Detecting and sensing actuation in a circuit interrupting device

• US 7,986,501 B2
• Filed: 03/05/2009
• Issued: 07/26/2011
• Est. Priority Date: 03/05/2009
• Status: Active Grant

• Current Assignee: Leviton Manufacturing Company Incorporated
• Original Assignee: Leviton Manufacturing Company Incorporated
• Inventors: Kamor, Michael, Bonasia, Gaetano, Moadel, Benjamin Mehdi, Angelides, Mario, Mernyk, Ross
• Primary Examiner(s): Jackson; Stephen W
• Application Number:
  US12/398,550
• Publication Number:
  US 20100226053A1
• Time in Patent Office: 873 Days
• Field of Search: 361/42
• US Class Current: 361/42
• CPC Class Codes: H01H 83/04 with testing means for indicating the ability of the switch or relay to function properly
• CPC Class Codes: H01R 13/713 the switch being a safety switch
• CPC Class Codes: H01R 2103/00 Two poles
• CPC Class Codes: H01R 24/78 with additional earth or shield contacts

Abstract

A circuit interrupting device configured to cause electrical discontinuity along a conductive path upon the occurrence of a predetermined condition is disclosed. The device includes a fault sensing circuit detecting the predetermined condition and generating a circuit interrupting actuation signal, and a coil and plunger assembly actuatable by the circuit interrupting actuation signal so that, upon detecting the predetermined condition, the plunger will move in a fault direction from a non-actuated to an actuated configuration a distance sufficient to cause disengagement of at least one set of contacts from each other to cause electrical discontinuity along the conductive path; and a test assembly causing the plunger to move in a test direction, from a pre-test configuration to a post-test configuration, a distance insufficient to disengage the at least one set of contacts from each other. Analogous methods of testing the circuit interrupting device are also disclosed.

Claims

1. A circuit interrupting device configured to cause electrical discontinuity along a conductive path upon the occurrence of a predetermined condition, comprising:

a fault sensing circuit configured to detect the predetermined condition and to generate a circuit interrupting actuation signal; and

a coil and plunger assembly, having at least one coil and a plunger actuatable by the circuit interrupting actuation signal and configured and disposed within the circuit interrupting device so that upon detection of the occurrence of the predetermined condition the plunger will move in a fault direction from a non-actuated configuration to an actuated configuration a distance sufficient to cause disengagement of at least one set of contacts from each other and thereby cause electrical discontinuity along the conductive path; and

a test assembly configured to cause the plunger to move in a test direction, from a pre-test configuration to a post-test configuration, a distance insufficient to disengage the at least one set of contacts from each other.

2. The circuit interrupting device according to claim 1, wherein the test direction of the plunger is in the same direction as the fault direction.

3. The circuit interrupting device according to claim 1, wherein the test direction of the plunger is in a direction different from the fault direction.

4. The circuit interrupting device according to claim 3, wherein the test direction of the plunger is in a direction opposite to the fault direction.

5. The circuit interrupting device according to claim 1, further comprising:

at least one sensor disposed to detect a change in plunger position from the pre-test configuration to the post-test configuration.

6. The circuit interrupting device according to claim 5, wherein the test assembly comprises:

a test initiation circuit configured to initiate and conduct a test of the circuit interrupting device that includes initiating movement of the plunger from the pre-test configuration to the post-test configuration; and

a test sensing circuit in electrical communication with the at least one sensor and configured to sense a result of the test of the circuit interrupting device.

7. The circuit interrupting device according to claim 5,

wherein, when the circuit interrupting device is in the pre-test configuration, the plunger is not in contact with the at least one sensor, and when the circuit interrupting device is in the post-test configuration, the plunger is in contact with the at least one sensor.

8. The circuit interrupting device according to claim 5,

wherein, when the circuit interrupting device is in the pre-test configuration, the plunger is in contact with the at least one sensor, and when the circuit interrupting device is in the post-test configuration, the plunger is not in contact with the at least one sensor.

