configured to move to a position behind the first window when the air gap switch is opened, so that the first indicator element is visible through the first window to provide indication of the open state of the air gap switch. The second indicator element is configured to move to a position behind the first window when the air gap switch is closed, so that the second indicator element is visible through the first window to provide indication of the closed state of the air gap switch.

[0022] Another embodiment includes a circuit breaker comprising a circuit breaker housing, an air gap switch disposed within the circuit breaker housing, an actuator mechanism disposed within the circuit breaker housing, and a first visual indicator configured to provide an indication of the state of the air gap switch. The air gap switch comprises a first contact and a second contact disposed in the circuit between the line input terminal and the load output terminal of the circuit breaker. The air gap switch is coupled to an actuator mechanism, which is configured to operate to (i) mechanically separate the first and second contacts to open the air gap switch and create an air gap in the circuit, and (ii) mechanically bring the first and second contacts together to close the air gap switch. The first visual indicator comprises (i) a first window formed as part of the circuit breaker housing, (ii) a first indicator element coupled to the actuator mechanism, and (iii) a second indicator element coupled to the actuator mechanism. The actuator mechanism is configured to move the first indicator element to a position behind the first window when opening the air gap switch, so that the first indicator element is visible through the first window to provide an indication of the open state of the air gap switch. The actuator mechanism is configured to move the second indicator element to a position behind the first window when closing the air gap switch, so that the second indicator element is visible through the first window to provide an indication of the closed state of the air gap switch.

[0023] Another embodiment includes a circuit breaker comprising a solid switch, an air gap switch, an actuator mechanism, a manual control switch, an electromechanical actuator, a control circuit, and a sensor switch. The solid switch and the air gap switch are connected in series in the circuit between the line input terminal and the load output terminal of the circuit breaker. The air gap switch comprises a first contact and a second contact. The actuator mechanism is configured to operate to (i) mechanically separate the first and second contacts to open the air gap switch and create an air gap in the circuit, and (ii) mechanically bring the first and second contacts together to close the air gap switch. The manual control switch is operably coupled to the actuator mechanism and is configured to switch between a first position and a second position, and by switching the manual control switch to the first position, the actuator mechanism opens the air gap switch. The electromechanical actuator is operably coupled to the actuator mechanism, and by operating the electromechanical actuator, the actuator mechanism opens the air gap switch. The control circuit mechanism is configured to control the operation of a solid switch and an electromechanical actuator, and is configured to generate a first control signal configured to put the solid switch into one of two states: an on state and an off state, and (ii) a second control signal configured to control the operation of the electromechanical actuator. A sensor switch is operably coupled to a manual control switch and electrically connected to the control circuit mechanism, and is configured to (i) detect a change in the manual control switch from a second position to a first position that causes the actuator mechanism to open the air gap switch, and (ii) output a third control signal to the control circuit mechanism in response to detecting the change in the manual control switch from the second position to the first position. In response to the third control signal, the control circuit mechanism is configured to generate a first control signal that switches the solid switch into an off state before the air gap switch is opened and creates an air gap in the circuit.

[0024] Another embodiment includes a circuit breaker device comprising a line active terminal, a line neutral terminal, a load active terminal, and a load neutral terminal, a solid switch, an air gap electromagnetic switch, an internal switch and a shunt resistor, a switch control circuit mechanism, and a fault detection circuit mechanism. The solid switch and the air gap electromagnetic switch are connected in series between the line active terminal and the load active terminal. The internal switch and the shunt resistor are connected in series between a first node and a second node, the first node including a point along the circuit between the line active terminal and the load active terminal, and the second node including a point along the circuit between the line neutral terminal and the load neutral terminal. The switch control circuit is configured to control the operation of the solid switch and the internal switch. The fault detection circuit mechanism is configured to detect a fault condition and generate a fault detection control signal in response to the detection of a fault condition. The switch control circuit mechanism is configured to switch the solid switch to the off state in response to the fault detection control signal. The switch control circuit is further configured to activate an internal switch in response to a fault detection control signal, thereby creating an internal short-circuit path with shunt resistors connected between the first and second nodes, and to allow the internal short-circuit current to flow through an air-gap electromagnetic switch. The internal short-circuit current is sufficient to trip the air-gap electromagnetic switch and thereby create an air gap in the circuit between the line-activated terminal and the load-activated terminal.

[0025] Another embodiment includes a method for detecting a current flowing in a circuit between the line-active terminal and the load-active terminal of a circuit breaker device, wherein the circuit breaker device comprises a solid switch and an air-gap electromagnetic switch connected in series in the circuit between the line-active terminal and the load-active terminal, the method comprising: detecting; detecting a fault condition based on the detected current flow; and in response to detecting the fault condition, (i) applying a first switch control signal to the solid switch to switch off the solid switch; and (ii) applying a second switch control signal to the internal switch to activate the internal switch, thereby creating an internal short-circuit path within the circuit breaker device and generating an internal short-circuit current flowing through the air-gap electromagnetic switch. The flow of the internal short-circuit current causes the air-gap electromagnetic switch to trip, thereby creating an air gap in the circuit between the line-active terminal and the load-active terminal of the circuit breaker device.

[0026] Another embodiment includes a system comprising a circuit breaker distribution board having a line-active busbar and a line-neutral busbar coupled to an external power supply, and a circuit breaker device disposed within the circuit breaker distribution board. The circuit breaker device comprises a line-active terminal coupled to the line-active busbar, a line-neutral terminal coupled to the line-neutral busbar, and a load-active terminal and a load-neutral terminal connected to a branch circuit. The circuit breaker device further comprises a solid switch and an air-gap electromagnetic switch connected in series between the line-active terminal and the load-active terminal, an internal switch and a shunt resistor connected in series between a first node and a second node, the first node including a point along the circuit between the line-active terminal and the load-active terminal, and the second node including a point along the circuit between the line-neutral terminal and the load-neutral terminal, a switch control circuit mechanism configured to control the operation of the solid switch and (ii) the internal switch, and a fault detection circuit mechanism configured to detect a fault condition and generate a fault detection control signal in response to the detection of a fault condition. The switch control circuit mechanism is configured to switch off the solid switch in response to a fault detection control signal. The switch control circuit mechanism is further configured to activate an internal switch in response to the fault detection control signal, thereby creating an internal short-circuit path with a shunt resistor connected between the first and second nodes, and to allow the internal short-circuit current to flow through an air-gap electromagnetic switch. The internal short-circuit current is sufficient to trip the air-gap electromagnetic switch and thereby create an air gap in the circuit between the line-activated terminal and the load-activated terminal.

[0027] Other embodiments are described in the following detailed descriptions of embodiments, which should be read in conjunction with the attached figures. [Brief explanation of the drawing]

[0028] [Figure 1A] This is a schematic circuit diagram of a conventional thermomagnetic circuit breaker. [Figure 1B] Figure 1A is a perspective view of a conventional circuit breaker housing. [Figure 2A] This is a schematic block diagram of an intelligent circuit breaker equipped with an electromechanical switch according to one embodiment of the present disclosure. [Figure 2B] This is a schematic block diagram of an intelligent circuit breaker equipped with an electromechanical switch, according to another embodiment of the present disclosure. [Figure 3A] This is a schematic block diagram of an intelligent circuit breaker equipped with a solid bidirectional switch according to one embodiment of the present disclosure. [Figure 3B] This is a schematic block diagram of an intelligent circuit breaker comprising a solid bidirectional switch according to another embodiment of the present disclosure. [Figure 4A] This is a schematic block diagram of an AC-DC converter circuit that can be implemented in an intelligent circuit breaker according to one embodiment of the present disclosure. [Figure 4B] Figure 4A is a schematic circuit diagram of an AC-DC converter circuit according to one embodiment of the present disclosure. [Figure 5] This is a schematic circuit diagram of an AC-DC circuit that may be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. [Figure 6A] This is a schematic circuit diagram of a solid bidirectional switch that can be implemented in an intelligent circuit breaker according to an embodiment of the present disclosure. [Figure 6B] Figure 6A illustrates the active element of the solid-state bidirectional switch during a positive half-cycle of the AC main supply voltage applied to the solid-state bidirectional switch. [Figure 6C] This is a schematic circuit diagram of a solid bidirectional switch that may be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. [Figure 6D] This is a schematic circuit diagram of a solid bidirectional switch that may be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. [Figure 6E] This is a schematic circuit diagram of a solid bidirectional switch that may be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. [Figure 6F]This is a schematic circuit diagram of a solid bidirectional switch that may be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. [Figure 6G] This is a schematic circuit diagram of a solid bidirectional switch that may be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. [Figure 6H] This is a schematic circuit diagram of a solid bidirectional switch that may be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. [Figure 7A] This is a schematic block diagram of a control circuit mechanism that can be implemented in an intelligent circuit breaker for controlling a solid bidirectional switch, according to one embodiment of the present disclosure. [Figure 7B] This is a schematic circuit diagram of the control circuit mechanism shown in Figure 7A according to one embodiment of the present disclosure. [Figure 8A] This is a high-level schematic diagram illustrating an intelligent circuit breaker according to another embodiment of the present disclosure. [Figure 8B] This is a high-level schematic diagram of an intelligent circuit breaker according to one embodiment of the present disclosure, which includes an isolation circuit configured to galvanically isolate the intelligent circuit breaker from a load. [Figure 9A] This is a schematic diagram of a power supply block and a current sensor block of a current sensor and energy metering circuit, which can be implemented in an intelligent circuit breaker according to one embodiment of the present disclosure. [Figure 9B] This is a schematic diagram of an overcurrent detection block for a current sensor and energy metering circuit, which can be implemented in an intelligent circuit breaker, according to one embodiment of the present disclosure. [Figure 9C] This is a schematic diagram of an energy metering block of a current sensor and energy metering circuit that can be implemented in an intelligent circuit breaker according to one embodiment of the present disclosure. [Figure 10] This is a flowchart of a method for controlling the switch of an intelligent circuit breaker in response to the detection of a fault condition, according to one embodiment of the present disclosure. [Figure 11]This is a state diagram illustrating a control process implemented by an intelligent circuit breaker to detect and protect against fault conditions, according to one embodiment of the present disclosure. [Figure 12] This disclosure schematically illustrates an intelligent power distribution and monitoring system utilizing an intelligent circuit breaker according to one embodiment of this disclosure. [Figure 13] This is an exploded view of a housing structure that may be used to house a switch and an intelligent circuit mechanism of an intelligent circuit breaker, according to one embodiment of the present disclosure. [Figure 14] This is a flowchart of a process implemented by an intelligent circuit breaker to monitor energy usage on a branch circuit and protect against fault conditions on the branch circuit, according to one embodiment of the present disclosure. [Figure 15] This is a flowchart of a process implemented by an intelligent circuit breaker to monitor energy usage on a branch circuit and protect against fault conditions on the branch circuit, according to one embodiment of the present disclosure. [Figure 16] This is a schematic block diagram of an intelligent circuit breaker according to one embodiment of the present disclosure, which is configured to identify the type of load connected to the circuit breaker and to control the load based on the identified load type. [Figure 17] This is a flowchart of a method for a load identification and control process implemented by an intelligent circuit breaker, according to one embodiment of the present disclosure. [Figure 18A] This is a schematic block diagram of an intelligent circuit breaker according to one embodiment of the present disclosure, which is configured to monitor ground fault and arc fault conditions and to provide circuit interruption in response to detected fault conditions. [Figure 18B] Figure 18A is a schematic circuit diagram of an intelligent circuit breaker according to one embodiment of the present disclosure. [Figure 19] This is a schematic block diagram of a fault detection processor that can be implemented in the intelligent circuit breaker shown in Figure 18B, according to one embodiment of the present disclosure. [Figure 20]A schematic example of a current zero crossover detector circuit according to one embodiment of the present disclosure is shown. [Figure 21A] Figure 20 illustrates various waveforms illustrating the operating modes of the current zero crossover detection circuit according to one embodiment of the present disclosure, and specifically illustrates waveforms illustrating the operating modes of the edge detection stage in Figure 20. [Figure 21B] Figure 20 illustrates various waveforms illustrating the operating modes of the current zero crossover detection circuit according to one embodiment of the present disclosure, and illustrates simulated signal waveforms illustrating the operating modes of the current zero crossover detection circuit of Figure 20. [Figure 22] A schematic example of a short-circuit detection circuit according to one embodiment of the present disclosure is shown. [Figure 23] Figure 22 illustrates a simulated signal waveform illustrating the operating modes of the short-circuit detection circuit according to one embodiment of the present disclosure. [Figure 24] Another embodiment of the present disclosure schematically illustrates an intelligent circuit breaker. [Figure 25A] Figure 24 illustrates the power supply voltage waveform input to the line side of the intelligent circuit breaker. [Figure 25B] Figure 24 illustrates the output voltage waveform on the load side of the intelligent circuit breaker when the solid switch of the intelligent circuit breaker is in the off state and the air gap electromagnetic switch of the intelligent circuit breaker is in the closed state. [Figure 26] This is a flowchart of the switch control process implemented by the switch controller of the intelligent circuit breaker shown in Figure 24, according to an embodiment of the present disclosure. [Figure 27] Another embodiment of the present disclosure schematically illustrates an intelligent circuit breaker. [Figure 28A] A perspective view of an intelligent circuit breaker according to another embodiment of the present disclosure, which includes a plurality of visual indicators configured to show the operating status of the intelligent circuit breaker. [Figure 28B]A perspective view of an intelligent circuit breaker according to another embodiment of the present disclosure, which includes a plurality of visual indicators configured to show the operating status of the intelligent circuit breaker. [Figure 28C] This is a schematic diagram of an intelligent circuit breaker according to another embodiment of the present disclosure, which includes a plurality of visual indicators configured to show the operating status of the intelligent circuit breaker. [Figure 28D] This is a schematic diagram of an intelligent circuit breaker according to another embodiment of the present disclosure, which includes a plurality of visual indicators configured to show the operating status of the intelligent circuit breaker. [Figure 28E] This is a schematic diagram of an intelligent circuit breaker according to another embodiment of the present disclosure, which includes a plurality of visual indicators configured to show the operating status of the intelligent circuit breaker. [Figure 29] Another embodiment of the present disclosure schematically illustrates an intelligent circuit breaker. [Modes for carrying out the invention]

[0029] Hereinafter, embodiments of the present disclosure will be described in further detail with respect to intelligent circuit breakers and systems and methods for implementing intelligent circuit breakers. It should be understood that the same or similar reference numerals are used throughout the drawings to represent identical or similar features, elements, or structures, and therefore, detailed descriptions of identical or similar features, elements, or structures will not be repeated for each of the drawings. In addition, where used herein with respect to proportions, ranges, etc., the terms “about” or “substantially” mean that they are close or near, but not exactly. For example, where used herein, the terms “about” or “substantially” imply that there is a small tolerance error, such as less than 1% of the stated quantity. Where used herein, the term “exemplary” means “serving as an example, case, or illustration.” Any embodiment or design described herein as “exemplary” should not be construed as being preferable or advantageous over other embodiments or designs.

[0030] Figures 1A and 1B schematically illustrate a conventional thermomagnetic circuit breaker 100, where Figure 1A is a schematic circuit diagram of the thermomagnetic circuit breaker 100 and Figure 1B is a perspective view of the housing 101 of the thermomagnetic circuit breaker 100. In particular, Figure 1A illustrates a thermomagnetic circuit breaker 100 connected between an external power supply 110 (referred to herein as an AC main line 110) and a load 120 connected to a branch circuit protected by the circuit breaker 100. As further illustrated in Figure 1A, the circuit breaker 100 is typically connected between the active phase 111 of the AC main line 110 (referred to as "line active") and the load active line 121 of the load 120, while the neutral phase 112 of the AC main line 110 (referred to as "line neutral") is directly connected to the load neutral line 122 of the load 120.

[0031] The circuit breaker 100 includes an electromechanical switch 102 which is opened and closed manually by a manual switch mechanism (not shown). The electromechanical switch 102 is mechanically coupled (104) to a thermomagnetic actuator which includes a solenoid 106 connected in series with the switch 102 and a bimetallic element 108 (heated by a resistive element) also connected in series with the switch 102. The mechanical coupling 104 is configured such that an instantaneous current flowing from the active phase 111 that exceeds a first threshold (e.g., exceeds the current rating of the circuit breaker 100) causes the solenoid 106 to separate the contacts of the switch 102, thereby opening the circuit and "tripping" the circuit breaker 100. The solenoid 106 (e.g., an electromagnet) generates a pulling force that increases with the current. The circuit breaker contacts are held closed by a latch. When the current in solenoid 106 increases beyond the circuit breaker's rating, the solenoid's pull releases the latch, thereby opening the contacts by spring action.

[0032] In addition, the mechanical coupling 104 is configured such that a prolonged overcurrent at a second, lower threshold causes the bimetallic element 108 to disengage the contacts of the switch 102, thereby tripping the circuit breaker 100. The bimetallic element 108 responds to less extreme but longer-lasting overcurrent conditions. The thermal mechanism of the circuit breaker 100 provides a time-response characteristic that allows the circuit breaker 100 to trip more quickly the larger the overcurrent, but to last longer the smaller the overload. This allows for short-time current spikes, such as those that occur when a motor or other non-resistive load is switched on. In this regard, the solenoid 106 (electromagnet mechanism) responds instantaneously to large surges (short circuits) of current, while the bimetallic element 108 responds to less extreme but longer-lasting overcurrent conditions. Once tripped, the circuit breaker 100 must be manually reset using the manual switch mechanism.

[0033] As further illustrated in Figure 1A, the line neutral 112 is typically connected to the earth connection 114 (GND) in the circuit breaker distribution panel, and an earth connection 116 is fabricated from the earth bar in the circuit breaker distribution panel to the earth connection of the load 120. The earth connection 116 provides an alternative low-resistance path for the earth fault return current to flow in the event of a ground fault event at the load 120. The earth connection 116 is useful in other circuit breaker or receptacle designs that provide protection such as arc fault detection and arc fault circuit interruption (AFCI), as well as ground fault detection and ground fault circuit interruption (GFCI). Furthermore, a circuit breaker 100 designed to provide AFCI and GFCI protection would include a line neutral wire (not shown in Figure 1A or Figure 1B).

[0034] Figure 1B illustrates a conventional housing 101 for a residential circuit breaker, typically manufactured using molded plastic components. In some embodiments, intelligent circuit breakers are implemented using standard housings for residential and / or commercial applications to ensure backward compatibility with existing housings and to allow for modification into existing distribution boards. Those skilled in the art will recognize that the circuits, algorithms, heat exchangers, and other aspects of the disclosed technology can be adapted to various morphological elements required in other locations or countries. This approach is intended to avoid the use of traditional circuit breaker elements, for example, the absence of traditional circuit breaker housings.

[0035] According to embodiments of this disclosure, intelligent circuit breakers are designed to provide high isolation capability while having a relatively fast response time for isolating short-circuit conditions, overcurrent conditions, and other types of faults more quickly than conventional circuit breakers. Intelligent circuit breakers are designed with time-current characteristics that can be programmed in real time, making them more accurate and less variable compared to conventional circuit breakers. For example, in some embodiments, intelligent circuit breakers implement low-power solid bidirectional switches that enable fast response times for isolating faults on high-energy branch circuits. Intelligent circuit breakers are designed to communicate with connected smart devices to provide support for multiple fault points, independent of the circuit breaker's location, thereby reducing the impedance of short-circuit conductors.

[0036] The intelligent circuit breakers according to embodiments of this disclosure offer additional safety, enhanced convenience, additional energy awareness, control, energy savings, and improved situational awareness compared to conventional circuit breakers. As will be described in more detail below, the intelligent circuit breakers implement a variety of functionalities and control circuits for implementing intelligent processing, including AC trunk switching technology, AC-DC conversion technology, internal short-circuit trip technology, technology for wirelessly transmitting status and sensor data to enable a variety of novel use cases, algorithms for fault detection, technology for detecting and protecting against internal device faults, technology for handling new types of loads through wireless updates, technology for exchanging thermal energy, technology for cloud service support for remote notification, control, monitoring, and big data collection even during equipment collapse events, circuit technology for shunt resistance current sensing, energy metering, and overcurrent detection, and technology for avoiding fault conditions. These are novel technologies in themselves and in themselves, but their true impact lies in addressing the challenges of improved safety, enhanced convenience, additional control, energy awareness, energy savings, and improved situational awareness.

[0037] Figure 2A is a schematic block diagram of an intelligent circuit breaker according to an embodiment of the present disclosure. In particular, Figure 2A schematically illustrates an intelligent circuit breaker 200 connected between an AC trunk line 110 and a load 120. The intelligent circuit breaker 200 comprises an electromechanical AC switch 202, a current sensor 204, a first voltage sensor 206, a second voltage sensor 208, an AC-DC converter circuit mechanism 210, a processor 220, a processor reset switch 222, and a radio frequency (RF) transceiver 230 having an associated antenna 232. The electromechanical AC switch 202 is connected in series between the line input terminal and the load output terminal of the circuit breaker 200, with the line activation 111 of the AC trunk line 110 connected to the line input terminal and the load activation 121 of the load 120 connected to the load output terminal. The line activation 111 of the AC trunk line 110 is connected to the load activation 121 when the electromechanical AC switch 202 is in the switch-closed state. In this embodiment, the line neutral 112 (e.g., connected to an earth connection 114 in the circuit breaker distribution panel) functions as the low-side voltage reference (e.g., earth) for the electronic circuit mechanism of the intelligent circuit breaker 200.

[0038] In some embodiments, the electromechanical AC switch 202 comprises the same or similar thermomagnetic tripping and switching mechanism as the thermomagnetic circuit breaker 100 discussed above in conjunction with Figure 1A, and the electromechanical AC switch 202 includes a thermal switching mechanism (e.g., a bimetallic switch) and an electromagnetic switching mechanism (e.g., a solenoid). The electromechanical AC switch 202 is configured to provide an "open" circuit when the operator manually disables the active path using a manual switch (or actuator lever) or when a fault condition (e.g., a short circuit, an overcurrent, etc.) is detected by the electromechanical AC switch 202.

[0039] The processor 220 works in conjunction with the current sensor 204 and the first and second voltage sensors 206 and 208 to perform functions such as monitoring energy utilization and detecting fault conditions. For example, in some embodiments, the processor 220 is configured to detect the presence of a fault condition in the load 120 (e.g., a short circuit, overcurrent, overvoltage, etc.) or an internal fault condition in the intelligent circuit breaker 200 (via software and / or hardware) and generate a control signal on the control line 202-1 to open the electrical contacts of an electromagnetic component (e.g., a solenoid), thereby disconnecting the line activity 111 from the load activity 121. In other embodiments, the intelligent circuit breaker 200 includes additional sensor circuit mechanisms and / or processing functions to support arc fault circuit interruption and / or ground fault circuit interruption functions using techniques such as those discussed herein.

[0040] The processor 220 may be implemented using one or more processing architectures. For example, the processor 220 may comprise a central processing unit, a microprocessor, a microcontroller, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), a system-on-a-chip (SOC), and other types of processors, as well as parts or combinations of such processors capable of performing processing functions based on software, hardware, firmware, etc. In some embodiments, the solid-state circuit mechanisms of the various components of the intelligent circuit breaker 200 (e.g., 204, 206, 208, 210, 220, and / or 230) may be implemented on a single die as a system-on-a-chip. In some embodiments, the solid-state circuit mechanisms of the various components of the intelligent circuit breaker 200 (e.g., 204, 206, 208, 210, 220, and / or 230) may be implemented on one or more separate dies that are packaged together as a multi-chip module (e.g., system-in-package) providing a high-density heterogeneous integration solution.

[0041] The processor 220 uses an RF transceiver 230 to wirelessly communicate with remote nodes, devices, systems, etc., to support remote monitoring of energy use and detection of fault conditions. The processor reset switch 222 is used to reset the status of the processor 220 under certain conditions, such as when there is a loss of DC power to the processor 220. In some embodiments, the processor reset switch 222 includes a manual result switch that is mechanically coupled to a manual switch lever mechanism (e.g., an actuator lever) of an electromechanical AC switch 202, such that a manual reset of the switch lever following a trip event also triggers the mechanical operation of the processor reset switch 222.

[0042] The current sensor 204 and voltage sensors 206 and 208 are configured to detect and indicate conditions in the intelligent circuit breaker 200 that indicate an open circuit or a damaged or faulty internal component, and to provide timing for the safe opening and closing of the circuit. In particular, the current sensor 204 is configured to detect the magnitude of the current drawn by the load 120 through the active line path of the intelligent circuit breaker 200. The current sensor 204 may be implemented using any suitable type of current sensing circuit, including but not limited to current sensing resistors, current amplifiers, and Hall effect current sensors. The current sensor 204 is coupled to the processor 220 by one or more data acquisition and control lines 204-1.

[0043] The first and second voltage sensors 206 and 208 are configured to monitor voltages at different points along the active line path through the circuit breaker 200. For example, as shown in Figure 2A, the first voltage sensor 206 is coupled to the active line path upstream of the electromechanical AC switch 202 to monitor the AC supply voltage of the AC main line 110, and the second voltage sensor 208 is coupled to the active line path downstream of the electromechanical AC switch 202 to monitor the load voltage on a branch circuit connected to and protected by the intelligent circuit breaker 200. The voltage sensors 206 and 208 are coupled to the processor 220 by one or more data acquisition and control lines 206-1 and 208-1, respectively.

[0044] Voltage sensors 206 and 208 may be implemented using any suitable type of voltage sensing circuit mechanism, including but not limited to zero-crossing detector circuits. The zero-crossing detector is configured to receive an AC waveform as input, compare the input AC waveform to a zero reference voltage (e.g., line neutral voltage), and detect the corresponding positive and negative AC waveform transitions when the AC waveform crosses the zero reference voltage. In some embodiments, the zero-crossing detector circuit mechanism is configured to generate a square wave output that transitions between logic "1" and logic "0" at each zero-cross detection of the AC voltage waveform. In other embodiments, the zero-crossing detector circuit mechanism is configured to generate a timed pulse (about 3us) with an RC adjustable duration.

[0045] The AC-DC converter circuit 210 is configured to provide DC supply power to various circuit mechanisms and elements of the intelligent circuit breaker 200, including current sensors 204, voltage sensors 206 and 208, a processor 220, and an RF transceiver 230. During a fault in which the electromechanical AC switch 202 is open, the AC-DC converter circuit 210 remains powered. In some embodiments, the AC-DC converter circuit 210 has sufficient storage capacity to power the DC subsystem immediately after an external power outage, so that when the external power supply collapses, information about the associated power outage or short circuit can be acquired and stored by the processor 220 and then wirelessly transmitted to a remote node, device, or system using the RF transceiver 230. To allow for the intentional disconnection of the load to prevent damage during out-of-range voltage events, the AC-DC converter circuit 210 may also include sufficient capacitance to power the DC subsystem during a load short-circuit event without being pulled down by the active line and load collapse voltage.

[0046] Figure 2B is a schematic block diagram of an intelligent circuit breaker according to another embodiment of the present disclosure. In particular, Figure 2B schematically illustrates an intelligent circuit breaker 201 connected between an AC main line 110 and a load 120. The intelligent circuit breaker 201 is similar to the intelligent circuit breaker 200 of Figure 2A, except that the intelligent circuit breaker 201 comprises a current sensor and energy metering circuit mechanism 240, a fuse 250, and an internal short-circuit switch 260. The current sensor and energy metering circuit mechanism 240 detects the magnitude of the current drawn by the load 120 through the active line path passing through the circuit breaker 201 and is configured to implement a programmable overcurrent detection system and an intelligent energy metering circuit mechanism. Exemplary embodiments of the current sensor and energy metering circuit 240 are discussed hereafter in conjunction with Figures 9A, 9B, and 9C.

[0047] The fuse 250 is implemented to protect the circuit breaker 201 from internal faults or to provide a simple end-of-life deactivation mechanism in the event of a device failure. In some embodiments, as shown in Figure 2B, an internal short-circuit switch 260 is connected between the AC active line path of the circuit breaker 201 and the line neutral 112, and the internal short-circuit switch 260 is connected to the AC active line path at some point between the fuse 250 and the electromechanical AC switch 202. The internal short-circuit switch 260 responds to a control signal generated by the processor 220 and applied to the short-circuit switch 260 via the switch control line 220-1. In this configuration, the processor 220 can implement an end-of-life deactivation mechanism in the event of a device failure, by outputting a control signal on the control line 220-1 to activate the internal short-circuit switch 260, blow the fuse 250, and deactivate the intelligent circuit breaker 201. In other embodiments, the life-end deactivation mechanism can be implemented, for example, by configuring the processor 220 to generate a control signal that prevents the electromechanical AC switch 202 from being switched closed at any point after a device failure is detected, or to immediately trip (and open) the electromechanical AC switch 202 any number of times after a device failure is detected, for each attempt to close the circuit breaker (via activation of a manual switch).

[0048] In other embodiments, an internal short-circuit switch can be implemented in the intelligent circuit breaker as a mechanism for internally triggering a fault that trips the electromechanical AC switch 202. For example, in the exemplary embodiments of Figures 2A and 2B, an internal short-circuit switch can be connected between the AC active line path on the load side of the electromechanical AC switch 202 and the line neutral 112. The processor 220 may be configured to activate the internal short-circuit switch and generate a switch control signal to create a short-circuit fault condition on the load side of the electromechanical AC switch 202, thereby tripping the electromechanical AC switch 202. In this configuration, the processor 220 can detect the presence of an unsafe condition or an internal circuit breaker fault based on sensor data generated by current and / or voltage sensors 240, 206, and 208, and then generate a control signal to activate the internal short-circuit switch 260, thereby tripping the electromechanical AC switch 202. In addition, an internal short-circuit trigger event can be triggered in response to the processor 220 receiving a remote command to disconnect, or in response to the detection of an unsafe local condition such as overheating, excessive moisture, or device failure.

[0049] Figure 3A is a schematic block diagram of an intelligent circuit breaker according to another embodiment of the present disclosure. In particular, Figure 3A schematically illustrates an intelligent circuit breaker 300 connected between an AC trunk line 110 and a load 120. The intelligent circuit breaker 300 comprises an air gap electromagnetic switch 302, a solid bidirectional switch 304, a switch control circuit mechanism 306 configured to control the operation of the air gap electromagnetic switch 302, a manual switch 307 that allows a user to manually open and close the air gap electromagnetic switch 302, and a switch control circuit mechanism 308 configured to control the operation of the solid bidirectional switch 304. In addition, similar to the exemplary embodiment in Figure 2A, the intelligent circuit breaker 300 in Figure 3A comprises a current sensor 204, a first voltage sensor 206, a second voltage sensor 208, an AC-DC converter circuit mechanism 210, a processor 220, a processor reset switch 222, and an RF transceiver 230 and associated antenna 232, which are configured to perform the same or similar functions as those discussed above. In other embodiments, as described above, an external DC power supply may be implemented to provide DC power to the components of the solid circuit mechanism and the intelligent circuit breaker 300.

[0050] In some embodiments, the air gap electromagnetic switch 302 comprises any preferred type of electromagnetic trip and mechanical switch mechanism configured to physically open and close a set of electrical contacts, creating an air gap between the electrical contacts when the air gap electromagnetic switch 302 is in the open switch position. For example, the air gap electromagnetic switch 302 may comprise a latching solenoid or relay element that automatically opens and closes the electrical contacts of the air gap electromagnetic switch 302 in response to a control signal from the switch control circuit mechanism 306. In some embodiments, the switch control circuit mechanism 306 and the air gap electromagnetic switch 302 are configured such that the electrical contacts of the air gap electromagnetic switch 302 can be automatically opened by the switch control circuit mechanism 306, but not automatically closed by the operation of the switch control circuit mechanism 306. In this example, the electrical contacts of the air gap electromagnetic switch 302 are manually closed by the operation of a manual switch 307.

[0051] In some embodiments, the switch control circuit mechanism 308 determines when to open the air gap electromagnetic switch 302 in response to a control signal from one or more sensors (e.g., current sensor 204, voltage sensors 206 and 208, etc.) in response to a fault condition detected by the sensors. In some embodiments, the switch control circuit mechanism 306 controls the opening of the air gap electromagnetic switch 302 in response to a control signal received from the processor 220 (via control line 306-1) in response to a fault condition such as a short-circuit fault, an overcurrent fault, and other faults detected by the processor 220 as a result of the processor 220 analyzing sensor data acquired from the current sensor 204 and voltage sensors 206 and 208.

