1. Field
The present disclosure relates to circuit interrupting devices. In particular, the present disclosure is directed to re-settable circuit interrupting devices and systems that comprises ground fault circuit interrupting devices (GFCI devices), arc fault circuit interrupting devices (AFCI devices), immersion detection circuit interrupting devices (IDCI devices), appliance leakage circuit interrupting devices (ALCI devices), equipment leakage circuit interrupting devices (ELCI devices), circuit breakers, contactors, latching relays and solenoid mechanisms. More particularly, the present disclosure is directed to circuit interrupting devices that include a circuit interrupter that can break electrically conductive paths between a line side and a load side of the devices.
2. Description of the Related Art
Many electrical wiring devices have a line side, which is connectable to an electrical power supply, and a load side, which is connectable to one or more loads and at least one conductive path between the line and load sides. Electrical connections to wires supplying electrical power or wires conducting electricity to the one or more loads are at line side and load side connections. The electrical wiring device industry has witnessed an increasing call for circuit breaking devices or systems which are designed to interrupt power to various loads, such as household appliances, consumer electrical products and branch circuits. In particular, electrical codes require electrical circuits in home bathrooms and kitchens to be equipped with circuit interrupting devices, such as ground fault circuit interrupting devices (GFCI), for example.
In particular, GFCI devices protect electrical circuits from deleterious effects that may occur when electrical current being supplied to an operating electrical appliance, light fixture, power tool or other similar electrical device is being short to ground. When the short to ground occurs through a human being, electrocution occurs. To prevent continued operation of the particular electrical device under such conditions, a GFCI device monitors the difference in current flowing into and out of the electrical device. A load-side terminal connects to the hot wire and provides electricity to the electrical device.
A differential transformer may measure the difference in the amount of current flow through the hot and neutral wires. Via a current signal analyzer, when the difference in current exceeds a predetermined level, e.g., 5 milliamps, indicating that a ground fault may be occurring, the GFCI device interrupts or terminates the current flow within a particular time period, e.g., 25 milliseconds or greater. The current may be interrupted via a solenoid coil that mechanically opens switch contacts to shut down the flow of electricity. A GFCI device includes a reset button that allows a user to reset or close the switch contacts to resume current flow to the electrical device. A GFCI device may also include a user-activated test button that allows the user to activate or trip the solenoid to open the switch contacts to verify proper operation of the GFCI device.
A more detailed description of a GFCI device is provided in U.S. Pat. No. 4,595,894, which is incorporated herein in its entirety by reference. Presently available GFCI devices, such as the device described in commonly owned U.S. Pat. No. 4,595,894 (the '894 patent), use an electrically activated trip mechanism to mechanically break an electrical connection between the line side and the load side. Such devices are resettable after they are tripped by, for example, the detection of a ground fault. In the device discussed in the '894 patent, the trip mechanism used to cause the mechanical breaking of the circuit (i.e., the conductive path between the line and load sides) includes a solenoid (or trip coil). A test button is used to test the trip mechanism and circuitry used to sense faults, and a reset button is used to reset the electrical connection between line and load sides.
In addition, intelligent ground fault circuit interrupting (IGFCI) devices are known in the art that can automatically test internal circuitry on a periodic basis, thereby boosting probability of proper operation in the event of a real ground fault. Such GFCI devices can perform self-testing on a monthly, weekly, daily or even hourly basis. In particular, all key components can be tested except for the relay contacts. This is because tripping the contacts for testing has the undesirable result of removing power to the user's circuit. However, once a month, for example, such GFCI devices can generate a visual and/or audible signal or alarm reminding the user to manually test the GFCI device. The user, in response to the signal, initiates a test by pushing a test button, thereby testing the operation of the contacts in addition to the rest of the GFCI circuitry. Following a successful test, the user can reset the GFCI device by pushing a reset button.
Examples of such intelligent ground fault circuit interrupter devices can be found in U.S. Pat. No. 5,600,524, U.S. Pat. No. 5,715,125, and U.S. Pat. No. 6,111,733 each by Nieger et al. and each entitled “INTELLIGENT GROUND FAULT CIRCUIT INTERRUPTER,” and each of which is incorporated herein by reference in its entirety. Additionally, another example of an intelligent ground fault current interrupter device can be found in U.S. Pat. No. 6,052,265 by Zaretsky et al., entitled “INTELLIGENT GROUND FAULT CIRCUIT INTERRUPTER EMPLOYING MISWIRING DETECTION AND USER TESTING,” which is incorporated herein by reference in its entirety.
The present disclosure is directed to detecting and sensing solenoid plunger movement in a current interrupting device. In particular, the present disclosure relates to a circuit interrupting device configured to cause electrical discontinuity along a conductive path upon the occurrence of a predetermined condition, that includes a fault sensing circuit configured to detect the predetermined condition and to generate a circuit interrupting actuation signal, and a coil and plunger assembly, having at least one coil and a plunger actuatable by the circuit interrupting actuation signal. The plunger is configured and disposed within the circuit interrupting device so that upon detection of the occurrence of the predetermined condition the plunger will move in a fault direction from a non-actuated configuration to an actuated configuration a distance sufficient to cause disengagement of at least one set of contacts from each other and thereby cause electrical discontinuity along the conductive path. The circuit interrupting device also includes a test assembly that is configured to cause the plunger to move in a test direction, from a pre-test configuration to a post-test configuration, a distance insufficient to disengage the at least one set of contacts from each other.
The present disclosure relates also to a method of testing a circuit interrupting device that includes the steps of: generating an actuation signal; causing a plunger to move in response to the actuation signal, without causing the circuit interrupting device to trip; measuring the movement of the plunger; and determining whether the movement reflects an operable circuit interrupting device.
