Systems and methods for remote operation of circuit protection devices

Abstract

Circuit protection devices with coordinated remote control and manual control functionality are described. In one example, a circuit interrupter includes separable contacts and a handle. The handle may be configured for manual operation of the circuit interrupter and / or to provide a visual indication of the normal / faulted state of the circuit interrupter. The circuit interrupter may further include a solenoid plunger configured to be actuated in response to a remote command received at the circuit interrupter through wired or wireless communication from a remote computing device, in which actuation of the bidirectional solenoid assembly causes simultaneous movement of the handle and at least one of the separable contacts to cause the separable contacts and the handle to be in a same state, for instance, an open state preventing current flow through the circuit interrupter or a closed state allowing current flow through the circuit interrupter.

Description

SYSTEMS AND METHODS FOR REMOTE OPERATION OF CIRCUIT PROTECTION DEVICESCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 725,663, filed on November 27, 2024 and entitled “Isolation Contact and Switching Device and a Circuit Interrupter Having the Same,” the contents of each of which are hereby incorporated by reference in their entirety.TECHNOLOGICAL FIELD

[0002] The described technology generally relates to circuit protection devices and, in particular, to a circuit isolation switch system configured for remote control of the isolation mechanism and coordinated physical control of the system manual switching components.BACKGROUND

[0003] Circuit interrupters (for example and without limitation, circuit breakers) are typically used to protect electrical circuitry from damage due to an overcurrent condition, such as an overload condition, a short circuit, an arc fault, a ground fault, or another fault condition. A load center or panel board receives power from a power source (for instance, a utility provider transformer) and routes the power through a main circuit interrupter and then through branch circuit interrupters, which supply current to corresponding loads. For residential and light commercial use, circuit interrupters may have a smaller form factor (for example, “miniature circuit breakers,” that may be approximately one or three-quarter inches wide) compared with commercial or industrial applications.

[0004] Branch circuit interrupters are provided in narrow width molded cases, which fit into designated pole openings in the panel board. Branch circuit interrupters conventionally utilize an electromechanical isolation switching device having a thermal / magnetic trip mechanism including a bimetal member and an armature. In response to, for example, a sudden high current overload condition, the bimetal member becomes heated and moves, and the armature is attracted by the magnetic field generated in a magnetic core.

[0005] For faster tripping, solid state circuit interrupters may be employed. Solid state circuit interrupters use solid state components (for instance, semiconductor devices) to switch on and off current flowing from a power source to a load. However, solid state circuit interrupters face higher power losses compared with electromechanical circuit interrupters when conducting power during normal operation of the device. As a result, hybrid circuit interrupters, which combine solid state switching elements in parallel with electromechanical switching elements, combine advantages of both the conventional circuit interrupters and solid state circuit interrupters.

[0006] The demand for remote controlled (or remote-controllable) circuit interrupters (for instance, operating via wired or wireless instructions from a remote computing device) has increased due to various advantages of remote-based systems, including energy savings, convenience, and flexibility in energy control and monitoring. However, remote -based systems are required to use a handle and / or a mechanical status flag or other indicator of the position of the physical contacts (for instance, OPEN or CLOSED) in a circuit interrupter due to electrical standards (for example and without limitation, International Electrotechnical Commission (IEC) standards). Accordingly, a circuit interrupter implementing remote control using conventional components is required to have dual manual control (via a physical handle, button, and / or the like) and remote control systems.

[0007] Typically, breaker manual switching operations are performed through physically operating a handle or push buttons at the panel or directly on the breaker device. However, the design of conventional handles, push buttons, switches, and / or the like do not provide for the remote control of the circuit interrupters. For example, existing push button designs require an additional mechanical flag to display the breaker contact status, and the buttons are too large and spaced, rendering existing buttons too cumbersome and inconvenient for use in a remote control application. Similarly, the size, shape, and force requirements for existing breaker or panel handles do not allow existing handles to be adaptable to remote operation

[0008] As a result, conventional circuit interrupters are not able to coordinate the state of the isolated contacts operated via remote control with the physical handle and status display indicators. For example, a circuit interrupter may be able to open / close contacts in response to a remote signal, however, the physical handle / button and / or status display flags or other indicatorsof conventional devices are not able to be remotely controlled to coordinate with the contact state resulting from the remote signals.SUMMARY

[0009] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended as an aid in determining the scope of the claimed subject matter.

[0010] The present disclosure describes various embodiments of circuit protection devices configured to provide coordinated remote operation and local, manual operation.

[0011] In one example, a circuit protection device may include an isolation contact and switching device comprising: separable contacts configured to be arranged in a contact state including one of an open state and a closed state, and a bidirectional solenoid assembly configured to be actuated, in response to a remote command to change the contact state of the separable contacts, to move at least one of the separable contacts to cause the separable contacts to be in the contact state associated with the remote command; and a handle configured to be arranged in a handle state including one of an open handle state and a closed handle state, the open handle state corresponding with the open state and the closed handle state corresponding with the closed state, in which actuation of the bidirectional solenoid assembly in response to the remote command causes a change in the handle state of the handle to correspond with the contact state of the separable contacts.

[0012] In some embodiments of the circuit protection device, the circuit protection device further includes an isolation contact and switching device controller connected to the isolation contact and switching device, the isolation contact and switching device controller configured to receive the remote command from a remote computing device.

[0013] In various embodiments of the circuit protection device, the isolation contact and switching device controller is configured to transmit a control signal to the bidirectional solenoid assembly to change the contact state of the separable contacts based on the remote command.

[0014] In some embodiments of the circuit protection device, the remote command is a wireless command transmitted via a remote computing device.

[0015] In various embodiments of the circuit protection device, the bidirectional solenoid assembly may include a solenoid plunger configured to be actuated to engage with a movable contact of the separable contacts to change the contact state of the separable contacts.

[0016] In exemplary embodiments of the circuit protection device, a portion of the handle is fixedly attached to the solenoid plunger such that actuation of the solenoid plunger to change the contact state of the separable contacts causes the handle to rotate to change the handle state.

[0017] In some embodiments of the circuit protection device, the circuit protection device further includes a sensing device comprising a contact position feedback sensor configured to indicate the contact state of the separable contacts.

[0018] In various embodiments of the circuit protection device, the contact position feedback sensor is configured to transmit a signal indicating the contact state based on an engagement state of the contact position feedback sensor with a solenoid plunger of the bidirectional solenoid assembly, the solenoid plunger configured to be actuated to change the contact state of the separable contacts.

[0019] In some embodiments of the circuit protection device, the circuit protection device further includes a handle position sensor configured to engage with a portion of the handle to detect the handle state.

[0020] In various embodiments of the circuit protection device, the handle position sensor is configured to transmit a handle state signal indicating the handle state.

[0021] In exemplary embodiments of the circuit protection device, the contact state of the separable contacts is changed based on the handle state signal.

[0022] In one example, a circuit interrupter may include separable contacts; a handle; and a solenoid plunger configured to be actuated in response to a remote command received at the circuit interrupter from a remote computing device, actuation of the bidirectional solenoid assembly causing simultaneous movement of the handle and at least one of the separable contacts to be in a corresponding state, the corresponding state comprising one of an open circuit interrupter state or a closed circuit interrupter state.

[0023] In some embodiments of the circuit interrupter, the circuit interrupter further includes a linkage assembly connected to the handle and the solenoid plunger and configured to cause actuation of the solenoid plunger to move the handle to the corresponding state.

[0024] In various embodiments of the circuit interrupter, the circuit interrupter further includes a contact spring connected to the solenoid plunger and a moveable contact of the separable contacts, the contact spring configured to cause actuation of the solenoid plunger to move the moveable contact to place the separable contacts in the corresponding state.

[0025] In some embodiments of the circuit interrupter, the circuit interrupter further includes a contact position feedback sensor configured to transmit a signal indicating a contact state of the separable contacts based on an engagement state of the contact position feedback sensor with the solenoid plunger of the bidirectional solenoid assembly.

[0026] In various embodiments of the circuit interrupter, the circuit interrupter further includes a handle position sensor configured to: engage with a portion of the handle to detect a handle state of the handle, and transmit a handle state signal indicating the handle state, wherein a contact state of the separable contacts is changed based on the handle state signal.

