Eaton Corporation

Kohler Company

Brown Industrial Gas, Inc.

James A Becker

Kurt Von Eckroth

Christopher John Wieloch

Jan J Walker

Frank W Kussy

Lawrence F Freitag

Xin Zhou

James J Kinsella

Edward Louis Wellner

David S Hunter

Michael Thomas Little

Mark G Solveson

Ronald J Fritsch

Richard J Holland

Mike T Little

Robert F Klobuchar

The present invention provides an electrical isolation apparatus having independently controllable contactors. The isolation apparatus includes a contactor for each phase or pole of an electrical device as well as each phase or pole of a load. Each contactor is constructed so that each includes multiple contact assemblies that may be independently controlled to open and close. Moreover, the contactors within a single contactor assembly or housing can be independently controlled so that the contacts of one contactor can be opened without opening the contacts of the other contactors in the contactor assembly. Additionally, the contactors are construct and controlled such that a single line side contactor and a single load contactor open simultaneously when an open circuit condition is desired.

Isolation contactor assembly having independently controllable contactors

A solid state motor starter, commonly referred to as a soft starter, is constructed in a manner to be easily manufacturable while at the same time combining all the required components in a relatively small package. A solid state power switch is clamped between a pair of bus bars in an offset manner to accommodate a discrete switching relay mounted in an inverted manner between the line input and the bus bar in communication with the load outputs. When in a motor run mode, current is shunted away from the solid state power switching device and through the switching relay, a substantially linear current path is achieved to reduce power loss and heat buildup. The arrangement allows for a heat sink mounted to one of the bus bars with adequate spacing between the heat sink and the discrete relay for insertion of a cooling fan. Current sensing is achieved with a Hall effect sensor mounted to the bus bar in a small current sensing region that is created by having a pair of slots in the bus bar to direct current. A pair of magnetic pins extend perpendicular from the bus bar to create the magnetic flux for the Hall effect sensor to sense current flow through the current sensing region. The Hall effect sensor circuit board also contains a thermistor which is mounted with adequate insulation yet in thermal communication with the bus bar.

Integrated soft starter for electric motor

A motor starter thermal-compensation control is disclosed in which an ambient temperature sensor is positioned to sense ambient temperature and provide an ambient temperature signal in a motor starter. Additional temperature sensors are mounted in thermal communication with each bus bar in a motor starter and to monitor the temperature of each pole. A microprocessor is connected to each of the temperature sensors and periodically receives the temperature signals to monitor change in operating temperature of the motor starter. The control adjusts the output of the motor starter based on the change in the operating temperature so as to maintain a constant output as the ambient temperature increases, or the internal resistance of the device increases with temperature increase. In order to adjust the output, the system increases the FLA ampacity to compensate for the temperature increase. If the ampacity reaches the device's limits, the starter is prevented from engaging the motor with the power supply until it has sufficiently cooled down. The control calculates an estimated cool down time and displays the cool down time to prevent unnecessary start attempts during cool down.

Thermal compensation control for a motor starter

A motor starter control is disclosed in which an ambient temperature sensor is positioned to sense ambient temperature and pole temperature sensors are used to sense each pole temperature in a motor starter. A microprocessor is connected to periodically receive the temperature signals and monitor change in operating temperature of a motor starter system. The microprocessor models cool down characteristics of the motor starter system and compares currently acquired ambient and pole temperature signals to the modeled cool down characteristics and determines whether the motor starter system is cooled to a safe start temperature. The control ensures that a maximum number of starts per hour is not exceeded and prevents attempted starts that not only waste energy, but further prolong time to a successful start.

Frequent start protection and economizer control for a motor starter

An apparatus for use in sensing electrical current in a conductor includes a flux concentrator and one or more magnetic flux sensors. The flux concentrator includes main sections which are formed of a magnetic material. One or more intermediate sections, formed of a nonmagnetic material, extend between the main sections of the magnetic flux concentrator. The main sections and intermediate section of the magnetic flux concentrator cooperate to at least define an opening through which a portion of the conductor extends.

Electrical current sensing apparatus

A magnetic flux concentrator shield is disclosed for use with magnetic flux sensors in an overload relay for multiple pole electromagnetic contactor applications. The magnetic flux concentrating shield has slotted layers of laminated members. The layers have a series of pole shielding slots which concentrate magnetic flux generated by conductors carrying current through conductor apertures in each layer. Magnetic flux sensors are positioned within air gaps within each pole of the shield. By shielding the generated magnetic flux from reaching the magnetic flux sensor of another pole, the pole shielding slots minimize cross pole magnetic flux sensor interference.