The present disclosure relates to a current interrupting device configured to perform an automatic self-test sequence on a periodic basis (e.g.,—every few cycles of alternating current (AC), hourly, daily, weekly, monthly, or other suitable time period) without the need for user intervention and, in addition, wherein the current interrupting device includes members configured to enable the self-test sequence or procedure to test the operability and functionality of the device's components up to and including the movement of the solenoid plunger.
The description herein is described with reference to a ground fault circuit interrupting (GFCI) device for exemplary purposes. However, aspects of the present disclosure are applicable to other types of circuit interrupting devices, such as arc fault circuit interrupting devices (AFCI devices), immersion detection circuit interrupting devices (IDCI devices), appliance leakage circuit interrupting devices (ALCI devices), equipment leakage circuit interrupting devices (ELCI devices), circuit breakers, contactors, latching relays and solenoid mechanisms.
As defined herein, the terms forward, front, etc. refers to the direction in which the standard plunger moves in order to trip the GFCI. Terms such as front, forward, rear, back, backward, top, bottom, side, lateral, transverse, upper, lower and similar terms are used solely for convenience of description and the embodiments of the present disclosure are not limited thereto.
Turning now to
A detailed description of such a circuit interrupting device can be found in U.S. Patent Application Publication US 2004/0223272 A1, by Germain et al, entitled “CIRCUIT INTERRUPTING DEVICE AND SYSTEM UTILIZING BRIDGE CONTACT MECHANISM AND RESET LOCKOUT,” the entire contents of which are incorporated herein by reference.
A test button 22 extends through opening 23 in the face portion 36 of the housing 12. The test button 22 is used when it is desired to manually set the device 10 to a trip condition. The circuit interrupter, to be described in more detail below, breaks electrical continuity in one or more conductive paths between the line and load side of the device. The one or more conductive paths form a power circuit in the GFCI 10. A reset button 20 forming a part of the reset portion extends through opening 19 in the face portion 36 of the housing 12. The reset button 20 is used to activate a reset operation, which reestablishes electrical continuity through the conductive paths.
Still referring to
Referring to
Frame 48 is made from an electricity conducting material from which the receptacles aligned with openings 16 and 24 are formed. The receptacle aligned with opening 24 of face portion 36 is constructed from extensions 50B and 52B of frame 48. Also, frame 48 has a flange the end of which has electricity conducting contact 56 attached thereto. Frame 46 is made from an electricity conducting material from which receptacles aligned with openings 18 and 26 are formed.
The receptacle aligned with opening 18 of frame portion 36 is constructed with frame extensions 42A and 44A. The receptacle aligned with opening 26 of face portion 36 is constructed with extensions 42B and 44B. Frame 46 has a flange the end of which has electricity conducting contact 60 attached thereto. Therefore, frames 46 and 48 form the face terminals implemented as receptacles aligned to openings 16, 18, 24 and 26 of face portion 36 of GFCI 10 (see
Referring now to
Similarly, movable bridge 64 has bent portion 64B and connecting portion 64A. Bent portion 64B is electrically connected to the other line terminal (not shown); the other line terminal being located on the side opposite that of line terminal 34. Connecting portion 66A of movable bridge 66 has two fingers each having a bridge contact (68, 70) attached to its end. Connecting portion 64A of movable bridge 64 also has two fingers each of which has a bridge contact (72, 74) attached to its end. The bridge contacts (68, 70, 72 and 74) are made from relatively highly conductive material. Also, face terminal contacts 56 and 60 are made from relatively highly conductive material. Further, the load terminal contacts 58 and 62 are made from relatively highly conductive material. The movable bridges 64, 66 are preferably made from flexible metal that can be bent when subjected to mechanical forces.
The connecting portions (64A, 66A) of the movable bridges 64, 66, respectively, are mechanically biased downward or in the general direction shown by arrow 67. When the GFCI device 10 is reset, the connecting portions of the movable bridges are caused to move in the direction shown by arrow 65 and engage the load and face terminals thus connecting the line, load and face terminals to each other.
In particular connecting portion 66A of movable bridge 66 is bent upward (direction shown by arrow 65) to allow contacts 68 and 70 to engage contacts 56 of frame 48 and contact 58 of load terminal 32 respectively. Similarly, connecting portion 64A of movable bridge 64 is bent upward (direction shown by arrow 65) to allow contacts 72 and 74 to engage contact 62 of load terminal 54 and contact 60 of frame 46 respectively.
The connecting portions of the movable bridges are bent upwards by a latch/lifter assembly positioned underneath the connecting portions where this assembly moves in an upward direction (direction shown by arrow 65) when the GFCI device is reset. It should be noted that the contacts of a movable bridge engaging a contact of a load or face terminals occurs when electric current flows between the contacts; this is done by having the contacts touch each other. Some of the components that cause the connecting portions of the movable bridges to move upward are shown in
Referring again also to
One end 80a of plunger 80 is shown extending outside of the bobbin cavity 50. The other end of plunger 80 (not shown) is coupled to or engages a spring that provides the proper force for pushing a portion of the plunger 80 outside of the bobbin cavity 50 after the plunger 80 has been pulled into the cavity 50 due to a resulting magnetic force when the coil is energized. Electrical wire (not shown) is wound around bobbin 82 to form a coil of the combination solenoid coil and plunger assembly 8. Although for clarity of illustration the coil wire wound around bobbin 82 is not shown in
Accordingly, the fault circuit interrupting coil and plunger assembly 8 (hereinafter referred to as coil and plunger assembly 8 or combination coil and plunger assembly 8) has at least one coil 82 and is actuatable by the circuit interrupter actuation signal generated by the fault sensing circuit and is configured to cause electrical discontinuity of power supplied to a load (not shown) by the GFCI device 10 via actuation by the fault sensing circuit upon detection of the occurrence of the predetermined condition.
