Note: Descriptions are shown in the official language in which they were submitted.
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CIRCUIT BRB~CBR WITH MULTIPLE TEST SWITCH ASSEMBLY
The present invention relates generally to circuit
breakers, and in particular, to an improved circuit
breaker arrangement that can simulate at least two
different test conditions to ensure that the circuit
breaker is operating properly.
Circuit breakers that include a single push button
to provide a user With the ability to simulate only one
fault condition are known. That is, there is no ability
to simulate a second and different fault condition in the
known breaker. However, it is desirous to be able to
test whether the circuit breaker will trip upon the
detection of a plurality of fault conditions if the
breaker is constructed to trip upon the detection of at
least two different fault conditions. The known circuit
breaker includes a button and leaf contact to permit the
testing of only one fault condition, which by way of
example, is a ground fault condition.
The present state of the art, therefore, is
deficient in that there is no circuit breaker
arrangements that permit the simulation of more than one
fault condition, such as a ground fault condition and a
line to line arc fault. The ability to simulate more
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than one fault condition is advantageous and desirable to
ensure that the circuit breaker which may sense more than
one fault condition (such as arcing to ground (i.e.
ground fault) and arcing line to line or neutral) is
operating properly.
It is therefore desirable to provide a circuit
breaker which overcomes the aforementioned deficiency.
The circuit breaker disclosed herein achieves the
aforementioned and below mentioned objectives.
Generally speaking, in accordance with the
invention, a circuit breaker for simulating a~ plurality
of fault or test conditions is provided. In the
preferred embodiment, the circuit breaker detects at
least two fault conditions. The circuit breaker includes
a circuit trip assembly having an armature latch moving
between a first position when the circuit breaker is in
an operating condition and at least a second position
when the circuit breaker is in a first or second tripped
condition. The armature latch moves from its first
position to its second position in response to both the
first and second fault conditions. To this end, the
circuit breaker can simulate at least two fault or test
conditions by incorporating a switch assembly, supported
by the housing, for initiating the first and second fault
conditions. Hereinafter, reference to the simulation of
a fault condition should also be understood to mean the
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simulation of a test condition, as the present invention
is applicable to simulating a plurality of conditions,
such as fault conditions. Therefore, the reference to
simulating other test conditions is equally applicable.
Additionally, the circuit breaker includes an electronic
circuit board, an integrated circuit and a solenoid
preferably mounted thereon, where upon the initiation of
the first fault/test condition or the second fault/test
condition, the integrated circuit sends respective
signals to the solenoid which interfaces with the
armature latch causing the armature latch to move from
its first position to its second position.
Accordingly, it is an object of the present
invention to provide a circuit breaker with a multiple
test arrangement for testing the proper working order
thereof .
Another object of the present invention is to provide a
circuit breaker that can simulate more than one fault or
test condition.
Another object of the.present invention is to provide a
user friendly method of testing a circuit breaker for the
proper detectability of a ground fault or arc fault
condition.
Still other objects and advantages of the invention will
in part be obvious and will in part be apparent from the
specification.
The invention accordingly comprises the features of
construction, combination of elements and arrangement of
parts which will be exemplified in the construction
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hereinafter set forth, and the scope of the invention
will be indicated in the claims.
For a fuller understanding of the invention,
reference is had to the following description taken in
connection with the accompanying figures, in which:
Fig. 1 is a perspective view of a switch assembly
constructed in accordance with the present invention;
Fig. 2 is a front elevational view of the switch assembly
constructed in accordance with the present invention;
Fig. 3 is a front elevational view of a circuit breaker
in the operating condition and the switch assembly in the
neutral position, all constructed in accordance with the
present invention;
Fig. 4 is another elevational view of the circuit breaker
along a different cross-section thereof, more
particularly illustrating the circuit board,.a solenoid
mounted thereon and the switch assembly, all constructed
in accordance with the present invention;
Fig. 5 is a simplified elevational view of the present
invention, with certain components removed for ease of
illustration, and particularly illustrating the alignment
of the solenoid with respect to the armature latch; and
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Fig. 6 is a detailed elevational view illustrating the
circuit breaker, constructed in accordance with the
present invention, in the tripped condition.