Magnetic flux concentrator shield for use in overload relay

A motor starter temperature protection control in which an ambient temperature sensor is positioned on an inside cover of the motor starter to sense ambient temperature across the power poles and heat sinks and provide an ambient temperature signal indicative of the ambient temperature in the motor starter enclosure. A power pole temperature sensor is positioned in thermal communication with each power pole and produce pole temperature signals indicative of the temperature of each power pole. A microprocessor is connected to each of the temperature sensors and receives the ambient temperature and the pole temperature signals to control the motor starter operation based on the temperature inputs. The microprocessor is programmed to periodically monitor the ambient and power pole temperature signals and compare these signals against a fan-on limit, and if the signals exceed the fan-on limit, the control turns on the internal fans of the motor starter. The control continues to monitor the ambient and power pole temperatures and if either should exceed a maximum temperature limit, the motor starter is placed in a motor shutdown mode, unless an optional temperature override has been set. Upon motor shutdown, the control continues to monitor temperatures and track how long it takes for the motor starter to cool down, and if it takes too long to cool down, a maintenance flag is set to indicate that cleaning or preventive maintenance is required.

Temperature protection control for a motor starter

A solid state motor starter, commonly referred to as a soft starter, is constructed in a manner to be easily manufacturable while at the same time combining all the required components in a relatively small package. A solid state power switch is clamped between a pair of bus bars in an offset manner to accommodate a discrete switching relay mounted in an inverted manner between the line input and the bus bar in communication with the load outputs. When in a motor run node, current is shunted away from the solid state power switching device and through the switching relay, a substantially linear current path is achieved to reduce power loss and heat buildup. The arrangement allows for a heat sink mounted to one of the bus bars with adequate spacing between the heat sink and the discrete relay for insertion of a cooling fan. Current sensing is achieved with a Hall effect sensor mounted to the bus bar in a small current sensing region that is created by having a pair of slots in the bus bar to direct current. A pair of magnetic pins extend perpendicular from the bus bar to create the magnetic flux for the Hall effect/sensor to sense current flow through the current sensing region. The Hall effect sensor circuit board also contains a thermistor which is mounted with adequate insulation yet in thermal communication with the bus bar.

An electromagnetic starter with an overload relay having magnetic flux shielding is disclosed for use in industrial contactor applications. The starter includes a multi-pole DC controlled contactor which is interlockingly coupled to an overload relay. The overload relay has a simplified interlocking connection to the contactor, which when made, corresponds to an abutting electrical connection between the contactor and the overload relay also being made. The contactor further has a guiding pin that promotes even contact closure within the contactor.

Electromagnetic contactor with overload relay

A plate pivotally mounted to a padlock hasp adjacent a reciprocally movable operator handle is pivotable from a stored position to one covering the opening of the hasp, the plate having a hole aligned with the opening and smaller than the opening to receive the shackle of a single, scissors-type safety lockout and maintain the shackle in position to block movement of the operator handle to an operated position. The hole is preferably rectangular to conform to the flat, thin shape of the safety lockout shackle to maintain the shackle properly oriented. An additional round hole for a smaller diameter padlock shackle may be provided in said plate.

Handle lock for reciprocally movable operator handle

A flexible electrical connector is attached to a movable contact finger and a stationary termianl by placing the components in a work chamber and positioning a first end of the flexible connector against an attachment surface of the contact finger, preferably in a perpendicular orientation. After evacuating the work chamber, the output of an electron gun is directed toward a joint formed between the flexible connector and the contact finger. The electron beam forms a weld zone which fuses the the flexible connector with the contact finger without degrading the flexibility of the connector or the mechanical strength of the contact finger. A second end of the flexible connector is positioned against an attachment surface of the stationary terminal, such as in a parallel orientation, and attached in a similar manner.

Method for attaching a flexible connector

A switch has contacts constructed so that an electro-dynamic force is created by the current flowing through the switch which tends to maintain the switch in a closed state. This force counteracts other electro-dynamic forces which tend to open the switch. The contact design is particularly adapted from use in a single pole-double throw switch having a contact arm that is movable between two fixed contacts. The electro-dynamic force compensation exists between the contact arm and whichever one of the fixed contacts the contact arm is against. The fixed contacts also include arc runners so that any arc that develops as the contacts separate eliminates electro-dynamic force which tends to maintain the switch in a closed state.

Electric switch with counteracting electro-electro-dynamic forces

An automatic electric load transfer switch incorporates an over-the-center spring mechanism to operate switch contacts. The spring mechanism has a first position at which the electric load is connected to one electricity source and a second position at which the load is connected to another electricity source. The spring mechanism is driven by a solenoid activated cam shaft. An apparatus is provided for halting the movement of the spring mechanism at a position intermediate the first and second positions at which the load is not connected to either electricity source. The halting apparatus is releasable so that the spring mechanism can continue its movement between the first and second positions.

Growing community of inventors

Grafton, WI, United States of America

James A Becker