This disclosure generally relates to electrical switching devices such as circuit breakers. More particularly, this disclosure describes a switching device having an improved design to help prevent the device's switch from closing if closure would cause an unsafe condition.
In a self-contained switching device such as a circuit breaker with an electronic trip unit (ETU), features are sometimes added to prevent closing the device and completing the primary circuit. These are often user-configurable features of the ETU that protect against closure if the closure would cause an unsafe condition. A simple example of an unsafe condition is a ground fault or other overcurrent condition. As another example, in power delivery systems that supply two loads from two power sources in a main-tie-main configuration, closing the system's tie breaker when the sources are not well-matched in voltage, frequency or phase could cause damage to system components. If the tie breaker's ETU detects such a mismatch, or if a remote controller that is monitoring the system detects the mismatch, the ETU or remote controller may respond by blocking any attempts to close the tie breaker.
Configurations in which the ETU or remote controller prevents closing are effective when the close command is initiated electronically, such as by a remote or local electrical actuator. In such situations, the system's programming may prioritize a “block closure” command over a command to close the switch. However, such configurations are not effective to block closure when closure is initiated locally by physical action, such as by an operator who depresses a mechanical pushbutton to manually operate the switch. This ineffectiveness occurs because electronic logic cannot intervene in the direct mechanical actuation of the circuit breaker mechanism. In order to prevent closing, the circuit breaker's ETU would need to operate the trip actuator and override the closing attempt, but trip actuators are typically intermittent operation devices and are not always maintained in an active state. Further, the trip actuators of some circuit breakers cannot mechanically operate to stop a close attempt when the circuit breaker is open. This is because the circuit breaker mechanism holds the trip actuator mechanism in the reset position whenever the switch is open. Further, ETUs of prior art circuit breakers typically will not detect when closure starts, but instead will only detect when the breaker's contacts touch, at which point it will have been too late to prevent the closure from happening. Even a few milliseconds of closure could damage system components and/or create safety hazards in overcurrent or voltage mismatch conditions.
This document describes an improved switching mechanism that is designed to help prevent closure of a switching device, even if the closure is initiated manually, when closure could result in an unsafe condition.
In various embodiments, a circuit breaker includes a moveable contact, an opening spring that is operably connected to the moveable contact, and a sensor that operates as a full open sensor. The sensor exhibits a first output condition when the moveable contact is in a fully open position, and it exhibits a second output condition when the moveable contact leaves the fully open position. An electronic trip unit (ETU) is electrically connected to the sensor and, when in a close break mode, blocks the circuit breaker from closing. The ETU does this by, in response to detecting that the sensor is in the second output condition (which corresponds to the moveable contact leaving the fully open position), generating a signal that will cause the opening spring to return the moveable contact to the fully open position.
In some embodiments, the circuit breaker may include a trip actuator. The circuit breaker also may include an opening latch that, when in a latched position, will hold a linkage in a position which allows closing, and which thus holds the opening spring in a loaded position. In these embodiments, to cause the opening spring to return the moveable contact to the fully open position unit, the ETU's signal may cause the trip actuator to release the opening latch. Releasing the opening latch will allow the linkage to move and permit the opening spring to return to an unloaded condition. When the opening spring returns to its unloaded condition, the moveable contact will return to the fully open position. Optionally, the trip actuator may include a plunger having a retracted position and an extended position. The extended position may be operably connected to the opening latch. When the trip actuator receives the signal from ETU, the trip actuator will cause the plunger to move from the retracted position to the extended position and thus release the opening latch. When the moveable contact returns to the fully open position, the trip actuator will be reset.
In various embodiments, the circuit breaker may include: a moveable arm that is operably connected to the moveable contact, and an axle that is operably and rotatably connected to the moveable arm. The circuit breaker also may include a linkage that operably connects the opening spring with the moveable arm via the axle, along with an extended member (such as a cam) that is connected to the axle. The sensor may be positioned to detect the extended member when a position of the moveable contact corresponds to the fully open position. Alternatively, the sensor may be configured to detect a rotational position of the axle.
Other embodiments are directed to a method of operating a circuit breaker that has a moveable contact, an opening spring, a sensor and an ETU. The method includes, by the sensor, detecting that the moveable contact is in a fully open position. After the sensor initially detects that the moveable contact is in the fully open position, the sensor may detect that the moveable contact has moved away from the fully open position. When this happens, then in response the sensor will change from a first output condition to a second output condition (such as from off to on, or from on to off). When the ETU detects that the sensor has changed to the second output condition, then in response it will cause the opening spring to return the moveable contact to the fully open position.
In some embodiments of the method, the circuit breaker also includes an opening latch that is operably connected to the opening spring. In such embodiments, causing the opening spring to return the moveable contact to the fully open position may be effected as the ETU causes the opening latch to release, which in turn causes the opening spring to relax (i.e., return to an unloaded condition). The opening spring may be operably connected to a lever that is operably connected to an axle, and the moveable contact is operably connected to a moveable arm that is also operably connected to the axle. In such a case, causing the opening spring to retract to the unextended condition may turn the axle, turning the axle rotates the moveable arm, and rotating the moveable arm moves the moveable contact to the fully open position. The axle may include an extended member (such as a cam). Detecting that the moveable contact is in the fully open position may include detecting, by the sensor that the extended member has moved away from the sensor or that the extended member has moved over the sensor. Other sensors (such as a sensor that detects rotational position of the axle) may be used to detect whether the moveable contact has left the fully open position.
In some embodiments of the method, the circuit breaker also includes a trip actuator that includes a plunger having a retracted position and an extended position. The trip actuator may be operably connected to the opening latch when in the extended position. If so, then in the method, causing the opening latch to release may include, by the ETU, generating a signal causes the trip actuator to release the opening latch by extending the plunger from the retracted position to the extended position. In such embodiments, the moveable contact may be connected to a moveable arm; and returning the moveable contact to the fully open position may cause the plunger to move to the retracted position and reset the trip actuator.
