Portable Racking Tool for Circuit Breaker Replacement

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Solution Overview

Problem

Existing methods for maintaining or replacing electrical equipment in facilities like hospitals and hotels require shutting down power, which is costly and risky, as it can lead to arcing and safety hazards, necessitating a tool that allows for safe, single-handed operation without full power shutdowns.

Innovation Solution

A portable racking tool that enables the removal and installation of electrical equipment without shutting down the entire facility, using a motorized system with remote operation to prevent arc flashes, allowing for safe maintenance and operation by untrained personnel.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If power is shut down to replace circuit breakers, then safety from arcing is improved, but facility downtime and operational disruption increase

Engineering Contradiction:

Improvesafety from arcingVSAvoidfacility downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

A portable racking tool serves as an intermediary device that enables circuit breaker replacement without requiring complete power shutdown. The tool allows operators to safely rack and unrack breakers while maintaining power to the facility, thus mediating between the need for safety and the need for continuous operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention enables localized maintenance of individual circuit breakers without affecting the global power supply. By allowing selective replacement of breakers in place, the system maintains power quality and continuity for the facility while enabling local safety improvements during maintenance operations.

Inventive Principle:

Principle #3Local quality

2Productivity

If power remains on during circuit breaker replacement, then facility continuity is improved, but risk of arcing and harm to operators increases

Engineering Contradiction:

Improvefacility continuityVSAvoidarcing hazard to operators

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The portable racking tool acts as a protective intermediary between the operator and the live electrical equipment. It provides a safe interface for interacting with circuit breakers while power remains on, eliminating the need for operators to directly handle potentially hazardous live components.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention replaces manual mechanical handling of live circuit breakers with a motorized racking tool. The motorized mechanism performs the racking operation remotely, substituting direct mechanical interaction with automated controlled operation, thereby reducing operator exposure to arcing hazards.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If manual handling of circuit breakers is used, then equipment replacement is simple, but operators require extensive training and protective gear

Engineering Contradiction:

Improvesimplicity of equipment replacementVSAvoidtraining and protective gear requirements

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The portable racking tool enables untrained personnel to perform circuit breaker replacement without requiring specialized knowledge or protective equipment. The tool is self-contained and guides the operation automatically, allowing anyone to safely replace breakers without extensive training or arc flash protective gear.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The motorized racking tool replaces manual mechanical operations with automated motor-driven mechanisms. This substitution eliminates the need for operators to physically manipulate heavy breakers and complex switching mechanisms, reducing the skill level required and removing the need for specialized protective equipment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If complete power shutdown is implemented for maintenance, then safety of all equipment is improved, but critical facilities like hospitals and hotels suffer operational disruption

Engineering Contradiction:

Improvesafety of electrical equipmentVSAvoidoperational continuity of critical facilities

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention segments the power distribution system into individually replaceable circuit breaker units. This allows maintenance to be performed on one breaker at a time while other breakers remain operational, enabling localized safety improvements without facility-wide power shutdowns that would disrupt critical operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The portable racking tool enables continuous operation of the facility by allowing circuit breaker replacement without interrupting power supply. The tool maintains the useful action of power delivery to critical loads while enabling necessary maintenance activities to proceed concurrently.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS8519660B1Portable racking tool for electric equipment replacement and method for replacing electrical components

Publication Date: 2013.08.27 CBS ARCSAFE INC

AI summary

An electrical device removal tool for electrical equipment, such as circuit breakers, is disclosed herein. The tool can be lightweight, portable, and rugged for providing electrically operated controlled insertion and removal of the electrical equipment by an operator from a remote location using a coupling device engaged with the electrical equipment housing.