Square D Company

James V Fixemer

John M Winter

Charles H Wagner

Dennis William Fleege

Brett E Larson

Randall L Siebels

Thomas A Edds

Matthew D Sortland

Teresa I Hood

Dale W Bennett

Douglas Paul Van Waart

Gary W Scott

George H Studtmann

Julius Michael Liptak

Duane Lee Turner

Eugene W Wehr

Donald H Ward

Neil R Palmer

Charles E Netolicky

Joel L Miller

Douglas A Hinkley

Donald H Haase

Rodney J Brune

Fred Kaveh

Tamara L Schultz

Guntis U Strauss

John J Barta

The present invention provides an apparatus for use in arcing fault detection systems within circuit breakers and which is adapted for automated production by top-down assembly. In one embodiment, the apparatus includes a circuit board and a two-piece sensing coil within a two piece housing with its center oriented horizontally relative to the circuit board. In other embodiments the sensing coil is one-piece and is either preassembled with a sensing bus and oriented horizontally or oriented vertically relative to the circuit board. The invention also includes several methods for making electrical connections to the circuit breakers.

Assembly methods for miniature circuit breakers with electronics

An apparatus for use in arcing fault detection systems within circuit breakers and which is adapted for automated production by top-down assembly. The invention also includes several devices for making electrical connections to the circuit breakers, including a lug having a top and a hollow center, the top having a hole connecting the top to the hollow center for accessing a wirebinding screw, a neutral bus having a first end and a second end, the first end disposed within the hollow center beneath the hole, a wire binding screw disposed in the hole and extending through the hollow center for securing a first wire to the first end of the neutral bus, and a strain relief member connected to the second end of the neutral bus for securing a second wire connected to the second end of the neutral bus. In another embodiment, a strain relief member has a top section and a bottom section, the top section being substantially flat and having a threaded hole disposed therein and adapted for use in securing a wire by means of a screw engaging said threaded hole, the bottom section defining a cavity for receiving a wire, the top section and the bottom section being connected together and separated by a solid member, the strain relief member having a sire welded to the strain relief member and extending through the cavity of the bottom section, the bottom section of the strain relief member preventing strain on the weld connection.

Automated assembly methods for miniature circuit breakers with wire attachment clamps

An apparatus for use in arcing fault detection systems within circuit breakers and which is adapted for automated production by top-down assembly. In one embodiment, the apparatus includes a circuit board and a two-piece sensing coil within a two piece housing with its center oriented horizontally relative to the circuit board. In other embodiments the sensing coil is one-piece and is either preassembled with a sensing bus and oriented horizontally or oriented vertically relative to the circuit board. Also included are several methods for making electrical connections to the circuit breakers.

Apparatus for use in arcing fault detection systems

An arrangement is provided for welding together current carrying members of an electrical distribution device which are made of similar conductive material. The arrangement includes an electron beam gun capable of generating an electron beam sufficient to penetrate and heat the material, thereby providing mixing of the material to form a joint which is constructed substantially of a portion of each of the current carrying members.

Conductive joint formed by electron beam welding and method thereof

An arc stack for receiving a circuit breaker blade moveable between a closed position and an open position, includes a plurality of arc plates positioned substantially parallel to one another and arranged in a plurality of adjacent groups. Each of the groups includes one or more arc plates having substantially similar respective arc throats formed therein. The respective arc throats progressively decrease in size from group to group along the length of the arc stack in a direction extending away from the closed position of the blade. A connecting support maintains the plurality of arc plates substantially parallel to one another.

Arc stack for a circuit breaker

An arc stack for receiving a circuit breaker blade moveable between a closed position and an open position, includes a plurality of generally rectangular are plates having substantially similar length and width dimensions and positioned substantially parallel to one another. The straight edges of the arc plates are in line with one another so that the are stack is generally rectangular in shape. The arc plates have respective arc throats formed therein having a plurality of sizes so as to form a longitudinal passageway extending through the arc throats following the arc generated by the blade moving between the closed and open positions. The arc plates include sets of arc plates with the arc plates in each set having identical arc throats. The sets of arc plates are arranged in order of decreasing arc throat size with the set having the largest arc throats being positioned adjacent the circuit breaker blade in the closed position. The arc stack is formed in two sections with each section including a selected number of arc plates. The arc plates in each section are interconnected by a pair of side fibers engaging associated edges of the arc plates. The two sections are connected to form the arc stack by engaging the inner edges of the pair of side fibers of one section with mating inner edges of the pair of side fibers of the other section.