[0027] In one example, a circuit interrupter structured to be connected between a power source and a load may include a housing; an isolation contact and switching device including: a line terminal structured to connect to the load, separable contacts including a movable contact and a stationary contact connected to the line terminal, the separable contacts being structured to be in a contact state including one of an open state to provide galvanic isolation and a closed state to allow current flow, and a bidirectional solenoid assembly including a solenoid plunger and a contact spring connected to the movable contact, the solenoid plunger being structured to be actuated to position the separable contacts in one of the open state or the closed state; a handle assembly including a handle fixedly attached to the solenoid plunger and configured to move to change a handle position of the handle, the handle position comprising one of a handle open position and a handle closed position; and an isolation contact and switching device controller connected to the isolation contact and switching device, the isolation contact and switching device controller structured to receive a remote command and transmit a control signal to the bidirectional solenoid assembly to cause the separable contacts to change the contact state based on the remote command.

[0028] In some embodiments of the circuit interrupter, the circuit interrupter further includes a linkage assembly including a handle close linkage having a handle close slot, a handle close pin, a handle open pin and a handle open linkage having a handle open slot, the handle close pin and the handle open pin fixedly attached to the solenoid plunger and structured to slide within arespective slot to allow the handle to move between the handle open position and the handle closed position.

[0029] In exemplary embodiments of the circuit interrupter, the handle further includes a positive OFF component structured to engage with a handle close linkage of the handle to cause the handle close linkage to block the handle from being moved to the handle open position when the separable contacts have failed to open in response to an open command.

[0030] In various embodiments of the circuit interrupter, the isolation contact and switching device includes a trip FREE mechanism including a clutching device, the clutching device comprising a clutch spring structured to be compressed and expand immediately upon tripping the separable contacts to cause the handle to move to the handle open position.

[0031] In one example, a circuit interrupter is structured to be connected between a power source and a load. The circuit interrupter may include a housing; an isolation contact and switching device including: a line terminal structured to connect to the load; separable contacts including a movable contact and a stationary contact connected to the line terminal, the separable contacts being structured to provide galvanic isolation in the open state; a bidirectional solenoid assembly including a solenoid plunger and a contact spring connected to the movable contact, the solenoid plunger being structured to be actuated to open or close the contacts; a handle assembly including a handle having an engagement arm and a toggle plate, the handle being structured to rotate between a handle open position and a handle closed position; a linkage assembly including a handle close linkage having a handle close slot, a handle close pin, a handle open pin and a handle open linkage having a handle open slot, the handle close pin and the handle open pin being fixedly attached to the solenoid plunger and structured to slide within respective slot and cause the handle to rotate towards the handle open position and the handle closed position; a toggle assembly including a toggle spring connected to the toggle plate of the handle assembly and structured to toggle the handle into the handle open position or the handle closed position; a sensing device including a handle position sensor disposed beneath the top of the housing and proximate to the handle assembly, the handle position sensor being structured to engage or disengage with the engagement arm of the handle and indicate instantaneous contact state and provide a command to open or close the circuit interrupter based on the handle position; a semiconductor switching device connected in series to the isolation contact and switching device and structured to interrupt current flowing to the load; an isolation contact and switching devicecontroller connected to the isolation contact and switching device, the isolation contact and switching device controller structured to receive a command and transmit a control signal to the bidirectional solenoid assembly to open or close the contacts based on the command; and a remote controller communicatively connected to the isolation contact and switching device controller and structured to transmit a remote command to remotely open or close the contacts.

[0032] In one example, an isolation contact and switching device for use in a remote-controlled circuit interrupter may be structured to be connected between a power source and a load. The circuit interrupter has an isolation contact and switching device controller, a remote controller structured to remotely open or close the isolation contact and switching device, and a semiconductor switching device connected in series to the isolation contact and switching device and structured to open to interrupt current. The isolation contact and switching device may include: a line terminal structured to connect to the load; separable contacts including a movable contact and a stationary contact connected to the line terminal, the separable contacts being structured to provide galvanic isolation in the open state; a bidirectional solenoid assembly connected to the isolation contact and switching device and including a solenoid plunger and a contact spring connected to the movable contact, the solenoid plunger being structured to be actuated to open or close the contacts; a handle assembly including a handle having an engagement arm and a toggle plate, the handle being structured to move between a handle open position and a handle closed position; a linkage assembly including a handle close linkage having a handle close slot, a handle close pin, a handle open pin and a handle open linkage having a handle open slot, the handle close pin and the handle open pin being fixedly attached to the solenoid plunger and structured to slide within respective slots and cause the handle to rotate towards the handle open position and the handle closed position; a toggle assembly including a toggle spring connected to the toggle plate of the handle assembly and structured to toggle the handle into the handle open position or the handle closed position; and a sensing device including a handle position sensor disposed beneath the top of the housing and proximate to the handle assembly, the handle position sensor being structured to engage or disengage with the engagement arm of the handle and indicate instantaneous contact state and provide a command to open or close the circuit interrupter based on the handle position.BRIEF DESCRIPTION OF THE DRAWINGS:

[0033] By way of example, features of the disclosed components and systems are described with reference to the accompanying drawings, in which:

[0034] FIG. 1 depicts an illustrative example of a circuit protection device in accordance with the present disclosure;

[0035] FIG. 2 depicts an illustrative example of a housing of the circuit protection device of FIG. 1;

[0036] FIG. 3 depicts an illustrative example of an isolation contact and switching device in accordance with the present disclosure;

[0037] FIGS. 4 and 5 depict an illustrative example of a bidirectional solenoid assembly of an isolation contact and switching device in accordance with the present disclosure;

[0038] FIGS. 6 and 7 depict different views of the isolation contact and switching device in accordance with the present disclosure;

[0039] FIGS. 8 and 9 depict an illustrative example of a handle of an isolation contact and switching device in accordance with the present disclosure;

[0040] FIGS. 10-12 depict an illustrative example of a sensing device and an indication device of an isolation contact and switching device in accordance with the present disclosure;

[0041] FIGS. 13 and 14 depict an illustrative example of a normal manual switching operation of an isolation contact and switching device in accordance with the present disclosure;

[0042] FIGS. 15-17 depict an illustrative example of a remote closing operation of an isolation contact and switching device in accordance with the present disclosure;

[0043] FIGS. 18-23 depict an illustrative example of a remote opening operation of an isolation contact and switching device in accordance with the present disclosure;

[0044] FIGS. 24-26 depict an illustrative example of a positive OFF feature of the isolation contact and switching device in accordance with the present disclosure;

[0045] FIGS. 27-30 depict an illustrative example of a trip FREE feature of the isolation contact and switching device in accordance with the present disclosure;

[0046] FIGS. 31-40 depict various views of an illustrative example of a manual opening lever and interlock assembly of the isolation contact and switching device in accordance with the present disclosure;

[0047] FIG. 41 illustrates a switching sequence of an example electromechanical circuit breaker in accordance with the present disclosure;

[0048] FIG. 42 illustrates a switching sequence of an example solid state circuit breaker in accordance with the present disclosure; and

[0049] FIG. 43 illustrates the switching sequence of an example hybrid circuit breaker in accordance with the present disclosure.DETAILED DESCRIPTION

[0050] Various features of a remote-controllable circuit protection device are described in the present disclosure, with reference to the accompanying drawings, in which one or more features of a remote-controlled circuit protection device are shown and described. The various features described in the present disclosure and depicted in the accompanying drawings may be used independently of, or in combination with, each other. A remote-controllable circuit protection device as disclosed herein may be embodied in many different forms and should not be construed as being limited to the examples set forth herein. Rather, these examples are provided to convey certain features of the circuit interrupter calibration system to those skilled in the art.

[0051] A remote-controllable circuit protection device may be or may include various types of circuit protection assemblies, mechanisms, devices, and / or the like. For example and without limitation, a remote-controllable circuit protection device may be or may include a circuit breaker, a miniature circuit breaker, an isolation switch, an isolation contact switching mechanism, a circuit interrupter, a hybrid circuit breaker, a solid state circuit breaker, a mechanical circuit breaker, a power electronics (PE) component, an isolation contact (IC) component, and / or the like.

[0052] Directional phrases used herein, such as, for example, left, right, front, back, top, bottom and derivatives thereof, relate to the orientation of the elements shown in the drawings and are not limiting upon the claims unless expressly recited therein.

