Patent Description:
<CIT> describes an electrical distribution system wherein information is communicated to and/or from an electrical component of the electrical distribution system using near-field communications. The information may be communicated to and/or from the electrical component using an electronic device such as a dedicated near-field device, a smartphone or a configuration card device. <CIT> describes A circuit breaker (such as a miniature circuit breaker) that wirelessly communicates state and fault information to a main energy monitoring module. The wireless circuit breaker includes a transceiver and a power supply that harvests energy inductively from the line current conductor without the need for a connection to a neutral conductor.

Currently, there is no easy way to understand why a residential circuit breaker trips on electrical loads that seem completely safe and normal. Also troubleshooting problems associated with these unwanted trips are time consuming and expensive to the business.

The present way to get insight into the unwanted tripping problem is to hook up oscilloscopes to an electronic circuit breaker while in the panel to retrieve more information. Alternately, the circuit breaker is brought back to a R&D lab facility to retrieve information that was saved previously in the circuit breaker. After analyzing the load data in the R&D lab, one has to alter a breaker algorithm to treat these unusual loads as normal and safe. After this, new firmware code of the circuit breaker would have to get tested with a problematic electrical load to make sure the circuit breaker doesn't still trip on it.

Therefore, there is a need for a better electronic circuit breaker for a residential application.

Briefly described, aspects of the present invention relate to an electronic circuit breaker for a residential application. Real time monitoring and parametric modifications for electronic circuit breakers through a remote device with a graphical interface is provided. The invention lets a user retrieve information from an electronic circuit breaker installed in the panel wirelessly to a mobile phone application (APP). The APP can show live current, voltage and RF signal data which are used in a breaker algorithm to trip in case of an unsafe and arcing electrical load. The APP working in tandem with the electronic circuit breaker can act like an oscilloscope where the user can set certain trigger conditions and the APP would show captured results. The APP can also share the retrieved data by means of email or messaging Apps outside of the mobile phone. The R&D experts can now look at the waveforms of the problematic electrical load very quick and recommend fixes in the breaker algorithm. The APP can also allow the user to tweak some of the breaker thresholds to alter the breaker algorithm. Alternately, if there is a code update that is necessary to fix the issue then a new firmware code can be programmed into the electronic circuit breaker wirelessly through the APP. The electronic circuit breaker can then be tested with the problematic electrical load to make sure the new firmware code has helped fix the unwanted tripping problem. This invention speeds up troubleshooting time significantly and saves on costs involved in making expensive field visits from R&D staff or shipping expensive equipment around the country for troubleshooting visits. The new breaker algorithm also can store previous trip events with a time stamp. This information can be retrieved on power up to find how many days power has been down on that breaker.

In accordance with one illustrative embodiment of the present invention, a system comprising an electronic circuit breaker and a mobile application (APP) running on a remote device with a graphical user interface, the electronic circuit breaker comprises a transceiver to wirelessly transmit information including waveform data and a microcontroller including a processor and a memory. The breaker further comprises computer-readable firmware code stored in the memory which, when executed by the processor, causes the microcontroller to: monitor in real-time one or more breaker functional parameters to determine parametric modifications, wirelessly transmit the information that was saved previously in the electronic circuit breaker about the one or more breaker functional parameters to a remote device with a graphical user interface, alter a breaker algorithm after analyzing load data of problematic electrical loads in a mobile application (APP) of the remote device to treat the problematic electrical loads as normal and safe and test the computer-readable firmware code with a problematic electrical load to make sure the electronic circuit breaker doesn't still trip on the problematic electrical load.