A lifter 78 and latch 84 assembly is shown where the lifter 78 is positioned underneath the movable bridges. The movable bridges 66 and 64 are secured with mounting brackets 86 (only one is shown) which is also used to secure line terminal 34 and the other line terminal (not shown) to the GFCI device 10. It is understood that the other mounting bracket 86 used to secure movable bridge 64 is positioned directly opposite the shown mounting bracket. The reset button 20 has a reset pin 76 which engages lifter 78 and latch 84 assembly.
Thus, referring again to
Referring also to
As explained in more detail below with respect to
As defined herein, insufficient movement includes either no detectable movement of the plunger or movement of the plunger that is not sufficient to disengage the at least a set of contacts during a required real transfer of the circuit interrupting device from the non-actuated configuration to the actuated configuration, the actuated configuration resulting in a trip of the GFCI device 10.
Unless otherwise noted, the non-actuated configuration and the pre-test configuration of the GFCI device 10 are equivalent. However, since the actuated configuration of the GFCI device 10 occurs following a real transfer of the GFCI device 10 from the non-actuated configuration, during which time power is supplied to the load side connections through a conductive path in the GFCI device 10, to the actuated configuration, and thus involves causing the plunger 80 to move a distance sufficient to disengage the at least one set of contacts, e.g., contacts 72 and 74, and 68 and 70, the actuated configuration differs from the post-test configuration.
The post-test configuration as defined herein is not a static configuration of the GFCI device 10 but is a transitory state that occurs over a period of time beginning with the initiation of the test actuation signal and ending with the resultant final plunger movement, or lack thereof depending on the results of the test.
To support the detecting and sensing members of the test assembly 100 of the present disclosure, GFCI device 10 also includes a rear support member 102 that is positioned or disposed on the printed circuit board 38 and with respect to the cavity 50 so that one surface 102′ of the rear support member 102 may be in interfacing relationship with the first end 80a of the plunger 80 and may be substantially perpendicular or orthogonal to the movement of the plunger 80 as indicated by arrow 81.
Additionally, first and second lateral support members 104a and 104b, respectively, are positioned or disposed on the printed circuit board 38 and with respect to the cavity 50 so that one surface 104a′ and 104b′ of first and second lateral support members 104a and 104b, respectively, may be substantially parallel to the movement of the plunger 80 as indicated by arrow 81 and is in interfacing relationship with the plunger 80. Thus, the rear support member 102 and the first and second lateral support members 104a and 104b, respectively, partially form a box-like configuration partially around the plunger 80. The rear support member 102 and the first and second lateral support members 104a and 104b, respectively, may be unitarily formed together or be separately disposed or positioned on the circuit board 38. The printed circuit board 38 thus serves as a rear or bottom support member for the combination solenoid coil and plunger that includes the coil or bobbin 82 and the plunger 80.
In conjunction with
In an alternate embodiment, at least one sensor 1000′ of the test assembly 100 is disposed at a position with respect to the plunger 80 such that when the circuit interrupter 10′ transfers from the pre-test configuration 1001a (see
In an alternate embodiment, referring to
As discussed in more detail below, the one or more sensors 1000 or 1000′ may include at least one electrical element.
A voltmeter 112 is electrically coupled to the piezoelectric sensor 110 via first and second connectors/connector terminals 112a and 112b, respectively. The test assembly 100a of the GFCI device 10a further includes a test initiation circuit and a test sensing circuit, which are illustrated schematically as a combined self-test initiation and sensing circuit 114, although the test initiation features and the sensing features can be implemented by a separate test initiation circuit and a separate test sensing circuit. The voltmeter 112 is also electrically coupled to the sensing features of the circuit 114.
Due to the physical characteristics of piezoelectric members such as the piezoelectric member 110, a voltage is only output from the piezoelectric member 110 when it is dynamically contacted by a separate object, e.g., plunger 80, traveling with a velocity sufficient to cause an impact force or pressure to produce a measurable voltage output that is indicative of prior movement of the plunger 80 away from, and re-contact of the plunger 80 with, the piezoelectric member 110.
Thus, the GFCI device 10a has a three-phase post-test configuration. In the first phase of the post-test configuration, the GFCI device 10a assumes the post-test configuration 1002b illustrated in
In the third phase of the post-test configuration, the GFCI device 10a moves in the test direction 83 to assume the post-test configuration 1001b illustrated in
As defined herein, the plunger 80 dynamically contacting the piezoelectric member 110 refers to the plunger 80, or other object, impacting the piezoelectric member 110 with a force sufficient to produce a measurable or detectable voltage output from the piezoelectric member 110, as opposed to substantially stationary contact wherein the plunger 80, or other object, does not produce a measurable or detectable voltage output.
In the event of an at least initially successful test of the combination solenoid coil and plunger assembly 8, the test initiation feature of the circuit 114 causes at least partial movement of the plunger 80 in the test direction 83′ that is in the same direction as the forward or fault direction as indicated by arrow 81 so as to sever contact between the first end 80a of the plunger 80 and the surface 110′ of the piezoelectric sensor 110, thereby maintaining the voltage sensed by the voltmeter 112 at essentially substantially zero. Alternatively, in the event of an initially unsuccessful test of the combination solenoid coil and plunger assembly 8, the test initiation feature of the circuit 114 still attempts to cause at least partial movement of the plunger 80 in the forward or fault direction as indicated by arrow 81 by producing a magnetic field due to electrical current flow through the coil (not shown) around bobbin 82 so as to sever contact between the first end 80a of the plunger 80 and the surface 110′ of the piezoelectric member 110, thereby also maintaining the voltage sensed by the voltmeter 112 at essentially or substantially zero, although no movement of the plunger 80 in the forward direction as indicated by arrow 81 may have occurred.