9. The circuit interrupting device according to claim 5, wherein the at least one sensor comprises at least one electrical element.

10. The circuit interrupting device according to claim 9, wherein the at least one electrical element comprises:

a piezoelectric member, wherein, when the circuit interrupting device is in the pre-test configuration, the piezoelectric member produces substantially no voltage when the plunger is one of (a) in substantially stationary contact with the at least one electrical element, and (b) not in contact with the at least one electrical element.

11. The circuit interrupting device according to claim 10,

wherein, when the circuit interrupting device is in the post-test configuration, the piezoelectric member produces a voltage output when the plunger dynamically contacts the at least one electrical element.

12. The circuit interrupting device according to claim 11,

wherein the voltage output is of a magnitude pre-determined to be indicative of movement of the plunger that is a pre-cursor to one of (a) sufficient movement and (b) insufficient movement of the plunger during a required real transfer of the circuit interrupting device from the non-actuated configuration to the actuated configuration.

13. The circuit interrupting device according to claim 12,

wherein a voltage output of substantially zero by the piezoelectric member is indicative of insufficient movement of the plunger during a required real transfer of the circuit interrupting device from the non-actuated configuration to the actuated configuration.

14. The circuit interrupting device according to claim 9,

wherein the at least one electrical element is characterized by an impedance value,

the at least one electrical element is disposed such that when the plunger is in contact with the electrical element, a first impedance value is produced by the at least one electrical element, and when the plunger is not in contact with the at least one electrical element, a second impedance value is produced by the at least one electrical element.

15. The circuit interrupting device according to claim 9,

wherein the at least one electrical element is characterized by an impedance value,

the at least one electrical element is disposed such that when the plunger is in the proximity of the electrical element, a first impedance value is produced by the at least one electrical element, and when the plunger is not in the proximity of the at least one electrical element, a second impedance value is produced by the at least one electrical element.

16. The circuit interrupting device according to claim 14, wherein the at least one electrical element characterized by an impedance value is at least one of a resistor and a capacitor.

17. The circuit interrupting device according to claim 15, wherein the at least one electrical element characterized by an impedance value is an inductor.

18. The circuit interrupting device according to claim 14, wherein when the circuit interrupting device transfers to one of (a) the pre-test configuration from the post-test configuration, and (b) the post-test configuration from the pre-test configuration, a difference between the first impedance value and the second impedance value is indicative of sufficient movement of the plunger during a required real transfer of the circuit interrupting device from the non-actuated configuration to the actuated configuration.

19. The circuit interrupting device according to claim 14, wherein, when the circuit interrupting device transfers one to of (a) the pre-test configuration from the post-test configuration, and (b) the post-test configuration from the pre-test configuration, a second impedance value of the at least one electrical element that is substantially equal to the first impedance value is indicative of insufficient movement of the plunger during a required real transfer of the circuit interrupting device from the non-actuated configuration to the actuated configuration.

20. The circuit interrupting device according to claim 9, wherein the at least one electrical element comprises:

first and second electrically conductive members electrically isolated from one another and with respect to the coil and plunger assembly such that, when the circuit interrupting device transfers to one of (a) the pre-test configuration from the post-test configuration, and (b) the post-test configuration from the pre-test configuration, the plunger makes electrical contact with both the first and second conductive members to form a continuous conductive path.

21. The circuit interrupting device according to claim 20,

wherein the circuit interrupting device is configured wherein upon the circuit interrupting device transferring from one of the pre-test configuration and the post-test configuration, the plunger moves away from at least one of the first and second conductive members.

22. The circuit interrupting device according to claim 21, wherein termination of the continuity of the conductive path is indicative of sufficient movement of the plunger during a required real transfer of the circuit interrupting device from the non-actuated configuration to the actuated configuration.

23. The circuit interrupting device according to claim 21, wherein continued electrical continuity of the conductive path is indicative of insufficient movement of the plunger during a required real transfer of the circuit interrupting device from the non-actuated configuration to the actuated configuration.

