Smart circuit breaker

A smart residential circuit breaker includes a hybrid assembly that incorporates a solid-state circuit element integrated into a simplified mechanical pole having main contacts. The solid-state circuit element includes a printed circuit board (PCB) with a micro SD reader to provide faster opening speeds. The smart residential circuit breaker is configured for use for different current levels and controlled by the PCB. The smart residential circuit breaker includes a mag-latch. The PCB is configured to send a signal to the mag-latch to open and close the main contacts within microseconds of detecting an over-current.

BACKGROUND

Aspects of the present invention generally relate to smart circuit breakers and in particular to smart residential circuit breakers.

2. Description of the Related Art

Due to the enormous demand of energy worldwide, usage of alternative energy production methods has increased. In response to this changing energy landscape, power distribution companies are working on innovations to safely manage and distribute the energy produced. At the same time, the ushering in of the digital/communication age is putting a premium on products that provide customers with data and the ability to control devices. These two major trends provide an opportunity to incorporate new technology into residential circuit breakers.

Many digital enabled services exist, including but not limited to: the ability to provide customers with visibility to their energy usage, the ability for remote control of a circuit breaker, and the ability to notify customers about events in their panel. Innovating in these areas for residential circuit breakers will make manufacturers more competitive as they move towards a more connected future.

On the technical side, current residential circuit breaker designs are subjected to undesirable characteristics such as long arcing times and switch bouncing, both of which result in contact damage. They need to solve these issues to exhibit faster switching times that will result in higher reliability and a longer lifetime of the circuit breaker due to the lowered risk of arcing. To quantify the difference in switching time, current circuit breakers switch in a matter of milliseconds, while a design is required that will switch in a matter of microseconds.

Therefore, there is a need for innovating smart residential circuit breakers by manufacturers to stay competitive as world moves towards a more connected future.

SUMMARY

Briefly described, aspects of the present invention relate to a new structure being added to a smart or hybrid circuit breaker with main contacts in terms of a communication facility. The smart or hybrid circuit breaker accomplishes this with the use of a wireless module such as a Wi-Fi module, a software module with an algorithm, a mag-latch and a microprocessor. These components add the ability for communications within a smart or hybrid residential circuit breaker. The smart or hybrid circuit breaker includes a hybrid assembly that incorporates a solid-state circuit element integrated into a simplified mechanical pole having main contacts. The solid-state circuit element includes a printed circuit board (PCB) with a micro SD reader. A micro SD card determines an amperage rating of the smart or hybrid circuit breaker by a number of exposed pins. The algorithm would identify a number of active pins and with preset conditions identify the amperage rating. The algorithm of the software module monitors a breaker signal and communicates with the Wi-Fi module. This signal can then be transmitted to a receiver in a cell phone. For example, a cell phone application (APP) would receive the signal and display a predetermined information sent from the Wi-Fi module. The algorithm of the software module monitors the smart or hybrid circuit breaker for arc, ground fault, overload or increased instantaneous levels. Based on preset conditions, the mag-latch is configured to be activated to open the main contacts of the smart or hybrid circuit breaker. This monitoring within the algorithm is configured to send a signal to the Wi-Fi module. The Wi-Fi module is configured to send a signal to the receiver of the mobile device such as the cell phone to display the information in the cell phone APP. While the hybrid circuit breaker includes a push to test button to manually turn the device on or off. The cell phone APP application would provide a means to send a signal to the Wi-Fi module within the circuit breaker. Once the algorithm receives a signal from the APP application, a signal would be sent to the mag-latch to open or close.

In accordance with one illustrative embodiment of the present invention, a smart circuit breaker is provided that comprises a wireless communication module, a storage device to store a software module comprising instructions, a hybrid assembly and a mag-latch. The wireless communication module is configured to communicate with an application (APP) stored on a mobile device of a user. The software module is to be executed by a controller. The software module is configured to monitor the smart circuit breaker for at least one of arc, ground fault, overload or increased instantaneous levels. The hybrid assembly incorporates a solid-state circuit element integrated into a simplified mechanical pole having main contacts. The solid-state circuit element includes a printed circuit board (PCB) with a micro SD reader to provide a signal for faster opening speeds. The smart circuit breaker is configured for use for different current levels and controlled by the PCB. The PCB includes a microprocessor and the software module comprising the instructions to communicate with the wireless communication module. The PCB is configured to send a signal to the mag-latch to open and close the main contacts within microseconds of detecting an over-current.