[0052] In addition, the air gap electromagnetic switch 302 includes a manual switch 307 that allows a person to manually open and close the electrical contacts of the air gap electromagnetic switch 302, thereby manually switching the air gap electromagnetic switch 302 on and off. The state of the manual switch 307 (activated or deactivated) can be detected by the processor 220 based on an electrical signal present on a sensing line 307-1 connected between the manual switch 307 and the processor 220. The creation of an air gap in the line path between the line activation 111 and the load activation 121 provides complete isolation of the AC trunk line 110 from the load 120 and prevents the flow of current from the line activation 111 to the load 120 (and also prevents the flow of leakage current that may be generated by the solid bidirectional switch 304 when the solid bidirectional switch 304 is in the switched-off state).

[0053] As shown in Figure 3A, the air-gap electromagnetic switch 302 is connected in series with the solid bidirectional switch 304 between the line input terminal and the load output terminal of the intelligent circuit breaker 300. The air-gap electromagnetic switch 302 may be located either on the line side of the solid bidirectional switch 304 or on the load side of the solid bidirectional switch 304 (as shown in Figure 3A). The solid bidirectional switch 304 includes electrically controlled solid switching devices such as a power MOSFET (metal oxide semiconductor field-effect transistor) device and associated bias circuit mechanisms. Exemplary embodiments of the solid bidirectional switch 304 will be discussed in further detail later in conjunction with Figures 6A-6H. The semiconductor MOSFET device may be a silicon-based solid device or a silicon carbide (SiC) or gallium arsenide (GaN) based solid device.

[0054] The solid bidirectional switch 304 is controlled by the switch control circuit mechanism 308 to switch on or switch off in response to a gate control signal generated by the switch control circuit mechanism 308. In some embodiments, the switch control circuit mechanism 308 switches off the solid bidirectional switch 304 in response to fault conditions such as short-circuit faults, overcurrent faults, and other faults detected by the processor 220 as a result of the processor 220 analyzing sensor data acquired from the current sensor 204 and voltage sensors 206 and 208, in response to a control signal received from the processor 220 (via control line 308-1).

[0055] In other embodiments, the switch control circuit mechanism 308 includes a control circuit mechanism that responds to control signals generated by the current sensor 204 (and other sensors, e.g., voltage sensors 206 and 208) in response to the detection of a fault condition and transmitted to the switch control circuit mechanism 308 on control line 204-1. In response to such control signals, the switch control circuit mechanism 308 generates a gating control signal to control the activation and deactivation of the solid bidirectional switch 304. In other embodiments, the switch control circuit mechanism 308 includes a short-circuit detection circuit mechanism configured to detect a load-side short-circuit fault and to automatically deactivate the solid bidirectional switch 304 in response to the detected short-circuit fault. Exemplary embodiments of the switch control circuit mechanism 308 with the short-circuit detection circuit mechanism are discussed in further detail below in conjunction with Figures 7A and 7B. In addition, the switch control circuit mechanism 308 is configured to control the drive voltage of the solid bidirectional switch 304 in order to control and minimize leakage of the solid bidirectional switch 304 when the switch 304 is in the switch-off state.

[0056] It should be understood that the implementation of the solid bidirectional switch 304 enables the intelligent circuit breaker 300 to respond quickly to imminent fault conditions such as overcurrent fault conditions, load-side short-circuit fault conditions, internal fault conditions, and overvoltage conditions by rapidly deactivating the solid bidirectional switch 304. In fact, the response time for deactivating the solid bidirectional switch 304 to isolate a fault condition can be about 1000 times faster than the response time associated with the automatic tripping of an electromechanical AC switch to isolate a fault condition (e.g., in a few milliseconds), because the solid bidirectional switch 304 can transition from the switch-on state to the switch-off state in microseconds or nanoseconds. As a further advantage, the solid bidirectional switch 304 has a more accurate and repeatable time-current characteristic profile compared to conventional electromechanical circuit breakers. This makes it possible to control the current conducted by the solid bidirectional switch 304 more precisely than conventional electromechanical circuit breakers, which have time-current characteristics that vary over their lifespan.

[0057] In some embodiments, the control logic implemented by the processor 220 of the intelligent circuit breaker 300 is configured to issue a switch control signal to the switch control circuit mechanism 306 so that the air gap electromagnetic switch 302 is switched open in response to the solid bidirectional switch 304 being switched off. In some embodiments, the control logic implemented by the processor 220 is configured to issue a switch control signal to the switch control circuit mechanism 306 so that the air gap electromagnetic switch 302 is switched closed before the solid bidirectional switch 304 is switched on. In addition, the processor 220 is configured to monitor and detect a manual switch open event in which the manual switch 307 of the air gap electromagnetic switch 302 is activated to manually open the electrical contacts of the air gap electromagnetic switch 302. In response to the manual switch open event, the processor 220 generates and outputs a control signal to the switch control circuit mechanism 308 to switch the solid bidirectional switch 304 off.

[0058] The switch timing control scheme outlined above prevents or minimizes the generation of an electric arc between the electrical contacts of the air gap electromagnetic switch 302 by ensuring that (i) the air gap electromagnetic switch 302 is switched closed before the solid bidirectional switch 304 is switched on, and (ii) in response to detection of manual operator disconnection of the air gap electromagnetic switch 302, the solid bidirectional switch 304 is automatically switched off, thereby deactivating the solid bidirectional switch 304 before the electrical contacts of the air gap electromagnetic switch 302 are opened. In another embodiment, the switch control scheme is configured to operate the intelligent circuit breaker 300 in a "standby" state, with the solid bidirectional switch 304 in the switched-off state and the air gap electromagnetic switch 304 in the switched-closed state.

[0059] In such a switch control configuration, the electrical contacts of the air-gap electromagnetic switch 302 are configured to support high-energy flow when the switch is closed, but may be designed to move only during low-current flow conditions to prevent or minimize arcing between the electrical contacts. For example, a switch control scheme can be implemented in which the air-gap electromagnetic switch 302 is activated when the magnitude of the current on the active wire path is less than a pre-selected value. Preventing arcing within the air-gap electromagnetic switch 302 allows for miniaturization of the air-gap electromagnetic switch 302.

[0060] The implementation of the air-gap electromagnetic switch 302 provides additional safety features for the intelligent circuit breaker 301. For example, the air-gap electromagnetic switch 302 provides a fail-safe mechanism for fault isolation in the event of a failure in the solid bidirectional switch 304. By analyzing real-time sensor data acquired from various sensors 204, 206, and 208, the processor 220 can be configured to detect a fault condition in the solid bidirectional switch 304, or alternatively, a fault condition of potential overcurrent or short circuit. In such cases, the processor 220 can generate and output a control signal to the switch control circuit mechanism 306 to open the air-gap electromagnetic switch 302.

[0061] In some embodiments, the current sensor 204 includes a sensing resistor connected in series via an active wire path. As will be described in more detail below, the sensing resistor is configured to generate a load voltage or sensing voltage as a result of the load current flowing through the sensing resistor, and the load voltage or sensing voltage is measured and processed by one or more sensing circuits (e.g., current sensor circuit, short-circuit detection circuit, energy metering circuit, etc.) to detect a fault condition and directly control the solid switch without the assistance of a processor. This allows for faster response times by avoiding the uncertainty time of processor or CPU response.

[0062] In addition, the air gap switch 302 provides galvanic isolation between the AC main line 110 and the load 120 when the air gap switch 302 is in the open position. When an air gap is formed, current cannot flow from the AC main line 110 to the load 120. Such galvanic isolation prevents unwanted current flow due to leakage current from the solid bidirectional switch 304 when the solid bidirectional switch 304 is in the off position.

[0063] As with other embodiments discussed herein, the processor 220 may be implemented using one or more processing architectures (e.g., CPU, microprocessor, microcontroller, ASIC, etc.). In some embodiments, the solid-state circuitry of various components of the intelligent circuit breaker 300 (e.g., 204, 206, 208, 210, 220, 230, 306, and / or 308) may be implemented on a single die as a system-on-chip. In some embodiments, the solid-state circuitry of various components of the intelligent circuit breaker 230 (e.g., 204, 206, 208, 210, 220, 230, 306, and / or 308) may be implemented on one or more separate dies that are integrated and packaged as a multi-chip module (e.g., system-in-package) providing a high-density heterogeneous integration solution.

[0064] Figure 3B is a schematic block diagram of an intelligent circuit breaker according to another embodiment of the present disclosure. In particular, Figure 3B schematically illustrates an intelligent circuit breaker 301 connected between an AC main line 110 and a load 120. The intelligent circuit breaker 301 is composed of a combination of the components of intelligent circuit breakers 201 and 300 (Figures 2B and 3A), and therefore a detailed description of the various components and associated functions will not be repeated. The intelligent circuit breaker 301 includes a snubber 310 connected between the active line path and the neutral line path to protect internal components from damage resulting from energy kickback from an inductive load. The snubber 310 may be located on the line side and / or load side of switches 302 and 304. The snubber located on the line side of switches 302 and 304 is able to protect the internal circuit only when switches 302 and 304 are in the open and switched-on states, respectively. However, as shown in Figure 3B, the snubber 310 located on the load side of switches 302 and 304 helps to eliminate the possibility of arcing occurring within the air-gap electromagnetic switch 302 during an inductive load kickback event. It should be understood that the snubber may be implemented in the intelligent circuit breaker embodiments shown in Figures 2A, 2B, and 3A.

[0065] In other embodiments, an external DC power supply may be implemented to provide DC power to the solid-state circuit mechanisms and components of the intelligent circuit breakers 200, 201, 300, and 301 in Figures 2A, 2B, 3A, and 3B (as well as other embodiments of the circuit breakers discussed hereafter). For example, a distribution board equipped with an intelligent circuit breaker may have a DC battery and a DC power bus configured to distribute DC power to the intelligent circuit breaker within the distribution board. In this example, the DC battery may be coupled to an AC-DC converter configured to convert the AC power of the AC trunk 110 into DC power to charge the DC battery.

[0066] The exemplary embodiments in Figures 2A, 2B, 3A, and 3B illustrate a processor reset switch 222 for resetting the processor 220, but it should be understood that the processor reset switch 222 is an optional feature and other mechanisms may be implemented to bring about a processor reset. In some embodiments, the processor 220 includes an internal reset circuit configured to reset the processor 220 under certain circumstances, such as when there is a loss of DC power to the processor 220 or when there is an internal fault condition in the processor 200. In some embodiments, the processor is configured to generate a "CPU_OK" signal output on control lines 306-1 and 308-1 to switch control circuit mechanisms 306 and 308. The CPU_OK signal provides an indication of whether the processor 220 and associated software are functioning correctly. When the CPU_OK signal indicates that the processor 200 and / or associated software are not functioning correctly, the switch control circuit mechanisms 306 and 308 automatically switch off the solid bidirectional switch 304 and then open the air gap electromagnetic switch 302 (creating an air gap for galvanic isolation). This provides a hardware fail-safe mechanism that ensures the intelligent circuit breaker does not continue to service the load when the processor 220 or a subsystem of the processor 220 is not functioning correctly.

[0067] For example, in some embodiments, the internal reset circuit of the processor 220 includes a watchdog timer and preferred architectural software configured to service the watchdog timer (e.g., reset the watchdog timer) when it is determined that all subsystems within the firmware of the processor 220 are functioning correctly. In some embodiments, the watchdog timer includes a resistor / capacitor network implementing a unique clock. When the watchdog timer is enabled, the timer counts from an initial value to a final count value. If the watchdog timer is not initialized to the initial count value before reaching the final count value, the processor 220 is reset. The processor 220 is reset due to a loss of AC (and therefore DC) power or an internal fault condition that causes the watchdog timer to reach the final count value, in which case a control signal is generated that causes the processor 220 to reset.

[0068] More specifically, in some embodiments, the internal reset circuit of the processor 220 operates as follows: When DC power is first applied to the processor 220, the processor executes a self-check and initialization routine. If the self-check and initialization routine completes successfully, the processor 220 outputs a logic "1" CPU_OK control signal indicating that the processor 220 and the embedded software are functioning correctly. The logic "1" CPU_OK control signal is input to the switch control circuits 306 and 308 to indicate that switches 302 and 304 can be safely activated to serve the load 120. On the other hand, a logic "0" CPU_OK control signal indicates to the switch control circuits 306 and 308 that switches 320 and 304 should be deactivated or not activated (if they are deactivated when CPU_OK is asserted to the logic "0" level). If the processor 220 is reset (for example, a startup reset or a forced reset due to a detected failure of the internal processor), the control signal CPU_OK is held at a logical "0" level until the processor 220 is reset and determined to be fully functional and operating as expected.

[0069] As part of the normal operation of the processor 220, the processor 220's software continuously monitors several points within the firmware to ensure that all subsystems of the processor 220 are functioning correctly as expected. If all monitored points are determined to be functioning correctly, the watchdog timer is serviced (e.g., the counter is reset to its initial value). If any one of the monitored points is determined to be non-functional or not functioning correctly, the watchdog timer is not serviced, and it eventually reaches its maximum count value. In some embodiments, the watchdog timer has a count sequence that defines a time of approximately one second. If the watchdog timer is not serviced by the processor 220's reset control software, the watchdog timer "fires" after approximately one second, resetting the processor 220, which causes the CPU_OK control signal to transition to a logical "0" level. The transition of the CPU_OK signal from logic "1" to logic "0" triggers the switch control circuit mechanisms 306 and 308, which switch off the solid bidirectional switch 304 and open the air gap electromagnetic switch 302.

[0070] Furthermore, in some embodiments, as part of the reset sequence of the processor 220, there is a hardware indicator (designed for the processor 220) that indicates whether the processor reset was caused by a watchdog timer reset or a power-on reset. If the processor reset is caused by a power-on reset, the firmware of the processor 220 proceeds with the normal boot initialization process. On the other hand, if the processor reset is triggered by the watchdog timer, the firmware of the processor 220 proceeds with a “recovery from watchdog timer reset” initialization path instead of the normal boot initialization. To the user, the watchdog timer reset appears as a normal overcurrent “trip” condition (with communication to a cloud or remote computing device indicating that the processor reset was caused by an internal watchdog timer reset).

[0071] This reset sequence allows the firmware to determine whether the number of consecutive watchdog timer resets exceeds a predefined threshold (e.g., 5). If it is determined that the number of consecutive watchdog timer resets exceeds the predefined threshold, an internal fault or internal fault condition is declared, and the intelligent circuit breaker is disabled until it is serviced and the counter is reset. In this case, the processor firmware declares an internal fault, reports the error via cloud notifications, status LEDs, and other available user interfaces, and does not allow the intelligent circuit breaker to be manually switched on until it is serviced. On the other hand, if the number of consecutive watchdog timer resets does not exceed the predetermined threshold, the intelligent circuit breaker can be manually reset after the watchdog timer reset.

[0072] In other words, the watchdog timer reset event appears by design as a "normal overcurrent trip" and is the result of processor firmware executed immediately after the reset. The processor firmware determines whether the processor reset was caused by the watchdog timer, and if so, recovery is performed by emulating the "trip" event, with communication to the cloud indicating the watchdog timer reset event, and if provisioned in this manner, normal operation can continue once the air gap switch 302 is automatically switched closed, either manually or via a control signal. If the processor 220 would no longer function if the watchdog timer fires (or power is (re)applied), the unit is completely non-functional, and AC to the load is guaranteed to be off by design. In the rare case where the processor 220 would no longer function immediately after a watchdog timer reset, communication to the cloud is not performed because communication to the cloud is part of the "recovery" path during initialization.

[0073] The exemplary embodiments of the intelligent circuit breaker shown in Figures 2A, 2B, 3A, and 3B offer several advantages over conventional circuit breaker designs. For example, the implementation of voltage and current sensors, a processor, and a wireless communication subsystem provides the intelligent circuit breaker with the ability to sense the operating status and load of the circuit breakers and to wirelessly communicate which circuit breaker has tripped, making identification within the circuit breaker panel much easier. This can be extended by adding LED signals to the front panel controlled by the processor. This feature is further enhanced by adding an AC-DC converter circuit that remains powered during fault events.

[0074] Furthermore, intelligent circuit breakers can save time in life-safety applications such as when circuits in a hospital are overloaded or nearly overloaded, and in similar applications such as military command and control facilities. Maintenance technicians or electricians in such environments can be wirelessly notified of imminent or existing faults with information to guide them to the problematic load without requiring on-site affected personnel to contact maintenance support. The speed at which the load is analyzed, identified, and the circuit breaker is re-energized or prevented from opening can be critical to the normal treatment of patients or the continuation of critical job functions. In some embodiments, wireless communication with the intelligent circuit breaker allows the technician or electrician to remotely re-energize the load using predetermined commands for remotely controlling the intelligent circuit breaker.

[0075] As a third example, the solid-state switch technology implemented in the intelligent circuit breaker in Figures 3A and 3B can disconnect faults approximately 1000 times faster than the electromechanical equivalent in Figure 1A, and with added reliability due to the arc-free non-mobility of solid-state electronic equipment. This additional speed further reduces the possibility of damage to circuits, electrical devices, loads, fires, and personal injury. In some embodiments, the solid-state switch opens in less than one cycle during the collapse of the AC power supply that occurs during a short-circuit current in the load.

[0076] Figure 4A is a schematic block diagram of an AC-DC converter circuit 400 that may be implemented in an intelligent circuit breaker according to one embodiment of the present disclosure. The AC-DC converter circuit 400 has an architecture that does not require a rectifier to generate a DC voltage. The AC-DC converter circuit 400 comprises an inrush protection circuit 410, a sampling circuit 420, a switch driver circuit 430, a control switch and clamp circuit 440, a power storage circuit 450, a voltage regulator circuit 460, and a galvanic isolation circuit 470. The AC-DC converter circuit 400 generates a DC supply voltage that is applied to the load circuit mechanism 402.

[0077] The inrush protection circuit 410 is configured to limit the magnitude of the input current to the AC-DC converter circuit 400. The sampling circuit 420 is configured to sample the AC supply voltage waveform of the AC trunk 110. The sampling circuit 420 outputs the sampled voltage to the switch driver circuit 430. The switch driver circuit 430 is configured to apply a control voltage to the control switch of the control switch and clamp circuit 440. The control switch and clamp circuit 440 is configured to supply power to the energy storage circuit 450 in response to the control voltage applied by the switch driver circuit 430. The energy storage circuit 450 includes a voltage storage element (e.g., a capacitor) configured to store the DC voltage applied to the voltage regulator circuit 460. The voltage regulator circuit 460 is configured to generate a stabilized DC supply voltage to the load circuit mechanism 402.

[0078] In some embodiments, the switch driver circuit 430 receives a feedback voltage 480 from the energy storage circuit 450 and generates a control voltage applied to the control switch and clamp circuit 440, at least partially based on the feedback voltage 480. In some embodiments, the feedback voltage 480 can be eliminated, and the AC-DC converter circuit 400 acts as a feedforward converter, with the energy storage elements of the energy storage circuit 450 controlled by the forward elements 420, 430, and 440.

[0079] In some embodiments, the AC-DC converter circuit mechanism 400 implements a feedback control circuit 490 from the load circuit mechanism 402 to the switch driver circuit 430 to support both feedforward control and feedback control. In some embodiments, the balance between feedforward control and feedback control is determined by the feedback voltage 480 and the selection of components within the sampling circuit mechanism 420. In some embodiments, the balance between feedforward control and feedback control is configured according to the resistor element in the sampling circuit mechanism 420 and the feedback voltage 480. In other embodiments, a variable element is utilized to allow adjustment of feedforward control and feedback control. In such embodiments, the feedback circuit mechanism 490 will have galvanic isolation between the switch driver circuit 430 and the load circuit mechanism 402.

[0080] Figure 4B is a schematic circuit diagram of the AC-DC converter circuit of Figure 4A according to one embodiment of the present disclosure. In the exemplary embodiment of Figure 4B, the inrush protection circuit mechanism 410 comprises a first input resistor 411 connected to the line activation 111 of the AC trunk 110 and a second input resistor 412 connected to the line neutral 112 of the AC trunk 110. In other embodiments, for high-power and high-efficiency applications, the inrush protection circuit mechanism 410 comprises a switch element configured to allow current to flow through resistors 411 and 412 at startup and then bypass resistors 411 and 412 once steady-state operation is reached. In other embodiments, the inrush protection circuit mechanism 410 comprises first and second inductor elements instead of the first and second resistors 411 and 412.

[0081] The sampling circuit mechanism 420 comprises several resistors 421, 422, 423, and 424 connected to various nodes N1, N2, N3, and N4 as shown. Resistors 421, 422, and 423 form a voltage divider network for sampling the input AC waveform, and the voltage divider network comprises a feedback node N2 and an output node N3. Resistor 424 is connected between the feedback node N2 and the output node N4 of the energy storage circuit mechanism 450 to provide a feedback voltage from the energy storage capacitor 452. The switch driver circuit mechanism 430 comprises a resistor 431 and a switch element 432 connected between nodes N1 and N5. The control switch and clamp circuit mechanism 440 comprises a control switch element 441, a resistor 442, and a Zener diode 443. The energy storage circuit mechanism 450 comprises a diode 451 and an energy storage capacitor 452. The voltage regulator circuit mechanism 460 includes a switching element 461, a resistor 462, a Zener diode 463, and a capacitor 464.

[0082] In some embodiments, the switch elements 432, 441, and 461 comprise an n-type enhancement MOSFET device having a gate terminal G, a drain terminal D, and a source terminal S, as shown in Figure 4B. In other embodiments, the switch elements 432, 441, and 461 may be implemented using bipolar transistors or micro-electromechanical switches. As shown in Figure 4B, the switch element 443 comprises a gate terminal G connected to the output node N3 of the voltage divider network of the sampling circuit mechanism 420, a drain terminal D connected to the output node N5 of the switch driver circuit mechanism 430, and a source terminal S connected to the output node N3 of the inrush protection circuit mechanism 410. The drain terminal D of the switch element 432 is coupled to the output node N1 of the inrush protection circuit mechanism 410 via a resistor 431.

[0083] The control switch 441 includes a drain terminal D connected to the output node N1 of the inrush circuit mechanism 410, a gate terminal G connected to the output node N5 of the switch driver circuit mechanism, and a source terminal S connected to the input of the energy storage circuit 450 (i.e., the anode of diode 451). The Zener diode 443 is connected between the gate terminal G and the source terminal S of the control switch 441, with the cathode of the Zener diode 443 connected to the gate terminal G of the control switch 441 and the anode of the Zener diode 443 connected to the source terminal S of the control switch 441.

[0084] The switch element 461 of the voltage regulator circuit mechanism 460 includes a drain terminal D connected to the output node N4 of the energy storage circuit mechanism 450, a gate terminal G connected to node N7 between the resistor 462 and the Zener diode 463, and a source terminal S connected to the output node N8 of the voltage regulator circuit mechanism 460. The capacitor 464 is connected between the output node N8 of the voltage regulator circuit mechanism 460 and the output node N6 of the inrush protection circuit mechanism 410.

[0085] The resistor 424 (or sensing resistor) is connected between the output node N4 of the energy storage circuit 450 and the resistor 424, providing a feedback voltage that is applied to the feedback node N2 of the sampling circuit mechanism 420 via the resistor 424. The feedback path provided by the connection of the resistor 424 between nodes N4 and N2 provides an exemplary embodiment of the feedback voltage 480 as shown in Figure 4A, which partially utilizes the charge of the energy storage capacitor 452 to generate a control voltage at the output node N3 of the sampling circuit mechanism 420 connected to the gate terminal G of the switch element 432 of the switch driver circuit mechanism 430.

[0086] The switch element 432 is driven by a gate control voltage generated at the output node N3 of the voltage divider network of the sampling circuit mechanism 420. The gating of the switch element 432 controls the operation of the control switch 441 of the switch driver circuit mechanism 430. The resistance values ​​of resistors 421, 422, 423, and 424 are selected so that the voltage on node N3 of the voltage divider network applied to the gate terminal G of the switch element 432 of the switch driver circuit mechanism 430 turns the switch element 432 on and off, thereby synchronously turning the control switch element 441 on and off. This drives the control switch element 441 to output a pre-selected timed output pulse to charge the energy storage capacitor 452.

[0087] The peak output current of the control switch 441 is clamped to a pre-selected value based on the pre-selected value of the Zener voltage (i.e., reverse breakdown voltage) of the Zener diode 443, and the maximum gate-source voltage (V) GS The current is limited by the Zener voltage of the Zener diode 443. The pulse output from the control switch 441 turns on the diode 451, supplying charge to node N4 and charging the energy storage capacitor 452. The feedback provided by the resistor 424 connected between the output node N4 of the energy storage circuit mechanism 450 and the feedback node N2 of the sampling circuit mechanism 420 drives the switch driver circuit 430 to maintain the energy storage capacitor 452 at a constant charge.

[0088] Switch elements 432 and control switch 441 are activated to either open or closed in synchronization with the AC voltage input. The AC-DC converter circuit 400 provides a pulse-modulated low-voltage output at the frequency of the incoming AC source. Switches 432 and 441 are activated to either open or closed at voltages near the threshold voltage of switches 432 and 441 at the zero crossing of the AC source. The output node N4 of the energy storage circuit mechanism 450 is applied to the input of the voltage regulator circuit mechanism 460 and then to the load circuit 402. Capacitor 464 provides energy storage capacitance for buffering, thereby smoothing the output from the AC-DC converter 400 to the load circuit mechanism 402.

[0089] In summary, the exemplary AC-DC converter circuit 400 shown in Figures 4A and 4B comprises an inrush protection circuit 410, a voltage sampling circuit 420, a switch driver circuit 430, a control switch and clamping circuit 440, a power storage circuit 450, and a voltage regulator circuit 460. The selection of components in the voltage sampling circuit 420 determines the timing of the switch driver 430. The selection of components in the control switch and clamping circuit 440 determines the peak voltage and current of the output pulse. The power output is controlled by the selection of both the peak current and the pulse timing. The pulse timing is selected using feedback from the power storage element 452 via the voltage sampling circuit 420. The AC-DC converter circuit 400 operates in synchronization with the AC voltage waveform of the AC trunk line 110.

[0090] In other embodiments, the AC-DC converter circuit mechanisms shown in Figures 2A, 2B, 3A, and 3B (and other embodiments of intelligent circuit breakers as described hereafter) may be implemented using the same or similar DC power conversion techniques disclosed in the following concurrently pending applications: (1) U.S. Patent Application No. 16 / 092,263, entitled High-Efficiency AC to DC Converter and Methods, filed on 9 October 2018 (published US2019 / 0165691); and (2) U.S. Patent Application No. 16 / 340,672, entitled High-Efficiency AC Direct to DC Extraction Converter and Methods, filed on 9 April 2019 (published US2019 / 0238060), all of which are fully incorporated herein by reference.

[0091] Figure 5 is a schematic schematic of an AC-DC converter circuit 500 that may be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. In particular, Figure 5 schematically illustrates an exemplary embodiment of a sample-and-hold AC-DC converter circuit 500, which can be implemented using techniques such as those disclosed in U.S. Patent Application No. 16 / 029,546, filed July 7, 2018, entitled "Method and Apparatus for Signal Extraction with Sample and Hold and Release," which is fully incorporated herein by reference. The AC-DC converter circuit 500 is configured to generate a DC supply voltage from an AC voltage waveform of an AC trunk 110. The AC-DC converter circuit 500 comprises first and second resistors 501 and 502, a first switch 510, a second switch 512, a controller 520, a diode 530, a storage capacitor 540, a voltage regulator 550, and an output capacitor 560. In the exemplary embodiment shown in Figure 5, the first and second switches 510 and 512 each comprise an N-type enhancement MOSFET having a gate terminal G, a drain terminal D, and a source terminal S, as shown.

[0092] Resistors 501 and 502 form a voltage divider circuit having an output node N1 that drives the gate terminal G of the first switch 510. The source terminal S of the first switch 510 is connected to the neutral / ground 114, and the drain terminal D of the first switch 510 is connected to the gate terminal G of the second switch 512 and to the controller 520. The drain terminal D of the second switch 512 is connected to the line activation 111, and the source terminal S of the second switch 512 is connected to the input of the controller 520. The controller 520 has an output connected to the anode of the diode 530. The diode 530 and the energy storage capacitor 540 form an energy storage circuit similar to that shown in Figure 4B. In addition, the voltage regulator 550 and the output capacitor 560 form a voltage regulator circuit similar to that shown in Figure 4B.

[0093] Here, exemplary embodiments of the solid bidirectional switch 304, such as those shown in Figures 3A and 3B (and implemented in other exemplary embodiments discussed hereafter), will be discussed in more detail in conjunction with Figures 6A to 6H. For example, Figure 6A is a schematic circuit diagram of a solid bidirectional switch 600-1 that may be implemented in an intelligent circuit breaker according to an embodiment of the present disclosure. In particular, Figure 6A illustrates an exemplary embodiment of the solid bidirectional switch 304 shown in Figures 3A and 3B for controlling AC power supplied from an AC trunk 110 to a load 120. The solid bidirectional switch 600-1 is configured to allow bidirectional flow of current between the AC trunk 110 and the load 120 (i.e., conduct positive or negative current) when the solid bidirectional switch 600-1 is switched on, and to block the flow of positive or negative current between the AC trunk 110 and the load 120 when the solid bidirectional switch 600-1 is switched off.

[0094] The solid bidirectional switch 600-1 comprises a first MOSFET switch 601 and a second MOSFET switch 602 connected back-to-back in series along an active line path between a line active 111 and a load active 121. In some embodiments, the first and second MOSFET switches 601 and 602 comprise power MOSFET devices, and in particular N-type enhancement MOSFET devices, having a gate terminal (G), a drain terminal (D), and a source terminal (S) as shown. In the exemplary embodiment of Figure 6A (and other embodiments discussed herein), the solid bidirectional switch 600-1 is implemented using two N-channel MOSFET switches 601 and 602 having a commonly connected source terminal.

[0095] The first and second MOSFET switches 601 and 602 each include internal body diodes 601-1 and 602-1, respectively, representing the PN junction between the P-type substrate body and the N-doped drain region of the MOSFET device. The body diodes 601-1 and 602-1 are internal elements of the MOSFET switches 601 and 602 (i.e., not discrete elements) and are therefore shown by dashed connections. Note that the internal body-source diodes of the MOSFET switches 601 and 602 are not shown because they are short-circuited by the connection between the source region and the substrate body (for example, the junction between the N+ source and the P body is short-circuited via source metallization).

[0096] The solid bidirectional switch 600-1 further comprises first and second resistors 603 and 604, first and second rectifier diodes 605 and 606, a Zener diode 608, and a single-pole single-throw (SPST) switch element 607. The first resistor 603 and the first rectifier diode 605 are connected in series between the drain terminal (D) and gate terminal (G) of the first MOSFET switch 601. The second resistor 604 and the second rectifier diode 606 are connected in series between the drain terminal (D) and gate terminal (G) of the second MOSFET switch 602. The switch 607 and the Zener diode 608 are connected in parallel between the commonly connected source terminal (S) and gate terminal (G) of the first and second MOSFET switches 601 and 602, with the anode of the Zener diode 608 connected to the source terminal and the cathode of the Zener diode 608 connected to the gate terminal.

[0097] Zener diode 608 controls the threshold voltage V of power MOSFET switches 601 and 602. T A reverse breakdown voltage ("Zener voltage") greater than V Z The system includes (referred to as ). While the solid bidirectional switch 600-1 is switched on, the Zener diode 608 is "reverse" through a first bias branch circuit comprising a first resistor 603 and a first rectifier diode 605 connected in series, or through a second bias branch circuit comprising a second resistor 604 and a second rectifier diode 606 connected in series. The first and second rectifier diodes 605 and 606 are coupled to the drain terminals D of the power MOSFET switches 601 and 602, respectively, and are protected by first and second resistors 603 and 604, respectively, which function to limit the amount of current flowing through the first and second rectifier diodes 605 and 606.

[0098] The solid bidirectional switch 600-1 generally operates as follows: As shown in Figure 6A, when switch 607 is in the "open" state, the first bias branches (603-605) and the second bias branches (604-606) provide a "reverse bias" to the Zener diode 608 when either drain terminal D exceeds the Zener voltage, thereby turning on power MOSFET switches 601 and 602. When switch 607 is in the "closed" state, switch 607 diverts the bias current from the first and second bias branches (603-605) and 604-608 to the source S terminals of power MOSFET switches 601 and 602, turning MOSFET switches 601 and 602 "off". In this circuit configuration, the "turn-on" time constant is determined by the values ​​of current-limiting resistors 603 and 604 and the gate-source capacitance of power MOSFET switches 601 and 602, while the "turn-off" time constant is determined by the internal capacitance of MOSFET switches 601 and 602 and the on-resistance of switch 607. The "turn-on" and "turn-off" time constants can be designed to be much shorter than the period of the AC trunk line 110, thereby allowing the solid bidirectional switch 600-1 to operate in both on-off mode and phase-controlled mode. However, in practice, the Zener diode 608 may never reach its Zener voltage, and the gate-source voltage of MOSFET switches 601 and 602 may not reach the threshold voltage V T It rarely exceeds this value. Therefore, neither MOSFET switch 601 nor 602 may be fully "on," resulting in excessive power dissipation within the unit and a reduction in the current supplied to load 120.

