Patent Description:
A motor starter may be used to deliver power to a motor by electrically coupling the motor to a power supply. The motor starter may also protect the motor from irregularities in the power signal output by the power supply that may shorten a lifespan of the motor. For example, the motor starter may electrically decouple the motor from the power supply upon determining that more than a threshold amount of current is passing through the motor starter. In some embodiments, multiple motor starters may be positioned adjacent to one another, such as within a common enclosure. Accordingly, it may be desirable to reduce the footprint of each motor starter in order to increase the number of motor starters that an enclosure can hold and/or to reduce the volume of the enclosure. <CIT> discloses a contactor of generally known design which consists of a housing comprising vacuum switching chambers as main contacts, upper and lower terminals, a magnet system with a fixed magnet, coil, and a movable anchor as a switching device for loads in particular motors. The contactor function is implemented by the sensor, which is integrated into the contactor housing. The current sensor may be a Rogowski coil or a Hall sensor and is connected to the controller. By positioning the controller in the head part of the contactor, all connectors and the user interface elements can be directly attached to the circuit board of the controller and accessible from the front of the contactor. <CIT> discloses a motor control device, particularly a motor control device comprising a plurality of power circuitry units in a housing unit of said motor control device, wherein at least one power circuitry unit is provided with a contact rail, an electronic contact element and one electromechanical contact element configured as a bridging element. Connecting elements are provided in the housing unit, connecting the electronic contact element of one power circuitry unit to corresponding contact rail parts of the contact rail and to the electromechanical contact element of said power circuitry unit both electrically and mechanically such that the contact rail parts of the power circuitry unit can be interconnected via the electronic contact element and the electromechanical contact element. <CIT> discloses motor starting or motor control device, which is designed to control the connection between its input-side and corresponding output-side terminals in such a way that an electric motor can be started or stopped gently, wherein the device has i) a semiconductor power component for control between the input-side terminals and the respective output-side terminals; ii) a bridging part for low-loss bridging of the input-side terminals with the respective output-side terminals; and iii) a control part for switching from the semiconductor power part to the bridging part if the electric motor has been ramped up. The semiconductor power part is fitted on a lower part which has been provided with a cooling plate as substrate, and the control part is fitted on the semiconductor power part. It is the object of the present invention to provide an improved motor starting device and system. The invention is as defined by the independent claims <NUM> and <NUM>. Any embodiment in the description which is not covered by the claims is for illustrative purposes only.

Motor starters are implemented in industrial automation systems to act as an interface between a motor and a power supply. Motor starters may have two primary functions: enable current flow from the power supply to the motor to power the motor, and disable or suspend current flow from the power supply to the motor to protect the motor from irregularities in the current flow from the power supply. For example, the motor starter may include a contactor portion that may provide an electrical connection between the motor and the power supply that may supply the current. As used herein, a contactor portion may include any component, such as a component of a contactor, that may switch between enabling power to be supplied to the motor and disrupting power supply to the motor. The contactor portion may include one or more moveable contacts that electrically couple the motor to the power supply (e.g., in a closed position of the contact(s)) to enable current flow from the power supply to the motor. Further, the contactor portion may electrically decouple the motor from the power supply (e.g., in an open position of the contact(s)) to disrupt current flow from the power supply to the motor. The motor starter may operate with or without user control. In other words, the motor starter may automatically couple and decouple the motor from the power supply without a user manually adjusting the position of the contact(s).

In some embodiments, the contactor portion and the motor protection system may be positioned adjacent to one another in a longitudinal direction of the motor starter. For example, the contactor and the motor protection system may be separate components, coupled to one another to interface with one another. However, this arrangement may increase an equipment footprint of the motor starter where available physical space for placing various items is limited. For example, the motor starter may be positioned on a surface within the enclosure and may occupy an excessive amount of space on the surface. As such, a limited quantity of motor starters may be positioned on the surface, or the motor starters may occupy a greater amount of space than desired.

Accordingly, the present invention is related to a motor starter having a decreased equipment footprint. The motor starter includes a contactor portion and a motor protection system that are integrated in a vertical direction, rather than the longitudinal or horizontal direction, and disposed within a single housing or otherwise packaged together. That is, rather than having a separate contactor or contactor portion and a separate motor protection system coupled to one another, the contactor portion and the motor protection system are combined into a single collective assembly, thus reducing the equipment footprint of the motor starter.