In accordance with another illustrative embodiment of the present invention, a smart residential circuit breaker is provided that includes a hybrid assembly that incorporates a solid-state circuit element integrated into a simplified mechanical pole having main contacts. The solid-state circuit element includes a printed circuit board (PCB) with a micro SD reader to provide faster opening speeds. The smart residential circuit breaker is configured for use for different current levels and controlled by the PCB. The smart residential circuit breaker includes a mag-latch. The PCB is configured to send a signal to the mag-latch to open and close the main contacts within microseconds of detecting an over-current.

DETAILED DESCRIPTION

To facilitate an understanding of embodiments, principles, and features of the present invention, they are explained hereinafter with reference to implementation in illustrative embodiments. In particular, they are described in the context of a smart or a hybrid circuit breaker with digital enabled services including but not limited to: an ability to provide customers with visibility to their energy usage, an ability for remote control of a circuit breaker, and an ability to notify customers about events in their panel. Embodiments of the present invention, however, are not limited to use in the described devices or methods.

In one embodiment, a smart or a hybrid circuit breaker includes algorithms to determine an amperage rating using an SD card. A Wi-Fi module is integrated to provide a signal to a receiver in a receiving device such as a cell phone. A mag-latch is directly connected to a moveable contact arm with a contact. A push to test button to manually send a signal to the mag-latch to open or close the main contacts of the smart or the hybrid circuit breaker. A visual display is configured to show the status and/or error messages of the smart or a hybrid circuit breaker.

The advantages of the smart and the hybrid circuit breaker include: the ability of the user to better understand what is the breaker status without opening the panel door. People are typically unaware or afraid to open the panel. The smart and the hybrid circuit breaker alerts the end user that there is a breaker that has tripped or that there is an issue with a circuit breaker. Today this is only known if the power goes off in a room the person is in. In this case, the user may open the panel but maybe unaware which circuit is open. The ability is provided to change the amperage rating by swapping out a micro SD card. A micro SD card could be identified by the number of active pins to determine the amperage rating. The smart and the hybrid circuit breaker combines the ability of opening or closing a circuit with a combination of components. In this case, a Wi-Fi module (in the breaker), receivers (in the cell phone) and a software interface are deployed.

Consistent with one embodiment of the present invention,FIG. 1represents a representation of perspective views of a smart and the hybrid circuit breaker5comprising a communications facility (not seen) that is configured to provide digital enabled services including but not limited to: an ability to provide customers with visibility to their energy usage, an ability for remote control of a circuit breaker, and an ability to notify customers about events in their panel in accordance with an exemplary embodiment of the present invention. The smart or hybrid circuit breaker5includes a wireless module such as a Wi-Fi module, a software module with an algorithm, a mag-latch and a microprocessor. These components add the ability for communications within the smart or hybrid residential circuit breaker5. The smart or hybrid circuit breaker5includes a hybrid assembly that incorporates a solid-state circuit element (not seen) integrated into a simplified mechanical pole having main contacts. The solid-state circuit element determines an amperage rating of the smart or hybrid circuit breaker5.

A general overview or a foot print of the smart and the hybrid circuit breaker5is shown inFIG. 1. The smart or hybrid circuit breaker5comprises a base7, a cover10and a set of four rivets12(1-4) to hold the base7and the cover10together.

Referring toFIG. 2, it illustrates schematically an exploded view of the smart or the hybrid circuit breaker5ofFIG. 1in accordance with embodiments disclosed herein. The smart or hybrid circuit breaker5includes a wireless communication module205configured to communicate with an application (APP) stored on a mobile device of a user. The smart or hybrid circuit breaker5further includes a storage device207to store a software module210comprising instructions to be executed by a controller212. The software module210is configured to monitor the smart or hybrid circuit breaker5for at least one of arc, ground fault, overload or increased instantaneous levels.

The smart or hybrid circuit breaker5further includes a hybrid assembly215that incorporates a solid-state circuit element217integrated into a simplified mechanical pole having main contacts. The solid-state circuit element217includes a printed circuit board (PCB)220with a micro SD reader222to provide a signal for faster opening speeds. The smart or hybrid circuit breaker5is configured for use for different current levels and controlled by the PCB220. The PCB220includes a microprocessor225and the software module210comprising the instructions to communicate with the wireless communication module205. The smart or hybrid circuit breaker5further includes a mag-latch230. The PCB220is configured to send a signal to the mag-latch230to open and close the main contacts within microseconds of detecting an over-current.

