Circuit Breaker Handle Opto-Mechanical Status Sensing
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Solution Overview
Problem
Existing miniature circuit breakers (MCBs) lack a reliable status indicator, requiring users to visually inspect the device to determine its operational status, which can be cumbersome and prone to errors due to size constraints and lack of integrated monitoring components.
Innovation Solution
A circuit breaker with an optical-mechanical sensor configuration integrated into the handle, utilizing a light source, optical sensor, and movable light control plate to determine the operational status based on the amount of light allowed to pass between the light source and sensor, corresponding to different handle positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual inspection is used to determine circuit breaker status, then no additional components are needed, but user safety and efficiency are reduced and the process is cumbersome
Solution Approach 1:
The patent replaces the mechanical visual inspection method with an optical sensing system. A light source emits light that passes through a light control plate (which moves with the handle) to an optical sensor. The sensor detects light intensity variations and converts them to electrical signals, automatically indicating circuit breaker status without requiring user visual inspection.
Solution Approach 2:
The circuit breaker performs self-monitoring of its own status through the integrated optical system. The handle's position automatically controls the light control plate, which in turn automatically modulates the light signal to the sensor, creating a self-indicating system that continuously reports its state without external intervention.
2Reliability
If additional status monitoring components are incorporated into the circuit breaker, then status indication is improved, but device size increases
Solution Approach 1:
The patent merges the status indication function with the existing handle mechanism. The light control plate is integrated into the handle assembly, so that the handle's mechanical movement directly controls the optical modulation. This combines the actuation function and the indication function into a single integrated system, avoiding additional space-consuming components.
Solution Approach 2:
The light control plate serves multiple functions: it is part of the handle assembly for circuit operation, acts as a mechanical linkage for the trip mechanism, and simultaneously functions as an optical modulator for status indication. This multi-functionality eliminates the need for separate dedicated status indication components.
3Ease of manufacture
If the circuit breaker design is simplified without status monitoring, then manufacturing is easier, but status determination becomes less reliable
Solution Approach 1:
The patent introduces a light control plate as an intermediary element that translates mechanical handle position into optical signal modulation. This intermediary converts the handle's positional information into light intensity variations that the optical sensor can detect, providing precise status detection while maintaining compatibility with the existing simple mechanical handle structure.
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
The solution provides a reliable and non-invasive method to determine the operational status of the circuit breaker, enhancing user safety and efficiency by eliminating the need for visual inspection and accommodating size constraints.
Implementation Method 1
a light source for emitting light
Implementation Method 2
an optical sensor for detecting light emitted by the light source
Implementation Method 3
Each of the different light passage regions allows a different amount of light emitted from the light source to pass to the optical sensor
Data Source
AI summary
A circuit breaker can include a light source, an optical sensor, a handle and a processor. The handle can be movable between different handle positions which correspond to different circuit breaker statuses. The handle can include a handle body and a light control plate which moves along with the handle body. The light control plate can have different light passage regions each of which is configured to be positioned between the light source and the optical sensor when the handle is moved to a corresponding one of the different handle positions. Each of the different light passage regions allows a different amount of light emitted from the light source to pass to the sensor when positioned between the light source and the sensor. The processor is configured to determine a status of the circuit breaker based on the sensed amount of light which relates to a position of the handle.