[0053] As employed herein, the statement that two or more parts or components are “coupled” shall mean that the components are joined or operate together either directly or indirectly, for instance, through direct contact, through one or more intermediate parts or components, and / or through the communication or flow of data, electricity, current, and / or the like between the components (for example, “communicatively coupled” or “electrically coupled).

[0054] As employed herein, ordinal terms such as “first” and “second” are used to distinguish one item from another, and are not intended to require a sequential order unless specifically stated.

[0055] FIG. 1 depicts an illustrative example of a circuit protection device in accordance with the present disclosure. As shown in FIG. 1 , the circuit protection device 1 may be implemented as a solid state circuit breaker. In some embodiments, the solid state circuit breaker 1 is structured to be connected between a power source, for example, a utility transformer (not shown) and loads (not shown). The solid state circuit breaker 1 may include a housing 2, an isolation contact and switching device 100, a semiconductor switching device 300, and / or an isolation contact and switching device controller 6.

[0056] FIG. 2 depicts a housing of the circuit protection device of FIG. 1 in accordance with the present disclosure. As shown in FIG. 2, The housing 2 may have the dimensions of a length 3, width 4, and a depth 5. In some embodiments, the length 3 may be about 10.36 centimeters (cm) (4.080 inches), the width 4 may be about 6.51 cm (2.563 inches), and the depth 5 may be about 2.51 cm (0.988 inches). In various embodiments, the length 3 may be about 5 centimeters (2 inches) to about 20 centimeters (7.9 inches). In various embodiments, the width 4 may be about 3 centimeters (1.2 inches) to about 15 centimeters (5.9 inches). In various embodiments, the depth 5 may be about 1 centimeter (0.8 inches) to about 5 centimeters (2 inches). However, each of the dimensions of the housing 2 may be scaled up or down, for example, in order to fit in existing or future-developed systems.

[0057] In some embodiments, remote computing device, such as a user device 8, may be communicatively coupled to the solid state circuit breaker 1 and / or one or more operational units of the solid state circuit breaker 1. The user device 8 may be, may include, or may implement a remote controller 7. In some embodiments, the remote controller 7 may be, for example and without limitation, an individual hardware and / or software component. In other embodiments, the remote controller 7 may be an application or functions performed by the user device. The remote controller 7 may be configured to perform circuit breaker control functions according to various embodiments of the present disclosure. In some embodiments, the user device 8 may be the remote controller 7 (for instance, perform the functions described with respect to the remote controller 7).

[0058] The user device 8 and / or the remote controller 7 may include a microprocessor, a microcontroller, or some other suitable processing device or circuitry. The user device 8 and / or the remote controller 7 may be or may include software, firmware, code, instructions, logic, and / or the like (for instance, executed by the user device 8 and / or the remote controller 7). The user device 8 and / or the remote controller 7 may include a memory. The memory can be any of one or more of a variety of types of internal and / or external storage media such as, without limitation, RAM, ROM, EPROM(s), EEPROM(s), FLASH, and the like that provide a storage register, for instance, a machine readable medium, for data storage such as in the fashion of an internal storage area of a computer, and can be volatile memory or nonvolatile memory. The user device 8 may be, for example and without limitation, a personal computer (PC), a laptop, a workstation, a server computing device, a smartphone, a tablet computing device, a cellular device, a logic device, and / or the like communicatively coupled to the isolation contact and switching device controller 6 in a wired or wireless connection.

[0059] The remote controller 7 is structured, either alone or via the user device 8, to transmit a remote signal to the isolation contact and switching device controller 6 to remotely control the isolation contact and switching device 100.

[0060] The isolation contact and switching device controller 6 may be an electronic trip unit (ETU) or a standalone control circuit including a processor and a memory. The processor may be, for example and without limitation, a microprocessor, a microcontroller, or some other suitable processing device or circuitry. The memory can be any of one or more of a variety of types of internal and / or external storage media that provide a storage register, for instance, a machine readable medium, for data storage such as in the fashion of an internal storage area of a computer, and can be volatile memory or nonvolatile memory.

[0061] The isolation contact and switching device controller 6 is structured to receive a command (manual or remote) and transmit a command to the isolation contact and switching device 100 to open or close the solid state circuit breaker 1, for instance, to sequentially open or close the semiconductor switching device 300 and the isolation contact and switching device 100 (see, for example, FIG. 42).

[0062] The isolation contact and switching device 100 is electrically connected to the isolation contact and switching device controller 6 and communicatively connected to the user device 8 and / or the remote controller 7 via a wired or wireless connection. The isolation contact andswitching device 100 may include a contact assembly 110, a bidirectional solenoid assembly 120, a linkage assembly 130, a handle assembly 140, a toggle assembly 160, a sensing device 170, a manual opening lever and interlock assembly 180, and / or an indication device 190. The isolation contact and switching device 100 is structured to open and close the contacts 112 and 114. In some embodiments, the toggle assembly 160 may include a toggle spring 161.

[0063] The semiconductor switching device 300 is electrically connected in series to the isolation contact and switching device 100. The semiconductor switching device 300 may be the same or substantially similar to the semiconductor switching device 20B depicted in FIG. 42, and, accordingly, overlapping description is omitted for the sake of brevity. The solid state circuit breaker 1 may also include other standard circuit breaker components, the description of which is omitted for the sake of brevity. The semiconductor switching device 300 is structured to be turned ON to supply current from a power source to a load during normal operation. The semiconductor switching device 300 is structured to be turned OFF to interrupt the current from flowing to the loads in an overcurrent or overload condition or to interrupt rated current during normal operation.

[0064] In some embodiments, a normal operation, normal manual operation, or normal manual switching operation may include or be the result of a manual opening operation by an operator when the solid state circuit breaker 1 is operating normally (for example and without limitation, close, open, and trip as designed or for maintenance). In exemplary embodiments, a manual forced opening operation may include or be the result of circumstances in which an operator is manually forcing the solid state circuit breaker 1 to open, for example and without limitation, during a power outage or when the solid state circuit breaker 1 is non-responsive.

[0065] The semiconductor switching device 300 may operate to interrupt the current from flowing to the loads in an overcurrent or overload condition and / or to interrupt the rated current during normal operation. The isolation contact and switching device 100 provides galvanic isolation when placed in an open state. Accordingly, the contacts 112 and 114 open and close only when the solid state circuit breaker 1 is not carrying a current, for instance, when the power electronics is turned OFF. As a result, the isolation contact and switching device 100 needs to be driven electronically (for example, in accordance with the switching sequence as described with reference to FIG. 42).

[0066] However, electrical standards (for example and without limitation, International Electrotechnical Commission (IEC) standards) require circuit breakers to include a handle and associated components for manual operation. Conventional physical operating components, such as handles, buttons, indicators, and / or the like required for circuit breakers and other circuit protection devices cannot be remotely or electronically controlled using existing technologies. Accordingly, if a circuit protection device is operated remotely using electronic signals to change the state of the device (for instance, to open / close the contacts and place the device in an ON / OFF state), the physical operating components are not changed to correspond to the current state.

[0067] For instance, a circuit breaker may be in the OFF state, with a set of isolating contacts in an open state and the handle and corresponding physical components (including, for example, indicators) in the OFF state / position. A remote ON or close command may be received at the circuit breaker to place the circuit breaker in the ON state and to close the set of isolating contacts. However, the handle and the corresponding physical components are not modified by the remote command. Therefore, a mismatch would be created between the actual state of the circuit breaker (in the ON state with the set of contacts closed) and the handle and the corresponding physical components (in the OFF state, indicating that the set of contacts is open).

[0068] A circuit protection device 1 according to embodiments described in the present disclosure is able to coordinate the remote control of the circuit protection device 1 with the manual control of the circuit protection device 1. A circuit protection device 1 may include elements and functionality to control and coordinate the physical components of the circuit protection device 1 to correspond with remote control functions of the circuit protection device 1.

[0069] Accordingly, for example, the circuit protection device 1 may include an isolation contact and switching device 100 operative to resolve the problem of having a handle that is not controllable remotely to open or close the contacts 112 and 114 by utilizing a bidirectional solenoid assembly 120 to open or close the contacts 112 and 114 automatically based on a remote signal from the remote controller 7 or manually by a user input provide onsite. For instance, the isolation contact and switching device 100 no longer requires the manual closing or opening of the handle 141 in order to close or open the contacts 112 and 114 as required by existing circuit breakers.