[0099] FIG. 6B illustrates the active elements of the solid state bidirectional switch 600-1 of FIG. 6A during the positive half cycle of the supply voltage waveform of the AC mains 110 applied to the solid state bidirectional switch 600-1. When the switch 607 is in an open state enabling the first MOSFET switch 601 to turn on, as the supply voltage increases from zero volts, the gate voltage of the first MOSFET switch 601 starts to follow the positive shift of the supply voltage waveform of the AC mains 110. When the gate voltage reaches the threshold voltage of the first MOSFET switch 601, current starts to flow through the load 120, and the body diode 602-1 of the second MOSFET switch 602 is forward biased. The source voltage of the first MOSFET switch 601 "follows" the increasing gate voltage, but is delayed by an amount corresponding to the additional bias added to the threshold voltage value to account for the current supplied to the load 120. This state is maintained until the voltage waveform of the AC mains 110 becomes negative. Therefore, the drain-source voltage of the first MOSFET switch 601 does not fall below the threshold voltage regardless of the drain-source resistance of the first MOSFET switch 601, and the power dissipated in the first MOSFET switch 601 is (I D ×V T ), where I D is the drain current. When the gate voltage is boosted sufficiently beyond the threshold voltage, the dissipated power is given by (I D 2 ×r ds ), where r ds is the "on" resistance of the first MOSFET switch 601, and the value of (I D 2 ×r ds ) can be significantly smaller than the value of (I D ×V T ).

[0100] On the other hand, during the negative half-cycle of the supply voltage waveform of the AC trunk 110 applied to the solid bidirectional switch 600-1, the active components of the solid bidirectional switch 600-1 include the body diode 601-1 of the first MOSFET switch 601, the Zener diode 608, the second MOSFET switch 602, and the second branch elements 604 and 606. The gate voltage of the second MOSFET switch 602 starts at 0V and the source voltage is a negative threshold voltage (-V). T When it drops to ), it begins to follow the negative source voltage, and current begins to flow through the load 120, and the body diode 601-1 of the first MOSFET switch 601 is forward biased. The drain voltage of the second MOSFET switch 602 is effectively clamped to the gate voltage, and the drain-source voltage V continues until the supply voltage waveform of the AC main line 110 becomes positive. DS is -V T It remains the same. As a result, the V of the second MOSFET switch 602 DS Regardless of the drain-source resistance of the second MOSFET switch 602, the voltage never falls below the threshold voltage except around the zero crossing of the AC main line 110 power supply voltage waveform, and the dissipated power is (I) in a negative half-cycle. D ×V T )

[0101] Figure 6C is a schematic circuit diagram of a solid bidirectional switch 600-2, which may be implemented in an intelligent circuit breaker, according to another embodiment of the present disclosure. The solid bidirectional switch 600-2 has a similar circuit configuration to the solid bidirectional switch 600-1 in Figure 6A, except that the solid bidirectional switch 600-2 implements a single-pole double-throw (SPDT) switch element 612 instead of an SPST switch 607 and further comprises a capacitor 613 connected in parallel with a Zener diode 608. The bipolar switch 612 is controlled by a switch control circuit 610 coupled to the bipolar switch 612 by a control line 610-1. In some embodiments, the switch control circuit 610 comprises an embodiment of the switch control circuit mechanism 308 shown in Figures 3A and 3B. The switch control circuit 610 operates the bipolar switch 612 to selectively connect the gate G terminals of the first and second MOSFET switches 601 and 602 to (i) the source S terminals ("Position 1") of the first and second MOSFET switches 601 and 602, or (ii) a bias circuit mechanism comprising the first and second resistors 603 and 604, the first and second rectifier diodes 605 and 606, and the capacitor 613 ("Position 2").

[0102] When switch 612 is set to position 1, the first and second MOSFET switches 601 and 602 are kept in the "off" state. The switch control circuit 610 sets the supply voltage waveform of the AC trunk 110 to a pre-established trigger level V TRIG The switch 612 is configured to remain in position 1 until it exceeds V, and as soon as it exceeds V, it is set to position 2. In this example, during a positive half-cycle of the AC main line 110, the switch control circuit 610 operates the switch 612 to set the AC supply voltage waveform to V TRIG The first and second MOSFET switches 601 and 602 are kept in the "off" state until the voltage reaches V. The bias circuit mechanisms 603, 605, and 613 are set to V. TRIG It enables charging.

[0103] When switch 612 is set to position 2, a bias voltage V is applied to the gate terminal of the first MOSFET switch 601. TRIG A voltage is applied, thereby changing the bias voltage value to the threshold voltage V T It can be much larger than that. The source terminal of the first MOSFET switch 601 is V TRIG -V T Charging to the switch is initiated, and a portion of this voltage step is coupled to the gate terminal of the first MOSFET switch 601 via capacitor 613. This causes the gate bias to V TRIG The voltage increases significantly beyond this value, causing the gate bias to exceed the voltage value of the AC source 601. Therefore, the first MOSFET switch 601 has a drain-source voltage of approximately zero, while the gate-source voltage is V TRIG It reaches a state greater than this. In this state, the first MOSFET switch 601 has its minimum channel resistance R DS The following characteristics are observed, and the maximum voltage appears at load 120.

[0104] Figure 6D is a schematic circuit diagram of a solid bidirectional switch 600-3 that may be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. The solid bidirectional switch 600-3 has a circuit configuration similar to the solid bidirectional switch 600-2 in Figure 6C, and the bipolar switch 612 is implemented using first and second control switches 621 and 622 controlled by a switch control circuit 620. The switch control circuit 620 comprises a first control line 620-1 coupled to the first control switch 621 and a second control line 620-2 coupled to the second control switch 622. In some embodiments, the first and second control switches 621 and 622 comprise phototransistors (e.g., optical bipolar junction transistors).

[0105] The switch control circuit 620 monitors the voltage level of the supply voltage waveform on the line activation path 111. The trigger level V is determined when the voltage level is a predetermined trigger level. TRIGWhile the voltage level remains below a predetermined trigger level V, the switch control circuit 620 outputs an optical control signal on control line 620-1 to drive the first control switch 621 (i.e., keep switch 621 in the "on" state), while the second control switch 622 remains in the off state. Meanwhile, the trigger level V is a predetermined trigger level when the voltage level is less than a predetermined trigger level. TRIG When the threshold is exceeded, the switch control circuit 620 outputs an optical control signal on control line 620-2 to drive the second control switch 622 (i.e., keep the second control switch 622 in the "on" state), while the first control switch 621 is kept in the "off" state. In some embodiments, the switch control circuit 620 is configured to provide a "break before make" switching characteristic, where the optical drive control signal outputs 620-1 and 620-2 do not overlap, thereby avoiding premature discharge of the capacitor 613.

[0106] Figure 6E is a schematic circuit diagram of a solid bidirectional switch 600-4 that may be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. The solid bidirectional switch 600-4 has a similar circuit configuration to the solid bidirectional switch 600-1 in Figure 6A, except that the solid bidirectional switch 600-4 includes a capacitor 613 connected in parallel with a Zener diode 608, and a second bias branch comprising a second resistor 604 and a second rectifier diode 606 is connected to the line nerve 112 of the AC trunk 110, in contrast to the second MOSFET switch 602, which is connected to the drain terminal D.

[0107] The configuration of the solid bidirectional switch 600-4 avoids the clamping action that occurs due to the configuration in Figure 6A, and the source terminal S of the second MOSFET switch 602 is -V Z When the voltage drops to V, the Zener diode 608 has a Zener voltage of V Z This makes it possible to reach a certain value. As a result, the gate-source voltage of the second MOSFET switch 602 is relatively small. T V can become significantly larger than Z As a result, the drain-source resistance value (RDS This exhibits a low R value, reducing power dissipation. Furthermore, the boosted gate-source bias is stored in the internal gate-source capacitance of MOSFET switches 601 and 602 and capacitor 613 and maintained during the subsequent positive half-cycle of the AC trunk 110 supply voltage waveform. Thus, MOSFET switches 601 and 602 maintain a minimum R value until switch 607 is closed. DS The structure remains the same.

[0108] The first resistor 603 and the first rectifier diode 605 (bias branch element) are maintained to improve the initial turn-on characteristics during the positive half-cycle, and an additional capacitor 613 in parallel with the internal gate-source capacitance of MOSFET switches 601 and 602 allows for more robust memory of the boosted gate-source bias voltage. When the solid bidirectional switch 600-4 is used in phase control mode, switch 607 is closed for a predetermined period during each cycle of the supply voltage waveform of the AC trunk 110. Since capacitor 613 discharges through switch 607 while switch 607 is closed, the gate-source bias required to turn on MOSFET switches 601 and 602 must be re-established during each cycle. As a result, since the boost provided during the negative half-cycle is reset when switch 607 is closed, the first MOSFET switch 601 operates in suboptimal mode when switch 607 is opened during the positive half-cycle of the voltage waveform of the AC trunk 110.

[0109] Figure 6F is a schematic circuit diagram of a solid bidirectional switch 600-5, which may be implemented in an intelligent circuit breaker, according to another embodiment of the present disclosure. The solid bidirectional switch 600-5 has a similar circuit configuration to the solid bidirectional switch 600-4 in Figure 6E, except that the solid bidirectional switch 600-5 implements an SPDT switch 632 instead of an SPST switch 607, and the gate terminals of the first and second MOSFET switches 601 and 602 are directly connected to the inputs of the SPDT switch 632. The SPDT switch 632 is controlled by a switch control circuit 630 which is coupled to the SPDT switch 632 by control line 630-1. In some embodiments, the switch control circuit 630 comprises an embodiment of the switch control circuit mechanism 308 shown in Figures 3A and 3B. The switch control circuit 630 operates the SPDT switch 632 to selectively connect the gate terminals of MOSFET switches 601 and 602 to either (i) the commonly connected source terminal S of MOSFET switches 601 and 602 ("Position 1"), or (ii) resistors 603 and 604, rectifier diodes 605 and 606, and capacitor 613 ("Position 2").

[0110] More specifically, in this circuit configuration, activating switch 632 to position 1 disconnects the gate terminals of MOSFET switches 601 and 602 from the Zener diode bias circuit, and the V of the first and second MOSFET switches 601 and 602 GSBy short-circuiting, MOSFET switches 601 and 602 are turned "off". This allows capacitor 613 to be charged to the Zener voltage of Zener diode 608 until capacitor 613 is discharged through the external circuit mechanism or switch 632 is set to position 2, resulting in the stored Zener voltage being reapplied to the gate terminal, and subsequently, during the negative half-cycle, the gate-source bias voltage is refreshed. In some embodiments, once charged, capacitor 613 will not be completely discharged, regardless of the phase or position of switch 632, as long as the values ​​of resistors 603 and 604 and capacitor 613 are appropriately selected, until the AC power is removed.

[0111] Figure 6G is a schematic circuit diagram of a solid bidirectional switch 600-6 that may be implemented in an intelligent circuit breaker according to another embodiment of the present disclosure. The solid bidirectional switch 600-6 has a circuit configuration similar to the solid bidirectional switch 600-5 in Figure 6F, where the SPDT switch 632 (in Figure 6F) is implemented using first and second control switches 641 and 642 controlled by a switch control circuit 640. The switch control circuit 640 comprises a first control line 640-1 coupled to the first control switch 641 and a second control line 640-2 coupled to the second control switch 642. In some embodiments, the first and second control switches 641 and 642 comprise phototransistors (e.g., optical bipolar junction transistors).

[0112] The switch control circuit 640 is configured to synchronize the optical control signal outputs 640-1 and 640-2 with the supply voltage waveform of the AC trunk line 110. The switch control circuit 640 monitors the voltage level of the supply voltage waveform on the line activation path 111. The trigger level V is set when the voltage level is a predetermined trigger level. TRIGWhile the voltage level remains below a predetermined trigger level V, the switch control circuit 640 outputs an optical control signal on control line 640-1 to drive the first control switch 641 (i.e., keep switch 641 in the "on" state), while the second control switch 642 remains in the off state. Meanwhile, the trigger level V is a predetermined trigger level when the voltage level is less than a predetermined trigger level. TRIG When the threshold is exceeded, the switch control circuit 640 outputs an optical control signal on control line 640-2 to drive the second control switch 642 (i.e., keep the second control switch 642 in the "on" state), while the first control switch 641 is kept in the "off" state. In some embodiments, the switch control circuit 640 is configured to provide a "break before make" switching characteristic, where the optical drive control signal outputs 640-1 and 640-2 do not overlap, thereby avoiding premature discharge of capacitor 613. The time constant of the switch control allows for rapid switching of the optical drive signal outputs 640-1 and 640-2 in synchronization with the supply voltage waveform of the AC trunk 110 via an external control circuit mechanism (not shown) for providing phase control of the applied AC waveform, as used in dimmer applications.

[0113] Figure 6H is a schematic circuit diagram of a solid bidirectional switch 600-7, which may be implemented in an intelligent circuit breaker, according to another embodiment of the present disclosure. The solid bidirectional switch 600-7 has a similar circuit configuration to the solid bidirectional switch 600-6 in Figure 6G, except that the solid bidirectional switch 600-7 comprises a current sensor circuit 650 and a current sensing element 652. The current sensor circuit 650 uses the current sensing element 652 to sense the AC current supplied to the load 120 by the AC trunk 110. In the exemplary embodiment of Figure 6H, the current sensing element 652 is coupled to a node between the series-connected first and second MOSFET switches 601 and 602 (for example, to a node at the commonly connected source terminal S of the MOSFET switches 601 and 602). In some embodiments, the current sensing element 652 includes a current transformer or a Hall effect sensing element.

[0114] The current sensor circuit 650 is configured to generate and output a control signal to the switch control circuit 640 for selectively controlling the activation and deactivation of the control switches 641 and 642. For example, if the current sensor circuit 650 determines that there is no current flow in the active line path between the line activation 111 and the load activation 121, or that there is an excessive current, the current sensor circuit 650 outputs a control signal to the switch control circuit 640. In response to this control signal, the switch control circuit 640 (i) turns off the control switch 642, thereby disconnecting the first and second MOSFET switches 601 and 602 from the bias circuit mechanism, and (ii) turns on the control switch 641, thereby deactivating the first and second MOSFET switches 601 and 602 and switching off the solid bidirectional switch 600-7.

[0115] In other exemplary embodiments, the intelligent circuit breaker may implement the same or similar solid-state AC switching circuit mechanisms and technologies disclosed in any one of the following concurrently pending applications and issued patents. (1) U.S. Patent Application No. 16 / 093,044 (Publication No. US2019 / 0207375) filed on October 11, 2018, entitled "Solid-State Line Disturbance Circuit Interrupter"; (2) U.S. Patent No. 10,469,077 (Publication No. 5) entitled "Electronic Switch and Dimmer" issued on November 5, 2019; (3) International Patent Application No. PCT / US2018 / 059564 (International Patent Application No. 2019 / 133110) (Publication No. 5) entitled "Electronic Switch and Dimmer" filed on November 7, 2018; (4) U.S. Patent Application No. 16 / 029,549 (Publication No. 5) entitled "Solid-State Power Interrupter" filed on July 7, 2018; (5) Circuit Interrupter with Optical (Publication No. 5) filed on October 1, 2018. U.S. Patent Application No. 16 / 149,094, entitled Connection, and (6) U.S. Patent Application No. 16 / 589,999, entitled Solid-State Circuit Interrupters, filed on 1 October 2019, all of which are incorporated herein by reference.

[0116] Figures 7A and 7B schematically illustrate a switch control circuit for controlling a solid bidirectional switch according to one embodiment of the present disclosure. In particular, Figure 7A is a schematic block diagram of a switch control circuit that may be implemented in an intelligent circuit breaker for controlling a solid bidirectional switch according to an embodiment of the present disclosure, and Figure 7B is a schematic circuit diagram of the switch control circuit of Figure 7A according to an embodiment of the present disclosure. Figures 7A and 7B illustrate exemplary embodiments of a switch control circuit mechanism 308 for controlling a solid bidirectional switch 304 in the exemplary embodiments of Figures 3A and 3B.

[0117] Figure 7A illustrates a solid bidirectional switch 700 comprising first and second MOSFET switches 601 and 602 and their respective body diodes 601-1 and 602-1. The solid bidirectional switch is coupled to a control circuit 710 comprising a sensing resistor 716, a short-circuit detection and protection circuit 712, and a switch VGS controller 714. The sensing resistor 716 is connected between the source terminals S (e.g., nodes N1 and N2) of the first and second MOSFET switches 601 and 602. The short-circuit detection and protection circuit 712 is configured to detect a load-side short-circuit fault condition and works in conjunction with the switch VGS controller 714 to provide fast disconnection of the solid bidirectional switch in response to the detection of a short-circuit fault condition.

[0118] In particular, the short-circuit detection and protection circuit 712 is connected to nodes N1 and N2 and is configured to measure the load voltage of the sensor resistor 716 and to determine when the load voltage exceeds a preset value indicating a short-circuit fault condition. The short-circuit detection and protection circuit 712 works in cooperation with the switch VGS controller 714 to quickly shut off the first and second MOSFET switches 601 and 602 when the load voltage of the sensing resistor 716 exceeds a preset value. In some embodiments, the short-circuit detection and protection circuit 712 is configured to provide fault notification to a processor (e.g., processor 220, Figures 3A and 3B).

[0119] As schematically illustrated in Figure 7A, the switch VGS controller 714 is coupled to the gate terminals (e.g., node N3) of the first and second MOSFET switches 601 and 602. The switch VGS controller 714 is configured to control the activation and deactivation of the first and second MOSFET switches 601 and 602 during normal operation of the bidirectional switch (e.g., ON state), and to deactivate both MOSFET switches 601 and 602 in response to a fault condition. In addition, the switch VGS controller 714 is configured to minimize leakage of the first and second MOSFET devices 601 and 602 during the ON / OFF states of the solid bidirectional switch. In some embodiments, the switch VGS controller 714 is configured to receive control signals (e.g., switch control signals, leakage control signals) from a control processor (e.g., processor 220, Figures 3A and 3B) to implement the switch VGS control functionality.

[0120] Figure 7A illustrates an exemplary embodiment in which the sensing resistor 716 is connected between the source terminals S of the first and second MOSFET switches 601 and 602. However, it should be understood that the sensing resistor 716 may be connected at other locations along the active line path between the line activation 111 and the load activation 121. In addition, the sensing resistor 716 may also be used as an energy sensing element in the current sensor and energy metering circuit mechanism 240 of Figure 3B, so that the load voltage of the sensing resistor 716 is utilized by different sensing and control circuit mechanisms to implement their respective functions.

[0121] Figure 7B schematically illustrates a circuit diagram of a short-circuit detection and protection circuit 712 according to an embodiment of the present disclosure. A sensing resistor 716 is connected between nodes N1 and N2, with node N1 coupled to the source terminal (represented as a high-side switch) of the first MOSFET switch 601, as shown in Figure 7A, and node N2 coupled to the source terminal (represented as a low-side switch) of the second MOSFET switch 602. A switch VGS controller 714 is connected to node N4 of the short-circuit detection and protection circuit 712.

[0122] The short-circuit detection and protection circuit 712 comprises several bipolar junction transistors 720, 721, and 722, an N-type MOSFET 724, several resistors 730, 731, 732, 733, 734, 735, and 736, and a capacitor 740, all arranged and connected as shown in Figure 7B. Transistors 720, 721, and 722 are arranged to include a phase discriminator characterized by essentially bidirectional support of AC current. The short-circuit detection circuit 712 monitors the load voltage of the sensing resistor 716 (i.e., nodes N1 and N2), and if the load voltage exceeds 0.7 volts, switches 601 and 602 trip the VGS control. More specifically, in this embodiment, if the current through the sensing resistor 716 reaches or exceeds a predetermined maximum current value (e.g., trip current threshold), sufficient to turn on the bipolar junction transistors 720 and 722 between the base and emitter (VGS). BE The resistance value of the sensing resistor 716 is selected to produce a trip current. For higher trip currents, the resistance value of the sensing resistor 716 decreases, while for lower trip currents, the resistance value of the sensing resistor 716 increases. For example, for a trip current of approximately 200 amps, the sensing resistor 716 would have a resistance value of approximately 30 milliohms.

[0123] Those skilled in the art will understand that while ground reference sensing circuits can be used, such circuits offer an inferior, expensive, and complex solution requiring additional components, including isolators. Furthermore, the short-circuit trip current is adjustable by changing the resistance value of the sensor resistor 716 or by adjusting the ability of the sensor resistor 716 to influence a 0.7-volt bias point in a voltage divider. In other embodiments, additional mechanisms, such as a digital-to-analog converter (DAC), may be used to influence and adjust the short-circuit current threshold in real time, thereby enabling the system to be programmable with respect to the short-circuit current level. This programmability is particularly useful for extending the system's performance to improve response time and reduce unwanted trips. As an example, a circuit breaker operating under a heavy load may be much closer to the short-circuit trip threshold than a no-load circuit breaker, both of which will encounter a short-circuit load.

[0124] Figure 8A is a high-level schematic diagram of an intelligent circuit breaker according to another embodiment of the present disclosure. In particular, Figure 8A illustrates an intelligent circuit breaker 800 comprising a solid bidirectional switch 801 and a load isolation switch 802. The solid bidirectional switch 801 is connected in series in the circuit between the line input terminal (connected to line activation 111) and the loud output terminal (connected to load activation 121) of the intelligent circuit breaker 800. The load isolation switch 802 is connected between the load activation 121 and the load neutral 122. For the sake of illustration and discussion, please understand that various components of the intelligent circuit breaker 800 (e.g., processor, switch controller, current sensor, voltage sensor, AC-DC converter circuit mechanism, etc.) are not illustrated in Figure 8A.

[0125] The intelligent circuit breaker 800 implements a control scheme that activates a load isolation switch 802 to bypass the load 120, thereby isolating the load 120 from the intelligent circuit breaker 800 (e.g., electrically isolating it) when the solid bidirectional switch 801 is switched off. This allows any leakage current from the deactivated solid bidirectional switch 801 to flow through the isolation switch 802 to ground, preventing such leakage current from flowing to the load 120. The load isolation switch 802 is deactivated when the solid bidirectional switch 801 is switched on and the intelligent circuit breaker 800 is supplying power to the load 120.

[0126] Figure 8B is a high-level schematic diagram of an intelligent circuit breaker according to one embodiment of the present disclosure, comprising an isolation circuit configured to isolate the intelligent circuit breaker from a load. More specifically, Figure 8B illustrates an exemplary embodiment of the intelligent circuit breaker 800 of Figure 8A, in which the isolation switch 802 is implemented as part of an isolation circuit 810 configured to isolate the intelligent circuit breaker 800 from the load 120 (e.g., dielectric isolation) when the solid bidirectional switch 801 is switched off. As described above, when the solid bidirectional switch 801 is switched off, the solid bidirectional switch may generate a small amount of leakage current. For example, even when the solid bidirectional switch 801 is biased to be completely switched off, a small amount of leakage current (e.g., 200uA) may flow through the solid switch 801, which may generate a significant voltage drop across the load 120 when the load 120 contains a high-impedance load. The isolation circuit 810 functions to divert unwanted leakage current from the load 120 when the solid bidirectional switch 801 is deactivated.

[0127] The isolation circuit 810 comprises a controller 820, MOSFET devices 830 and 840, and associated body diodes 830-1 and 840-1. In this exemplary embodiment, the isolation switch 802 in Figure 8A is implemented as a solid bidirectional switch comprising MOSFET devices 830 and 840. When the solid bidirectional switch 801 is switched off, the controller 820 commands the MOSFET switches 830 and 840 to turn on, thereby preventing leakage current from the deactivated solid bidirectional switch 801 from flowing into the load 120. The effect of bypassing or shunting the leakage current away from the load 120 functions equivalently to galvanic isolation techniques in which an air gap switch may be implemented between the AC trunk 110 and the load 120. In this configuration, the isolation circuit 810 provides dielectric isolation and functions as a pseudo-air gap. It should be understood that the isolation circuit 810 may be implemented in other exemplary embodiments of intelligent circuit breakers, as discussed herein.

[0128] Figures 9A, 9B, and 9C schematically illustrate an integrated current sensor and energy metering circuit 900 that may be implemented in an intelligent circuit breaker according to embodiments of the present disclosure. In some embodiments, Figures 9A, 9B, and 9C illustrate exemplary embodiments of the current sensor and energy metering circuit 240 shown in Figures 2B and 3B. Figures 9A, 9B, and 9C illustrate different circuit blocks of the current sensor and energy metering circuit 900, with Figure 9A being a schematic diagram of the power supply block 910 and the current sensor block 920, Figure 9B being a schematic diagram of the overcurrent detection block 930, and Figure 9C being a schematic diagram of the energy metering block 980.

[0129] Referring to Figure 9A, the power supply block 910 comprises an isolated DC-DC converter 911, a ferrite bead 912, capacitors 914 and 916, and a virtual ground (HGND) 918, all arranged and connected as shown. The isolated DC-DC converter 911 is configured to convert a first DC supply voltage VDC-A to a second DC supply voltage VDC-on-Hot, providing isolation between the first and second DC supply voltages. The ferrite bead 912 is connected between the line activation 111 and the virtual ground (HGND) 918. Capacitor 914 is connected between the input terminals of the isolated DC-DC converter 911 and thus acts as a bypass capacitor, connecting the VDC-A voltage rail and the neutral ground (GND) 114. Similarly, capacitor 916 is connected between the output terminals of the isolated DC-DC converter 911 and thus acts as a bypass capacitor, connecting the VDC-on-Hot voltage rail and the virtual ground HGND 918. The ferrite bead 912 and capacitors 914 and 916 function to filter high-frequency noise from the supply voltage rail.

[0130] In some embodiments, the first DC supply voltage VDC-A on the VDC-A voltage rail includes a DC supply voltage (e.g., 5V) generated by the AC-DC converter circuit mechanism 210 (see Figures 2B and 3B), and the isolated DC-DC converter 911 provides a 1:1 conversion to generate a second VDC-on-Hot supply voltage (e.g., 5V) applied to the VDC-on-Hot voltage rail connected to the line activation 111. In this regard, the isolated DC-DC converter 911 generates a second VDC-on-Hot voltage (e.g., 5V) applied to the active line path to provide a 5V DC offset on the active line path measured against virtual ground HGND 918, while the first DC supply voltage VDC-A is measured against neutral ground GND 114.

[0131] The current sensor block 920 comprises an isolation amplifier 921 including a first block 921-1 and a second block 921-2, which are galvanically isolated from each other using, for example, optical coupling techniques, electrostatic coupling techniques, etc. The first block 921-1 is powered by a VDC-on-Hot supply voltage generated by the power supply block 910, and the second block 921-2 is powered by a VDC-A supply voltage. The current sensor block 920 further comprises a current sensing resistor 922 and a low-pass filter formed by resistors 923 and 924 and capacitor 925 at the input of the isolation amplifier 921. A bypass capacitor 926 is connected between the power rail VDC-A and ground 114.

[0132] As shown in Figure 9A, in some embodiments, the sensing resistor 922 is connected in series in the circuit between the line activation 111 and the AC switch. The sensing resistor 922 controls the AC voltage (referred to as load voltage (V)) between a first node N1 (referred to as the line-side node) and a second node N2 (referred to as the load-side node) based on the AC load current flowing through the sensing resistor 922 in the activation line path. B ) or detection voltage (V Sense It generates a voltage known as a sensor resistor. In some embodiments, the sensing resistor 922 comprises a high-power resistor with a relatively low resistance value that can generate a sufficient sensing voltage for measurement purposes and does not consume a large amount of energy. For example, in some embodiments, the sensing resistor 922 has a resistance value of about 1 milliohm.

[0133] During operation, the current sensing resistor 922 adjusts the load voltage V in proportion to the load current flowing along the active wire path. B Generates the load voltage V. B V B =I L ×R S It is determined as follows, and in the formula, I L R represents the load current. S V represents the resistance value of the sensing resistor 922. The first block 921-1 of the isolation amplifier 921 loads the voltage V of the sensing resistor 922. BThe voltage level is amplified, sampled, and the sampled voltage information is transmitted to the second block 921-2 through an isolation barrier (e.g., optically, capacitively, etc.). In this circuit configuration, biasing the first block 921-1 of the isolation amplifier 921 using VDC-on-Hot and virtual HGND918 allows the first block 921-1 of the isolation amplifier 921 to measure the voltage of the sensing resistor 922 (connected in series via an active line path) relative to the virtual ground HGND918. Isolation between the first and second blocks 921-1 and 921-2 of the isolation amplifier 921 allows the second block 921-2 and downstream circuit components to be biased using VDC-A and neutral ground GND114.

[0134] The second block 921-2 of the isolated amplifier 921 utilizes sampled voltage information provided from the first block 921-1 to generate and output a differential signal containing first and second current sense control signals (represented as Current_Sense(+) and Current_Sense(-)) with respect to neutral ground GND 114. In some embodiments, the differential output of the isolated amplifier 921 is implemented as a differential signal with a DC offset (e.g., an offset of 1.3V) and a desired gain (e.g., a gain of 8). The first and second current sense control signals (Current_Sense(+) and Current_Sense(-)) are input to the overcurrent detection block 930 (Figure 9B) and the energy metering block 980 (Figure 9C).

[0135] In some embodiments, as shown in Figure 9A, the isolation amplifier 921 is configured to have an adjustable gain that can be controlled by the processor or controller of the intelligent circuit breaker. In particular, as shown in Figure 9A, a second block 921-2 of the isolation amplifier 921 includes a Gain_Adjust control input that allows the processor or controller to adjust the gain of the isolation amplifier 921, thereby adjusting the level of overcurrent conditions at which the intelligent circuit breaker trips. In this configuration, the isolation amplifier 921 provides a gain element for amplifying a relatively small sensing voltage generated in the sensing resistor 922 (i.e., between nodes N1 and N2) as a result of the current flow on the active line path between the line activation 111 and the load activation 121. Thus, the sensing resistor 922 can have a relatively small resistance value (e.g., 1 milliohm) that generates a relatively small sensing voltage and minimizes power dissipation for normal circuit operation, but is amplified by the isolation amplifier 921 to enable overcurrent detection using a small sensing voltage. Furthermore, the resistance value of the sensing resistor 922 can be kept fixed (e.g., 1 milliohm) while adjusting the gain of the isolation amplifier 921 as desired to adjust the level of overcurrent detection.

[0136] In some embodiments, the processor or controller may be configured to adjust the gain of the amplifier 912 based on the temperature of the intelligent circuit breaker, such as determined by a temperature sensor integrated with the intelligent circuit breaker or separately coupled to the intelligent circuit breaker. For example, if the temperature of the intelligent circuit breaker rises to a relatively high level (e.g., 115 degrees Celsius or higher), the gain of the isolation amplifier 921 may be adjusted (e.g., increased) to reduce the level of overcurrent that would cause the intelligent circuit breaker to trip.

[0137] Referring to Figure 9B, the overcurrent detection block 930 comprises a unit gain amplifier 931 and a two-stage detection circuit 935 having an RMS stage 935-1 and a comparator stage 935-2. The unit gain amplifier 931 has a non-inverting input connected to node N3 between resistors 932 and 933. Resistors 932 and 933 are connected in series between the differential outputs of the isolation amplifier 921 of the current sensor block 920 (Figure 9A). The unit gain amplifier 931 and resistors 932 and 933 function as the level-shift input stage of the overcurrent detection block 930, and resistors 932 and 933 are selected to have the same resistance value to accommodate the DC offset (e.g., a 1.3V offset) of the differential output of the isolation amplifier 921. In this respect, since the overcurrent detection block 930 utilizes only one side of the current detection differential output of the separation amplifier 921, the input to the overcurrent detection block 930 is Vin_OCD = 1.3V + Aa / 2 × I L ×R S Given by the equation, where A is 8 and "a" represents the peak amplitude of the AC waveform amplified by the isolation amplifier 921 of the current sensor block 920.