In the event of an at least initially successful test, when the test initiation feature of the circuit 114 stops influencing or causing movement of the plunger 80, a compression spring (not shown) is housed and disposed in the bobbin 82 such that a compression force caused by the compression spring acts against the plunger 80. The force of the spring is biased against the surface 110′ of the piezoelectric sensor 110 when the coil of the bobbin 82 is not energized. The plunger 80 assumes the third phase 1001b of the post-test configuration (see
In the event of a completely successful test, the detectable voltage sensed or detected by the sensing feature of the test initiation and sensing circuit 114 via the voltmeter 112 is of a magnitude V1 or greater that is pre-determined to be indicative of movement of plunger 80 during the test that is a pre-cursor to adequate or sufficient movement of the plunger 80 during a required real actuation of the GFCI device 10, i.e., a required real transfer of the GFCI device 10 from the non-actuated configuration to the actuated configuration as described above with respect to
In the event of an initially unsuccessful test of the combination solenoid coil and plunger assembly 8, the test initiation feature of the circuit 114, despite attempting to produce a magnetic field due to electrical current flow through the coil (not shown) around bobbin 82, causes no or insufficient movement of the plunger 80 so that no voltage is detected by the voltmeter 112 or a voltage is detected by the voltmeter 112 having a magnitude that is less than or equal to the magnitude V1′ that is pre-determined to be indicative of movement of plunger 80 during the test that is a pre-cursor to inadequate or insufficient movement of the plunger 80 during a required real actuation of the GFCI device 10 as previously described.
In one embodiment, the sensing feature of the circuit 114 is electrically coupled to a microprocessor (not shown) residing on the printed circuit board 38 that annunciates, or trips the GFCI device 10a, in the event of failure of the self-test.
Thus, GFCI device 10a is an example of a GFCI device according to the present disclosure wherein the plunger is configured to move in a first direction, e.g., as indicated by arrow 81, to cause electrical discontinuity in power output to a load upon actuation by the fault sensing circuit (residing in the printed circuit board 38) and that further includes at least one sensor configured and disposed wherein the plunger 80 is in contact with the one or more sensors when the circuit interrupter 10′ is in a pre-test configuration, and wherein the plunger 80 is not in contact with the one or more sensors when the circuit interrupter 10′ is in a post-test configuration.
Those skilled in the art will recognize that the GFCI device 10a may be configured wherein when the circuit interrupter 10′ is in a pre-test configuration, the plunger 80 may not be in contact with the piezoelectric member 110 but again dynamically contacts the piezoelectric surface 110′ to produce a voltage upon returning from a post-test configuration, or upon being transferred from a pre-test configuration. The location of the piezoelectric member(s) 110 may be adjusted accordingly.
Additionally, those skilled in the art will recognize that GFCI device 10a is configured to perform an automatic self-test sequence on a periodic basis (e.g.,—every few cycles of alternating current (AC), hourly, daily, weekly, monthly, or other suitable time period) without the need for user intervention and, in addition, GFCI device 10a includes members, e.g., the test initiation and sensing circuit 114 and the test assembly 100a, that are configured to enable the self-test sequence or procedure to test the operability and functionality of the device's components up to and including the movement of the solenoid plunger 80.
Those skilled in the art will recognize that the self-test initiation to conduct the periodic self-test sequence may be implemented by a simple resistance-capacitance (RC) timer circuit, a timer chip such as a 555 timer, a microcontroller, another integrated circuit (IC) chip, or other suitable circuit. In addition, a manual operation by the user may trigger the self test sequence.
Thus, the circuit interrupter 10′ includes a fault sensing circuit (not shown but may be integrated within and reside within the printed circuit board 38) that is configured to detect the predetermined condition and to generate a circuit interrupting actuation signal, and actuate the fault circuit interrupting coil and plunger assembly 8. The coil and plunger assembly 8 has at least one coil 82 and is actuatable by the circuit interrupting actuation signal generated by the fault sensing circuit and is configured and disposed wherein movement of the plunger 80 causes the electrical discontinuity by disengagement of at least one set of the sets of contacts, e.g., 72 and 74 or 68 and 70, and thereby cause electrical discontinuity along a conductive path upon detection of the occurrence of the predetermined condition.
The GFCI device 10 also includes the test assembly 100 that is configured to enable periodically an at least partial operability self test of the circuit interrupter, without user intervention, via self testing at least partially operability of coil and plunger assembly 8 and/or of the fault sensing circuit.
As will be appreciated and understood by those skilled in the art, the foregoing description of the circuit interrupter 10′ is applicable to the remaining embodiments of the GFCI device 10 as described with respect to, and illustrated in,
Alternatively, as described below in
Accordingly,
More particularly, GFCI device 10b is essentially identical to GFCI device 10a except that the piezoelectric member 110 of test assembly 100a is replaced by a resistive member, e.g., resistive pad or sensor 120 of test assembly 100b, voltmeter 112 and connector/connector terminals 112a and 112b of test assembly 100a are replaced by ohmmeter 122 and connector/connector terminals 122a and 122b, respectively, of test assembly 100b and test initiation and test sensing circuit 114 of test assembly 100a is replaced by test initiation and test sensing circuit 124 of test assembly 100b. Thus, the first end 80a of the plunger 80 is now in contact with surface 120′ of resistive member 120 when the combination solenoid coil and plunger assembly 8 is in the pre-test configuration 1002a so that the plunger 80 is disposed on the printed circuit board 38 and with respect to the resistive member 120 so that the first end 80a of the plunger 80 is in contact with the surface 120′ to cause a sensible or measurable first impedance value or load represented by first resistance value R1 characteristic of the resistive member 120 when the GFCI device 10b is in pre-test configuration 1002a. In a similar manner, the resistance meter 122 is electrically coupled to the resistive member or sensor 120 via first and second connectors/connector terminals 122a and 122b, respectively.
The test assembly 100b of GFCI device 10b again further includes a test initiation circuit and a test sensing circuit, which are illustrated schematically as a combined self-test initiation and test sensing circuit 124, although the test initiation features and the sensing features again can be implemented by separate test initiation and test sensing circuits as explained above. The resistance meter 122 is also electrically coupled to the sensing features of the circuit 124.
