Plug-on Ground Fault Module with Pass-through Conductors
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Solution Overview
Problem
Conventional circuit breakers with ground fault circuits have complex wiring arrangements that complicate assembly and limit amperage and interrupting levels, with sensitive electronics being exposed to arcing components.
Innovation Solution
A plug-on ground fault module with pass-through power conductors for circuit interrupters, featuring a first and second housing with a current transformer and load collars, allowing power conductors to extend through an open channel, simplifying assembly and reducing exposure to arcing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ground fault circuits are placed inside the circuit breaker housing, then ground fault protection is provided, but sensitive electronics are exposed to arcing components which limits amperage and interrupting levels
Solution Approach 1:
The device is divided into two separate housings: a first housing containing the circuit interrupter with arcing components, and a second housing containing the ground fault circuit with sensitive electronics. This segmentation isolates the electronics from harmful arcing effects while maintaining ground fault protection functionality.
Solution Approach 2:
The ground fault circuit is extracted from the first housing and placed in a separate second housing. This removes the sensitive electronics from the environment containing arcing components, eliminating the limitation on amperage and interrupting levels while preserving the ground fault protection function.
2Reliability
If conventional thermal magnetic circuit breakers with ground fault circuits are used, then ground fault protection is provided, but wiring arrangements are complicated making assembly challenging
Solution Approach 1:
The ground fault circuit is integrated into the second housing as a unified assembly with the current transformer and load collars. This merging of components into a pre-assembled module eliminates the need for complex field wiring arrangements and simplifies the overall assembly process.
Solution Approach 2:
The ground fault circuit, current transformer, and associated components are pre-assembled in the second housing before final installation. This preliminary assembly reduces on-site complexity and makes the overall assembly process more straightforward by preparing sub-assemblies in advance.
3Ease of operation
If power conductors are routed through conventional arrangements, then electrical connection is provided, but wiring complexity increases and assembly becomes challenging
Solution Approach 1:
The second housing serves multiple functions: it contains the ground fault circuit, houses the current transformer, provides load collars for conductor termination, and acts as a protective enclosure. This multi-functionality reduces the need for separate components and simplifies the overall wiring arrangement.
Solution Approach 2:
The invention introduces a spatial dimension by using two separate housings arranged in series along the conductor path. Conductors pass through the first housing, then through the second housing containing the current transformer, creating a linear progression that simplifies routing compared to complex internal arrangements.
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
This configuration simplifies the assembly process, reduces the complexity of wiring, and enhances the protection against overcurrent conditions by allowing precise measurement of current imbalance and amperage leakage, while keeping sensitive electronics away from arcing components.
Implementation Method 1
The second housing (101) can include a current transformer (120)... The at least one power conductor (12) can extend through an open channel (120c) in the current transformer (120)
Implementation Method 2
In the event of an overcurrent condition (e.g., a short circuit), extremely high electromagnetic forces can be generated. The electromagnetic forces can be used to separate the movable contact from the stationary contact.
Implementation Method 3
Arc chutes can be used to direct an arc away from the electrical contacts into the arc chute. The arc chute is situated proximate to the stationary contact of the circuit.
Data Source
AI summary
Circuit interrupter devices have a first housing with a circuit interrupter, a second housing coupled to the first housing, a ground fault circuit and current transformer in the second housing. The current transformer has an open channel. The circuit interrupter devices also include at least one power conductor having a rigid or semi-rigid body with opposing first and second end portions extending between the first and second housings. The second end portion of the at least one power conductor extends through the open channel in the current transformer and terminates in a breaker load collar(s).