In accordance with one illustrative embodiment of the present invention, a method of retrieving waveform data from an electronic circuit breaker wirelessly and altering a breaker code wirelessly is provided. The method comprises providing a transceiver to wirelessly transmit information including waveform data, providing a microcontroller including a processor and a memory, providing computer-readable firmware code stored in the memory which, when executed by the processor, causes the microcontroller to: monitor in real-time one or more breaker functional parameters to determine parametric modifications, wirelessly transmit the information that was saved previously in the electronic circuit breaker about the one or more breaker functional parameters to a remote device with a graphical user interface, alter a breaker algorithm after analysis of load data of problematic electrical loads in a mobile application (APP) of the remote device to treat the problematic electrical loads as normal and safe and test the computer-readable firmware code with a problematic electrical load to make sure the electronic circuit breaker doesn't still trip on the problematic electrical load.

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 real time monitoring and parametric modifications for electronic circuit breakers through a remote device with a graphical interface. The invention provides ability to retrieve waveform data from a breaker wirelessly or have ability to alter the breaker code wirelessly. The invention here reduces troubleshooting time and costs significantly by incorporating an oscilloscope feature within an electronic circuit breaker itself and adding the feature to wirelessly retrieve information from a mobile phone. The ability to update code on the electronic circuit breaker wirelessly speeds up time in verifying new code against the problematic electrical load. Also, giving the user information on how long the electronic circuit breaker was down is useful information. Embodiments of the present invention, however, are not limited to use in the described devices or methods.

The components and materials described hereinafter as making up the various embodiments are intended to be illustrative and not restrictive. Many suitable components and materials that would perform the same or a similar function as the materials described herein are intended to be embraced within the scope of embodiments of the present invention.

These and other embodiments of the electronic circuit breaker according to the present disclosure are described below with reference to <FIG> herein. Like reference numerals used in the drawings identify similar or identical elements throughout the several views. The drawings are not necessarily drawn to scale.

Consistent with one embodiment of the present invention, <FIG> represents a block diagram of an electronic circuit breaker <NUM> that wirelessly communicates with a mobile application (APP) <NUM> for diagnostics purposes via a wireless link <NUM> in accordance with an exemplary embodiment of the present invention. The present invention generally relates to real time monitoring and parametric modifications for the electronic circuit breaker <NUM> through a remote device (e.g., a mobile phone) <NUM> with a graphical user interface <NUM>. The electronic circuit breaker <NUM> comprises a transceiver <NUM> to wirelessly transmit information including waveform data <NUM>. The electronic circuit breaker <NUM> further comprises a microcontroller <NUM> including a processor <NUM>(<NUM>) and a memory <NUM>(<NUM>). The electronic circuit breaker <NUM> further comprises computer-readable firmware code <NUM> stored in the memory <NUM>(<NUM>) which, when executed by the processor <NUM>(<NUM>), causes the microcontroller <NUM> to monitor in real-time one or more breaker functional parameters <NUM>(<NUM>-n) to determine parametric modifications <NUM>(<NUM>-n), wirelessly transmit information <NUM> that was saved previously in the electronic circuit breaker <NUM> about the one or more breaker functional parameters <NUM>(<NUM>-n) to the remote device <NUM> with the graphical user interface <NUM>, alter a breaker algorithm <NUM> after analyzing load data <NUM> of problematic electrical loads <NUM> in the mobile application (APP) <NUM> of the remote device <NUM> to treat the problematic electrical loads <NUM> as normal and safe and test the computer-readable firmware code <NUM> with a problematic electrical load <NUM>(<NUM>) to make sure the electronic circuit breaker <NUM> doesn't still trip on the problematic electrical load <NUM>(<NUM>).

The computer-readable firmware code <NUM> lets the mobile application (APP) <NUM> wirelessly retrieve the information <NUM> from the electronic circuit breaker <NUM> installed in a panel. The mobile application (APP) <NUM> is configured to show live current <NUM>(<NUM>), voltage <NUM>(<NUM>) and Radio Frequency (RF) signal data (<NUM>(<NUM>) which are used in the breaker algorithm <NUM> to trip in case of an unsafe and arcing electrical load such as the problematic electrical load <NUM>(<NUM>). The mobile application (APP) <NUM> is configured to work in tandem with the electronic circuit breaker <NUM> so it can act like an oscilloscope where a user can set certain trigger conditions <NUM>(<NUM>-n) and the mobile application (APP) <NUM> will show captured results <NUM>. The mobile application (APP) is configured to share any retrieved data <NUM> by means of email or messaging Apps outside of a mobile phone <NUM> on which the mobile application (APP) <NUM> is installed.

