Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. provisional application entitled “PORTABLE ACTUATOR AND METHOD” having Ser. No. 61/369,918, filed Aug. 2, 2010, the entirety of which is hereby incorporated by reference. 
    
    
     BACKGROUND 
     A circuit breaker is designed to protect an electrical circuit from damage caused by a short circuit. For example, the circuit breaker may interrupt the continuity of the electrical circuit, thereby discontinuing the electrical flow. In large scale electrical systems, a typical circuit breaker is operated by a human operator who physically pushes a “trip” or “close” button located on the face of the circuit breaker. For instance, the human operator may stand within a close proximity to the circuit breaker and manually actuate the button. Upon actuating the button, the circuit breaker functions to interrupt the electrical flow within the circuit. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. 
         FIG. 1  is a drawing of a typical circuit breaker according to various embodiments of the present disclosure. 
         FIG. 2  is a perspective view of the under-side of an actuator frame. 
         FIG. 3A  is a view of the right side of the actuator where the actuator is in a neutral position. 
         FIG. 3B  is a view of the right side of the actuator where the actuator is in a “close” position. 
         FIG. 4A  is a view of the left side of the actuator where the actuator is in a neutral position. 
         FIG. 4B  is a view of the “trip” pushrod and cam, in the neutral position. 
         FIG. 4C  is a view of the “trip” pushrod and cam, in the “trip” position. 
         FIG. 5A  is a top view of the actuator with the safety interlock in the normal position. 
         FIG. 5B  is a top view of the actuator with the safety interlock in the “prohibit” position. 
         FIG. 6  is a perspective view of the actuator installed on a typical circuit breaker, along with the remote control for the actuator. 
         FIG. 7  is a perspective view of the portable actuator in place, as viewed from the right side of the actuator cover and with the safety interlock removed. 
         FIGS. 8A ,  8 B, and  8 C are block diagrams of one embodiment of a control system for the portable actuator. 
     
    
    
     DETAILED DESCRIPTION 
     Disclosed are various embodiments for a portable actuator capable of being remotely operated to actuate a circuit breaker. In the following discussion, a general description of the system and its components is provided, followed by a discussion of the operation of the same. 
     With reference to  FIG. 1 , shown is a portable actuator  200  according to various embodiments. The portable actuator  200  may be affixed to a circuit breaker  100  and configured to actuate the circuit breaker  100 . In one embodiment, the portable actuator  200  includes a protective covering  201  that protects a gearbox configured to actuate the circuit breaker  100 , as will be described. In addition, a set of geometric dimensions of the portable actuator  200  may correspond to the geometric dimensions of the circuit breaker  100 . For instance, the length and width of the portable actuator  200  may correspond substantially to the length and width of a front dimension of the circuit breaker  100 . 
     In one embodiment, the portable actuator  200  may engage the breaker pull handle  130  to initiate affixing to the circuit breaker  100 . For instance, engaging the breaker pull handle  130  may ensure that the portable actuator  200  is properly aligned with the circuit breaker  100  to effectively actuate the circuit breaker  100 . The portable actuator  200  may be affixed to the circuit breaker  100  by aligning a bottom portion of the portable actuator  200  with the breaker pull handle  130  at an acute angle, as shown in  FIG. 1 . Then, as shown in  FIG. 1 , by rotating a top portion of the portable actuator  200  in a clockwise direction until the top portion engages the front dimension of the circuit breaker  100 , the portable actuator  200  may be affixed to the circuit breaker  100 . In one embodiment, proper alignment with the circuit breaker  100  may ensure that the gearbox being protected by the protective covering  201  is properly positioned over the circuit breaker controls  110 / 120 . 
     Moving now to  FIG. 2 , shown is an under-side view of the portable actuator  200  according to various embodiments. In one embodiment, magnets  205 ,  206 , and  207  may be used to secure the portable actuator  200  onto the circuit breaker  100  once the portable actuator  200  is aligned properly against the circuit breaker  100 . In another embodiment, any other form of securing mechanism may be used, such as, for instance, adhesives, Velcro, screws, nuts and bolts, and/or any other securing mechanism. Further, the number of magnets  205 / 206 / 207  may correspond to the geometric dimensions of the portable actuator  200 . For instance, a larger set of geometric dimensions may require a higher number of magnets  205 / 206 / 207  to effectively secure the portable actuator  200  onto the circuit breaker  100 . 