Reference is first made to FIGS. 1 and 2 wherein a switch
assembly, generally indicated at 100, is constructed in
accordance with the present invention. Switch assembly
100 preferably includes a rockable .switch 102, a first
contact 145, a second contact 150 and a third contact
155. In the preferred embodiment, contacts 145, 150 and
155 are metal leaf contacts. It will be understood by
one of skill in the art that the reference to rockable
will also include a switch that is slidable, pivotable or
the like. Switch 102, preferably of a unitary plastic
construction, includes integrally extending teeth 110 and
111 in facing alignment with each other. Teeth 110 and
111 together engage one end of contact 150.
Referring briefly to FIG. 3 for a moment, it is clear
that a circuit breaker 10, constructed in accordance with
the invention by its inclusion of switch assembly 100,
includes a housing' 12, a line terminal 14, a load
terminal 16, and a circuit trip assembly, generally
indicated at 20, connected between line terminal 14 and
load terminal 16. Circuit trip assembly 20 is similar to
circuit trip assembly 120 disclosed in pending
application Serial No. 09/196,647, filed on November 19,
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1998, which is assigned to the present assignee and
incorporated by reference as if fully set forth herein.
For example, and discussed in greater detail in
application Serial No. 09/196,647, when armature latch 28
moves in the "xi" direction, a cradle 22 disengages from
armature latch 28 and rotates in a direction indicated by
arrow "yl." An arm 44 likewise rotates in the direction
of arrow "zl." Upon the rotation of cradle 22, a knee
portion 150 thereof will engage a trip support 130 so as
to cause trip cam 130 to rotate about pin 132. As an
advantageous feature, circuit breaker 10 may include a
trip indicator 140 rotatable about a pin 142 on housing
12 from a first position where it is not visible through
a window 72 in housing 12 to a second position where trip
indicator 140 is visible through window 72. An aperture
145 in the body of trip indicator 140 receives a guide
pin 144 of trip cam 130. Guide pin 144 is provided to
transfer the movement of trip cam 130 to trip indicator
140 to rotate trip indicator 140 about pin 142. In this
way, upon a simulated or real fault or test condition, a
portion of trip indicator 140 is visible through window
72. This tripped condition is illustrated in FIG. 6, for
example, and also illustrates components, such as trip
indicator 140, trip cam 130, cradle 22 and arm 44 in
their rotated positions so as to cause line terminal 14
to electrically disconnect from load terminal 16.
Referring to FIGS. 4 and 5, also included within housing
12 is a circuit board 140 that, in combination with
components such as an integrated circuit (as discussed
below) provides the electrical circuitry necessary for
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the proper operation of a solenoid 160 and the circuit
breaker disclosed herein. The manner in which circuit
board 140 and solenoid 160 is incorporated into housing
12 would be well understood by one of skill in the art.
Reference is again made to FIGS. 1 and 2 wherein housing
12 is depicted with a plurality of integrally molded
posts 120, 125, 130 and 135. Positioned between posts
120 and I25 is contact 145. Likewise positioned between
posts 125 and 130 is contact 150. Similarly, positioned
between posts 130 and 135 is contact 155. As depicted in
FIG. 2, contact 145 is preferably bent over an inwardly
angled top surface 126 of post 125, .while contact 155 is
preferably bent over an inwardly angled top surface 131
of post 130. Contact 150 extends above the top of posts
125 and 130 so as to be engaged by teeth 110 and 111 of
switch 102. It should now be understood that as switch
102 is "rocked" or pivoted (as explained below) in either
a clockwise (or "a" direction (FIG. 2)) or
counterclockwise (or "b" direction (FIG. 2)) direction,
the first (or extended) end of contact 150 will
respectively electrically contact either the first end of
contact 155 or the first end of contact 145. The second
ends of contacts 145, 150 and 155 each have an "L" shaped
leg so as to be inserted into respective apertures 146,
151 or 156 and connected to circuit board 140. It should
also be understood that posts 120, 125, 130 and 135 may
be mounted on the face of board 140 as depicted in FIG.