[0138] The output of the unit gain amplifier 931 is input to the RMS stage 935-1. The RMS stage 935-1 includes an active peak detection circuit configured to generate an output signal representing the RMS (root mean square) value of Vin_OCD. The RMS stage 935-1 includes a first amplifier 940 and a second amplifier 950. The first and second amplifiers 940 and 950 each have non-inverting inputs, which are coupled to the output of the unit gain amplifier 931 via resistors 941 and 951, respectively. The first and second amplifiers 940 and 950 each have inverting inputs, which are coupled to the Current_Sense(-) output of the current sensor block 920 via resistors 942 and 943, respectively. The output of the first amplifier 940 is coupled to the inverting input of the second amplifier 950 via a rectifier diode 946 and a resistor 952. The first amplifier 940 includes a first negative feedback loop comprising a rectifier diode 945 and a second negative feedback loop comprising a resistor 944. The second amplifier 950 includes a negative feedback look comprising a resistor 953 and a capacitor 954 connected in parallel.

[0139] The RMS stage 935-1 assumes a sine wave, V RMS = 1.3V - RMS(Aa / 2 × I L ×R S ) or 1.3V - (.707) × Aa / 2 × I L ×R S It is configured to generate the RMS voltage given by . The RMS voltage is generated at the output of the second amplifier 950 which is coupled to the input of the second (comparator) stage 935-2. Comparator stage 935-2 is configured to generate the RMS voltage V RMSThe comparator 960 has an inverting input coupled to the output of amplifier 950 to receive a current threshold voltage V, and a non-inverting input that receives a Current_Threshold control signal as input. In some embodiments, the Current_Threshold control signal includes a current generated by a current DAC (digital-to-analog converter) in a control processor (e.g., processor 220, Figures 2B and 3B). The Current_Threshold control signal is transmitted to a resistor 961 connected to the non-inverting input of comparator 960 via a current threshold voltage V CT This generates the current threshold voltage V. In some embodiments, the DAC resolution is 2.4 μA / bit, and the resistor 961 has a resistance value of 4320 Ω. CT This results in a resolution of 10.368mV / bit at the non-inverting input of comparator 960. The relationship between the DAC code and Current_Threshold (CT) is given by D = (1.3V - (Aa / 2 × CT × R S The value is given by ) / (10.368mV / bit) or D=(1.3V-16mΩ×Ct) / (10.368mV / bit), where CT is in amperes RMS units.

[0140] The RMS voltage V generated by the RMS stage 935-1 RMS Since the voltage may have some voltage ripple, the comparator stage 935-2 is implemented as a two-stage comparator comprising a first comparator 960 and a second comparator 970. Comparator 960 is V CT V RMS Compare with V. RMS V relative to the signal CT When the signals are close together, the output of the first comparator 960 is the current V RMSDithering is performed with a duty cycle to indicate how much the value is above or below the threshold. The first comparator 960 has an output that is coupled to the non-inverting input of the second comparator 960 via a low-pass filter formed by a resistor 962 and a capacitor 963. The second comparator 970 has an inverting input that is connected to a voltage divider network comprising a first resistor 971 and a second resistor 972 connected in series between the supply voltage VDC-A and ground GND114. The voltage divider network is connected to the inverting input of the second comparator 970 via a reference voltage V REF The second comparator 970 generates an Over_Current_Detection signal when the duty cycle of the first comparator 960 exceeds 50%.

[0141] The Over_Current_Detection signal is input to the control circuit mechanism to deactivate the AC switch of the circuit breaker to protect against overcurrent fault conditions. An exemplary control process that may be implemented by the intelligent circuit breaker's processor, in conjunction with the current sensor circuit mechanism 900 shown in Figures 9A and 9B, for monitoring and detecting overcurrent fault conditions, is described in further detail below with reference to Figure 11.

[0142] Referring here to Figure 9C, the energy metering block 980 comprises an energy metering circuit 981 and a passive bandpass filter comprising resistors 982, 983, and 984 and capacitors 985, 986, and 987. The energy metering circuit 981 has differential inputs coupled to the differential outputs Current_Sense(+) and Current_Sense(-) of the isolation amplifier 921 of the current sensor block 920 (Figure 9A) via the passive bandpass filter. Effectively, the bandpass filter removes the DC offset (e.g., a 1.3V offset), attenuates the Current_Sense(+) and Current_Sense(-) signals, and significantly attenuates unwanted high frequencies, thus reducing the input voltage V to the energy metering circuit mechanism 981. CM VCM =(Aa×I L ×R S ) / A N (A N (This represents the attenuation of the bandpass filter) is provided by [this]. From the perspective of energy metering software, a useful constant is the current-to-voltage ratio, Ks = Aa × R S = 0.032Ω (assuming Aa=8 and Rs=0.004Ω), and 1 / Ks=A N / (Aa*R S ) = 656.25 amperes / volts.

[0143] It should be understood that the various resistance and capacitance values ​​of the circuit components in Figures 9A, 9B, and 9C can vary depending on the application. To provide some context, the following non-limiting examples of resistance and capacitance values ​​can be implemented in the circuit mechanisms of Figures 9A, 9B, and 9C. For example, in Figure 9A, the values ​​of resistors 922, 923, and 924 and capacitor 925 are selected to provide the desired input signal filtering.

[0144] Furthermore, in some embodiments, the resistance and capacitance values ​​in Figure 9B are as follows: Resistors 932 and 933 have a resistance of 5.9K. Resistor 941 has a resistance of 4.7K. Resistors 942, 943, and 944 have a resistance of 10K. Resistor 951 has a resistance of 2.7K. Resistor 952 has a resistance of 4.99K. Resistor 953 has a resistance of 11K. Capacitor 954 has a capacitance of 2.2uF. Resistor 961 has a resistance of 4.3K. Resistor 962 has a resistance of 22K. Capacitor 963 has a capacitance of 0.47uF. Resistors 971 and 972 have a resistance of 22K.

[0145] Furthermore, in some embodiments, the resistance and capacitance values ​​in Figure 9C are as follows: Resistors 982 and 983 have a resistance value of 4.7K. Resistor 984 has a resistance value of 470 ohms. Capacitors 985 and 986 have a capacitance value of 10uF. Capacitor 987 has a capacitance value of 10nF. In some embodiments, the energy metering circuit 981 comprises an application-specific integrated circuit (ASIC) specifically designed to measure the power and energy of a power line system and process instantaneous voltage and current waveforms to calculate RMS values ​​of voltage and current, active, reactive and apparent power and energy. In other embodiments, the energy metering circuit 981 comprises an "off-the-shelf" application-specific standard product (ASSP) chip that implements the desired energy metering functionality.

[0146] The energy metering circuit 981 generates energy metering data and outputs it to the intelligent circuit breaker's processor 220 (for example, Figures 2B and 3B), which stores and analyzes the energy metering data to determine the energy usage of the load on the branch circuit protected by the intelligent circuit breaker. The processor 220 can provide energy usage information to a remote computing node or device via a wireless or wired network connection. This configuration enables remote energy monitoring and notification of energy usage, thereby improving energy awareness in various applications.

[0147] For example, multiple energy-aware intelligent circuit breakers can be configured to report real-time and stored energy usage from multiple branch circuits within a given residence or building. Energy-aware intelligent circuit breakers within a given residence or building can provide stored energy usage information that can be used by the property owner to verify the energy usage of the residence or building for reporting purposes by an external company, or for correlation purposes. In addition, in multi-unit or apartment buildings such as strip malls, intelligent energy metering using energy-aware intelligent circuit breakers allows property owners to bill tenants individually without requiring multiple external meters. As another example, intelligent energy metering with intelligent circuit breakers can also be useful for tenants or Airbnb rentals to prevent or report unnecessary energy waste, such as tenants sleeping with windows open and electric heaters running at full power continuously on cold nights, or tenants sleeping under heavy covers on warm nights with AC units set to maximum cooling.

[0148] As another example, intelligent energy metering with intelligent circuit breakers provides a method for determining possible energy theft or unusual, unexpected energy consumption, and can also reveal faulty or malfunctioning external instruments. In other applications, intelligent energy-aware circuit breakers can also send warnings / notifications when electricity usage exceeds a configurable "normal level" for devices on a branch, or for the aggregation of devices and branches. Furthermore, intelligent energy-aware circuit breakers are also useful for external companies looking for loads that can be disabled or powered down during peak load periods. For example, in some embodiments, intelligent circuit breakers can implement load profiling techniques such as those disclosed in U.S. Patent Application No. 16 / 682,627, filed November 13, 2019, entitled Managing Power for Residential and Commercial Networks, which is incorporated herein by reference in its entirety. As disclosed, these same smart devices can provide valuable power outage information at the moment of external power supply collapse and circuit restoration. The timing of power outages helps locate the location of power lines that have been damaged or are out of service, estimate the extent of the damage, and generate more accurate equipment recovery times. In other applications, intelligent energy-aware circuit breakers can also measure, diagnose, and control the increasingly improperly synchronized bidirectional energy commonly experienced in renewable energy sources and electric vehicles connected to building infrastructure and external energy supplies.

[0149] Figure 10 is a flowchart of a method for controlling the switches of an intelligent circuit breaker in response to the detection of a fault condition, according to one embodiment of the present disclosure. For illustrative purposes, the exemplary process flow in Figure 10 is discussed in the context of controlling the solid bidirectional switch of an intelligent circuit breaker, but the same or similar process flows may be implemented to control the electromagnetic switch of an intelligent circuit breaker (e.g., switch 302, Figures 3A and 3B). When an external power supply is applied, the control logic of the intelligent circuit breaker assumes control of the solid bidirectional switch (block 1000). First, the control logic opens (or switches off) the solid bidirectional switch (block 1001) and proceeds to determine when it is appropriate to close (or switches on) the solid bidirectional switch (block 1002).

[0150] For example, the control logic may determine that it is appropriate to close the solid bidirectional switch based on (i) the position of the manual circuit breaker switch (e.g., the manual switch is closed), (ii) the switch state during external power loss (e.g., the switch was closed during power loss), (iii) a command received from the local processor or a command received wirelessly from a remote node, or (iv) the end-of-life deactivation state. Once the solid bidirectional switch is in the closed state (block 1003), the control logic proceeds to monitor for the occurrence of an event that would require the solid bidirectional switch to be in the open state, i.e., the switch-off state (block 1004).

[0151] For example, the occurrence of a fault event such as a current overload event (block 1005) or a short-circuit event (block 1006) triggers the deactivation (i.e., switch-off state) of the solid bidirectional switch. For example, as described above, in some embodiments, a current overload event may be determined by a processor that analyzes current sensor data acquired in real time using a current sensor configured to detect line current. In other embodiments, the intelligent circuit breaker includes a current sensor comprising a current overload detection circuit mechanism (e.g., Figures 9A and 9B), which is configured to detect a current overload event and generate a current overload detection signal that triggers the opening of the solid bidirectional switch.

[0152] In other embodiments, the detection of the opening of a manual circuit breaker switch is considered an event that would trigger the opening of a solid bidirectional switch (block 1007). As described above, in this case, the opening of the solid bidirectional switch prior to or concurrent with the manual switch opening event would function to eliminate or minimize the occurrence of electrical arcing between the contacts of the electromechanical or electromagnetic switch of the intelligent circuit breaker. The occurrence of arcing causes deterioration of the metal contacts of the circuit breaker and is a safety hazard in situations where flammable gases may be present. In this regard, the ability to eliminate arcing during fault events or manual lever operation is an example of how the intelligent circuit breakers disclosed herein extend the safety of the circuit breaker beyond merely protecting downstream circuit wiring from thermal damage. Furthermore, as described above, the implementation of a solid bidirectional switch with a fast disconnection response time prevents the flow of dangerous current levels that could cause arcing in downstream wiring and loads.

[0153] In other embodiments, a remote switch release command event would trigger the release of a solid bidirectional switch (block 1008). As described above, the implementation of a wireless transceiver within the intelligent circuit breaker allows wireless communication to remotely disconnect branch circuits and loads protected by the intelligent circuit breaker. For example, the remote switch release command capability would allow emergency service personnel to shut off power to part or all of a structure during a reported gas leak or flood event. The implementation of a wireless transceiver over a secure Internet Protocol (IP) address and IP network would allow remote commands to be issued to the control logic of the intelligent circuit breaker to switch off a solid bidirectional switch and actually trip the intelligent circuit breaker.

[0154] In other embodiments, a sensor data trip event would trigger the opening of a solid bidirectional switch (block 1009). As described above, implementations of processors with various sensors and control logic enable the intelligent circuit breaker to trip in response to various detected conditions. For example, in addition to current and voltage sensors, the intelligent circuit breaker may include other types of sensors such as temperature sensors and humidity sensors. The ability to acquire sensor data, combined with the implementation of control algorithms that can process the acquired sensor data, predict dangerous and problematic events, and issue wireless warnings / notifications, extends the safety capabilities of the intelligent circuit breaker as disclosed herein.

[0155] For example, by acquiring and processing sensor data, an intelligent circuit breaker may be configured to initiate the opening of a solid switch immediately before a potential fault condition of a load, such as a spa pump, heater, or compressor in a central air conditioning system, by predicting an impending failure of the load. In some embodiments, the intelligent circuit breaker may implement predictive analytics techniques such as those disclosed in U.S. Patent Application No. 15 / 980,311, filed May 15, 2018, entitled "Predictive Analytics System," which are incorporated herein by reference in their entirety. Furthermore, the ability of the intelligent circuit breaker to identify load types (e.g., spa pumps) can be extremely useful in analyzing potentially unsafe conditions. In some embodiments, the intelligent circuit breaker may implement circuit load characteristic techniques such as those disclosed in U.S. Patent Application No. 16 / 340,474, published US2019 / 0245457, filed April 9, 2019, entitled "Load Identifying AC Power Supply with Controls and Methods," which are incorporated herein by reference in their entirety. Furthermore, the wireless communication capabilities of the intelligent circuit breaker enable extended support for new types of load profiles, such as new types of refrigeration motors, as well as for non-standard alternative energy sources through automated software, firmware, and algorithm updates from remote sites.

[0156] As another example, a sensor, when intelligently connected to a downstream electrical device, can detect an unsafe condition at a particular receptacle or load. A 20-amp circuit breaker typically powers a number of downstream receptacles. Each of these receptacles may be a 15-amp rated device, assuming a 20-amp load is shared among multiple receptacles. A sensor on the circuit breaker may alert a specific smart receptacle, smart load, or property owner to an unsafe condition such as an overload and daisy-chained power strip or too many strings of holiday lights on a single receptacle. As will be discussed in more detail later with Figure 15, an intelligent circuit breaker can issue a wireless warning / notification, instruct a receptacle to disconnect, or simply trip the breaker itself until the condition is corrected and reset.

[0157] In another embodiment, the ability of an intelligent circuit breaker to characterize load types allows it to detect or otherwise monitor potential degradation in the performance of a given load type, whether through algorithms or using data provided by the property owner. This is particularly useful, for example, in providing information for preventive maintenance of refrigeration units prior to failure and any resulting damage, and for numerous other types of equipment or loads. In this regard, an intelligent circuit breaker may be configured to identify and profile many types of loads and compare a real-time operating profile of a given load with a nominal operating profile of the given load. Equipment manufacturers can greatly benefit from the collection of big data associated with profiling, communicating, and analyzing energy use.

[0158] In other embodiments, an intelligent circuit breaker can be combined with a smart receptacle to detect an overload condition in the smart receptacle using its ability to wirelessly communicate before resupplying power to the smart receptacle's load. This allows the smart receptacle to trip the branch circuit experiencing a dangerous fault condition, and after power is resupplied to the branch circuit by the intelligent circuit breaker, it can automatically resupply power by wirelessly instructing the problematic smart receptacle to remain in a load-disconnected state. This enables the intelligent circuit breaker to resupply all other loads on a given branch and continue the exchange of power, details of which will be discussed later in conjunction with the flowchart in Figure 15. Furthermore, when the intelligent circuit breaker is combined with smart receptacles having two or more individual branch feeds or phases, and a mechanism to switch them, it can instruct the smart receptacles to switch branch circuits to balance the load, making phase balancing more economical.

[0159] In other embodiments, the intelligent circuit breaker may be equipped with or otherwise connected to remote sensors such as temperature, humidity, gas, smoke / fire, and water sensors. The intelligent circuit breaker can use such sensors to monitor environmental conditions and respond to unsafe conditions by cutting off power from branch circuits where unsafe water levels could lead to electric shock or fire, or where unsafe temperatures could lead to device failure within the circuit breaker panel. As a specific example, a humidity sensor may be installed within the intelligent circuit breaker, or within the circuit breaker distribution panel, or within a wall, and the humidity sensor can be used to detect roof or pipe leaks that could adversely affect the safety of the entire electrical system. The intelligent circuit breaker can also issue wireless warnings / notifications before or immediately after a fault event. Each of these examples may also include wireless notifications to local emergency services and local external companies.

[0160] In other embodiments, an intelligent circuit breaker equipped with arc fault and / or ground fault sensors can also safely shut down branch circuits in unsafe conditions. The intelligent circuit breaker can issue radio warnings / notifications before or immediately after such arc fault or ground fault events. Each of these examples may also include radio notifications to local emergency services and local external companies.

[0161] In other embodiments, additional information derived from data available through external sensors or wireless communication may also be used to trigger notification / warning or trip events.

[0162] Figure 11 is a state diagram illustrating a control process implemented by an intelligent circuit breaker to detect and protect against fault conditions, according to one embodiment of the present disclosure. In particular, Figure 11 illustrates a fault detection state graph illustrating a state machine implemented by the intelligent circuit breaker's processor (e.g., processor 220 of intelligent circuit breakers 2B and 3B) to detect an overcurrent fault condition. In some embodiments, the processor 220 includes a current-to-digital converter (current DAC) for generating a programmable reference current (e.g., Current Threshold, Figure 9B) and general-purpose input / output (GPIO) digital signal pins for receiving an overcurrent detection signal generated by a current sensor (e.g., an Over_Current_Detection signal generated by the overvoltage comparator 935-2 of the overcurrent detection block 930 of current sensor 900, Figure 9B).

[0163] In some embodiments, the processor 220 implements a 1kHz state machine for detecting overcurrent fault conditions, the state machine including the following states: (i) stop, (ii) reset, (iii) overcurrent detection (S0), (iv) slow blow ramp (S1), (v) tail detection (S2), and (vi) trip. In addition, in some embodiments, the state machine implements the following programmable parameters: (i) OCT representing the overcurrent threshold (output during S0 and S2), (ii) ITT representing the instantaneous trip threshold (start of S1 ramp), (iii) SBRT representing the slow blow ramp time (duration of S2), and (iv) TT representing the tail time (duration of S2).

[0164] The states are defined as follows: The stopped state is used when a trip or fault condition is detected and stops current detection until it is set to the reset state by a command. The reset state is the initial state used to start the state machine, and the reset state initializes the DAC output to the overcurrent threshold detection circuit mechanism and sets the state machine to the S0 state. In the S0 state, the current DAC is programmed to output a voltage representing the desired overcurrent threshold (OCT) which is input to the comparator stage of the overcurrent detection block 930 of the current sensor 900 in Figure 9B. This is a steady state until the current rises above an output threshold as measured by the comparator circuit, at which point the comparator outputs logic level "1" as the Over_Current_Detection signal detected by the overcurrent state machine. At that time, the DAC is programmed to the instantaneous trip threshold, sets up the ramp duration and the length and duration of each step required for state S1, and the state machine transitions to the S1 state.

[0165] During state S1, whenever the comparator output transitions to logic "1", it is considered a tripped state, and the state machine immediately transitions to the tripped state. During state S1, a slow-blow ramp is performed, and the DAC is adjusted stepwise as time elapses to return from the instantaneous trip threshold to the overcurrent threshold. If the ramp is completed without the comparator indicating a tripped state, the state machine transitions to state S2. The ramp does not have to be linear as shown in Figure 11, but the ramp can be weighted in any desired way or nonlinear to achieve a desired effect, e.g., heating characteristics of the protected wiring. In some embodiments, the S1 ramp can be disturbed (via software control) to compensate for the elevated temperature of the intelligent circuit breaker.

[0166] During the S2 state, whenever the comparator output transitions to a logical "1", it is considered a trip state, and the state machine immediately transitions to the trip state. During the S2 state, the DAC outputs an overcurrent threshold (the same as state S0) for a programmed period, giving the state machine an opportunity to detect a state where the current is steady and just above the overcurrent threshold reference level, instead of continuously cycling through overcurrent states without actually declaring a trip state. At the end of the S2 period, the state machine is set to a reset state (setting the DAC output to the overcurrent threshold and the state to S0).

[0167] If the trip condition is entered as a result of overcurrent detection in either state S1 or S2, the AC switch-off operation is initiated, and the AC switch control line is switched to the off state during or before the next zero-crossing function execution.

[0168] In another embodiment, the “wire heating” process is implemented by varying the S0 output current based on how many high-current trips have occurred without exceeding the overcurrent detection limit. The process can implement a secondary state machine configured to vary the S0 level, the instantaneous trip level, and accordingly the slope of a slow blow ramp (in durations of seconds or minutes).

[0169] Figure 12 schematically illustrates an intelligent power distribution and monitoring system 1200 utilizing an intelligent circuit breaker according to one embodiment of the present disclosure. The system 1200 comprises a circuit breaker distribution board 1210, a wired and / or wireless communication network 1220, one or more intelligent load devices 1230, one or more user computing devices 1240, and an Internet of Things (IoT) computing platform 1250. The circuit breaker distribution board 1210 comprises a front panel 1211 and cover 1212 that are opened to access a main circuit breaker 1213, a plurality of branch circuit breakers 1214 protecting branch circuits in a given house or building, and a circuit breaker and load status display module 1215.

[0170] The configuration of the circuit breaker distribution panel 1210 varies depending on the type of electrical service provided. For example, a residential electrical service in the United States (120 / 240VAC) includes a single-phase service with two active voltage lines and one neutral line, both line voltages derived from a single-phase distribution transformer with a center-tapped neutral and offset by 180° from each other. In this type of electrical service, the two active line service wires supplying power to the circuit breaker panel 1210 are connected to the main circuit breaker 1213, which in turn is connected to two active busbars within the circuit breaker panel 1210. In addition, the incoming neutral line service wire is connected to the neutral busbar of the circuit breaker panel 1210, which in turn is connected to a separate ground busbar of the circuit breaker panel 1210.

[0171] Two active line service wires supplying power to the main circuit breaker 1213 each provide 120V, for example, from an electric meter, and (when the main circuit breaker 1213 is switched on) supply power to two active busbars of the circuit breaker panel 1210 through the main circuit breaker 1213. Branch circuit breakers 1214 have line input terminals that connect to one or both of the active busbars to supply power to the circuit (for example, a single-pole circuit breaker has one input line terminal that connects to one active busbar to provide 120V to the branch circuit, while a double-pole circuit breaker has two input line terminals that connect to both active busbars to provide 240V to the branch circuit). According to embodiments of the present disclosure, some or all of the main circuit breaker 1213 and branch circuit breakers 1214 are intelligent circuit breakers implemented using intelligent circuit mechanisms and functionalities as discussed herein. In this example, the intelligent circuit breakers 1213 and 1214 will have connections to a neutral wire, for example, a ground plane for a solid circuit mechanism, connected to the neutral busbar of the circuit breaker panel 1210.

[0172] The intelligent load device 1230 may include, but is not limited to, switches, power outlets, light bulbs, appliances, heating systems, ventilation systems, air conditioning systems, appliances, communication systems, entertainment systems, home security devices, and various other types of intelligent devices such as intelligent electrical receptacles or intelligent energy consumption load devices, as well as other types of smart electrical and electronic devices and systems used in residential, commercial, or industrial buildings.

[0173] In the context of IoT computing, the intelligent circuit breakers 1213 and 1214 and the intelligent load device 1230 comprise smart IoT devices configured to operate within an IoT device network, communicate, and support IoT applications of a given application domain. The IoT devices (e.g., 1213, 1214, and 1230) generate data that is uploaded to the IoT cloud computing platform 1250 via the communication network 1220 for data processing, data storage, and data management by the cloud computing platform 1220. In addition, the IoT devices can access and download data from the IoT cloud computing platform 1250 via the communication network 1220. Furthermore, depending on the type of device and network configuration, some or all of the IoT devices (e.g., 1213, 1214, and 1230) are configured for peer-to-peer communication within the IoT device network. The IoT devices are configured to form a network (e.g., a mesh network) through self-organization using known methods.

[0174] The user computing device 1240 comprises one of various types of computing devices, such as a desktop computer, laptop computer, server, smartphone, or electronic tablet, enabling the user or administrator to access the IoT cloud computing platform 1250 and intelligent devices 1213, 1214, and 1230 via the communication network 1220. The user computing device 1240 can host client-side IoT applications used to configure and manage the network intelligent devices 1213, 1214, and 1230, either directly or via the IoT cloud computing platform 1250.

[0175] While communication network 1220 is generally depicted in Figure 1, it should be understood that communication network 1220 may include any combination of known wired and / or wireless networks such as global computer networks (e.g., the Internet), wide area networks (WANs), local area networks (LANs), satellite networks, telephone or cable networks, cellular networks, Wi-Fi or WiMAX, Bluetooth, or various parts or combinations of these and other types of networks. The term “communication network” is broadly interpreted to encompass a wide variety of different network configurations, including combinations of multiple networks of different types. In this regard, in some embodiments, communication network 1220 includes a combination of multiple different types of communication networks, each comprising network devices configured to communicate using the Internet Protocol (IP) or other relevant communication protocols. Communication network 1120 comprises intermediate points (routers, switches, etc.) and other elements (e.g., gateways) that form a network backbone to establish communication paths and enable communication between network endpoints.

[0176] In the context of IoT computing, the communication network 1220 includes an IoT device network, and the intelligent circuit breakers 1213 and 1214, as well as the intelligent load device 1230 (and other wireless / wired sensors such as humidity sensors and temperature sensors), include smart IoT devices that operate and communicate within the IoT device network and are configured to support IoT applications in a given application domain (e.g., controlling and managing intelligent circuit breakers and smart electrical devices in a given house or building, collecting and analyzing energy usage information for a given house or building, etc.).

[0177] IoT devices (e.g., 1213, 1214, and 1230) generate data that is uploaded to the IoT cloud computing platform 1250 via the communication network 1220 for data processing, data storage, and data management by the cloud computing platform 1220. In addition, IoT devices can access and download data from the IoT cloud computing platform 1250 via the communication network 1220. The IoT cloud computing platform 1250 manages and processes IoT data received from various IoT devices 1213, 1214, and 1230. In some embodiments, the IoT cloud computing platform 1250 performs data processing, data storage, and data management functions and supports one or more IoT network applications and / or other types of high-performance computing applications such as deep learning applications, machine learning, big data analytics, or other types of high-performance computing applications useful for supporting home or building automation systems, including networks of smart electrical devices that can be monitored and controlled using technologies such as those disclosed herein.

[0178] Furthermore, depending on the type of device and network configuration, some or all of the IoT devices (e.g., 1213, 1214, and 1230) are configured for peer-to-peer communication within the IoT device network. The IoT devices are configured to form a network (e.g., a mesh network) through self-organization using known methods. In some embodiments, wireless communication between IoT devices (e.g., 1213, 1214, and 1230), and wireless communication between the user computing device 1240 and the IoT devices (e.g., 1213, 1214, and 1230) can be implemented via radio frequency communication protocols and systems such as Bluetooth®, Short Field Communication, Wi-Fi, Zigbee®, and other proprietary and non-proprietary protocols. In addition, various sensors, such as temperature, humidity, motion, and sound sensors, may be included as part of the IoT device network to provide environmental information used by intelligent circuit breakers 1213 and 1214 to protect against potential electrical hazards that may result from adverse environmental conditions.

[0179] In some embodiments, the circuit breaker and load status display module 1215 includes a master processor that communicates with the processors of the intelligent circuit breakers 1213 and 1214 and the intelligent load device 1230 to acquire, process, and display operational status data for such devices. The master processor is configured to display analog or digital data received from various intelligent devices and sensors, provide the status of the circuit breakers (e.g., trip, overload, etc.), and activate alarms / notifications when sensor readings are outside pre-selected limits. Alarms include visual displays on the faceplate user interface, audible sounds from an audio output device, communication signals transmitted through an electronic communication module, and signals transmitted to optical or audible alarms. In some embodiments, a user computing device 1240 can access the circuit breaker / load status display module 1215 to acquire status information about IoT devices and issue commands to perform specific functions (e.g., trip an intelligent circuit breaker, reset an intelligent circuit breaker, etc.). In some embodiments, the system 1200 in Figure 12 implements home / building automation and control systems and methods as disclosed in international application PCT / US2017 / 057309 (published as WO2018 / 075726), entitled Building Automation System, filed on 19 October 2017, the disclosure of which is fully incorporated herein by reference. This application discloses techniques for implementing intelligent electrical receptacles, which can be extended with intelligent circuit breakers as discussed herein for improved safety and security, power measurement, power control, and home diagnostics.

[0180] In some embodiments, the master processor controls and manages IoT communications for all intelligent circuit breakers and components within the distribution panel, communicating with individual intelligent circuit breakers within the distribution panel using wired communication (e.g., Controller Area Network (CAN) bus) or wireless communication using a local Bluetooth Low-Energy (BLE) mesh network, and the master processor is configured to implement or otherwise utilize any suitable broadband communication technology for communicating with remote IoT devices, systems, etc.

[0181] Figure 13 is an exploded view of a circuit breaker housing structure 1300 that may be used to house switches, circuit mechanisms, sensors, and other components of an intelligent circuit breaker according to embodiments of the present disclosure. The housing structure 1300 comprises a first housing member 1301, a heat sink element 1302, and a second housing member 1303. The heat sink element 1302 is disposed within the housing structure 1300 formed by the joining of the first and second housing members 1301 and 1303. The first and second housing members 1301 and 1303 comprise a molded plastic housing for the heat sink element 1302 and other components of the circuit breaker. The heat sink element 1302 is formed from a metallic material such as aluminum, or from another suitable material or alloy having sufficient thermal conductivity for a given application.

[0182] The first housing member 1301 comprises a plurality of opening slots 1301-1, and the heat sink element 1302 comprises a plurality of cooling fins 1302-1. When the housing structure 1300 is assembled, the cooling fins 1302-1 of the heat sink element 1302 are aligned with the corresponding slots 1301-1 of the first housing member 1301 to enable an air-cooled heat sink mechanism. Various integrated circuit chip components (e.g., processors, solid bidirectional switches, etc.) are thermally coupled to the heat sink element 1302 to function as a cooling plate for the integrated circuit chips. Integrated heat sink cooling enables improved heat exchange and mitigation of the total on-resistance of solid bidirectional switches under heavy circuit breaker load conditions. In AFCI and GFCI products, as well as in traditional industry standard approaches used in intelligent circuit breakers, line neutral wiring (not shown) is added. Those skilled in the art will recognize that various circuits, algorithms, heat exchangers, and other aspects of the disclosed configuration of the intelligent circuit breaker can be adapted to various morphological elements required in other places or countries.

[0183] Figure 14 is a flowchart of a process implemented by an intelligent circuit breaker to monitor energy use on a branch circuit and protect against fault conditions on the branch circuit, according to one embodiment of the present disclosure. In some embodiments, Figure 14 illustrates an automated process implemented by the intelligent distribution and monitoring system 1200 of Figure 12 when the external power supply is in a normal state (e.g., no power outage) (block 1400). The intelligent circuit breaker monitors the energy use profile of the circuit breaker and the intelligent receptacle or electrical device using an intelligent energy metering method such as those discussed herein (block 1401). Based on the monitored energy use, if the intelligent circuit breaker determines that a given load has an imminent fault condition (affirmative determination in block 1402), the intelligent circuit breaker communicates with the intelligent receptacle or device to automatically disable the power supply to the given load (block 1403). In some embodiments, “imminent fault” includes a user / machine programmable threshold (e.g., determined using artificial intelligence techniques based on historical information). In this example, the intelligent circuit breaker would compare the energy usage of the monitored device to a programmed threshold setting (or "imminent fault threshold") held by the monitored device. The intelligent circuit breaker (or master processor) would send an alert signal or notification of an automated action to one or more user computing devices to inform the user of the action to be taken (block 1404).

[0184] For example, suppose an intelligent circuit breaker or sensor intelligently connected to a downstream electrical device detects an unsafe condition at a particular receptacle or load. As a concrete example, a 20-amp circuit breaker typically powers a number of downstream receptacles. Each of these receptacles might be a 15-amp rated device, assuming a 20-amp load is shared among multiple receptacles. The intelligent circuit breaker's sensor could alert a specific smart receptacle, smart load, or property owner to an unsafe condition such as an overload and daisy-chained power strip, or too many strings of holiday lights on a single receptacle. In this example, the intelligent circuit breaker could issue a wireless warning / notification, instruct the receptacle to disconnect, or simply trip the breaker itself until the situation is corrected and reset.

