Circuit Breaker Sensor Calibration via Segmentation

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Solution Overview

Problem

Existing circuit breakers require the simultaneous assembly and calibration of sensors and electronics on the same production line, complicating the manufacturing process and making it difficult to calibrate the sensors with the actuator effectively.

Innovation Solution

A method for manufacturing a circuit breaker that includes a measurement sensor comprising a toroid, current transformer, and data management unit with non-volatile memory, allowing for the characterization and calibration of phase shift, current gain, and voltage gain, which are then recorded and used to automatically pair with the control unit for precise actuator triggering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If sensor assembly and calibration are performed on the same production line, then calibration precision is improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvecalibration precisionVSAvoidmanufacturing process complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent divides the circuit breaker manufacturing process into separate modules: sensor assembly can be manufactured independently with pre-calibration, then assembled with the actuator later. The sensor unit includes its own calibration data storage, allowing calibration to be separated from final assembly while maintaining precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sensor is calibrated in advance during its manufacturing process, and calibration parameters are stored in the sensor's memory. This preliminary calibration action eliminates the need for complex simultaneous calibration during final assembly, reducing manufacturing complexity while maintaining calibration precision.

Inventive Principle:

Principle #10Preliminary action

2Measurement precision

If manual calibration procedures are used, then measurement precision is improved, but productivity decreases

Engineering Contradiction:

Improvecalibration accuracyVSAvoidmanufacturing throughput

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The sensor unit performs self-calibration by automatically reading calibration parameters from its internal memory and applying them during operation. This self-service capability eliminates manual calibration intervention while maintaining high precision, thereby increasing manufacturing productivity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical calibration procedures with an automated electronic system. Calibration data is stored digitally in non-volatile memory and automatically applied by the control unit, substituting manual operations with automated electronic processes that are both precise and rapid.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If calibration data is stored in volatile memory, then device complexity is reduced, but reliability decreases

Engineering Contradiction:

Improvememory system complexityVSAvoidcalibration data retention

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent implements a backup mechanism by storing calibration data in non-volatile memory before operation. This beforehand cushioning ensures that calibration data is preserved even during power interruptions or system failures, maintaining reliability without significantly increasing device complexity.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

Facilitates simple and automatic calibration of the sensors and actuator control unit during assembly, ensuring precise and continuous operation of the circuit breaker, with automatic data recording and emergency mode operation to maintain functionality in case of link interruptions.

Implementation Method 1

a current measurement unit comprising a toroid capable of being crossed by a primary conductor and comprising a first conductor wound around the toroid

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a voltage measurement unit adapted to be connected to the primary conductor to measure a potential appearing in the primary conductor

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP3552034B1Method for manufacturing a measurement sensor for a circuit breaker

Publication Date: 2023.03.22 HAGER ELECTRO SAS

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AI summary

- 15 - ABSTRACT *************** Method for manufacturing a measurement sensor for a circuit breaker The subject of the present invention is a method for manufacturing a measurement sensor (10), a measurement sensor manufactured using said method, a circuit breaker comprising such a measurement sensor (10) and a method for controlling such a circuit breaker (100). The measurement sensor (10) comprises at least one current measurement unit (12) comprising a torus through which a main conductor (R, S, T, N) is able to pass, and a first conductor wound around the torus, a current transformer (14) through which the main conductor (R, S, T, N) passes and a data management unit (18). The measurement sensor (10) comprises a voltage measurement unit (16) linked to the main conductor (R, S, T, N) to measure a potential in the main conductor (R, S, T, N). - Fig. 1 -