[0070] In addition, understanding the user familiarity with the handle position relative to the contact positions, the isolation contact and switching device 100 advantageously utilizes the position of the handle 141 as an indicator of the contact state during remote controlled switching operations and as a command to open or close the solid state circuit breaker 1 , for instance, sequentially open or close the semiconductor switching device 300 and the isolation contact and switching device 100 (see, for example, FIG. 42), during a normal manual switching operation. In addition, as described in the present disclosure, the isolation contact and switching device 100 provides multiple technological advantages over existing systems including, without limitation, a positive OFF feature, a trip FREE feature, a safety interlock feature, and / or a contact position feedback feature to further improve the reliability, efficiency, and user experience.

[0071] FIG. 3 depicts an illustrative example of an isolation contact and switching device in accordance with the present disclosure. Referring to FIGS. 1 and 3, the contact assembly 110 may include a stationary arm 111 having a stationary contact 112 and a movable arm 113 having a movable contact 114. The isolation contact and switching device 100 may also include a line terminal 102, a flexible shunt 104, and a power electronics line connection 106. The stationary contact 112 is connected to the power source (not shown) via the line terminal 102. The movable contact 114 is connected to the movable arm 113, which is in turn connected to the flexible shunt 104 and the power electronics line connection 106. The power electronics line connection 106 is connected to the semiconductor switching device 300.

[0072] The contacts 112 and 114 are structured to open only after the semiconductor switching device 300 has fully opened and the semiconductor switching device 300 is structured to close only after the contacts 112 and 114 are fully closed (see, for example, FIG. 42). In the open state, the isolation contact and switching device 100 provides galvanic isolation for the protection circuit within the solid state circuit breaker 1.

[0073] FIGS. 4 and 5 depict an illustrative example of a bidirectional solenoid assembly of the isolation contact and switching device of FIG. 3. More specifically, FIG. 4 depicts a side view of the bidirectional solenoid assembly 120 with a transparent frame 121 and FIG. 5 depicts a side sectional view of the bidirectional solenoid assembly 120.

[0074] Referring to FIGS. 3-5, the bidirectional solenoid assembly 120 is connected to the movable arm 113 and is structured to cause the contacts 112 and 114 to open or close based on a remote command or a normal (for instance, not forced) manual operator input. The bidirectionalsolenoid assembly 120 may include a frame 121, a solenoid plunger 122, a permanent magnet 125, coils 126, and / or a contact spring 127. The solenoid plunger 122 extends vertically and includes a handle close pin hole 123 and a handle open pin hole 124.

[0075] FIGS. 6 and 7 depict different views of the isolation contact and switching device of FIG. 3. More specifically, FIGS. 6 and 7 depict a side view and a side perspective view, respectively, of the isolation contact and switching device 100.

[0076] Referring to FIGS. 3-7, the solenoid plunger 122 is connected to the linkage assembly 130 via a handle close pin 132 and a handle open pin 133 of the linkage assembly 130. The handle close pin 132 and a handle open pin 133 are fixedly attached to the plunger 122 via the handle close pin hole 123 and the handle open pin hole 124, respectively. Responsive to receiving a command to open the solid state circuit breaker 1 (for instance, sequentially opening the semiconductor switching device 300 and contacts 112 and 114 as described with in FIG. 42) from the isolation contact and switching device controller 6, the solenoid plunger 122 is actuated and moves upward to open the contacts 112 and 114.

[0077] For example, in response to receiving the open command, the coils 126 may be energized by reversing the polarity of the current (for example and without limitation, from + polarity to - polarity) to move the solenoid plunger 122 upward by compressing the contact spring 127 until the solenoid plunger 122 is latched to the permanent magnet 125, thereby holding the contacts 112 and 114 in the open state.

[0078] In response to receiving a command to close the solid state circuit breaker 1 (for instance, sequentially closing the contacts 112 and 114 and the semiconductor switching device 300 as described with reference to FIG. 42) from the isolation contact and switching device controller 6, the solenoid plunger 122 is actuated and moves downward to close the contacts 112 and 114.

[0079] For example, in response to receiving the close command, the coils 126 are energized by reversing the polarity (for instance, imparting a polarity opposite the polarity of the opening operation, for example, from - polarity to + polarity) of the current to de-latch the solenoid plunger 122 from the permanent magnet 125 so that the contact spring 127 moves the solenoid plunger 122 downward to close the contacts 112 and 114. The downward movement of the solenoid plunger 122 causes the contacts 112 and 114 to close.

[0080] In some embodiments, the contact spring 127 may be, for example and without limitation, a conical compressed spring to facilitate a compact design. Optionally, the isolationcontact and switching device 100 allows for compensation of, for example and without limitation, at least 1 millimeter (mm) of contact erosion. For instance, the contacts 112 and 114 may be held in the close position by the contact spring 127, which eliminates the need for a secondary spring arrangement for such compensation as required by existing circuit interrupters. Accordingly, the isolation contact and switching device 100 may be formed with compact dimensions, providing a compact design that may fit within the limited space of the solid state circuit breaker 1 (including, for instance, in a miniature circuit breaker form factor).

[0081] In various embodiments, the solenoid plunger 122 may include an insulator 128 attached to the movable arm 113 and structured to prevent the current from flowing into the bidirectional solenoid assembly 120.

[0082] The handle assembly 140 of the solid state circuit breaker 1 may be configured as a state indicator for the solid state circuit breaker 1. In some embodiments, for example, the handle assembly 140 may not cause the contacts 112 and 114 to open or close. Instead, the handle assembly 140 is utilized as, among other functions, to indicate the contact position of the solid state circuit breaker 1. As such, the handle position of the handle assembly 140 operates as a visual indicator of the instant contact position for remote controlling and a command to open or close the solid state circuit breaker 1 (for instance, to sequentially open or close the semiconductor switching device 300 and the isolation contact and switching device 100 as described with reference to FIG. 42) for the normal switching operation. Accordingly, in some embodiments, the handle assembly 140 is not directly connected to the contacts 112 and 114 and does not directly cause the contacts 112 and 114 to open or close, in contrast to corresponding handle assemblies of existing circuit breakers.

[0083] In various embodiments, the handle 141 may be placed in the handle open or closed position via the operation of the bidirectional solenoid assembly 120 (in some embodiments, in particular, via the operation of the solenoid plunger 122), and the linkage assembly 130, the handle assembly 140, the toggle assembly 160, and the sensing device 170 may correspondingly operate together according to various embodiments.

[0084] The linkage assembly 130 links the solenoid plunger 122 to the handle assembly 140 and rotates the handle 141 to the handle open position or the handle closed position. The linkage assembly 130 may include a handle close linkage 131, a handle close pin 132, a handle open pin 133, and a handle open linkage 134. The handle close linkage 131 may include a first closelinkage portion 131a and a second close linkage portion 131b. The first close linkage portion 131a includes a handle close linkage slot 135 via which the handle close pin 132 slides vertically, causing the handle close linkage 131 to rotate. The second close linkage portion 131b may include a tip (for example, tip 13 lb 1 depicted in FIG. 16). The handle open linkage 134 includes a first open linkage portion 134a having a handle open linkage slot 136 via which the handle open pin 133 slides vertically, causing the handle open linkage 131 to rotate. It also includes a second open linkage portion 134b as (see also, FIGS. 21-23). The linkage assembly 130 causes the handle assembly 140 to rotate towards the handle open position or the handle closed position based on the contact position.

[0085] FIGS. 8 and 9 depict an illustrative example of a handle of an isolation contact and switching device in accordance with the present disclosure.

[0086] The handle assembly 140 may include a handle 141, a toggle plate 142 and a clutching device 143 (see, for example, FIG. 8). The handle assembly 140 is hinged to the solid state circuit breaker 1 (for example and without limitation, via the housing 2) and structured to rotate pivotally between the handle open position and the handle closed position based on a command from the isolation contact and switching device controller 6 or a manual force applied by an operator. The handle open position indicates the position in which the handle 141 has rotated clockwise (see, for example, FIG. 14) and corresponds to the contact open position. The handle closed position indicates the position in which the handle 141 has rotated counterclockwise (see, for example, FIG. 13) and corresponds to the contact closed position. Accordingly, the handle position indicates the instantaneous position of the contacts 112 and 114.

