Motorized Circuit Breaker Cooling Interval Control
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Solution Overview
Problem
Existing remotely controllable circuit breakers require external power supplies and additional space due to the need for continuous high electrical currents, which is not feasible within the limited housing of standard circuit breakers.
Innovation Solution
A miniaturized power-supply circuit and wireless transceiver are integrated within the circuit breaker housing, allowing for remote control and eliminating the need for an external DC power supply by using an actuator power supply circuit coupled to the AC power source and a processing circuit that enforces a cooling interval to manage power dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a power supply circuit is integrated within the circuit breaker housing, then the device complexity is reduced and remote control capability is achieved, but the housing space becomes insufficient due to the need to accommodate high current components
Solution Approach 1:
The patent applies periodic action by implementing a cooling interval between successive actuator activations. The processing circuit enforces a predetermined cooling interval to allow the current limiting resistor to dissipate heat between high-current pulses, enabling the use of smaller, lower-rated components that can be accommodated within the standardized housing volume.
Solution Approach 2:
The patent changes the operational parameters of the current limiting resistor by limiting the duty cycle of high-current operations. By controlling the frequency and duration of actuator activations through the cooling interval, the average power dissipation is reduced below the continuous power rating, allowing smaller component specifications that fit within the housing constraints.
2Ease of operation
If the circuit breaker is made remotely controllable with integrated power supply, then the ease of operation is improved, but the manufacturing complexity increases due to integration requirements
Solution Approach 1:
The patent merges the processing circuit and power supply circuit into a single integrated assembly that fits within the circuit breaker housing. The controller is positioned adjacent to the actuator with the current limiting resistor, creating a compact integrated unit that combines control functionality with power delivery, simplifying the overall system architecture despite increased manufacturing integration requirements.
3Power
If high current is continuously supplied to the actuator, then the power is improved, but the component temperature increases beyond safe operating limits
Solution Approach 1:
The patent implements periodic action by enforcing a cooling interval between successive actuator activations. This periodic operation allows the current limiting resistor and other high-current components to cool down between power pulses, maintaining average temperature within safe operating limits while still delivering high peak power when needed for actuator operation.
Solution Approach 2:
The patent applies preliminary action by pre-determining the cooling interval duration based on the thermal characteristics of the current limiting resistor. The processing circuit is configured to enforce this predetermined interval, proactively preventing temperature buildup before it reaches dangerous levels, rather than reacting to temperature measurements.
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
This solution enables a self-contained, remotely controllable circuit breaker that fits within standard housing dimensions, suitable for home automation and power efficiency applications, while ensuring component safety and efficiency.
Implementation Method 1
a current limiting resistor that has a continuous power rating less than the average power dissipated by the current limiting resistor during any activation of the actuator
Implementation Method 2
an electrically controlled actuator, such as a DC motor, operable to move a breaker contact between an open position and a closed position
Data Source
AI summary
A circuit breaker module includes an electrically controlled actuator, such as a DC motor, operable to move a breaker contact between open and closed positions. An actuator power supply circuit coupled to an AC power source is configured to selectively energize the actuator, responsive to an actuation input. A processing circuit is configured to control the actuator power supply circuit to activate the actuator in response to breaker command signals, using the actuation input. The processing circuit is further configured to delay activations of the actuator as needed to enforce a predetermined cooling interval between successive actuations.