Solid-State Circuit Breaker Module With Dual Power Sensing
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Solution Overview
Problem
Electrical circuit breakers, relays, and contactors face limitations such as large footprint sizes, slow response times, varying reliability, limited detection capabilities for inrush, current, temperature, and phase imbalance, lack of remote monitoring and control, and inadequate diagnostics under line power failure scenarios.
Innovation Solution
Integrated circuit modules with solid-state switching modules, line and switched power sensors, and a power module that controls operating states based on sensor readings, including active cooling and remote monitoring capabilities, to enhance detection and response to electrical conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If electro-mechanical components are used in circuit breakers, relays, and contactors, then the devices can perform basic switching and protection functions, but they suffer from large footprint sizes, slow response times, and limited detection capabilities
Solution Approach 1:
The patent replaces electro-mechanical components with solid-state electronic components. Specifically, it uses microcontrollers, sensors, and electronic switching devices to perform functions previously handled by mechanical relays and breakers. This substitution eliminates moving parts, reducing response time from milliseconds to microseconds while enabling integrated monitoring and control capabilities.
Solution Approach 2:
The patent integrates multiple functions into a single electronic module. The microcontroller unit coordinates current sensing, voltage monitoring, fault detection, switching control, and communication functions within one compact device. This multi-functionality replaces multiple separate electro-mechanical components, reducing both footprint and response time while enhancing detection capabilities.
2Measurement precision
If electro-mechanical components are used, then the devices can provide basic protection, but they have limited detection capabilities for inrush, current, temperature, and phase imbalance
Solution Approach 1:
The patent combines multiple sensing functions into integrated sensor modules. Current sensors, temperature sensors, and phase detection circuits are merged into a unified monitoring system coordinated by the microcontroller. This integration enables simultaneous measurement of multiple parameters (current, voltage, temperature, phase balance) with high precision, while the compact electronic design keeps the overall device complexity manageable.
Solution Approach 2:
The patent implements continuous feedback monitoring through sensors that constantly measure electrical parameters and feed data to the microcontroller. The system monitors current magnitude, rate of change, temperature, and phase relationships in real-time, enabling precise detection of fault conditions such as inrush currents, overloads, thermal issues, and phase imbalances with high measurement precision.
3Extent of automation
If electro-mechanical components are used, then the devices can operate independently, but they lack remote monitoring, control, and warning capabilities
Solution Approach 1:
The patent introduces communication modules as intermediaries between the local electronic components and remote monitoring systems. These modules (such as WiFi, Ethernet, or cellular communicators) enable the microcontroller to transmit operational data, fault alerts, and status information to external devices or cloud platforms, providing remote monitoring and control capabilities while keeping the core protection function independent and reliable.
4Reliability
If electro-mechanical components are used, then the devices can provide basic switching, but they have varying reliability and limited diagnostics under line power failure
Solution Approach 1:
The patent implements beforehand cushioning through backup power sources (such as capacitors or batteries) and fault prediction algorithms. The system monitors component health and power conditions continuously, preparing backup mechanisms in advance. During line power failures, the backup power maintains critical monitoring and control functions, ensuring reliable operation and enabling diagnostics even when main power is unavailable.
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 integrated circuit modules provide improved detection and response to electrical conditions, enabling faster response times, enhanced reliability, and remote monitoring and control, addressing the limitations of existing technologies.
Implementation Method 1
a first solid state switching module (SSWM(1)) configured to receive a first line power having a first phase (LP(1)) from an electrical source, the SSWM(1) configured to switchable control the LP(1), and output a first switched power at the first phase (SP(1))
Implementation Method 2
a first line power sensor (LPS(1)), configured to sense at least one characteristic of the LP(1)
Implementation Method 3
a first switched power sensor (SPS(1)), configured to sense at least one characteristic of the SP(1)
Implementation Method 4
a power module, coupled to each of the SSWM(1), the LPS(1), and the SPS(1), configured to control operating states of the SSWM(1) based upon at least one sensor reading received by the power module from at least one of the LPS(1) and the SPS(1)
Data Source
AI summary
An integrated circuit breaker includes a solid state switching module (SSWM) configured to receive and switchable control a line power (LP) for a given phase, and output a first switched power (SP) to a load. A first sensor (LPS) senses LP currents. A second sensor (SPS) senses SP currents. A power module controls operating states of the SSWM based upon LPS and SPS reading(s). The LPS and/or the SPS may also sense temperatures. The power module includes a high voltage domain, isolated from a low voltage domain, that includes a gate driver coupled to the SSWM and a high voltage controller providing drive signals to the gate driver. The low voltage domain includes an LP monitor and an SP monitor that detects anomalous LP and/or SP conditions and communicates error signals to the high voltage domain and to users for reporting, diagnostic, and/or other purposes via an external communications module.