Magnetic Circuit Breaker Sensor for Panelboard Trip Detection

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Solution Overview

Problem

Conventional load centers or panelboards do not provide external notifications when a circuit breaker trips, making it difficult for users to identify and address the issue, especially in inaccessible or hard-to-reach locations.

Innovation Solution

A circuit breaker sensor with a magnetically attached accelerometer that monitors vibrations on the panelboard surface, identifies tripped circuit breakers by analyzing movement samples, and provides notifications through LED displays, wireless signals, or audible alerts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of information

If conventional load centers or panelboards are used without additional monitoring devices, then the device complexity is low, but the ability to identify tripped circuit breakers becomes difficult and time-consuming

Engineering Contradiction:

Improvenotification of tripped circuit breakerVSAvoidsensor assembly with accelerometer and controller

Core Design Contradiction:

Loss of informationVSDevice complexity

Solution Approach 1:

The patent uses an accelerometer as an intermediary device that detects vibrations from tripped circuit breakers through the panelboard surface. The accelerometer translates mechanical vibrations into electrical signals that the controller can analyze, serving as a mediator between the physical tripping event and the digital notification system.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces manual inspection of circuit breakers with an automated sensor-based system. The accelerometer and controller automatically detect and identify tripped breakers through vibration analysis, substituting the mechanical/manual process of visually checking each breaker with an automated electronic monitoring system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Loss of time

If manual inspection of circuit breakers is performed, then no additional devices are needed, but the time required to identify tripped breakers increases significantly

Engineering Contradiction:

Improvetime to identify tripped circuit breakerVSAvoidautomatic detection and notification capability

Core Design Contradiction:

Loss of timeVSEase of operation

Solution Approach 1:

The sensor assembly continuously monitors vibrations in advance, so when a circuit breaker trips, the system has already detected and recorded the event. The notification is prepared and can be immediately transmitted, eliminating the time delay associated with manual inspection after a trip occurs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system provides immediate feedback through notifications (visual, audible, or wireless) when a circuit breaker trips. This closed-loop feedback mechanism allows users to know instantly about tripped breakers without having to physically search through the panelboard, significantly reducing identification time.

Inventive Principle:

Principle #23Feedback

3Measurement precision

If circuit breaker monitoring is implemented, then accurate identification of tripped breakers is achieved, but the ease of installation becomes more complex

Engineering Contradiction:

Improveidentification accuracy of tripped circuit breakerVSAvoidinstallation simplicity of sensor assembly

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The sensor assembly is designed as a separate, self-contained unit with the accelerometer, controller, and notification components integrated into a single housing. This segmentation allows the monitoring function to be added as a modular component rather than requiring modification of the entire panelboard system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The magnet serves as an intermediary mounting mechanism that enables easy attachment of the sensor assembly to the panelboard surface without permanent modifications. The magnetic coupling provides secure attachment during operation while allowing for simple removal and repositioning if needed.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables quick and accurate identification of tripped circuit breakers, allowing users to take corrective measures without extensive searching, and is inexpensive and easy to install.

Implementation Method 1

a magnet coupled to the bottom portion and configured to magnetically couple the circuit breaker sensor to a surface of the panelboard

Methodology Applied

Scientific EffectMagnetic coupling: Magnetism

Implementation Method 2

an accelerometer coupled to the magnet and configured to sample movement of the surface via the magnet

Methodology Applied

Scientific EffectVibration detection: Vibration

Data Source

PatentEP3091553B1Circuit breaker sensor

Publication Date: 2019.07.10 SCHNEIDER ELECTRIC IT CORP

Figure 1A~1B
Figure 1C
Figure 1D

AI summary

According to one aspect, embodiments herein provide a circuit breaker sensor for use in a panelboard including a plurality of circuit breakers, the circuit breaker sensor comprising a housing having a top portion and a bottom portion, a magnet coupled to the bottom portion and configured to magnetically couple the circuit breaker sensor to a surface of the panelboard, an accelerometer coupled to the magnet and configured to sample movement of the surface via the magnet; and a controller coupled to the accelerometer and configured to identify, based on the samples taken by the accelerometer, whether one of the plurality of circuit breakers in the panelboard has tripped.