In the mobile application (APP) <NUM>, waveforms <NUM> of the problematic electrical load <NUM>(<NUM>) can be examined and fixes <NUM> in the breaker algorithm <NUM> recommended. The mobile application (APP) <NUM> enables a user to tweak one or more of breaker thresholds <NUM>(<NUM>-m) to alter the breaker algorithm <NUM>.

If there is a code update that is necessary to fix an issue, a new code <NUM> can be programmed into the electronic circuit breaker <NUM> wirelessly through the mobile application (APP) <NUM>. The electronic circuit breaker <NUM> can then be tested with the problematic electrical load <NUM>(<NUM>) to ensure the new code <NUM> has helped fix a unwanted tripping problem <NUM>. The breaker algorithm <NUM> is configured to store previous trip events <NUM> with a time stamp <NUM>.

For example, Arc Fault Circuit Interrupter (AFCI) Diagnostics is a mobile App that is available both in Android and iOS platforms to communicate with the breakers to perform diagnostic troubleshooting. A mobile phone communicates with a breaker over Bluetooth Low Energy <NUM> protocol. The mobile App can be downloaded and installed using information from the manual document. Once the mobile App is installed, a user can follow a manual document to set up the breaker for troubleshooting and collecting data. The manual document identifies the features present in the mobile App. Also, the manual document assumes the communicating breaker is running a certain firmware version. Click on the mobile App icon from the mobile phone to see a splash screen followed by a screen showing the list of available breaker devices in the vicinity.

Referring to <FIG>, it illustrates a schematic of a user interface <NUM> of a mobile phone application (APP) that shows available devices <NUM>(<NUM>-<NUM>) showing breakers in the vicinity in accordance with an exemplary embodiment of the present invention. The available devices screen is the first screen that a user will view after the mobile App is loaded. It will display any wireless breaker ("AFCIBLE") that is within range. Available Devices screen also has a view history button <NUM> that allows the user to view any previously saved records.

Turning now to <FIG>, it illustrates a schematic of a display screen <NUM> of a mobile phone application (APP) that shows pairing of a mobile phone with an electronic circuit breaker in accordance with an exemplary embodiment of the present invention. To connect to a breaker, the user can click on the device of interest from the displayed list. If this is the first time that the user is connecting their phone to a given breaker, they will have to enter the multi-digit passcode to pair the phone to the breaker. Once the pairing process is complete, the user will be navigated to the Dashboard section of the mobile App, showing the breaker details. The user can also view additional information about the app from this page by clicking the "i" icon.

<FIG> illustrates a schematic of offline records <NUM> stored in the mobile phone in accordance with an exemplary embodiment of the present invention. When on the available devices screen the user has the option to view, share and delete previously saved records (on the mobile phone), without having to connect to the breaker.

As seen in <FIG>, it illustrates a schematic of browsing through offline records <NUM> in accordance with an exemplary embodiment of the present invention. Click a "show" button <NUM> to view a record <NUM> or click a "share" button <NUM> to send the record <NUM> via email or messaging.

As shown in <FIG>, it illustrates a schematic of view after clicking show on the view history screen in accordance with an exemplary embodiment of the present invention. The display includes a graph for a load current <NUM>, RF signal <NUM> and a line voltage <NUM>. A trigger is also shown.