24. The circuit interrupting device according to claim 9, wherein the at least one electrical element comprises:

a first conductive member and a second conductive member, wherein, when the circuit interrupting device is in one of (a) the pre-test configuration, and (b) the post-test configuration, the plunger is in a position with respect to the first and second conductive members indicative of one of a corresponding pre-test capacitance value and a corresponding post-test capacitance value, respectively.

25. The circuit interrupting device according to claim 24, wherein, when the circuit interrupting device is in one of (a) the pre-test configuration, and (b) the post-test configuration, the plunger is in a position between the first and second conductive members indicative of one of the corresponding pre-test capacitance value and the corresponding post-test capacitance value, respectively.

26. The circuit interrupting device according to claim 24, wherein the circuit interrupting device is configured wherein movement of the plunger has occurred if the post-test capacitance value differs from the pre-test capacitance value by a predetermined range.

27. The circuit interrupting device according to claim 24, wherein the circuit interrupting device is configured wherein insufficient movement of the plunger has occurred if the post-test capacitance value differs from the pre-test capacitance value by a predetermined range.

28. The circuit interrupting device according to claim 5, further comprising:

an optical emitter emitting a light beam in a path therefrom, and

wherein the at least one sensor is an optical sensor, the optical emitter and the optical sensor being configured with respect to the plunger wherein, when the circuit interrupting device is in one of (a) the pre-test configuration, and (b) the post-test configuration, the plunger at least partially interrupts the path of the light beam emitted from the optical emitter.

29. The circuit interrupting device according to claim 28, wherein, when the circuit interrupting device transfers from one of (a) the pre-test configuration to the post-test configuration and (b) the post-test configuration to the pre-test configuration, respectively, movement of the plunger enables the light beam to propagate from the optical emitter to the optical sensor.

30. The circuit interrupting device according to claim 29, wherein measurement by the optical sensor of the continuity of the path of the light beam is indicative of sufficient movement of the plunger during a required real transfer of the circuit interrupting device from the non-actuated configuration to the actuated configuration.

31. The circuit interrupting device according to claim 29, wherein measurement by the optical sensor of discontinuity of the path of the light beam is indicative of insufficient movement of the plunger during a required real transfer of the circuit interrupting device from the non-actuated configuration to the actuated configuration.

32. The circuit interrupting device according to claim 1, wherein the test assembly configured to enable a self test of the circuit interrupter via self testing at least partially movement of the plunger without causing electrical discontinuity along the conductive path.

33. The circuit interrupting device according to claim 1, wherein the circuit interrupting device is one of the group consisting of a (a) a ground fault circuit interrupting (GFCI) device;

(b) an arc fault circuit interrupting (ACFI) device;

(c) immersion detection circuit interrupting (IDCI) device;

(d) appliance leakage circuit interrupting (ALCI) device;

(e) circuit breaker;

(f) contactor;

(g) latching relay; and

(h) solenoid mechanism.

34. A method of testing a circuit interrupting device comprising the steps of:

generating an actuation signal;

causing a plunger to move in response to said actuation signal, without causing said circuit interrupting device to trip;

measuring said movement of said plunger; and

determining whether said movement reflects an operable circuit interrupting device.

35. The method of testing according to claim 34,

wherein the plunger moves in a fault direction during operation of the circuit interrupting device, and

wherein the step of causing the plunger to move in response to said actuation signal is performed by causing the plunger to move in a test direction.

36. The method of testing according to claim 35,

wherein the test direction is in the same direction as the fault direction.

37. The method of testing according to claim 35,

wherein the test direction is in a direction different from the fault direction.

38. The method of testing according to claim 37, wherein the test direction of the plunger is in a direction opposite to the fault direction.

