Circuit Breaker Switch Module Layout for Non-Interruptive Leakage Testing

Solution Overview

Problem

Conventional circuit breakers with leakage protection units cause circuit interruption during testing, affecting power system stability and incurring economic losses.

Innovation Solution

A circuit breaker design with a first and second switch module, where the second switch module is controlled to remain on during testing, ensuring the first switch module can be tested for normal off-state functionality without powering off the entire circuit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the leakage switch immediately trips after pressing the test button, then the protection mechanism is verified, but circuit interruption occurs affecting power system stability

Engineering Contradiction:

Improveprotection mechanism verificationVSAvoidpower system stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The circuit breaker is divided into a first switch module (main circuit breaker) and a second switch module (leakage protection circuit breaker), each with independent driving components. This segmentation allows the leakage protection function to be tested by controlling only the second switch module to trip, while the first switch module remains closed to maintain power supply to the load, thus verifying protection mechanism reliability without compromising overall power system stability.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the leakage switch immediately trips after pressing the test button, then the protection mechanism is verified, but economic losses occur due to circuit interruption

Engineering Contradiction:

Improveprotection mechanism verificationVSAvoideconomic losses

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The circuit breaker is divided into a first switch module (main circuit breaker) and a second switch module (leakage protection circuit breaker), each with independent driving components. This segmentation allows the leakage protection function to be tested by controlling only the second switch module to trip, while the first switch module remains closed to maintain power supply to the load, thus verifying protection mechanism reliability without compromising overall power system stability.

Inventive Principle:

Principle #1Segmentation

3Ease of operation

If a test function is provided in the leakage protection unit, then periodic checking of leakage switch state is enabled, but complete circuit shutdown occurs during testing

Engineering Contradiction:

Improveperiodic checking capabilityVSAvoidcircuit continuity

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The circuit breaker is divided into a first switch module (main circuit breaker) and a second switch module (leakage protection circuit breaker), each with independent driving components. This segmentation allows the leakage protection function to be tested by controlling only the second switch module to trip, while the first switch module remains closed to maintain power supply to the load, thus verifying protection mechanism reliability without compromising overall power system stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The circuit board assembly acts as an intermediary control system that receives signals from the test button assembly and selectively controls the driving components of the first and second switch modules. During testing, the circuit board assembly enables the second switch module to trip while keeping the first switch module closed, allowing test functionality without complete circuit interruption.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20260074135A1Circuit breaker

Publication Date: 2026.03.12 SCHNEIDER ELECTRIC IND SAS

AI summary

Embodiments of the disclosure provide a circuit breaker. Each of a first switch module and a second switch module of the circuit breaker includes a driving component, a plurality of connecting members coupled to the driving component, and a plurality of first contacts and a plurality of second contacts disposed corresponding to the plurality of connecting members. A circuit board assembly is electrically connected to the driving component of the first switch module and the driving component of the second switch module. A test button assembly is disposed on the circuit board assembly.