[0087] The toggle plate 142 includes a connector 142a (for example and without limitation, a hook) affixed to the toggle spring 161 that is structured to rotate the handle 141 to the handle open position or the handle closed position. The clutching device 143 includes a clutch spring 144. The clutch spring 144 may be, for example, a compression spring and structured to provide a trip FREE function (see, for example, FIGS. 27-30).

[0088] The handle 141 includes a handle base 145, a top lever 146, an engagement arm 147, a clutch holding arm 148, and a securing element 149. The handle base 145 may be in a shape of an annulus including a hinge hole 145a via which a hinging fixture (not shown) secures the handle 141 to the solid state circuit breaker 1. The top lever 146 extends upward from the handle base 145 and protrudes outward from the top surface of the housing 2. The top lever 146 isstructured to rotate pivotally between the handle open position and the handle closed position based on a command from the isolation contact and switching device controller 6 or a manual force applied by an operator.

[0089] The engagement arm 147 extends outward from the handle base 145 and includes a closed engagement ridge 147a and an open engagement recess 147b. The engagement arm 147 is structured to engage or disengage with the handle position sensor 172 and transmit a signal to the isolation contact and switching device controller 6, indicating the handle position. The handle 141 is in the fully closed position when the closed engagement ridge 147a is fully engaged with the handle position sensor 172 (see, for example, FIG. 13). The handle 141 is in the fully open position, when the engagement arm 147 is disengaged from the handle position sensor 172 and the handle open pin 133 is engaged within the open engagement recess 147b of the engagement arm 147 (see, for example, FIG. 23).

[0090] The clutch holding arm 148 extends outward from the handle base 145 and fixedly holds the clutching device 143. For example, the clutch holding arm 148 may surround one end of the clutching device 143 within a cavity 148a (see, for example, FIG. 8). The securing element 149 is disposed on the handle base 145 proximate to the engagement arm 147. The securing element 149 may include a positive OFF component 150 and a remote close / open engagement portion 151 (see, for example, FIGS. 15-26).

[0091] In some embodiments, the sensing device 170 may include a human machine interface (HMI) 171, a handle position sensor 172, an interlock sensor 173, and a contact position feedback sensor 174. The sensors 172-174 may be or may include, for example and without limitation, a microswitch.

[0092] The handle position sensor 172 may be disposed below the HMI 171 and structured to sense the handle position and transmit a signal to the isolation contact and switching device controller 6, indicating that the handle 141 is in the handle open position or the handle closed position. If the closed engagement ridge 147a of the engagement arm 147 of the handle 141 is fully engaged with the handle position sensor 172, the handle 141 is in the handle closed position and the handle position sensor 172 transmits a signal to the isolation contact and switching device controller 6, indicating that the handle 141 is in the handle closed position.

[0093] For the normal manual closing operation, the isolation contact and switching device controller 6 transmits a command to the bidirectional solenoid assembly 120 to close the contacts112 and 114 based on manual user input (for example and without limitation, a pull or push of the handle lever 146). If the engagement arm 147 is disengaged from the handle position sensor 172, the handle 141 is in the handle open position and the handle position sensor 172 transmits a signal to the isolation contact and switching device controller 6, indicating that the handle 141 is in the handle open position.

[0094] For the normal manual opening operation, the isolation contact and switching device controller 6 transmits a command to the bidirectional solenoid assembly 120 to open the contacts 112 and 114 based on the signal.

[0095] FIGS. 10-12 depict an illustrative example of a sensing device and an indication device of an isolation contact and switching device in accordance with the present disclosure.

[0096] The interlock sensor 173 may be disposed on top of the HMI 171 (see, for example, FIG. 10) and structured to detect whether the manual forced open lever and interlock assembly 180 is accessible to the user. The contact position feedback sensor 174 is disposed below the HMI 171 (see, for example, FIG. 12) and is structured to indicate that the contacts 112 and 114 are in the closed state or the open state.

[0097] When the contacts 112 and 114 are in the open state, the contact position feedback sensor 174 engages with the top surface of the solenoid plunger 122 and transmits a signal to the isolation contact and switching device controller 6 that the contacts 112 and 114 are in the open state. When the contacts 112 and 114 are in the closed state, the contact position feedback sensor 174 disengages with the top surface of the solenoid plunger 122 and transmits a signal to the isolation contact and switching device controller 6 that the contacts 112 and 114 are in the closed state.

[0098] The indication device 190 may include, for example and without limitation, a trip indicator 191 (see, for example, FIG. 10). The trip indicator 191 is disposed on the HMI 171 and may include one or more, for example and without limitation, LEDs or push buttons. For example, a red LED 192 may indicate that the solid circuit breaker 1 has been tripped. In other examples, a blue LED button 193 may indicate that the solid circuit breaker 1 is in or out of the standby mode (for instance, a state in which the contacts 112 and 114 are closed and the semiconductor switching device 300 is open).

[0099] In various embodiments, when the solid state circuit breaker 1 is in the closed state, pressing the blue LED button 193 may cause the semiconductor switching device 300 to openand the blue LED to turn ON, and pressing the blue LED button 193 again may close the semiconductor device 300 and the blue LED will be turned OFF, indicating that the solid state circuit breaker 1 is in the closed state. The standby mode is utilized to extend the life of the mechanical components without operating the contacts 112 and 114.

[0100] FIGS. 13 and 14 depict a normal manual switching operation of an isolation contact and switching device in accordance with the present disclosure. More specifically, FIGS. 13 and 14 illustrate the normal (not forced) manual switching operation of the isolation contact and switching device 100 according to various embodiments.

[0101] Referring to FIGS. 13 and 14, to manually close the contacts 112 and 114, an operator rotates the handle 141 counterclockwise as shown by the arrow 152a, placing the handle 141 in the handle closed position. The handle position sensor 172 then engages with the engagement arm 147 (for instance, with the closed engagement ridge 147a) and transmits a signal indicating that the handle 141 is in the handle closed position to the isolation contact and switching device controller 6. Based on the handle closed signal, the isolation contact and switching device controller 6 transmits a close command to the bidirectional solenoid assembly 120 to close the contacts 112 and 114. Responsive to receiving the close command, the bidirectional solenoid assembly 120, and not the handle 141, actuates the solenoid plunger 122 to move downward, releasing the contact spring 117 and causing the contacts 112 and 114 to close.

[0102] As shown in FIG. 13, the engagement arm 147 may be fully engaged with the handle position sensor 172 and the contacts 112 and 114 in the fully closed state. To manually open the contacts 112 and 114, the operator rotates the handle 141 clockwise (as shown by the arrow 152b) and places the handle 141 in the handle open position. The handle position sensor 172 disengages from the engagement arm 147 (for instance, from the closed engagement ridge 147a) and transmits a signal indicating that the handle 141 is in the handle open position to the isolation contact and switching device controller 6. Based on the handle open signal, the isolation contact and switching device controller 6 transmits an open command to the bidirectional solenoid assembly 120 to open the contacts 112 and 114. Responsive to receiving the open command, the bidirectional solenoid assembly 120, and not the handle 141, actuates the solenoid plunger 122 to move upward, compressing the contact spring 117 and causing the contacts 112 and 114 to open. As shown in FIG. 14, the engagement arm 147 may be fully disengaged from the handle position sensor 172 and the contacts 112 and 114 in the fully open state.

[0103] FIGS. 15-17 depict an illustrative example of a remote closing operation of an isolation contact and switching device in accordance with the present disclosure. More specifically, FIGS. 15-17 illustrate remote contact closing of the isolation contact and switching device 100 according to various embodiments.

[0104] Referring to FIG. 15, initially at Stage 1, the contacts 112 and 114 are in the open state. The contact spring 127 is compressed upward, latching the contacts 112 and 114 in the open state, and the bidirectional solenoid assembly 120 is not actuated. At this stage, the user may transmit a remote close command to the isolation contact and switching device 100 via the remote controller 7 and / or the user device 8 to remotely close the contacts 112 and 114.Responsive to receiving the remote close command, the isolation contact and switching device controller 6 transmits a contact close command to the bidirectional solenoid assembly 120.

[0105] At Stage 2 as depicted in FIG. 16, the bidirectional solenoid assembly 120 actuates the solenoid plunger 122 to move downward and close the contacts 112 and 114. As the solenoid plunger 122 moves downward, the handle close linkage 131 and the handle open linkage 134 rotate clockwise as shown by the arrow 154a. As the handle close and open linkages 131 and 134 rotate, the tip 13 lb 1 of the first handle close linkage portion 131b pushes the remote close / open engagement portion 151 of the handle 141, rotating the handle 141 counterclockwise (as shown by the arrow 152a) into the toggle position as shown by the line 155a.