In <FIG>, it illustrates a schematic of a dashboard screen in accordance with an exemplary embodiment of the present invention. The mobile App displays a dashboard page <NUM>, upon a successful connection. The other pages like the status, record and settings page can be accessed by clicking on their respective icons on the bottom of the mobile App screen. The dashboard page <NUM> shows the Breaker Name (centered on the top), breaker rating, type, firmware revision and the date/time as set in the breaker device. Arc fault and overcurrent fault statuses are displayed in the form of LED bars <NUM>(<NUM>-<NUM>) to represent how close the breaker is to trip on these faults. The breaker name and date/time fields can be edited from the settings page.

With regard to <FIG>, it illustrates a schematic of clicking "view all" soft button <NUM> to see a list of all alerts in accordance with an exemplary embodiment of the present invention. Alert notifications are displayed on this screen if any of the following conditions happen: i. if breaker is close to tripping on an arc fault, ii. if breaker is close to tripping on an overcurrent fault, iii. if the peak current or RMS current levels go beyond set threshold limits. if breaker completed an oscilloscope capture and v. if phone lost connection with the breaker unexpectedly.

With respect to <FIG>, it illustrates a schematic of a list <NUM> of all alerts in accordance with an exemplary embodiment of the present invention. A list of all the alerts and notifications (maximum of <NUM>) along with a time stamp can be viewed by clicking on the view all soft button next to the alert on the dashboard page or breaker status screen. The individual alert message can be deleted from the list by swiping the finger across the alert. There is also an option to delete all alerts or notifications by pressing delete all soft button <NUM> that is at the bottom of a notifications screen <NUM>.

<FIG> illustrates a schematic of a status screen <NUM> in accordance with an exemplary embodiment of the present invention. The status screen <NUM> shows more details of a circuit breaker like load current <NUM> and RF signal data <NUM> in the form of LED bars <NUM>(<NUM>-<NUM>). It also shows live peak <NUM> and RMS <NUM> current values. The status screen <NUM> also has details of a trip state <NUM> including the last time the breaker tripped, including the fault condition that led to the trip and the timestamp of that event. The alert/notification messages <NUM> are also displayed on the status screen <NUM>.

<FIG> illustrates a schematic of a record screen <NUM> showing the <NUM> tabs in accordance with an exemplary embodiment of the present invention. The record screen <NUM> has two tabs - new record <NUM> and history <NUM>. The record screen <NUM> provides an oscilloscope like interface to set up trigger conditions and to display the captured waveform while also giving the user the option to save all this data and view previously saved data. The new record <NUM> tab lets the user configure a scope capture and view the associated data. This tab has two sections- settings and graph.

<FIG> illustrates a schematic of a new record screen <NUM> with trigger settings option in accordance with an exemplary embodiment of the present invention. Scope trigger settings <NUM> are shown (expanded) by clicking on a down arrow to the right of settings (if it is not already expanded). After the trigger settings <NUM> are selected, click on save settings <NUM> to save these into the breaker's memory. The following are the list of parameters to set up a scope capture: Trigger Source <NUM>, Trigger Direction <NUM>, Trigger Window <NUM>, Trigger Level <NUM> and Buffer Size <NUM>.

This determines the signal that would be used for the triggering the capture. The options for Trigger Source <NUM> are:.

The Trigger Window <NUM> defines the length of data captured before and after the trigger event. Range: <NUM> cycles before trigger - <NUM> cycles before and <NUM> cycles after trigger - <NUM> cycles after trigger.

The Trigger Level <NUM> is the value in ADC bits at which the oscilloscope function should trigger (dependent upon the Trigger Direction <NUM>).

The buffer size <NUM> represents the size of the waveform captured in the breaker.

<FIG> illustrates a schematic of a record screen1305 - how to set up a new capture in accordance with an exemplary embodiment of the present invention. After adjusting the trigger settings <NUM> in the settings section, expand a Graph section <NUM> by clicking on the down arrow to the right. A scope trigger can be started by clicking on a Record button <NUM>. This brings up a pop-up window that says, "Waiting for capture". This is when the scope is waiting for the trigger condition to happen. If the user wants to cancel the waveform capture for some reason, they can press Cancel on a pop-up window (not shown) on the bottom of the record screen <NUM>. Once a trigger occurs, the waveform data will be downloaded. The download progress is indicated on the screen.

