Circuit Breaker Stop Mechanism for Pre-Closure Testing
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Solution Overview
Problem
Electronic circuit breakers, such as AFCIs and GFCIs, lose their protective ability when electronic components fail, and there is a need to safely verify the functionality of these components before reactivating the breaker.
Innovation Solution
A circuit breaker mechanism that includes main contacts, a handle for adjusting positions, secondary contacts for powering a test circuit, and a stop mechanism that maintains separation until a successful test is performed, allowing for the safe resumption of power to electronic components and subsequent resetting of the main contacts if the test is passed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the main contacts are closed to restore power, then the circuit breaker becomes operational, but electronic components may fail causing unsafe operation
Solution Approach 1:
The patent implements a test circuit that activates before the main contacts close, allowing electronic components to be verified in advance. The secondary contacts provide power to the test circuit while the moving arm is held by the stop mechanism, enabling pre-closure testing of electronic components including AFCI and GFCI functionality before full power restoration
Solution Approach 2:
The patent introduces a stop mechanism as an intermediary element that physically blocks the moving arm from closing the main contacts until the test circuit confirms safety. This mechanical intermediary prevents direct closure even when the handle is in the on position, ensuring electronic components are verified through the test circuit first
2Reliability
If the stop mechanism is added to prevent premature closing, then safety is improved, but device complexity increases
Solution Approach 1:
The stop mechanism serves multiple functions: it physically blocks the moving arm from closing main contacts, provides a mounting point for secondary contacts, and acts as a visual indicator that the breaker cannot be closed until testing is complete. The secondary contacts also serve dual purposes by providing power to the test circuit and enabling the unlocking of the stop mechanism when testing succeeds
3Ease of operation
If secondary contacts are used to power the test circuit, then component verification is enabled, but the structure becomes more complex
Solution Approach 1:
The patent combines the test circuit power function with the existing secondary contacts structure. The secondary contacts are integrated into the handle assembly and work together with the stop mechanism to provide both the electrical connection for testing and the mechanical blocking function, rather than adding separate independent systems
Data Source
AI summary
A circuit breaker and method include main contacts configured to connect in an on position and be separated in an off position. A handle is coupled to one of the main contacts to adjust the contacts between the on position, the off position, a trip position and an over on position. Secondary contacts are configured to provide power when connected using the handle in the over on position, even when the main contacts are separated. A stop mechanism configured to maintain separation between the main contacts to enable testing using the secondary contacts to power a test circuit such that if a test passes, the stop mechanism is released to permit resetting of the main contacts.