Patent Application
20190140429
The field of the disclosure relates generally to circuit breakers, such as a ground fault circuit interrupt (GFCI) circuit breaker, an arc fault circuit interrupt (AFCI) circuit breaker, or a dual function circuit interrupt (DFCI) circuit breaker, and more particularly, to a circuit breaker with communications and processing capabilities.
Circuit breakers are well known devices for protecting circuits against electrical faults. At least some known circuit breakers may be so-called “smart” circuit breakers having a microcontroller monitoring operating conditions. The microcontroller may determine a fault condition and in response, causes a switch to open an associated circuit. At least some known “smart” circuit breakers may additionally provide a notification of the type of fault that occurred. However, while at least some “smart” circuit breakers communicate a fault to other devices, such circuit breakers may be relatively limited in diagnosing the cause of the fault.
In one aspect, a circuit breaker is provided. The circuit breaker includes a housing, a circuit protection device disposed within the housing, the circuit protection device operable to i) sense operating conditions associated with at least one current path through the circuit breaker and ii) selectively open the at least one current path based on the sensed operating conditions, a processing device communicatively coupled to the circuit protection device, the processing device operable to collect operating conditions data from the circuit protection device, the operating conditions data including the sensed operating conditions and a trip indication that indicates whether the circuit protection device has opened the at least one current path, and at least one communications interface communicatively coupled to the processing device, the at least one communications interface operable to receive the operating conditions data from the processing device to facilitate exporting the operating conditions data to a remote computing device.
In another aspect, an electrical distribution center is provided. The electrical distribution center includes a mounting rail including a bus bar, at least one circuit breaker mounted to the mounting rail and electrically coupled to the bus bar, the at least one circuit breaker including a housing, a circuit protection device disposed within the housing, the circuit protection device operable to i) sense operating conditions associated with at least one current path through the circuit breaker and ii) selectively open the at least one current path based on the sensed operating conditions, a processing device communicatively coupled to the circuit protection device, the processing device operable to collect operating conditions data from the circuit protection device, the operating conditions data including the sensed operating conditions and a trip indication that indicates whether the circuit protection device has opened the at least one current path, and at least one communications interface communicatively coupled to the processing device, the at least one communications interface operable to receive the operating conditions data from the processing device to facilitate exporting the operating conditions data to a remote computing device.
In yet another aspect, a method of monitoring operation of a circuit breaker is provided. The method includes sensing operating conditions associated with at least one current path through the circuit breaker, the operating conditions sensed by a circuit protection device disposed within a housing of the circuit breaker, selectively opening, by the circuit protection device, the at least one current path based on the sensed operating conditions, determining that the at least one current path was selectively opened, and generating a corresponding trip indication, collecting, at a processing device disposed within the housing of the circuit breaker, operating conditions data from the circuit protection device, the operating conditions data including the sensed operating conditions and the trip indication, and exporting, using a communications interface communicatively coupled to the processing device, the operating conditions data to a remote computing device.
These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of the disclosure. These features are believed to be applicable in a wide variety of systems comprising one or more embodiments of the disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.
In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.
The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
“Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.
Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.
Embodiments of the present disclosure relate to a circuit breaker having communications and processing capabilities. The circuit breaker includes a communications interface for communicating with a remote computer system. The circuit breaker further includes a non-volatile memory that stores operating data and fault event data. This non-volatile memory may be removable for exporting the stored data, and/or the circuit breaker may transmit the stored data over a wired and/or wireless communications channel to a remote computing device (e.g., a computing device running management software). The operating data may include, for example, current readings, voltage readings, power readings, energy usage readings, waveform captures, temperature, transient events, and/or conditions that caused the circuit breaker to trip. This data can then be used for troubleshooting, software updates, individualized custom solutions, cloud based diagnostics software/database/management system, and/or branch circuit level metering.
Currently, at least some known circuit breakers may collect and analyze similar data, but that data is typically analyzed using a microcontroller contained within the circuit breaker to generate results data. The results data may be communicated to an external device, but the raw data collected by at least some known circuit breakers is not provided to the external device. Exemplary embodiments of the disclosure describe a circuit breaker that stores a complete data set to removable memory for later analysis, or that stores the complete data locally for later exporting to a remote computing device (e.g., a computing device running management software).