A micro SD card231determines an amperage rating of the smart or the hybrid circuit breaker5by a number of exposed pins. An algorithm of the software module210identifies a number of active pins and with preset conditions identifies the amperage rating. The algorithm of the software module210monitors a breaker signal and communicates with the wireless communication module205such as a Wi-Fi module. This signal can then be transmitted to a receiver in a cell phone.

The smart or the hybrid residential circuit breaker5provides a user with direct breaker status without the need to locate and open a panel door. For example, ON, OFF or an error message may be provided. The present invention introduces a communications facility in the smart or a hybrid residential circuit breaker5that can easily display information to an end user. With the reduction of mechanical components needed to open and close the main contacts, the main contacts can be separated quicker using a signal that is sent to the mag-latch230.

A typical residential circuit breaker consists of a handle, an armature, a cradle, a bimetal, a movable arm with a contact and a cradle to armature latching surface to function properly. A smart or a hybrid residential circuit breaker mechanism does not need a cradle to armature latch surface. The smart or a hybrid residential circuit breaker5does not include a bimetal and therefore does not require thermal calibration in a factory. Thermal calibration of a typical residential circuit breaker requires constant monitoring and consistent audits to verify production lots.

The smart or hybrid circuit breaker5further includes a base232and a cover235which can be attached with rivets or snaps. The base232includes a line terminal237and a lug connector239. The smart or hybrid circuit breaker5further includes a flexible braid241, a contact arm243and a load terminal245. The smart or hybrid circuit breaker5further includes a digital status indicator247.

The mag-latch230is a device that opens and closes the smart or hybrid circuit breaker5every time a signal is received from the PCB220. The mag-latch230also has an incorporated neutral connection250which will avoid an additional step to connect the neutral for the customer. The copper alloy contact arm243is attached to the mag-latch230and the base232. In the contact arm243, one side of the copper alloy flexible braid241is mechanically attached to the contact arm243and the other end of the flexible braid241is mechanically attached to the load terminal245of the smart or hybrid circuit breaker5that at the same time is mechanically connected with the lug connector239. To close the smart or hybrid circuit breaker5the line terminal237is assembled into the base232and the cover235.

The smart or the hybrid circuit breaker5further comprises the micro SD card231(e.g., a generally known memory card for storage) that determines an amp rating of the smart or the hybrid circuit breaker5by a number of exposed active pins. The software module210is configured to identify the number of exposed active pins and based on one or more preset conditions identify the amp rating. The software module210monitors arc, ground fault, overload or increased instantaneous levels to communicate a breaker signal to the wireless communication module205being a Wi-Fi module. The breaker signal is then transmitted to a receiver in the mobile device being a cell phone such that the APP receives the breaker signal and displays predetermined information sent from the wireless communication module205. The APP is configured to send a first signal to the wireless communication module205such that the software module210receives the first signal from the APP in order to send a second signal to the mag-latch230to open or close.

Based on one or more preset conditions, the mag-latch230is activated to open the contacts of the smart or the hybrid circuit breaker5. The mag-latch230is directly connected to a moveable contact arm with a contact and the main contacts are separated using a signal that is sent to the mag-latch230.

The software module210to determine an amp rating of the smart or the hybrid circuit breaker5using the micro SD card231such that the wireless communication module205, i.e., the Wi-Fi module in the mobile device is configured to send a signal of an amperage rating to use in the smart or the hybrid circuit breaker5to the wireless communication module205of the PCB220which sends a signal to the software module210to program the amperage rating to use. The wireless communication module205is integrated into the smart or the hybrid circuit breaker5to provide a signal to be received in the mobile device being a cell phone.

The smart or the hybrid circuit breaker5further comprises a push to test button to manually turn the smart or the hybrid circuit breaker5ON or OFF. The push to test button to manually send a signal to the mag-latch230to open or close the main contacts.

The smart or the hybrid circuit breaker5further comprises a display to visually show at least one of status and error messages of the smart or the hybrid circuit breaker5. The smart or the hybrid circuit breaker5provides a user with a direct breaker status without the need to locate and open a panel door.

