Modular Residential Circuit Breaker Design
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Solution Overview
Problem
The continuous changes in electrical distribution standards and codes necessitate frequent updates in circuit breaker designs, leading to lengthy and costly product development cycles, and existing modular designs primarily cater to three-phase and higher voltage applications, failing to address the needs of residential and commercial circuit breakers efficiently.
Innovation Solution
A modular residential circuit breaker design featuring a single operation module with plug-in type application modules that can be easily assembled to form various breaker frames, allowing for faster adaptation to changing codes and reducing inventory complexity by using a single operation module for multiple applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional circuit breaker designs are used to adapt to code changes, then product functionality can be maintained, but product development time increases to 3-5.5 years and costs increase to multi-million dollars
Solution Approach 1:
The circuit breaker is divided into separate functional modules: an operation module containing the operation mechanism, trip system, and arc suppression system, and application modules containing the mounting structure and current application components. This segmentation allows independent development and assembly of modules to meet different code requirements without redesigning the entire product.
Solution Approach 2:
The operation module is designed as a universal component that can be combined with multiple different application modules to create various circuit breaker configurations. This multi-functionality enables a single operation module to serve multiple code compliance scenarios, reducing development time and costs.
2Adaptability or versatility
If multiple product designs are maintained to fulfill different breaker applications, then customer demands can be met, but inventory complexity and manufacturing costs increase
Solution Approach 1:
By segmenting the circuit breaker into standardized operation modules and application modules, the system reduces inventory complexity while maintaining application coverage. Instead of stocking multiple complete breaker designs, manufacturers can stock standardized modules and assemble them as needed.
Solution Approach 2:
The universal operation module can be paired with different application modules to fulfill various breaker applications, reducing the need to maintain multiple complete product designs in inventory while still meeting diverse customer demands.
3Productivity
If traditional non-modular designs are used, then manufacturing processes are simpler, but response time to market demands decreases
Solution Approach 1:
The modular architecture segments the circuit breaker into independently manufacturable modules that can be produced through streamlined processes and assembled quickly, enhancing market response speed while maintaining manufacturing efficiency.
Solution Approach 2:
Standardized modules are designed and pre-tested in advance, allowing for rapid assembly and deployment when market demands change. This preliminary preparation of modular components accelerates the response to new code requirements and market opportunities.
Data Source
AI summary
A modular residential circuit breaker comprises an assembly including an operation module and a first application module. The operation module includes an operation mechanism, a trip system, and an arc suppression system except a specific mounting and a current application. The first application module is configured to mate with the operation module to form a complete circuit breaker and define a replacement breaker frame for having an external modularity for the modular residential circuit breaker.