     In one embodiment, the portable actuator  200  may also include openings for portions of the motor to interact with controls  110 / 120  ( FIG. 1 ) of the circuit breaker  100 . For instance, a portion of an actuator arm  225  and an anti-friction roller  230  may interact with the circuit breaker  100  through an insert to perform various functions, as will be described. Additionally, a portion of a trip pushrod  255  and a portion of a safety interlock  300  may be visible on the under-side of the portable actuator  200  to perform various functions, as will be described. Further, in one embodiment, the portable actuator  200  may also include status openings  140 / 150  to ensure the ability to view status indicators appearing on the circuit breaker  200  when the portable actuator  200  is secured against the circuit breaker  200 . 
     Next, in  FIG. 3A , shown is a right-side view of the portable actuator  200  according to various embodiments. As shown in  FIG. 3A , the portable actuator  200  is in a neutral position as exhibited by the actuator arm  225  being positioned such that there is no contact with the control button  120 . For instance, in this example, the control button  120  is a “close” button  120 . In addition, the actuator arm  225  being in a neutral position allows for a magnetic interaction between the safety interlock retention magnet  325  and the safety interlock ferrous target  320 . In one embodiment, the magnetic interaction between the safety interlock retention magnet  325  and the safety interlock ferrous target  320  overcomes a rotational force exhibited by a safety interlock actuating spring  330  to function as a safety locking mechanism and prevent the installation of the portable actuator  200  onto to the circuit breaker  100 , as will be described with respect to  FIG. 9 . 
     In one embodiment, the actuator arm  225  is controlled by a gear motor output shaft  220  which can be rotated in either a clockwise or counter-clockwise direction based on a received signal. As viewed from the right side of the actuator, the gear motor output shaft  220  may rotate in a clock-wise direction if a “neutral” command is received. By rotating in a clock-wise direction, the gear motor output shaft  220  rotates the actuator arm  225  away from the “close” button  120  thereby placing the portable actuator  200  in a “neutral” position. For example, the actuator arm  225  cannot actuate the “close” button  120  without being in contact with the “close” button  120 . In one embodiment, the gear motor output shaft  220  may always keep the actuator arm  225  in a “neutral” position unless a “close” command or a “trip” command is received. 
     In  FIG. 3B , shown is a right-side view of the portable actuator  200  according to various embodiments. As shown in  FIG. 3B , the portable actuator  200  is in a “close” position as exhibited by the actuator arm  225  being in contact with the close button  120 . In addition, the safety interlock  300  is not secured by any magnetic attraction between the safety interlock retention magnet  325  and the safety interlock ferrous target  320 . 
     In one embodiment, upon receiving a signal to “close” the circuit breaker  100 , the gear motor output shaft  220  rotates in a counter-clockwise direction causing the actuator arm  225  to press against the close button  120  with a predetermined amount of rotational force to actuate the close button  120 . For instance, an anti-friction roller  230  attached at one end of the actuator arm  225  actuates the close button  120  when the actuator arm  225  is rotated towards the portable actuator  200 . In one embodiment, the gear motor output shaft  220  provides a predetermined amount of rotational force to actuate the close button  120 . For example, the gear motor output shaft  220  may provide a sufficient amount of force to depress the close button  120  for a predetermined amount of time. In addition, the gear motor output shaft  220  may retain the actuator arm  225  in position such that the anti-friction roller  230  is actuating the close button  120  until a “close” signal is no longer received. 