Proceeding to the figures, <FIG> is a schematic view of an embodiment of an industrial automation system <NUM> that includes a motor starter <NUM> having a contactor portion <NUM> and a motor protection system <NUM>. The motor starter <NUM> may act as an interface between a motor <NUM> and a power supply <NUM> to electrically couple and decouple the motor <NUM> from the power supply <NUM>. For example, the power supply <NUM> may supply a current that flows through the contactor portion <NUM> of the motor starter <NUM>, such that the contactor portion <NUM> directs the current to the motor <NUM> to power the motor <NUM>. In some cases, there may be irregularities in the current provided by the power supply <NUM> and/or by the motor <NUM> (e.g., phase loss, stall), such that the irregularities may cause undesirable stress on the motor <NUM>. In response, the motor protection system <NUM> may disrupt the flow of current to the motor <NUM> to increase a lifespan of the motor <NUM>.

The motor protection system <NUM> may include an actuation mechanism or component that may physically move the contactor portion <NUM> from a closed position in which the contactor portion <NUM> conducts current and an open position in which the contactor portion <NUM> isolates current from the motor <NUM>. For instance, a determination of irregular current flow through the motor starter <NUM> may cause the motor protection system <NUM> to effectuate and disable or suspend current flow through the motor starter <NUM>. Additional details regarding the motor protection system <NUM> will be discussed herein.

The motor starter <NUM> has a motor starter housing <NUM> that encloses the contactor portion <NUM> and the motor protection system <NUM> and separates the motor starter <NUM> from the motor <NUM> and the power supply <NUM>. As will be further described herein, the contactor portion <NUM> and the motor protection system <NUM> are arranged in a manner to reduce a size or an equipment footprint of the motor starter housing <NUM>. Additionally, the industrial automation system <NUM> may include a first set of electrical connections <NUM> (e.g., wires) to couple the motor <NUM> to the motor starter <NUM>, and a second set of electrical connections <NUM> to couple the power supply <NUM>, and therefore the motor <NUM>, to the motor starter <NUM>.

In some embodiments, the motor starter <NUM> includes an interface <NUM>, which may enable external control of the motor starter <NUM>, such as of the contactor portion <NUM> and/or the motor protection system <NUM>. In one example, the interface <NUM> may be a user interface that enables a user or operator to control the motor starter <NUM> manually. In another example, the interface <NUM> may be a network interface that communicatively couples the motor starter <NUM> to a network and enable remote control of the motor starter <NUM> (e.g., via a computing device).

<FIG> is a schematic view of an embodiment of the industrial automation system <NUM> providing additional details regarding the components of the motor starter <NUM>. As illustrated, the power supply <NUM> provides current to the motor starter <NUM>. As referred to herein, the current provided by the power supply <NUM> is in the form of a constant three-phase alternating-current (AC) voltage or current waveform, but in additional embodiments, the power supply <NUM> may provide a different waveform, such as a two-phase AC voltage waveform, a six-phase AC voltage waveform, or the like. In further embodiments, the current may be provided by the power supply <NUM> in the form of a direct-current (DC) voltage waveform.

In general, the power supply <NUM> supplies a three-phase AC voltage waveform by delivering three AC voltage waveforms of approximately identical amplitudes and frequencies, but offset by a time difference to one another. That is, each AC voltage waveform alternates between a positive voltage or current amplitude (e.g., maximum voltage or current value) and a negative voltage or current amplitude (e.g., minimum voltage or current value), and crossing a zero voltage or current value between the respective positive and negative voltage amplitudes. Each AC voltage waveform includes substantially the same positive voltage amplitude and substantially the same negative voltage amplitude. Furthermore, each AC voltage waveform approaches the positive voltage amplitude, approaches the negative voltage amplitude, and crosses the zero voltage value at substantially the same frequency (i.e., a quantity per second). However, each AC voltage waveform may not reach the respective positive voltage amplitude, the negative voltage amplitude, and the zero voltage value at the same point in time. For instance, at a single point in time, one of the AC voltage waveforms may be crossing the zero voltage value, another AC voltage waveform may be at a positive voltage value that is less than the positive voltage amplitude, and the remaining AC voltage waveform may be at a negative voltage value that is greater than the negative voltage amplitude. Each AC voltage waveform may be offset by an equal time difference. That is, for example, a first AC voltage waveform may reach its positive voltage amplitude at a first time, a second AC voltage waveform may reach its positive voltage amplitude at a second time, a third AC waveform may reach its positive voltage amplitude at a third time, and the first AC voltage waveform may reach its positive voltage amplitude again at a fourth time. The difference between the first time and the second time, between the second time and the third time, and between the third time and the fourth time are substantially the same time interval.