4, molded into housing 12 as shown in FIG. 1, or may be
eliminated altogether. The connection to circuit board
140 also permits the electrical connection to an
integrated circuit thereon. Specifically, circuit board
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140 has mounted thereon an integrated circuit 142 which
is preferably an ASIC. Connections between contacts 145,
150 and 155 are made to circuit 142 such that the
electrical connection between contact 145 and 150 causes
a first output signal to be generated by circuit 142 and
the electrical connection between contact 150 and 155
causes a second output signal to be generated by circuit
142.
As stated above, electrical contact between contact 150
and the respective contacts 145 and 155 is achieved by
the rocking or pivoting nature of switch 102. To achieve
this rocking action, housing 12 preferably includes a
recess 115 within the inner housing wall thereof. Recess
115 may be formed by two smaller arcing recesses 116, 117
and a notch portion 118 therebetween. Notch portion 118
will engage a complimentary shaped tab 106 integrally
molded on switch 102. Switch I02 also includes an
integrally formed rail I05 extending along the front and
back surfaces of switch 102. In this manner both sides
of housing 12 can support switch 102 in the manner herein
described. The combination of tab 106 and rail 105
permits the pivoting within recess 115 so as to achieve
the limiting rocking movement of switch 102: As stated
above, it would be within the scope of the artisan to
construct the present invention using a pivotable or
somewhat slidable switch configuration while remaining
within the scope of the invention. Moreover, the shape
of switch I02 is by way of example and not limitation, as
it could also be made with a concave top surface for
example, as opposed to the disclosed rounded top surface.
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The multiple test switch assembly constructed in
accordance with the present invention is mountable within
the circuit breaker housing. Switch 102, however, may
extend outside the housing so as to be accessible to a
user. The remaining and preferred construction of the
circuit breaker is more particularly disclosed in the
aforementioned U.S. application Serial No. 09/196,647,
but it should be understood that such disclosure. is only
by way of example, as it will become evident that the
present invention is adaptable and utilizable in any
number of circuit breaker configurations that are
constructed to detect at least two fault or test
conditions.
Accordingly, it will now be appreciated how the
present invention simulates the above two mentioned arc
fault or ground fault/test conditions. In particular,
the rotation of switch 102 in a first direction, for
example, so as to achieve electrical contact between
contacts 150 and 145, will simulate the first fault/test
condition which may be the arc fault condition so as to
insure the circuit breaker is operating properly. In
particular, the contact of contacts 145 and 150 causes
integrated circuit 142 to send a first signal to solenoid
160. Solenoid 160 then engages armature latch 28 (FIGS.
3 and 5) causing armature latch 28 to move in the "xl"
direction, thereby achieving a fault condition and moving
the armature latch to its second position. Specifically,
FIG. 5 illustrates the positioning of solenoid 160 with
respect to armature latch 28 although it should be
understood that FIG. 5 is a simplified illustration since
solenoid 160 is preferably not on the same side of board
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140 as circuit trip assembly 20. However, FIGS. 4 and 5
in combination adequately discloses how a portion of
board 140 may be removed to permit solenoid 160 to engage
latch 28. Similarly, the rotation of switch 102 in the
second direction to achieve electrical contact between
contacts 150 and 155 likewise causes integrated circuit
142 to output a second signal to solenoid 160 causing
solenoid 160 to engage armature latch 28 in a similar
manner causing armature latch 28 ~to move from its
operating position to its second position thereby
simulating the second fault or test condition.
It will thus be seen that the present invention
makes it possible for an end user to verify that the
circuit breaker including all mechanical and electrical
components are functioning properly. For an AFCI/GFCI
combined circuit breaker, the switch assembly constructed
in accordance with the present invention allows the user
to test the AFCI mode of operation by rocking or rotating
the switch in one direction and to test the GFCI mode by
rocking or rotating the switch in the other direction.
Moreover, it should be understood that the switch
assembly disclosed herein is not and should not be
limited to incorporation with an AFCI and/or GFCI circuit
breaker. That is, if a breaker is required to trip upon
the detection of any other fault or test conditions, the
present invention is equally utilizable therewith, merely
with the programming of the integrated circuit to
simulate the desired testing or faulting conditions.
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