In a similar manner as before, the GFCI device 10b assumes the post-test configuration 1002b as illustrated in
When the plunger 80 returns to the pre-test configuration 1002a following the post-test configuration 1002b, the plunger 80, and particularly the first end 80a, contacts the resistive member 120, and particularly the surface 120′, to again produce a resistance output from the resistive member 120 that is substantially equal to the first resistance value R1 prior to the test. The connectors/connector terminals 122a and 122b connected to the resistance member 120 enable measurement by the resistance meter 122 of the resistance output produced by the resistance member 120.
Those skilled in the art will recognize that the GFCI device 10b may also be configured with the test assembly 100 illustrated in
In a similar manner as described above, those skilled in the art will recognize that GFCI device 10b is configured to perform an automatic self-test sequence on a periodic basis (e.g.,—every few cycles of alternating current (AC), hourly, daily, weekly, monthly, or other suitable time period) without the need for user intervention and, in addition, GFCI device 10b includes members, e.g., the test initiation and sensing circuit 124 and the test assembly 100b, that are configured to enable the self-test sequence or procedure to test the operability and functionality of the device's components up to and including the movement of the solenoid plunger 80.
Those skilled in the art will recognize that the self-test initiation to conduct the periodic self-test sequence may be implemented by a simple resistance-capacitance (RC) timer circuit, a timer chip such as a 555 timer, a microcontroller, another integrated circuit (IC) chip, or other suitable circuit. In addition, a manual operation by the user may trigger the self test sequence.
In a similar manner,
More particularly, GFCI device 10c is again essentially identical to GFCI device 10b except that the resistive pad or indicator 120 of test assembly 100b is replaced by capacitive pad or indicator 130 of test assembly 100c, resistance meter 122 and connector/connector terminals 122a and 122b of test assembly 100b are replaced by capacitance meter 132 and connector/connector terminals 132a and 132b, respectively, of test assembly 100c and test initiation and test sensing circuit 124 of test assembly 100b is replaced by test initiation and test sensing circuit 134 of test assembly 100c. The capacitive pad or indicator or transducer, referred to as a capacitive member 130 has an initial charge providing an impedance value or load or a capacitance value or load C. Thus, the first end 80a of the plunger 80 is now in contact with surface 130′ of capacitance member 130 when the combination solenoid coil and plunger assembly 8 is in the pre-test configuration 1002a so that the plunger 80 is disposed on the printed circuit board 38 with respect to the capacitive member 130 so that the first end 80a of the plunger 80 is in contact with the surface 130′ to cause a sensible or measurable first impedance or capacitance value C1 (different from C) characteristic of the capacitive member 130 when the GFCI device 10c is in the pre-test configuration 1002a. In a similar manner, the capacitance meter 132 is electrically coupled to the capacitive member 130 via first and second connectors/connector terminals 132a and 132b, respectively.
The test assembly 100c of GFCI device 10c again further includes a test initiation circuit and a test sensing circuit, which are illustrated schematically as a combined self-test initiation and test sensing circuit 134, although the test initiation features and the sensing features again can be implemented by separate circuits as previously described above. The capacitance meter 132 is also electrically coupled to the sensing features of the circuit 134.
In a similar manner as before, the GFCI device 10 assumes the post-test configuration 1002b as illustrated in
When the plunger 80 returns to the pre-test configuration 1002a following the post-test configuration 1002b, the plunger 80, and particularly the first end 80a, contacts the capacitive member 130, and particularly the surface 130′, to again produce a capacitance output from the capacitive member 130 that is substantially equal to the first capacitance value prior to the test. The connectors/connector terminals 132a and 132b connected to the capacitance member 130 enable measurement by the capacitance meter 132 of the capacitance output produced by the capacitance member 130.
Those skilled in the art will recognize that the GFCI device 10c may also be configured with the test assembly 100 illustrated in
In a similar manner as described above, those skilled in the art will recognize that GFCI device 10c is configured to perform an automatic self-test sequence on a periodic basis (e.g.,—every few cycles of alternating current (AC), hourly, daily, weekly, monthly, or other suitable time period) without the need for user intervention and, in addition, GFCI device 10c includes members, e.g., the test initiation and sensing circuit 134 and the test assembly 100c, that are configured to enable the self-test sequence or procedure to test the operability and functionality of the device's components up to and including the movement of the solenoid plunger 80.
Those skilled in the art will recognize that the self-test initiation to conduct the periodic self-test sequence may be implemented by a simple resistance-capacitance (RC) timer circuit, a timer chip such as a 555 timer, a microcontroller, another integrated circuit (IC) chip, or other suitable circuit. In addition, a manual operation by the user may trigger the self test sequence.
In a still similar manner,
In addition, test assembly 100d includes a current source 142′ such as a battery or power supply that is disposed with respect to a circuit 140 formed by the first and second electrically conductive tape strips 140a and 140b, respectively, the current meter 142 and the connector/connector terminals 142a and 142b to enable an electrically conductive path therein. In place of a battery or similar power supply, current may be supplied to the circuit 140, in the same manner as with respect to the fault or failure sensing circuit described above, the current for the electrically conductive tape strips 142a and 142b may be supplied by a circuit that is electrically coupled to the printed circuit board 38 and the connection points of the tape can be positioned anywhere on the printed circuit board. The first and second electrically conductive members 140a and 140b, respectively, are disposed on the surface 102′ of the rear support member 102 to be electrically isolated from one another and with respect to the solenoid coil and plunger 80 such that when the plunger 80 is in pre-test configuration 1002a, the first end 80a of the plunger 80 makes electrical contact with both the first and second conductive members 140a and 140b, respectively, to form a continuous electrical circuit or conductive path.