A mid terminal for a double break circuit breaker comprises first and second elongated conductive plates, where each of the plates have first and second ends. The second end of the first plate is longitudinally spaced from the first end of the second plate and the first end of the first plate is connected to the second end of the second plate by a lateral conductive plate. A first are runner is electron beam welded to the second end of the first plate, and a second are runner is electron beam welded to the first end of the second plate. The first and second arc runners are preferably made of steel. A first stationary contact is mounted on the first plate adjacent the first arc runner, and a second stationary contact is mounted on the second plate adjacent the second arc runner. To manufacture the mid terminal, the first and second plates and the lateral plate are formed from a single strip of copper bent into a shape having a pair of longitudinal sections extending in opposite directions from opposing ends of a lateral section. The longitudinal sections correspond to the first and second plates, and the lateral section corresponds to the lateral plate.

Mid terminal for a double break circuit breaker

An improved miniature circuit breaker is provided which is adapted to improved automatic assembly of all components thereof. Key components of the breaker are individually and collectively designed to be susceptible to total Z-axis assembly. In particular, the circuit breaker operating mechanism which operates the contacts thereof to make or break the electric circuit is formed of elements designed to interact in a Z-axis assemblable fashion. The movable contact is defined on a contact carrier or blade assembly which is adapted for Z-axis assembly and also provides increased arc erosion resistance and improved opening of the breaker contacts.

Automatic miniature circuit breaker with Z-axis assemblable contact

An improved miniature circuit breaker is provided which is adapted to improved automatic assembly of all components thereof. Key components of the breaker are individually and collectively designed to be susceptible to total Z-axis assembly. In particular, the magnetic-yoke and armature which comprise the current response mechanism for the circuit breaker are designed to interact with each other so that the magnetic armature can easily be Z-axis assembled onto the magnetic yoke.

Automatic miniature circuit breaker with Z-axis assemblage current

An improved miniature circuit breaker is provided which is adapted to improved automatic assembly of all components thereof. Key components of the breaker are individually and collectively designed to be susceptible to total Z-axis assembly. In particular, the trip mechanism including the trip lever, and the associated activation means, tension means and reset means are defined by elements designed to interact in a Z-axis assemblable fashion. The trip mechanism components are also designed for improved trip action and enhanced breaker performance in repeated OPEN, CLOSED, and TRIP operations.

Automatic miniature circuit breaker with Z-axis assemblable trip

A solid state circuit interruption arrangement in a distributed power network provides fast and reliable circuit interruption. A common power source provides power to a plurality of loads via respective current paths. A main circuit breaker and a plurality of solid state circuit breakers are arranged to interrupt the current paths in response to command signals sent from a central controller. Current sensors and voltage sensors are coupled to the current paths for monitoring purposes. An automatic controller responds to any of the current sensors detecting a fault condition by automatically generating a command signal, which forces the associated solid state breaker to interrupt the associated current path. Thereafter, the controller automatically generates a signal to the main circuit breaker to interrupt the power provided from the common power source in the event that the associated current path is not interrupted by the solid state breaker. Alternatively, or in addition, the main interruption device may interrupt the current path when its own internal sensing mechanism detects a magnitude of current that is beyond a predetermined level. Also, the controller automatically generates a signal to the main breaker to interrupt the power provided from the common power source in the event that any of the branch breakers fails in the 'off' or interrupted, condition. Other features include a finned housing structure which provides cooling means for the breaker system without the need for cooling fans.

Fail-resistant solid state interruption system

An automatic electric side-by-side two-pole circuit breaker having an insulating casing formed from the complementary association of a base casing, an intermediate casing and a cover which provide a pair of mechanism receiving compartments in side-by-side association. Each compartment carries a pivotally supported operating handle which extends partially outward from the casing for external manual operation, a line terminal, a load terminal electrically connected to said line terminal, a stationary contact intermediate said line terminal and said load terminal and a movable blade which carries a movable contact on one end and has its opposite end connected to the handle. A releasably latched generally thin trip lever is pivotally mounted within the compartment and is releasable from its latched position to a tripped position to effect separation of the contacts. The trip lever includes an upstanding leg which is engaged by a protuberance on the handle for resetting the trip lever. The handle overlaps the trip lever as does the movable contact blade which has an extending top segment received in a recess of the handle for operation of the movable blade by the handle. A spring is connected between the generally J-shaped blade and the trip lever for snap action of the blade.

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Denton, NE, United States of America

James V Fixemer