Add-on Trip Module for Multi-pole Circuit Breakers

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Solution Overview

Problem

Multi-pole circuit breakers using electronic actuators are not suitable for DC power systems due to the high cost of DC electronic trip units, which require complex iron cores or external power supplies, as traditional current measurement transformers cannot generate power in the absence of alternating current.

Innovation Solution

An add-on module for multi-pole circuit breakers that replaces electronic trip actuators with electromechanical actuators, utilizing extended terminal plates, electromechanical transducers, and a mechanical actuator to operate the trip mechanism in response to electrical current, allowing for cost-effective conversion to AC and DC power system compatibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electronic trip actuators are used in multi-pole circuit breakers, then the breaker can detect and respond to fault conditions, but the cost increases significantly for DC power systems

Engineering Contradiction:

Improvefault detection capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces electronic trip actuators with electromechanical trip actuators that use electromagnetic fields generated by DC current flowing through terminal plates to actuate trip mechanisms. This substitution eliminates the need for expensive DC electronic trip units while maintaining fault detection and response capabilities through the electromechanical transducer system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If DC electronic trip units with complex iron cores or Hall effect sensors are used, then continuous DC current monitoring is achieved, but device complexity and cost increase

Engineering Contradiction:

ImproveDC current monitoring capabilityVSAvoidtrip unit structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex electronic monitoring devices (iron cores, Hall effect sensors) with a simplified electromechanical system where DC current flowing through terminal plates directly generates electromagnetic fields that actuate transducers. This substitution maintains measurement precision for trip-level detection while dramatically reducing device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The terminal plates serve dual functions: conducting electrical current and generating electromagnetic fields for trip actuation. This self-service approach eliminates separate sensing components, reducing overall system complexity while maintaining monitoring capability.

Inventive Principle:

Principle #25Self-service

3Use of energy by moving object

If traditional current measurement transformers are used in DC systems, then power generation for trip actuation is achieved, but the system requires one-time operation and complex iron cores

Engineering Contradiction:

Improvepower generation for trip actuationVSAvoidiron core structure

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The patent replaces traditional current measurement transformers with terminal plates that generate electromagnetic fields directly from DC current. This substitution enables continuous operation (not just one-time trips) and eliminates complex iron core structures while maintaining the ability to generate power for trip actuation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables the use of electromechanical sensing and trip-actuating devices in multi-pole circuit breakers, reducing manufacturing costs and maintaining the economic benefits of mass-produced mechanical structures, while providing reliable operation across AC and DC power systems.

Implementation Method 1

an electromechanical transducer coupled to one of the extended terminal plates for producing a mechanical movement in response to a predetermined magnitude of electrical current in the extended terminal plate

Methodology Applied

Scientific EffectElectromagnetic force: Lorentz Force

Data Source

PatentUS8093964B2Add-on trip module for multi-pole circuit breaker

Publication Date: 2012.01.10 SCHNEIDER ELECTRIC USA INC

AI summary

An add-on module adapted to be attached to the basic mechanical structure of a multi-pole circuit breaker includes multiple extended terminal plates each of which is adapted to replace one of the input and output terminals for one of the poles, multiple electromechanical transducers each of which is coupled to one of the extended terminal plates for producing a mechanical movement in response to a predetermined magnitude of electrical current in the extended terminal plate to which that transducer is coupled, a mechanical actuator coupled to the electromechanical transducers and to the breaker contacts for operating a trip mechanism in response to a predetermined mechanical movement of any of the transducers, and a mechanical reset arm coupling the reset mechanism to the mechanical actuator for resetting the actuator in response to the resetting of the host circuit breaker.