When the power supply <NUM> provides current, each AC voltage waveforms of the three-phase AC voltage waveforms is transmitted from the power supply <NUM> through a respective first electrical connection <NUM> of the first set of electrical connections <NUM> to the motor starter <NUM>. In some embodiments, the motor starter <NUM> is energized (e.g., powered) to move a respective movable contact system <NUM> of the contactor portion <NUM> to the closed position. As used herein, the movable contact system <NUM> may include components such as a contact, a contact holder, a lever, and so forth, that are adjustable to enable or disrupt current flow through the motor starter <NUM>. In the closed position, the movable contact system <NUM> electrically couples the first electrical connection <NUM> with a respective second electrical connection <NUM> of the second set of electrical connections <NUM> to enable one of the AC voltage waveforms to flow through the second electrical connection <NUM> to the motor <NUM>. However, if the motor starter <NUM> is not energized (e.g., unpowered), the corresponding movable contact system <NUM> opens and, therefore, the first electrical connection <NUM> is not electrically coupled to the second electrical connection <NUM>.

The motor protection system <NUM> may control an operation of the contactor portion <NUM> to prevent current flow through the movable contact system <NUM>. For example, the motor protection system <NUM> may cause a component to engage in response to detecting an overload condition (i.e., undesired amount of current flow) and/or a short circuit condition (i.e., excessive current flow) in the motor starter <NUM>. For example, the motor protection system <NUM> may block a respective AC voltage waveform from flowing through the respective movable contact system <NUM> to the motor <NUM>, such as upon a determination that the AC voltage waveform is uncharacteristic (e.g., having excessive current). In some embodiments, the motor protection system <NUM> may be communicatively coupled to a controller <NUM> that may adjust the movable contact system <NUM> to enable or disable the current flow through the movable contact system <NUM> of the contactor portion <NUM>. The controller <NUM> may include a memory <NUM> and a processor <NUM>. The memory <NUM> may be a mass storage device, a flash memory device, removable memory, or any other non-transitory computer-readable medium that includes instructions for the processor <NUM> to execute, such as instructions to operate the motor protection system <NUM>. The memory <NUM> may also include volatile memory, such as randomly accessible memory (RAM), and/or non-volatile memory, such as hard disc memory, flash memory, and/or other suitable memory formats. In additional embodiments, the motor protection system <NUM> may effectuate and move the movable contact system <NUM> based on a characteristic of the current (e.g., an amount of current flow). By way of example, excessive current will electrically effectuate the motor protection system <NUM> (i.e., without the use of the controller <NUM>) to open the movable contact system <NUM> and block the current from flowing through the motor starter <NUM> to the motor <NUM>. Furthermore, in certain embodiments, the motor starter <NUM> may additionally include a motor protection system <NUM> implemented to open the second set of electrical connections <NUM> to decouple the motor <NUM> from the motor starter <NUM>.

In some embodiments, the interface <NUM> may be communicatively coupled to the motor protection system <NUM> and/or the contactor portion <NUM>. In one example, the interface <NUM> may enable a user to effectuate the motor protection system <NUM>, such as to block the current from flowing through the motor starter <NUM> (e.g., manually block the flow of the current), and/or to enable the current to flow through the motor starter <NUM> (e.g., manually enable current flow to start or restart through the motor starter <NUM>). The interface <NUM> may, for instance, enable a user to open the contactor portion <NUM> to block the current from flowing through the motor starter <NUM>.

<FIG> is a perspective view of an embodiment of the motor starter <NUM> having the motor starter housing <NUM>. The motor starter housing <NUM> encloses and may block external debris, such as dust, from contacting the contactor portion <NUM> and the motor protection system <NUM>. The motor starter housing <NUM> includes terminal openings <NUM> that enable the motor <NUM> or the power supply <NUM> to electrically couple to terminals (not shown) of the motor starter <NUM>. Moreover, the motor starter housing <NUM> may include a mounting interface <NUM> that enables the motor starter <NUM> to couple to another component, such as a control panel enclosure. The motor starter <NUM> may have a longitudinal length <NUM> extending in a longitudinal direction <NUM>, a lateral length <NUM> extending in a lateral direction <NUM>, and a vertical length <NUM> extending in a vertical direction <NUM>. The longitudinal length <NUM> may be a value between <NUM> millimeters (mm) and <NUM>, the lateral length <NUM> may be a value between <NUM> and <NUM>, and the vertical length <NUM> may be a value between <NUM> and <NUM>. While attached via the mounting interface <NUM>, the equipment footprint of the motor starter <NUM> may primarily be based on the longitudinal length <NUM> and the lateral length <NUM>. In the present disclosure, the contactor portion <NUM> and the motor protection system <NUM> may be arranged such that the motor starter housing <NUM> may be dimensioned to reduce the longitudinal length <NUM> of the motor starter <NUM> and, therefore, limiting the equipment footprint of the motor starter <NUM>.

