Miniature Circuit Breaker Trip Data Capture for Remote Diagnostics
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Solution Overview
Problem
Diagnosing field issues with miniature circuit breakers, such as arc fault circuit interrupters, is challenging due to reliance on poor quality user reports and the lack of comprehensive storage mechanisms for trip information, leading to costly and time-consuming on-site visits by design engineers.
Innovation Solution
A remote diagnostic system for miniature circuit breakers that includes wireless communication capabilities and non-volatile memory, such as FRAM, allowing continuous data storage and transmission of detailed trip information to a remote location for analysis, eliminating the need for on-site visits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single byte of trip information is stored in EEPROM per trip event, then the circuit breaker can reliably store trip cause data, but comprehensive diagnostic information is lost
Solution Approach 1:
The trip information storage is segmented into multiple components: a single byte in EEPROM for reliable trip cause identification, and additional waveform data stored in separate memory structures (circ buffers) for comprehensive diagnostic analysis. This segmentation allows the system to maintain reliability for critical trip cause data while capturing extensive diagnostic information through multiple storage segments.
Solution Approach 2:
The patent implements a nested storage structure where the single byte trip cause code is nested within a broader context of waveform data. The waveform data is organized in circular buffers that contain detailed pre-trip and post-trip information, with the EEPROM byte providing a reliable summary identifier that nests within this larger data structure. This nested approach allows reliable quick identification while preserving comprehensive diagnostic details.
2Loss of information
If the microprocessor delays circuit interruption to store information, then comprehensive trip data can be captured, but circuit protection response time is increased
Solution Approach 1:
The system performs preliminary data capture by continuously sampling and storing waveform data in circular buffers before the trip event occurs. This preliminary action ensures that comprehensive diagnostic information is already captured in memory when the trip is triggered, eliminating the need to delay circuit interruption for data collection. The microprocessor can immediately interrupt the circuit while the diagnostic data is already prepared and stored.
Solution Approach 2:
The patent implements continuous waveform sampling and storage in circular buffers that operate continuously during circuit operation. This continuous data collection ensures that trip information is captured without interruption to the normal circuit operation or protection response. The useful action of data collection continues uninterrupted alongside circuit protection functions.
3Loss of information
If extensive trip information is stored in memory, then diagnostic quality is improved, but the time required to store information increases
Solution Approach 1:
The patent replaces traditional mechanical/electrical data storage methods with efficient digital memory systems. Circular buffers in RAM provide rapid write capability for capturing extensive waveform data, while EEPROM provides reliable long-term storage for critical trip cause codes. This substitution of storage mechanisms enables high-speed capture of comprehensive diagnostic information without the time constraints of older storage technologies.
Solution Approach 2:
The system changes the storage parameters by using different memory types with different characteristics for different data types. RAM provides fast write access for continuous waveform data, while EEPROM provides reliable but slower storage for trip cause codes. This parameter change in storage medium selection allows extensive information to be stored with minimal time penalty by optimizing the storage approach for each data type.
4Measurement precision
If a design engineer visits the field location with diagnostic equipment, then firsthand information can be collected, but the process becomes time consuming and costly
Solution Approach 1:
The circuit breaker performs self-diagnostic data collection and storage automatically at the field location without requiring external diagnostic equipment or engineer presence. The device captures waveform data, stores trip cause codes, and maintains operational logs autonomously. This self-service capability provides accurate diagnostic information that would otherwise require on-site engineer intervention with specialized equipment.
Solution Approach 2:
The patent introduces an intermediary data storage system that bridges the gap between field operations and remote analysis. The circuit breaker stores comprehensive diagnostic data locally, which can then be remotely accessed and analyzed by engineers without requiring physical presence at the field location. This intermediary storage mechanism enables accurate remote diagnostics, eliminating the need for time-consuming on-site visits.
Data Source
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AI summary
A system for diagnosing circuit protection device field issues includes a remote computer system (58) and a diagnostic circuit protection device (2) installed at a customer location, wherein the circuit protection device includes a processor (10) configured to execute a number of routines (12), a plurality of sensors structured to sense power circuit information, a memory accessible by the processor, and a communications module (44) coupled to the non-volatile memory. The routines are structured to input sensed power circuit information and determine trip information for one or more trip cycles and cause the stored power circuit information and trip information to be transmitted to the remote computer system (58) by the communications module over a network (56) for storage and subsequent access for diagnostic purposes.