Electrical Circuit Breaker Operating Handle Block

1. Field of the Invention

This invention relates to electrical circuit breakers and more particularly to electrical circuit breakers which incorporate apparatus which restricts the travel of the circuit breaker operating handle when the contacts of the circuit breaker are closed due to an obstruction or contact welding.

2. Description of the Prior Art

Molded case circuit breakers are generally old and well known in the art. Examples of such circuit breakers are disclosed in U.S. Pat. Nos. 4,489,295; 4,638,277; 4,656,444 and 4,679,018. Such circuit breakers are used to protect electrical circuitry from damage due to an overcurrent condition, such as an overload and relatively high level short circuit. An overload condition is about 200-300% of the nominal current rating of the circuit breaker. A high level short circuit condition can be 1000% or more of the nominal current rating of the circuit breaker.

Molded case circuit breakers include at least one pair of separable contacts which may be operated either manually by way of a handle disposed on the outside of the case or automatically in response to an overcurrent condition. In the automatic mode of operation the contacts may be opened by an operating mechanism or by a magnetic repulsion member. The magnetic repulsion member causes the contacts to separate under relatively high level short circuit conditions. More particularly, the magnetic repulsion member is connected between a pivotally mounted contact arm and a stationary conductor. The magnetic repulsion member is a generally V-shaped member defining two legs. During high level short circuit conditions, magnetic repulsion forces are generated between the legs of the magnetic repulsion member as a result of the current flowing therethrough which, in turn, causes the pivotally mounted contact arm to open.

In a multipole circuit breaker, such as a three-pole circuit breaker, three separate contact assemblies having magnetic repulsion members are provided; one for each pole. The contact arm assemblies are operated independently by the magnetic repulsion members. For example, for a high level short circuit on the A phase, only the A phase contacts would be blown open by its respective magnetic repulsion member. The magnetic repulsion members for the B and C phases would be unaffected by the operation of the A phase contact assembly. The circuit breaker operating mechanism is used to trip the other two poles in such a situation. This is done to prevent a condition known as single phasing, which can occur for circuit breakers connected to rotational loads, such as motors. In such a situation, unless all phases are tripped, the motor may act as a generator and feed the fault.

In the other automatic mode of operation, the contact assemblies for all three poles are tripped together by a current sensing circuit and a mechanical operating mechanism. More particularly, current transformers are provided within the circuit breaker housing to sense overcurrent conditions. When an overcurrent condition is sensed, the current transformers provide a signal to electronic circuitry which actuates the operating mechanism to cause the contacts to be separated.

The operating mechanism of the circuit breaker is designed to rapidly open and close the separable contacts thereby preventing the moveable contact from stopping at any position which is intermediate the fully open or fully closed position. This accomplishes two purposes. First, when the contacts are quickly closed, the resultant force with which the moveable contact strikes the fixed contact ensures good electrical conduction between the contacts since impurities, such as dust and dirt, are dislodged. Second, when the contacts are quickly opened, the opportunity for electrical arcing between the fixed contact and the moveable contact is minimized since the contacts are quickly separated, through an arc suppressor, by a distance which is sufficient to prevent such arcing.

The moveable electrical contact is designed not only to strike the fixed contact, when closed, but also to slide across the surface of the fixed contact. This sliding action further aids in ensuring good electrical conductivity between the fixed member and the moveable member.

Despite the above described features, small amounts of debris may, nevertheless, become interposed between the fixed contact and the moveable contact. Under such circumstances, the possibility exists that the fixed contact will weld to the moveable contact thereby preventing the circuit breaker from opening either during an overcurrent condition or during manual operation. Contact welding can also occur due to a mechanical failure of the breaker wherein the force exerted by the moveable contact on the fixed contact is reduced.

The circuit breaker includes a pivoting operating handle, which projects through an opening formed in the breaker housing, for manual operation. The handle may assume one of three positions during normal operation of the circuit breaker. In the ON position, the handle is positioned at one end of its permissible travel. When the operating handle is moved to this position, and the breaker is not tripped, the contacts of the circuit breaker close thereby allowing electrical current to flow from the current source to an associated electrical circuit. At the opposite end of the travel of the handle is the OFF position. When the handle is moved to that position, the contacts of the circuit breaker open, except as described below, thereby preventing current from flowing through the circuit breaker.

A third position is the tripped position which is approximately midway between the ON position and the OFF position. The handle automatically assumes this position whenever the operating mechanism or the magnetic repulsion members have tripped the circuit breaker and opened the contacts. Once the circuit breaker has been tripped, the electrical contacts cannot be reclosed until the operating handle is first moved to the OFF position and then back to the ON position.

