Circuit Interrupter Nonvolatile Memory Trip Cause Storage
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Solution Overview
Problem
Circuit interrupters, such as miniature circuit breakers, face delays in responding to fault conditions and lack diagnostic capabilities, as they do not store information on trip causes or current levels, making it difficult to diagnose faults upon return to the manufacturer.
Innovation Solution
A circuit interrupter with a processor, nonvolatile memory, and sensors to determine and store trip conditions, including arc fault, ground fault, and overload conditions, along with trip counts, allowing for post-trip analysis and improved fault diagnosis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If circuit breakers use thermal-magnetic trip devices with bimetal and armature mechanisms, then they provide reliable overcurrent and short circuit protection, but they lack diagnostic capabilities to store trip cause information
Solution Approach 1:
The patent introduces an intermediary electronic system comprising a processor, memory, and communication interface that mediates between the traditional thermal-magnetic trip device and the external diagnostic system. This intermediary captures trip cause information (overload, short circuit, ground fault) and stores it in memory, enabling downstream diagnostic capabilities without modifying the core protective function of the bimetal and armature mechanisms.
Solution Approach 2:
The patent replaces the purely mechanical thermal-magnetic trip device with a hybrid system that incorporates electronic sensing, processing, and memory components. The processor electronically detects trip conditions and stores diagnostic information, substituting the need for mechanical indicators while maintaining the mechanical trip actuation for actual circuit interruption.
2Speed
If circuit breakers open separable contacts quickly to interrupt fault conditions, then they minimize damage from faults, but they disconnect the electronic circuit from power source before storing diagnostic information
Solution Approach 1:
The patent implements preliminary action by having the processor detect and record trip cause information in memory immediately when a fault condition is sensed, before the separable contacts actually open. This ensures diagnostic information is captured and stored in advance, eliminating the risk of information loss due to power disconnection when contacts open.
Solution Approach 2:
The patent maintains continuity of useful action by keeping the electronic circuit powered and operational throughout the trip process. The processor continues to function, detect faults, and store information even as the mechanical trip mechanism activates and contacts begin to open, ensuring uninterrupted diagnostic capability.
3Device complexity
If circuit breakers return to manufacturer without stored diagnostic data, then they maintain simple structure, but they require extensive testing equipment and time for fault analysis
Solution Approach 1:
The patent creates a digital copy of the trip event information by storing detailed diagnostic data (trip cause, current level, timestamp) in non-volatile memory. This digital copy travels with the circuit breaker when returned to the manufacturer, eliminating the need for complex physical testing and reconstruction of fault conditions at the manufacturer's facility.
Solution Approach 2:
The patent implements feedback by providing a communication interface that allows the circuit breaker to output stored diagnostic information to external systems. This feedback mechanism enables quick retrieval of trip cause data without requiring the manufacturer to perform time-consuming manual testing or analysis.
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 quick fault response and provides diagnostic information on trip causes and current levels, enhancing fault analysis and maintenance efficiency.
Implementation Method 1
a bimetal which is heated and bends in response to a persistent overcurrent condition
Implementation Method 2
An armature, which is attracted by the sizable magnetic forces generated by a short circuit or fault
Implementation Method 3
This trip signal energizes a shunt trip solenoid, which unlatches the operating mechanism
Data Source
AI summary
A circuit breaker includes separable contacts, an operating mechanism structured to open and close the separable contacts, and a trip mechanism. The trip mechanism includes a sensor structured to sense current flowing through the separable contacts, a processor cooperating with the sensor to determine a plurality of different trip conditions responsive to the sensed current, a nonvolatile memory operatively associated with the processor, and a trip actuator cooperating with the processor and the operating mechanism to trip open the separable contacts responsive to one of the different trip conditions from the processor. The processor is structured to save in and retrieve from the nonvolatile memory cause-of-trip information for the different trip conditions including the one of the different trip conditions.