Circuit Breaker Trip Unit Calibration via Main Reference
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Solution Overview
Problem
Existing circuit breaker trip units at lower levels of the circuit hierarchy suffer from reduced accuracy due to space constraints and high costs of accurate sensors, leading to unreliable current detection with error ranges that change over time.
Innovation Solution
A computer-implemented system that includes a networked computing device communicating with main and circuit breaker trip units to collect and analyze current data, determining calibration factors to correct variance and transmit them to the trip units for continuous calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If accurate sensors are installed at lower levels of the circuit hierarchy, then measurement precision is improved, but device complexity and cost increase due to space constraints and limited availability
Solution Approach 1:
The patent introduces an intermediary calibration system that uses the main trip unit as a reference standard to calibrate lower-level trip units. Instead of installing expensive accurate sensors at every lower level, the system uses the main trip unit's accurate measurements to generate calibration factors that correct the readings from lower-level trip units, thereby achieving accurate current detection without complex sensor installations at each location.
Solution Approach 2:
The patent creates a virtual copy of the accurate measurement capability by using the main trip unit's measurements to generate calibration factors. These calibration factors are then applied to lower-level trip units, effectively copying the accuracy of the main trip unit to the lower levels without physically installing identical high-precision sensors at each location.
2Measurement precision
If accurate sensors are provisioned at lower levels of the circuit hierarchy, then measurement precision is improved, but cost increases due to the expense of high accuracy sensors
Solution Approach 1:
The patent enables the lower-level trip units to self-calibrate using calibration factors generated from the main trip unit's measurements. The system automatically performs calibration without requiring manual intervention or replacement of sensors, thereby maintaining accurate measurements at lower levels without the ongoing cost of high-precision sensors at each location.
Solution Approach 2:
The main trip unit serves multiple functions: it acts as both a monitoring device for the main circuit and as a reference standard for calibrating all lower-level trip units. This multi-functionality allows the system to achieve accurate measurements throughout the entire circuit hierarchy using a single high-precision device rather than requiring multiple expensive accurate sensors.
3Device complexity
If lower level trip units use standard sensors, then device complexity is reduced, but measurement precision deteriorates over time as sensor accuracy changes
Solution Approach 1:
The patent implements a feedback mechanism where the main trip unit's accurate measurements are continuously used to generate calibration factors for lower-level trip units. This feedback loop compensates for drift in the lower-level sensors over time, maintaining measurement precision without requiring complex sensor configurations or frequent manual recalibration.
Solution Approach 2:
The system performs preliminary calibration by using the main trip unit's accurate measurements to establish calibration factors before the lower-level trip units are fully deployed or before measurements are taken. This preliminary calibration action ensures that the lower-level units start with accurate reference values, compensating for potential future drift in sensor accuracy.
4Measurement precision
If calibration is performed manually at lower level trip units, then measurement precision can be improved, but loss of time increases due to the need for physical calibration at each location
Solution Approach 1:
The patent replaces the mechanical process of manual calibration with an automated electronic system. Instead of physically calibrating each lower-level trip unit individually, the system uses the main trip unit's measurements to automatically generate and transmit calibration factors through a communication network, dramatically reducing the time required for calibration while maintaining or improving measurement precision.
Solution Approach 2:
The patent introduces an intermediary automated calibration system that mediates between the main trip unit and lower-level trip units. This intermediary system automatically processes the calibration data and transmits calibration factors to all lower-level units simultaneously, eliminating the need for time-consuming manual calibration at each location while ensuring consistent accuracy across the entire system.
Data Source
AI summary
A computer for continuous calibration of circuit breaker trip units and metering devices includes a processor and a memory device. The computer is configured to request and receive circuit breaker current data from a plurality of circuit breaker trip units. The circuit breaker current data represents current data associated with the circuit breaker trip units over a collection interval. The computer is configured to receive main current data from a main trip unit. The computer is configured to determine a plurality of calibration factors for the circuit breaker trip units based upon the circuit breaker current data and the main current data. The computer is additionally configured to transmit the calibration factors to the circuit breaker trip units.