Drive Unit for Circuit Breakers with Proximity Sensor Alignment
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Solution Overview
Problem
Manual actuation of circuit breakers in high-risk environments like industrial plants and offshore oil platforms poses a risk of arc-flash, and existing automated solutions often require redesign or replacement of existing manually operated systems.
Innovation Solution
A remote racking tool with a drive unit that uses a stepper motor and control circuitry to automate the engagement and disengagement of circuit breaker contacts with a power bus, incorporating a proximity detector to align and align the tool with the receptacle, reducing the need for manual intervention and minimizing arc-flash risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual actuation is used to engage/disengage circuit breaker contacts, then ease of operation is maintained, but the risk of arc-flash increases
Solution Approach 1:
A drive unit with a tool carrying apparatus serves as an intermediary between the control system and the circuit breaker actuator. The drive unit includes a tool that interfaces with the circuit breaker's actuator mechanism, allowing automated engagement and disengagement of contacts without direct manual intervention in the arc-flash zone.
Solution Approach 2:
The patent replaces manual mechanical operation with an automated drive unit that uses a motorized mechanism to rotate the tool and actuate the circuit breaker. This substitution eliminates the need for technicians to physically handle the actuator during contact engagement/disengagement, reducing arc-flash exposure.
2Reliability
If automated remote actuation is implemented, then arc-flash risk is reduced, but device complexity increases
Solution Approach 1:
The drive unit is designed with a universal interface that can work with various circuit breaker types. The tool carrying apparatus can accommodate different tool configurations, and the drive unit can perform multiple functions including engagement, disengagement, and positioning operations across different circuit breaker models.
Solution Approach 2:
The tool is nested within the tool carrying apparatus, which is integrated into the drive unit housing. This nested structure allows the tool to be stored, protected, and precisely positioned within the drive unit, reducing overall system complexity while maintaining functionality.
3Ease of manufacture
If existing manually operated circuit breakers are used, then ease of manufacture is maintained, but automation capability is limited
Solution Approach 1:
The drive unit acts as an intermediary layer between existing manually operated circuit breakers and automated control systems. By interfaceing with the existing actuator mechanism through a standardized tool connection, the drive unit enables remote actuation without requiring redesign of the original circuit breaker.
Solution Approach 2:
The drive unit is designed to be compatible with multiple circuit breaker types and configurations. The tool carrying apparatus can adapt to different actuator designs, allowing the same drive unit to automate various existing circuit breaker models without requiring custom modifications to each breaker.
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 enables safe and automated remote actuation of circuit breakers, reducing the risk of arc-flash and allowing for integration with existing manually operated systems without redesign, enhancing operational safety and efficiency.
Implementation Method 1
A motor apparatus, which may be comprised of a stepper motor, gearbox, and/or other components, may be mechanically coupled to rotate the tool carrying apparatus.
Implementation Method 2
A proximity detector may be incorporated into the drive unit to detect when the tool is properly aligned with the receptacle.
Data Source
AI summary
Disclosed herein is a drive unit for driving a tool mated with a tool receptacle in a device. The drive unit includes a tool carrying apparatus configured to carry the tool, and a proximity sensor cooperating with at least a portion of the tool carrying apparatus so as to detect movement of the tool carrying apparatus along a longitudinal axis thereof. A motor apparatus is configured to rotate the tool carrying apparatus. Control circuitry is configured to operate the motor in an engagement mode to rotate at least a portion of the tool carrying apparatus until the tool is rotationally aligned with the tool receptacle so as to permit insertion thereinto, based on the proximity sensor not detecting movement of the tool carrying apparatus a threshold distance along the longitudinal axis toward the tool receptacle.