In the smart or the hybrid circuit breaker5, a cradle to armature latch surface of the smart circuit breaker is not provided. A bimetal of the smart or the hybrid circuit breaker5is not provided and therefore does not require a thermal calibration in a factory.

The smart or the hybrid circuit breaker5further comprises a first self-test module (see a self-test module ofFIG. 17) comprising instructions that if not functioning properly will automatically open the main contacts and disable the smart circuit breaker. The smart or the hybrid circuit breaker5further comprises a second self-test module (see a self-test module ofFIG. 17) comprising instructions that if not functioning properly will prevent the mag-latch from receiving a signal to close the main contacts.

The smart or the hybrid circuit breaker5is configured to alert an end user that a breaker trip has occurred or that there is an issue with a circuit breaker operation. The smart or the hybrid circuit breaker5is configured to provide an ability to change an amp rating by swapping out a micro SD card.

Turning now toFIG. 3, it illustrates a view of the mag-latch230of the smart or the hybrid circuit breaker5in accordance with an exemplary embodiment of the present invention. The mag-latch230may operate with a 24±2.5 VDC pulse. Aside from a frame and supports, the mag-latch230includes some basic components. For example, the mag-latch230includes a mag-latch plunger305, a permanent magnet310and a coil315. A 24 VDC pulse is applied to the mag-latch230for 23-25 milliseconds to retract the mag-latch plunger305and less than 5 milliseconds to extend the mag-latch plunger305.

FIG. 4illustrates schematically a cross-sectional view of the smart or the hybrid circuit breaker5in an ON position in accordance with an exemplary embodiment of the present invention. The smart or the hybrid circuit breaker5includes an area for an arc chamber400and a contact system including a movable contact arm405and a stationary terminal407. The smart or the hybrid circuit breaker5further includes a device load terminal410, a torsion spring412and the mag-latch230.

When the smart or the hybrid circuit breaker5in ON position the PCB220de-energizes the mag-latch230and the torsion spring412that is attached between the contact arm243and the base232close the contact arm243until a movable contact420make contact with a stationary contact422of the line terminal237. The fast opening of the smart or the hybrid circuit breaker5will be possible by the PCB220(shown inFIG. 2), that is integrated to this device. The PCB220will send a signal to the mag-latch230to open main contacts430within microseconds of detecting an over-current.

As seen inFIG. 5, it illustrates schematically a cross-sectional view of the smart or the hybrid circuit breaker5in an OFF position in accordance with an exemplary embodiment of the present invention. When the PCB220receives a signal to turn OFF the smart or the hybrid circuit breaker5, the mag-latch230is reenergized and a magnet overcomes the force of the torsion spring412to open the main contacts430. An open area is provided where the arc chamber400is located for arc extinguishing.

As shown inFIG. 6, it illustrates schematically means of attachment of the contact arm243with the mag-latch230and the contact arm243with the base232in accordance with an exemplary embodiment of the present invention. A contact arm pivot pin600is used to mechanically attach the contact arm243with the mag-latch230and a pivot pin605is used to assemble the contact arm243to the base232. In this way, a mag-latch and a contact arm interface is provided.

InFIG. 7, it illustrates a view of a neutral connection700that is an assembly between a base705and a cover in accordance with an exemplary embodiment of the present invention. This neutral connection700replaces a regular “pig tail” wire used in a regular electronic circuit breaker. This neutral connection700facilitates the electrical installation process. The way that a neutral bar is intended to work is that when the smart or the hybrid circuit breaker5is installed in a load center or a panel board the neutral connection700feature will make contact with the neutral bar of the system providing a neutral connection to the smart or the hybrid circuit breaker5that is required in every installation for residential application. Between the neutral connection700feature and the base705a compression spring710is assembled that is there to provide or translate the proper contact force required to have a good connection between the neutral connection700and the neutral bar of the system.

With regard toFIG. 8, it illustrates a view of a PCB800and a digital status indicator802assembled into a cover805of the smart or the hybrid circuit breaker5in accordance with an exemplary embodiment of the present invention. Also, in this sameFIG. 8an electrical connection807between the neutral connection700feature and the PCB800is shown.

With respect toFIG. 9, it illustrates several views of a PCB900with a built-in micro SD reader902in accordance with an exemplary embodiment of the present invention. In particular, a view (A) is a perspective view, a view (B) is a side view and a view (C) is a front view.