In some embodiments, the interface <NUM> of the motor starter <NUM> may be disposed externally to the motor starter housing <NUM>, such as away from the mounting interface <NUM> in the vertical direction <NUM>. In the illustrated embodiment, the interface <NUM> includes a user interface <NUM> that is separate from a network interface <NUM>. In certain embodiments, the user interface <NUM> may include a component, such as a dial, a switch, a pushbutton, a touchpad, and the like, with which a user may interact to control an operation of the motor starter <NUM> (e.g., of the contactor portion <NUM> and/or the motor protection system <NUM>). Moreover, the network interface <NUM> may couple the motor starter <NUM> to a network component, such as a router, a network drive, and so forth, and communicatively couple the motor starter <NUM> with a computing device. As such, a user may control the operation of the motor starter <NUM> remotely via the computing device.

<FIG> is an exploded perspective view of the motor starter <NUM> with the motor starter housing <NUM> removed to illustrate internal components of the motor starter <NUM>. The motor starter <NUM> may be divided into three distinct functional sections: the interface <NUM>, a contactor portion and motor protection assembly <NUM>, and an actuation system <NUM>. Each functional section may interact with the other functional sections to maintain operation of the motor starter <NUM> to enable the power supply <NUM> to power the motor <NUM>.

The contactor portion and motor protection assembly <NUM> includes the components that enable the contactor portion <NUM> and the motor protection system <NUM> to interact with one another within an integrated system. The illustrated embodiment of the contactor portion and motor protection assembly <NUM> includes first terminals <NUM> and second terminals <NUM>. The first terminals <NUM> and second terminals <NUM> may each receive the current. In some embodiments, the power supply <NUM> may electrically couple to the first terminals <NUM> and the motor <NUM> may electrically couple to the second terminals <NUM>. Additionally, the power supply <NUM> may electrically couple to the second terminals <NUM> and the motor <NUM> may electrically couple to the first terminals <NUM>.

In order for the current to pass through the motor starter <NUM>, each respective movable contact system <NUM> may close to electrically couple the respective first terminals <NUM> to the respective second terminals <NUM>. In certain embodiments, each movable contact system <NUM> includes a first arm <NUM> that extends toward first stationary contacts <NUM> that are electrically coupled to the first terminals <NUM> and a second arm <NUM> that extends toward second stationary contacts <NUM> that are electrically coupled to the second terminals <NUM>. As illustrated in <FIG>, the first stationary contacts <NUM> may be positioned below the first terminals <NUM> in the vertical direction <NUM>, and the second stationary contacts <NUM> may be positioned below the second terminals <NUM> along in vertical direction <NUM>. While the movable contact system <NUM> is closed (e.g., when the current is flowing through the terminals <NUM>, <NUM>), the first arm <NUM> may engage the first stationary contacts <NUM> and electrically couple to the first terminals <NUM>, and the second arm <NUM> may engage the second stationary contacts <NUM> and electrically couple to the second terminals <NUM>. Therefore, the first terminals <NUM> may electrically couple to the second terminals <NUM> such that current may flow through the first terminals <NUM> and the second terminals <NUM> via the arms <NUM>, <NUM> of the movable contact system <NUM>.

For example, the actuation system <NUM> closes each movable contact system <NUM> to enable current flow through the motor starter <NUM>. The actuation system <NUM> includes a plurality of actuators <NUM>, in which each actuator <NUM> energizes upon receiving a voltage. In some embodiments, each actuator <NUM> may be electrically coupled to the controller <NUM>, and may be energized based on an activation signal received from the controller <NUM>. For example, a user may input instructions to the controller <NUM> via the user interface <NUM> and/or remotely via the network interface <NUM>, such that the instructions cause the controller <NUM> to send a signal to the actuation system <NUM> to energize the actuators <NUM>. After the actuators <NUM> are energized, the contactor portion <NUM> moves in a direction (e.g., vertical direction <NUM>) to physically engage with the first stationary contacts <NUM> and second stationary contacts <NUM>. In certain embodiments, the actuators <NUM> may include a linear actuator, such as a plunger type actuator, a magnetic actuator, a piston type actuator, a sliding wedge type actuator, and the like. Additionally, the actuation system <NUM> may include other types of actuators <NUM> to enable current flow through the motor starter <NUM>.

