Solenoid Actuated Circuit Breaker Locking Clip

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Solution Overview

Problem

The lifespan of solenoids used in remotely resettable circuit breakers is limited, leading to premature replacement of the entire unit, increasing costs and posing a safety hazard due to potential arc creation during manual operation in hazardous environments.

Innovation Solution

A modular, self-contained actuator module with flexible legs and a locking clip mechanism that securely attaches to the circuit breaker housing, allowing for easy installation and removal, and includes a solenoid for remote operation, enhancing durability and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a solenoid is used to reset the circuit breaker remotely, then the circuit breaker can be operated remotely without arc hazards, but the solenoid has limited lifespan and wears out before other components

Engineering Contradiction:

Improveremote operation capabilityVSAvoidsolenoid lifespan

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The circuit breaker is divided into modular components: a permanent housing containing the circuit breaker mechanism and a replaceable actuator module containing the solenoid. This segmentation allows the solenoid to be replaced independently when worn, extending the overall system lifespan while maintaining remote operation capability.

Inventive Principle:

Principle #1Segmentation

2Duration of action of stationary object

If the solenoid is made more robust to increase lifespan, then the solenoid durability improves, but the costs, power consumption, and size increase beyond acceptable limits

Engineering Contradiction:

Improvesolenoid lifespanVSAvoidsolenoid size and power consumption

Core Design Contradiction:

Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

Instead of making the solenoid more robust and expensive, the patent uses a less robust but cheaper solenoid that can be easily replaced. The actuator module is designed as a disposable/replaceable unit, allowing economical replacement of the wear-prone solenoid without investing in an overly robust design.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If the entire circuit breaker unit is replaced when the solenoid fails, then a functional unit is restored, but costs increase and premature replacement occurs

Engineering Contradiction:

Improvecircuit breaker functionalityVSAvoidreplacement cost efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The circuit breaker is segmented into a permanent housing and a replaceable actuator module. When the solenoid fails, only the actuator module needs replacement, not the entire circuit breaker unit. This significantly reduces replacement costs and avoids premature disposal of functional components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The actuator module is designed to be easily discarded and replaced when the solenoid wears out. The permanent housing with its valuable circuit breaker mechanism is recovered and reused, maximizing component utilization and reducing waste.

Inventive Principle:

Principle #34Discarding and recovering

4Ease of operation

If manual operation of the circuit breaker is performed, then the breaker can be reset, but arc creation poses safety hazards in hazardous environments

Engineering Contradiction:

Improvebreaker reset capabilityVSAvoidarc hazard

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The manual mechanical operation of the circuit breaker is replaced with a remote solenoid-actuated system. The solenoid electrically actuates the trip mechanism remotely, eliminating the need for personnel to physically interact with the breaker in hazardous environments and thus eliminating arc exposure risks.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 modular design extends the lifespan of the circuit breaker unit, reduces replacement costs, and enhances safety by allowing remote operation, minimizing the risk of arcs and facilitating easier maintenance.

Implementation Method 1

an actuator module adapted to move the switch handle from the off position to the on position. The actuator module is a self-contained modular assembly... the actuator module including at least one flexible portion having a protrusion formed thereon

Methodology Applied

Scientific EffectSolenoid: Solenoid

Data Source

PatentEP3240007B1Solenoid actuated circuit breaker with locking clip

Publication Date: 2019.01.30 CARLING TECHNOLOGIES INC

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AI summary

A circuit breaker includes a housing having a channel formed therein, the channel being defined by at least one side wall having a detent formed therein, a circuit breaker mechanism, a switch handle configured to toggle the circuit breaker, and an actuator module adapted to move the switch handle from the off position to the on position. The module includes a flexible portion having a protrusion formed thereon, the protrusion being sized, shaped and located to engage the detent when the module is mounted within the channel. The module also includes a locking clip moveable from an unlocked position, in which flexing of the at least one flexible portion is permitted, and a locked position, in which flexing of the at least one flexible portion is limited or prevented, such that when the module is mounted within the channel, removal of the module is inhibited.