The PCB900may have a first corner905(1) and a second corner905(2) which is offset from the first corner905(1). The micro SD reader902may be situated at an edge on the first corner905(1). The micro SD reader902may have an opening910to receive a micro SD card (not shown). The micro SD reader902is an example of a memory card reader so other card readers than micro SD card readers are also contemplated.

FIG. 10illustrates multiple views of a contact arm1000in accordance with an exemplary embodiment of the present invention. In particular, a view (A) is a perspective view, a view (B) is a top view, a view (C) is a front view and a view (D) is a side view. The contact arm1000includes four arms1002(1-4) extending from a base plate1005. One of the arms of the four arms1002(1-4) is located on each corner of the base plate1005. Two of the arms1002(1-2) are identical and other two1002(3-4) are different. The fourth arm1002(4) has a curved side end extending away sideways from the base plate1005.

FIG. 11illustrates multiple views of a torsion spring1100in accordance with an exemplary embodiment of the present invention. In particular, a view (A) is a perspective view, a view (B) is a front view and a view (C) is a side view. The torsion spring1100comprises a spring1102with two aims and a coil1105. The torsion spring1100comprises an arm1107extending away from the spring1102.

FIG. 12illustrates multiple views of a compression spring1200in accordance with an exemplary embodiment of the present invention. In particular, a view (A) is a side view and a view (B) is a front view.FIG. 13illustrates a view of a cover1300in accordance with an exemplary embodiment of the present invention.FIG. 14illustrates a view of a base1400in accordance with an exemplary embodiment of the present invention.

FIG. 15illustrates the smart or a hybrid circuit breaker5with software functions in accordance with an exemplary embodiment of the present invention. A flow chart1500of software functions include four subroutines—A, B, C, D1502(1-4). At step1505an amp rating is determined. If a decision is no “N” meaning it is unknown at step1507then the process ends and initiates the subroutine C1502(3). If a decision is yes “Y” meaning it is programmed at step1509then the process checks contact status in step1511. If the contact status is “open” at step1513the subroutine D1502(4) is to be executed. Then a self test pass check is made a step1515. If not (N) “pass” then the subroutine C1502(3) is executed. If “pass” is yes “Y” a current level check is made at step1517. If the contact status is “closed” at step1519then a self test pass check is made at step1521. If not (N) “pass” then the subroutine C1502(3) is executed. If “pass” is yes “Y” a current level check is made at the step1517.

From the current level in step1517, check an instantaneous level in step1523. If the instantaneous level is below 10× then run the subroutine A1502(1). However, if the instantaneous level is above 10× then run the subroutine B1502(2). From the current level in step1517, check an overload status in step1525. If the overload status is below 1.25% then run the subroutine A1502(1). However, if the overload status is above 1.25% then run the subroutine B1502(2).

The subroutine A1502(1) includes a status indicator step1530and a step of displaying1532as “On”, “Current” or “Voltage”. Next a send signal step1535sends a signal via a network1537such as Internet to a phone APP in step1540. A display status “On” is displayed in step1542.

The subroutine B1502(2) includes in step1545a mag-latch is activated to open main contacts. In step1547, the device overcomes a torsion spring force. Then in step1550, the status indicator changes states. Next is a step of displaying1552as “Off”, “--”, “--.” Next via the network1537such as Internet the subroutine B1502(2) sends a signal to a phone APP in step1554. A display status “Off” is displayed in step1555.

The subroutine C1502(3) includes in step1557a mag-latch is activated to open main contacts. In step1559, the device overcomes a torsion spring force. Then in step1560, the status indicator changes states. Next is a step of displaying1562as “error message”. Next via the network1537such as Internet the subroutine C1502(3) sends a signal to a phone APP in step1564. A display status “error message” is displayed in step1565.

The subroutine D1502(4) includes in step1567a mag-latch is activated to close main contacts. In step1569, the main contacts of the smart and the hybrid circuit breaker5close. Next is a step of displaying1572as “On”, “Current” or “Voltage”. Next via the network1537such as Internet the subroutine D1502(4) sends a signal to a phone APP in step1574. A display status “On” is displayed in step1575.

