Abstract:
A portable actuator system enables the remote operation of electrical disconnect switches with a portable actuator device that is temporarily installed at the disconnect switch location. An embodiment, among others, of the portable actuator device has an electric motor having a drive shaft that can be controlled to rotate about a longitudinal axis. The actuator device also has elongated movable first and second arms that are controlled by the drive shaft. The first arm engages and moves the disconnect handle in a first rotational direction so that the disconnect handle is switched to the open position. The second arm engages and moves the disconnect handle in a second rotational direction so that the disconnect handle is switched to the closed position.

Description:
CLAIM OF PRIORITY 
     This application claims priority to U.S. application No. 62/291,685, filed Feb. 5, 2016, which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     Disconnect switches, such as molded-case circuit breakers, motor circuit protectors, and fused or non-fused air switches, are commonly operated by a handle located on the outside of the equipment enclosure. Typically, the disconnect handle associate with the disconnect switch is oriented to be moved in a vertical direction and will have as many as three positions, specifically, open, closed and tripped. The angular travel of the disconnect switch disconnect handle will vary among various manufacturer&#39;s designs, but typically will be between 60 and 180 degrees. The closed and open positions are located at opposing extremes of travel. If the design is such that a tripped condition can exist, then the disconnect handle of the disconnect switch will typically move to an intermediate position between the closed and open positions. 
     From a personnel safety perspective, it is in the best interest of the person operating this type of equipment to be positioned at a safe distance away from the equipment in case a sudden and catastrophic failure occurs when the disconnect switch is opened or closed. 
     SUMMARY OF THE INVENTION 
     The present disclosure provides embodiments of a portable actuator device and system that require no modification to existing equipment and is suitable for remotely operating disconnect switches. The portable actuator device does not require pre-positioning of its actuating arms to match the current position of the disconnect handle. The portable actuator device is capable of quickly performing all actions that a human operator might wish to accomplish, such as closing the disconnect switch, opening the disconnect switch, or resetting the disconnect switch from a tripped position. 
     An embodiment, among others, of a portable actuator device can be summarized as follows. The portable actuator device has an electric motor having a drive shaft that can be controlled to rotate about a longitudinal axis. The actuator device also has elongated movable first and second arms. The first arm has a distal end and a proximal end. The first arm is capable of pivoting at the proximal end about the axis when the drive shaft is rotated in a first rotational direction so that the distal end is moved about the axis in the first rotational direction. The first arm engages and moves the disconnect handle in the first rotational direction so that the disconnect handle is switched to the open position. The second arm also has a distal end and a proximal end. The second arm is capable of pivoting at the proximal end about the axis when the drive shaft is rotated in a second rotational direction so that the distal end is moved about the axis in the second rotational direction. The second rotational direction is opposite to the first rotational direction. The second arm engages and moves the disconnect handle in the second rotational direction so that the disconnect handle is switched to the closed position. 
     An embodiment, among others, of a portable actuator system can be summarized as follows. The portable actuator system has the portable actuator device described in the previous paragraph as well as a controller and operator interface. The controller is communicatively coupled to the electric motor to control the electric motor and the arms. The operator interface is communicatively coupled to the controller. The operator interface is designed to enable an operator to remotely control the electric motor and the arms in order to selectively engage and move the disconnect handle to the open and closed positions. 
     Other embodiments, devices, systems, features, characteristics, and methods of the present invention will become more apparent in the “Detailed Description of Embodiments” and accompanying drawings and claims, all of which form a part of this specification. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The various embodiments and features of the invention will be clearly depicted in the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. 
         FIG. 1A  is a perspective view of a typical motor control center (MCC) disconnect switch of the prior art with a disconnect handle in an off position. 
         FIG. 1B  is a perspective view of the disconnect handle of  FIG. 1A  in an on position. 
         FIG. 2A  is a front view of an example embodiment of a portable actuator device of the present disclosure. 
         FIG. 2B  is a rear view of the portable actuator device of  FIG. 2A . 
         FIG. 3A  is a front view of the portable actuator device of  FIG. 2  with a top actuating arm in the (actuated) down position, i.e., the disconnect handle is moved to the open position (from a closed or tripped position). 