While the movable contact system <NUM> is open, the first arm <NUM> may not be engaging the first stationary contacts <NUM>, and the second arm <NUM> may not be engaging the second stationary contacts <NUM>. For example, the first arm <NUM> may be positioned between the first terminals <NUM> and the first stationary contacts <NUM>, and the second arm <NUM> may be positioned between the second stationary contacts <NUM> such that the movable contact system <NUM> is not electrically coupled to the first terminals <NUM> and the second terminals <NUM>, and the first terminals <NUM> is not electrically coupled to the second terminals. In this manner, current may not flow through the motor starter <NUM> when the movable contact system <NUM> is in the open position.

The motor protection system <NUM> may open each movable contact system <NUM>. In some embodiments, the motor protection system <NUM> may include a sensor <NUM> that determines an overload condition. For example, the sensor <NUM> may determine a characteristic of the current flowing through one of the first terminals <NUM>. The sensor <NUM> may be communicatively coupled to the controller <NUM>, in which the controller <NUM> may adjust the position of each movable contact system <NUM>. For example, the sensor <NUM> may determine a value of the characteristic of the current and transmit the value to the controller <NUM>. The controller <NUM> may determine if the value is indicative of an overload condition (e.g., the value exceeds a threshold value) and, in response to determining the value is indicative of the overload condition, the controller <NUM> may open the corresponding movable contact system <NUM> to block the current from flowing to the motor <NUM>. Thus, the controller <NUM> may avoid operating the motor <NUM> in the overload condition.

The motor protection system <NUM> may also include a coil system <NUM> implemented to move as a result of a short circuit condition occurring in the motor starter <NUM>. For example, the coil system <NUM> may be positioned electrically in series with the terminals <NUM>, <NUM> and may receive the current flowing through the motor starter <NUM>. If the current flow indicates an excessive current flow, such as when current is unintentionally routed through the motor starter <NUM> (e.g., the power supply supplies an unintended amount of current), the coil system <NUM> may effectuate and open the contactor portion <NUM>.

In the illustrated embodiment, the contactor portion and motor protection assembly <NUM> may be integrated with one another generally in the vertical direction <NUM>. That is, the contactor portion <NUM> and the motor protection system <NUM> may be positioned adjacent to one another in the vertical direction <NUM> to reduce a distance that the motor starter <NUM> extends in the longitudinal direction <NUM>. Furthermore, the contactor portion <NUM> and/or the motor protection system <NUM> may each be structured to reduce a size of the contactor portion and motor protection assembly <NUM>. For example, the contactor portion <NUM> may share a substantial amount of volume (e.g., each movable contact system <NUM> is positioned between the sensors <NUM> and the coil system <NUM>). Thus, the contactor portion and motor protection assembly <NUM> is further compacted as compared to coupling the contactor portion <NUM> and the motor protection system <NUM> together as separate components.

<FIG> is a perspective view of the motor starter <NUM> of <FIG> that illustrates the interactions between the internals components of the motor starter <NUM>. In the illustrated embodiment, each movable contact system <NUM> may be coupled to a biasing member <NUM> (e.g., spring coil) coupling the movable contact system <NUM> to a stationary base <NUM>. The biasing member <NUM> may be implemented to impart a force onto the movable contact system <NUM> to extend the movable contact system <NUM> in a first direction <NUM> (e.g., generally upward in the vertical direction <NUM>) toward the first stationary contacts <NUM> and the second stationary contacts <NUM> and away from the base <NUM>. As such, the first arm <NUM> and the second arm <NUM> are engaging the first stationary contacts <NUM> and the second stationary contacts <NUM>, respectively. For example, adjustment of the user interface <NUM> may enable the biasing member <NUM> to extend the movable contact system <NUM> in the first direction <NUM>, thereby enabling the movable contact system <NUM> to close when the actuators <NUM> are energized (e.g., by the controller <NUM>) Adjustment of the user interface <NUM> may also block the movable contact system <NUM> from moving in the direction <NUM>. That is, adjusting the user interface <NUM> may cause the movable contact system <NUM> to move in a second direction <NUM> such that the first arm <NUM> and the second arm <NUM> no longer engage the first stationary contacts <NUM> and the second stationary contacts <NUM>, respectively. As a result, the position of the movable contact system <NUM> disrupts the flow of current through the motor starter <NUM>, and current may not flow through the motor starter <NUM> even when the actuators <NUM> are energized. In some embodiments, each movable contact system <NUM> is coupled to a respective mechanism <NUM> that may move the movable contact system <NUM>. The mechanism <NUM> is coupled to the controller <NUM> and/or the coil system <NUM>. As such, the controller <NUM> and/or the coil system <NUM> open the movable contact system <NUM> and block current flow through the motor starter <NUM> by moving the mechanism <NUM>. For example, upon determining that the current received by the motor starter <NUM> is not desirable, the controller <NUM> may instruct the mechanism <NUM> to move in the second direction <NUM> toward the base <NUM> to open the movable contact system <NUM>.

