Digital Circuit Breaker Control With Bistable Switching Module
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Solution Overview
Problem
Conventional circuit breaker control systems are inefficient and prone to contactor damage during short-circuit faults, and solid-state breakers are not suitable for all applications.
Innovation Solution
A switching module with a bistable solenoid actuator and laminated arm design that allows for remote and digital control of circuit breakers, featuring a bi-directional solenoid mechanism and alternating materials to withstand high currents and short-circuit events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If motor operators and contactors are added to enable remote operation of circuit breakers, then remote control capability is improved, but device complexity increases and reliability decreases due to contactor destruction during short-circuit faults
Solution Approach 1:
The invention separates the remote control function from the circuit breaking function. The motor operator is separated into a standalone control module that can remotely operate the circuit breaker mechanism without requiring a contactor in series with the load circuit. This segmentation eliminates the vulnerability of contactors during short-circuit events while preserving remote control capability.
Solution Approach 2:
The contactor component is extracted and eliminated from the system. Instead of using a contactor to enable remote operation, the invention directly couples the motor operator with the circuit breaker mechanism, removing the vulnerable intermediate component that would be exposed to short-circuit currents.
2Reliability
If solid-state breakers are used to improve reliability and reduce mechanical wear, then durability is improved, but adaptability decreases as they are not suitable for all applications
Solution Approach 1:
The invention selectively applies solid-state technology only to the switching components that require high reliability (the remote control switching elements), while maintaining the proven mechanical circuit breaker mechanism for the main circuit protection function. This hybrid approach preserves adaptability to various applications while improving durability where needed.
3Ease of operation
If additional contactors and motor operators are added for remote control, then remote operation capability is improved, but device complexity and space requirements increase
Solution Approach 1:
The invention merges the motor operator functionality directly into the circuit breaker mechanism, eliminating the need for separate contactors. The control module integrates the motor operator with the breaker mechanism, reducing the total component count while maintaining remote operation capability.
Solution Approach 2:
The circuit breaker mechanism is designed to serve multiple functions: it acts as both the primary circuit protection device and the remote control switching element. This multi-functionality eliminates the need for separate contactors and reduces overall system complexity.
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 remote and digital control of electrical circuits, preventing contact damage during short-circuit events and providing a compact, durable solution for existing circuit breakers.
Implementation Method 1
A solenoid can be included proximate the first magnet, configured to cancel, at least partially, a magnetic field of the first magnet with the first solenoid energized
Implementation Method 2
The armature can include a ferromagnetic material
Implementation Method 3
A biasing member can be mounted to the armature and to the actuator body configured to bias the armature to a position between the first and second bistable positions
Data Source
AI summary
A system includes a circuit breaker and a switching module with a first module terminal for electrically connecting the switching module to an electrical circuit, and a second module terminal connected in electrical series with a first terminal of the circuit breaker. A switching device of the switching module is connected in electrical series between the first and second module terminals and is configured to switch between an ON state for allowing electrical current through the electrical circuit and an OFF state for opening the electrical circuit to stop current flow therethrough. The circuit breaker has a first housing that houses the breaker mechanism therein. The switching module has a second housing that houses the switching device therein. The second housing can be mounted to the first housing. The first and second housings together can be configured to fit in a physical envelope of a molded case circuit breaker (MCCB).