Eaton Intelligent Power Limited

Santhosh Kumar Chamarajanagar Govinda Nayaka

Xin Zhou

Robert Michael Slepian

Andrew Lawrence Gottschalk

Jayaraman Muniyappan

Jianyang Liu

Brian E Carlson

Michael Slepian

Yanjun Feng

R Michael Slepian

Asish Das

Theodore James Miller

Ganesh Kumar Balasubramanian

Andrew W Lichauer

Zhixi Deng

An assembly for manufacturing the insulation layer of a Thomson coil includes a base plate, a coil housing, and a cover plate. The base plate securely seats the coil housing, and the coil housing securely seats a Thomson coil and the cover plate. The cover plate has several ribs that hold multiple turns of a Thomson coil in place while epoxy is applied to the coil, thus ensuring that the epoxy is evenly distributed on the coil surface and that the coil windings remain level. The cover plate and coil housing are structured to either receive a high-pressure epoxy injection or to be used in an epoxy potting process, during which all exposed areas of the Thomson coil are coated by liquid epoxy. After the epoxy has solidified, the Thomson coil is coupled to the coil housing, and the housed and insulated Thomson coil is removed from the assembly.

Thomson coil design and potting process

Multi-part assemblies for driving a movable conductor away from a stationary conductor of a circuit interrupter decrease separable contact opening time by reducing the number of components that must travel during an initial stage of an opening stroke to achieve an initial gap between the separable contacts. The components that must travel in order to open the separable contacts are included in only some portions of the movable assembly, rather than all portions. In one embodiment, a split switch shaft coupled to a movable conductor includes a head shaft coupled to a tail shaft using a sliding pin, enabling the head shaft to travel an initial distance while the tail shaft remains stationary, thus achieving an initial gap between the contacts. In another embodiment, the movable conductor assembly is coupled to hydraulics, enabling the assembly to travel an initial distance at high speeds before damping by the hydraulic fluid.

Multi-part moving shaft assembly for ultra high speed actuator used in a hybrid circuit breaker

A hydraulic multi-pole actuation system opens all poles of a circuit interrupter simultaneously. The system utilizes Thomson coil arrangements with a wide piston attached to the conductive member of each arrangement. A narrow piston is attached to the movable conductor of each pole assembly in the circuit interrupter. The wide and narrow pistons are contained within a hydraulic tank. Activating the Thomson coils causes the wide pistons to displace the hydraulic fluid, and the displaced fluid pushes against the narrow pistons to cause the movable conductors to open the line connections in their respective pole assemblies. The wide pistons have a greater collective surface area that interfaces with the hydraulic fluid than the narrow pistons do, enabling fewer Thomson coils arrangements to be used than there are poles in the circuit interrupter, and enabling movement of the wide pistons to be amplified during translation into movement of the narrow pistons.

Hydraulic simultaneous multi-pole contact opening mechanism for circuit interrupters

An improved PCB Rogowski coil addresses the challenges presented by space constraints within circuit interrupters. The disclosed coil comprises a plurality of PCBs that are coupled together, in contrast with known coils constructed from only a single PCB. During a pre-assembly stage, three PCBs are coupled to one another in order to form a partial coil assembly structured to be mounted onto a circuit interrupter primary conductor. After the partial coil assembly is mounted onto the primary conductor, a fourth PCB is connected to the partial coil assembly via press-fit connectors to form a complete coil. In contrast with known PCB Rogowski coils which are structured to be mounted perpendicularly to the primary conductor, the disclosed modular PCB Rogowski coil enables a substantial portion of the PCB surface area to be mounted in parallel to the primary conductor and to thus occupy significantly less space than known PCB Rogowski coils.

Compact flat-mount segmented Rogowski coil

A dual conductor Thomson coil actuator for use in opening the separable contacts of a circuit interrupter comprises two nested conductors wound to form a single coil, rather than the traditional design comprising one single conductor wound to form a coil of the same size. Each of the two conductors can be excited by half the capacitance that would be used to excite the traditional single conductor coil, using the same voltage as the single conductor coil. When the same total capacitor-stored energy that would be used to excite the single conductor coil is instead used to excite the dual conductor coil, the initial pulse of aggregate current through the dual conductor coil is greater than the initial pulse of current through the single conductor coil, resulting in a faster initial opening distance of the separable contacts during an opening stroke.

Dual conductor Thomson coil for faster opening of a hybrid circuit breaker

An actuator for opening the separable contacts of a circuit interrupter integrates a Thomson coil arrangement into the movable and stationary conductor assemblies. A movable separable contact is coupled to one end of the movable conductor, and a stationary separable contact is coupled to one end of the stationary conductor. The movable and stationary conductors are each formed with a collar positioned near the respective movable and stationary separable contacts. The actuator further includes a coil seated within a coil housing, and the coil housing is coupled to the stationary conductor collar. A conductive member shaped as a cup and structured to be actuated by the coil is coupled to the movable conductor collar, such that the rim of the cup faces the coil. A housing is positioned around the conductive member cup body with bellows and coupled to the coil housing, forming a vacuum chamber around the separable contacts.

