Miniature Circuit Breaker With Smart Controller And Current Transformers
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Solution Overview
Problem
Current miniature circuit breakers have poor short-circuit breaking capacity, high energy consumption, and lack adjustable protection features, failing to provide selective protection for motor and power distribution systems, leading to low reliability and increased equipment volume.
Innovation Solution
A miniature circuit breaker design incorporating a current transformer, zero-sequence current transformer, and smart controller module with a tripping mechanism and arc extinguishing chambers, enabling quick current breaking and adjustable protection settings, reducing energy consumption and equipment size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional thermomagnetic technology is used for overload and short circuit protection, then the circuit breaker can provide basic protection, but the short circuit breaking capacity is poor and energy consumption is high
Solution Approach 1:
The patent replaces the traditional thermal-magnetic protection mechanism with an electronic protection system using current transformers (CT1, CT2), zero-sequence current transformers, and a smart controller module. This electronic system detects currents and triggers tripping through a magnetic actuator, eliminating the need for continuous thermal heating elements and improving both breaking capacity and energy efficiency.
Solution Approach 2:
The patent introduces current transformers and zero-sequence current transformers as intermediary devices to sense current conditions. These transformers convert high currents into measurable signals that the smart controller can process, enabling precise protection without direct thermal contact and reducing energy loss while maintaining high breaking capacity.
2Measurement precision
If traditional heating element is used to sense overload current, then the circuit breaker can detect overload conditions, but energy loss occurs
Solution Approach 1:
The patent replaces the traditional heating element-based thermal sensing with electromagnetic sensing using current transformers and zero-sequence current transformers. These devices detect current magnitudes and patterns electromagnetically without thermal conversion, providing precise overload sensing while eliminating the continuous energy consumption associated with thermal elements.
Solution Approach 2:
The current transformers and zero-sequence current transformers are connected in series with the circuit and automatically sense current conditions without requiring additional power input. The system uses the circuit's own current to generate the sensing signals, achieving energy-efficient overload detection.
3Reliability
If miniature residual-current circuit breaker is assembled with traditional residual current tripping module, then the circuit breaker can provide residual current protection, but the width modulus is significantly increased and volume is large
Solution Approach 1:
The patent merges the residual current protection function into the same electronic control system that handles overload and short-circuit protection. The zero-sequence current transformer detects residual currents, and the smart controller integrates this detection with other protection functions, eliminating the need for separate mechanical tripping modules and reducing overall device volume.
Solution Approach 2:
The smart controller module serves multiple protection functions simultaneously - overload protection, short-circuit protection, and residual current protection - all through a single integrated electronic system. This multi-functionality eliminates the need for separate dedicated modules for each protection type, significantly reducing the overall equipment volume while maintaining comprehensive protection capabilities.
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 solution enhances short-circuit breaking capacity, provides selective protection, reduces energy consumption, and allows for adjustable settings, improving the reliability and flexibility of power distribution systems while minimizing equipment volume.
Implementation Method 1
a current transformer CT1 and a zero-sequence current transformer CT2, wherein the current transformer CT1 and the zero-sequence current transformer CT2 are straddled on main-loop outgoing terminals
Implementation Method 2
a magnetic tripping push rod, wherein the movable contact is mounted on the tripping mechanism through a pin shaft
Implementation Method 3
the tripping mechanism is further provided with a torsional spring to press the movable contact closely against the fixed contact
Implementation Method 4
The miniature circuit breaker body is internally provided with a main arc extinguishing chamber
Data Source
AI summary
A miniature circuit breaker with quick current breaking capability which includes a miniature circuit breaker body, a current transformer CT1, a zero-sequence current transformer CT2 and a smart controller module. The miniature circuit breaker body is internally provided with a main arc extinguishing chamber, a fixed contact, a movable contact, a tripping mechanism, and a magnetic tripping push rod. The tripping mechanism includes a lock catch, a movable contact rocker arm, a jump pin, a connecting rod, and a tension spring. A rotated-hinge repulsive force structure is applied between the fixed contact and the movable contact. The tripping mechanism is further provided with a torsional spring to press the movable contact close to the fixed contact. A shunt tripping device controlling the miniature circuit breaker switch to be turned off is arranged in the smart controller module.