<FIG> illustrates a schematic of waveform data showing graph in accordance with an exemplary embodiment of the present invention. The waveform data is displayed on the graph once the data has been downloaded. The waveform shows <NUM> signals that are plotted:.

The user can turn a signal on/off on graph <NUM> by checking/unchecking the corresponding tick box <NUM>(<NUM>-<NUM>) below the graph <NUM>. The user can also zoom in and out of the graph by using finger pinching actions. The graph can be scrolled through using finger sliding action.

<FIG> illustrates a schematic of saving waveform data in accordance with an exemplary embodiment of the present invention. A user can save the waveforms along with the trigger settings associated with the capture by clicking on a save button on top of the graph. This brings up a textbox <NUM> to enter a file name. The file name can accept alphabets, numbers, or characters like hyphen(-), underscore(_) and hash(#). Once the file name is entered, click save <NUM> to store the waveform file in the mobile App. The waveforms can be shared outside the mobile phone by clicking on a share button on top of the graph. This brings up the messaging or email Apps that can be used to message or email the waveform data.

<FIG> illustrates a schematic of viewing list of saved records in accordance with an exemplary embodiment of the present invention. A history tab <NUM> shows all the waveforms that were captured on the circuit breaker (using the mobile phone) and saved to the mobile phone. It displays a list <NUM> of all the waveform records by the file name and time stamp. A delete all button <NUM> at the bottom of the list, deletes all the records related to the circuit breaker that were stored on the mobile phone. The user can view a record in detail by clicking on a down arrow button <NUM> next to a filename <NUM>.

<FIG> illustrates a schematic of viewing details from a saved record <NUM> in accordance with an exemplary embodiment of the present invention. The record <NUM> details include all trigger settings <NUM> that were used for the capture. The user can press a show button <NUM> to view the graph which provides a very similar user interface like the graph section of a new record tab <NUM>. The user can also share the waveform record via email or message from this screen by pressing a share button <NUM> next to the show button <NUM>. In addition, the user can also delete a record from the phone by clicking a delete button <NUM> next to the share button <NUM>.

The mobile App has a settings page where the user can view and update the mobile App and breaker settings. The following settings can be updated: Breaker Time and Date, Breaker Name, Breaker Firmware (Application Coprocessor and Wireless Coprocessor), Variables, Notification Settings and Demo Mode.

A screen allows the user to set the Time and Date of the breaker. This setting will be active in the breaker until it loses power. By default, the time and date on this screen will match the time that is set on the user's mobile phone. A screen allows the user to set the Breaker Name. It allows up to <NUM> alpha numeric characters. This setting will be permanently saved in the breaker when "Save Changes" is clicked.

<FIG> illustrates a schematic of starting firmware upgrade in accordance with an exemplary embodiment of the present invention. This screen <NUM> allows the user to do a wireless firmware update to the circuit breaker <NUM>. Updating the firmware include the following steps.

<FIG> illustrates a schematic of editing variables in accordance with an exemplary embodiment of the present invention. A variables screen <NUM> has five variables that are stored to Flash. After making changes to the variables, click a Save Variables button <NUM> to permanently save these parameters to the circuit breaker <NUM>.

<FIG> illustrates a schematic of editing threshold settings for alerts in accordance with an exemplary embodiment of the present invention. This screen <NUM> allows the user to set thresholds for Faults and Current. The threshold values for the following alerts can be set here: Arc Fault (Range of <NUM>-<NUM>), Overcurrent Fault (Range of <NUM>-<NUM>), Minimum/ Maximum Peak Current, Minimum/ Maximum RMS Current and Maximum number of waveform records that can be saved per breaker. In addition, Peak current and RMS current related alerts can be enabled or disabled by using the Activate switch. After adjusting the threshold values here, the user needs to press a save button <NUM> for the settings to be stored in the mobile App database for each breaker device.