[0106] At Stage 3 depicted in FIG. 17, The toggle assembly 160 then toggles the handle 141 to rotate fully into the handle closed position in which the engagement arm 147 engages with the handle position sensor 172.

[0107] FIGS. 18-23 depict an illustrative example of a remote opening operation of an isolation contact and switching device in accordance with the present disclosure. More specifically, FIGS. 18-23 illustrate the sequence of the remote opening of the contacts 112 and 114 in accordance various embodiments, in which FIGS. 18-20 depict a front view of the remote opening of the contacts 112 and 114 and FIGS. 21-23 depict a rear view of the remote opening of the contacts 112 and 114.

[0108] At Stage 1 as depicted in FIG. 18 and 21, the contacts 112 and 114 are in the closed state and the handle 141 (particularly, the engagement arm 147) is in the handle closed position. Thus, the handle 141 is engaged with the handle position sensor 172, indicating that the contacts 112 and 114 are in the closed state. At Stage 1, the remote controller 7 and / or the user device 8 maytransmit a remote open command to the isolation contact and switching device controller 6 to remotely open the solid state circuit breaker 1 , thereby sequentially opening the semiconductor switching device 300 and the isolation contact and switching device 100 (see, for example FIG. 42).

[0109] At Stage 2 as depicted in FIG. 19 and 22, responsive to receiving the remote open command, the isolation contact and switching device controller 6 transmits a contact open command to the bidirectional solenoid assembly 120. Based on the contact open command, the bidirectional solenoid assembly 120 actuates the solenoid plunger 122 to move upward, causing the contacts 112 and 114 to open. As the solenoid plunger 122 moves upward, the handle close linkage 131 and the handle open linkage 134 rotate counterclockwise as shown by the arrow 154b, causing the handle 141 to rotate clockwise (as shown by the arrow 152b) into the toggle position as shown by the line 155b and to disengage from the handle position sensor 172. The toggle assembly 160 continues to toggle the handle 141 to rotate towards the handle open position.

[0110] At Stage 3 as depicted in FIGS. 20 and 23, the handle 141 has been fully rotated to the handle open position and the engagement arm 147 is disengaged from the handle position sensor 172. In the handle open position, the second close linkage portion 131b is in full contact with the remote close / open engagement portion 151 (see, for example, FIG. 15) and the handle open pin 133 is held within the open engagement recess 147b of the engagement arm 147. In some embodiments, the contacts 112 and 114 are latched in the open position by the compressed contact spring 127. Therefore, the remote opening of the contacts 112 and 114 is actuated by the bidirectional solenoid assembly 120, and not by the handle assembly 140. In addition, in response to remotely opening the contacts 112 and 114 by the bidirectional solenoid assembly 120, the handle 141 is placed in the handle open position to indicate that the contacts 112 and 114 are now in the fully open state.

[0111] FIGS. 24-26 depict an illustrative example of a positive OFF feature of the isolation contact and switching device in accordance with the present disclosure. More specifically, FIGS. 24-26 illustrate the operation of the positive OFF component 150 of the handle 141 of the isolation contact and switching device 100 in accordance various embodiments.

[0112] The positive OFF component 150 may be, for example and without limitation, a tip or a corner of the securing element 149. In some embodiments, the positive OFF component 150 maybe configured to ensure that the handle 141 remains in the handle closed position in a circumstance in which an open command is given, but the contacts 112 and 114 have failed to open due to, for example and without limitation, contact welding, solenoid failure, breaker controller failure, and / or the like.

[0113] As shown in FIG. 24, in the closed state, the solenoid plunger 122 has moved downward, causing the contacts 112 and 114 to close, and the handle position sensor 172 is fully engaged with the engagement arm 147 of the handle 141, indicating that the contacts 112 and 114 are in the closed state. However, the contacts 112 and 114 may be prevented from opening. If the contacts 112 and 114 cannot open or fail to open, the handle 141 must still correctly indicate the contact status (for instance, the closed state) regardless of the given open command. In the circumstances in which the contacts 112 and 114 have failed to open, the positive OFF component 150 of the handle 141 blocks forceable separation of the contacts 112 and 114 and rotation of the handle 141 to the handle open position, thereby protecting the solid state circuit breaker 1 and providing an accurate indication of the status of the contacts 112 and 114.

[0114] Responsive to receiving an open command (remote or manual), the bidirectional solenoid assembly 120 actuates the solenoid plunger 122 to move partially upward to open the contacts 112 and 114, causing the handle close linkage 131 and the handle open linkage 134 to rotate counterclockwise via the handle close pin 132 and the handle open pin 133. As the second close linkage portion 131b is rotated, the handle 141 starts to move to the handle open position. As the handle 141 starts to rotate counterclockwise towards the handle open position, the toggle assembly 160 toggles the handle 141 towards the handle open position as shown by the line 155c of FIG. 25.

[0115] However, the positive OFF component 150 engages with the tip 13 lb 1 of the second close linkage portion 131b and causes the handle close linkage 131 to block the handle 141 from rotating to the handle open position. The toggle assembly 160 then rotates the handle 141 back to the handle closed position as shown in FIG. 26. As such, the engagement arm 147 is engaged with the handle position sensor 172, indicating that the handle 141 is in the handle closed position, and thus the contacts 112 and 114 are in the closed state. Thus, by blocking the handle 141 from rotating towards the handle open position when the contacts 112 and 114 have failed to open, the positive OFF component 150 ensures that the handle 141 remains in the handle closed position so as to prevent a false indication of the contact state (and, thereby, visually alerting anoperator of the failed contact opening). In addition, by blocking the solenoid plunger 122 from moving further upward, the positive OFF component 150 prevents the contacts 112 and 114 from forcefully separating, which could result in damage to the solid state circuit breaker 1.

[0116] FIGS. 27-30 depict an illustrative example of a trip FREE feature of the isolation contact and switching device in accordance with the present disclosure. More specifically, FIGS. 27-30 illustrate an exemplary sequence of the trip FREE function performed by the isolation contact and switching device 100 in accordance with some embodiments. In general, the trip FREE function may be applied when the contacts 112 and 114 are tripped open upon detection of an overcurrent or overload condition during the normal closing operation.

[0117] At Stage 1 as depicted in FIG. 27, an operator may rotate the handle 141 from the handle open position to the handle closed position during a normal closing operation and the contacts 112 and 114 are in the fully closed state. However, an operator may interfere with the movement of the handle 141. For example, a hand of an operator may be in contact with the handle 141 at least for a brief period (for example and without limitation, in the range of seconds to fractions of a second). If an overcurrent or overload condition is detected during that brief period, the solid state circuit breaker 1 may open immediately, and the operator holding the handle 141 during the brief period may prevent the contacts 112 and 114 of the solid state circuit breaker 1 from being opened. Accordingly, the isolation contact switching device 100 includes the clutching device 143 to allow the contacts 112 and 114 to freely trip immediately upon detecting the overcurrent or overload condition regardless of whether an operator is holding handle 141 in place.

[0118] At Stage 2 depicted in FIG. 28, the clutch spring 144 is compressed. Then, once the operator takes their hand from the handle 141, the clutch spring 144 expands and causes the toggle assembly 160 to rotate the handle 141 into the toggle position at Stage 3 as depicted by the line 155d illustrated in FIG. 29. The toggle assembly 160 continues to toggle the handle 141 to rotate until the handle 141 is placed in the handle open position at Stage 4 as depicted in FIG. 30. As such, the clutching device 143 of the isolation contact and switching device 100 allows for immediate tripping upon detection of the overcurrent or overload condition during the normal closing operation without any interference from an operator.

[0119] FIGS. 31-40 depict various views of an illustrative example of a manual opening lever and interlock assembly of the isolation contact and switching device in accordance with the present disclosure. More specifically, FIGS. 31-40 illustrate the operations of the manualopening lever and interlock assembly 180 of the isolation contact and switching device 100 in accordance with a non-limiting, example embodiment of the disclosed concept. The manual opening lever and interlock assembly 180 may be configured to provide operator awareness regarding the manual forced opening process and user safety. FIGS. 31-33 and 40 illustrate the unactuated manual opening lever and interlock assembly 180 in the fully closed state and FIGS. 34-39 illustrate the actuated manual opening lever and interlock assembly 189 in the manually forced open state.

