Circuit Interrupter Sensor Module for Plug-in Position Monitoring

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional circuit breakers in aerospace applications require additional wires for monitoring, which are prone to damage and increase costs due to the need for gold contacts to prevent false sensing, making them inefficient for automatic status indication.

Innovation Solution

A circuit interrupter apparatus with a sensor module that includes a Hall Effect sensor and current transformer for plug-in connection, allowing for the detection of the circuit breaker's position and current level without additional wires, using a simple plug-in connection to a panel board.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Difficulty of detecting and measuring

If additional wires are added to sense micro switch position, then position monitoring capability is improved, but reliability deteriorates due to wire damage from environmental and mechanical factors

Engineering Contradiction:

Improveposition monitoring capabilityVSAvoidwire reliability

Core Design Contradiction:

Difficulty of detecting and measuringVSReliability

Solution Approach 1:

The patent replaces the mechanical wire-based sensing system with a magnetic field-based sensing system. The Hall effect sensor detects the position of the circuit breaker by sensing magnetic field changes from a magnet attached to the moving contact, eliminating the need for additional physical wires that are susceptible to damage from environmental and mechanical factors.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a magnet as an intermediary element attached to the moving contact and a Hall effect sensor as an intermediary detection device. This intermediary magnetic field system serves as a reliable mediator between the moving contact and the sensing circuit, avoiding direct physical wire connections that are prone to failure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If gold contacts are used in micro switches, then sensing reliability is improved, but manufacturing cost increases

Engineering Contradiction:

Improvesensing reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the electrical contact-based sensing mechanism with a magnetic field-based sensing mechanism. Instead of using gold contacts in micro switches to achieve reliable logic level circuits, the invention uses a Hall effect sensor to detect magnetic field changes, eliminating the need for expensive gold plating and associated manufacturing costs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs inexpensive magnetic field sensing components (Hall effect sensor and magnet) instead of expensive gold contacts. This substitution with cheaper components achieves the same sensing reliability function without the high material costs associated with gold plating.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Difficulty of detecting and measuring

If micro switches with logic level current are used, then position sensing is achieved, but false sensing occurs causing missed or false open/closed detections

Engineering Contradiction:

Improveposition sensing capabilityVSAvoidsensing accuracy

Core Design Contradiction:

Difficulty of detecting and measuringVSMeasurement precision

Solution Approach 1:

The patent replaces the electrical current-based sensing method with a magnetic field-based sensing method. The Hall effect sensor detects the position of the circuit breaker by sensing magnetic field changes rather than relying on logic level current flow, thereby eliminating false sensing issues and improving measurement precision.

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

Enables reliable monitoring of the circuit breaker's position and current level with a 100% plug-in solution, reducing the need for extra wires and minimizing mechanical and environmental damage, while maintaining accurate sensing without false openings or closures.

Implementation Method 1

a Hall Effect sensor (20) for detecting the current position of the moveable contact

Methodology Applied

Scientific EffectHall Effect: Hall Effect

Implementation Method 2

a current transformer for detecting the level

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP3078090B1Method and apparatus for sensing the status of a circuit interrupter

Publication Date: 2017.10.18 LABINAL LLC

AI summary

A circuit interrupter apparatus (2) structured for plug-in connection to a panel board (40). The circuit interrupter apparatus (2) includes a line terminal (12) structured for plug-in connection with a line power member (52) provided as part of the panel board (40), a load terminal (14) structured for plug-in connection with a load power member (54) provided as part, of the panel board (40), and a moveable contact (26) moveable between a closed position wherein the line terminal (12) is electrically coupled to the load terminal (14) and an open position wherein the line terminal (12) is not electrically coupled to the load terminal (14). The circuit interrupter apparatus (2) also includes a sensor module (16) structured for a plug-in connection to a number of signal conductors provided as part, of the panel board (40). The sensor module (16) is structured and configured to detect whether the moveable contact (26) is in the closed position or the open position and output a signal to a t least one of the signal conductors indicating a current position of the moveable contact (26).