As previously described, it is possible for the contacts of the circuit breaker to weld closed thereby preventing the contacts from opening when the circuit breaker is tripped or when the handle is moved to the OFF position. However, the handle may still be manually moved to the OFF position even when the electrical contacts are welded closed and, hence, the electrical circuit is energized. This is because the moveable contacts are mechanically connected to the lever through biasing springs. The handle, therefore, may be moved to the OFF position by overcoming the biasing force of the springs.

This can create a hazard if, for example, a person were to move the handle to the OFF position thereby believing that the electrical contacts are open and that the electrical circuit, connected to the circuit breaker, is therefore, de-energized when in actuality it is not. A person could attempt to manually access energized portions of the circuit and unexpectedly receive an electrical shock. The present invention reduces the risk of such occurrence by providing apparatus which mechanically limits the travel of the operating handle so that it may not be moved to the OFF position when the electrical contacts are closed, such as when they are welded.

Apparatus is provided for restricting the movement of the operating handle of an electrical circuit breaker to a predetermined limit which includes a handle arm, an operating handle which may assume an ON position and an OFF position and electrical contacts which are moveable between an open position and a closed position. The apparatus includes handle restrictor apparatus which is mechanically connected to and out of direct contact with the handle arm of the electrical circuit breaker for restricting the movement of the operating handle to a predetermined limit between the ON position and the OFF position when the operating handle is moved from the ON position toward the OFF position and the electrical contacts of the electrical circuit breaker are in the closed position.

The invention may be better understood and further advantages and uses thereof are readily apparent, when considered in view of the following detailed description of the preferred embodiment taken with the accompanying drawings in which:

FIG. 1 is a plan view of a molded case circuit breaker in accordance with the present invention;

FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1 according to one embodiment of the invention.

FIG. 3 is a cross-sectional view taken along line 2--2 of FIG. 1 according to a second embodiment of the invention;

FIG. 2B shows the toggle mechanism according to the first embodiment when the circuit breaker is not tripped;

FIG. 2C shows the toggle mechanism according to the second embodiment where the circuit breaker is untripped;

FIGS. 2D1 and 2D2 illustrate schematically the operation of the toggle mechanism according to the first embodiment when the circuit breaker has tripped.

FIG. 2E shows the toggle mechanism according to the second embodiment when the circuit breaker has tripped;

FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 1 illustrating an outside pole;

FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 2;

FIG. 5 is a perspective view of a portion of the shock absorber assembly used for outside poles;

FIG. 6 is a cross-sectional view taken along line 6--6 of FIG. 3;

FIG. 7 is a cross-sectional view taken along line 7--7 of FIG. 4;

FIG. 8 is a plan sectional view taken along line 8--8 of FIG. 7;

FIG. 9 is an enlarged cross-sectional view taken along line 9--9 of FIG. 8;

FIG. 10 is an exploded perspective view of the cam roller pin assembly;

FIG. 11 is an exploded perspective view of the laminated copper assembly;

FIG. 12 is an exploded perspective view of the crossbar assembly;

FIG. 12A is like FIG. 12 but modified so as to show the upper link of the toggle mechanism with its projection according to the second embodiment of the invention;

FIG. 13 is a bottom plan view taken along line 13--13 of FIG. 2;

FIG. 14 is a cross-sectional view taken along line 14--14 of FIG. 2;

FIG. 15 is a plan sectional view taken along line 15--15 of FIG. 14;

FIG. 16 is a plan sectional view taken along line 16--16 of FIG. 14;

FIG. 17 is a cross-sectional view taken along line 17--17 of FIG. 1;

FIG. 18 is an exploded perspective view of the modular option deck assembly;

FIG. 19 shows a typical plate as can be used for the upper toggle link of FIG. 2A or 12A; and

FIG. 20 is illustrative of another design for the plate of FIG. 19.

A molded case circuit breaker, generally indicated by the reference numeral 20, comprises an electrically insulated housing 21 having a molded base 22 and a molded coextensive cover 24, assembled at a parting line 26. The internal cavity of the base 22 is formed as a frame 28 for carrying the various components of the circuit breaker. However, the principles of the present invention are applicable to various types of molded case circuit breakers.

At least one pair of separable contacts 30 are provided within the housing 21. More specifically, a main pair of contacts 30 are provided which include a fixed main contact 32 and a movable main contact 34. The fixed main contact 32 is electrically connected to a line side conductor 36, bolted to the frame 28 with a plurality of fasteners 38. A T-shaped stab 40 is fastened to the line side conductor 36 with a plurality of fasteners 42. A depending leg 44 of the stab 40 extends outwardly from the rear of the circuit breaker housing 21. This depending leg 44 is adapted to plug into a line side conductor disposed on a panelboard (not shown).

Similarly, the movable main contact 34 is electrically connected to a load side conductor 46 fastened to the frame 28 with a plurality of fasteners 48. Another T-shaped stab 50 is connected to the load side conductor 46 with a plurality of fasteners 52. A depending leg 53 of the stab 50, which extends outwardly from the rear of the circuit breaker housing 21, is adapted to plug into a load side conductor within a panelboard.