Furthermore, effectuation of the coil system <NUM> (e.g., due to excessive current) may cause the coil system <NUM> to move the mechanism <NUM> in the second direction <NUM> toward the base <NUM> to open the movable contact system <NUM>. As an example, the coil system <NUM> may receive excessive current that causes the coil system <NUM> to create a magnetic field. The created magnetic field may physically cause the coil system <NUM> (e.g., a plunger of the coil system <NUM>) to move (e.g., contract). A large enough current may cause enough movement of the coil system <NUM> to move the mechanism <NUM> in the second direction <NUM> to open the movable contact system <NUM>. As a result, the mechanism <NUM> may be electrically activated by the current without the use of the controller <NUM>, such that the coil system <NUM> (e.g., a mechanical connection between the coil system <NUM> and the mechanism <NUM>) may open the contactor portion <NUM> more quickly than using the controller <NUM> to open the contactor portion <NUM>. Additionally, the coil system <NUM> may move the mechanism <NUM> in a different manner, such as using components (e.g., bimetals) that bend at a high temperature to cause movement of the mechanism <NUM>.

As should be noted, the mechanism <NUM> may primarily open the movable contact system <NUM> during current irregularities, such as overload and/or short circuit conditions. Operation of the motor starter <NUM> in the presence of current irregularities may shorten a lifespan of the motor <NUM>. Thus, the mechanism <NUM> may be automatically effectuated upon a determination of a current irregularity to increase the lifespan of the motor <NUM>. Moreover, the actuators <NUM> may be used to open and close the movable contact system <NUM> in a controlled manner (e.g., via the interface <NUM>). That is, the position of the movable contact system <NUM> may be desirably set in either the open position or the closed position by the actuators <NUM>, and the mechanism <NUM> may be used to override a set closed position of the movable contact system <NUM> in response to a determination of a current irregularity.

In the illustrated embodiment, the interface <NUM>, the contactor portion <NUM>, the motor protection system <NUM>, and the actuation system <NUM> are positioned adjacent to one another in the vertical direction <NUM>. In this manner, the motor starter <NUM> generally extends in the vertical direction <NUM>, rather than in the longitudinal direction <NUM> that may limit an equipment footprint of the motor starter <NUM> in the longitudinal direction <NUM>. It should also be noted that the interface <NUM>, the contactor portion <NUM>, the motor protection system <NUM>, and the actuating system <NUM> may be aligned with one another in a different order than described herein. As an example, although <FIG> and <FIG> illustrate the actuation system <NUM> and the contactor portion <NUM> are positioned below the motor protection system <NUM> and the contactor portion <NUM>, the actuation system <NUM> and/or the contactor portion <NUM> may be positioned above the motor protection system <NUM> and/or the interface <NUM> or in any other suitable manner. In additional embodiments of the motor starter <NUM>, the components of the motor starter <NUM> may be positioned along the lateral direction <NUM>. For example, the contactor portion <NUM> may be disposed laterally with respect to the motor protection system <NUM>. As such, the motor starter <NUM> may extend in the lateral direction <NUM>, but the longitudinal length <NUM> of the motor starter <NUM> may remain substantially the same to limit the equipment footprint of the motor starter <NUM> in the longitudinal direction.

In certain embodiments, the controller <NUM> and/or the coil system <NUM> may simultaneously open each movable contact system <NUM> of the contactor portion <NUM>. That is, when the controller <NUM> determines the current is not desirable and/or if the coil system <NUM> receives excessive current, the mechanism <NUM> of each movable contact system <NUM> may move at approximately the same time such that each movable contact system <NUM> may open at approximately the same time. In additional embodiments, the motor starter <NUM> may include a contactor portion controller <NUM> implemented to open each movable contact system <NUM> independently at a different time from one another, such as based on the respective AC voltage waveforms (e.g., point on wave control). The contactor portion controller <NUM> may be the same controller as the controller <NUM>, but the contactor portion controller <NUM> may alternatively be a controller that is separate from the controller <NUM>. The contactor portion controller <NUM> may controllably open each movable contact system <NUM> to limit the effects of opening each movable contact system <NUM>. For example, adjusting the movable contact system <NUM> when current is flowing through the movable contact system <NUM> may cause electrical arcs (e.g., current flow through the air) that shorten a lifespan of the motor starter <NUM> (e.g., by affecting structure of the movable contact system <NUM>). For a motor starter <NUM> having single contact system, or a single movable contact system <NUM>, and employing the features described herein to compact the size of the motor starter <NUM>, the effects of the structure of the movable contact system <NUM> may cause frequent replacement of the movable contact system <NUM>. For this reason, in general, the contactor portion controller <NUM> may open the movable contact system <NUM> when substantially no current is flowing through the movable contact system <NUM> to limit the effect that current flow may have on the other components. That is, opening the movable contact system <NUM> when the AC voltage waveform crosses the zero voltage value reduces or limits the interaction between the current flow and the components of the motor starter <NUM>. In this way, the contactor portion controller <NUM> may improve the performance of the motor starter <NUM> and/or increase a lifespan of the motor starter <NUM>, thereby reducing costs associated with implementing and/or operating the motor starter <NUM>.