     Next, in  FIG. 4A , shown is a left-side view of the portable actuator  200  according to various embodiments. As shown in  FIG. 4A , the portable actuator  200  is in a “neutral” position as exhibited by a tip of the trip pushrod  255  being in position along a same plane as the portable actuator  200 . In one embodiment, the gear motor output shaft  220  pushes the trip pushrod  255  through an insert in the plane of the portable actuator  200  thereby breaking the plane of the portable actuator  200 . The gear motor output shaft  220  may push the trip pushrod  255  a predetermined amount in order to actuate the “trip” button  110  ( FIG. 1 ) upon receiving a “trip” signal, as will be described. 
     In one embodiment, as viewed from the left side of the actuator, the gear motor output shaft  220  rotates in a counter clock-wise direction causing the trip pushrod  255  to actuate the trip button  110  upon receiving a “trip” signal to trip the circuit breaker  100 . For instance, a gear motor  245  energizes the gear motor output shaft  220  which initiates the process to push the trip pushrod  255  using an actuating cam  260 , a cam follower  250 , and a pushrod support  280 , as will be described with respect to  FIGS. 4B and 4C . 
     Moving now to  FIG. 4B , the trip pushrod  255  is depicted in a neutral position shown from the left side, according to various embodiments. In one embodiment, an actuating cam  260  is adjoined to the gear motor output shaft  220 . As such, the actuating cam  260  rotates in either a clockwise direction or a counter-clockwise direction along with the gear motor output shaft  220 . Thus, if the gear motor  245  causes the gear motor output shaft  220  to rotate in a clockwise direction, the actuating cam  260  also rotates in a clockwise direction at the same speed. Further, also shown in  FIG. 4B , is a pushrod return screw  275  comprising a pushrod return spring  270  and a pushrod screw flange nut  285 . The pushrod return screw  275  functions with the pushrod support  280  to actuate the trip button  110  ( FIG. 1 ) using the trip pushrod  255 , as will be described in  FIG. 4C . 
     Next, in  FIG. 4C , the trip pushrod  255  is depicted in a trip position shown from the left side. In this example, the trip pushrod  255  is pushed in a linear manner thereby causing the trip pushrod  255  to break the plane of the portable actuator  200  and actuate the trip button  110  ( FIG. 1 ), as described above. In one embodiment, the gear motor  245  receives a “trip” command causing the gear motor output shaft  220  to rotate in a counter-clockwise direction. As such, the actuating cam  260  also rotates in a counter-clockwise direction while acting upon the cam follower  250 . In one embodiment, the rotating actuating cam  260  causes the trip pushrod  155  to pull on the pushrod return screw  275  thereby compressing the pushrod return spring  270  between the pushrod screw flange nut  285  and the pushrod support  280 . While pulling on the pushrod return screw  275 , the trip pushrod  255  moves in a linear direction towards the circuit breaker  100  with the aid of the trip actuating cam  260 . As such, the trip pushrod  255  moves in a linear direction to depress the trip button  110  on the circuit breaker  100  while being spring loaded via the pushrod return spring  270 . 
     Then, in one embodiment, when the gear motor  245  stops receiving a “trip” signal and/or receives a “neutral” signal, the gear motor  245  reverses direction causing the gear motor output shaft  220  to rotate in a clockwise direction. As such, the trip actuating cam  260  also rotates in a clockwise direction causing the compressed pushrod return spring  270  to begin decompressing by pushing against both the pushrod support  280  and the pushrod screw flange nut  285 . Thus, the trip pushrod  255  returns to the neutral position as shown in  FIG. 4A  by moving in a linear direction away from the circuit breaker  100 . 
     As shown in  FIG. 5A , shown is a top view of the portable actuator  200  in a neutral position. In the neutral position, the safety interlock  300  allows for the portable actuator  200  to be affixed to the circuit breaker  100 . In one embodiment, the safety interlock retention magnet  325  displaced on one end of the actuator arm  225  is magnetically connected to the safety interlock ferrous target  320  displaced on one end of the safety interlock  300 . In this example, the magnetic attraction between the safety interlock retention magnet  325  and the safety interlock ferrous target  320  is sufficient to overcome any rotational forces produced by the safety interlock actuating spring  330  ( FIG. 3A ). As such, the safety interlock  300  remains in position despite the rotational forces of the safety interlock actuating spring  300 . Thus, the magnetic attraction between the safety interlock retention magnet  325  and the safety interlock ferrous target  320  functions to hold the safety interlock  300  in position while the portable actuator  200  is in a neutral position. 