A donut-type current transformer (CT) 54 is disposed about the load side conductor 46. This current transformer 54 is used to detect current flowing through the circuit breaker 20 to provide a signal to an electronic trip unit (not shown) to trip the circuit breaker 20 under certain conditions, such as an overload condition. The electronic trip unit is not part of the present invention.

An operating mechanism 58 is provided for opening and closing the main contacts 30. The operating mechanism includes a toggle assembly 60 which includes a pair of upper toggle links 62 and a pair of lower toggle links 64. Each upper toggle link 62 is pivotally connected at one end to a lower toggle link 64 about a pivot point 66. Each of the lower toggle links 64 are pivotally connected to the molded crossbar assembly at a pivot point 70. The contact arm carrier 68 forms a portion of a crossbar assembly 72. The upper toggle links 62 are each pivotally connected to depending arms 73 of a cradle 74 at a pivot point 76. A biasing spring 78 is connected between the pivot point 66 and an operating handle 80. The biasing spring 78 biases the toggle assembly 60 to cause it to collapse whenever the cradle 74 is unlatched from a latch assembly 82 causing the movable main contacts 34 to rotate about a cam roll pin assembly 176 to cause the main contacts 30 to separate.

The latch assembly 82 latches the cradle 74 and toggle assembly 60. The latch assembly 82 includes intermediate latch 84 and latch link 86, pivotally connected end to end at a pivot point 88. The free end of intermediate latch 84 is pivotally connected to left and right sideplates of frame 28 about a pivot point 90. The free end of the upper latch link 86 is pivotally connected to a latch lever 92 about a pivot point 94. The other end of the latch lever 92 is pivotally connected to the frame 28 about a pivot point 96.

Operation of the latch assembly 82 is controlled by a trip bar 98 having a depending lever 100 extending outwardly. The depending lever 100 engages a cam surface 102, formed on the pivotally connected end of the upper latch link 86 when the latch assembly 82 is in a latched position. In response to an overcurrent condition, the trip bar 98 is rotated clockwise to move the depending lever 100 away from the latch surface 102. Once the latch lever 92 has cleared the cam surface 102, a biasing spring 104, connected between the lower latch link 84 and the frame 28, causes the lower latch link 84 to toggle to the left causing the latch lever 92 to rotate clockwise thereby releasing the cradle 74. Once the cradle 74 is released from the latch assembly 82, the cradle 74 rotates counterclockwise under the influence of the biasing spring 78. This causes the toggle assembly 60 to collapse which, in turn, causes the main contacts 30 to separate. The handle 80 is integrally formed with an inverted U-shaped operating lever 106 which pivots about a pivot point 108.

The trip bar 98 is controlled by an electronic trip unit which actuates a solenoid (not shown) having a reciprocally mounted plunger which engages the lever 100 which, in turn, causes the trip bar 98 to rotate in a clockwise direction to unlatch the latch assembly 82. The electronic trip unit actuates the solenoid in response to an overcurrent condition sensed by the current transformer 54.

After the overcurrent condition has subsided, circuit breaker 20 may be reset to the ON position by moving operating handle 80 to the OFF position, thereby resetting operating mechanism 58, and then moving operating handle 80 to the ON position, thereby closing the circuits of all poles of the circuit breaker.

The current path through circuit breaker 20 may be manually opened and closed by moving operating handle 80 between its ON position and its OFF position. Operating mechanism 58 is positioned as shown in solid in FIG. 2 when operating handle 80 is in the ON position and moveable main contact 34 is in contact with main contact 32 thereby allowing current flow through circuit breaker 20. As operating handle 80 is moved toward the OFF position from the ON position, spring 78 applies a biasing force which is upward and to the right on pivot point 66. That in turn causes upper toggle link 62 to pivot counterclockwise about pivot point 76 and lower toggle link 64 to pivot clockwise and raise vertically. That action causes arm carrier 68 to pivot about carrier pivot pin 230 thereby separating moveable main contact 34 from main contact 32 and assume the position shown in shadow in FIG. 2.

FIG. 2 shows a projection 500 which is an integral part of the lower toggle link 64. When the contacts 34 (the moveable contact) and 32 (the fixed contact) are welded, the crossbar surface 72 remains where it was when the contacts were closed, and the projection 500 will encounter surface 72 when, under toggle mechanism operation, the lower toggle link 64 is forced to rotate about the fixed pivot 70 in an attempt to fold.

FIG. 2A is like FIG. 2, but the upper link 62 is now provided with a projection 501 turned on the opposite side of the line joining the pivots 70, 66 and 76 of the toggle mechanism. At the same time, the operative member 106 of the handle 80 will encounter, with its pin 502, the projection 501, whenever the toggle mechanism is held in position by a welded contacts situation, as explained hereinafter, thereby preventing the handle from going further into the OFF position which would be erroneous in such situation.