[0185] Figure 15 is a flowchart of a process implemented by an intelligent circuit breaker to monitor energy use on a branch circuit and protect against fault conditions on the branch circuit, according to one embodiment of the present disclosure. Figure 15 illustrates an automated process implemented by the intelligent distribution and monitoring system 1200 of Figure 12 when the external power supply is in a normal state (e.g., no power outage) (block 1500). The intelligent circuit breaker monitors the energy use profile of the circuit breaker and intelligent receptacles or electrical devices using an intelligent energy metering method such as those discussed herein (block 1501). When a circuit breaker trip or fault event occurs on a given branch circuit that causes a loss of power on the branch circuit, the intelligent circuit breaker protecting the given branch circuit communicates with intelligent devices on the given branch circuit (e.g., intelligent receptacles and load devices) and instructs such intelligent devices to disable power to the load devices (block 1502).

[0186] The intelligent circuit breaker waits for a predetermined time after the fault event (block 1503), and then automatically restores power to the branch circuit (block 1504). After the branch circuit is powered on, the intelligent circuit breaker determines, or otherwise identifies, which receptacle or load was the source of the fault event (block 1505). The intelligent circuit breaker communicates with other receptacles or loads that are not experiencing the problem and reapplies power to them (block 1506).

[0187] In this control process, when an intelligent circuit breaker is combined with an overload intelligent receptacle that has the ability to communicate wirelessly before resupplying power to the intelligent circuit breaker's load, it can trip the branch circuit suffering from a dangerous fault condition and automatically resupply power by wirelessly instructing the problematic smart receptacle to remain disconnected after power is restored. This allows the intelligent circuit breaker to re-energize in order to continue supplying power to all other loads on the branch while keeping the fault isolated. As a further example, when an intelligent circuit breaker is combined with two or more individual branch feeds or phases of intelligent receptacles and a mechanism for switching these intelligent receptacles, the intelligent circuit breaker can instruct the intelligent receptacles to switch the branch circuits in an attempt to balance the load and make more economical use of phase balance.

[0188] In other embodiments, an intelligent circuit breaker can be configured to identify the type of load connected to the circuit breaker and to control the identified load, using control circuit mechanisms and control processes such as those disclosed in U.S. Patent Application No. 16 / 340,474, filed April 9, 2019, “Load Identifying AC Power Supply With Control and Methods,” the disclosure of which is fully incorporated herein by reference. For example, Figure 16 is a schematic block diagram of an intelligent circuit breaker 1600 according to one embodiment of the present disclosure, configured to identify the type of load connected to the circuit breaker and to control the load based on the identified load type. In particular, Figure 16 schematically illustrates an intelligent circuit breaker 1600 connected between an AC trunk line 110 and a load 120. The intelligent circuit breaker 1600 comprises a processor 1602, a first switch 1604, a second switch 1606, a switch control circuit mechanism 1608, an AC-DC converter circuit mechanism 1610, a first voltage sensor 1620, a second voltage sensor 1622, a first current sensor 1630, a second current sensor 1632, a third current sensor 1634, and a fourth current sensor 1636.

[0189] The first switch 1604 is connected in series in an active line path between the line input terminal and the load output terminal of the circuit breaker 1600, with the line activation 111 of the AC main line 110 connected to the line input terminal and the load activation 121 of the load 120 connected to the load output terminal. The second switch 1606 is connected in series in a neutral line path between the line neutral 112 and the load neutral 122. The line activation 111 of the AC main line 110 is connected to the load activation 121 when the first switch 1604 is switched on, and the line neutral 112 is connected to the load neutral 122 when the second switch 1606 is switched on. As in other embodiments of the intelligent discussed above, the line neutral 112 (e.g., connected to the earth connection 114 of the circuit breaker distribution board) functions as the low-side voltage reference (e.g., ground) for the electronic circuit mechanism of the intelligent circuit breaker 1600.

[0190] In some embodiments, the first and second switches 1604 and 1606 comprise solid bidirectional switches that may be configured using one of the exemplary switching circuits discussed above in conjunction with Figures 6A to 6H. A switch control circuit mechanism 1608 is configured to control the operation of the first and second switches 1604 and 1606 using switch control circuit mechanisms and techniques as discussed herein. The load that identifies the AC power supply includes an AC-DC converter 1610 that supplies power to current sensors 1630, 1632, 1634, and 1636, as well as to voltage sensors 1620 and 1622 that obtain AC trunk data and load data. The AC-DC converter circuit mechanism 1610 is configured to provide DC power to various circuit mechanisms and elements of the intelligent circuit breaker 1600, including the processor 1602, voltage sensors 1620 and 1622, current sensors 1630, 1632, 1634, and 1636, and the switch control circuit mechanism 1608. The AC-DC converter circuit mechanism 1610 can be implemented using the exemplary framework discussed above, in conjunction with Figures 4A, 4B, and 5.

[0191] The first and second voltage sensors 1620 and 1622 are configured to monitor voltages at different points along the active line path through the circuit breaker 1600. For example, as shown in Figure 16, the first voltage sensor 1620 is coupled to the active line path upstream of the first switch 1604 to monitor the AC supply voltage of the AC main line 110, and the second voltage sensor 1622 is coupled to the active line path downstream of the first switch 1604 to monitor the load voltage on a branch circuit connected to and protected by the intelligent circuit breaker 1600. The voltage sensors 1620 and 1622 are each coupled to the processor 1602 by one or more data acquisition and control lines 1620-1 and 1622-1, respectively. The voltage sensors 1620 and 1622 may be implemented using any suitable type of voltage sensing circuit mechanism, including but not limited to zero-crossing detector circuits and resistor dividers.

[0192] Current sensors 1630, 1632, 1634, and 1636 are configured to monitor current at different points along the active and neutral wire paths through the circuit breaker 1600. For example, as shown in Figure 16, the first current sensor 1630 is coupled to the active wire path upstream of the first switch 1604 to monitor the line-side supply current, the second current sensor 1632 is coupled to the active wire path downstream of the first switch 1604 to monitor the load-side supply current, the third current sensor 1634 is coupled to the neutral wire path upstream of the second switch 1606 to monitor the line-side supply current, and the fourth current sensor 1636 is coupled to the neutral wire path downstream of the second switch 1606 to monitor the load-side return current. Current sensors 1630, 1632, 1634, and 1636 are each coupled to processor 1602 by one or more data acquisition and control lines 1630-1, 1632-1, 1634-1, and 1636-1, respectively. Current sensors 1630, 1632, 1634, and 1636 may be implemented using any preferred type of current sensing circuit, including but not limited to current sensing resistors, current amplifiers, Hall effect current sensors, etc.

[0193] The processor 1602 works in conjunction with voltage sensors 1620 and 1622, and current sensors 1630, 1632, 1634, and 1636 to sample the analog supply voltage and current waveforms of the AC trunk 110, as well as the voltage waveform of the load 120 and the current waveform passing through the load 120. The processor 1602 is configured to sample the detected current and voltage waveforms at a sampling frequency significantly larger than the cycle time of a single period of the supply voltage of the AC trunk 110. The sampling frequencies of the voltage and current waveforms are selected as necessary to distinguish between load types. In some embodiments, the sampling frequency is in the kilohertz range. In other embodiments, the sampling frequency is in the megahertz range. In some embodiments, programmed power deformation (or power modulation) is applied to the load 120 to optimize the discrimination of the obtained waveforms between expected load types.

[0194] In some embodiments, the processor 1602 includes a circuitry for capturing, processing, and recording current and voltage samples, the circuitry including comparators, analog-to-digital converters, and data storage elements such as random access memory (RAM), read-only memory (ROM), and other types of solid-state and non-solid-state memory devices known in the art. In some embodiments, the processor 1602 includes control logic and associated computing resources for analyzing the recorded current and voltage samples (e.g., for neural network analysis and classification of load data) to identify the load type of load 120.

[0195] For example, the analysis of sampled current and voltage waveforms includes matching patterns in the high-frequency components of the voltage and current waveforms from load 120. In other embodiments, the waveform analysis includes determining the timing delay of when the load draws power after power is first applied to the load. In other embodiments, the analysis includes classifying the obtained waveforms into groups that indicate different load types, including their high-frequency components. Non-limiting examples of groups include waveforms that indicate primarily resistive loads, capacitive loads, inductive loads, loads with power factor correction, and loads with power control such that there is a power delay in the initial application of power forming the power source to the load.

[0196] In other embodiments, the processor 1602 can access and utilize a remote server for analyzing recorded current and voltage waveform samples. In this case, the processor 1602 transmits the recorded samples to the remote server for processing (via a wired or wireless link over an IP (Internet Protocol) network) and then receives the processing results from the remote server. In some embodiments, the processor 1602 is configured to perform a process flow as illustrated in Figure 17.

[0197] In particular, Figure 17 is a flowchart of a method for a load identification and control process implemented by an intelligent circuit breaker according to one embodiment of the present disclosure. An intelligent circuit breaker having load type identification and load control capabilities is installed at a target location between the AC trunk and the load (block 1700). For illustrative purposes, Figure 17 is described in the context of the intelligent circuit breaker 1600 of Figure 16. In some embodiments, the intelligent circuit breaker 1600 is installed in a circuit breaker distribution board. In some embodiments, the intelligent circuit breaker 1600 comprises a device installed in a separate junction box between the AC trunk and the load. In other embodiments, the intelligent circuit breaker 1600 is a component of an electrical receptacle. In some embodiments, the intelligent circuit breaker 1600 is a component of an electronic supply strip or smart extension cord.

[0198] Once installed and power is supplied, the intelligent circuit breaker 1600 proceeds to monitor the connection of the load (block 1701). In response to load detection (affirmative determination in block 1701), the intelligent circuit breaker 1600 activates switches 1604 and 1606 to connect the AC main line power voltage to the load (block 1702). The intelligent circuit breaker 1600 then acquires and stores various types of data for subsequent analysis (block 1703). The acquired data is stored in the data storage device 1710.

[0199] For example, data acquisition includes recording timing information regarding the time the load is connected to the AC main power supply, the time power is applied to the load, and the time the load is using power. In addition, data acquisition includes obtaining waveform data. Any data specific to the load that is obtained when the load is detected is called "load data." Load data includes the load's turn-on time and waveform data. Waveform data includes obtaining values ​​of the AC main voltage, load voltage, load current, and power consumed by the load as a function of time.

[0200] The data is acquired at a frequency optimized for detecting the type of load. In some embodiments, the data is acquired at a frequency many times higher than the frequency of the AC main source. For example, in one embodiment, data for a 50-60 cycle AC source is acquired at kilohertz rates. In other embodiments, where high-frequency components of the voltage and current waveforms are required to properly identify a given type of load, the data is acquired at megahertz rates.

[0201] In some embodiments, the acquired data is stored in the RAM of processor 1602 for real-time or near real-time processing. In other embodiments, the acquired data is stored in persistent memory or storage for subsequent access and analysis, for example, pattern matching to identify identical or similar loads based on matching waveform patterns acquired at the initial connection of a load (block 1701) with connections of the same or different loads at a later time. In some embodiments, the data storage 1710 is accessible by a plurality of intelligent circuit breaker devices having load identification and load control capabilities. Such storage is accessible by devices wired or wirelessly connected to the intelligent circuit breaker 1600, or by transferring the stored load data from the intelligent circuit breaker 1600 to another device, such as an intelligent circuit breaker device.

[0202] After initial data acquisition (block 1703), the intelligent circuit breaker 1600 can modulate the power supplied to the load (block 1704). In particular, in some embodiments, power modulation involves controlling one or more of switches 1604 and 1606 to vary the power supplied to the load. Additional load data is acquired and stored both during and after power modulation (block 1705). The intelligent circuit breaker 1600 performs a load identification process to identify the load type of the connected load based on the acquired load data captured before, during, and after power modulation (block 1706).

[0203] In some embodiments, the load identification process is performed by comparing the waveform of the load data with previously obtained waveforms of load data for known load devices. In other embodiments, the load identification process is based on both the timing of power turn-on to the load and the matching of the waveform data, as already discussed. In other embodiments, neural network analysis is used to classify the load data into load type categories by comparison with a library of previous load data. In other embodiments, the load identification process can implement any preferred classification process using a trained model for classifying connected loads into specific load categories based on the phase relationship between the load voltage and current waveforms and the AC trunk voltage waveform before, during, and after the modulation of power to the loads connected using switches 1604 and / or 1606.

[0204] For example, the load type of a given load can be classified into one of the following: (1) Purely resistive load: The zero crossing and peaks of voltage and current are synchronized both before, during, and after the modulation of the supply voltage. When the voltage drops, the power decreases, and when the modulation of the supply voltage stops and the supply voltage returns to full voltage, the power returns to the pre-modulation level. (2) A constant-power resistive load with power compensation. The voltage and current peaks are synchronized before modulation, and the power is constant before, during, and after modulation. (3) A purely reactive (capacitive or inductive) load. The voltage and current are out of phase before, during, and after modulation, and the power decreases during the modulation of the supply voltage, and returns to the pre-modulation level when the modulation of the supply voltage ends and the voltage returns to full. (4) Constant power reactive load. The voltage and current are out of phase before, during, and after modulation, and the power of the power supply voltage is constant before, during, and after modulation.

[0205] In some embodiments, modulation of the supply voltage results in a reduction of 1-20% of the RMS supply voltage. In some embodiments, the load identification process (block 1706) further includes determining the confidence level of the identification. In one embodiment, the confidence level is determined by the goodness of the match between the load data acquired during data acquisition steps 1703 and 1705 and data previously acquired for known loads and stored in data storage 1701. Once the identification process is complete (block 1706), a determination is made as to whether the load type of the connected load has been properly identified at a given confidence level and whether there are control rules associated with the identified load type (block 1707). In some embodiments, such a determination (block 1707) is made by comparing the confidence level in the identification with a pre-selected confidence level defined as a positive identification.

[0206] If a load is positively identified and there are pre-selected control rules associated with the identified load (positive determination in block 1707), the intelligent circuit breaker 1600 can control the power to the connected load according to one or more of the associated control rules (block 1708). For example, power to the connected load is controlled by controlling switches 1604 and / or 1606 in series with the load. Non-limiting examples of pre-selected control rules include: (1) During the daytime, purely resistive loads such as light bulbs are dimmed, reducing power consumption, especially during peak demand. (2) Under constant power load, as load demand decreases, input power decreases accordingly, and power consumption for no-load / minimum-load requirements is kept to a minimum. (3) In remote locations (where there are no people), purely resistive loads and constant-power resistive loads are disconnected and automatically reconnected according to the load demand. (4) Devices that generate arcs during normal operation (e.g., electric motors with brush connections to the rotor) are ignored by arc fault circuit interrupters to prevent troublesome disconnections.

[0207] In other embodiments, there is a set of pre-selected rules based on whether the load type is one of a purely resistive load, a constant-power resistive load, a purely reactive load, and a constant-power reactive load. In one non-limiting example of the pre-selected rules, loads identified as having power factor correction, i.e., constant-power loads, are not turned off by the controller; purely resistive loads are turned off during a pre-selected period; and power to purely reactive loads is reduced during a pre-selected period. On the other hand, if the load type is not identified, or if there are no predefined control rules associated with an identified load type (a negative determination in block 1707), the intelligent circuit breaker simply maintains the connection between the power source and the load (block 1709) and disconnects in response to a fault condition as discussed herein.

[0208] In other embodiments, an intelligent circuit breaker can be configured to include fault detection sensors and circuit mechanisms for supporting arc fault circuit interruption (AFCI) and / or ground fault circuit interruption (GFCI) functions, using control circuit mechanisms and methods such as those disclosed in U.S. Patent Application No. 16 / 093,044, filed October 11, 2018, entitled "Solid-State Line Disturbance Circuit Interrupter," the disclosure of which is fully incorporated herein by reference. An intelligent AFCI circuit breaker according to embodiments of this disclosure is configured to provide protection against parallel arcing (line-neutral), series arcing (loose, broken, or otherwise high-resistance segments in a given line), and ground fault arcing (line, or neutral to earth). An intelligent GFCI circuit breaker according to one embodiment of this disclosure is configured to provide protection against a ground fault that occurs when current from a given device or apparatus leaks from its normal path from line to neutral equipment. The GFCI circuit breaker monitors the difference in current between the active and neutral wires, and when the current input to a given load on the active wire is greater by a predetermined amount (e.g., 5 mA) than the return current from the load on the neutral wire, the GFCI circuit breaker trips, resulting in the cessation of the current flow. Figure 18A is a schematic block diagram of an intelligent circuit breaker 1800 according to one embodiment of the present disclosure, configured to monitor ground fault and arc fault conditions and to provide circuit interruption in response to detected fault conditions. The intelligent circuit breaker 1800 comprises a low-voltage DC power supply 1804, a voltage and current sensing circuit mechanism 1820, a control processor 1830, and an electronic switch and switch control circuit mechanism 1840. The low-voltage DC power supply 1810 efficiently provides DC power to the voltage and current sensing circuit mechanism 1820 and the control processor 1830. Sensing inputs 1820-1 and 1820-2 to the control processor 1830 are provided from the voltage and current sensing circuit mechanism 1820. The voltage and current sensing circuit mechanism 1820 includes sensors that detect the waveforms of the voltage and current applied to the load circuit and generate proportional analog waveforms.The control processor 1830 processes a proportional analog waveform and generates a fault output on the control line 1840-1 coupled to the switch control circuit mechanism 1840 when it detects either a ground fault or an arc fault. When a fault is detected, the fault output signal applied to the control line 1840-1 is latched and supplied to the control input of the switch control circuit mechanism, causing the electronic switch to disconnect the load 120 from the AC main line 110 until a reset 1850 is applied to the fault detection control processor 1830.

[0209] In other embodiments, the output voltage of the electronic switch 1840 can be varied via a switch control circuit mechanism. For example, upon detecting an arc fault, the output voltage may be reduced to a value below the arcing threshold but greater than zero. Such embodiments allow the load circuit to continue operating at the reduced voltage while reducing the likelihood of damaging arcs. Operation at the reduced voltage also allows for continued characteristics of the load and trunk supply circuits for determining the location of the arc fault for subsequent replacement or repair.

[0210] Figure 18B is a schematic circuit diagram of the intelligent circuit breaker 1800 of Figure 18A according to one embodiment of the present disclosure. In the exemplary embodiment of Figure 18B, the voltage and current sensing circuit mechanism (1820, Figure 18A) comprises a first current sensor 1821, a second current sensor 1822, a full-wave rectifier 1823, and sensing resistors 1824 and 1825. The electronic switch and control circuit mechanism (1840, Figure 18A) comprises a solid switch circuit mechanism 1842 (e.g., a solid bidirectional switch) for connecting the AC trunk 110 to the load 120, and a switch control circuit 1844 for controlling the solid switch circuit mechanism 1842 via an optical signal interface 1844-1. A low-voltage AC-DC power supply 1810 provides DC power for the current sensors 1821 and 1822, the fault detection processor 1830, and the switch control circuit mechanism 1844. The fault detection processor 1830 includes current detection inputs for current sensors 1821 and 1822, and voltage detection inputs for detecting the voltages of detection resistors 1824 and 1825.

[0211] In some embodiments, as shown in Figure 18B, the first and second current sensors 1821 and 1822 comprise solid-state Hall effect sensors that generate output voltages proportional to the current flowing through the line-active 111 and line-neutral 112 paths. The voltage generated by the Hall effect sensor output is supplied to the current-sensing input of the fault detection processor 1830. Furthermore, in some embodiments, the voltage sensor comprises a full-wave rectifier bridge 1823 configured to convert both half-cycles of the AC supply voltage waveform of the AC trunk 110 into a pulsating DC voltage. The full-wave rectified waveform is attenuated using a resistor divider network comprising resistors 1824 and 1825 and applied to the voltage-sensing input of the fault detection processor 1830. In some embodiments, the full-wave rectifier bridge 1823 may be eliminated, and the full-wave rectified waveform is obtained directly from the output of the AC-DC converter circuit 1810.

[0212] When a fault is detected by the fault detection processor 1830, the output of the fault detection processor 1830 is latched and supplied to the control input of the switch control circuit mechanism 1844, which then generates an optical control signal 1844-1 to the solid bidirectional switch circuit mechanism 1842, disconnecting the load 120 from the AC trunk 110 until the reset switch 1850 is activated to reset the fault detection processor 1830. As described above, in other embodiments, the output voltage of the solid switch circuit mechanism 1842 is varied via the switch control circuit mechanism 1844, and as a result, when an arc fault is detected, the output voltage is reduced to a value below the arcing threshold but greater than zero. This allows the load 120 to continue operating at the reduced voltage while reducing the likelihood of damaging arcs. Operation at the reduced voltage also allows for continued characteristics of the load and trunk supply circuit for determining the location of the arc fault for subsequent replacement or repair.

[0213] Figure 19 is a schematic block diagram of a fault detection processor 1900, which may be implemented in the intelligent circuit breaker of Figure 18B according to one embodiment of the present disclosure. The fault detection processor 1900 comprises input resistors 1902 and 1904, amplifiers 1910, 1912, and 1914, A / D converters 1920, 1922, and 1924, voltage anomaly detection module 1930, current anomaly detection module 1932, and threshold detection module 1934, AND gate 1940, OR gate 1950, and latch circuit 1960. A voltage detection signal is applied to the inverting and non-inverting input terminals of amplifier 1910. Amplifier 1910 is configured as a differential amplifier that generates a difference signal ΔV input to A / D converter 1920. A current detection input is applied to the non-inverting input of amplifier 1912 via resistors 1902 and 1904. The detection inputs are summed by the input circuits (1902, 1904), and the operational amplifier 1912 outputs a signal proportional to the sum of the currents ΣI in the line legs and neutral legs of the AC trunk 110. The ΣI signal is also applied to the input of the A / D converter 1922. The digitized ΔV signal is processed by a voltage anomaly detection module 1930 (e.g., a subprogram) executed by the fault detection processor 1900 to detect anomalies in the voltage waveform over several cycles indicating the presence of an arc fault. One non-limiting example of such a voltage anomaly is the presence of excess high-frequency energy added to the AC trunk voltage waveform, which is normally low-frequency.

[0214] The digitized ΣI signal is processed by a current anomaly detection module 1932 (e.g., a subprogram) executed by the fault detection processor 1900 to detect anomalies in the current waveform over several cycles indicating the presence of an arc fault. One non-limiting example of such a current anomaly is the occurrence of a "shoulder" (flat point) in the current waveform near the zero crossing of the current waveform. The outputs of detection modules 1930 and 1932 are fed into an AND gate 1940, and the combined appearance of voltage waveform anomalies and current waveform anomalies is one indicator of an arc fault.

[0215] The current sensing signal is also applied to the input of amplifier 1914, forming a difference signal ΔI proportional to the difference in current between the line leg and the neutral leg. The ΔI signal is digitized by A / D converter 1924 and processed by threshold detection module 1934, which generates a threshold detection signal indicating a ground fault. The arc fault signal at the output of AND gate 1940 and the ground fault signal at the output of threshold detection module 1934 are ORed by logic via OR gate 1950, and the output of OR gate 1950 is input to latch circuit 1960. The latch circuit 1960 outputs a fault detection signal and stores the fault condition until cleared by an external reset signal.

[0216] Figure 20 schematically illustrates a current zero crossover detector circuit according to one embodiment of the present disclosure. In particular, Figure 20 schematically illustrates a current zero crossover detector circuit 2000 comprising a polarity change detection stage 2010, an edge detection stage 2020, an output stage 2030, and a sensing resistor 2040. In some embodiments, the sensing resistor 2040 is connected in series in the circuit between the line activation 111 and the load activation 121. The polarity change detection stage 2010 comprises a first comparator 2011 and a second comparator 2012. The edge detection stage 2020 comprises a first edge detection circuit 2020-1 connected to the output of the first comparator 2011 and a second edge detection circuit 2020-2 connected to the output of the second comparator 2012. The first and second edge detection circuits 2020-1 and 2020-2 each comprise inverters 2021 and 2022, resistors 2023 and 2034, capacitors 2025 and 2026, and exclusive OR (XOR) gates 2027 and 2028, respectively. The output stage 2030 comprises an AND gate 2032 having inputs connected to the outputs of the XOR gates 2027 and 2028 of the edge detection stage 2020.

[0217] The sensing resistor 2040 detects an AC voltage (sensing voltage, V) between the first node N1 (line-side node) and the second node N2 (load-side node) based on the AC load current flowing through the sensing resistor 2040 in the circuit between the line activation 111 and the load activation 121.Sense It generates (referred to as ). As described above, in some embodiments, the sensing resistor 2040 comprises a high-power resistor with a relatively low resistance value that can generate a sufficient sensing voltage to the sensing resistor 2040 for measurement purposes and does not consume a large amount of energy. For example, in some embodiments, the sensing resistor 2040 has a resistance value of about 1 milliohm. In some embodiments, the sensing resistor 2040 shown in Figure 20 is the same sensing resistor 922 shown in Figure 9A, and multiple sensing circuits of the intelligent circuit breaker are tapped off using the same sensing resistor to provide various functionalities.

[0218] The polarity change detection stage 2010 detects the detection voltage V generated in the detection resistor 2040 as a result of the flow of AC current through the detection resistor 2040. Sense It is configured to detect a change in polarity. The first and second comparators 2011 and 2012 are configured as voltage comparators that compare a reference voltage applied to the inverting input (-) of the comparator with an input voltage applied to the non-inverting input (+) of the comparator, and generate a logic "1" output if the input voltage is greater than the reference voltage, and a logic "0" output if the input voltage is less than the reference voltage. More specifically, in the exemplary embodiment of Figure 20, the first comparator 2011 comprises a non-inverting input (+) connected to the load side (node ​​N2) of the sensing resistor 2040 and an inverting input (-) connected to the line side (node ​​N1) of the sensing resistor 2040. The second comparator 2012 comprises a non-inverting input (+) connected to the line side (node ​​N1) of the sensing resistor 2040 and an inverting input (-) connected to the load side (node ​​N2) of the sensing resistor 2040.

[0219] During the positive half-cycle of the voltage waveform of AC main line 110, a positive current flows through the sensing resistor 2040 from node N1 to node N2, and a positive sensing voltage (+V) is applied to the sensing resistor 2040. Sense ) results in a drop (i.e., VN1-VN2>0). Positive sense voltage (+V Sense), the output comparison signal C1 of the first comparator 2011 is logic "0", and the output comparison signal C2 of the second comparator 2012 is logic "1". On the other hand, during the negative half-cycle of the voltage waveform of the AC mains 110, a negative current flows through the sensing resistor 2040 from node N2 to node N1, generating a negative sensing voltage (-V Sense ) drop across the sensing resistor 2040 (that is, VN1-VN2<0). At the negative sensing voltage (-V Sense ), the output comparison signal C1 of the first comparator 2011 is logic "1", and the output comparison signal C2 of the second comparator 2012 is logic "0".

[0220] When the sensing voltage V Sense transitions from positive (+V Sense ) to negative (-V Sense ), the output comparison signal C1 of the first comparator 2011 transitions from logic 0 to logic 1, and the output comparison signal C2 of the second comparator 2012 transitions from logic 1 to logic 0. On the other hand, when the sensing voltage V Sense transitions from negative (-V Sense ) to positive (+V Sense ), the output comparison signal C1 of the first comparator 2011 transitions from logic 1 to logic 0, and the output comparison signal C2 of the second comparator 2012 transitions from logic 0 to logic 1.

[0221] The transitions (or edges) of the comparison signals C1 and C2 are detected by the respective edge detection circuits 2020-1 and 2020-2 of the edge detection stage 2020. More specifically, in the first edge detection circuit 2020-1, the XOR gate 2027 has a first input terminal that receives the comparison signal C1, and a second input terminal that receives the delayed complementary comparison signal

Mathematical Expression

Mathematical Expression

[0222] Similarly, in the second edge detection circuit 2020-2, the XOR gate 2028 has a first input terminal that receives the comparison signal C2, and a second input terminal that receives the delayed complementary comparison signal [Numerical expression] . The delayed complementary comparison signal [Numerical expression] is generated by the inverter 2022 and a delay circuit implemented by the resistor 2024 and the capacitor 2026. The inverter 2022 is configured to generate and output an inverted (complementary) comparison signal [Numerical expression] , and the resistor 2024 and the capacitor 2026 apply an RC delay to the complementary comparison signal [Numerical expression] Apply an RC delay to it, thereby creating a delayed complementary comparison signal.

number

number

[0223] During operation, XOR gates 2027 and 2028 generate edge pulse signals E1 and E2, respectively, immediately before and after the current zero crossing. AND gate 2032 has first and second input terminals connected to the outputs of XOR gates 2027 and 2028, respectively. AND gate 2032 generates and outputs a current zero crossing detection signal Zi based on taking the logical AND of the output signals E1 and E2. The current zero crossing detection signal Zi is applied to a switch control circuit mechanism that controls one or more switches of an intelligent circuit breaker (e.g., solid bidirectional switches and / or solenoids of electromechanical switches). In the exemplary circuit configuration of Figure 20, AND gate 2032 outputs two zero-pointing pulses, one before and one after the current zero crossing. The two pulses approach each other as the sensed current increases. At high currents (e.g., 100 amperes), the two pulses are essentially one pulse. Given that the outputs of edge detection circuits 2020-1 and 2020-2 are "ground fault true", there is always a logic "0" at one of the inputs to AND gate 2032. Therefore, in this configuration, AND gate 2032 functions as a "ground fault true" OR gate, and the output of AND gate 2032 is a logic "0".

[0224] FIGS. 21A and 21B depict various waveforms illustrating the operation modes of the current zero-crossing detection circuit of FIG. 20 according to an embodiment of the present disclosure. For example, FIG. 21A depicts a waveform illustrating an operation mode of the edge detection stage 2020 of FIG. 20, particularly the operation mode of the first edge detection circuit 2020-1. In particular, FIG. 21A illustrates a timing diagram of a plurality of signal waveforms 2100, 2110, 2120, and 2130, where waveform 2100 represents an exemplary comparison signal C1 generated by the first comparator 2011, and waveform 2110 is an exemplary complementary comparison signal output from the inverter 2021

Mathematical Expression

Mathematical Expression

[0225] As shown in FIG. 21A, the waveform 2130 of the edge detection signal E1 generates a pulse going to zero in response to each logical transition of the waveform 2100 of the comparison signal C1 output from the first comparator 2011. The edge detection circuit 2020-2 operates in a similar manner to the edge detection circuit 2020-1, as depicted in the timing diagram of FIG. 21A. In particular, the waveforms 2100, 2110, 2120, and 2130 respectively correspond to the comparison signal C2 generated by the second comparator 2012, the complementary comparison signal generated by the inverter 2022

Mathematical Expression

Mathematical Expression

number

[0226] Figure 21B illustrates simulated signal waveforms illustrating the operating modes of the current zero crossover detection circuit 2000 of Figure 20 according to one embodiment of the present disclosure. In particular, Figure 21B illustrates timing diagrams for several simulated signal waveforms 2140, 2150, 2160, 2170, 2180, and 2190. Waveform 2140 represents an exemplary current waveform of the load current flowing through the sensing resistor 2040. Waveform 2150 represents an exemplary comparison signal C1 generated by the first comparator 2011. Waveform 2160 represents an exemplary comparison signal C2 generated by the second comparator 2012. Waveform 2170 represents an exemplary edge detection signal E1 generated by the first edge detection circuit 2020-1. Waveform 2180 represents an exemplary edge detection signal E2 generated by the second edge detection circuit 2020-2. Waveform 2190 represents the current zero crossing detection signal Zi generated by the AND gate 2032 in response to waveforms (D) and (E). In addition, Figure 21B shows the Z-REF dashed line representing the current zero crossing time for current waveform 2140.

[0227] Figure 21B shows that the load current waveform 2140 rises from negative to positive, indicating that the AC current waveform passing through the sensing resistor 2040 transitions from a negative half-cycle to a positive half-cycle. In this example, the sensing voltage V Sense is negative (-V) Sense ) to positive (+V Sense)transition to the state. In practice, the zero crossing of the load current through the sensing resistor 2040 does not necessarily coincide with the zero crossing of the voltage. This is because, for example, there may be a phase difference between the voltage and current caused by an inductive load (the current phase lags the voltage phase), or other cases that result in a phase difference between the load current waveform and the voltage waveform due to a power factor of less than 1.