Vacuum interrupter conductor assembly with integrated Thomson coil

An acoustic sensing system for detecting movement of an ultra-fast actuator in a hybrid circuit interrupter is disclosed. The system comprises a number of acoustic sensors structured to perform active or passive position sensing. For active sensing, the sensors emit sound waves toward a number of targeted portions of the actuator moving assembly and detect the positions of the targets based on acoustic signals reflected back to the sensors by the targets. For passive sensing, the sensors detect acoustic wavelets generated as a result of the moving assembly components moving during opening and closing operations. Acoustic signals can propagate through air or solids and thus the sensors can be mounted in a variety of locations within the circuit interrupter. Acoustic sensors are particularly well-suited for the circuit interrupter environment, as they are resilient to the environmental and external factors, such as dust, that can affect the performance of non-acoustic sensors.

Acoustic sensing of thomson coil based vacuum circuit interrupter operation

A circuit interrupter including a current sensor having a normal sensor output and an over current detection output, a solid state switch module structured to have a closed state to allow current to flow through the circuit interrupter and an open state to interrupt current flowing through the circuit interrupter, a gate driver structured to control the solid state switch module including a desaturation function output, wherein the gate driver is structured to cause the solid state switch module to interrupt current flowing through the circuit interrupter when the DESAT function output changes to the on state, and an electronic trip circuit structured to output a trip signal to the gate driver when the normal sensor output reaches a first threshold level or the overcurrent detection output changes to the on state.

Solid state circuit interrupter

A latching assembly for latching the moving conductor assembly of a circuit interrupter after an opening stroke includes a streamlined latch that omits components commonly prone to damage during latching operations in existing latching assemblies. The disclosed latching assembly comprises a fixed latch block, a driven latch rotatably coupled to the latch block, and a pivoting hammer with a square pin positioned to always be engaged with the driven latch. The latching assembly is structured to be engaged by a switch shaft once an opening stroke is initiated. When the latching assembly engages, the hammer square pin pushes the driven latch into engagement with a shelf formed in the switch shaft, which prevents the switch shaft from rebounding after the opening stroke. Rebounding is further prevented due to the hammer being structured to be biased toward the open state once the driven latch has engaged the switch shaft shelf.

Direct driven latch for ultra-fast switch

A circuit breaker includes a vacuum interrupter. The interrupter includes a first movable electrode to which a first contact is connected and a second movable electrode to which a second contact is connected. The interrupter is operable between an open state and a closed state. In the open state, the first contact and the second contact are separated by a contact gap distance. In the closed state, the first contact and the second contact touch each other. The circuit breaker includes an ultrafast actuator operatively connected to each of the first and second movable electrodes. The ultrafast actuator is configured to change the vacuum interrupter from the closed state to the open state by simultaneously moving the first contact in a first direction along a first distance portion of the contact gap, and the second contact in a second direction along a second distance portion of the contact gap.

Vacuum circuit interrupter with dual plate actuation

An electrical switching device, such as a high-speed switching device, has a damper and latching assembly. The assembly is configured to dampen the movement of a moving contact of the switching device as the moving contact translates from its closed position to its open position. The assembly also is configured to restrain the moving contact in its open position. The assembly stores at least some of the energy associated with the damping process, and uses the stored energy to assist in the release of the moving contact during the subsequent re-closing of the switching device.

Damper and latching assemblies for electrical switching devices

A closing spring assembly for an electrical switching device is provided. The closing spring assembly is configured to exert a closing force on a moving contact of the switching device. The closing force helps to maintain physical and electrical contact between the moving contact and an associated stationary contact, so that the moving and stationary contacts form a path for conducing electric current through the switching device. The closing spring assembly is configured so that the closing force remains constant or decreases as the moving contact is driven away from the stationary contact during switching of the current path away from the moving and stationary contacts.

Closing spring assemblies for electrical switching devices

A circuit interrupter including a current sensor having a normal sensor output and an over current detection output, a solid state switch module structured to have a closed state to allow current to flow through the circuit interrupter and an open state to interrupt current flowing through the circuit interrupter, a gate driver structured to control the solid state switch module including a desaturation function output, wherein the gate driver is structured to cause the solid state switch module to interrupt current flowing through the circuit interrupter when the DESAT function output changes to the on state, and an electronic trip circuit structured to output a tri when the normal sensor output reaches a first threshold level or the overcurrent detection output changes to the on state.

Growing community of inventors

Moon Township, PA, United States of America

Santhosh Kumar Chamarajanagar Govinda Nayaka