The embodiments described herein allow an end user to view transient event data to determine a cause of a circuit breaker tripping. Previously, at least some known circuit breakers did not store this data for subsequent analysis. Therefore it was generally known that the circuit breaker tripped, but no further analysis was possible. In contrast, embodiments of the circuit breakers described herein store operating data and fault event data to a removable and/or non-removable memory device, and export the stored data to a remote management computing device. The stored data may include current, voltage, and/or energy consumption measurements. Transient events may also be monitored. In the exemplary embodiments, the memory is non-volatile such that a tripping event does not cause data loss. The data may be transmitted to the remote management computing device via TCP/IP, Modbus, Bluetooth, NFC, cellular data, or any other secure data transmission protocol. The circuit breakers described herein store the operating data continually, and are capable of exporting this data to a management computing device that will process the data.
A first load lug 16 and a second load lug 18 of MCB 10 are each operable to electrically couple MCB 10 to other devices. For example, first load lug 16 and second load lug 18 may each include a set screw to facilitate clamping a wire to the respective lug. In the exemplary embodiment, a first electrical path is defined within housing 12 between an electrical power source (not shown) and first load lug 16. Further, first load lug 16 is electrically coupled to the switching components to enable selectively opening the first electrical path between first load lug 16 and the electrical power source. Accordingly, first load lug 16 may also be referred to as a live load lug. Similarly, a second electrical path is defined within housing 12 between second load lug 18 and a neutral wire 109. Accordingly, second load lug 18 may also be referred to as a neutral load lug. Neutral wire 109 is electrically coupled to a neutral source.
One or more sensing components of circuit protection device 14 are operable to sense an operating condition associated with at least one current path through MCB 10, such as the first and second electrical paths. For example, circuit protection device 14 may be sense current flowing through first and second electrical paths, a temperature of circuit protection device 14, a current imbalance between the first and second electrical paths, a voltage difference between the first and second electrical paths, etc. In the exemplary embodiment, circuit protection device 14 is in communication with a circuit board 20. Circuit board 20 includes a processing unit (not shown in
The processing unit of circuit board 20 is further operable to receive or collect operating conditions data from circuit protection device 14, and store the operating conditions data to non-volatile memory, such as a memory card 26. Specifically, circuit board 20 includes a communications interface 25 operable to communicatively couple memory card 26 to circuit board 20, and to transfer operating conditions data from circuit board 20 to memory card 26. Using non-volatile memory allows the stored data to be retrieved after a loss of power, such as when the MCB 10 is tripped. Further, in the exemplary embodiment, memory card 26 is removable from housing 12, allowing the stored data to be accessed by other devices. Operating conditions data includes data representing operating conditions of MCB 10 as sensed by the sensing components of MCB 10. Further, in the exemplary embodiment, the operating conditions data also includes a trip indication that indicates whether circuit protection device 14 has opened at least one current path in MCB 10. Specifically, in the exemplary embodiment, if a current path has been selectively opened (i.e., MCB 10 has tripped), circuit protection device 14 determines that the current path has been selectively opened, and generates a trip indication that indicates that the at least one current path has been selectively opened. If, however, the at least one current path has not been selectively opened (i.e., MCB 10 has not tripped), circuit protection device 14 generates a trip indication that indicates the at least one current path has not been selectively opened. This trip indication is included in the operating conditions data collected by the processing unit from circuit protection device 14.
The sensing components of circuit protection device 32 are operable to sense an operating condition, such as current flowing through each pole, a temperature of circuit protection device 32, a current imbalance between the poles, a voltage difference between the poles, etc. In the exemplary embodiment, circuit protection device 32 is in communication with a circuit board 38. Circuit board 38 includes a processing unit (not shown in
In block 56, memory card 26 is inserted into analysis device 44 and read by analysis device 44. Analysis device 44 may be, for example, a personal computer running an application for analysis of data contained on memory card 26. The operating conditions data may be stored in any format suitable for organization of values and time. For example, in some embodiments, the operating conditions data may be stored in a simple comma separated value text document, with each field having a time stamp and any corresponding measured information.
In block 58, analysis device 44 displays the operating conditions data to a user for analysis. The user may then troubleshoot operation of MCB 10 based on the displayed operating conditions data. Notably, in contrast to at least some known circuit breaker systems, in the exemplary embodiment, the operating conditions data includes not the trip indication, but also sensed operating conditions that may have led to any tripping of MCB 10. This allows a user to determine not only that MCB 10 tripped, but also what caused MCB 10 to trip.
In the exemplary embodiment, the processing device on circuit board is operable to transmit operating conditions data stored on the memory device to analysis device 44 through communications port 62. Specifically, a communications cable 64 (e.g., a USB cable) may be coupled between communications port 62 and analysis device 44. Accordingly, the operating conditions data may be transferred from MCB 60 to analysis device 44 through communications cable 64, for further analysis at analysis device 44.