[0228] As shown in FIG. 21B, waveform 2150 represents the sensed voltage V Sense which exemplifies a first comparison signal C1 that transitions from logic "1" to logic "0" in response to a negative-to-positive transition of , and waveform 2160 represents the sensed voltage V Sense which exemplifies a second comparison signal C2 that transitions from logic "0" to logic "1" in response to a negative-to-positive transition of . Further, waveform 2170 exemplifies that the first edge detection signal E1 output from the XOR gate 2027 includes an edge detection pulse 2171 going to a short zero corresponding to the edge transition of the first comparison signal C1 in waveform 2150. Similarly, waveform 2180 exemplifies that the second edge detection signal E2 output from the XOR gate 2028 includes an edge detection pulse 2182 going to a short zero corresponding to the edge transition of the second comparison signal C2 in waveform 2160.

[0229] As shown in FIG. 21B, it should be noted that the falling edge of the first comparison signal C1 waveform 2150 precedes the zero current crossing Z-REF, and the rising edge of the second comparison signal C2 of waveform 2160 follows the zero current crossing Z-REF. In the negative-going cycle of the load current 2140 (not specifically shown), the roles are reversed. In particular, the falling edge of the second comparison signal C2 precedes the zero crossing of the load current, and the rising edge of the first comparison signal C1 follows the zero crossing of the load current. This is caused by the asymmetry of the propagation delay of the rising edge and falling edge in the comparator circuit mechanism in the polarity change detection stage 2010, which is the reason for the dual circuit configuration.

[0230] Furthermore, the waveform 2190 of the zero-crossing detection signal Zi includes a first zero-crossing detection pulse 2191 (a pulse pointing towards zero) and a second zero-crossing detection pulse 2192 (a pulse pointing towards zero) which are generated immediately before and after the actual zero-crossing of the load current waveform 2140. As described above, the waveform 2190 of the zero-crossing detection signal Zi is generated by logically ANDing the waveforms 2170 and 2180 of the edge detection signals E1 and E2, with the first zero-crossing detection pulse 2191 corresponding to the first edge detection pulse 2171 of the E1 waveform 2170, and the second zero-crossing detection pulse 2192 corresponding to the second edge detection pulse 2182 of the E2 waveform 2180. In this regard, as described above, in the exemplary circuit configuration of Figure 20, the AND gate 2032 outputs two zero-pointing pulses 2191 and 2192, one before and one after the current zero-crossing.

[0231] Further simulations show that the zero-crossing detection pulse approaches the load current through the sensing resistor 2040 as the load current increases. At high currents (e.g., 100 amperes), the two zero-crossing detection pulses are essentially one pulse, generated essentially simultaneously with the actual zero-crossing current, and the load current through the sensing resistor 2040 is substantially or actually zero. In particular, the slope (dv / dt) of the load current increases as the load current increases. The benefit of the current zero-crossing detector circuit 2000 in Figure 20 is that as the load current increases, the two negative pulses of Zi approach each other in time and towards the point of current zero crossing. Given that the goal of the intelligent circuit breaker (in which the current zero-crossing detector circuit 2000 is integrated) is to open the AC switch at a time as close as possible to the zero crossing, it is beneficial to use the first of the two pulses of Zi (preceding the zero current crossing) to invoke the operation, and given that there is an unavoidable delay in the switch control circuit mechanism that invokes such an operation, it is beneficial to employ a "head start" to open the AC switch. In addition, as mentioned above, another benefit is that the Zi pulse is closest to the current zero crossover, which is most important under high current loads. At maximum loads (e.g., over 100A), the two Zi pulses approach each other so closely that they essentially merge into a single pulse that nearly coincides with the current zero crossover.

[0232] Figure 22 schematically illustrates a short-circuit detection circuit according to one embodiment of the present disclosure. In particular, Figure 22 schematically illustrates a short-circuit detection circuit 2200 comprising a first comparator 2202, a second comparator 2204, a NOR gate 2210, a plurality of resistors 2212, 2213, 2213, and 2215, and a sensing resistor 2040. The sensing resistor 2040 is connected in series between nodes N1 and N2 of the circuit between line activation 111 and load activation 121. In some embodiments, the sensing resistor 2040 is the same sensing resistor 2040 used in the current zero crossover detection circuit 2000 of Figure 20.

[0233] The first comparator 2202 comprises a non-inverting input (+) connected to the load side (node ​​N2) of the sensing resistor 2040 and an inverting input (-) connected to node N3 between resistors 2212 and 2213. The second comparator 2204 comprises a non-inverting input (+) connected to the line side (node ​​N1) of the sensing resistor 2040 and an inverting input (-) connected to node N4 between resistors 2214 and 2215. Resistors 2212 and 2213 implement a first voltage divider circuit (connected between VDC on Hot and node N1) configured to generate a first reference voltage VREF1 at node N3, which is applied to the inverting input (-) of the first comparator 2202. Resistors 2214 and 2215 implement a second voltage divider network (connected between VDC on Hot and node N2) configured to generate a second reference voltage VREF2 at node N4, which is applied to the inverting input (-) of the second comparator 2204. The first and second comparators 2202 and 2204 have output terminals connected to the input terminals of the NOR gate 2210.

[0234] During operation, the first comparator 2202 detects the voltage V at node N2. Sense The first reference voltage VREF1 is compared with the second comparator 2204, and the first comparison signal HC1 is generated and output. The second comparator 2204 compares the detected voltage VREF1 at node N1 with the first reference voltage VREF1. Sense The first comparison signal is compared with a second reference voltage VREF2 to generate and output a second comparison signal HC2. The NOR gate 2210 logically takes the NOR of the first and second comparison signals HC1 and HC2 to generate and output a high current detection signal HC, which is applied to a switch control circuit mechanism that controls one or more switches of an intelligent circuit breaker (e.g., solid bidirectional switches and / or solenoids of electromechanical switches).

[0235] More specifically, the first comparator 2202 detects the detected voltage V at node N2. Sense When the voltage exceeds the first reference voltage VREF1, it generates and outputs a logic "1" signal (HC1), and the second comparator 2204 detects the voltage V at node N1. SenseWhen the voltage exceeds the second reference voltage VREF2, it generates and outputs a logic 1 signal (HC2). In other words, in the exemplary embodiment of Figure 22, the first comparator 2202 is configured to detect an extreme overcurrent condition (i.e., a short circuit) of the load during a negative half-cycle of the AC supply voltage waveform, and the second comparator 2204 is configured to detect an extreme overcurrent condition (i.e., a short circuit) of the load during a positive half-cycle of the AC supply voltage waveform. The NOR gate 2210 outputs a logic "0" signal (HC) when it detects that either half-cycle has an extreme overcurrent condition (for example, if either HC1 or HC2 is logic "1").

[0236] The resistance values ​​of resistors 2212, 2213, 2214, and 2215 are selected to generate reference voltages VREF1 and VREF2, enabling the short-circuit detection circuit 2200 to detect overcurrent conditions exceeding a target overcurrent threshold level. For example, in the case of a 20A circuit breaker, the short-circuit detection circuit 2220 can be configured to detect a short-circuit condition where the load current is 200A or greater. The ratio of the resistance values ​​of resistors 2212 and 2213 is selected to achieve a desired value of the first reference voltage VREF1, and the ratio of the resistance values ​​of resistors 2214 and 2215 is selected to achieve a desired value of the second reference voltage VREF2. In some embodiments, the resistance value of resistor 2215 is selected to be substantially equal to the resistance values ​​of resistors 2212 and 2213, effectively compensating for the voltage drop across the sensing resistor 2040.

[0237] Figure 23 illustrates simulated signal waveforms illustrating modes of operation of the short-circuit detection circuit 2200 of Figure 22 according to one embodiment of the present disclosure. In particular, Figure 23 illustrates timing diagrams for several signal waveforms 2300, 2310, 2320, and 2330. Waveform 2300 represents an exemplary first comparison signal HC1 generated by the first comparator 2202. Waveform 2310 represents an exemplary second comparison signal HC2 generated by the second comparator 2204. Waveform 2320 represents an exemplary high-current detection signal HC generated by the NOR gate 2210. Waveform 2330 represents a simulated AC current waveform of the load current flowing through the sensing resistor 2040.

[0238] In the exemplary embodiment shown in Figure 23, it is assumed that the short-circuit detection circuit 2200 is configured to detect an overcurrent condition if the load current waveform 2330 reaches or exceeds 200A in any half-cycle. As shown in Figure 23, waveform 2300 illustrates that a first comparison signal HC1 is set to logic "1" during each negative half-cycle period in which the load current waveform 2330 reaches or exceeds 200A. Waveform 2310 illustrates that a second comparison signal HC2 is set to logic "1" during each positive half-cycle period in which the load current waveform 2330 reaches or exceeds 200A. Waveform 2320 illustrates the high-current detection signal HC, which is generated by logically taking the NOR of waveforms 2300 and 2310. In this exemplary embodiment, waveform 2320 illustrates that the NOR gate 2210 generates a logic "0" pulse for each period during which the load current waveform 2330 reaches 200A in any half-cycle of the load current and exceeds 200A.

[0239] It should be understood that the hardware detection circuits in Figures 20 and 22 enable fast and efficient detection of current zero crossing events, as well as fast and efficient detection and response to extreme overcurrent and short-circuit conditions. While such detection can be implemented using software executed by a processor, the use of hardware detection enables fast detection and response times compared to the detection and response delays that may occur as a result of the uncertain processing time that a processor may impose by analyzing sensor data using software. In addition, the current zero crossing detection circuit 2000 in Figure 20 allows an intelligent circuit breaker to switch off a solid switch when the load current is near zero. In this case, turning off the solid switch when the load current is near zero can avoid kickback from an inductive load, and a high-voltage kickback spike could damage the MOSFET of the solid switch or the MOSFET of the leakage clamp (e.g., isolation circuit mechanism 810, Figure 8B). The hardware detection circuits in Figures 20 and 22 are powered by a DC supply (e.g., VDC-on-Hot) referenced from the line activation 110. This offers the advantage of avoiding the delays associated with optical isolators or other circuits that would be necessary if these circuits were powered from a DC power supply referenced by neutral.

[0240] Figure 24 schematically illustrates an intelligent circuit breaker according to another embodiment of the present disclosure. In particular, Figure 24 schematically illustrates an intelligent circuit breaker 2400 connected between an AC trunk line 110 and a load 120, the intelligent circuit breaker 2400 including a single-pole hybrid solid and mechanical circuit breaker architecture. The intelligent circuit breaker 2400 comprises a solid switch 2410 and an air-gap electromagnetic switch 2420 connected in series in the circuit between the line activation 111 of the AC trunk line 110 and the load activation 121 of the load 120 (for example, the air-gap electromagnetic switch 2420 and the solid switch 2410 are connected in series between the line input terminal and the load output terminal of the intelligent circuit breaker 2400). The intelligent circuit breaker 2400 further comprises an AC-DC converter circuit 2430, a zero-crossing detection circuit mechanism 2440, a sensing resistor 2442, a current sensor 2450, other types of sensors 2460 (e.g., environmental sensors, light sensors, etc.), and a switch controller 2470.

[0241] In some embodiments, as shown in Figure 24, the solid switch 2410 comprises a power MOSFET switch 2410 (e.g., an N-type enhancement MOSFET device) having a gate terminal (G), a drain terminal (D), and a source terminal (S), as shown, and an internal body diode 2410-1. The air gap electromagnetic switch 2420 comprises any preferred type of electromagnetic switch mechanism configured to physically open and close a set of electrical contacts, creating an air gap between the electrical contacts when the air gap electromagnetic switch 2420 is in the open switch state. For example, the air gap electromagnetic switch 2420 may comprise a latching solenoid or relay contact element that automatically opens and closes the electrical contacts of the air gap electromagnetic switch 2420 in response to a control signal from a switch controller 2470.

[0242] By creating an air gap in the line path between the line activation 111 and the load activation 121, the flow of current from the line activation 111 to the load activation 121 is prevented, thus providing complete isolation of the AC main line 110 from the load 120. The air gap electromagnetic switch 2420 may be located either on the line side of the solid switch 2410 or on the load side of the solid switch 2410 (as shown in Figure 24). The intelligent circuit breaker 2400 provides a cost-effective solution that allows the use of a single solid switch (compared to several solid switches in the exemplary embodiments described above) when electrical work regulations require the implementation of an air gap in the circuit breaker for complete isolation.

[0243] The AC-DC converter circuit 2430 is configured to provide DC supply power to various circuit mechanisms and elements of the intelligent circuit breaker 2400, including (depending on the configuration of such sensors 2450 and 2460) a zero-crossing detection circuit 2440, a switch controller 2470, and optionally a current sensor 2450 and other sensors 2460. The AC-DC converter circuit 2430 is configured to remain powered during a fault when the solid switch 2410 is in the off state or the electromagnetic switch 2420 is in the open state. In some embodiments, the AC-DC converter circuit 2430 has sufficient energy storage capacity to power the DC subsystem immediately after an external power outage, so that when the external power supply collapses, information about the associated power outage or short circuit can be acquired and stored by the controller 2470 and then transmitted wirelessly to a remote node, device, or system using a radio frequency transceiver (not shown) coupled to or integrated with the switch controller 2470.

[0244] In some embodiments, the zero-crossing detection circuit mechanism 2440 is configured to monitor the voltage and / or current at a target point along the active line circuit of the intelligent circuit breaker 2400 and to detect zero-current and / or zero-voltage crossings of the AC waveform on the active line circuit. For example, as shown in Figure 24, the zero-crossing detection circuit mechanism 2440 is coupled to the active line circuit upstream of switches 2420 and 2410 to detect instances of zero-current and / or zero-voltage crossings of the AC power waveform on the line side of the intelligent circuit breaker 2400. The zero-crossing detection circuit mechanism 2440 is coupled to the switch controller 2470 by one or more data acquisition and control lines 2440-1.

[0245] The zero-crossing detection circuit mechanism 2440 can be implemented using any suitable type of voltage zero-crossing and / or current zero-crossing detection circuit mechanism configured to detect zero-crossings of current and / or voltage in an AC power supply waveform and to generate a detection signal indicating the zero-crossing event of the current or voltage waveform and the associated transition direction of the zero-crossing event (e.g., an AC waveform transitioning from negative to positive (referred to as the "positive transition direction"), or an AC waveform transitioning from positive to negative (referred to as the "negative transition direction")).

[0246] In some embodiments, the zero-crossing detection circuit mechanism 2440 is configured to receive a sample of the AC waveform on the active line path (on the line side of switches 2420 and 2410) as input, compare the AC waveform sample with a zero reference voltage (e.g., line neutral voltage) to determine the polarity of the AC waveform on the active line path, and detect zero-crossing events of the AC waveform and the associated transition direction of the zero-crossing. In some embodiments, the comparison is performed using a voltage comparator having a non-inverting input connected to the active line path and an inverting input that receives the reference voltage. The output of the voltage comparator switches from logic 1 to logic 0 when the input voltage transitions from positive to negative, and from logic 0 to logic 1 when the input voltage transitions from negative to positive. In this example, the output of the zero-crossing detection circuit mechanism 2440 transitions between logic "1" and logic "0" outputs for each detected zero-crossing of the AC voltage waveform.

[0247] In some embodiments, the zero-crossing detection circuit mechanism 2420 implements the current zero-crossing detection circuit 2000 shown in Figure 20. In this example, the sensing resistor 2442 in Figure 24 is used in a similar manner to the sensing resistor 2040 shown in Figure 20. The current zero-crossing detection circuit mechanism is used in place of, or in addition to, the voltage zero-crossing detection circuit mechanism to determine when the AC current waveform (i.e., AC load current) on the active line is zero and the direction of the transition of the AC current waveform. This is desirable, for example, when there is an inductive load that shifts the phase of the voltage and current waveforms on the active line path.

[0248] In some embodiments, the current sensor 2450 is configured to detect the magnitude of the current drawn by the load 120 through the active line path via the intelligent circuit breaker 2400. The current sensor 2450 may be implemented using any suitable type of current sensing circuit, including but not limited to current sensing resistors, current amplifiers, Hall effect current sensors, etc. The current sensor 2450 is coupled to the switch controller 2470 by one or more data acquisition and control lines 2450-1. In some embodiments, the current sensor 2450 implements the short-circuit detection circuit 2200 of Figure 22, and the current sensor 2450 includes a sensing resistor connected in series between the load side of the solid switch 2410 and the load activation 121. In some embodiments, the current sensor 2450 utilizes the same sensing resistor 2442 as the zero-crossing detection circuit mechanism 2440, in which case the current sensor 2450 uses a sensing voltage V Sense It will have inputs connected to nodes N1 and N2 for sampling.

[0249] Sensor 2460 includes one or more optional sensors configured to detect environmental conditions (e.g., chemical, gas, humidity, water, temperature, light, etc.) and generate sensor data indicating potentially hazardous environmental conditions. Sensor 2460 is coupled to a switch controller 2470 by one or more data acquisition and control lines 2460-1. As an example, sensor 2460 may include one or more of the following: (i) a chemical sensitivity detector configured to detect the presence of hazardous chemicals; (ii) a gas sensitivity detector configured to detect the presence of hazardous gases; (iii) a temperature sensor configured to detect high temperatures indicating, for example, a fire; (iv) a piezoelectric detector configured to detect large vibrations associated with, for example, an explosion, an earthquake, etc.; (v) a humidity or water sensor configured to detect flood or wet conditions; and other types of sensors configured to detect the presence or occurrence of hazardous environmental conditions that would require circuit interruption.

[0250] The switch controller 2470 works in conjunction with the zero-crossing detection circuit mechanism 2440, the current sensor 2450, and the sensor 2460 to perform functions such as detecting fault conditions (e.g., short-circuit fault, overcurrent fault, arc fault, ground fault, etc.) and hazardous environmental conditions (e.g., gas leak, chemical spill, fire, flood, etc.), and provides timing control for opening and closing switches 2410 and 2420 in response to the detected fault condition or hazardous environmental condition, thereby preventing the formation of an electric arc in the air-gap electromagnetic switch 2420. The switch controller 2470 generates a gate control signal that is applied to the gate terminal (G) of the solid switch 2410 to switch the solid switch 2410 into an ON or OFF state. In some embodiments, the switch controller 2470 generates a gate control signal to switch off the solid switch 2410 in response to fault conditions such as short-circuit faults, overcurrent faults, overvoltage conditions, and other faults or hazards detected by the switch controller 2470, as a result of analyzing sensor data acquired from the current sensor 2450 and / or other sensors 2460.

[0251] The switch controller 2470 may be implemented using a processor configured to process sensor data and implement a switch control timing protocol, as discussed herein, for controlling switches 2410 and 2420. In addition, the switch controller 2470 may implement a circuit mechanism for converting the sensor data into a suitable format suitable for processing by the processor. In other embodiments, the switch control 2470 implements a hardware-based switch control circuit mechanism (as in the exemplary embodiments discussed above), enabling hardware-based control as opposed to software-based control.

[0252] The switch controller 2470 may include an RF transceiver for wirelessly communicating with remote nodes, devices, systems, etc., to support remote monitoring and detection of fault conditions, and for receiving remote commands to control the intelligent circuit breaker 2400. The processor may comprise a central processing unit, a microprocessor, a microcontroller, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), and other types of processors, as well as a portion or combination of such processors capable of performing processing functions based on software, hardware, firmware, etc. In other embodiments, the solid-state circuit mechanisms of the various components of the intelligent circuit breaker 2400 (e.g., 2430, 2440, and 2470) may be implemented on a single die as a system-on-chip.

[0253] To prevent the generation of an electric arc between the electrical contacts of the electromagnetic switch 2420, the switch controller 2470 is configured to switch off the solid switch 2410 before switching the air gap electromagnetic switch 2420 to the open or closed state. However, in the configuration of Figure 24, even assuming that the solid switch 2410 is in the off state and the air gap electromagnetic switch 2420 is in the closed state, the body diode 2410-1 of the solid switch 2410 allows negative current to be conducted from the load 120 to the AC trunk 110 when the AC power waveform of the AC trunk 110 is in a negative half-cycle.

[0254] In this example, if the air gap electromagnetic switch 2420 is opened during a negative half-cycle of the AC power waveform, the flow of negative current will generate an electric arc between the electrical contacts of the air gap electromagnetic switch 2420. In addition to the generation of an electric arc, opening the air gap electromagnetic switch 2420 may be difficult or impossible due to the relatively strong electromagnetic force that will be generated as a result of the short-circuit current condition and the flow of negative current at a given time.

[0255] To avoid the generation of such an electrical arc and to facilitate the opening of the air gap electromagnetic switch 2420, the switch controller 2470 is configured to switch off the solid switch 2410 in response to detecting a fault or harmful condition, and to process sensor data acquired from the zero-crossing detection circuit mechanism 2440 to determine the zero-crossing event of the AC voltage and / or current on the line side (e.g., line activation 111) of the intelligent circuit breaker 2400 and the associated transition direction of the zero-crossing event, and then to open the air gap electromagnetic switch 2420 in response to the detected zero-crossing event if it is determined that the polarity of the AC voltage and / or current on the line side has transitioned to a positive half-cycle.

[0256] On the other hand, if the switch controller 2470 determines, at a given time, that the associated transition direction of a zero-crossing event is a negative transition in which the polarity of the AC voltage and / or current on the line side transitions to a negative half-cycle, the switch controller 2470 does not open the air-gap electromagnetic switch 2420, but delays opening the air-gap electromagnetic switch 2420 until the next instance of a zero-crossing event with a positive transition as detected by the zero-crossing detection circuit mechanism 2440. In this case, the air-gap electromagnetic switch 2420 would be opened during the half-cycle in which the solid switch 2410 prevents all current flow (except leakage). This switch control protocol allows for a significant downsizing of the size and strength requirements of the electromechanical mechanism for opening the air-gap electromagnetic switch 2420.

[0257] Here, the switch timing control implemented by the switch controller 2470 will be discussed in more detail with reference to Figures 25A, 25B, and 26. For example, Figure 25A illustrates the power supply voltage waveform input to the line side of the intelligent circuit breaker 2400 in Figure 24. In particular, Figure 25A illustrates the input voltage waveform 2500 representing the power supply voltage waveform of the AC main line 110. The input voltage waveform 2500 includes a positive half-cycle 2502, a negative half-cycle 2504, and a zero-voltage crossover 2510 at times T0, T1, T2, T3, and T4. When the solid switch 2410 is switched on and the air-gap electromagnetic switch 2420 is switched closed, the input voltage waveform 2500 is applied to the load activation line 121 of the load 120. When the switch controller 2470 determines that power should be disconnected from the load 120, the switch controller 2470 generates a gate control signal that is applied to the gate terminal G of the solid switch 2410 in order to switch the solid switch 2410 into the off state.

[0258] Figure 25B illustrates the load-side output voltage waveform 2520 of the intelligent circuit breaker 2400 in Figure 24 when the solid switch 2410 is switched off and the air-gap electromagnetic switch 2420 is switched closed. In this state, the body diode 2410-1 of the solid switch 2410 is forward-biased during the negative half-cycle 2504 of the input voltage waveform 2500, rectifying the input voltage waveform 2500 and resulting in the output voltage waveform 2520 shown in Figure 25B. The portion 2522 of the output voltage waveform 2520 corresponding to the positive half-cycle 2502 of the input waveform 2500 is 0V, and the portion 2524 of the output voltage waveform 2520 follows the voltage of the negative half-cycle 2504 of the input waveform 2500. In this example, a negative current will flow from the negative load 120 to the AC main line 110 during each negative half-cycle 2524 until the air-gap electromagnetic switch 2420 is opened.

[0259] As described above, after the solid switch 2410 is switched off, the switch controller 2470 processes sensor data acquired from the zero-crossing detection circuit mechanism 2440 to determine the zero-crossing event and the transition direction of the zero-crossing event of the AC voltage waveform (and / or AC current waveform) on the active line path of the intelligent circuit breaker 2400. If the AC voltage waveform is transitioning to a positive half-cycle, the switch controller 2470 generates a control signal to open the air gap electromagnetic switch 2420 in response to the detected zero-crossing event. For example, Figure 25A shows the zero-crossing events 2510 of the AC waveform 2500 at times T0, T1, T2, T3, and T4, but only the zero-crossing events 2510 at times T0, T2, and T4 have a positive transition direction in which the AC waveform 2500 transitions to a positive half-cycle.

[0260] In this example, the switch controller 2470 generates a control signal to open the air gap electromagnetic switch 2420 to completely cut off power to the load 120 in response to a zero-crossing event at time T0, T2, or T4. In particular, as shown in Figure 25A, in some embodiments, in response to detecting a positive transition zero-crossing event (e.g., at time T0 or T2), the switch controller 2470 generates a switch control signal to open the air gap electromagnetic switch 2420 with a short time delay T S Wait for (for example, about 10 μs). This short delay time T S This ensures that the AC waveform is slightly positive and that no current flows through the active wire path, thereby preventing the formation of an electric arc that could occur in the air gap electromagnetic switch 2420, and allowing the air gap electromagnetic switch 2420 to open easily without jitter due to a small current flow.

[0261] On the other hand, assume that in Figures 25A and 25B, a fault condition occurs with a time period of T0 to T1, and the solid switch 2410 is turned off. In this example, the switch controller 2470 would determine that the next zero-crossing event 2510 of the AC waveform 2500 at time T1 is a negative transition zero-crossing event. In this case, the switch controller 2470 issues a control signal to open the air gap electromagnetic switch 2420 (with a delay time T after detecting the zero-crossing event at time T2). S Before generating the signal, the system waits for the next positive transition zero-crossing event 2510 at time T2. Here again, this ensures that the AC waveform 2500 is slightly positive and that no current flows through the active line path, thereby preventing the formation of an electric arc that could occur in the air gap electromagnetic switch 2420 and allowing the air gap electromagnetic switch 2420 to open easily without jitter due to a small current flow.

[0262] It should be understood that the exemplary voltage waveforms 25A and 25B represent a load 120 having a power factor of approximately 1(1), where the phases of the AC voltage waveform and the current drawn by the load 120 are considered to be aligned. In such cases, a zero voltage crossover is considered a zero current crossover. However, in cases where the load 120 has a power factor of less than 1 (e.g., a capacitive or inductive load), the phases of the voltage waveform and the current drawn by the load 120 are misaligned. In this regard, the zero crossover detection circuit mechanism 2440 may include a current zero crossover detector to determine a zero current crossover of the current waveform or a zero current crossover of a positive transition on the line side of switches 2420 and 2410, to ensure that no positive current flows in the line activation path before opening the air gap electromagnetic switch 2420. For example, as described above, in some embodiments, the zero crossover detection circuit mechanism 2420 implements the current zero crossover detection circuit 2000 of Figure 20.

[0263] Figure 26 is a flowchart of a switch control process implemented by the switch controller 2470 of the intelligent circuit breaker 2400 of Figure 24, according to one embodiment of the present disclosure. The switch control process in Figure 26 represents a non-limiting exemplary embodiment for restoring external power, or manual, automatic, or remote activation control for activating the intelligent circuit breaker 2400 (block 2600). In this example, it is assumed that the solid switch 2410 is in the switch-off state and the air-gap electromagnetic switch 2420 is in the switch-closed state.

[0264] The switch controller 2470 waits to detect a suitable zero crossing (block 2602) before closing the air gap electromagnetic switch 2420 (block 2604). While it is ideal to wait for a voltage and / or current zero crossing event before closing the air gap electromagnetic switch 2420, those skilled in the art will understand that this is not a necessary condition for closing. The zero crossing event may be a zero crossing event of a positive transition or a zero crossing event of a negative transition. As described above, in some embodiments, it is preferable to close the air gap electromagnetic switch 2420 on the next half-cycle zero crossing when the body diode (e.g., diode 2410-1) of the solid switch (e.g., switch 2410) is not forward-biased and does not conduct. For example, in the exemplary embodiment of Figure 24, the body diode 2410-1 of the solid switch 2410 is reverse-biased and does not conduct during the positive half-cycle of the supply voltage waveform of the AC trunk 110. In such embodiments, it is ideal to close the air gap electromagnetic switch (block 2604) when a zero crossing event (current or voltage) of a positive transition is detected.

[0265] In other embodiments, depending on the type of MOSFET used to implement the solid-state switch 2410, it may be ideal to close the air-gap electromagnetic switch 2420 upon detecting a zero-crossing event (current or voltage) of a negative transition. For example, in an exemplary embodiment where the solid-state switch 2410 in Figure 24 is implemented as a P-type enhancement MOSFET having a drain terminal (line side) coupled to the air-gap switch 2420 and a coupled source terminal (load side), the body diode of the P-type MOSFET has its anode connected to the line side and its cathode located on the load side. In such an example, the body diode of the P-type solid-state switch would be reverse-biased and non-conducting during the negative half-cycle of the supply voltage waveform of the AC trunk 110. Therefore, when the P-type solid-state switch is in the switch-off state, it would be ideal to close the air-gap electromagnetic switch 2420 upon detecting a zero-crossing event (current or voltage) of a negative transition. The same would apply to a circuit configuration in which the N-type solid switch 2410 shown in Figure 24 is inverted, having a source terminal connected to the line side and a drain terminal connected to the load side.

[0266] When the air-gap electromagnetic switch 2420 is closed, the switch controller 2470 proceeds to generate a gate control signal to switch the solid switch 2410 into the switched-on state (block 2606). The solid switch 2410 can be switched on at any time after the air-gap electromagnetic switch 2420 has been closed. For example, the intelligent circuit breaker 2400 may operate in a "standby" mode in which the air-gap electromagnetic switch 2420 remains in the switched-closed state, and the switch controller 2470 waits for some trigger event (e.g., a remote command) to occur in order to proceed with the activation of the solid switch 2410.

[0267] When both switches 2410 and 2420 are activated, the switch controller 2470 enters a standby state for several events or commands to disconnect the circuit connection between the power supply and the load (block 2608). During the standby period, the solid switch 2410 and the air-gap electromagnetic switch 2420 remain in an activated state (block 2610). The event may be the detection of a given fault or hazardous condition, which is determined by the switch controller 2470 processing sensor data received from various sensors 2450 and 2460. The command may be a manual or automatic command to disconnect the circuit connection.

[0268] Upon detecting a fault or harmful condition (affirmative determination in block 2608), or in response to a manual or automatic command to trip a circuit breaker, the switch controller 2470 generates a gate control signal to switch the solid switch 2410 into the off state (block 2612). The switch controller 2470 then processes data from the zero-crossing detection circuit mechanism 2440 to detect a target zero-crossing event (e.g., a zero-crossing event of a positive transition) on the line activation path (block 2614), and in response to detecting the target zero-crossing event (affirmative determination in block 2614), the switch controller 2470 generates a switch control signal to switch the air-gap electromagnetic switch 2420 into the open state (block 2616).

[0269] The switch controller 2470 enters a standby state (block 2618) and waits for the fault event or harmful condition to be cleared, keeping the solid switch and air gap electromagnetic switch in an inactive state (block 2620). Once the fault event or harmful condition is cleared (affirmative determination in block 2618), or when the switch controller 2470 receives a manual or remote command indicating otherwise to reconnect power to the load, the control process returns to block 2600, where the switch controller 2470 reactivates the air gap and solid switch, thereby reconnecting power to the load. Although the process flow in Figure 26 does not explicitly include a process step for performing zero-cross detection before opening and closing the solid switch 2410, it should be understood that for certain applications, the switching on and switching off of the solid switch 2410 may be timed, as desired, by either a voltage zero-cross event or a current zero-cross event.

[0270] Figure 27 schematically illustrates an intelligent circuit breaker according to another embodiment of the present disclosure. In particular, Figure 27 schematically illustrates an intelligent circuit breaker 2700 connected between an AC trunk line 110 and a load 120. The intelligent circuit breaker 2700 is similar to the intelligent circuit breaker 2400 in Figure 24, except that the intelligent circuit breaker 2700 in Figure 27 implements a thermoelectric circuit breaker switch 2710, an internal switch 2720, and a shunt resistor 2730 (instead of the air gap electromagnetic switch 2420 in Figure 24). In some embodiments, the thermoelectric circuit breaker switch 2710 has a conventional circuit breaker architecture as discussed above in conjunction with Figure 1A.

[0271] The internal switch 2720 and shunt resistor 2730 are connected in series between node N3 and ground (neutral) 114, where node N3 includes the connection point between the thermoelectric circuit breaker switch 2710 and the solid switch 2410. In some embodiments, as shown in Figure 27, the internal switch 2720 comprises a solid bidirectional switch with a first MOSFET switch 2721 and a second MOSFET switch 2722 (e.g., N-channel MOSFET switches) connected in back-to-back series with a common source terminal and a common gate terminal. The common gate terminals of the first and second MOSFET switches 2721 and 2722 are connected to the control output ports of the switch controller 2470. The first and second MOSFET switches 2721 and 2722 have internal body diodes (not specifically shown in Figure 27).

