Hybrid Circuit Breaker Handle Sensing for Safe Functional Testing
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Solution Overview
Problem
Existing protective switching devices for low-voltage circuits lack a simple and effective architecture that ensures operational reliability and safety, particularly in monitoring and testing the functionality of both mechanical and electronic interruption units.
Innovation Solution
A protective switching device with a mechanical disconnect contact unit and an electronic interruption unit, where the mechanical unit is assigned to load-side connections and the electronic unit to mains-side connections, incorporating a control unit that determines the position of the mechanical handle to perform functional tests and ensure safe operation, including voltage and current threshold checks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a circuit breaker uses a traditional arc quenching mechanism with fixed components, then the structure is simple and easy to manufacture, but the arc cannot be effectively extinguished under high current conditions leading to reliability issues
Solution Approach 1:
The patent applies the dynamics principle by making the arc quenching components movable rather than fixed. The arc quenching plate is connected to a driving mechanism that can dynamically adjust its position and orientation during arc extinction. The arc quenching groove can also move to optimize the arc path. This dynamic adjustment allows the system to adapt to varying current conditions and effectively extinguish arcs under high current conditions while maintaining a relatively compact structure.
Solution Approach 2:
The patent applies segmentation by dividing the arc quenching system into multiple independent components: arc quenching plate, arc quenching groove, driving mechanism, and support structures. Each component has a specific function and can be optimized independently. The arc quenching plate is divided into multiple sections with different angles and positions, allowing selective activation based on current conditions. This segmentation enables complex arc control functionality while keeping individual components simple and manufacturable.
2Reliability
If a circuit breaker uses multiple movable components for arc quenching, then arc extinction effectiveness is improved, but the number of parts increases making the device more complex and harder to manufacture
Solution Approach 1:
The patent applies the merging principle by integrating multiple functions into fewer components. The arc quenching plate serves multiple purposes: it acts as both a structural support and an active arc control element. The driving mechanism is integrated with the existing circuit breaker actuation system, sharing motors and control circuits. The arc quenching groove is formed as part of the housing structure rather than a separate component. This merging reduces the total number of parts while maintaining the complex arc extinction capability.
Solution Approach 2:
The patent applies universality by designing components that perform multiple functions. The arc quenching plate can be positioned at different angles to handle various arc conditions, serving both low current and high current scenarios. The driving mechanism that moves the arc quenching plate also controls the main circuit breaker operation. The support structure provides both mechanical strength and guidance for movable components. This multi-functionality reduces the need for specialized components for each function, simplifying manufacturing.
3Volume of moving object
If the circuit breaker uses a compact design with integrated components, then the overall size is reduced, but the arc quenching space is limited reducing effectiveness
Solution Approach 1:
The patent applies the dimensionality change principle by utilizing three-dimensional space more effectively. The arc quenching plate can rotate and move in multiple directions, creating dynamic spatial configurations within the compact housing. The arc quenching groove is designed with a three-dimensional path that guides the arc through a extended route without increasing the external dimensions. Support structures are arranged vertically and diagonally to maximize space utilization. This multi-dimensional arrangement provides sufficient arc quenching space within a compact overall size.
Solution Approach 2:
The patent applies the nesting principle by placing components within each other to maximize space utilization. The arc quenching plate is nested within the housing structure, with its movement path defined by the housing contours. The driving mechanism is nested within the same space as the arc quenching components, sharing the same volume. Support structures are nested along the periphery, providing guidance without occupying central space. This nesting arrangement allows complex arc quenching functionality within a compact volume.
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
Enhances operational reliability by ensuring correct functioning of the electronic interruption unit and mechanical contacts, allowing for continuous operation and efficient testing without disrupting the load, thereby increasing safety and reliability in low-voltage circuits.
Implementation Method 1
the arc quenching plate and the arc quenching groove... guide and restrict the arc
Data Source
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AI summary
The invention relates to a circuit breaker for protecting an electric low-voltage circuit, having: - a housing with grid-side connections and load-side connections for the low-voltage circuit; - a mechanical separating contact unit which is connected to an electronic interruption unit in series, wherein - the mechanical separating contact unit is paired with the load-side connections, and the electronic interruption unit is paired with the grid-side connections, - the mechanical separating contact unit can be operated using a handle such that an opening function of contacts can be switched in order to prevent a current flow or a closing function of contacts can be switched for a current flow in the low-voltage circuit, and - as a result of semiconductor-based switch elements, the electronic interruption unit can be switched to a high-ohmic state of the switch elements in order to prevent a current flow or to a low-ohmic state of the switch elements for a current flow in the low-voltage circuit; - a current sensor unit for ascertaining the level of the current of the low-voltage circuit; and - a control unit which is connected to the current sensor unit, the mechanical separating contact unit, and the electronic interruption unit. A process for preventing a current flow in the low-voltage circuit is initiated if current thresholds and/or current/time thresholds are exceeded, and the mechanical separating contact unit has a handle sensor in order to ascertain position information of the handle.