Inline Dual Coil Circuit Breaker for Compact Retrofit
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current motor protection circuit breakers face inefficiencies due to power loss from heat generation and lack of integrated electronics for data measurement and communication, requiring a more efficient design that fits within smaller form factors to meet market demands for reduced power consumption and integration with control systems.
Innovation Solution
A circuit breaker system utilizing an inline dual coil design with embedded electronics, where the primary coil acts as a current transformer for power and measurement, and an integrated magnetic actuator for fast contact opening and preventing reclosing, allowing for reduced size and enhanced communication capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional bimetal strips and magnetic plungers are used for thermal and short circuit protection, then protection function is achieved, but power loss in the form of heat is significant
Solution Approach 1:
The patent replaces traditional mechanical thermal protection (bimetal strips) and magnetic protection (magnetic plungers) with electronic sensing and control systems. Current sensors detect overload conditions and trigger electronic tripping mechanisms, eliminating the need for heat-generating bimetal strips and reducing power loss while maintaining protection reliability.
Solution Approach 2:
The patent changes the operating parameters of the circuit breaker by using electronic control to detect and respond to overload conditions instead of relying on thermal and magnetic parameters. This allows for more efficient operation with reduced power loss while maintaining the same protection functions.
2Loss of information
If circuit breakers are designed with integrated electronics for data measurement and communication, then monitoring capability is improved, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single electronic control unit that performs current measurement, communication, and control functions. This multi-functional approach reduces overall device complexity compared to having separate components for each function, while enabling comprehensive monitoring and communication capabilities.
Solution Approach 2:
The patent combines current sensing, data processing, and communication functions into an integrated electronic system within the circuit breaker. This merging of functions reduces the number of separate components needed and simplifies the overall device structure while enabling advanced monitoring capabilities.
3Volume of stationary object
If circuit breaker size is reduced to fit smaller enclosures, then manufacturing cost decreases, but space for power-efficient electronics and communication modules is limited
Solution Approach 1:
The patent employs a compact nested arrangement where electronic components, current sensors, and communication modules are integrated within the circuit breaker structure in a space-efficient manner. Components are arranged concentrically or in layered configurations to maximize space utilization, enabling advanced functionality within a reduced form factor.
Solution Approach 2:
The patent utilizes three-dimensional space optimization by arranging components in vertical and radial dimensions rather than only horizontal layouts. This dimensional reorganization allows for efficient packing of electronics and communication modules within a smaller overall volume, maintaining integration capability while reducing circuit breaker size.
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 achieves reduced size and power efficiency, enabling faster overload detection and prevention of reclosing, while allowing for data collection and communication within existing enclosures, aligning with market requirements for reduced power consumption and integration with control systems.
Implementation Method 1
the primary coil acts as a current transformer for power and measurement
Implementation Method 2
an integrated magnetic actuator for fast contact opening and preventing reclosing
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A system comprising a magnetic actuator (104), a current transformer and operational electronics in a dual-coil circuit breaker. The system includes an inline implementation of the primary (102) and secondary (106) coils to maintain a narrow width suitable for retrofitting in currently designed industrial rack mounted enclosures. The system further comprises network connectivity allowing interrogation of the components for operational data associated with the component.