<FIG> is a block diagram illustrating an embodiment of a method or process <NUM> that may be used by the contactor portion controller <NUM> to open each movable contact system <NUM> of the contactor portion <NUM> in a controlled manner. The method <NUM> is an exemplary embodiment and similar methods or processes may be used to open each movable contact system <NUM>. For example, similar methods or processes may include additional and/or different steps than the steps illustrated by the method <NUM>.

At block <NUM>, the contactor portion controller <NUM> determines that the movable contact system <NUM> (e.g., a contact of the movable contact system <NUM>) of the contactor portion <NUM> is to be opened. In some embodiments, the contactor portion controller <NUM> may be communicatively coupled to the controller <NUM>, the sensor <NUM>, the coil system <NUM>, and/or the mechanism <NUM>, and may instruct the contact(s) <NUM> to open based on a condition of the controller <NUM>, the sensor <NUM>, the coil system <NUM>, and/or the mechanism <NUM>. As such, the contactor portion controller <NUM> may receive a signal from the controller <NUM>, the sensor <NUM>, the coil system <NUM> and/or the mechanism <NUM> indicative that the movable contact system <NUM> (e.g., a contact of the movable contact system <NUM>) is to be opened. For example, the controller <NUM> may transmit the signal in response to the controller <NUM> determining an overload condition. In another example, the sensor <NUM> may transmit the signal indicative of a characteristic of the current to the contactor portion controller <NUM>, and the contactor portion controller <NUM> may determine the overload condition based on the signal transmitted by the sensor <NUM>. In a further example, the coil system <NUM> may transmit the signal in response to receiving an excessive current. In yet another example, the mechanism <NUM> may transmit the signal when activated by the controller <NUM> and/or the coil system <NUM>.

In response to receiving the signal, the contactor portion controller <NUM> may open each movable contact system <NUM>, such as by transmitting a signal to the mechanism <NUM>, at a specific time (block <NUM>). For example, the contactor portion controller <NUM> may determine the respective AC voltage or current waveforms flowing through each movable contact system <NUM>, and may open each movable contact system <NUM> via point on wave control, or based on a point on each particular AC voltage or current waveform. In some embodiments, the contactor portion controller <NUM> may open each movable contact system <NUM> when the respective AC voltage or current waveforms are approximately at or crossing the zero voltage or current value, or when substantially no voltage is present on or current is flowing through the respective movable contact system <NUM>. As mentioned, opening each movable contact system <NUM> when substantially no voltage is present on or current is flowing through the respective movable contact system <NUM> may limit an impact that current flow may have on a performance of the motor starter <NUM> as a result of a sudden movement of the movable contact system <NUM>, and may increase the lifespan of the motor starter <NUM> as compared to opening each movable contact system <NUM> when voltage is present on or current is flowing through the respective movable contact system <NUM> (e.g., at a non-zero voltage value of the AC voltage waveform). Since the respective AC voltage or current waveforms of the movable contact system <NUM> may be at or may cross the zero voltage or current value at different points in time, each movable contact system <NUM> may be opened at a different time than one another, rather than at substantially the same time.

In certain embodiments, the contactor portion controller <NUM> may also determine the amount of time that elapses between when the contactor portion controller <NUM> receives the signal to open a particular movable contact system <NUM> and when the mechanism <NUM> effectively decouples the particular contact from the first and second stationary contacts <NUM>, <NUM>. The contactor portion controller <NUM> may factor the amount of time to determine when to instruct the mechanism <NUM> to open the movable contact system <NUM> (e.g., relative to when the corresponding AC voltage or current waveform will cross the zero voltage or current value).