In operation, once the smart and the hybrid circuit breaker5is activated the software module will make several decisions on the initial status of the smart and the hybrid circuit breaker5. First step is to determine if a micro SD card is installed and the amp rating for the smart and the hybrid circuit breaker5is defined. If no SD card is installed, then the smart and the hybrid circuit breaker5starts the subroutine “C”1502(3). In the subroutine “C”1502(3), the mag-latch230receives a 24 VDC signal for 25 milliseconds in the event that the main contacts are closed. This increases the magnetic field strength and attracts the mag-latch plunger. This magnetic force will overcome the torque applied from the torsion spring to the moveable arm with contact. The moveable contact arm rotates clockwise and separates the main contacts. A predetermined message is displayed in the display screen to alert the consumer. This same message is sent to the cell phone APP application thru Wi-Fi and a receiver in the cell phone. If the main contacts are already open, the predetermined message is sent.

If a SD card is installed, the software module determines if the main contacts430are closed or open. In the event that the main contacts430are closed, a self test is conducted to ensure that the electronics are working properly. If the self test passes, the current level is monitored and checked for a thermal overload and/or whether an instantaneous condition exists. If the thermal overload is determined to be 1.25% and/or the instantaneous levels are below 10× the smart and the hybrid circuit breaker5rating, the subroutine “A”1502(1) is started. Under these conditions, a predetermined message is displayed on the display screen to indicate the smart and the hybrid circuit breaker5is ON along with the current and voltage that is being applied to the smart and the hybrid circuit breaker5. This same message is sent to the cell phone APP application thru Wi-Fi and a receiver in the cell phone.

If the thermal overload is higher than 1.25% and/or the instantaneous levels are higher than 10x of the smart and the hybrid circuit breaker5rating, the subroutine “B”1502(2) will be initiated. In this routine, the mag-latch230is activated with a 24 VDC signal to open the main contacts430. This increases the magnetic field strength and attracts the mag-latch plunger. This magnetic force will overcome the torque applied from the torsion spring to the moveable arm with contact. The moveable contact arm rotates clockwise separates the main contacts430. A predetermine message is displayed on the display screen to indicate the smart and the hybrid circuit breaker5is OFF along with no current and voltage being applied. This same message is sent to the cell phone APP application thru Wi-Fi and a receiver in the cell phone.

In the event that the main contacts430are open, the subroutine “D”1502(4) is initiated. A 24 VDC signal is sent to the mag-latch for less than 5 milliseconds. This decreases the magnetic field strength and allows the contact arm with contact to rotate counterclockwise to close the main contacts430. Once the main contacts430are closed, a self test is conducted. If the self test passes, the current level is monitored and checked for a thermal overload and/or whether an instantaneous condition exists. If the thermal overload is determined to be 1.25% and/or the instantaneous levels are below 10x the smart and the hybrid circuit breaker5rating, the subroutine “A”1502(1) is started. In the event if the thermal overload is higher than 1.25% and/or the instantaneous levels are higher than 10x of the smart and the hybrid circuit breaker5rating, the subroutine “B”1502(2) will be initiated. In this routine, the mag-latch230is activated with a 24 VDC signal to ensure that the main contacts430are open. Depending on the subroutine initiated, a predetermined message is displayed on the display screen to indicate the smart and the hybrid circuit breaker5is ON or OFF along with the current and voltage that is being applied to the smart and the hybrid circuit breaker5. This same message is sent to the cell phone APP application thru Wi-Fi and a receiver in the cell phone.

FIG. 16illustrates the smart or the hybrid circuit breaker5turning ON or OFF from a cell phone application (APP)1600in accordance with an exemplary embodiment of the present invention. At the cell phone APP1600, in step1602a breaker is selected. Then at step1605a user can turn ON or OFF the smart or the hybrid circuit breaker5. The cell phone APP1600on a network1607such as Internet via Wi-Fi sends a signal to the smart or the hybrid circuit breaker5. If in step1610(1) the signal is “turn ON” the subroutine D1502(4) is executed. However, if the signal is “turn OFF” in step1610(2) the subroutine C1502(3) is executed. After the run of the subroutine D1502(4) at the step1505an amp rating is determined. Next the flow of the flow chart1500ofFIG. 15is followed.