         FIG. 3B  is a rear view of the portable actuator device of  FIG. 2  with the top actuating arm of  FIG. 3A  in the (actuated) down position, i.e., the disconnect handle is moved to the open position. 
         FIG. 4A  is a front view of the portable actuator device of  FIGS. 2 and 3  with a bottom actuating arm in the (actuated) up position, i.e., the disconnect handle is moved to the closed position (from an open or tripped position). 
         FIG. 4B  is rear view of the portable actuator device of  FIGS. 2 and 3  with the top actuating arm of  FIG. 4A  in the (actuated) down position, i.e., the disconnect handle is moved to the closed position. 
         FIG. 5  is an exploded assembly view of the portable actuator device of  FIGS. 2-4 . 
         FIG. 6  is a perspective view of the portable actuator device of  FIG. 2-5  with a frame and holding magnet assembly. 
         FIG. 7  is a perspective view of the portable actuator device of  FIG. 6  mounted on an MCC disconnect switch, with the position of both, the portable actuator device and disconnect handle in the closed position. 
         FIG. 8  is a perspective view of the portable actuator device of  FIGS. 6 and 7  mounted on an MCC disconnect switch, with the position of both, the portable actuator device and disconnect handle in the open position. 
         FIG. 9  depicts a portable actuator system for remotely operating an electrical disconnect switch with the portable actuator device of  FIGS. 6-8 . 
         FIG. 10  is a functional block diagram showing an embodiment of the electrical architecture of the portable actuator system of  FIG. 9 , which has a wired electrical connection between an operator interface and the portable actuator device. 
         FIG. 11  is a functional block diagram showing an alternative embodiment of the electrical architecture of the portable actuator system of  FIG. 9 , which has a wireless electrical connection between an operator interface and the portable actuator device. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     With reference to  FIGS. 1A and 1B , a typical motor control center (MCC) disconnect switch  100  is depicted.  FIG. 1A  shows the disconnect handle  102  in the open, or off, position, with  FIG. 1B  showing the disconnect handle  102  in the closed, or on position. 
       FIGS. 2A and 2B  are a simplified depiction of the primary mechanism of the portable actuator device  200  (perspective view in  FIG. 6 ), with the actuating arms  203  and  204  in the neutral, or parked position.  FIG. 2A  depicts the front side of the actuating arms  203  and  204 , which engage the disconnect handle  102  shown in  FIG. 1A .  FIG. 2B  depicts the back side of the actuating arms  203  and  204  and shows the top actuating arm return spring  205  and bottom actuating arm return spring  206 , which are connected by the return spring connecting cable  207 . The tension of the return springs  205  and  206  produce a force which tends to cause the actuating arms  203  and  204  to seek to return to the neutral position, as shown. In an alternative embodiment, the actuating arm return springs  205  and  206  may each be replaced with a different type as well as number of springs. 
       FIGS. 3A and 3B  are a simplified depiction of the primary mechanism of the portable actuator device  200  In this position, the gearmotor  201  has been caused to rotate in a clockwise rotational direction as viewed from the shaft end, as viewed in  FIG. 3A . A projection that extends from the drive cam  202  comes into contact with the top actuating arm  203  at a notch  223 , causing the arm  203  to rotate about the axis of the gearmotor shaft  211 . A generally rectangular finger  213  at the distal end of the top actuating arm  203  engages the breaker disconnect handle  102 , shown in  FIG. 1A , causing the disconnect handle  102  to move downward to the open position.  FIG. 3B  depicts the back side of the actuating arms  203  and  204  and shows the top actuating arm return spring  205  and bottom actuating arm return spring  206 , which are connected by the return spring connecting cable  207 . The tension of the return springs  205  and  206  produce a force which tends to cause the actuating arms  203  and  204  to seek to return to the neutral position, as shown in  FIG. 2A . 