The transition from the closed to the open position occurs just after operating handle 80 assumes a vertical position as it is pivoted. Just prior to the transition between the open and closed position, projection 500 (shown in FIGS. 2 and 12) of lower toggle link 64 approaches crossbar assembly 72. An important aspect of the present invention is the mechanical interaction between projection 500 and crossbar assembly 72.

Projection 500 would contact crossbar assembly 72 and, thereby, prevent operating handle 80 from moving any farther toward the OFF position if crossbar assembly 72 were to remain in the position as shown in shadow in FIG. 2. Crossbar assembly 72 remains in the position shown in solid in FIG. 2 as long as the contacts of circuit breaker 20 are closed.

However, projection 500 is sized and shaped to allow operating handle 80 to move just past the transition point, between the open and closed contact position, without contacting crossbar assembly 72. If the circuit breaker is functioning properly this causes the contacts of the circuit breaker to open and, simultaneously, rotates crossbar assembly 58 to the position shown in shadow in FIG. 2. Projection 500, therefore, will not contact crossbar assembly 72 as it is further moved toward the OFF position since crossbar assembly 72 has rotated out of the path of travel of projection 500.

If, however, the contacts would for some reason not open, such as when moveable main contact 34 is welded to main contact 32, it would be possible, if projection 500 were not provided, to move operating handle 80 to the OFF position even though the contacts would remain closed. This would provide a false indication that the current path through circuit breaker 20 had been opened and the electrical circuit, to which circuit breaker 20 is connected, is deenergized. The apparatus of the present invention prevents this from occurring.

If operating handle 80 is moved past the transition point and the contacts of the circuit breaker remain closed, crossbar assembly 72 will remain in the position shown in solid in FIG. 2 and not rotate to the position shown in shadow in FIG. 2. Further movement of operating handle 80 past the transition point toward the OFF position would then result in projection 500 coming in direct contact with crossbar assembly 72, thereby preventing further movement of lower toggle link 64.

The handle arm 16 is connected from its upper central inner point SP to the middle pivot 66 of the toggle link mechanism (three pivots: upper 76, middle 66 and lower 70, aligned when at rest) by an extension spring (78 on FIG. 2). It is the spring which, when extended by the handle arm 16, tends to pull pivot 66 away from alignment and folds the toggle mechanism, provided the contacts are free to separate and pivot 70 can be raised with the lower toggle link 64. Handle arm 16 and operating handle 80 are mechanically connected together and move in unison. Therefore, unless the toggle mechanism has been folding about its pivot point 66, further movement of operating handle 80 toward the OFF position is hampered since, upon reaching a predetermined limit position of the handle 80 and of the attached handle arm 16, spring 78 will be hard extended while projection 500 is being stopped against crossbar assembly 72. Therefore, the present invention effectively prevents operator control of the operating handle 80 to the OFF position when the contacts of the circuit breaker are closed, thereby preventing a false indication of contact position from occurring.

This will be explained in detail hereinafter from a consideration of FIGS. 2, 2A to 2C, 2D1, 2D2 and 2E. FIGS. 2, 2B, 2D1 and 2D2 relate to the first embodiment of the invention. The lower link 64 is here characterized by a projection, or nose 500, the latter being designed so as to engage the crossbar 72 whenever the toggle mechanism, under control of the handle 80 and its attached handle arm 16 toward the OFF position, tends to move but is held back by the crossbar 72, because it is in the way if it has remained in position because contacts 32 and 34 are welded. FIGS. 2A, 2C and 2E relate to the second embodiment of the invention. Here, in addition to the lower link projection, or nose 500, the upper link is also provided with a projection, or nose 501, the latter being designed and turned toward the pin 502 of the handle arm 16. As a result, whenever the handle 80 and the attached handle arm 16 are moved toward the OFF position while the contacts 32 and 34 are welded, pin 502 will engage projection, or nose 501, and the handle arm 16 (as well as the operating arm 80) will be blocked, thereby providing positive blockage of the handle 80 within a predetermined limit position not to be reached by manual control.

In this regard, it is observed that it has been the practice, among others, to mount an interlock device laterally of, and in proximity to, the handle 80, so that when pushing the handle toward the OFF position beyond said predetermined limit position, a bar, or plunger, will be thrown transversely, and be locked with a key, across and behind the handle. Therefore, it will be impossible to bring the handle back to the ON position, without releasing the interlock with the key. Accordingly, the present invention insures that such limit position will never be exceeded by manual control of the handle 80 toward the OFF position if the contacts have remained welded.

The operation of the handle 80, and its handle arm 16, and of the toggle link mechanism (upper link 62 and lower link 64) will now be explained successively for the two afore-stated embodiments of the invention.