In a similar manner as the previous embodiments, the test assembly 100d of GFCI device 10d again further includes a test initiation circuit and a test sensing circuit, which are illustrated schematically as a combined self-test initiation and sensing circuit 144, although again the test initiation features and the test sensing features again can be implemented by separate circuits as described above. The current meter 142 is also electrically coupled to the sensing features of the circuit 144. In addition, the current source 142′, when it is an independent member such as a battery or similar power supply, is also electrically coupled to the sensing features of the circuit 144.
In a similar manner as before, the GFCI device 10 assumes the post-test configuration 1002b as illustrated in
Conversely, in the event of an unsuccessful test of the combination solenoid coil and plunger assembly 8, the test initiation feature of the circuit 144 causes no or insufficient movement of the plunger 80, the conductive path provided by the circuit 140 is maintained so that a sensible or measurable current I′ substantially equal to the first current I remains sensed or measurable by the current meter 142. Since the test sensing feature of the circuit 144 is also electrically coupled to the current source 142′ to verify the presence of current I prior to the test, the chances of a false indication of a successful test are reduced. Again, in one embodiment, the sensing feature of the circuit 144 is electrically coupled to a microprocessor (not shown) residing on the printed circuit board 38 that annunciates, or trips the GFCI device 10d, in the event of failure of the self-test.
When the plunger 80 returns to the pre-test configuration 1002a following the post-test configuration 1002b, the plunger 80, and particularly the first end 80a, contacts the conductive members 140a and 140b to again provide electrical continuity to electrical circuit 140 to produce a current that that is substantially equal to the first current value I prior to the test. The connectors/connector terminals 142a and 142b connected to the current meter 142 enable measurement by the current meter 142 of the current I.
Thus the first and second conductive members 140a and 140b, respectively, are configured wherein when the plunger 80 is in pre-test configuration 1002a, the plunger 80 is in contact with the first and second conductive members 140a and 140b, respectively, forming a conductive path there between. Upon the plunger 80 entering the post-test configuration 1002b to move away from at least one of the first and second conductive members 140a and 140b, respectively, continuity of the conductive path of circuit 140 is terminated. Measurement, via the connectors/connector terminals 142a and 142b that is indicative of termination of the continuity of the conductive path of circuit 140 is indicative of movement of the plunger 80.
In a similar manner as described above, those skilled in the art will recognize that the GFCI device 10d may also be configured with the test assembly 100 illustrated in
Again, in a similar manner as described above, those skilled in the art will recognize that GFCI device 10d is configured to perform an automatic self-test sequence on a periodic basis (e.g.,—every few cycles of alternating current (AC), hourly, daily, weekly, monthly, or other suitable time period) without the need for user intervention and, in addition, GFCI device 10d includes members, e.g., the test initiation and sensing circuit 144 and the test assembly 100d, that are configured to enable the self-test sequence or procedure to test the operability and functionality of the device's components up to and including the movement of the solenoid plunger 80.
Those skilled in the art will recognize that the self-test initiation to conduct the periodic self-test sequence may be implemented by a simple resistance-capacitance (RC) timer circuit, a timer chip such as a 555 timer, a microcontroller, another integrated circuit (IC) chip, or other suitable circuit. In addition, a manual operation by the user may trigger the self test sequence.
Those skilled in the art will recognize that, when the at least one electrical element is characterized by an impedance load, e.g., an inductor or inductive member (not shown), the at least one electrical element may be disposed such that when the plunger 80 is in the proximity of the electrical element, a first impedance value characteristic thereof is produced by the at least one electrical element, and when the plunger 80 is not in the proximity of the at least one electrical element, a second impedance value characteristic thereof is produced by the at least one electrical element.
Turning now to
The test assembly 100′ is configured wherein when the plunger 80 is in a pre-test configuration 1005a, as illustrated in
More particularly, in the exemplary embodiment illustrated in
Those skilled in the art will recognize that when the GFCI device 10 assumes the post-test configuration 1005b, the plunger 80 may travel to a second position that is between sensors 1010a and 1010b in the path 160′ but such that the second position with respect to the sensors 1010a and 1010b differs from the first position with respect to the sensors 1010a and 1010b.
Referring again to
The test assembly 100′ is now configured wherein when the plunger 80 is in the pre-test configuration 1005a, as illustrated in
More particularly, in the exemplary embodiment illustrated in
Those skilled in the art will again recognize that when the GFCI device 10 assumes the post-test configuration 1005b, the plunger 80 may travel to a second position that is not between sensors 1010′a and 1010′b in the path 160″ but such that the second position with respect to the sensors 1010′a and 1010′b differs from the first position with respect to the sensors 1010′a and 1010′b.
In view of
More particularly, referring to
The combination solenoid coil and plunger assembly 8 is disposed on the printed circuit board 38 with respect to the conductive members 150a and 150b so that the plunger 80 is disposed in the region 151 between the conductive members 150a and 150b. The GFCI device 10e again further includes a test initiation circuit and a test sensing circuit, which are illustrated schematically as a combined self-test initiation and test sensing circuit 154, although the test initiation features and the sensing features can be implemented by separate circuits again as described above. The capacitance meter 152 is also electrically coupled to the sensing features of the circuit 154.
When the plunger 80 is in a position indicative of the pre-test configuration 1005a of the GFCI device 10e, the plunger 80 is not in contact with the first and second conductive members 150a and 150b, respectively, and is in a position with respect to the first and second conductive members 150a and 150b, respectively, that is indicative of a first capacitance value C1′ that differs from capacitance value C′ by a predetermined value due to the presence of the plunger 80 in the region 151. The predetermined value may be defined as a predetermined range of values that are more than, equal to, or less than the predetermined value. In the example illustrated in
Conversely, when the plunger 80 is in a position indicative of the post-test configuration 1005b of the GFCI device 10e, the plunger 80 is again not in contact with the first and second conductive members 150a and 150b, respectively, and additionally the plunger 80 is in a position with respect to, e.g., that is not between, the conductive members 150a and 150b (corresponding to first and second sensors 1010a and 1010b in
In the event of a successful test of the combination solenoid coil and plunger assembly 8, the test initiation feature of the circuit 154 causes at least partial movement of the plunger 80 in the test direction 83′ that is in the same direction as the forward or fault direction as indicated by arrow 81 so as to move the plunger 80 out of the region 151 between conductive members 150a and 150b, thereby changing the capacitance sensed by the capacitance meter 152 from C1′ to C2′. The difference between the second capacitance value C2′ and the first capacitance value C1′ that is indicative of movement of the plunger 80 is a predetermined value, wherein the predetermined value may be a predetermined range of values that is more than, equal to, or less than the predetermined value, that is also experimentally determined and is dependent upon the particular physical characteristics of the GFCI device 100e and the materials from which it is constructed.
