Universal Circuit Breaker with Sensor Ports for Hazard Detection
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Solution Overview
Problem
Conventional circuit breakers face challenges in standardized and efficient production, distribution, and installation, often requiring individualized components and sensors, which can lead to increased costs and risks of improper installation, potentially resulting in hazardous situations.
Innovation Solution
A circuit breaker system that incorporates a monitoring circuit with sensor ports for various sensors, including GFCI, AFCI, and DFCI, allowing for standardized manufacturing and easy installation, with automatic detection and comparison of sensor signals to predetermined limits, and automatic reset mechanisms to ensure safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional circuit breakers utilize individualized components and sensors for each breaker type, then the breakers can provide specific protection functions, but the manufacturing complexity and installation difficulty increase
Solution Approach 1:
The patent implements a universal circuit breaker platform with a standardized housing, mounting mechanism, and electronic components that can accommodate multiple sensor types (GFCI, AFCI, thermal, magnetic) through a common architecture. The breaker uses a single electronic control unit that can process signals from various sensors, allowing one base design to serve multiple protection functions without requiring entirely separate manufacturing lines for each breaker type.
Solution Approach 2:
The circuit breaker is divided into modular functional sections: a standardized mechanical housing and mounting mechanism, interchangeable sensor modules, and a common electronic control unit. This segmentation allows manufacturers to produce standardized base units and then configure specific protection functions by adding or configuring appropriate sensor modules, reducing overall manufacturing complexity while maintaining specialized protection capabilities.
2Reliability
If conventional circuit breakers require individualized components for each breaker type, then specific protection functions can be achieved, but distribution and installation efficiency decrease
Solution Approach 1:
The standardized housing and mounting mechanism allow electricians to install all breaker types using the same procedures and tools. The universal electrical connection points and sensor interfaces mean that installation steps remain consistent regardless of the specific protection function being installed, significantly improving installation efficiency while maintaining specialized protection capabilities.
3Productivity
If conventional circuit breakers use standardized components, then manufacturing efficiency improves, but the ability to detect and respond to specific hazardous conditions decreases
Solution Approach 1:
The circuit breaker employs a dynamic sensor selection and configuration system where the electronic control unit can adaptively recognize which sensors are present and configure its operation accordingly. The system can dynamically switch between different protection modes (GFCI, AFCI, thermal, magnetic) based on the configured sensors, allowing a standardized manufacturing platform to deliver customized hazard detection and response capabilities for each specific application.
4Reliability
If conventional circuit breakers require complex individualized designs, then specific protection functions can be provided, but the risk of improper installation increases
Solution Approach 1:
The standardized housing, mounting mechanism, and electrical interfaces create a uniform installation experience across all breaker types. Electricians encounter the same physical and electrical connection procedures regardless of the specific protection function being installed, reducing the likelihood of improper installation while maintaining specialized hazard protection capabilities through the configured sensors and electronic control.
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
Enables efficient production and distribution of circuit breakers with reduced risk of improper installation, providing enhanced safety by automatically detecting and responding to hazardous conditions, such as overloads, ground faults, and arc faults, while allowing for customization and modification post-manufacturing.
Implementation Method 1
The bimetal element is heated by current applied to the load coupled to the circuit breaker
Implementation Method 2
the bimetal element deforms and activates the contact arm operating mechanism
Implementation Method 3
A GFCI measures the current flowing through the hot wire and the neutral wire. If the current differs by more than a few milliamps, the current is assumed to be leaking to ground
Implementation Method 4
The arc-fault detection circuitry detects specific arcs that are determined to be likely to cause a fire. The AFCI uses electronics to recognize the current and voltage characteristics of the arcing faults
Data Source
AI summary
A system, method, and device for a circuit breaker used in residential and commercial panels are disclosed. The exemplary circuit may have an overload protection device causing a disruption in a circuit when the circuit is overloaded. One or more sensors may detect a condition of the circuit and transmit a signal associated the detected condition to an integrated circuit via sensor ports. The integrated circuit may cause a disruption in a circuit when the signal of the detected condition is out of predetermine limit. The integrated circuit may also determine if a sensor is coupled to a sensor port.