Modular Circuit Breaker Assembly Using Segmented Common Body
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Solution Overview
Problem
Conventional circuit breakers require specialized components and assembly methods for different types, hindering the implementation of technological improvements and efficient assembly processes.
Innovation Solution
A modular circuit breaker design featuring a primary assembly with a housing, separable contacts, terminal conductors, an operating mechanism, and a trip mechanism, along with a module assembly that can be easily coupled and decoupled, utilizing common components and a method of assembly that allows for the addition or removal of unique components as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional circuit breakers use specialized components for different types, then each type can be optimized for its specific function, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The circuit breaker is divided into a common body portion and interchangeable module portions. The common body portion contains shared components (housing, operating mechanism, trip mechanism, separable contacts), while different functional types are achieved by swapping module portions (arc fault module, ground fault module, dual function module). This segmentation allows functional optimization without increasing overall device complexity.
Solution Approach 2:
The common body portion is designed with universal interfaces and mounting structures that can accommodate different module portions. This universal design enables a single common body to support multiple circuit breaker types through module interchangeability, eliminating the need for completely specialized components for each circuit breaker type.
2Adaptability or versatility
If conventional circuit breakers use unique housings for different types, then each type can be customized, but the ease of manufacture and assembly efficiency decrease
Solution Approach 1:
The housing is segmented into a common body portion and module portions. The common body portion serves as a standardized platform that can accommodate different module types. This segmentation allows manufacturers to produce the common body portion in large quantities using standardized processes, improving ease of manufacture while maintaining adaptability through module customization.
Solution Approach 2:
The module portions are pre-assembled with their specific components (arc fault detectors, ground fault detectors, electronic circuitry) before being installed in the common body portion. This preliminary assembly of modules allows for efficient customization - different module types can be manufactured independently and then quickly installed in the standardized common body, improving both ease of manufacture and assembly efficiency.
3Reliability
If conventional circuit breakers use specialized components for each type, then functional requirements are met, but productivity and assembly efficiency are reduced
Solution Approach 1:
By segmenting the circuit breaker into common and module portions, the assembly process is simplified. The common body portion can be assembled once and reused across different circuit breaker types, while only the module portions need to be changed. This significantly improves productivity as the majority of the assembly remains constant across different product variants.
Solution Approach 2:
The universal common body portion with standardized interfaces allows the same base assembly to support multiple functional types through module interchangeability. This universality enables manufacturers to maintain high productivity by producing a standardized platform that can be quickly adapted to different functional requirements through simple module swaps, rather than assembling completely specialized units for each type.
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 modular design optimizes the use of common components, improves assembly efficiency, and allows for customization to meet specific application requirements, addressing the limitations of conventional designs.
Implementation Method 1
a bimetal, which heats and bends in response to a persistent overcurrent condition
Implementation Method 2
a solenoid structured to mechanically engage the operating mechanism upon receiving an electronic signal from the control unit
Data Source
AI summary
A modular circuit breaker includes a module assembly coupled to a primary assembly. The primary assembly includes a primary housing, separable contacts disposed therein, a first terminal conductor electrically connected to one of the separable contacts, a conductive tab electrically connected to another one of the separable contacts and which extends outward from a first end of the primary housing, an operating mechanism disposed in the primary housing for selectively opening and closing the separable contacts, and a trip mechanism disposed in the primary housing cooperative with the operating mechanism to trip open the separable contacts. The module assembly includes a module housing having a second terminal conductor positioned therein and electrically connected to the conductive tab, a third terminal conductor structured to be electrically connected to a neutral conductor of a load, and a fourth terminal conductor structured to be coupled to a neutral bus.