Sensor Module for Circuit Breakers with Molded Polymer Support
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Solution Overview
Problem
Existing branch circuit monitoring systems face challenges due to the mechanical weakness of current transformer (CT) boards, exposure to high voltages, and numerous soldered connections, which compromise stability and reliability, particularly in high-power applications where thick wires cause bending stress and safety hazards.
Innovation Solution
A sensor module with a molded polymer mounting support and a wiring channel that reduces the number of soldered connections and provides a more rugged packaging, allowing for safe routing of CT output wiring and alignment with circuit breakers, using a sensor support with angled surfaces and posts to insulate CTs from wires, and enabling interchangeable and inverted sensor assemblies to handle current polarity changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If CTs are mounted on a long thin circuit board within the circuit breaker panel, then multiple branches can be monitored from a single location, but the board becomes mechanically weak and compromises system stability
Solution Approach 1:
The patent transitions from a planar circuit board mounting approach to a three-dimensional housing structure with vertical stacking of CTs. The CTs are arranged in multiple levels within the housing, utilizing vertical space rather than extending horizontally, which eliminates the need for a long thin board and provides mechanical support through the housing structure itself.
2Volume of moving object
If high voltage terminations are placed close to exposed current sensor soldered connections, then wiring space is optimized, but dangerous voltages can enter low-voltage control circuit wiring creating safety hazards
Solution Approach 1:
The patent introduces an insulating barrier or shielding structure between the high voltage terminations and the low voltage control circuit wiring. This intermediary element prevents direct electrical contact and protects against voltage breakdown, allowing the high voltage and low voltage circuits to be positioned closer together while maintaining safety.
3Ease of manufacture
If typical CT boards require many extra soldered connections, then CTs can be mounted on standard circuit boards, but reliability is lowered due to lack of mechanical strength and numerous connection points
Solution Approach 1:
The patent combines the CT mounting structure, housing, and support elements into an integrated assembly that does not rely on a separate circuit board. The CTs are mechanically and electrically connected within the housing structure itself, eliminating the need for a fragile circuit board and reducing the number of soldered connections required.
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 enhances the reliability and safety of branch circuit monitoring by reducing mechanical stress, minimizing soldered connections, and maintaining alignment with circuit breakers, while allowing for efficient monitoring and handling of current polarity changes without disrupting power supply.
Implementation Method 1
the post adapted to insulate the current transformer from a wire passing through the post opening
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
The present disclosure provides a method and system for mounting a current transformer in proximity to a circuit breaker of an electrical system. Generally, a plurality of current transformers (CTs) are provided to measure a plurality of branches from a main power supply and are accumulated on a sensor module. In at least one embodiment, the sensor module includes a molded polymer mounting support that can support the CTs. The molded mounting support departs from the standard circuit board and is substantially less fragile. A wiring channel is provided within the sensor module so that CT output wiring can be safely routed to the output connector using as few as two soldered connections, rather than the typical six soldered connections required in existing branch monitoring systems. Multiple sensor modules can be stacked to allow continued alignment with the CTs and software/firmware/hardware can allow for any current polarity changes.