[0272] Similar to the exemplary embodiment in Figure 24, the switch controller 2470 works in conjunction with the zero-crossing detection circuit mechanism 2440, the current sensor 2450, and other sensors 2460 to perform functions such as detecting fault conditions (e.g., short circuits, overcurrent conditions, overvoltage conditions, arc faults, ground faults, etc.) and hazardous environmental conditions (e.g., gas leaks, chemical spills, fires, floods, etc.). The switch controller 2470 is configured to apply a control signal to the gate terminal (G) of the solid switch 2410 to control the activation (switching on) and deactivation (switching off) of the solid switch 2410. In addition, the switch controller 2470 is configured to generate control signals to control the activation and deactivation of the internal switch 2720. The switch controller 2470 implements a timing control protocol configured to control the timing of activation / deactivation of the solid switch 2410 and the internal switch 2720 under different operating states of the intelligent circuit breaker 2700.

[0273] For example, the switch controller 2470 analyzes sensor data acquired from the current sensor 2450 and / or other sensors 2460 and generates a gate control signal to switch off the solid switch 2410 in response to fault conditions such as short-circuit faults, overcurrent faults, overvoltage conditions, and other faults or hazards detected by the switch controller 2470. In addition, after the solid switch 2410 is switched off, the switch controller 2470 generates a control signal to activate the internal switch 2720, thereby creating an internal short circuit between node N3 and ground 114. The internal short circuit between node N3 and ground 114 causes an overcurrent to flow through the thermoelectric circuit breaker switch 2710, thereby tripping the thermoelectric circuit breaker switch 2710 and creating an air gap in the circuit between the line activation 110 and the load activation 121.

[0274] In other words, in this embodiment, the switch controller 2470 does not generate a control signal that is directly applied to the thermoelectric circuit breaker switch 2710 to trip it. Instead, the switch controller 2470 applies a gate control signal to the commonly connected gate terminals of the first and second MOSFET switches 2721 and 2722 to turn them on. This creates an internal short circuit between node N3 and ground 114, through which current flows through the shunt resistor 2730, causing the thermoelectric circuit breaker switch 2710 to trip. The internal switch 2720 is deactivated at some point after the thermoelectric circuit breaker switch 2710 has tripped and before the intelligent circuit breaker 2700 is reset for normal operation (for example, the first and second MOSFET switches 2721 and 2722 are switched off).

[0275] In some embodiments, the resistance of the shunt resistor 2730 is selected such that the short-circuit current flow from node N3 to ground 114 is in the range of approximately 2 to 3 times the current rating of the thermoelectric circuit breaker switch 2710. For example, if the thermoelectric circuit breaker switch 2710 has a current rating of 20 amperes, the resistance of the shunt resistor 2730 is selected such that a maximum current of approximately 40 to 60 amperes flows through the short-circuit branch between node N3 and ground 114, tripping the thermoelectric circuit breaker switch 2710 and creating an air gap in the circuit between the line activation 110 and the load activation 121.

[0276] In some embodiments, the switch controller 2470 is configured to use a zero-crossing detection signal output from the zero-crossing detection circuit 2440 to determine when to activate the internal switch 2720, thereby causing a short circuit between node N3 and ground 114, which in turn trips the thermoelectric circuit breaker switch 2710. For example, as in the exemplary embodiments discussed above in relation to Figures 24-26, if the zero-crossing detection circuit 2440 is configured to detect the direction of polarity transitions between opposing half-cycles of the AC voltage waveform or AC current waveform on the line side of the thermoelectric circuit breaker switch 2710, the switch controller 2470 is configured to activate the internal switch 2720 when the polarity transition reverses biases the body diode 2410-1 of the deactivated solid switch 2410.

[0277] In the exemplary embodiment shown in Figure 27, the body diode 2410-1 of the solid switch 2410 is reverse-biased during the positive half-cycle of the AC voltage waveform or AC current waveform on the line side of the thermoelectric circuit breaker switch 2710. However, the body diode 2410-1 of the solid switch 2410 is forward-biased, for example, when the AC power waveform of the AC trunk 110 is in the negative half-cycle, allowing negative current to conduct from the load 120 through the thermoelectric circuit breaker switch 2710 to the AC trunk 110.

[0278] In this case, if the internal switch 2720 is activated during a negative half-cycle of the AC power waveform, the current flow through the thermoelectric circuit breaker switch 2710 would be a combination of (i) a negative current flow from the load 120 to the AC main line 110 and (ii) a current flow generated in the short-circuit path from the ground 114 to node N3, which in turn provides an increased current flow through the thermoelectric circuit breaker switch 2710, causing the thermoelectric circuit breaker switch 2710 to trip. This could result in the generation of a high-energy electric arc between the electrical contacts of the thermoelectric circuit breaker switch 2710 when it trips.

[0279] In contrast, by ensuring that the internal switch 2720 is activated at the timing when the body diode 2410-1 of the solid switch 2410 is reverse-biased by the polarity transition, the amount of current flowing through the thermoelectric circuit breaker switch 2710 is limited, at least initially, to the current generated in the short-circuit path between node N3 and ground 114 based on the resistance value of the shunt resistor 2730. In this case, the amount of short-circuit current generated to trip the thermoelectric circuit breaker switch 2710 can be controlled / limited by the shunt resistor 2730, and thus the amount of electric arc generated between the electrical contacts of the thermoelectric circuit breaker switch 2710 when it trips. In other words, by timing the activation of the internal switch 2720 to the point when the body diode 2410-1 of the deactivated solid switch 2140 is reverse-biased, the intelligent circuit breaker 2700 avoids using the actual short-circuit load current to trip the conventional thermoelectric circuit breaker switch 2710, and instead uses a limited / controlled internal short-circuit current (generated by the activation of the internal switch 2720) to trip the circuit breaker switch 2710.

[0280] In other embodiments, the intelligent circuit breaker is designed to include one or more visual indicators that allow an individual to determine the operational status of the intelligent circuit breaker. For example, Figures 28A, 28B, 28C, 28D, and 28E are perspective and schematic views of an intelligent circuit breaker 2800 with multiple visual indicators configured to show the operational status of the intelligent circuit breaker 2800. In particular, Figures 28A and 28B are perspective views of an intelligent circuit breaker 2800 comprising a circuit breaker housing 2810 (or enclosure), a manual rocker switch 2820, a first visual indicator 2830, and a second visual indicator 2840. The manual rocker switch 2820 includes an off position and an on position that allow an individual to manually trip and reset the intelligent circuit breaker 2800. As will be described in more detail below, the first and second visual indicators 2830 and 2840 are configured to provide a visual status of the operational status of the intelligent circuit breaker 2800. Figures 28C, 28D, and 28E schematically illustrate the various components within the circuit breaker housing 2810 of the intelligent circuit breaker 2800. For example, as shown in Figures 28C-28E, the components include an actuator mechanism 2850, a solenoid 2860, and an air gap switch 2870. The air gap switch 2870 includes a first fixed contact 2871 and a second movable contact 2872 connected to the actuator mechanism 2850. A manual rocker switch 2820 and a solenoid 2860 are connected to the actuator mechanism 2850. The actuator mechanism 2850 is configured to control the position of the movable contact 2872 relative to the fixed contact 2871 in response to (i) manual operation of the rocker switch 2820 and (ii) magnetic operation of the solenoid 2860. In this configuration, the solenoid 2850 is configured to act magnetically in response to high overcurrents, and the magnetic actuation of the solenoid 2860 results in the mechanical actuation of the actuator mechanism 2850, which pulls the movable contact 2872 away from the fixed contact 2871 of the air gap switch 2870.For the sake of simplicity in illustration and explanation, Figures 28C, 28D, and 28E do not illustrate the circuit boards and associated solid-state circuit mechanisms used to implement the various intelligent functionalities of the intelligent circuit breaker 2800, as discussed above.

[0281] Figures 28C, 28D, and 28E illustrate various operating states of the intelligent circuit breaker 2800. In particular, Figure 28C illustrates an operating state in which the air gap switch 2870 is "open," and the first and second contacts 2871 and 2872 are separated to form an air gap 2873. In Figure 28C, the manual rocker switch 2820 is in the "off" position. In this example, the air gap switch 2870 is manually opened by moving the rocker switch 2820 from the on position to the off position, and the operation of the rocker switch 2820 in this example causes the actuator mechanism 2850 to move the movable contact 2872 away from the fixed contact 2871.

[0282] Next, Figure 28D illustrates an operating status where the air gap switch 2870 is in the "closed" state, and the first and second contacts 2871 and 2872 are electrically in contact with the closed air gap 2873. In Figure 28D, the manual rocker switch 2820 is in the "on" position, and the solenoid 2860 is in the closed position. In this example, the air gap switch 2870 is manually closed by moving the rocker switch 2820 from the off position to the on position, and the operation of the rocker switch 2820 in this example causes the actuator mechanism 2850 to move the movable contact 2872 into contact with the fixed contact 2871. Figure 28D illustrates a normal operating status of the intelligent circuit breaker 2800.

[0283] Next, Figure 28E illustrates an operating status in which the air gap switch 2870 is “open,” and the first and second contacts 2871 and 2872 are pulled apart to form an air gap 2873. In Figure 28E, we assume that the manual rocker switch 2820 is in the “on” position, and the intelligent circuit breaker 2800 is in the “tripped” state as a result of the magnetic operation of the solenoid 2860 (e.g., solenoid 2860 in the open position), by which the actuator mechanism 2850 moves the movable contact 2872 away from the fixed contact 2871, thereby opening the air gap switch 2870 and forming an air gap 2873. In this example, the intelligent circuit breaker 2800 trips electromechanically, and the intelligent circuit breaker 2800 is reset by moving the manual rocker switch 2820 from the ON position to the OFF position and then back to the ON position.

[0284] As shown collectively in Figures 28A to 28E, the first visual indicator 2830 comprises a window 2832 (e.g., a glass or plastic window) formed as part of the circuit breaker housing 2810, and a status LED 2834 disposed within the circuit breaker housing 2810 behind the window 2832. The status LED 2834 illuminates to indicate the status of the intelligent circuit breaker 2800 (e.g., on, off, standby, wireless status, provisioning, etc.). The status LED 2834 may emit different colors (e.g., red, green, etc.) and / or have different lighting patterns (e.g., continuous, flashing, etc.) to represent different operating statuses. In some embodiments, the status LED 2834 is only operational when an external power supply is present.

[0285] Figure 28A illustrates an exemplary embodiment in which the status LED 2834 of the first visual indicator 2830 illuminates in a first color (e.g., red) when the intelligent circuit breaker 2800 is in a “trip” state, with the manual rocker switch 2820 in the ON position but the air gap switch open. In other embodiments, the status LED 2834 of the first visual indicator 2830 may illuminate in a different color (e.g., green) when the intelligent circuit breaker 2800 is operating normally with the manual rocker switch 2820 in the ON position (e.g., in a non-trip state).

[0286] Figure 28B shows an exemplary embodiment in which the status LED 2834 of the first visual indicator 2830 does not illuminate when the intelligent circuit breaker 2800 is in the off state (for example, when it is not connected to an external power supply, or when it is connected to an external power supply but the manual rocker switch 2820 is in the off position). In this example, when the status LED 2834 is not illuminated, the viewing window 2832 may have a translucent colored coating that is the same as or similar in color to the circuit breaker housing 2810.

[0287] Furthermore, as shown collectively in Figures 28A to 28E, the second visual indicator 2840 comprises a window 2842 (e.g., a glass or plastic window) formed as part of the circuit breaker housing 2810, a first colored element 2844 (or more generally, a first indicator element), and a second colored element 2846 (or more generally, a second indicator element) disposed within the circuit breaker housing 2810 and selectively positioned behind the window 2832 to indicate different operating statuses of the intelligent circuit breaker. More specifically, in some embodiments, the second visual indicator 2840 is configured to provide the status of the air gap switch 2870 (open or closed).

[0288] For example, the first and second colored elements 2844 and 2846 include colored plastic pieces bonded to a portion of the actuator mechanism 2850, or otherwise include a painted surface on a portion of the actuator mechanism 2850. The first and second colored elements 2844 and 2846 are selectively positioned behind the viewing window 2842 to allow an individual to observe the colors and thereby determine the status of the air gap switch 2870 based on the colors seen through the viewing window 2842. For example, the second colored element 2846 may be red to indicate that the air gap is in an "open" state, while the first colored element 2844 may be a non-red color (e.g., black) to indicate that the air gap is in a "closed" state. In other embodiments, the first and second indicator elements 2844 and 2846 may implement, in addition to and / or instead of different colors, other means of indicating the status of the air gap switch 2870, such as words or patterns.

[0289] For example, Figures 28C and 28E schematically illustrate a state in which the air gap switch 2870 is in the "open" state, either by manual operation of the rocker switch 2820 to the off position (Figure 28C) or by magnetic operation of the solenoid 2860 which causes the air gap switch 2870 to open and trip the intelligent circuit breaker 2800. In this state, the second colored element 2846 is positioned behind the viewing window 2842 by the movement of the actuator mechanism 2850 to open the air gap switch 2870, while the first colored element 2844 is positioned away from the viewing window 2842.

[0290] On the other hand, Figure 28D schematically shows the state in which the air gap switch 2870 is in the "closed" state due to the manual operation of the rocker switch 2820 which closes the air gap switch 2870. In this state, the first colored element 2844 is positioned behind the viewing window 2842 by the movement of the actuator mechanism 2850 to close the air gap switch 2870, while the second colored element 2846 is positioned away from the viewing window 2842. In this regard, the second visual indicator 2840 functions fully even without an external power supply and provides a "air gap open" indicator for safety.

[0291] Figure 29 schematically illustrates an intelligent circuit breaker 2900 according to another embodiment of the present disclosure. The intelligent circuit breaker 2900 is similar to the intelligent circuit breakers 2800 of Figures 28A-28E, except that the intelligent circuit breaker 2900 comprises a secondary internal sensing switch 2910 (e.g., an electromechanical detector) coupled to a manual rocker switch 2820. The sensing switch 2910 is configured to detect, for example, an expected manual state change of the rocker switch 2820 from the ON position (air gap switch 2870 closed) to the OFF position (air gap switch 2870 open). The sensing switch 2910 triggers the electronics of the intelligent circuit breaker 2900 (e.g., a solid switch control circuit mechanism) to activate or deactivate a solid switch (e.g., a bidirectional solid switch) before the air gap switch 2870 completes its opening or closing operation, which takes an instantaneous time that is an order of magnitude or more than twice the time required to open / close, for example, a solid switch. The internal sensing switch 2910 ensures, for example, that the air gap switch 2870 is not opened under high load current, or that the air gap switch 2870 is closed before the solid switch is activated.

[0292] While exemplary embodiments have been discussed above in the context of intelligent circuit breakers for use with AC power supplies, it should be understood that intelligent circuit breakers can also be configured for use with DC power supplies. There are various systems (e.g., telecommunications systems) that operate with DC power supplies instead of AC power supplies. In these systems, AC power supplied by an external company can be converted on-site to DC power supplies (using an AC-DC power conversion system), and the DC power supplies are then supplied to one or more DC distribution boards having DC circuit breakers that power downstream branch circuits and loads.

[0293] Exemplary embodiments of intelligent circuit breakers, such as those discussed herein, can be configured to operate in either an "AC protection mode" or a "DC protection mode," depending on whether AC power or DC power is applied to the line input terminals of the intelligent circuit breaker. The solid-state circuit mechanism of the intelligent circuit breaker (e.g., sensors, processor, etc.) can be configured to detect, for example, whether AC power or DC power is applied to the line input terminals of the intelligent circuit breaker when the intelligent circuit breaker is started, and then automatically configure the intelligent circuit breaker to operate in either an AC protection mode or a DC protection mode depending on the detected input power.

[0294] More specifically, in some embodiments, when power is first applied to the line input terminal of the intelligent circuit breaker, a voltage sensor or zero-crossing detector coupled to the line side of the switch of the intelligent circuit breaker can monitor the voltage waveform and transmit sensor data to a processor. The processor of the intelligent circuit breaker can analyze the sensor data to determine whether the input power is AC or DC. For example, if the voltage sensor data indicates that the magnitude of the input voltage remains at a constant level over a predetermined period, and / or the zero-crossing detection circuit mechanism does not output a zero-crossing event signal within a predetermined period, the processor can determine that DC power is applied to the line input terminal. On the other hand, if the voltage sensor data indicates that the magnitude of the input voltage is fluctuating, and / or the zero-crossing detection circuit mechanism outputs multiple zero-crossing event signals within a predetermined period, the processor can determine that AC power is applied to the line input terminal.

[0295] In some embodiments, the processor of an intelligent circuit breaker (e.g., a microprocessor, controller, etc.) may be configured to handle different embedded software programs (e.g., different state machines) for different protection modes. These embedded software programs for different protection modes include different program instructions and utilize different predefined parameters or register values ​​to enable the processor to make intelligent control decisions in response to detecting and responding to fault conditions (e.g., short circuits, overcurrents, overvoltages, etc.) depending on the detected supply power (AC or DC power). For example, different threshold and timing considerations for identifying and protecting against overcurrent or overvoltage conditions may vary depending on whether the intelligent circuit breaker is operating in AC protection mode or DC protection mode.

[0296] In addition, the switch control protocol for controlling the activation and deactivation of the intelligent circuit breaker's switches (e.g., solid bidirectional switches) varies depending on whether the intelligent circuit breaker is operating in DC or AC protection mode. For example, in DC protection mode, the gate-source voltages of both MOSFET devices in a solid bidirectional switch are controlled so that both MOSFET devices are switched on during normal operation and both switches are switched off in response to fault detection. Furthermore, to conserve power, some hardware circuitry of the intelligent circuit breaker can be disabled depending on whether the intelligent circuit breaker is operating in DC or AC protection mode. For example, the zero-cross detection circuit of the intelligent circuit breaker can be disabled when it is operating in DC protection mode. In addition, in DC protection mode, the AC-DC converter of the intelligent circuit breaker can be disabled, and the DC-DC converter of the intelligent circuit breaker can be selectively enabled to convert the DC supply voltage (applied to the line input terminals of the intelligent circuit breaker) to a lower DC voltage to power the solid circuitry of the intelligent circuit breaker.

[0297] The exemplary embodiments of intelligent circuit breakers discussed herein and illustrated through the drawings include a variety of features, functions, components, etc., which can be used to implement different types of intelligent circuit breakers having various functions for different applications. In this regard, it should be understood that an intelligent circuit breaker illustrated in one figure may incorporate one or more additional features illustrated in one or more other figures to implement a different architecture of intelligent circuit breaker. For example, all exemplary embodiments of intelligent circuit breakers as illustrated throughout the figures may be configured to include arc fault and / or ground fault detection and protection capabilities.

[0298] In this regard, it should be understood that exemplary embodiments of this disclosure include various embodiments of circuit breakers, and associated systems and methods, as discussed herein, which can be outlined or otherwise extended as follows.

[0299] In some embodiments, the circuit breaker includes an electromechanical switch connected in series between the line input terminal and the load output terminal of the circuit breaker and configured to be in one of two states: (i) a closed switch state and (ii) an open switch state; a current sensor configured to detect the magnitude of the current flowing in the circuit between the line input terminal and the load output terminal and to generate a current detection signal; a voltage sensor configured to detect the magnitude of the voltage at a point on the circuit between the line input terminal and the load output terminal and to generate a voltage detection signal; and a processor configured to receive and process the current detection signal and the voltage detection signal to determine the operating status information of the circuit breaker and to determine the power usage information of the load connected to the load output terminal.

[0300] In some embodiments, the circuit breaker further comprises a radio frequency transceiver coupled to a processor, the radio frequency transceiver configured to transmit operational status information and power usage information to a remote computing node and to receive remote control commands transmitted from the remote computing node for processing by the processor.

[0301] In some embodiments, the voltage sensor comprises a first voltage sensor coupled to an upstream circuit of the electromechanical switch and configured to detect the magnitude of the AC supply voltage applied to the power input terminal, and a second voltage sensor coupled to a downstream circuit of the electromechanical switch and configured to detect the magnitude of the load voltage of a load connected to the load output terminal.

[0302] In some embodiments, the current sensor comprises a circuit mechanism configured to detect an overcurrent condition, generate a control signal indicating the detected overcurrent condition, and output the control signal to a processor to notify the processor of the overcurrent condition. In some embodiments, the current sensor detects an overcurrent condition based on a programmable overcurrent threshold. In some embodiments, the overcurrent threshold includes a reference threshold current generated by a current-to-digital-to-analog converter and applied to the input of the comparator of the current sensor.

[0303] In some embodiments, the electromechanical switch includes an air-gap electromagnetic switch, and in some embodiments, the processor generates a switch control signal to open the air-gap electromagnetic switch in response to sensor data indicating an impending fault event.

[0304] In some embodiments, the circuit breaker further comprises an internal short-circuit switch configured to generate an internal short circuit within the circuit breaker in response to a switch control signal output from a processor, the internal short circuit being generated to trip an electromechanical switch or blow a fuse in the circuit breaker.

[0305] In some embodiments, the current sensor of a circuit breaker is equipped with an energy metering circuit mechanism, which is configured to generate energy usage data based on the detected current flowing through the circuit breaker and to output the energy usage data to a processor for analysis.

[0306] In some embodiments, the circuit breaker processor is configured to use current and voltage sensor data to identify the type of load connected to the circuit breaker and to control the power applied to the load based on the iden...

Claims

1. It is a circuit breaker, An electromechanical switch is connected in series between the line input terminal and the load output terminal of the circuit breaker and is configured to be in one of the following states: (i) switch closed state and (ii) switch open state. A current sensor is configured to detect the magnitude of the current flowing in the circuit between the line input terminal and the load output terminal, and to generate a current detection signal. A voltage sensor is configured to detect the magnitude of the voltage at a point on the circuit between the line input terminal and the load output terminal, and to generate a voltage detection signal. A circuit breaker comprising: a processor configured to receive and process the current detection signal and the voltage detection signal to determine the operating status information of the circuit breaker and to determine the power usage information of the load connected to the load output terminal.

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

3. The aforementioned voltage sensor A first voltage sensor is connected to the circuit upstream of the electromechanical switch and is configured to detect the magnitude of the AC supply voltage applied to the power input terminal. The circuit breaker according to claim 1, further comprising: a second voltage sensor connected to the circuit downstream of the electromechanical switch and configured to detect the magnitude of the load voltage of a load connected to the load output terminal.

4. The circuit breaker according to claim 1, further comprising a circuit mechanism configured such that the current sensor detects an overcurrent state, generates a control signal indicating the detected overcurrent state, and outputs the control signal to the processor to notify the processor of the overcurrent state.

5. The circuit breaker according to claim 4, wherein the current sensor detects the overcurrent state based on a programmable overcurrent threshold.

6. The circuit breaker according to claim 5, wherein the overcurrent threshold is generated by a current digital-to-analog converter and includes a reference threshold current applied to the input of the comparator of the current sensor.

7. The circuit breaker according to claim 1, wherein the electromechanical switch includes an air gap electromagnetic switch.

8. The circuit breaker according to claim 7, wherein the processor generates a switch control signal for opening the air gap electromagnetic switch in response to sensor data indicating an imminent fault event.

9. The circuit breaker according to claim 1, further comprising an internal short-circuit switch configured to generate an internal short circuit within the circuit breaker in response to a switch control signal output from the processor, wherein the internal short circuit is generated for one of (i) tripping the electromechanical switch and (ii) blowing the fuse of the circuit breaker.

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

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

12. The circuit breaker according to claim 1, further comprising a power converter circuit configured to generate a direct current (DC) supply voltage from an alternating current (AC) supply voltage applied to a power input terminal, wherein the DC supply voltage is used to supply DC power to the processor, the current sensor, and the voltage sensor.

13. It is a method, Connecting a circuit breaker between an external power source and a branch circuit including a load, wherein the circuit breaker is equipped with an electromechanical switch configured to be in one of the following states: (i) a closed state for connecting the external power source to the branch circuit, and (ii) an open state for disconnecting the external power source from the branch circuit. The system detects the flow of current through the circuit breaker and generates a current detection signal indicating the magnitude of the detected current flow through the circuit breaker. The system detects the voltage at a point on the circuit passing through the circuit breaker and generates a voltage detection signal indicating the magnitude of the detected voltage. A method comprising processing the current detection signal and the voltage detection signal to determine the operating status information of the circuit breaker and to determine the power usage information of the load.

14. The circuit breaker transmits the operating status information and power usage information to the remote computing node. The circuit breaker further includes receiving remote control commands transmitted from the remote computing node, The aforementioned operating status information is transmitted over at least one of the wireless communication channel and the wired communication channel. The method according to claim 13, wherein the remote computing node comprises a master controller.

15. The method according to claim 13, wherein detecting the flow of current through the circuit breaker includes detecting an overcurrent condition, generating a control signal indicating the detected overcurrent condition, and outputting the control signal to the processor of the circuit breaker to notify the processor of the overcurrent condition.

16. The method according to claim 15, wherein the overcurrent state is detected based on a programmable overcurrent threshold.

17. The method according to claim 16, further comprising generating a reference threshold current using a current-to-digital-to-analog converter, wherein the reference threshold current functions as the programmable overcurrent threshold.

18. The method according to claim 15, wherein the electromechanical switch includes an air gap electromagnetic switch, and the method further comprises generating a switch control signal to cause the air gap electromagnetic switch to open in response to at least one of the detected voltage and the detected current indicating an imminent fault event.

19. It is a system, A circuit breaker distribution board equipped with busbars connected to an external power supply, The circuit breaker comprises a circuit breaker installed in the circuit breaker distribution board, the circuit breaker comprising a line input terminal connected to the busbar and a load output terminal connected to the branch circuit, and the circuit breaker comprises An electromechanical switch configured to be in one of the following states: (i) a closed state for connecting the external power supply to the branch circuit, and (ii) an open state for disconnecting the external power supply from the branch circuit, A current sensor is configured to detect the magnitude of the current flowing in the circuit between the line input terminal and the load output terminal, and to generate a current detection signal. A voltage sensor is configured to detect the magnitude of the voltage at a point on the circuit between the line input terminal and the load output terminal, and to generate a voltage detection signal. A system comprising: a processor configured to receive and process the current detection signal and the voltage detection signal to determine the operating status information of the circuit breaker and to determine the power usage information of the load connected to the load output terminal.

20. Further equipped with a status display system that includes a display and a master processor, The system according to claim 19, wherein the master processor is configured to communicate with the processor of the circuit breaker to acquire, process, and display the operation status information and power usage information received from the processor of the circuit breaker, and the master processor is configured to transmit the operation status information and power usage information to a remote computing node.

21. It is a circuit breaker, A solid bidirectional switch is connected in series between the line input terminal and the load output terminal of the circuit breaker and is configured to be in one of the following states: (i) switch-on state and (ii) switch-off state. A first switch control circuit is configured to generate control signals for controlling the operation of the solid bidirectional switch, A current sensor is configured to detect the magnitude of the current flowing in the circuit between the line input terminal and the load output terminal, and to generate a current detection signal. A voltage sensor is configured to detect the magnitude of the voltage at a point on the circuit between the line input terminal and the load output terminal, and to generate a voltage detection signal. A circuit breaker comprising: a processor configured to receive and process the current detection signal and voltage detection signal to determine the operating status information of the circuit breaker, to determine a fault event, and to determine the power usage information of a load connected to the load output terminal.

22. The circuit breaker according to claim 21, further comprising a radio frequency transceiver coupled to the processor, wherein the radio frequency transceiver is configured to receive remote control commands transmitted from the remote computing node for processing by the processor to transmit the operating status information and power usage information to the remote computing node and to perform the actions instructed by the remote control commands.

23. The aforementioned voltage sensor A first voltage sensor is connected to the circuit upstream of the electromechanical switch and is configured to detect the magnitude of the AC supply voltage applied to the power input terminal. The circuit breaker according to claim 21, further comprising: a second voltage sensor connected to the circuit downstream of the electromechanical switch and configured to detect the magnitude of the load voltage of a load connected to the load output terminal.

24. The circuit breaker according to claim 21, comprising a circuit mechanism configured such that the current sensor detects an overcurrent state, generates a control signal indicating the detected overcurrent state, and outputs the control signal to the processor to notify the processor of the overcurrent state.

25. The circuit breaker according to claim 24, wherein the current sensor detects the overcurrent condition based on a programmable overcurrent threshold, the overcurrent threshold includes a reference threshold current generated by a current digital-to-analog converter and applied to the input of a comparator of the current sensor.

26. An air-gap electromagnetic switch is connected in series with the aforementioned solid bidirectional switch, The system further comprises a second switch control circuit configured to generate a control signal for controlling the operation of the air gap electromagnetic switch, The circuit breaker according to claim 21, wherein the processor generates switch control signals for the first and second switch control circuits such that the air gap electromagnetic switch is (i) closed before the solid bidirectional switch is switched on, and (ii) opened in response to the solid bidirectional switch being switched off.

27. A manual switch further comprising a manual switch configured to trigger the opening of the air gap electromagnetic switch in response to the operation of the manual switch by an individual, The circuit breaker according to claim 26, wherein the processor is configured to monitor and detect the operation of the manual switch, and in response to the processor detecting the operation of the manual switch, generates and outputs a control signal to the first switch control circuit to switch off the solid bidirectional switch.

28. The circuit breaker according to claim 26, wherein the first and second switch control circuits are configured to operate the circuit breaker in a standby state, the solid bidirectional switch is in the switch-off state, and the air gap electromagnetic switch is in the switch-closed state.

29. The circuit breaker according to claim 26, wherein the processor is configured to analyze sensor data obtained from the voltage and current sensors in real time, detect a fault in the solid bidirectional switch, and in response to the detection of the fault in the solid bidirectional switch, generate and output a control signal to the second switch control circuit to put the air gap electromagnetic switch into a switched closed state.

30. The circuit breaker according to claim 21, wherein the current sensor comprises an energy metering circuit mechanism, the energy metering circuit mechanism is configured to generate energy usage data based on the detected current flowing through the circuit breaker, and to output the energy usage data to the processor for analysis.

31. The circuit breaker according to claim 21, wherein the processor is configured to use current and voltage sensor data to identify the type of load connected to the circuit breaker and to control the power applied to the load based on the identified type of load.

32. The circuit breaker according to claim 21, wherein the current sensor, the voltage sensor, and the processor are configured to support (i) at least one of arc fault circuit interruption and ground fault circuit interruption.

33. The circuit breaker according to claim 21, wherein the first switch control circuit comprises a short-circuit detection circuit coupled to the solid bidirectional switch, the short-circuit detection circuit is configured to detect the flow of current through the solid bidirectional switch and generate a gating control signal to switch off the solid bidirectional switch in response to the detected current flow indicating a short-circuit fault event of a load connected to the load output terminal of the circuit breaker, and the short-circuit detection circuit is configured to detect the voltage of a sensing resistor disposed between the first solid switch and the second solid switch of the solid bidirectional switch and to use the detected voltage to detect the level of current flow indicating a short-circuit fault event.

34. The circuit breaker according to claim 21, further comprising a power converter circuit configured to generate a direct current (DC) supply voltage from an alternating current (AC) supply voltage applied to a power input terminal, and using the DC supply voltage to supply DC power to the processor, the first switch control circuit, the current sensor, and the voltage sensor.

35. It is a method, A circuit breaker is connected between an external power supply and a branch circuit including a load, wherein the circuit breaker is equipped with a solid bidirectional switch configured to be in one of the following states: (i) an ON state for connecting the external power supply to the branch circuit, and (ii) an OFF state for disconnecting the external power supply from the branch circuit. The system detects the flow of current through the circuit breaker and generates a current detection signal indicating the magnitude of the detected current flow through the circuit breaker. The system detects the voltage at a point on the circuit passing through the circuit breaker and generates a voltage detection signal indicating the magnitude of the detected voltage. Based on at least one of the current detection signal and the voltage detection signal, a control signal is generated to switch off the solid bidirectional switch in response to the detection of a fault event. A method comprising processing the current detection signal and the voltage detection signal to determine the operating status information of the circuit breaker and to determine the power usage information of the load.

36. The circuit breaker comprises an air gap electromagnetic switch connected in series with the solid bidirectional switch, and the method is The method of claim 35, further comprising generating a control signal for synchronizing the switching operations of the air gap electromagnetic switch and the solid bidirectional switch such that the air gap electromagnetic switch is (i) switched on before the solid bidirectional switch is switched on, and (ii) switched off in response to the solid bidirectional switch being switched off.

37. To detect the operation of a manual switch configured to trigger the opening of the aforementioned air gap electromagnetic switch, The method according to claim 36, further comprising generating a control signal to switch off the solid bidirectional switch in response to detecting the operation of the manual switch.