In operation, once the selection to turn the smart or the hybrid circuit breaker5ON is selected, a signal is sent from the cell phone APP1600, thru Wi-Fi and to the smart or the hybrid circuit breaker5. The subroutine D1502(4) is initiated. A 24 VDC signal is sent to the mag-latch230for less than 5 milliseconds. This decreases the magnetic field strength and allows the contact arm243with contact to rotate counter-clockwise to close the main contacts430. Once the main contacts430are closed, the software module determines the amp rating for the smart or the hybrid circuit breaker5from a micro SD card. A self test is conducted. If the self test passes, the current level is monitored and checked for a thermal overload and/or whether an instantaneous condition exists. If the thermal overload is determined to be 1.25% and/or the instantaneous levels are below 10x the smart or the hybrid circuit breaker5rating, the subroutine “A”1502(1) is started. In the event. If the thermal overload is higher than 1.25% and/or the instantaneous levels are higher than 10x of the smart or the hybrid circuit breaker5rating, the subroutine “B”1502(2) will be initiated. In this routine, the mag-latch230is activated with a 24 VDC signal to open the main contacts430. Depending on the subroutine initiated, a predetermine message is displayed on the display screen to indicate the smart or the hybrid circuit breaker5is ON or OFF along with the current and voltage that is being applied to the smart or the hybrid circuit breaker5. This same message is sent to the cell phone APP1600thru Wi-Fi and a receiver in the cell phone. If no SD card is installed then the software module starts the subroutine “C”1502(3). In the C subroutine, the mag-latch230receives a 24 VDC signal for 25 milliseconds. This increases the magnetic field strength and attracts the mag-latch plunger. This magnetic force will overcome the torque applied from the torsion spring to the moveable arm with contact. The moveable contact arm rotates clockwise and separates the main contacts430. A predetermined message is displayed in the display screen to alert the consumer.

To turn the smart or the hybrid circuit breaker5OFF, the OFF selection is made using the cell phone APP1600. A signal is sent from the cell phone, through Wi-Fi and to the smart or the hybrid circuit breaker5. The subroutine “C”1502(3) will be initiated. In the C subroutine, the mag-latch230receives a 24 VDC signal for 25 milliseconds. This increases the magnetic field strength and attracts the mag-latch plunger. This magnetic force will overcome the torque applied from the torsion spring to the moveable arm with contact. The moveable contact arm rotates clockwise and separates the main contacts430. A predetermined message is displayed in the display screen to alert the consumer. This same message is sent to the cell phone APP1600through Wi-Fi and a receiver in the cell phone.

FIG. 17illustrates a self-test setup for the smart or a hybrid circuit breaker5in accordance with an exemplary embodiment of the present invention. Main contacts1705are provided between a line1707and a load1710across a neutral1712. A display screen1715is provided. A module1720includes a self-test module1722and an electronic detection module1725. The self-test module1722is connected to a mag-latch1727and the electronic detection module1725is connected to a Wi-Fi module1730. A signal1735is sent by the module1720.

In operation, the smart or a hybrid circuit breaker5begins to conduct self-test and/or arc detection once installed. If the self-test does not pass or an arc is detected on the line1707, a 24 VDC is not sent to the mag-latch1727to close the circuit. If the smart or a hybrid circuit breaker5is closed and a self-test non-conforms, an arc is detected on the line1707, overload and/or high instantaneous condition exists, a signal is sent to the mag-latch1727to open the circuit. In either condition, a microprocessor would send a signal to the Wi-Fi module1730to display a message to the display screen1715and indicate “On” to “Open” condition. In the algorithm, preset error messages would be programmed based on the various methods of tripping. In addition, a signal is sent to the Wi-Fi module1730and subsequently received by a cell phone receiver. The same message is displayed in a cell phone application (APP).

FIG. 18illustrates the smart or a hybrid circuit breaker5mechanism in an ON position in accordance with an exemplary embodiment of the present invention. A mag latch plunger1805is shown in an extended position. A mag-latch1807receives a 24 VDC signal that is initiated from several conditions. The signal can be triggered due to a signal from the cell phone APP or a by pressing a Push-To-Test button (PTT)1810. Algorithm in a microprocessor would include pre-setting to display a message for either of these conditions. Using the cell phone APP, a signal would be transmitted to a Wi-Fi module to initiate a signal to the mag-latch1807. As an alternate, a Push-To-Test event would also send a signal to the mag-latch1807that would open the circuit. Once either of these conditions is met, a 24 VDC signal is sent to the mag-latch1807for less than 5 milliseconds. This decreases the magnetic field strength and allows a torsion spring1812to rotate a contact arm or a movable arm with a contact1815counter-clockwise. The contact arm with contact1815rotates about a pivot pin1817. The pivot pin1817can be made of stainless steel material while the contact arm could be made of a copper alloy such as CDA260. The torsion spring1812applies a 1.41±0.1 inch-pound torque to the moveable arm with contact. The moveable arm with contact rotation is stopped when the moveable arm with contact touches a stationary terminal with contact1820. Once the current path has been completed, a message would be sent to a display screen and would switch from “Open” to “On.” In the algorithm, preset messages would be programmed based on the circuit closing. A signal is sent to the Wi-Fi module and subsequently received by a cell phone receiver. The same message is displayed in the cell phone APP.