In some embodiments of the method, the circuit breaker also includes a closing spring. In such embodiments, detecting that the moveable contact has moved away from the fully open position occurs in response to the closing spring generating a closing force that begins to move the movable contact toward a closed position. When the opening spring returns the moveable contact to the fully open position, the opening spring will do so after the release of the opening latch, which releases the linkage that connects the closing spring to the movable arm.
In other embodiments, a stored energy circuit breaker includes a moveable contact, and a sensor. The sensor is positioned to exhibit a first output condition when the moveable contact is in a fully open position, and to exhibit a second output condition when the moveable contact moves away from the fully open position.
The circuit breaker also may include an extended member that is positioned over the sensor which the moveable contact is in the fully open position, and that is not positioned over the sensor when the moveable contact leaves the fully open position. Alternatively, the extended member may be positioned over the sensor when the moveable contact is in any position other than the fully open position. Other methods of sensing the full open position may include continuous position sensors in place of the extended member interacting with a discrete sensor.
The circuit breaker may include an ETU that is electrically connected to the sensor and that is configured to, in response to detecting that the sensor is in the second output condition, cause the moveable contact to return to the fully open position. The circuit breaker also may include a trip actuator that is electrically connected to the electronic trip unit and that is configured to receive and implement a command to cause the moveable contact to return to the fully open position. The circuit breaker also may include an opening latch that is operably connected to the trip actuator. The circuit breaker also may include an opening spring that is operably connected to the opening latch and to the moveable contact. The opening latch may: (i) when latched, hold the opening spring in a loaded position; and (ii) when unlatched, permit the opening spring to return to an unloaded position.
As used in this document, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. As used in this document, the term “comprising” (or “comprises”) means “including (or includes), but not limited to.” When used in this document, the term “exemplary” is intended to mean “by way of example” and is not intended to indicate that a particular exemplary item is preferred or required.
Other terms that are relevant to this disclosure will be defined at the end of this Detailed Description section.
This disclosure describes a circuit breaker that incorporates a full open sensor that is used to help prevent closure of the breaker in conditions in which a closure could create an unsafe condition.
In a stored energy circuit breaker 100 such as that shown in
In the position shown in
In
In
In the prior art embodiments shown in
As shown in
Returning to
Upon detecting this change of condition of the full open sensor 452, as illustrated in
The breaker may then return to the fully open position as shown in
Thus, the incorporation of a full open switch into a stored energy (i.e., spring release) circuit breaker provides an improved closing prevention capability that can override not only an electronic signal, but also manual operation of the breaker's closing mechanism.
It should be noted that the incorporation of the embodiments described above will not necessarily prevent the moveable contact from starting to move in response to a manual close operation. However, it will prevent the moveable contact from touching the stationary contact and closing the circuit when the ETU is operating in a close block condition. An example sequence of operation is explained with reference to
It should also be noted that the description above, and in particular the figures, describe only an example circuit breaker operation, with only the functional elements of a circuit breaker that are necessary to describe the invention shown. In practice, other arrangements may be used, and the figures' illustrations that show certain components as interconnected does not necessarily mean that the components physically contact each other. The use of the word “operably” connected in the description and claims denotes, as defined below, that the parts need not physically touch each other.
In this document, when terms such “first” and “second” are used to modify a noun, such use is simply intended to distinguish one item from another, and is not intended to require a sequential order unless specifically stated. The term “approximately,” when used in connection with a numeric value, is intended to include values that are close to, but not exactly, the number. For example, in some embodiments, the term “approximately” may include values that are within +/−10 percent of the value.
In this document, the term “connected”, when referring to two physical structures, means that the two physical structures touch each other. Devices that are connected may be secured to each other, or they may simply touch each other and not be secured.
In this document, the term “operably connected”, when referring to two physical structures, means operation (i.e., movement) of one structure will cause the other structure to responsively move. Operably connected structures may be physically connected to each other, or they may be indirectly connected via one or more intermediate structures.
In this document, the term “electrically connected”, when referring to two electrical components, means that a conductive path exists between the two components. The path may be a direct path, or an indirect path through one or more intermediary components.
When used in this document, relative terms of position such as “up” and “down”, “upper” and “lower”, and “upward” and “downward” are not intended to have absolute orientations but are instead intended to describe relative positions of various components with respect to each other. For example, a first component may be an “upper” component and a second component may be a “lower” component when a device of which the components are a part is oriented in a first direction. The relative orientations of the components may be reversed, or the components may be on the same plane, if the orientation of the structure that contains the components is changed. The claims are intended to include all orientations of a device containing such components.
The features and functions described above, as well as alternatives, may be combined into many other different systems or applications. Various alternatives, modifications, variations or improvements may be made by those skilled in the art, each of which is also intended to be encompassed by the disclosed embodiments.
This patent document claims priority to U.S. Provisional Patent Application No. 62/953,281, filed Dec. 24, 2019. The disclosure of the priority application is fully incorporated into this document by reference.
Number | Name | Date | Kind |
---|---|---|---|
7186937 | Ricciuti et al. | Mar 2007 | B1 |
20080302645 | Rakus | Dec 2008 | A1 |
20120085627 | Yang | Apr 2012 | A1 |
20150153414 | Mills | Jun 2015 | A1 |
Number | Date | Country |
---|---|---|
1098344 | May 2001 | EP |
2001032 | Dec 2008 | EP |
Number | Date | Country | |
---|---|---|---|
20210193402 A1 | Jun 2021 | US |
Number | Date | Country | |
---|---|---|---|
62953281 | Dec 2019 | US |