Conversely, in the event of an unsuccessful test of the combination solenoid coil and plunger assembly 8, the test initiation feature of the circuit 154 causes no or insufficient movement of the plunger 80 so that capacitance sensed by the capacitance meter 152 remains at or nearly equal to C2′ in the circuit 150. In one embodiment, the test sensing feature of the circuit 154 is similarly electrically coupled to a microprocessor (not shown) residing on the printed circuit board 38 that annunciates, or trips the GFCI device 10b, in the event of failure of the self-test.
When the plunger 80 returns to the pre-test configuration 1005a following the post-test configuration 1005b, the plunger 80 returns substantially to its original position in the region 151 to again produce a capacitance value substantially of C1′ in the circuit 150. The connectors/connector terminals 152a and 152b connected to the conductive members 150a and 150b enable measurement of the capacitance of the conductive members 150a and 150b by the capacitance meter 152.
In a similar manner as described above, those skilled in the art will recognize that GFCI device 10e is configured to perform an automatic self-test sequence on a periodic basis (e.g.,—every few cycles of alternating current (AC), hourly, daily, weekly, monthly, or other suitable time period) without the need for user intervention and, in addition, GFCI device 10e includes members, e.g., the test initiation and sensing circuit 154 and the test assembly 100e, that are configured to enable the self-test sequence or procedure to test the operability and functionality of the device's components up to and including the movement of the solenoid plunger 80.
Those skilled in the art will recognize that the self-test initiation to conduct the periodic self-test sequence may be implemented by a simple resistance-capacitance (RC) timer circuit, a timer chip such as a 555 timer, a microcontroller, another integrated circuit (IC) chip, or other suitable circuit. In addition, a manual operation by the user may trigger the self test sequence.
Referring now to
The optical emitter 160a and the optical sensor 160b are configured in the exemplary embodiment of
The test assembly 100f of GFCI device 10f again further includes a test initiation circuit and a test sensing circuit, which are illustrated schematically as a combined self-test initiation and sensing circuit 164, although again the test initiation features and the sensing features can be implemented by separate circuits as described above. The test initiation feature of the circuit 164 is electrically coupled to the infrared emitter 160a while the sensing feature of the circuit 164 is electrically coupled to the infrared sensor 160b. The combination solenoid coil and plunger assembly 8 is disposed on the printed circuit board 38 and configured so that, when the plunger 80 is in a position indicative of the pre-test configuration 1005a, the plunger 80 interrupts the path 160′ of the light beam 160 emitted from the optical emitter 160a. In one embodiment, the light 160 is emitted from the emitter 160a only when initiated by the test initiation feature of the circuit 164.
Conversely, when the plunger 80 transfers to the post-test configuration 1005b to move away from the position indicative of the pre-test configuration 1005a, e.g., such as by at least partial movement of the plunger 80 in the test direction 83′ that is in the same direction as the forward or fault direction as indicated by arrow 81 to move out of the path 160′ of the light beam 160, the movement of the plunger 80 enables the light beam 160 to propagate in a path, i.e., path 160′, e.g., a continuous or direct path, from the optical emitter 160a to the optical sensor 160b. Thus, measurement via the optical sensor 160b of the continuity of the path 160′ of the light beam 160′ is indicative of movement of the plunger 80.
In a similar manner as described above for the GFCI devices 10a to 10e, in the event of a successful test of the combination solenoid coil and plunger assembly 8, a signal by the test initiation feature of the circuit 164 initiates emission of the light beam 160 and causes at least partial movement of the plunger 80 in the test direction 83′ that is in the same direction as the forward or fault direction as indicated by arrow 81 so as to move the plunger 80 out of the path 160′ to provide continuity of the path 160′ from the emitter 160a to the sensor 160b.
Conversely, in the event of an unsuccessful test of the combination solenoid coil and plunger assembly 8, a signal by the test initiation feature of the circuit 164 causes no or insufficient movement of the plunger 80 so that the plunger 80 remains in the path 160′ of the light beam 160. Since the plunger 80 is illustrated in
Those skilled in the art will recognize that the optical emitter 160a and the optical sensor 160b may be configured with respect to the plunger 80 wherein when the plunger 80 is in a position indicative of the pre-test configuration 1005a, the light beam 160 propagates in a path 160″, e.g., a continuous or direct path, from the optical emitter 160a to the optical sensor 160b (corresponding to first and second sensors 1010′a and 1010′b, respectively, in
Those skilled in the art will recognize also that the optical emitter 160a and the optical sensor 160b may be configured with respect to the plunger 80 in a pre-test configuration that is identical to the post-test configuration 1005b illustrated in
Again, in a similar manner as described above, those skilled in the art will recognize that GFCI device 10f is configured to perform an automatic self-test sequence on a periodic basis (e.g.,—every few cycles of alternating current (AC), hourly, daily, weekly, monthly, or other suitable time period) without the need for user intervention and, in addition, GFCI device 10f includes members, e.g., the test initiation and sensing circuit 164 and the test assembly 100f, that are configured to enable the self-test sequence or procedure to test the operability and functionality of the device's components up to and including the movement of the solenoid plunger 80.
