Proximity Sensor Test Actuation for Electrical Switching Panels

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Solution Overview

Problem

Existing electrical switching apparatus, particularly in aircraft and aerospace applications, face challenges in efficiently actuating a test function due to mechanical stress issues with mechanical pushbutton switches and the difficulty of accessing proximity sensors in densely packed panels, which can lead to unsafe and cumbersome testing procedures.

Innovation Solution

A method and apparatus that utilize a proximity sensor disposed within the housing of the electrical switching apparatus on one side of the panel, allowing a target to be sensed from the opposite side, thereby actuating the test function without the need to open the panel, using a Hall effect sensor or similar technology to simulate an arc fault condition and trip the circuit breaker.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mechanical pushbutton switch is used to actuate the test function, then the test function can be mechanically actuated, but the mechanical mechanism fails due to mechanical stress and may be actuated by mistake

Engineering Contradiction:

Improvetest function actuation reliabilityVSAvoidmechanical stress and accidental actuation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical pushbutton switch with a non-contact sensing system using a proximity sensor (optical, capacitive, or magnetic field-based) that detects the presence of a target object to actuate the test function. This eliminates mechanical wear and accidental actuation while maintaining the ability to trigger the test function reliably.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a target object (such as a magnetic target, optical reflector, or capacitive element) as an intermediary between the user and the test function actuation mechanism. The proximity sensor detects this target to trigger the test function, providing a reliable non-contact interface that avoids direct mechanical contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Difficulty of detecting and measuring

If the proximity sensor is disposed on the rear side of the panel, then the sensor can detect the target, but the panel must be opened to access the sensor for testing

Engineering Contradiction:

Improvesensor accessibilityVSAvoidtesting procedure complexity

Core Design Contradiction:

Difficulty of detecting and measuringVSEase of operation

Solution Approach 1:

The patent inverts the conventional arrangement by placing the proximity sensor on the front side of the panel (the side facing the user) rather than on the rear side. This allows the sensor to detect targets from the front, eliminating the need to open the panel for testing while maintaining effective sensor operation.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the spatial dimension of sensor placement from the rear side (internal dimension) to the front side (external dimension) of the panel. This dimensional repositioning allows the sensor to be accessed and operated from the front, simplifying the testing procedure while maintaining detection capability.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Productivity

If the panel is opened to access the rear terminals for testing, then the arc fault tester can be manually run, but the testing procedure becomes cumbersome and unsafe

Engineering Contradiction:

Improvetesting efficiencyVSAvoidtesting safety and convenience

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent enables the circuit breaker to perform self-testing through the proximity sensor that detects targets from the front side of the panel. This eliminates the need for external arc fault testers and manual panel opening, allowing the device to test itself automatically and safely without requiring technician intervention or panel disassembly.

Inventive Principle:

Principle #25Self-service

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 simplifies the testing process by allowing the test function to be actuated from the front side of the panel, reducing mechanical stress and improving safety by enabling testing without disassembling the panel, thus enhancing the reliability and ease of verifying the circuit breaker's functionality.

Implementation Method 1

A target, such as a magnetic tool or magnetic wand, is inserted within the rear opening to actuate the Hall effect sensor

Methodology Applied

Scientific EffectHall effect: Hall Effect

Data Source

PatentEP2235730B1Method of actuating a test function of an electrical switching apparatus at a panel and electrical switching apparatus employing the same

Publication Date: 2013.05.22 EATON CORP

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AI summary

An electrical switch apparatus (1; 121, 121' ) includes a panel (127) having a first side (129) and an opposite second side (131), a housing (125) coupled to the opposite second side of the panel, separable contacts (17), an operating mechanism structured (19) to open and close the separable contacts, and a trip mechanism (21,27) cooperating with the operating mechanism to trip open the separable contacts. The trip mechanism includes a test circuit (115) structured to simulate a trip condition to trip open the separable contacts, and a proximity sensor (101; 123; 123' ) disposed on or within the housing proximate the opposite second side of the panel. The proximity sensor is structured to sense a target (133) to actuate the test circuit when the target is disposed proximate the first side of the panel and opposite the proximity sensor.