     Next, in  FIG. 5B , shown is a top view of the portable actuator  200  in a trip position. In the trip position, the safety interlock prevents the portable actuator  200  from being affixed to the circuit breaker  100 . In this embodiment, the safety interlock retention magnet  325  is no longer magnetically connected to the safety interlock ferrous target  320 . Here, the magnetic attraction between the safety interlock retention magnet  325  and the safety interlock ferrous target  320  is no longer sufficient to overcome the rotational forces exhibited by the safety interlock actuating spring  330  ( FIG. 3A ). As such, the safety interlock  300  rotates approximately ninety degrees in a clockwise direction and protrudes from the portable actuator  200 , thereby prohibiting installation of the portable actuator  200 . Thus, the safety interlock  300  may prevent any inadvertent operation of the circuit breaker  100  by preventing the portable actuator from being affixed to the circuit breaker  100  when the portable actuator  200  is not in a neutral position. 
     Moving now to  FIGS. 6 and 7 , shown is one embodiment of a portable actuator  200  affixed to a circuit breaker  100 , according to the embodiments described above. In  FIG. 6 , a protective covering  201  protects the components energized by the gear motor  245  ( FIG. 4A ), as described above. Additionally, a remote control  500  is shown as providing input signals to the portable actuator  200 . For instance, the signals may be indicative of a command to trip the circuit breaker  100 , close the circuit breaker  100 , place the portable actuator  200  in a neutral position, and/or any other type of input signal. In  FIG. 7 , the protective covering  201  of  FIG. 6  is removed to reveal the protected components of the portable actuator  200 . In this example, the portable actuator  200  is viewed from the right side. 
     Next, shown in  FIG. 8A  is a block diagram of one embodiment for a bidirectional system of communication between the remote control  500  and a circuit board control system  400 . In one embodiment, the bidirectional communication between the remote control  500  and the circuit board control system may be accomplished using a communication cable  505 , radio communication as shown in  FIG. 8B  and infrared communication as shown in  FIG. 8C , and/or any other form of communication medium. As an example, the circuit board control system  400  receives input signals from the remote control  500 , such as, for example, trip, close, and/or neutral, and transmits a command to the motor driver electronics component  440  based on the received signal. For instance, the circuit board control system  400  may transmit a command to the motor driver electronics component  440  to energize the gear motor  245  if a trip signal is received from the remote control  500 . 
     In one embodiment, a power supply  450  provides energy to power the circuit board control system  400  and the motor driver electronics component  440 . In addition, an optional vibration sensor  420  may be employed to sense an operation of the circuit breaker  100  ( FIG. 1 ). For instance, the vibration sensor  420  may sense a vibration caused by the circuit breaker  100  opening and/or closing and may then transmit a command to the circuit board control system  400  to turn off the motor driver electronics component  440  and/or indicate to a user that the circuit breaker  100  has operated. In another embodiment, a shaft position sensor  405  may transmit a signal to the circuit board control system  400  based on angular position of the gear motor  245 . For instance, the circuit board control system  400  may transmit a command to the motor to rotate in a clockwise direction and/or a counter clockwise direction based on the signal received from the remote control  500 . 
     In another embodiment, the circuit board control system  400  may monitor the gear motor  245  to sense whether the portable actuator  200  is operating. For instance, the circuit board control system  400  may monitor a current level of the gear motor  245  to determine when the trip pushrod  255  is in operation and/or when the trip pushrod  255  ceases operation. Similarly, the circuit board control system  400  may also monitor the current level to determine when the actuator arm  225  is in and out of operation. In another embodiment, the circuit board control system  400  may measure any other component of the gear motor  245  to monitor the operating state of the portable actuator  200 . 
     It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.

Technology Category: h