<FIG> is a diagram illustrating respective equipment footprints of different motor starter embodiments. Particularly, each equipment footprint includes a longitudinal length in the longitudinal direction <NUM> and a lateral length in the lateral direction <NUM> for each motor start embodiment. For example, a first motor starter <NUM>, which may be a first motor starter embodiment available in the market, may have a first longitudinal length <NUM> that is a value between <NUM> and <NUM>. A second motor starter <NUM>, which may be a second motor starter embodiment available in the market, may have a second longitudinal length <NUM> that is a value between <NUM> and <NUM>. The motor starter <NUM> of the present disclosure may have the longitudinal length <NUM> that is between <NUM> and <NUM>, or any combination thereof. As such, the motor starter <NUM> may occupy a substantially smaller space in the longitudinal direction <NUM> as compared to the first motor starter <NUM> and the second motor starter <NUM>. Moreover, as shown in <FIG>, each motor starter <NUM>, <NUM>, <NUM> may have substantially the same lateral length <NUM>. As a result, the area occupied by the motor starter <NUM> based on the longitudinal length <NUM> and the lateral length <NUM> is substantially smaller than the respective areas occupied by the first motor starter <NUM> and the second motor starter <NUM>.

As should be noted, point on wave control (e.g., by the contactor portion controller <NUM>) may increase longevity of the motor starter <NUM>, particularly motor starters <NUM> using a single contact system, and may enable the particular alignment of the components of the motor starter <NUM> to be implemented as described herein to limit the longitudinal length <NUM> between <NUM> and <NUM>. For example, current may continue to flow through air when the position of the movable contact system <NUM> is adjusted to the open position. The interaction of the current flow through the air with the components of the motor starter <NUM> may decrease a lifespan of the motor starter <NUM>. However, controlling each movable contact system <NUM> to open when the respective AC voltage or current waveforms cross the zero voltage or current value may limit the effect of the current flow on the components of the motor starter <NUM>. In other words, opening each movable contact system <NUM> when substantially no current is flowing through the movable contact system <NUM> may limit the interaction between the current flow and the other components of the motor starter <NUM>. Thus, the point on wave control certain components of the motor starter <NUM>, such as the movable contact system <NUM> and the motor protection system <NUM>, to be positioned proximate to one another in the orientation discussed above without reducing a lifespan of the motor starter <NUM>.

In some embodiments, the respective equipment footprints represent an amount of space on a surface occupied by each motor starter <NUM>, <NUM>, <NUM> when coupled to the surface. The amount of space on the surface occupied by the motor starter <NUM> in the longitudinal direction <NUM> is substantially reduced relative to the amount of space on the surface occupied by the first motor starter <NUM> and the second motor starter <NUM>. As such, in some embodiments, implementing the motor starter <NUM> may enable placing a greater quantity of motor starters <NUM> onto the surface as compared to implementing the first motor starter <NUM> and/or the second motor starter <NUM>. That is, a greater space efficiency may be achieved with use of the motor starter <NUM>. Moreover, the first motor starter <NUM>, the second motor starter <NUM>, and the motor starter <NUM> may each have the same or similar operational specifications (e.g., power, short circuit rating, lifecycle time), even though the motor starter <NUM> occupies less space than the first motor starter <NUM> and the second motor starter <NUM>. In this manner, the motor starter <NUM> achieves the same operation as compared to the first motor starter <NUM> and/or the second motor starter <NUM>, while also having a smaller equipment footprint.

While only certain features of the disclosure have been illustrated and described herein, many modifications and changes will occur to those skilled in the art, without departing from the scope of the present invention, which is defined by the appended claims.

Claim 1:
A motor starter (<NUM>), comprising:
a housing (<NUM>);
a contactor portion (<NUM>) comprising a movable contact system (<NUM>), the contactor portion being disposed within the housing, wherein the contactor portion is configured to move between an open position and a closed position, wherein, in the open position, current does not flow through the motor starter and, in the closed position, current is allowed to flow through the motor starter, wherein the movable contact system comprises a first arm (<NUM>) that extends toward first stationary contacts (<NUM>) that are electrically coupled to first terminals (<NUM>) and a second arm (<NUM>) that extends toward second stationary contacts (<NUM>) that are electrically coupled to the second terminals (<NUM>);
a motor protection system (<NUM>) disposed within the housing adjacent to the contactor portion in a vertical direction (<NUM>), wherein the motor protection system comprises a plurality of components configured to move the contactor portion to the open position based on a current flow; and
an actuation system (<NUM>) disposed within the housing, wherein the actuation system is configured to move the contactor portion between the closed position and the open position in response to receiving an input,
wherein the actuation system comprises electromagnetic actuators (<NUM>) configured to drive a plurality of contacts of the contactor portion magnetically between the open position and the closed position, such that when the actuators are energized, the contactor portion moves in the vertical direction to physically engage with the first stationary contacts and second stationary contacts; and
wherein the motor protection system is configured to, when instructed by a controller or a coil system, open the movable contact system when the actuators are energized.