Programmable Electronic Circuit Breaker for Startup Current Ramping
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Solution Overview
Problem
Current electronic circuit breakers for high-voltage power distribution lack robust self-protection during startup and overloads, poor ride-through performance, increased component stress, limited support for various switching devices and configurations, and inadequate diagnostic features for maintenance and troubleshooting.
Innovation Solution
A programmable electronic circuit breaker (ECB) system using a microcontroller to control startup current, optimize current ramps, and implement multiple energy thresholds, along with diagnostic tools for improved self-protection and flexibility across different loads and voltages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional ECB is used for high-voltage power distribution, then basic on/off control and fault isolation are provided, but self-protection during startup and overloads is insufficient
Solution Approach 1:
The patent implements preliminary action by performing Low Energy Limit (LEL) calculations during startup before full power operation. The microcontroller incrementally increases voltage to a startup current limit value and performs interrupt-triggered LEL calculations based on current and voltage readings. This preliminary energy assessment during startup prevents overload conditions before they can cause damage, enhancing self-protection capability while maintaining manageable circuit complexity through software-based control.
2Reliability
If traditional ECB is used, then simple overload protection is provided, but ride-through performance during transient overloads is poor
Solution Approach 1:
The patent implements feedback mechanisms through continuous monitoring of current and voltage readings during operation. The microcontroller performs interrupt-triggered LEL calculations and HEL (High Energy Limit) calculations based on real-time measurements. When current exceeds thresholds, the system provides feedback by initiating shutoff routines only when energy limits are exceeded, allowing transient overloads to ride through while preventing sustained damage. This feedback-based approach improves ride-through performance without excessive shutdowns.
3Reliability
If traditional ECB is used, then basic current limiting is provided, but component stress during startup and fault conditions is increased
Solution Approach 1:
The patent applies parameter changes by implementing multiple energy thresholds (LEL and HEL) that dynamically adjust protection levels based on operating conditions. During startup, the system uses lower LEL thresholds to protect components during vulnerable startup phases. During normal operation, higher HEL thresholds allow for transient overloads. The microcontroller continuously monitors current and voltage parameters and adjusts protection responses accordingly, reducing component stress while maintaining reliability through adaptive threshold-based protection.
4Ease of repair
If traditional ECB is used, then standard protection functions are provided, but diagnostic features for maintenance are inadequate
Solution Approach 1:
The patent introduces an intermediary diagnostic system where the microcontroller acts as a mediator between the ECB circuitry and external monitoring systems. The microcontroller performs LEL and HEL calculations, monitors current and voltage readings, and can report diagnostic information to a host PC through wired or wireless connections. This intermediary layer provides comprehensive diagnostic capabilities including energy limit monitoring, overload detection, and operational status reporting without significantly increasing the complexity of the core ECB protection functions.
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
Enhances self-protection during startup and overloads, improves ride-through performance, reduces component stress, supports various switching devices, and provides better diagnostic tools for user-friendly maintenance.
Implementation Method 1
incrementally increase voltage to a startup current limit value that causes a metal-oxide-semiconductor field-effect transistor (MOSFET) to operate in a linear mode that is not fully enhanced
Implementation Method 2
a programmable circuit breaker for high voltage distribution relating to the MOSFET
Data Source
AI summary
An approach for controlling power distribution with respect to an ECB (electronic circuit breaker) is disclosed. The approach employs a microcontroller inside the ECB to directly control startup current, which facilitates optimization of startup and shutoff current ramp for specific switch and load types as well as mitigate the damaging negative voltages due to inductive “kick” at shutoff. Also, because of concurrent energy monitoring optimized for the MOSFET operating mode during startup, a pre-charge circuit is no longer needed. Furthermore, multiple overcurrent thresholds and energy limits allow for optimization of self-protection and system robustness. Downloadable thresholds provide flexibility to support variations in system configurations and ECB componentry.