Those skilled in the art will recognize that the self-test initiation to conduct the periodic self-test sequence may be implemented by a simple resistance-capacitance (RC) timer circuit, a timer chip such as a 555 timer, a microcontroller, another integrated circuit (IC) chip, or other suitable circuit. In addition, a manual operation by the user may trigger the self test sequence.
Those skilled in the art will recognize that although the test assembly 100, includes a test initiation circuit that is configured to initiate and conduct an at least partial operability test of the circuit interrupter, e.g., GFCI device 10, and a test sensing circuit that is configured to sense a result of the at least partial operability test of the circuit interrupter or GFCI device 10, has been illustrated in
As can be appreciated from the aforementioned disclosure, referring to
The method also includes measuring the movement of the plunger 80, e.g., measuring via piezoelectric member 110 in
The step of causing the plunger 80 to move in response to the actuation signal may be performed by causing the plunger 80 to move in a test direction that is in the same direction as the fault direction, e.g., test direction 83′ that is in the same direction as the fault direction 81. Alternatively, the step of causing the plunger 80 to move in response to the actuation signal may be performed by causing the plunger 80 to move in a test direction that is in a direction different from the fault direction, e.g., test direction 83 that is in a direction different from the fault direction 81, including a direction that is opposite to the fault direction 81.
The method of testing the GFCI device 10, wherein when the GFCI device 10a is in a pre-test configuration, e.g., pre-test configuration 1002a described above with respect to
The step of determining whether the movement reflects an operable circuit interrupting device may be performed by determining whether the voltage output is indicative of movement of the plunger 80 that is indicative of sufficient movement of the plunger 80 during a required real transfer of the circuit interrupting device, e.g., GFCI device 10a, from a non-actuated configuration to an actuated configuration, or alternatively is indicative of no or insufficient movement of the plunger 80 during a required real transfer of the circuit interrupting device, e.g., GFCI device 10a, from a non-actuated configuration to an actuated configuration. (As defined herein, a step of determining can also be determined by whether an action occurs).
In one embodiment of the method of testing a circuit interrupting device, the circuit interrupting device, e.g., GFCI device 10, includes at least one electrical element, e.g., resistive member 120 in
The step of determining whether the movement of the plunger 80 reflects an operable circuit interrupting device may be performed by determining whether the difference between the first electrical property and the second electrical property is indicative of sufficient movement of the plunger 80 during a required real transfer of the circuit interrupting device, e.g., GFCI device 10, from a non-actuated configuration to an actuated configuration, or alternatively, is indicative of no or insufficient movement of the plunger 80 during a required real transfer of the circuit interrupting device, e.g., GFCI device 10, from a non-actuated configuration to an actuated configuration.
In another embodiment of the method of testing a circuit interrupting device, the circuit interrupting device, e.g., GFCI device 10d of
When the circuit interrupting device, e.g., GFCI device 10d, transfers from pre-test configuration 1002a to post-test configuration 1002b, as per
In an alternate embodiment of the method of testing a circuit interrupting device, when the circuit interrupting device, e.g., a GFCI device analogous to GFCI device 10d illustrated in
In still another embodiment of the method of testing a circuit interrupting device, the circuit interrupting device, e.g., GFCI device 10e illustrated in
The step of determining whether the movement reflects an operable circuit interrupting device is performed by determining if the post-test capacitance value C2′ differs from the pre-test capacitance value C1′ by a predetermined value that is indicative of sufficient movement of the plunger 80 during a required real transfer of the circuit interrupting device, e.g., GFCI device 10e, from a non-actuated configuration to an actuated configuration, or alternatively, is indicative of no or insufficient movement of the plunger 80 during a required real transfer of the circuit interrupting device, e.g., GFCI device 10e, from a non-actuated configuration to an actuated configuration.
In yet another embodiment of the method of testing a circuit interrupting device, the circuit interrupting device, e.g., GFCI device 10f illustrated in
In still another embodiment of the method of testing a circuit interrupting device, the circuit interrupting device includes optical emitter 160a (corresponding to sensor 1010′a in
The step of determining whether the movement reflects an operable circuit interrupting device is performed by measuring discontinuity of the path 160″ of the light beam 160 wherein the discontinuity of the path 160″ of the light beam 160 is indicative of sufficient movement of the plunger 80 during a required real transfer of the circuit interrupting device, e.g., GFCI device 10f, from the non-actuated configuration to the actuated configuration. Alternatively, measuring continuity of the path 160″ of the light beam 160 is indicative of no or insufficient movement of the plunger 80 during a required real transfer of the circuit interrupting device, e.g., GFCI device 10f, from the non-actuated configuration to the actuated configuration.
The foregoing different embodiments of a circuit interrupting device according to the present disclosure are configured with mechanical components that break one or more conductive paths to cause the electrical discontinuity. However, the foregoing different embodiments of a circuit interrupting device may also be configured with electrical circuitry and/or electromechanical components to break either the phase or neutral conductive path or both paths. That is, although the components used during circuit interrupting and device reset operations are electromechanical in nature, electrical components, such as solid state switches and supporting circuitry, as well as other types of components capable or making and breaking electrical continuity in the conductive path may also be used.
Those skilled in the art will recognize that the test initiation and sensing circuits may also be programmed to return the plunger from the post-test configuration back to the pre-test configuration once the test measurements of plunger movement have been performed.
Further, those skilled in the art will recognize that although the foregoing description has been directed specifically to a ground fault circuit interrupting device, as discussed above, the disclosure may also relate to other circuit interrupting devices, including arc fault circuit interrupting (AFCI) devices, immersion detection circuit interrupting (IDCI) devices, appliance leakage circuit interrupting (ALCI) devices, circuit breakers, contactors, latching relays, and solenoid mechanisms.
Although the present disclosure has been described in accordance with the embodiments shown, one of ordinary skill in the art will readily recognize that there could be variations to the embodiment and these variations would be within the spirit and scope of the present disclosure. Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims.
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