Plug-on Ground Fault Module for Circuit Interrupters
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Solution Overview
Problem
Conventional circuit breakers with ground fault circuits face challenges such as limited amperage and interrupting levels due to sensitive electronics being close to arcing components and complex wiring arrangements, making assembly difficult and limiting their performance.
Innovation Solution
A plug-on ground fault module for circuit interrupters, which includes a housing with a ground fault circuit and terminals that can be easily coupled without loose wiring, featuring a solenoid assembly for magnetic attraction and printed circuit boards for components, allowing for higher current ratings and improved assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ground fault circuits are integrated inside the circuit breaker housing, then circuit protection function is achieved, but amperage and interrupting levels are limited due to sensitive electronics being close to arcing components
Solution Approach 1:
The invention divides the circuit breaker into separate modules: the ground fault module containing sensitive electronics is separated from the arc chamber. This segmentation allows the electronics to be protected from arcing while maintaining circuit protection functionality, thereby enabling higher amperage and interrupting levels.
Solution Approach 2:
The ground fault circuit is extracted from the traditional housing and placed in a separate plug-on module. This extraction removes the sensitive electronics from the harmful arcing environment, allowing the main circuit breaker to handle higher currents without damaging the electronic components.
2Reliability
If conventional wiring arrangements are used for ground fault circuits, then circuit functionality is achieved, but assembly becomes challenging due to complicated wiring
Solution Approach 1:
The ground fault circuit components are merged onto a single printed circuit board, which is then integrated into the plug-on module. This consolidation eliminates the need for separate wiring connections, significantly simplifying assembly while maintaining full circuit functionality.
Solution Approach 2:
Traditional mechanical wiring connections are replaced with printed circuit board traces and solder joints. This substitution eliminates complex wire routing and manual connections, making the assembly process much simpler and more reliable.
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 enables circuit interrupters with higher current ratings, up to 200 A, and simplifies assembly by eliminating the need for loose wiring, enhancing both performance and ease of use compared to conventional systems.
Implementation Method 1
a solenoid assembly comprising a respective magnetic or magnetized member in the second housing that is sized and configured to be able to magnetically attract the pivotable lever toward the solenoid assembly
Implementation Method 2
Arc chutes can be used to direct an arc away from the electrical contacts into the arc chute
Data Source
AI summary
Plug-on ground fault modules are configured with a housing and at least one ground fault terminal. The at least one ground fault terminal can be a rigid or semi-rigid member that is configured to slidably engage a circuit breaker terminal. The modules also include aground fault circuit coupled to the ground fault terminal and at least one printed circuit board in the housing with components of the ground fault circuit including at least one solenoid assembly coupled thereto with a respective magnetized or magnetic plunger member residing on or adjacent thereto, and at least one current transformer. The modules also include at least one collar assembly residing in the housing spaced apart from the solenoid assembly and plunger member that is arranged to be able to engage a lever in the circuit interrupter to delatch the circuit interrupter.