When the parameters go beyond the threshold values listed here, alerts would be generated on the Dashboard and Status page. In addition, if the waveform records have reached the maximum capacity as set by the threshold here, the related alert would be displayed when the user attempts to start a new scope capture on the Record screen. In that scenario, the user would have to delete at least one record before starting the new capture.

Demo Mode option allows the user that is connected to a breaker device to get sample data on the Dashboard and Status pages. This option is primarily used by developers and is for demonstration purpose only.

<FIG> illustrates a schematic view of a flow chart of a method <NUM> of retrieving waveform data from an electronic circuit breaker wirelessly and altering a breaker code wirelessly in accordance with an exemplary embodiment of the present invention. Reference is made to the elements and features described in <FIG>. It should be appreciated that some steps are not required to be performed in any particular order, and that some steps are optional.

The method <NUM> comprises a step <NUM> of providing a transceiver to wirelessly transmit information including waveform data. The method <NUM> further comprises a step <NUM> of providing a microcontroller including a processor and a memory. The method <NUM> further comprises a step <NUM> of providing computer-readable firmware code stored in the memory which, when executed by the processor, causes the microcontroller to: monitor in real-time one or more breaker functional parameters to determine parametric modifications, wirelessly transmit the information that was saved previously in the electronic circuit breaker about the one or more breaker functional parameters to a remote device with a graphical user interface, alter a breaker algorithm after analyzing load data of problematic electrical loads in a mobile application (APP) of the remote device to treat the problematic electrical loads as normal and safe and test the computer-readable firmware code with a problematic electrical load to make sure the electronic circuit breaker doesn't still trip on the problematic electrical load.

While an electronic circuit breaker for a residential application is described here a range of one or more other breakers or other forms of breakers are also contemplated by the present invention. For example, other types of 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 AFCI diagnostics via a mobile App. While particular embodiments are described in terms of these AFCI diagnostics, the techniques described herein are not limited to such a set-up but can also be used with other diagnostics.

While embodiments of the present invention have been disclosed in exemplary forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions can be made therein without departing from the spirit and scope of the invention and its equivalents, as set forth in the following claims.

Embodiments and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known starting materials, processing techniques, components and equipment are omitted so as not to unnecessarily obscure embodiments in detail. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments, are given by way of illustration only and not by way of limitation.

For example, a process, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, article, or apparatus.

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.

Claim 1:
System comprising an electronic circuit breaker (<NUM>) and a mobile application APP (<NUM>) running on a remote device (<NUM>) with a graphical user interface (<NUM>), the electronic circuit breaker (<NUM>), comprising:
a transceiver (<NUM>) to wirelessly transmit information from the electronic circuit breaker including waveform data;
a microcontroller (<NUM>) including a processor (<NUM> (<NUM>)) and a memory (<NUM> (<NUM>)); and
computer-readable firmware code (<NUM>) stored in the memory (<NUM> (<NUM>)) which, when executed by the processor, causes the microcontroller (<NUM>) to:
monitor in real-time one or more breaker functional parameters to determine parametric modifications,
wirelessly transmit information (<NUM>) that was saved previously in the electronic circuit breaker (<NUM>) about the one or more breaker functional parameters to the remote device (<NUM>),
characterized in that the processor further causes the microcontroller (<NUM>) to alter a breaker algorithm after an analysis of load data (<NUM>) of problematic electrical loads (<NUM>) in a mobile application, APP, (<NUM>) of the remote device (<NUM>) to treat the problematic electrical loads (<NUM>) as normal and safe, and
test the computer-readable firmware code with a problematic electrical load to make sure the electronic circuit breaker (<NUM>) doesn't still trip on the problematic electrical load (<NUM>).