FIGS. 2 and 2A relate to an untripped situation (the cradle 74 is still locked in position at 92, thus without tripping action of the trip bar). FIG. 2, according to the first embodiment of the present invention, shows a projection, or nose 500, which is an integral part of the lower toggle link 64. When the contacts 34 (the moveable contact) and 32 (the fixed contact) are welded, the crossbar surface 72 remains in position where it was when the contacts were closed, and the projection 500 will encounter surface 72 if, under toggle mechanism operation, the lower toggle link 64 is forced, by the spring 78 under control of the handle 80 and its attached handle arm 16, to rotate about the now fixed pivot 70, in an attempt to fold.

FIG. 2A is like FIG. 2, but the upper toggle link 62 is now also provided with a projection, or nose 501. The nose 501 is now turned on the opposite side in relation to the line joining the pivots 70, 66 and 76 of the toggle mechanism. At the same time, the handle arm 16, which possesses a projection 106 having a pin 502, will be blocked when pin 502 encounters the projection 501, since the toggle mechanism is held in position by nose 500 against the crossbar 72, if in a welded contacts situation. As explained hereinafter, this prevents the handle 80 from going any further to the OFF position, which would give an erroneous indication.

FIG. 2B is like FIG. 2 but it shows with more emphasis the toggle mechanism and the handle arm 16. According to the first embodiment of the invention, there is only one projection, or nose 500, in the toggle mechanism. The handle 80 when in the ON position would be along an axis H1 as shown to the extreme left. The handle arm 16 possesses a middle and upper portion (shown by an arcuate surface) now in position SP1. SP1 is mechanically connected to the middle pivot 66 of the toggle mechanism by an overcenter or tension spring (78 on FIG. 2). The handle arm 16 is articulated and mounted for rotation with a knee defining a pivot point PVH (shown much below pivot point 66 for improved clarity). Normally, as long as the handle remains to the left of a line (70, 66, 76) joining the pivots of the toggle mechanism, spring 78 has no effect on pivot 66. When the handle is pushed beyond line H1 (the ON position) to the right, line (SP1, 66) rotates clockwise about pivot 66, while the handle arm axis does the same about pivot PVH. In the process, the spring 78 becomes increasingly and quickly extended and tends to pull pivot 66 and fold the toggle mechanism. However, since pivot 70 is effectively fixed when the contacts are welded, the lower link will tend to rotate about pivot 70 so that projection, or nose 500 will come to hit the crossbar 72. This establishes a limit position LMT, defined by upper toggle link line (66, 76), which the handle 80 will eventually reach by forcing the spring to extend, until the spring has passed on the other side of such limit position. Then, the spring force is relaxed. It would still be possible to move the handle beyond it and have the key locked behind the OFF position side, an erroneous indication if the contacts are welded. FIG. 2B shows the ON position handle line H1 passing through pivot PVH of the handle arm knee. FIG. 2B also shows the critical limit position LMT defined by a line joining the middle point 66 of the toggle mechanism and the upper pivot 76 thereof when nose 500 is blocked. Moreover, the operating handle 80 is shown close to such limit position but still behind at H2, with the spring highly extended between SP2 and 66. Although the handle can still be pushed beyond the LMT line and cause, as just stated, locking of the key interlock, nose 500 still accomplishes its purpose. The nose 500 is holding pivot 66, and the operator will feel the extreme extension of the spring.

FIG. 2C is, like FIG. 2B, in the untripped situation (cradle 74 is locked by trip bar 92), but with the provision of a second nose 501 on the upper link 62, according to the second embodiment of the invention. The handle arm 16 has an extension 106 carrying a pin 502. Nose 501 is in the path of pin 502 if the handle is moved from the ON position H1 toward the OFF position to the right. Blockage by pin 501 occurs for a position H3 which is assumed, illustratively to be somewhat beyond the limit LMT, but not far enough that, considering the width of handle 80, the interlock bar could not be thrown behind it. Now, the operator does not have to count upon the strength of spring 78 as nose 500 is being blocked by crossbar 72, in order to be aware of the critical situation existing with the contacts 34 and 32. A positive blocking of the handle 80 has been insured by nose 501 and pin 502. The operator will not be able to move the handle any further than position H3, as illustrated in FIG. 2C.