39. The method of testing according to claim 34, wherein, when the circuit interrupting device is in a pre-test configuration, substantially no voltage is produced by at least one piezoelectric member when the plunger is one of (a) in substantially stationary contact with the at least one piezoelectric member, and (b) not in contact with the at least one piezoelectric member,

wherein the step of causing the plunger to move in response to said actuation signal further comprises:

causing the plunger to dynamically contact the at least one piezoelectric member to produce a voltage output.

40. The method of testing according to claim 39, wherein the step of measuring said movement of said plunger is performed by measuring the voltage output of the at least one piezoelectric member.

41. The method of testing according to claim 40, wherein the step of measuring said movement of said plunger is performed by measuring the voltage output upon the plunger dynamically contacting the at least one piezoelectric member.

42. The method of testing according to claim 40, wherein the step of determining whether said movement reflects an operable circuit interrupting device is determined by whether said voltage output is indicative of sufficient movement of the plunger during a required real transfer of the circuit interrupting device from a non-actuated configuration to an actuated configuration.

43. The method of testing according to claim 40, wherein the step of determining whether said movement reflects an operable circuit interrupting device is determined by whether said voltage output is indicative of insufficient movement of the plunger during a required real transfer of the circuit interrupting device from a non-actuated configuration to an actuated configuration.

44. The method of testing according to claim 34, wherein the step of measuring said movement of said plunger further comprises:

measuring a first value of an electrical property of at least one electrical element that is characteristic of when the plunger is in contact with the at least one electrical element;

measuring a second value of the electrical property of the at least one electrical element that is characteristic of when the plunger is not in contact with the at least one electrical element; and

measuring a difference between the first value of the electrical property and the second value of the electrical property.

45. The method of testing according to claim 34, wherein the step of measuring said movement of said plunger further comprises:

measuring a first value of an electrical property of at least one electrical element that is characteristic of when the plunger is in the proximity of the at least one electrical element;

measuring a second value of the electrical property of the at least one electrical element that is characteristic of when the plunger is not in the proximity of the at least one electrical element; and

measuring a difference between the first value of the electrical property and the second value of the electrical property.

46. The method of testing according to claim 44,

wherein the step of determining whether said movement of said plunger reflects an operable circuit interrupting device is determined by whether the difference between the first value of the electrical property and the second value of the electrical property is indicative of sufficient movement of the plunger during a required real transfer of the circuit interrupting device from a non-actuated configuration to an actuated configuration.

47. The method of testing according to claim 44,

wherein the step of determining whether said movement of said plunger reflects an operable circuit interrupting device is determined by whether the difference between the first value of the electrical property and the second value of the electrical property is indicative of insufficient movement of the plunger during a required real transfer of the circuit interrupting device from a non-actuated configuration to an actuated configuration.

48. The method of testing according to claim 44, wherein the at least one electrical element characterized by an impedance load that is at least one of a resistor and a capacitor.

49. The method of testing according to claim 45, wherein the at least one electrical element is characterized by an impedance load that is an inductor.

50. The method of testing according to claim 34, wherein the circuit interrupting device includes first and second electrically conductive members electrically isolated from one another and with respect to the coil and plunger assembly such that the plunger makes electrical contact with both the first and second conductive members to form a continuous conductive path,

wherein the step of measuring said movement of said plunger further comprises:

measuring electrical continuity of the conductive path following the step of causing the plunger to move in response to said actuation signal.

51. The method of testing according to claim 50, wherein the step of determining whether said movement reflects an operable circuit interrupting device is determined by,

when the circuit interrupting device transfers to a post-test configuration from a pre-test configuration,

determining whether the plunger moves away from at least one of the first and second conductive members,

wherein termination of the continuity of the conductive path is indicative of sufficient movement of the plunger during a required real transfer of the circuit interrupting device from a non-actuated configuration to an actuated configuration.

52. The method of testing according to claim 51, wherein continued electrical continuity of the conductive path is indicative of insufficient movement of the plunger during a required real transfer of the circuit interrupting device from the non-actuated configuration to the actuated configuration.