FIG. 19illustrates the smart or a hybrid circuit breaker5mechanism in an OFF position in accordance with an exemplary embodiment of the present invention. The mag latch plunger1805is shown in a retracted position. The mag-latch1807receives a 24 VDC signal that is initiated from several conditions. The signal can be triggered due to Arc Fault or Ground Fault condition, self test non-conformance, thermal over load, high instantaneous, signal from the cell phone APP application, and/or a by pressing the Push-To-Test button (PTT)1810. An overload condition would be controlled in an algorithm and could be set at 1.25±8% times the circuit breaker rating. An instantaneous condition would be controlled in the algorithm and could be set at 8-10 times the circuit breaker rating. The circuit breaker rating would be determined by the number of contacts exposed on a micro SD card. Alternate means of determining the circuit breaker rating could be The PCBA (printed circuit board assembly) to include a microprocessor with software that will communicate with the Wi-Fi module). The Wi-Fi module in the cell phone or computer will send a signal of what amperage rating to use in the smart or a hybrid circuit breaker5and that will be received by the breaker PCB Wi-Fi receiver and send a signal to the software to program the smart or a hybrid circuit breaker5amperage. A third option to determine the circuit breaker rating could be that the amperage rating of the breaker is adjusted directly to the breaker from where the breaker will have some feature(s) where the end user can adjust the amperage rating directly in the device and a mechanical/electronic interface located in the PCB that will send the signal to the PCB software. Once any of these conditions are met, a 24 VDC signal is sent to the mag-latch1807for 25 milliseconds. This increases the magnetic field strength and attracts the mag-latch plunger1805with a force of 5.0±0.2 pounds. This magnetic force will overcome the torque applied from the torsion spring1812to the moveable arm with contact1815. The moveable arm with contact1815rotates clockwise about the pivot pin1817and therefore separates the contacts. The pivot pin1817can be made of stainless steel material while the contact arm could be made of a copper alloy such as CDA260. Once the current path has been broken, a message would be sent to the display screen that would switch from “On” to “Open.” In the algorithm, preset messages would be programmed based on the various method of tripping. In addition, a signal is sent to the Wi-Fi module and subsequently received by the cell phone receiver. The same message is displayed in the cell phone APP.

While a smart circuit breaker in a residential configuration is described here a range of other constructions of circuit breaker are also contemplated by the present invention. For example, other types of circuit breakers may be implemented based on one or more features presented above without deviating from the spirit of the present invention.

The techniques described herein can be particularly useful for an integrated circuit breaker as a hybrid or a smart device that incorporates a solid-state circuit element integrated into a simplified mechanical pole having main contacts. While particular embodiments are described in terms of such an integrated circuit breaker configuration, the techniques described herein are not limited to a single pole or a partially electronic form but can also be used with other suitable forms.

Additionally, any examples or illustrations given herein are not to be regarded in any way as restrictions on, limits to, or express definitions of, any term or terms with which they are utilized. Instead, these examples or illustrations are to be regarded as being described with respect to one particular embodiment and as illustrative only. Those of ordinary skill in the art will appreciate that any term or terms with which these examples or illustrations are utilized will encompass other embodiments which may or may not be given therewith or elsewhere in the specification and all such embodiments are intended to be included within the scope of that term or terms.

Respective appearances of the phrases “in one embodiment,” “in an embodiment,” or “in a specific embodiment” or similar terminology in various places throughout this specification are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, or characteristics of any particular embodiment may be combined in any suitable manner with one or more other embodiments. It is to be understood that other variations and modifications of the embodiments described and illustrated herein are possible in light of the teachings herein and are to be considered as part of the spirit and scope of the invention.