The tripped situation will now be examined by reference to FIGS. 2D1, 2D2 and 2E. In these instances, the cradle has been moving counterclockwise about its pivot PVC after the trip bar has liberated arm 74 from its locking bar 92. As a result, the upper toggle link has been moved somewhat upwards and to the left by rotation of pin 76 about cradle pivot PVC. When forcing the handle from line H1 to the right, the toggle mechanism will come to sit with nose 500, now in position 500' against crossbar 72, as shown in FIG. 2D2. (It is observed, in this regard, that pin 502 will push the cradle back while moving to the right). However, the handle will now have moved further to the right than in the case of FIG. 2B. As a matter of fact, it will reach a position, indicated by line H4, which is beyond the limit assigned for safety by the interlock device. Therefore, despite the indication given to the operator by the extended spring 78, it will be too late to realize that the contacts are welded independently from any swift toggle mechanism folding. Such belated limit position of line H4 is reached when the lower toggle link nose 500 is blocked by crossbar 72. Therefore, positive blocking of the handle before the marked key interlock limit has been reached is necessary. This is provided by the second nose 501 on upper toggle link 62, as shown in FIG. 2E. Like in the situation of FIG. 2C, pin 502 encounters projection 501, while the handle line is still at position H2, thus, before the interlock critical position.

It may be appreciated, therefore, that the present invention provides substantial safety advantages over circuit breakers which allow the operating handle 80 to be positioned in the OFF position even when the contacts of the circuit breaker are closed. While, for the purposes of the discussion, the invention has been described with respect to circuit breaker contacts which are welded in the closed position, it may be appreciated that the present invention prevents the operating handle from being moved to the OFF position if the circuit breaker contacts are closed for any reason.

A laminated contact assembly 109 is formed from a plurality of individual movable main contact assemblies 110. The individual contact assemblies 110 are fastened together to form the laminated contact assembly 109. The individual contact assemblies 110 include an elongated electrical conductor portion 111 and a contact arm portion 114. Some of the contact arm portions 114 carry the movable main contacts 34 while some are used to carry arcing contacts 116. The contact arm portions 114 are coupled to stationary conductor portions 111 by way of repulsion members or flexible shunts 118.

Several different types of individual contact assemblies 110 are used to form the contact assembly 109. In a first type 119 (shown in FIG. 11), an L-shaped conductor portion 111 is provided having an arcuate slot or keyhole 122 disposed on an edge on a short leg 124 of the L-shaped conductor 111. The keyhole 122 is used to receive an end of the magnetic repulsion member 118. The assembly 110 also includes a contact arm 114 having an irregular shape for carrying either a main movable contact 34 or an arcing contact 116 at one end. Another arcuate slot or keyhole 122, formed in the contact arm portion 114, disposed at an end opposite the main movable contact 34 or the arcing contact 116, is used to receive the other end of the magnetic repulsion member 118. The ends of the magnetic repulsion members 118 are crimped prior to being inserted into the keyholes 122. A top edge 128 of the contact arm portion 114 is formed with a rectangular recess 129 for receiving a biasing spring 130. The other end of the spring 130 seats against a pivotally mounted bracket 132.

The spring 130 exerts a downward pressure or force on the contact arm portion 114 forcing it against the fixed main contact 32. This force may be about 4 to 5 pounds. The contact pressure from the spring 130 in conjunction with the magnetic repulsion forces produced as a result of current flowing in the magnetic repulsion member or shunt 118 controls the withstand rating of the circuit breaker. The withstand rating of a circuit breaker is the current at which the main contacts 30 begin to separate. Since the repulsion force generated by the magnetic repulsion member 118 is a function of the current flow through the magnetic repulsion member 118, the biasing springs 130 are used to oppose that force to control the withstand rating of the circuit breaker in certain conditions.

Each contact arm portion 114 is provided with an aperture 136 for receiving a pin 139 for fastening the contact arm portions 114 together which defines a pivot point for the contact arms. Pin 230, positioned within opening 228 provides a pivot point for contact assembly 109. The stationary conductor portion 111 of each of the individual contact assemblies 110 is provided with three spaced-apart apertures 137 for receiving a plurality of rivets or fasteners 138 for fastening the stationery conductor portions 111 together.

An important aspect of circuit breaker 20 relates to the method for connecting the contact assembly 109 to the base 22 of the circuit breaker by drilling and tapping holes in a base portion of the contact assembly. Fasteners are then screwed into the tapped holes to secure the contact arm assembly to the circuit breaker base. However, in such an arrangement, the tapped holes may become lose over time due to the dynamic forces within the circuit breaker. This problem is solved by providing T-shaped slots in the bottom portion of the contact arm assembly 56 for receiving square-headed bolts which are captured within the assembly 109.

Accordingly, a second type of individual contact assembly 140 (shown in FIG. 11) is provided having a T-shaped slot 142 formed on a bottom edge 144 of the stationary conductor portion 111. This T-shaped slot 142 is used to receive a square-headed bolt 147. The contact arm portion 114 of the assembly 140, as well as the magnetic repulsion member 118, are similar to those used in the contact assembly 110. Since the contact assemblies 140 with the T-shaped slots are sandwiched between adjacent contact arm assemblies which do not have such a T-shaped slot 142 formed on the bottom edge, the square-headed bolt 112, after assembly, will be captured in the T-shaped slot 142.

