Double Pole Breaker Tandem Arrangement
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Solution Overview
Problem
Existing multi-pole circuit breaker arrangements are bulky, require excessive space, and necessitate the manufacture of multiple unique parts, making them unsuitable for space-constrained applications and increasing manufacturing costs.
Innovation Solution
A slim-profile multi-pole circuit breaker design featuring a common trip coupler that connects two separate circuit breakers via an elongated trip member, with a handle connector system allowing simultaneous actuation, reducing the number of unique parts and enhancing manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a common trip coupler connects circuit breakers through abutting side walls with cavities, then simultaneous tripping is achieved, but the arrangement becomes bulky and requires large space
Solution Approach 1:
The patent repositions the coupling mechanism from side-wall cavities to end-face openings. The elongated trip member extends along the longitudinal axis of the circuit breaker, connecting end-to-end with adjacent breakers rather than through lateral walls. This dimensional reconfiguration reduces the lateral footprint while maintaining the simultaneous tripping function through the longitudinal arrangement.
Solution Approach 2:
The circuit breaker housing is designed with standardized end-face openings that serve dual purposes: accommodating the elongated trip member for inter-breaker coupling and providing a uniform interface for all breakers in the assembly. This universal design eliminates the need for different breaker types with varying cavity configurations, allowing compact end-to-end arrangement while achieving common tripping across all breakers.
2Reliability
If different types of circuit breakers are manufactured to accommodate side wall cavities, then interconnection is achieved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent employs a universal housing design where all circuit breakers feature identical end-face openings. This standardized interface allows any breaker to connect with any other breaker through the elongated trip member, eliminating the need for specialized side breakers with different cavity configurations. The same housing type serves all positions in the assembly, significantly reducing the number of unique parts required.
Solution Approach 2:
The coupling function previously requiring specialized cavities in specific breaker positions is merged into a universal end-face opening design. All breakers use the same housing configuration with openings positioned to accommodate the elongated trip member, consolidating what would have been multiple unique parts into a single standardized component type.
3Ease of operation
If side breakers have flat tops and center breaker has top opening for single handle, then handle arrangement is achieved, but at least six different cases must be manufactured
Solution Approach 1:
The patent designs all circuit breaker housings with identical top surfaces that can accommodate the same handle configuration. The standardized end-face openings and uniform top geometry allow any breaker to serve any position in the assembly, whether end or center position, eliminating the need for differentiated housing types for side versus center breakers.
Solution Approach 2:
The handle actuation function is segmented from the housing structure, allowing the handle and its actuation mechanism to be independently configured without requiring different housing types. The universal housing design with standardized openings separates the structural function from the operational function, enabling flexible handle arrangement while maintaining housing uniformity.
Data Source
AI summary
A circuit breaker assembly includes a plurality of circuit breakers each including a housing with a trip mechanism therein and each having an opening in a side of the respective housing. Each trip mechanism has a coupler disc connected thereto. The plurality of circuit breakers are aligned in an end-to-end fashion with a trip member positioned along a side of the housings and connected to the coupler discs such that if the first trip mechanism actuates from a untripped state to a tripped state the trip member actuates the second trip mechanism from a untripped state to a tripped state and vice versa.