PCB Coil Arc Fault Detection in Compact Circuit Interrupters
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Solution Overview
Problem
Circuit interrupters such as GFCIs and AFCIs face space constraints when integrated into electrical receptacles, requiring innovative designs to efficiently accommodate their components while maintaining functionality.
Innovation Solution
The use of printed circuit board coils and a microcontroller-based control system with integrated ground fault and arc fault detection units, which include coils configured to sense current and analyze signals for fault conditions, allowing for compact integration within the receptacle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional wire-wound coils are used in circuit interrupters, then the coils can effectively sense current and detect faults, but the device occupies excessive space within the electrical receptacle
Solution Approach 1:
The patent replaces traditional wire-wound coils with printed circuit board (PCB) coils, substituting a mechanical wire-winding process with a printed circuit fabrication process. This substitution dramatically reduces the space required for the sensing coils while maintaining their electrical functionality for current sensing and fault detection
Solution Approach 2:
The patent changes the physical form and geometric parameters of the coils from three-dimensional wire-wound structures to planar PCB traces. This parameter change allows the coils to be integrated directly into the circuit board layout, minimizing the overall device footprint while preserving the magnetic field sensing capability
2Reliability
If multiple fault detection functions (GFCI and AFCI) are integrated into a single receptacle, then user safety is enhanced, but the device complexity increases
Solution Approach 1:
The patent combines ground fault detection (GFCI) and arc fault detection (AFCI) functions into a single integrated control system. The microcontroller unit consolidates multiple detection algorithms and control logic into one processor, enabling dual functionality without proportionally increasing overall device complexity
Solution Approach 2:
The patent implements a universal control system that performs multiple safety functions. The same microcontroller and sensor infrastructure are used for both ground fault detection and arc fault detection, allowing the device to provide comprehensive safety protection while avoiding the need for separate dedicated hardware for each function
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
This solution enables effective detection and interruption of faults while minimizing the device's footprint, enhancing safety and usability within the limited space of electrical receptacles.
Implementation Method 1
coils configured to sense current and analyze signals for fault conditions
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A circuit interrupter including a line conductor, a neutral conductor, a printed-circuit board coil, and a test circuit. The printed-circuit board coil has an aperture configured to receive the line conductor. The test circuit is electrically connected to the printed-circuit board coil. The test circuit is configured to determine an arc fault condition based on a signal of the printed-circuit board coil.