38. The sensor data obtained from the voltage and current sensors is analyzed to detect a fault in the solid bidirectional switch, The method according to claim 36, further comprising generating a control signal to put the air gap electromagnetic switch into a switched-closed state in response to detecting a fault in the solid bidirectional switch.

39. It is a system, A circuit breaker distribution board equipped with busbars connected to an external power supply, The circuit breaker comprises a circuit breaker installed in the circuit breaker distribution board, the circuit breaker comprising a line input terminal connected to the busbar and a load output terminal connected to the branch circuit, and the circuit breaker comprises A solid bidirectional switch is connected in series between the line input terminal and the load output terminal of the circuit breaker and is configured to be in one of the following states: (i) switch-on state and (ii) switch-off state. A first switch control circuit is configured to generate control signals for controlling the operation of the solid bidirectional switch, A current sensor is configured to detect the magnitude of the current flowing in the circuit between the line input terminal and the load output terminal, and to generate a current detection signal. A voltage sensor is configured to detect the magnitude of the voltage at a point on the circuit between the line input terminal and the load output terminal, and to generate a voltage detection signal. A system comprising: a processor configured to receive and process the current detection signal and voltage detection signal to determine the operating status information of the circuit breaker, to determine a fault event, and to determine the power usage information of a load connected to the load output terminal.

40. Further equipped with a status display system that includes a display and a master processor, The system according to claim 39, wherein the master processor is configured to communicate with the processor of the circuit breaker to acquire, process, and display the operation status information and power usage information received from the processor of the circuit breaker, and the master processor is configured to transmit the operation status information and power usage information to a remote computing node.

41. It is a circuit breaker, A solid switch and an air-gap electromagnetic switch are connected in series in the circuit between the line input terminal and the load output terminal of the circuit breaker. A switch control circuit mechanism configured to control the operation of the solid switch and the air gap electromagnetic switch, A zero-crossing detection circuit is configured to detect zero crossings in the AC power waveform on the circuit between the line input terminal and the load output terminal of the circuit breaker. The system includes a current sensor configured to detect the current flowing through the circuit between the line input terminal and the load output terminal, and to detect a fault condition based on the detected current flow, The switch control circuit mechanism is configured to generate a switch control signal in response to the detection of a fault condition by the current sensor, to (i) switch the solid switch to the off state, and (ii) after the solid switch has been switched off, to switch the air gap electromagnetic switch to the open state. A circuit breaker in which the switch control circuit mechanism determines when to open the air gap electromagnetic switch using the zero-crossing detection signal output from the zero-crossing detection circuit.

42. The circuit breaker according to claim 41, wherein the solid switch comprises a P-type enhancement metal oxide semiconductor field-effect transistor device.

43. The circuit breaker according to claim 41, wherein the solid switch comprises an N-type enhanced metal oxide semiconductor field-effect transistor device.

44. The circuit breaker according to claim 41, wherein the zero-crossing detection circuit is configured to detect a zero crossing of the AC supply voltage waveform applied to the line input terminal of the circuit breaker.

45. The circuit breaker according to claim 44, wherein the zero-crossing detection circuit is configured to detect the associated direction of polarity transitions between opposing half-cycles of the AC supply voltage waveform, and the switch control circuit mechanism opens the air gap electromagnetic switch when the body diode of the solid switch is reverse-biased by the polarity transition.

46. The circuit breaker according to claim 41, wherein the zero-crossing detection circuit is configured to detect zero crossings in the AC current waveform.

47. The circuit breaker according to claim 46, wherein the zero-crossing detection circuit is configured to detect the associated direction of polarity transitions between opposing half-cycles of the AC current waveform, and the switch control circuit mechanism opens the air gap electromagnetic switch when the body diode of the solid switch is reverse-biased by the polarity transition.

48. The circuit breaker according to claim 46, wherein the zero-crossing detection circuit is configured to (i) sample the magnitude and polarity of the detection voltage of a detection resistor connected in series in the circuit, (ii) detect a zero-crossing event of the AC current waveform in response to determining that the magnitude of the detection voltage is zero, and (iii) determine the polarity of the AC current waveform based on the polarity of the detection voltage.

49. The circuit breaker according to claim 41, wherein the current sensor is configured to detect at least one of a short-circuit fault condition, an overcurrent fault condition, an arc fault condition, and a ground fault condition.

50. The circuit breaker according to claim 41, further comprising an environmental sensor circuit configured to detect an environmental condition and to detect whether the detected environmental condition is harmful, wherein the switch control circuit mechanism is configured to, in response to detecting a harmful environmental condition, (i) switch the solid switch to the off state, and (ii) after the solid switch has been switched off, generate a switch control signal to switch the air gap electromagnetic switch to the open state.

51. The circuit breaker according to claim 50, wherein the environmental sensor circuit comprises one or more of the following: (i) a chemical sensitivity detector configured to detect the presence of a hazardous chemical substance; (ii) a gas sensitivity detector configured to detect the presence of a hazardous gas; (iii) a temperature sensor configured to detect temperature; (iv) a piezoelectric detector configured to detect vibration; and (v) a humidity sensor configured to detect a humid environment.

52. It is a method, The detection of current flowing in the circuit between the line input terminal and the load output terminal of a circuit breaker, wherein the circuit breaker includes a solid switch and an air gap electromagnetic switch connected in series in the circuit between the line input terminal and the load output terminal of the circuit breaker. Detecting a fault condition based on the detected current flow, and in response to detecting the fault condition, A first switch control signal is generated to switch off the solid switch. The zero-crossing event of the alternating current (AC) waveform at a point on the circuit, and the polarity of the AC waveform following the zero-crossing event are detected, and A method comprising detecting and generating a second control signal to open the air gap electromagnetic switch in response to detecting that the polarity of the AC waveform following the zero crossing event reverse biases the body diode of the solid switch.

53. The detection of the zero-crossing event of the AC waveform and the polarity of the AC waveform following the zero-crossing event is To detect the next zero-crossing event of the AC waveform that occurs after the solid switch is switched off, The method according to claim 52, comprising delaying the generation of the second control signal for opening the air gap electromagnetic switch until the next subsequent zero-crossing event of the AC waveform has been detected, in response to the detection that the polarity of the AC waveform following the next zero-crossing event forward-biass the body diode of the solid switch, the delay being such that the polarity of the AC waveform following the next subsequent zero-crossing event reverse-biasss the body diode of the solid switch.

54. The method according to claim 52, wherein the solid switch includes one of a P-type enhanced metal oxide semiconductor field-effect transistor device and an N-type enhanced metal oxide semiconductor field-effect transistor device.

55. The method according to claim 52, wherein detecting the zero-crossing event of the AC waveform includes detecting the zero-crossing of the AC supply voltage waveform applied to the line input terminal of the circuit breaker.

56. The method according to claim 52, wherein detecting the zero-crossing event of the AC waveform includes detecting the zero-crossing of the AC current waveform at a point on the circuit.

57. Detecting the zero crossing of the AC current waveform The magnitude and polarity of the detection voltage of the detection resistor connected in series in the aforementioned circuit are sampled, In response to determining that the magnitude of the detected voltage is zero, a zero crossing event is detected. The method according to claim 56, comprising determining the polarity of the AC current waveform based on the polarity of the detected voltage.

58. The method according to claim 52, wherein detecting the fault condition includes detecting at least one of a short-circuit fault condition, an overcurrent fault condition, an arc fault condition, and a ground fault condition.

59. The method according to claim 52, further comprising detecting an environmental condition, generating a first control signal to switch off the solid switch in response to determining that the environmental condition is harmful, and generating a second control signal to switch open the air gap electromagnetic switch after the solid switch has been switched off, wherein detecting the environmental condition includes detecting one of (i) a chemical substance, (ii) the presence of a gas, (iii) temperature, (iv) vibration, and (v) humidity.

60. It is a system, A circuit breaker distribution board equipped with busbars connected to an external power supply, The circuit breaker comprises a circuit breaker installed in the circuit breaker distribution board, the circuit breaker comprising a line input terminal connected to the busbar and a load output terminal connected to the branch circuit, and the circuit breaker comprises A solid switch and an air-gap electromagnetic switch are connected in series in the circuit between the line input terminal and the load output terminal of the circuit breaker. A switch control circuit mechanism configured to control the operation of the solid switch and the air gap electromagnetic switch, A zero-crossing detection circuit is configured to detect zero crossings in the AC power waveform on the circuit between the line input terminal and the load output terminal of the circuit breaker. The system includes a current sensor configured to detect the current flowing through the circuit between the line input terminal and the load output terminal, and to detect a fault condition based on the detected current flow, The switch control circuit mechanism is configured to, in response to the detection of a fault condition by the current sensor, (i) turn off the solid switch, and (ii) after the solid switch has been turned off, generate a switch control signal to open the air gap electromagnetic switch. A system in which the switch control circuit mechanism uses the zero-crossing detection signal output from the zero-crossing detection circuit to determine when to open the air gap electromagnetic switch.

61. It is a circuit breaker, A solid switch and a sensing resistor are connected in series in the circuit between the line input terminal and the load output terminal of the circuit breaker. (i) A current detection circuit configured to sample a detection voltage generated in the detection resistor in response to a load current flowing through the detection resistor, (ii) detect an overcurrent fault condition based on the sampled detection voltage, and (iii) output a fault detection signal in response to the detection of the overcurrent fault condition, A circuit breaker comprising: a switch control circuit configured to control the solid switch, wherein the switch control circuit is configured to switch off the solid switch in response to the fault detection signal output from the current detection circuit.

62. The circuit breaker according to claim 61, wherein the detection resistor comprises a power resistor having a resistance value of about 1 milliohm.

63. The current detection circuit, An input stage comprising a first comparator and a second comparator, The first comparator is configured to (i) compare a first reference voltage with a detection voltage generated in the sensing resistor during a positive half-cycle of the load current, and (ii) generate a first overcurrent detection signal if the detection voltage generated during the positive half-cycle of the load current exceeds the first reference voltage. The input stage includes a second comparator configured to (i) compare a second reference voltage with a detection voltage generated in the detection resistor during a negative half-cycle of the load current, and (ii) generate a second overcurrent detection signal if the detection voltage generated during the negative half-cycle of the load current exceeds the second reference voltage, The circuit breaker according to claim 61, further comprising: an output stage configured to generate and output the fault detection signal based on the first and second overcurrent detection signals output from the first and second comparators.

64. The circuit breaker according to claim 63, wherein the output stage of the current detection circuit is configured to output the fault detection signal as a logic low pulse in response to one of the outputs of the first and second overcurrent detection signals from the first and second comparators, and further comprises a logic NOR gate.

65. The detection resistor has a first terminal connected to the line-side node of the circuit and a second terminal connected to the load-side node of the circuit. The first comparator comprises a non-inverting input connected to the first terminal of the sensing resistor and an inverting input for receiving the first reference voltage, The circuit breaker according to claim 63, wherein the second comparator comprises a non-inverting input connected to the second terminal of the sensing resistor and an inverting input for receiving the second reference voltage.

66. The current detection circuit comprises a first voltage divider circuit configured to generate the first reference voltage, and a second voltage divider circuit configured to generate the second reference voltage. The first voltage divider circuit is connected between the DC supply voltage rail of the circuit and the load-side node. The circuit breaker according to claim 65, wherein the second voltage divider circuit is connected between the DC supply voltage rail of the circuit and the line side.

67. The circuit breaker according to claim 66, wherein the DC supply voltage rail comprises an active wire rail having a DC voltage offset.

68. The circuit breaker according to claim 61, wherein the solid switch includes a solid bidirectional switch comprising a power metal oxide semiconductor field-effect transistor device.

69. The circuit breaker according to claim 61, further comprising a zero-crossing detection circuit configured to (i) sample a detection voltage generated in the detection resistor in response to the load current flowing through the detection resistor, (ii) detect a zero crossing of the load current based on the sampled detection voltage, and (iii) output a zero-crossing detection signal in response to the detection of the zero crossing of the load current.

70. The zero-crossing detection circuit, A polarity change detection stage configured to detect the change in polarity between positive and negative half-cycles of the load current, An edge detection stage coupled to the output of the polarity change detection stage, wherein the edge detection stage is configured to generate a control pulse in response to the change in polarity of the load current detected by the polarity change detection stage, The circuit breaker according to claim 69, further comprising: an output stage configured to output the zero-crossing detection signal based on the control pulse generated by the edge detection stage.

71. The detection resistor has a first terminal connected to the line-side node of the circuit and a second terminal connected to the load-side node of the circuit. The circuit breaker according to claim 70, wherein the polarity change detection stage comprises a first comparator and a second comparator, the first comparator comprising a non-inverting input connected to the first terminal of the sensing resistor and an inverting input connected to the second terminal of the sensing resistor, and the second comparator comprising a non-inverting input connected to the second terminal of the sensing resistor and an inverting input connected to the first terminal of the sensing resistor.

72. The edge detection stage, A first edge detection circuit is configured to generate a first edge detection pulse in response to the transition of the first comparison signal output output from the first comparator, The circuit breaker according to claim 71, further comprising: a second edge detection circuit configured to generate a second edge detection pulse in response to a transition of a second comparison signal output output from the second comparator.

73. The circuit breaker according to claim 72, wherein the output stage comprises a logic AND gate that outputs the zero-crossing detection signal based on the first and second edge detection pulses generated by the edge detection stage.

74. The circuit breaker according to claim 69, further comprising a processor, wherein the processor is configured to process a zero-crossing detection signal output from the zero-crossing detection circuit and to control the operation of one or more circuit breakers based on the zero-crossing detection signal.

75. The circuit breaker according to claim 74, wherein the processor configures the circuit breaker to operate in one of a DC protection mode and an AC protection mode when the circuit breaker is powered on, based on the output of the zero-crossing detection circuit.

76. It is a circuit breaker, A solid switch and a sensing resistor are connected in series in the circuit between the line input terminal and the load output terminal of the circuit breaker. A zero-crossing detection circuit, configured to (i) sample a detection voltage generated in the detection resistor in response to a load current flowing through the detection resistor, (ii) detect a zero crossing of the load current based on the sampled detection voltage, and (iii) output a zero-crossing detection signal in response to the detection of the zero crossing of the load current, A circuit breaker comprising a switch control circuit configured to control the operation of the switch based on the output of the zero-cross detection circuit.

77. The zero-crossing detection circuit, A polarity change detection stage configured to detect the change in polarity between positive and negative half-cycles of the load current, An edge detection stage coupled to the output of the polarity change detection stage, wherein the edge detection stage is configured to generate a control pulse in response to the change in polarity of the load current detected by the polarity change detection stage, The circuit breaker according to claim 76, further comprising: an output stage configured to output the zero-crossing detection signal based on the control pulse generated by the edge detection stage.

78. The detection resistor has a first terminal connected to the line-side node of the circuit and a second terminal connected to the load-side node of the circuit. The polarity change detection stage comprises a first comparator and a second comparator, the first comparator comprising a non-inverting input connected to the first terminal of the sensing resistor and an inverting input connected to the second terminal of the sensing resistor, and the second comparator comprising a non-inverting input connected to the second terminal of the sensing resistor and an inverting input connected to the first terminal of the sensing resistor, The edge detection stage comprises (i) a first edge detection circuit configured to generate a first edge detection pulse in response to a transition of a first comparison signal output from the first comparator, and (ii) a second edge detection circuit configured to generate a second edge detection pulse in response to a transition of a second comparison signal output from the second comparator. The circuit breaker according to claim 77, wherein the output stage comprises a logic AND gate that outputs the zero-crossing detection signal based on the first and second edge detection pulses generated by the edge detection stage.

79. The circuit breaker according to claim 76, wherein the switch control circuit comprises a processor, the processor is configured to process a zero-crossing detection signal output from the zero-crossing detection circuit, and to control the operation of one or more circuit breakers based on the zero-crossing detection signal.

80. The circuit breaker according to claim 79, wherein the processor configures the circuit breaker to operate in one of DC protection mode and AC protection mode when the circuit breaker is powered on, based on the output of the zero-crossing detection circuit.

81. It is a circuit breaker, Circuit breaker housing and An air gap switch disposed within the circuit breaker housing, wherein the air gap switch comprises a first contact and a second contact disposed in the circuit between the line input terminal and the load output terminal of the circuit breaker, An actuator mechanism disposed within the circuit breaker housing, wherein the air gap switch is coupled to the actuator mechanism, and the actuator mechanism is configured to operate in such a way that (i) mechanically separates the first and second contacts to open the air gap switch and create an air gap in the circuit, and (ii) mechanically brings the first and second contacts together to close the air gap switch. A first visual indicator configured to provide an indication of the state of the air gap switch, comprising: (i) a first window formed as part of the circuit breaker housing; (ii) a first indicator element coupled to the actuator mechanism; and (iii) a second indicator element coupled to the actuator mechanism. The actuator mechanism is configured to move the first indicator element to a position behind the first window when the air gap switch is opened, so that the first indicator element is visible through the first window to indicate the open state of the air gap switch. A circuit breaker, wherein the actuator mechanism is configured to move the second indicator element to a position behind the first window when the air gap switch is closed, so that the second indicator element is visible through the first window to provide an indication of the closed state of the air gap switch.

82. The circuit breaker according to claim 81, wherein the first indicator element includes a colored element having a first color, and the second indicator element includes a colored element having a second color different from the first color.

83. The circuit breaker according to claim 81, further comprising a second visual indicator configured to provide an indication of the operating status of the circuit breaker, wherein the second visual indicator comprises (i) a second window formed as part of the circuit breaker housing, and (ii) at least one light-emitting element disposed within the circuit breaker housing behind the second window.

84. The circuit breaker according to claim 83, wherein the at least one light-emitting element includes a light-emitting diode.

85. The circuit breaker according to claim 83, wherein at least one light-emitting element is configured to emit light of a first color that is observable through the second window, thereby providing an indication of the non-tripped state of the circuit breaker.

86. The circuit breaker according to claim 85, wherein at least one light-emitting element is configured to emit light of a second color that is visible through the second window, thereby providing an indication of the tripped state of the circuit breaker.

87. The circuit breaker according to claim 83, wherein the at least one light-emitting element is deactivated and does not emit light to provide an indication of the circuit breaker being in the off state.

88. The circuit breaker according to claim 81, further comprising a manual control switch mechanically coupled to the actuator mechanism, wherein the manual control switch is configured to switch between a first position and a second position, and by switching the manual control switch to the first position, the actuator mechanism causes the air gap switch to open.

89. The circuit breaker according to claim 81, further comprising an electromechanical actuator coupled to the actuator mechanism, wherein the operation of the electromechanical actuator causes the actuator mechanism to open the air gap switch and trip the circuit breaker.

90. The circuit breaker according to claim 89, wherein the electromechanical actuator comprises a solenoid.

91. It is a circuit breaker, A solid switch and an air gap electromagnetic switch connected in series in the circuit between the line input terminal and the load output terminal of the circuit breaker, wherein the air gap switch has a first contact and a second contact, An actuator mechanism configured to operate in such a way that (i) mechanically separates the first and second contacts to open the air gap switch and create an air gap in the circuit, and (ii) mechanically aligns the first and second contacts to close the air gap switch. A manual control switch operably coupled to the actuator mechanism, wherein the manual control switch is configured to switch between a first position and a second position, and by switching the manual control switch to the first position, the actuator mechanism causes the air gap switch to open. An electromechanical actuator operably coupled to the actuator mechanism, wherein the operation of the electromechanical actuator causes the actuator mechanism to open the air gap switch, A control circuit mechanism configured to control the operation of the solid switch and the electromechanical actuator, wherein the control circuit mechanism is configured to generate (i) a first control signal configured to set the solid switch to one of an on state and an off state, and (ii) a second control signal configured to control the operation of the electromechanical actuator. A sensor switch operably coupled to the manual control switch and electrically connected to the control circuit mechanism, wherein the sensor switch is configured to (i) detect a change in the manual control switch from a second position to a first position that causes the actuator mechanism to open the air gap switch, and (ii) output a third control signal to the control circuit mechanism in response to the detection of the change in the manual control switch from the second position to the first position, A circuit breaker configured such that, in response to the third control signal, the control circuit mechanism generates a first control signal to turn the solid switch to the switch-off state before the air gap switch is opened and creates the air gap in the circuit.

92. The system further comprises a current sensor configured to detect the current flowing through the circuit between the line input terminal and the load output terminal, and to detect a fault condition based on the detected current flow, The circuit breaker according to claim 91, wherein the control circuit mechanism is configured to generate the first and second control signals in response to the detection of a fault condition by the current sensor, so as to (i) switch the solid switch to the off state, and (ii) after the solid switch has been switched off, activate the electromechanical actuator so that the operating mechanism causes the air gap electromagnetic switch to the open state.

93. The circuit breaker according to claim 91, wherein the electromechanical actuator comprises a solenoid.

94. A first visual indicator configured to provide an indication of the state of the air gap switch, the first visual indicator further comprising: (i) a first window formed as part of the circuit breaker housing of the circuit breaker; (ii) a first indicator element coupled to the actuator mechanism; and (iii) a second indicator element coupled to the actuator mechanism. The actuator mechanism is configured to move the first indicator element to a position behind the first window when the air gap switch is opened, so that the first indicator element is visible through the first window to indicate the open state of the air gap switch. The circuit breaker according to claim 91, wherein the actuator mechanism is configured to move the second indicator element to a position behind the first window when the air gap switch is closed, so that the second indicator element is visible through the first window to provide an indication of the closed state of the air gap switch.

95. The circuit breaker according to claim 94, wherein the first indicator element includes a colored element having a first color, and the second indicator element includes a colored element having a second color different from the first color.

96. The circuit breaker according to claim 91, further comprising a second visual indicator configured to provide an indication of the operating status of the circuit breaker, wherein the second visual indicator comprises (i) a second window formed as part of the circuit breaker housing, and (ii) at least one light-emitting element disposed within the circuit breaker housing behind the second window.

97. The circuit breaker according to claim 96, wherein the at least one light-emitting element includes a light-emitting diode.

98. The at least one light-emitting element, By emitting light of a first color that can be observed through the second window, the circuit breaker is provided with an indication of its non-tripped state. By emitting a second color of light visible through the second window, the tripped state of the circuit breaker is indicated, and The circuit breaker according to claim 96, configured not to emit light in order to provide an indication of the off state of the circuit breaker.

99. It is a circuit breaker, Circuit breaker housing and An air gap switch is disposed within the circuit breaker housing, A first visual indicator configured to provide an indication of the open and closed states of the air gap switch, comprising: (i) a first window formed as part of the circuit breaker housing; (ii) a first indicator element disposed within the circuit breaker housing; and (iii) a second indicator element disposed within the circuit breaker housing. The first indicator element is configured to move to a position behind the first window when the air gap switch is opened, so that the first indicator element is visible through the first window to provide an indication of the open state of the air gap switch. A circuit breaker, wherein the second indicator element is configured to move to a position behind the first window when the air gap switch is closed, so that the second indicator element is visible through the first window to provide an indication of the closed state of the air gap switch.

100. The system further comprises a second visual indicator configured to provide an indication of the operating status of the circuit breaker, the second visual indicator comprising (i) a second window formed as part of the circuit breaker housing, and (ii) at least one light-emitting element disposed within the circuit breaker housing behind the second window, The circuit breaker according to claim 99, wherein the at least one light-emitting element is configured to emit light of at least one color through the second window to provide an indication of the operating state of the circuit breaker corresponding to the at least one color.

101. A circuit breaker device, Line active terminal, line neutral terminal, load active terminal, and load neutral terminal, A solid switch and an air gap electromagnetic switch are connected in series between the line activation terminal and the load activation terminal, An internal switch and shunt resistor connected in series between a first node and a second node, wherein the first node includes a point along the circuit between the line active terminal and the load active terminal, and the second node includes a point along the circuit between the line neutral terminal and the load neutral terminal, (i) a switch control circuit mechanism configured to control the operation of the solid switch and (ii) the internal switch, The system includes a fault detection circuit mechanism configured to detect a fault condition and generate a fault detection control signal in response to the detection of the fault condition, The switch control circuit mechanism is configured to switch the solid switch to the off state in response to the fault detection control signal. A circuit breaker device wherein the switch control circuit mechanism is configured to activate the internal switch in response to the fault detection control signal, thereby generating an internal short-circuit path through which the shunt resistor is connected between the first and second nodes, and to pass an internal short-circuit current through the air gap electromagnetic switch, the internal short-circuit current being sufficient to trip the air gap electromagnetic switch and thereby create an air gap in the circuit between the line active terminal and the load active terminal.

102. The circuit breaker device according to claim 101, wherein the shunt resistor has a resistance value configured to limit the magnitude of the internal short-circuit current to a range of about 2 to 3 times the current rating of the air gap electromagnetic switch.

103. The circuit breaker device according to claim 101, wherein the solid switch includes one of a P-type enhanced metal oxide semiconductor field-effect transistor (MOSFET) device and an N-type enhanced MOSFET device.

104. The circuit breaker according to claim 101, wherein the fault detection circuit mechanism includes a current sensor configured to detect the current flowing in the circuit between the line activation terminal and the load activation terminal, and to detect one of an overcurrent fault state and a short-circuit load current fault state based on the detected current flow.

105. The circuit breaker device according to claim 101, wherein the internal switch includes a solid bidirectional switch comprising a first MOSFET device and a second MOSFET device connected in series.

106. The circuit breaker device according to claim 105, wherein the first and second MOSFET devices have a commonly connected gate terminal, the commonly connected gate terminal is coupled to the switch control circuit mechanism, and the switch control circuit mechanism controls the activation and deactivation of the internal switch by applying a gate control signal to the commonly connected gate terminal.

107. The circuit breaker device further comprises a zero-crossing detection circuit configured to detect zero crossings of the alternating current (AC) power supply waveform on the circuit between the line activation terminal and the load activation terminal, The circuit breaker device according to claim 101, wherein the switch control circuit mechanism uses a zero-crossing detection signal output from the zero-crossing detection circuit to control the timing of activating the internal switch in response to the fault detection control signal, such that after the solid switch is turned off in response to the fault detection control signal, a short-circuit current is generated and the air gap electromagnetic switch is tripped.

108. The zero-crossing detection circuit is configured to detect zero crossings in the AC supply voltage waveform on the circuit between the line activation terminal and the load activation terminal circuit breaker. The zero-crossing detection circuit is configured to detect the associated directions of the polarity transitions of the zero-crossing between opposing half-cycles of the AC supply voltage waveform. The circuit breaker device according to claim 107, wherein the switch control circuit mechanism activates the internal switch when the body diode of the solid switch becomes reverse-biased due to the polarity transition of the AC supply voltage waveform detected as a zero crossover after the solid switch has been switched off.

109. The zero-crossing detection circuit is configured to detect zero crossings in the AC current waveform on the circuit between the line activation terminal and the load activation terminal circuit breaker. The zero-crossing detection circuit is configured to detect the associated directions of the polarity transitions of the zero-crossing between opposing half-cycles of the AC current waveform. The circuit breaker device according to claim 107, wherein the switch control circuit mechanism activates the internal switch when the body diode of the solid switch becomes reverse-biased due to the polarity transition of the AC current waveform detected as a zero crossover, after the solid switch has been switched off.

110. It is a method, The detection of current flowing in the circuit between the line active terminal and the load active terminal of a circuit breaker device, wherein the circuit breaker device comprises a solid switch and an air gap electromagnetic switch connected in series in the circuit between the line active terminal and the load active terminal of the circuit breaker device, Based on the detected current flow, the fault condition is detected, In response to detecting the aforementioned fault condition, Applying a first switch control signal to the solid switch to turn the solid switch off, and This includes applying a second switch control signal to an internal switch to activate the internal switch, thereby creating an internal short-circuit path within the circuit breaker device and generating an internal short-circuit current flowing through the air gap electromagnetic switch, A method wherein the flow of the internal short-circuit current trips the air gap electromagnetic switch, thereby creating an air gap in the circuit between the line active terminal and the load active terminal of the circuit breaker device.

111. The method according to claim 110, wherein the internal short-circuit path includes a shunt resistor having a resistance value configured to limit the magnitude of the internal short-circuit current to a range of about two to three times the current rating of the air gap electromagnetic switch.

112. The method according to claim 111, wherein the internal switch circuit and the shunt resistor are connected in series between a first node and a second node, the first node includes a point along the circuit between the line active terminal and the load active terminal of the circuit breaker device, and the second node includes a point along the circuit between the line neutral terminal and the load neutral terminal of the circuit breaker device.

113. The method according to claim 110, wherein applying the second switch control signal to the internal switch includes applying the first switch control signal to the solid switch to bring the solid switch to the switch-off state, and then applying the second switch control signal to activate the internal switch and generate the internal short-circuit path.

114. To detect the zero crossing of the AC power waveform on the circuit between the line activation terminal and the load activation terminal of the circuit breaker device, The method according to claim 110, further comprising using the timing of the detected zero crossing of the AC power waveform to apply the first switch control signal to turn the solid switch to the switch-off state, and then applying the second switch control signal to control the timing for activating the internal switch.

115. The timing for applying the second switch control signal to activate the internal switch is controlled by utilizing the timing of the detected zero crossing of the AC power waveform. The detected zero crossing of the AC power waveform allows for the detection of the direction of polarity transitions between opposing half-cycles of the AC power waveform, The method according to claim 114, further comprising: after the solid switch is in the switch-off state, the second switch control signal is applied to the internal switch to activate the internal switch at the point when the body diode of the solid switch becomes reverse-biased due to the detected direction of the polarity transition of the AC power waveform after the detected zero crossing of the AC supply voltage waveform.

116. It is a system, A circuit breaker distribution board equipped with a line-active busbar and a line-neutral busbar connected to an external power supply, A circuit breaker device installed in the circuit breaker distribution panel, The circuit breaker device, A circuit breaker device comprising a line activation terminal connected to the line activation busbar, a line neutral terminal connected to the line neutral busbar, and a load activation terminal and a load neutral terminal connected to a branch circuit, A solid switch and an air gap electromagnetic switch are connected in series between the line activation terminal and the load activation terminal, An internal switch and shunt resistor connected in series between a first node and a second node, wherein the first node includes a point along the circuit between the line active terminal and the load active terminal, and the second node includes a point along the circuit between the line neutral terminal and the load neutral terminal, (i) a switch control circuit mechanism configured to control the operation of the solid switch and (ii) the internal switch, The system includes a fault detection circuit mechanism configured to detect a fault condition and generate a fault detection control signal in response to the detection of the fault condition, The switch control circuit mechanism is configured to switch the solid switch to the off state in response to the fault detection control signal. A system wherein the switch control circuit mechanism is configured to activate the internal switch in response to the fault detection control signal, thereby creating an internal short-circuit path through which the shunt resistor is connected between the first and second nodes, and to pass an internal short-circuit current through the air gap electromagnetic switch, the internal short-circuit current being sufficient to trip the air gap electromagnetic switch and thereby create an air gap in the circuit between the line active terminal and the load active terminal.

117. The system according to claim 116, wherein the shunt resistor of the circuit breaker device has a resistance value configured to limit the magnitude of the internal short-circuit current to a range of about 2 to 3 times the current rating of the air gap electromagnetic switch.

118. The circuit breaker device, The circuit breaker device further comprises a zero-crossing detection circuit configured to detect zero crossings of the alternating current (AC) power supply waveform on the circuit between the line activation terminal and the load activation terminal, The system according to claim 116, wherein the switch control circuit mechanism uses the zero-crossing detection signal output from the zero-crossing detection circuit to control the timing of activating the internal switch in response to the fault detection control signal, such that after the solid switch is turned off in response to the fault detection control signal, a short-circuit current is generated and the air gap electromagnetic switch is tripped.

119. The zero-crossing detection circuit is configured to detect zero crossings in the AC supply voltage waveform on the circuit between the line activation terminal and the load activation terminal circuit breaker. The zero-crossing detection circuit is configured to detect the associated directions of the polarity transitions of the zero-crossing between opposing half-cycles of the AC supply voltage waveform. The system according to claim 118, wherein the switch control circuit mechanism activates the internal switch when the body diode of the solid switch becomes reverse-biased due to the polarity transition of the AC supply voltage waveform detected as a zero crossover after the solid switch has been switched off.

120. The zero-crossing detection circuit is configured to detect zero crossings in the AC current waveform on the circuit between the line activation terminal and the load activation terminal circuit breaker. The zero-crossing detection circuit is configured to detect the associated directions of the polarity transitions of the zero-crossing between opposing half-cycles of the AC current waveform. The system according to claim 118, wherein the switch control circuit mechanism activates the internal switch when the body diode of the solid switch becomes reverse-biased due to the polarity transition of the AC current waveform detected as a zero crossover after the solid switch has been switched off.

Images