In another type of individual contact assembly 146 (shown in FIG. 11), the stationary conductor portion 111 is similar to that provided with the contact assembly 119. The essential difference between the individual contact assemblies 119 and 146 is that the contact arm portions 114 in the assembly 146 carry arcing contacts 116 instead of main contacts 30 defining an arcing contact arm 148. These arcing contacts 116 extinguish the arc caused when the main contacts 30 are separated. An arc suppression chute 152 is provided within the circuit breaker housing 21 to facilitate extinguishment of the arc. Each of the arcing contact arms 148 are formed with a rectangular recess 129 for receiving a bracket 156 having parallel depending arms 158. The bracket 156 is received in the rectangular recesses 129. The bracket 156 also contains an upwardly-disposed protuberance 160 used to receive a spring 162 disposed between the bracket 160 and the underside 163 of the pivotally mounted bracket 132. The arcing contact arms 148, similar to the main contact arm portions 114, are rotatable about the pivot point 136.

As shown in FIG. 11, the various types of individual contact assemblies 119, 140 and 146 are stacked together such that the apertures 137 in the L-shaped conductor portions 111 are aligned. Rivets or fasteners 138 are then inserted into the apertures 137 to secure all of the L-shaped conductor portions 111 together. A pin or rivet defining a pivot point 139 is inserted through the apertures 136 in the contact arm portions 114 and arcing contact arms 148 to connect all of the contact arm portions 114 together and to the pivotal bracket 132. Barriers 166 are placed between the stationary conductor portions 111 of the individual contact arm assembly and the shunts 118. Barriers 166 are also provided between the individual contact arm portions 114 and 148. The completed assembly forms the contact carrier assembly 109.

The shunt or magnetic repulsion member 118 is a laminated member, form wound from a continuous, thin strip of an electrical conductive material, such as copper, forming a laminated magnetic repulsion member. The form wound shunt member 118 is formed into a V-shaped member defining a pair of legs 168 and 170. Current flowing through the legs 168 and 170 causes magnetic forces to be generated which repels the legs 168 and 170 apart. Above a certain level of overcurrent (e.g., above the withstand rating), the magnetic repulsion forces developed will be sufficient to blow open the main contacts 34 rather quickly. The biasing springs 130 oppose the magnetic repulsion forces generated by the magnetic repulsion member 118 to allow the current transformer 54 and the electronic trip unit to sense the overcurrent condition and trip or separate the contacts by way of the operating mechanism 58 for overcurrent conditions less than the withstand rating of the circuit breaker.

In order to improve the flexibility of the magnetic repulsion member, an apex portion 172 of the member 118 is coined or deformed into a bulb-like shape is shown best in FIG. 7. The extending legs 168 and 170 of the member 118 are crimped and inserted into the keyholes 122 in the stationary conductor portion 111 and the contact arm portions 114 of the individual main and arcing contact arm assemblies. Once the ends of the shunt legs are inserted into the keyholes 122, the assembly is mechanically crimped and then staked on both sides. The staking process provides a groove 174 in the assemblies adjacent the keyholes 122 to prevent wicking of solder used to secure the shunt legs 168 and 170 to the stationary conductor portions 110 and the contact arm portions 114 or 148.

As shown in FIG. 7, the cam roll pin assembly 176 is a dual-purpose assembly used to maintain the force between movable 34 and stationary contacts 32 during certain conditions, and maintain contact separation between these contacts when a blow open occurs until the circuit breaker trips by way of the mechanical operating mechanism 58. During normal operation, when the overcurrent is less than the withstand rating of circuit breaker 20, a cam roller pin 196 bears against a cam surface 180, integrally formed in the pivotally mounted bracket 132, which forms a portion of the contact arm assembly 109. This couples the crossbar assembly 72 to the contact arm assembly 109. Since the toggle assembly 60 is coupled to the crossbar assembly 72, this will allow the operation of the main contacts 34 to be controlled by the mechanical operating mechanism 58. As heretofore stated, the biasing springs 130 in the contact assembly 109 will cause a downward pressure or force on the movable contact 34 against the fixed main contact 32. For overcurrent conditions less than the withstand-rating of the circuit breaker 20, the contact arms 114 and 148 will pivot about an axis 139. During such an overcurrent condition, the magnetic repulsion forces generated by the extending legs 168 and 170 of the magnetic repulsion member 118 will cause the contact arms 114 and 148 to rotate about the axis 139 in a counterclockwise direction forcing the main contacts 34 together to allow the operating mechanism 58 to trip the circuit breaker. In this situation, due to the pivotal movement of the contact arms 114 and 148 about the axis 139, the magnetic repulsion members 118 act to close or "blow on" the main contacts 34.