[0120] The manual opening lever and interlock assembly 180 includes an interlock door 181 , an interlock spring 182, and a manual opening lever 183. The interlock door 181 is removably attached to the top of the housing 2 in proximity to the handle lever 146 as shown in FIGS. 31- 33. The interlock door 181 is structured to block access to the manual opening lever and interlock assembly 180 and engage with the interlock sensor 173. For instance, the interlock door 181 is engaged with the interlock sensor 173 at all times irrespective of the open or closed state of the contacts 112 and 114. The interlock sensor 173 then transmits a signal to the isolation contact and switching device controller 6, indicating that the manual opening lever and interlock assembly 180 is disposed within the housing 2 and is not accessible by the user for manual opening of the contacts 112 and 114. Upon removing the interlock door 181, the operator may perform manual forced opening according to various embodiments of the present disclosure.

[0121] In some embodiments, the manual opening lever 183 may include a leg 184 extending vertically. The leg 184 has a lever ridge 184a extending transversely, a lever top 184b extending vertically upward, and a slot 184c extending longitudinally. The leg 184 is attached to the solenoid plunger 122 via the handle close pin 132 of the linkage assembly 130. During the normal manual opening or remote switching operations, the handle close pin 132 slides within the slot 184c so that the manual opening lever 183 does not come in contact with the solenoid plunger 122. The interlock spring 182 is attached to the lever ridge 184a at the top and the bidirectional solenoid assembly 120 at the bottom. In the closed state, the interlock spring 182 is compressed, pulling the manual opening lever 183 such that the manual opening lever 183 contacts the top surface of the bidirectional solenoid assembly 120.

[0122] For the manual opening of the contacts 112 and 114, the user may remove the interlock door 181, thereby disengaging the interlock door 181 from the interlock sensor 173 as shown in FIG. 34. The interlock sensor 173 then transmits a signal to the isolation contact and switchingdevice controller 6, indicating that the manual opening lever and interlock assembly 180 is accessible by the user for manual opening of the contacts 112 and 114. When the interlock door 181 is removed, the physical and remote access to operate the isolation contact and switching device 100 is disabled.

[0123] An operator may perform the manual forced opening of the contacts 112 and 114, and the lever top 184b becomes visible and accessible to the user as shown in FIG. 35. For the forced manual opening, the operator may move (via, for example and without limitation, a screw driver or other tool) the lever top 184b transversely in the direction as shown by the arrow 185 of FIG. 36. Upon moving the lever top 184b transversely, the lever top 184b rises through the housing 2 and presses against the bottom of the handle lever 146. The raising of the lever top 184b through the housing 2 causes the interlock spring 182 to be released, thereby interlocking the handle lever 146 in the handle open position as shown in FIGS. 37-39.

[0124] In some embodiments, the manual lever and interlock assembly 180 is configured such that the interlock door 181 must be removed manually to open the contacts 112 and 114. The interlock door 181 may be configured to allow the user to only manually open the contacts 112 and 114, but not to close the contacts 112 and 114. In various embodiments, when installed, the interlock door 181 is always engaged with the interlock sensor 173. Removing the interlock door 181 causes the interlock door 181 to become disengaged from the interlock sensor 173, prompting the isolation contact and switching device controller 6 to run the normal opening operation sequence before the operator is able to pull the manual opening lever and interlock assembly 180 to forcefully open the contacts 112 and 114. In order to perform the normal or remote operating condition of the solid state circuit breaker 1 , the manual opening lever and interlock assembly 180 needs to be placed back to the original position in the closed state.

[0125] FIGS. 41-43 illustrate the switching sequences of example circuit breakers connected between a power source and one or more loads. More specifically, FIG. 41 depicts the switching sequence of a conventional electromechanical circuit breaker having only a thermal / mechanical isolation switching device, FIG. 42 depicts the switching sequence of a solid state circuit breaker having a thermal / mechanical isolation switching device and a semiconductor switching device connected in series to the thermal / mechanical isolation switching device, and FIG. 43 depicts the switching sequence of a hybrid circuit breaker having a thermal / mechanical isolation switching device, a semiconductor switching device, and a fast mechanical switch.

[0126] Referring to FIG. 41, current 9 flows from a line conductor (not shown) to a load conductor (not shown) via the closed isolation switching device 10 during normal operation of states 3A and 3C. As shown in state 3B, during a normal opening operation (for instance, due to an overcurrent or overload condition) of the opening sequence 3, the isolation switching device 10 is turned OFF and the current flow is stopped. Upon resolution of the overcurrent or overload condition (for instance, a return to a normal condition), the isolation switching device 10 is turned back ON, allowing the current 9 to flow from the power source to the loads again as shown in state 3C.

[0127] Referring to FIG. 42, therein is depicted a switching sequence of a solid state circuit breaker having a thermal / mechanical isolation switching device 20A and a semiconductor switching device (for example and without limitation, MOSFET, IGBT, and / or the like) 20B connected in series to the thermal / mechanical isolation switching device 20A.

[0128] The semiconductor switching device 20B is structured to be turned OFF upon detection of fault event (e.g., a fault or an overload condition) or a command event (e.g., receiving an open command (remote or manual)) to open the solid state circuit breaker 1 and interrupt the current 9 from flowing from the power source to the loads. The thermal / mechanical isolation switching device 20A is similar to the thermal / mechanical isolation switching device 10 and structured to be turned OFF only after the semiconductor switching device 20B has been turned OFF and provide galvanic isolation to absorb, for example and without limitation, leakage currents during the current interruption by the power electronics (for example and without limitation, the semiconductor switching device 20B).

[0129] The opening sequence 21 of the solid state circuit breaker 20B includes: (i) normal operation during which both the thermal / mechanical isolation switching device 20A and the semiconductor switching device 20B are turned ON and the current 9 flows from the line conductor to the load conductor as shown in state 21 A; (ii) turning OFF the semiconductor device 20B and interrupting the current flowing to the loads upon detection of a fault or overload condition or receiving an open command as shown in state 2 IB; and (iii) turning OFF the thermal / mechanical isolation switching device 20A after the semiconductor switching device 20B is fully opened as shown in state 21C.

[0130] The closing sequence 22 of the solid state circuit breaker includes: (i) the open state in which both the thermal / mechanical isolation switching device 20A and the semiconductorswitching device 20B are turned OFF as shown in state 22A; (ii) turning ON the thermal / mechanical isolation switching device 20A upon the resolution of the overcurrent or overload condition as shown in state 22B ; (ii) turning ON the semiconductor switching device 20B after the thermal / mechanical isolation switching device 20A is fully closed as shown in state 22C, which allows for the resumption of the normal operation in which both the thermal / mechanical isolation switching device 20A and the semiconductor switching device 20B are turned back ON, allowing the current 9 to flow from the power source to the loads.

[0131] Referring to FIG. 43, therein is depicted the switching sequence of a hybrid circuit breaker having a thermal / mechanical isolation switching device 30A, a semiconductor switching device 30B, and a fast mechanical switch 30C. The thermal / mechanical isolation switching device 30A is similar to thermal / mechanical isolation switching device 10. The semiconductor switching device 30B is similar to the semiconductor switching device 20B. The fast mechanical switch 30C is connected in parallel to the semiconductor switching device 30B and structured to balance and lower the on-state resistance and commutate the current to the semiconductor switching device 3 OB.

[0132] The opening sequence 31 of the hybrid circuit breaker includes: (i) the normal operation in which the thermal / mechanical isolation switching device 30A and the fast mechanical switch 30C are turned ON, but the semiconductor switching device 30B is turned OFF, the current 9 flowing to the loads via the closed thermal / mechanical isolation switching device 30A, and the fast mechanical switch 30C as shown in state 31 A; (ii) turning OFF the fast mechanical switch 30C and turning ON the semiconductor switching device 30B, the current 9 flowing to the loads via the closed semiconductor switching device 30B as shown in state 3 IB; (iii) turning OFF the semiconductor switching device 30B after the fast mechanical switch is fully turned OFF, interrupting the current 9 from flowing to the loads as shown in state 31C; and (iv) turning OFF the thermal / mechanical isolation switching device 30A while the semiconductor switching device 30B and the fast mechanical switch 30C as shown in state 3 ID.