       FIGS. 4A and 4B  are a simplified depiction of the primary mechanism of the portable actuator device  200  with the bottom actuating arm  204  in the up, or closed, position.  FIG. 4A  depicts the front side of the bottom actuating arm  204 , which engage the disconnect handle shown in  FIG. 1A   102 . The projection that extends from the drive cam  202  comes into contact with the bottom actuating arm  204  at a notch  224 , causing the arm  204  to rotate about the axis of the gearmotor shaft  211 . A generally rectangular finger  214  at the distal end of the bottom actuating arm  204  engages the breaker disconnect handle  102 , shown in  FIG. 1A , causing the disconnect handle  102  to move upward to the closed position.  FIG. 4B  depicts the back side of the actuating arms  203  and  204  and shows the top actuating arm return spring  205  and bottom actuating arm return spring  206 , which are connected by the return spring connecting cable  207 . The tension of the return springs  205  and  206  produce a force which tends to cause the actuating arms  203  and  204  to seek to return to the neutral position, as shown in  FIG. 2A . 
     The primary mechanism of the portable actuator device  200  is shown in exploded assembly form in  FIG. 5 . The actuator arms  203  and  204  are each generally flat planar members, each having a distal end near their respective fingers  213  and  214  and a proximal end near the gearmotor shaft  211 . Each of the actuator arms  203  and  204  has a respective circular aperture  233  and  234  near their respective proximal ends through which the drive shaft  211  passes. The actuator arms  203  and  204  reside adjacent to each other along the shaft  211  in the front slot of the drive cam  202 . The gearmotor shaft  211  passes through the drive cam  202  and actuator arms  203  and  204 . The drive cam  202  is rigidly affixed to a motor  211 , which is preferably a gearmotor shaft  211 . The gearmotor  211  is a combination of an electric motor and gears or a gear box. The motor associated with the gearmotor  101  can be an alternating current (AC) motor, brushed direct current (DC) motor, or brushless DC motor. The actuator arms  203  and  204  rotate freely on the gearmotor shaft  211 . One end of the top return spring  205  is connected to the top actuating arm  203 . The other end of the top return spring  205  is connected to the return spring connecting cable  207 . The opposite end of the return spring connecting cable  207  is connected to the bottom return spring  206 , with the opposite end of the bottom return spring  206  being connected to the bottom actuating arm  204 . The force that is applied to the actuating arms  203  and  204  by the return springs  205  and  206  tends to cause the actuating arms  203  and  204  to rotate in opposite directions. 
     A completely assembled portable actuator device  200  is shown in perspective in  FIG. 6 . The portable actuator device  200  is depicted in the non-actuated, or neutral, position. A generally planar actuator frame  209  supports the gearmotor  201  and has a holding magnet assembly  210 , which temporarily mounts the portable actuator device  200  to the MCC disconnect switch  100 . The opening, or aperture, in the generally planar actuator frame  209  is sized to approximate the size of the base  101  of the disconnect handle  101  as shown in  FIG. 1 . 
       FIG. 7  depicts the portable actuator device  200  mounted on and to the MCC disconnect switch  100 . The actuator frame  209  has an opening that approximates the size and shape of the base  101  of the disconnect handle  101 , as shown in  FIG. 1 , which provides for proper alignment of portable actuator device  200  and the disconnect handle  102 . In this depiction, the bottom actuating arm  204  has rotated in a counter-clockwise rotational direction as viewed from the shaft end. The bottom actuating arm  204  comes into contact with the disconnect handle  102 , moving it up to the closed position, as shown. 
       FIG. 8  depicts the portable actuator device  200  mounted on the MCC disconnect switch  100 . In this depiction, the top actuating arm  203  has rotated in a clockwise rotational direction as viewed from the shaft end. The top actuating arm  203  comes into contact with the disconnect handle  102 , moving it down to the open position, as shown. 
       FIG. 9  depicts a portable actuator system  300  for remotely operating electrical disconnect switches with the portable actuator device  200 . When a remote actuator device  200  is affixed to a disconnect switch  100 , a control cable  301  connects the portable actuator device  200  to an operator interface  302 , for example, a handheld control station  302 , thus allowing the portable actuator device  200  to be remotely operated by the operator from a safe distance. In an alternative embodiment, the handheld control station  302  could be communicatively coupled to the remote actuator device  200  via a suitable wireless interface. In this embodiment, the handheld control station  302  has a rotary dial switch  303  that controls the gearmotor  201 . The dial switch  303  is shown in an off position in  FIG. 9 . When the dial switch is rotated counterclockwise, the gearmotor  201  is commanded to rotate its shaft  211  counterclockwise as viewed from the shaft end. Conversely, when the dial switch  303  is rotated clockwise, the gearmotor  201  is commanded to rotate its shaft  211  clockwise from the perspective of the shaft end. Other types of operator interfaces are possible, such as those with a display screen, other types of controls, inputs, and outputs, etc. 