53. The method of testing according to claim 50, wherein the step of determining whether said movement reflects an operable circuit interrupting device is determined by,

when the circuit interrupting device transfers to a post-test configuration from a pre-test configuration,

determining whether the plunger moves towards at least one of the first and second conductive members,

wherein establishment of continuity of the conductive path is indicative of sufficient movement of the plunger during a required real transfer of the circuit interrupting device from a non-actuated configuration to an actuated configuration.

54. The method of testing according to claim 34, wherein the circuit interrupting device comprises:

a first conductive member and a second conductive member, wherein, when the circuit interrupting device is in one of a pre-test configuration and a post-test configuration, the plunger is in a position with respect to the first and second conductive members indicative of one of a corresponding pre-test capacitance value and a corresponding post-test capacitance value, respectively,

wherein the step of measuring said movement of said plunger is performed by measuring the pre-test capacitance value and the post-test capacitance value.

55. The method of testing according to claim 54,

wherein the step of determining whether said movement reflects an operable circuit interrupting device is performed by determining if the post-test capacitance value differs from the pre-test capacitance value by a predetermined value that is indicative of sufficient movement of the plunger during a required real transfer of the circuit interrupting device from a non-actuated configuration to an actuated configuration.

56. The method of testing according to claim 54,

wherein the step of determining whether said movement reflects an operable circuit interrupting device is performed by determining if the post-test capacitance value differs from the pre-test capacitance value by a predetermined value that is indicative of no or insufficient movement of the plunger during a required real transfer of the circuit interrupting device from a non-actuated configuration to an actuated configuration.

57. The method of testing according to claim 54, wherein, when the circuit interrupting device is in one of the pre-test configuration and the post-test configuration, the plunger is in a position between the first and second conductive members indicative of one of the corresponding pre-test capacitance value and the corresponding post-test capacitance value, respectively.

58. The method of testing according to claim 34, wherein the circuit interrupting device further comprises:

an optical emitter emitting a light beam in a path therefrom,

wherein the step of measuring said movement of said plunger is performed by

measuring whether the plunger at least partially interrupts the path of the light beam emitted from the optical emitter.

59. The method of testing according to claim 58, wherein the step of causing the plunger to move in response to said actuation signal is performed wherein movement of the plunger enables the light beam to propagate in a path from the optical emitter to an optical sensor.

60. The method of testing according to claim 58, wherein the step of determining whether said movement reflects an operable circuit interrupting device is performed by measuring continuity of the path of the light beam wherein the continuity of the light path is indicative of sufficient movement of the plunger during a required real transfer of the circuit interrupting device from the non-actuated configuration to the actuated configuration.

61. The method of testing according to claim 58, wherein the step of determining whether said movement reflects an operable circuit interrupting device is performed by measuring discontinuity of the path of the light beam wherein discontinuity of the path of the light beam is indicative of insufficient movement of the plunger during a required real transfer of the circuit interrupting device from the non-actuated configuration to the actuated configuration.

62. The method of testing according to claim 34, wherein the circuit interrupting device includes an optical emitter emitting a light beam in a path therefrom,

wherein the step of measuring said movement of said plunger further comprises:

measuring whether the light beam propagates in a path from the optical emitter.

63. The method of testing according to claim 62, wherein the step of causing the plunger to move in response to said actuation signal further comprises the plunger at least partially interrupting the path of the light beam emitted from the optical emitter.

64. The method of testing according to claim 62, wherein the step of determining whether said movement reflects an operable circuit interrupting device further comprises measuring discontinuity of the path of the light beam wherein the discontinuity of the path of the light beam is indicative of sufficient movement of the plunger during a required real transfer of the circuit interrupting device from the non-actuated configuration to the actuated configuration.

65. The method of testing according to claim 62, wherein the step of determining whether said movement reflects an operable circuit interrupting device is determined by measuring continuity of the path of the light beam wherein the continuity of the path of the light beam is indicative of insufficient movement of the plunger during a required real transfer of the circuit interrupting device from the non-actuated configuration to the actuated configuration.