Circuit Breaker Power Control Circuit Automatic Battery Switching

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Solution Overview

Problem

Conventional circuit breaker trip units require a separate battery button to power the keypad when external power is not available, leading to unnecessary power consumption and reduced battery life.

Innovation Solution

A power control circuit that automatically connects the battery power source to the power conditioner upon activation of any keypad input, switching to external power if available, and powering only essential components in the absence of external power to minimize consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a separate battery button is added to power the keypad when external power is not available, then the keypad can be powered during outages, but power consumption increases and battery life decreases

Engineering Contradiction:

Improvekeypad operability during power outageVSAvoidpower consumption

Core Design Contradiction:

Ease of operationVSUse of energy by moving object

Solution Approach 1:

The system dynamically switches between battery power and external power sources based on availability. The power control circuit automatically detects when external power is present and transitions to that source, using the battery only when necessary, thereby optimizing power consumption while maintaining keypad operability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The power management system automatically monitors power source availability and switches between sources without user intervention. The microcontroller and power control circuit continuously monitor the external power connection status and autonomously manage the battery connection, eliminating the need for manual battery button operation while preventing unnecessary power consumption.

Inventive Principle:

Principle #25Self-service

2Reliability

If the battery is continuously connected to power the trip unit, then power is always available, but unnecessary power consumption occurs when external power is available

Engineering Contradiction:

Improvepower availabilityVSAvoidunnecessary battery power consumption

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The system employs feedback through continuous monitoring of external power availability by the microcontroller. This feedback mechanism enables the power control circuit to automatically disconnect the battery when external power is present, preventing unnecessary energy consumption while ensuring power availability is maintained through the external source.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The power control circuit acts as an intermediary between the battery and the trip unit, controlled by the microcontroller. This intermediary component automatically manages the connection state based on external power availability, ensuring the battery is only connected when truly needed, thus eliminating wasteful energy consumption while maintaining reliable power supply.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS8018092B2System and method for managing power supply to a circuit breaker control unit

Publication Date: 2011.09.13 ABB SPA

AI summary

A system for controlling power in a circuit breaker trip unit is disclosed. The system includes: a user interface operably coupled to the trip unit and having a plurality of input keys; a power conditioner operably coupled to the user interface and operably coupled to a battery power source and an external power source; and a power control circuit. The power control circuit is configured to automatically electrically connect the battery power source to the power conditioner in response to activation of any of the plurality of input keys, and in the absence of an electrical connection between the external power source and the power conditioner.