       FIG. 10  is a functional block diagram showing an embodiment of the electrical architecture of the portable actuator system of  FIG. 9 , which has a wired electrical connection  301  between the operator interface  302  and the portable actuator device. In this example, the operator interface  302  has an on switch  303  and off switch  304  for moving the disconnect switch to the on and off positions, respectively. The portable actuator system  300  has a computer-based controller  309  on a circuit board with a processor for executing a set of programmable instructions stored in a nonvolatile storage medium, also situated on the circuit board. The circuit board and its power supply  308  are situated within the housing associated with the gearmotor  201 , in this embodiment. The controller  309  controls a motor driver  306 , which drives the gearmotor  201  and drive shaft  211 . 
       FIG. 11  is a functional block diagram showing an embodiment of the electrical architecture of the portable actuator system of  FIG. 9 , which has a wireless electrical connection  301  between the operator interface  302  and the portable actuator device. In this example, the architecture includes a wireless transmitter  310  associated with the operator interface  302  that is communicatively coupled with a wireless receiver  311  that is connected with the controller  309  to enable the operator interface  302  to communicate commands to the controller  309 . 
     The gearmotor  201  can also include an internal shaft position sensor  305  (for example, a potentiometer) that communicates signals to the controller  309  that are indicative of the rotational position of the gearmotor shaft  211 , so that the controller  309  can track movement of the gearmotor shaft  211 . Thus, the controller can sense when the actuator arms  203  and  204  are in the open position, closed position, or neutral position. So, in operation, the actuating arms  203  and  204  start in the neutral position ( FIGS. 2A and 2B ). Then, if the controller  309  controls the gearmotor  201  to rotate its shaft  211  to move the top actuating arm  203  to the open position ( FIGS. 3A and 3B ), the controller then controls the gearmotor  201  to rotate its shaft  211  so that the actuating arm  203  is returned to the neutral position ( FIGS. 2A and 2B ). If the controller  309  controls the gearmotor  201  to rotate its shaft  211  to move the bottom actuating arm  204  to the closed position ( FIGS. 4A and 4B ), the controller then controls the gearmotor  201  to rotate its shaft  211  so that the bottom actuating arm  204  is returned to the neutral position ( FIGS. 2A and 2B ). 
     In an alternative embodiment, the gearmotor  201 , controller, or frame  209  can be equipped with a sensor  307 , for example, an accelerometer, gyroscope, etc., that detects an orientation and communicates this information to the controller  309 . With this information, the controller  309  can make adjustments to the operator interface  302 . For instance, the operator interface  302  may have indicators, such as up and down, right and left, or open and close. With this orientation information, the controller  309  can ensure that these indicators are in fact the way the disconnect handle will be controlled. 
     It should be emphasized that the above-described embodiments of the present invention are merely a possible non-limiting examples of implementations, merely set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiments of the invention without departing substantially from the spirit and principles of the invention. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present invention. 
     For example, note that for reasons of simplicity and clarity, the description of the disclosed invention assumes it is applied to a vertically operated switch. However, the disclosed device is equally suitable for use with a disconnect handle that operates in a horizontal orientation. Such a device would be an alternative embodiment to that described above. 
     In another alternative embodiment, the gearmotor  201 , controller, or frame  209  can be equipped with a sensor, for example, an accelerometer, gyroscope, etc., that detects an orientation and communicates this information to the controller. With this information, program code associated with the controller can make adjustments to the operator interface. For instance, the operator interface may have indicators, such as up and down, right and left, or open and close. With this orientation information, the controller can ensure that these indicators are in fact the way the disconnect handle will be controlled. 
     In another alternative embodiment, the holding magnet assembly  210  can be replaced with one or more suction cups in order to mount the frame  209  of the portable actuator device  200  to the disconnect switch  100 . 
     In another alternative embodiment, the holding magnet assembly can be replaced by mounting the frame  209  of the portable actuator device  200  to the disconnect switch  100  by attaching it to a feature, for example, a bolt, opening, hole, bracket, stud, or edge, associated with the disconnect switch  100  with, for example, a clamp, bolt. etc.