Circuit Breaker Lockout Mechanism for Self-Test
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Circuit breakers with electronic components may fail to protect electrical circuits if the components malfunction, necessitating a mechanism to ensure the integrity of the electronic circuit before allowing main contacts to close.
Innovation Solution
An electronic circuit breaker with a lockout mechanism featuring a moveable contact arm, a lockout latch with pivot joints, a moveable stop, and an unlock actuator that blocks and releases the contact arm based on a self-test result, ensuring the circuit is functioning correctly before allowing the main contacts to close.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lockout mechanism is added to ensure electronic circuit integrity before closing main contacts, then the reliability of circuit protection is improved, but the device complexity increases
Solution Approach 1:
The lockout mechanism is integrated with the handle assembly, where the lockout latch works in conjunction with the handle's movement between ON and OFF configurations. The secondary electrical contacts are merged into the same assembly, allowing multiple functions (handling, locking, and electrical connection) to be combined in a single integrated structure, thereby improving reliability without proportionally increasing complexity.
Solution Approach 2:
The lockout mechanism performs a preliminary check by requiring the handle to be in the OFF configuration before allowing the main contacts to close. The electronic circuit conducts a self-test through the secondary contacts before enabling the locking mechanism to release, ensuring circuit integrity is verified in advance before full operation begins.
2Adaptability or versatility
If secondary contacts are reopened during configuration changes, then the adaptability of the circuit breaker is improved, but the loss of time and operational efficiency deteriorates
Solution Approach 1:
The secondary electrical contacts remain continuously closed throughout the handle's movement between ON and OFF configurations, eliminating the need to reopen and reclose them during operation. This continuous connection maintains electrical continuity and allows the electronic circuit to remain powered and functional throughout configuration changes, saving time and improving operational efficiency.
3Manufacturing precision
If the lockout mechanism is designed with multiple pivot joints and offset engagement portions, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The lockout latch features an engagement portion that is offset from the pivot axis, creating an asymmetric geometry that provides precise engagement with the handle assembly. This asymmetric design allows for controlled movement and reliable locking without requiring multiple complex pivot joints, achieving manufacturing precision through clever geometric design rather than increased mechanical complexity.
Data Source
AI summary
Embodiments provide an electronic circuit breaker. The electronic circuit breaker has a moveable contact arm having a moveable main electrical contact, and a lockout mechanism operable to contact the moveable contact arm and block motion of thereof, the lockout mechanism having a lockout latch with one or more pivot joints, a moveable stop on, and an offset engagement portion, the moveable stop adapted to contact the moveable contact arm, and an unlock actuator providing an unlock force at the engagement portion causing lockout latch pivoting and release of the moveable contact arm. Also disclosed are secondary electrical contacts configured to engage each other in the ON configuration, with a leaf spring operably supporting a moveable one of the secondary contacts, the leaf spring configured to be flexed to close the secondary contacts. A method of operating the electronic circuit breaker is provided, as are other aspects.