[0133] The closing sequence 32 of the hybrid circuit breaker includes: (i) the open state in which all of the thermal / mechanical isolation switching device 30A, the semiconductor switching device 30B, and the fast mechanical switch 30C are turned OFF as shown in state 32A; (ii) turning ON the thermal / mechanical isolation switching device 30A while the semiconductor switching device 30B and the fast mechanical switch 30C remain turned OFF as shown in state32B; (iii) turning ON the semiconductor switch 30B after the thermal / mechanical isolation switching device 30A is fully closed, the current 9 flowing to the loads via the closed thermal / mechanical isolation switching device 30A and the semiconductor switching device 30B as shown in state 32C; (iv) turning ON the fast mechanical switch 30C after the semiconductor switching device 30B is fully closed, the current 9 flowing to the loads via the closed thermal / mechanical isolation switching device 30A and fast mechanical switch 30C as shown in state 32D; and (v) turning OFF the semiconductor switching device 30B for the normal operation, the current 9 flowing to the loads via the closed thermal / mechanical isolation switching device 30A and fast mechanical switch 30C as shown in state 32D.

[0134] Due to the standards requiring the inclusion of a handle and / or other manual operating elements for circuit protection devices, such as circuit breakers, some embodiments provide for devices in which the isolation contact and switching device is remote-controllable, is able to electrically operate with the toggle handle in coordination with breaker controls and power electronics, and prohibits manual switching operations (particularly, the manual closing) during one or more states. An isolation contact and switching device 100 configured according to various embodiments solves multiple technological challenges through, among other things, the configuration and use of the bidirectional solenoid assembly 120, innovative mechanical linkages 130 and 180, and handle 141 that may fit within the form factor of existing or future-developed circuit protection equipment.

[0135] Accordingly, the isolation contact and switching device 100 not only satisfies the functional and / or standards requirements of circuit protection devices, but also provides numerous technological advantages over conventional systems and techniques. Non-limiting technological advantages may include carrying 30 Amp continuous current with 6 Newton contact force; having a 4 mm contact gap with less than a 1 mm over travel, totaling approximately a 5 mm gap range; performing at least 3 times the interruptions over the breaker life as compared to existing circuit breakers; providing a two-position-toggle handle for manual open and close of the contacts 112 and 114; being remotely controllable to open and close the contacts 112 and 114; providing a trip indicator 192 (for example and without limitation, an LED); having a stand-by mode push button and / or LED indicator; providing the contact position feedback for the remote controller 7; allowing the manually forced opening of the contacts 112 and 114 and disabling of the remote control as needed with the manual opening lever andinterlock assembly 180; providing the trip FREE functionality; providing the positive OFF functionality in order to address contact weld scenarios under the standards; and supporting the IEC solid state miniature circuit breaker isolation switch and switching mechanism design requirements.

[0136] While specific embodiments have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of disclosed embodiments, which are to be given the full breadth of the claims appended and any and all equivalents thereof.

Claims

CLAIMSWhat is claimed is:

1. A circuit protection device, comprising: an isolation contact and switching device comprising: separable contacts configured to be arranged in a contact state including one of an open state and a closed state, and a bidirectional solenoid assembly configured to be actuated, in response to a remote command to change the contact state of the separable contacts, to move at least one of the separable contacts to cause the separable contacts to be in the contact state associated with the remote command; and a handle configured to be arranged in a handle state including one of an open handle state and a closed handle state, the open handle state corresponding with the open state and the closed handle state corresponding with the closed state, wherein actuation of the bidirectional solenoid assembly in response to the remote command causes a change in the handle state of the handle to correspond with the contact state of the separable contacts.

2. The circuit protection device of claim 1 , further comprising an isolation contact and switching device controller connected to the isolation contact and switching device, the isolation contact and switching device controller configured to receive the remote command from a remote computing device.

3. The circuit protection device of one of claim 1 or 2, wherein the isolation contact and switching device controller is configured to transmit a control signal to the bidirectional solenoid assembly to change the contact state of the separable contacts based on the remote command.

4. The circuit protection device of any of claims 1-3, wherein the remote command is a wireless command transmitted via a remote computing device.

5. The circuit protection device of any of claims 1-4, wherein the bidirectional solenoid assembly comprises a solenoid plunger configured to be actuated to engage with a movable contact of the separable contacts to change the contact state of the separable contacts.

6. The circuit protection device of claim 5, wherein a portion of the handle is fixedly attached to the solenoid plunger such that actuation of the solenoid plunger to change the contact state of the separable contacts causes the handle to rotate to change the handle state.

7. The circuit protection device of any of claims 1-6, further comprising a sensing device comprising a contact position feedback sensor configured to indicate the contact state of the separable contacts.

8. The circuit protection device of any of claims 1-7, wherein the contact position feedback sensor is configured to transmit a signal indicating the contact state based on an engagement state of the contact position feedback sensor with a solenoid plunger of the bidirectional solenoid assembly, the solenoid plunger configured to be actuated to change the contact state of the separable contacts.

9. The circuit protection device of any of claims 1-8, further comprising a handle position sensor configured to engage with a portion of the handle to detect the handle state.

10. The circuit protection device of claim 9, wherein the handle position sensor is configured to transmit a handle state signal indicating the handle state.

11. The circuit protection device of claim 10, wherein the contact state of the separable contacts is changed based on the handle state signal.

12. A circuit interrupter, comprising: separable contacts; a handle; anda solenoid plunger configured to be actuated in response to a remote command received at the circuit interrupter from a remote computing device, actuation of the bidirectional solenoid assembly causing simultaneous movement of the handle and at least one of the separable contacts to be in a corresponding state, the corresponding state comprising one of an open circuit interrupter state or a closed circuit interrupter state.

13. The circuit interrupter of claim 12, further comprising a linkage assembly connected to the handle and the solenoid plunger and configured to cause actuation of the solenoid plunger to move the handle to the corresponding state.

14. The circuit interrupter of one of claims 12 or 13, further comprising a contact spring connected to the solenoid plunger and a moveable contact of the separable contacts, the contact spring configured to cause actuation of the solenoid plunger to move the moveable contact to place the separable contacts in the corresponding state.

15. The circuit interrupter of any of claims 12-14, further comprising a contact position feedback sensor configured to transmit a signal indicating a contact state of the separable contacts based on an engagement state of the contact position feedback sensor with the solenoid plunger of the bidirectional solenoid assembly.

16. The circuit interrupter of any of claims 12-15, further comprising a handle position sensor configured to: engage with a portion of the handle to detect a handle state of the handle, and transmit a handle state signal indicating the handle state, wherein a contact state of the separable contacts is changed based on the handle state signal.

17. A circuit interrupter structured to be connected between a power source and a load, comprising: a housing; an isolation contact and switching device including:a line terminal structured to connect to the load, separable contacts including a movable contact and a stationary contact connected to the line terminal, the separable contacts being structured to be in a contact state including one of an open state to provide galvanic isolation and a closed state to allow current flow, and a bidirectional solenoid assembly including a solenoid plunger and a contact spring connected to the movable contact, the solenoid plunger being structured to be actuated to position the separable contacts in one of the open state or the closed state; a handle assembly including a handle fixedly attached to the solenoid plunger and configured to move to change a handle position of the handle, the handle position comprising one of a handle open position and a handle closed position; and an isolation contact and switching device controller connected to the isolation contact and switching device, the isolation contact and switching device controller structured to receive a remote command and transmit a control signal to the bidirectional solenoid assembly to cause the separable contacts to change the contact state based on the remote command.

18. The circuit interrupter of claim 17, further comprising a linkage assembly including a handle close linkage having a handle close slot, a handle close pin, a handle open pin and a handle open linkage having a handle open slot, the handle close pin and the handle open pin fixedly attached to the solenoid plunger and structured to slide within a respective slot to allow the handle to move between the handle open position and the handle closed position.

19. The circuit interrupter of one of claims 17 or 18, wherein the handle further includes a positive OFF component structured to engage with a handle close linkage of the handle to cause the handle close linkage to block the handle from being moved to the handle open position when the separable contacts have failed to open in response to an open command.

20. The circuit interrupter of any of claims 17-19, wherein the isolation contact and switching device includes a trip FREE mechanism including a clutching device, the clutching device comprising a clutch spring structured to be compressed and expand immediately upon tripping the separable contacts to cause the handle to move to the handle open position.

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