Universal Shunt Solenoid Assembly for Multi-Voltage Circuit Breakers
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Solution Overview
Problem
Existing shunt trip assemblies for miniature circuit breakers are not versatile enough to operate effectively under different voltage and temperature conditions, leading to production inefficiencies due to the need for multiple specific designs for various operating conditions.
Innovation Solution
A standardized shunt trip assembly is developed, incorporating a solenoid with a ferromagnetic plunger and lever mechanism that can operate across a range of AC and DC voltage levels (12V, 24V, and 48V) and temperatures (-40°C to +60°C), using a single housing design compatible with both ¾-inch and 1-inch circuit breaker installations, with three solenoid models to ensure consistent force generation for actuating the circuit breaker mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple specific shunt trip assembly designs are produced for different voltage and temperature conditions, then reliability under specific conditions is improved, but device complexity and production inefficiency increase
Solution Approach 1:
The shunt trip assembly is designed with a universal solenoid mechanism that can operate across multiple voltage conditions (12V, 24V, 48V AC/DC) and temperature ranges (-40°C to +60°C) using the same basic assembly design. The solenoid is engineered to generate sufficient magnetic force to actuate the circuit breaker operating mechanism across all specified operating conditions, eliminating the need for multiple specialized designs.
2Productivity
If a standardized shunt trip assembly is used across different voltage levels, then production efficiency is improved, but the ability to generate sufficient actuating force under all conditions may worsen
Solution Approach 1:
The solenoid is designed with specific magnetic circuit parameters and coil characteristics that enable it to generate the required actuating force across a wide range of voltage conditions. The magnetic circuit geometry, material properties, and coil winding parameters are optimized to ensure sufficient magnetic flux density and force generation at 12V, 24V, and 48V AC/DC supply voltages, maintaining reliable operation under all specified conditions.
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 standardized shunt trip assembly ensures reliable and efficient operation across various conditions, reducing production complexities and allowing for the use of off-the-shelf components, while preventing solenoid burnout through self-disconnect design, thus enhancing operational safety and efficiency.
Implementation Method 1
the solenoid is activated when it receives AC or DC Voltage, where the solenoid pulls the plunger further into the housing of the solenoid when activated
Data Source
AI summary
A shunt trip assembly structured to be operatively coupled to a number of circuit breakers uses a lever to actuate an operating mechanism of the circuit breakers and uses a selectively powered solenoid to power the lever. The shunt trip assembly is composed from a standardized shunt assembly designed for use with a plurality of different solenoid coils, such that a given standardized shunt assembly will be operative regardless of which of the solenoid coils are added to the standardized shunt assembly. The shunt trip assembly requires less than 10 amps of current to operate; can be powered by any of a 12 volt AC/DC, 24 volt AC/DC, or 48 volt AC/DC power source; and is functional in temperatures ranging from −40° C. to +60° C.