Memory card interface 72 is accessible through a corresponding aperture defined in housing 12 of MCB 70, and is communicatively coupled to the processing unit of the circuit board. Further, memory card interface 72 is sized and shaped to receive memory card 26 such that memory card 26 is communicatively coupled to the circuit board. In the exemplary embodiment, communications port 62 is also accessible through a corresponding aperture defined in housing 12 of MCB. Communications port 62 is communicatively coupled to the processing unit of the circuit board, and the processing unit is operable to transmit operating conditions data to analysis device 44 through communications port 62 (e.g., using communications cable 64). Thus, operating conditions data may then be transferred to analysis device 44 through communications cable 64, or may be transferred using memory card 26 (e.g., as described in method 50).
In the exemplary embodiment, communications port 62 is located in a different position on MCB 70 than communications port 62 on MCB 60 (shown in
In the embodiment shown in
First communications port 81 and second communication port 82 are also communicatively coupled to the processing unit. Further, the processing unit is operable to transmit operating conditions data to analysis device 44 (shown in
If a fault condition is identified in block 166, then a type of the fault condition (e.g., whether the fault condition is an overcurrent condition) is recorded at block 168. The operating conditions data and any fault condition data (i.e., identifying the fault condition and the type of the fault condition) are then bundled at block 170. For example, the operating conditions data and fault condition data may be stored as a single data file. The bundled data is then stored to memory at block 172. The memory may be a non-volatile memory device on the circuit board, or a removable memory card coupled to the circuit breaker. Alternatively or additionally, the bundled data may be transmitted to a remote computing device over wired and/or wireless communications channels for storage at the remote computing device. The bundled data may further be transmitted to an alert system for alerting an operator, user, etc. to the presence of the fault condition.
In the exemplary embodiment, circuit board 200 includes a memory device 202 and a processor 204 coupled to memory device 202. Processor 204 may include one or more processing units or processing devices, such as, without limitation, a multi-core configuration. Processor 204 is any type of processor that permits circuit board 200 to operate as described herein. In some embodiments, executable instructions are stored in memory device 202. Circuit board 200 is configurable to perform one or more operations described herein by programming processor 204. For example, processor 204 may be programmed by encoding an operation as one or more executable instructions and providing the executable instructions in memory device 202. In the exemplary embodiment, memory device 202 is one or more devices that enable storage and retrieval of information such as executable instructions or other data. Memory device 202 may include one or more computer readable media, such as, without limitation, random access memory (RAM), dynamic RAM, static RAM, a solid-state disk, a hard disk, read-only memory (ROM), erasable programmable ROM, electrically erasable programmable ROM, or non-volatile RAM memory. The above memory types are exemplary only, and are thus not limiting as to the types of memory usable for storage of a computer program.
Memory device 202 may be configured to store any type of data, including, without limitation, operating conditions data associated with the circuit breaker. In some embodiments, processor 204 removes or “purges” data from memory device 202 based on the age of the data. For example, processor 204 may overwrite previously recorded and stored data associated with a subsequent time or event. In addition, or alternatively, processor 204 may remove data that exceeds a predetermined time interval.
In the exemplary embodiment, a communications interface 206 is coupled to processor 204. For example, communications interface 206 may include, without limitation, a memory card interface, a communications port, and/or a wireless communications interface, as described herein. Communications interface 206 may be, for example, a wired network adapter, a wireless network adapter, a mobile telecommunications adapter, a serial communication adapter, or a parallel communication adapter. Communications interface 206 may receive a data signal from or transmit a data signal to one or more remote devices, as described herein.
Embodiments of a circuit breaker, as described above, thus facilitate the analysis of fault conditions, operating conditions, and general troubleshooting of an electrical circuit. The circuit breakers described herein are capable of continuously storing operating condition data to a memory device that may be local or remote. In addition, in at least some embodiments, the memory device may be removable from the circuit breaker.
Exemplary technical effects of the circuit breakers described herein include, for example: (a) monitoring operating conditions prior to tripping the circuit breaker; (b) providing a real-time indication of circuit faults; (c) and facilitating remote monitoring of circuit breakers.
Exemplary embodiments of a circuit breaker and related components are described above in detail. The system is not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the configuration of components described herein may also be used in combination with other processes, and is not limited to practice with the systems and related methods as described herein. Rather, the exemplary embodiments can be implemented and utilized in connection with many applications.
Although specific features of various embodiments of the present disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the present disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.
This written description uses examples to disclose the embodiments of the present disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the embodiments described herein is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
