Miniature Circuit Breaker Diagnostic LED Interface
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Solution Overview
Problem
Existing circuit breakers do not effectively indicate the type of fault condition that caused a trip, relying on time delays that can be confusing for users and requiring power cycling to activate diagnostic features, which disrupts downstream loads.
Innovation Solution
A method that detects fault conditions, stores a trip code, and displays it using an LED interface without tripping the circuit breaker, allowing users to identify fault types without power disruption through a momentary press of a test button.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If time delay trip sequences are used to indicate fault types, then diagnostic information can be conveyed without additional hardware, but users have difficulty distinguishing between different indication time periods and the process is confusing
Solution Approach 1:
The patent replaces the mechanical/time-based indication system with an optical display system using LEDs. Instead of relying on users to interpret time delay periods during handle movement, the system uses LED flash patterns to visually encode fault type information, making it immediately distinguishable and eliminating confusion about timing interpretation.
Solution Approach 2:
The patent uses different colored LEDs (red, yellow, green) to represent different fault types. This color-coding system provides intuitive visual differentiation between fault conditions, replacing the ambiguous time-based indication with easily distinguishable color signals that users can immediately interpret.
2Device complexity
If power cycling is required to activate diagnostic features, then the diagnostic function can be implemented with minimal additional complexity, but downstream loads experience unnecessary start/stop stress
Solution Approach 1:
The patent implements a test button that can be pressed at any time to immediately activate the diagnostic display function. The system is designed to read and display the last fault code on demand without requiring power cycling, allowing users to diagnose faults while maintaining continuous power to downstream loads.
Solution Approach 2:
The circuit breaker's memory retains fault information automatically without requiring external activation through power cycling. The diagnostic system serves itself by continuously monitoring and storing fault codes, ready for immediate display when the test button is pressed, eliminating the need for disruptive power cycles to access diagnostic data.
3Adaptability or versatility
If multiple circuit breakers are in a load center, then power distribution is improved, but a second person must switch off and switch on several circuit breakers to activate the diagnostic feature for a previously tripped breaker
Solution Approach 1:
Each circuit breaker independently maintains its own fault memory and diagnostic capability. When a breaker trips, it automatically stores the fault information in its non-volatile memory. Any user can immediately press the test button on any breaker to view its stored fault code without needing to manipulate other breakers or cycle power, making the diagnostic process independent and immediate for each device in the load center.
4Ease of operation
If the handle position is used to indicate trip status, then the circuit breaker state is clearly visible, but the type of fault that caused the trip cannot be determined
Solution Approach 1:
The patent separates the indication of trip status (handle position) from the indication of fault type (LED flash patterns). The handle clearly shows whether the breaker is tripped, while the LED display provides segmented, coded information about the specific fault type. This segmentation allows both pieces of information to be conveyed independently and clearly without confusion.
Solution Approach 2:
The LED display acts as an intermediary that translates internal fault code information into visible, interpretable signals. When the test button is pressed, the intermediary LED system decodes and displays the fault type information stored in memory, bridging the gap between the tripped handle state and the specific fault condition that caused it.
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
Enables users to easily and accurately determine the type of fault without cycling power, improving user experience and reducing unnecessary stress on downstream loads by displaying stored trip codes through a simple and intuitive LED interface.
Implementation Method 1
activating a light-emitting diode (LED) interface in the circuit breaker in a manner that indicates the trip code
Data Source
AI summary
A method for identifying a type of fault condition with a circuit breaker includes detecting by the circuit breaker a fault condition of a plurality of fault conditions, storing in a memory device a trip code representing a type of the detected fault condition, interrupting current flow through the branch circuit in response to detecting the fault condition, and receiving a reset of the circuit breaker. The trip code may then be displayed in response to a momentary press of a test button that is a short duration press, and activating an LED interface in the circuit breaker to indicate the trip code representing the type of the detected fault condition.