As shown in FIGS. 8 and 9 for overcurrent conditions below the withstand rating of the circuit breaker, the cam roller pin 196 will ride in the cam surface 180 to mechanically couple the contact assembly 109 to the crossbar assembly 72. In this situation, the current transformer 54 will sense an overcurrent condition and provide a signal to an electronic trip unit which will in turn cause the operating mechanism 58 to trip the circuit breaker and open the main contacts 34. However, for a relatively higher overcurrent condition, greater than the withstand rating the pivot point for the contact arm assemblies 109 will change to allow the contact assemblies 109 to blow open. More specifically, the magnetic repulsion forces generated by the magnetic repulsion member 118 will cause the cam roller pin 176 to move away from the cam surface 180 to a second cam surface 182 to allow the movable contact assembly 109 to pivot about axis 230. In this situation, the magnetic repulsion forces generated by the magnetic repulsion member blow open the main contacts 34. After blow open, once the cam roller pin 176 reaches the cam surface 182, it will keep the main contacts 34 separated. Otherwise, after the overcurrent condition ceased, there would not be any magnetic repulsion forces to keep the main contacts 34 separated.

As seen in FIG. 9, there are two points of contact at each end of the cam roller pin 176 on the outside poles. One point of contact 184 is disposed intermediate the end. It is the point where the cam roller pin 176 rides along the cam surfaces 180 and 182 of the pivotally mounted bracket 132. The other point of contact 186 is at the ends of the cam roller pin 176 where it is received within a pair of slots 188 in an electrically-insulated sleeve which forms a portion of the crossbar assembly 72. When a blow open condition occurs, the contact points 184 and 186 may rotate in opposite directions. In such a situation, relatively large torsional and frictional forces are created on the cam roller pin 176 which may cause the blow open speed to be reduced or possibly cause the breaker not to trip after blow open has occurred. An important aspect of circuit breaker 20 is that a cam roller pin 176 is provided which has independently rotatable portions for each contact point 184 and 186 at each end to reduce the frictional and torsional forces which may be generated during a blow open condition.

As shown in FIGS. 10 and 11 the cam roller pin assembly 176 includes a cylindrical portion 192 having extending axles 194 disposed at each end. A small roller 196 and a large roller 198 are disposed on each axle 194. After the rollers 196 and 198 are placed on the axle 194, a retaining ring 197 is used to secure the rollers 196 and 198 to the axle 194. The small roller 196 is used to engage the cam surfaces 180 and 182 on the pivotally mounted bracket 132 while the larger roller 198 is received within the slot 188 in the electrically insulated sleeve 190. Since individual rollers are used for each of the contact points, supported on a common axle, both rollers are independently rotatable. Thus, in situations where the contact points are forced to rotate in opposite directions, such as during a blow open condition, the frictional forces will be greatly reduced, thus resulting in a smoother action of the circuit breaker 20.

As shown in FIG. 8, the cam roller pin assembly 176 is coupled to the pin 230 about which the pivotally mounted bracket 132 rotates, by way of a plurality of springs 200. Radial grooves 204 formed in the cylindrical portion 192 of the cam pin roller assembly 176 receive hook shaped ends of the springs 200. Similar type grooves may be formed (not shown) on the pin 230 to receive the other end of the springs 200 to prevent axial movement of the springs 200 to couple the cam roller pin assembly 176 to the pin 230.

Referring to FIG. 12, the crossbar assembly 72 is coupled to the contact assemblies 109 for each of the poles by way of cam roll pin assemblies 176. More specifically, the crossbar assembly 72 includes an elongated shaft 206 which may be formed with a rectangular cross section. The elongated shaft 206 is used to support a pair of crossbar plates 68 coupled to the lower toggle links 64 of the toggle assembly 60. Two contact arm carriers 68 are provided adjacent the center pole in a multipole circuit breaker 20. Each crossbar plate 68 is generally L-shaped having an aperture 210 in a short leg 212. The aperture 210 is rectangular in shape and slightly larger than the cross sectional area of the shaft 206 such that the contact arm carriers 68 can be slidingly received on the shaft 206 and rotate therewith.

The crossbar plates 68 is a laminated assembly formed from a pair of L-shaped brackets 214, spaced apart to receive the lower toggle link 64 from the toggle assembly 60. The apertures in the lower toggle links 64 (defining the pivot point 70) are aligned with apertures 215 in the L-shaped members 214. Metal pins 216 are inserted through the apertures to form a pivotable connection between the contact arm carriers 68 and the lower toggle links 64. Insulated sleeves 218 having a generally rectangular cross sectional bore are slidingly received on the ends of the crossbar shaft 206. These insulated sleeves 218 are disposed adjacent the outside poles. Oppositely disposed plates portions 220 and 222 are integrally formed with the insulated sleeve 218 from an electrically insulating material. The plate portions 220 and 222 are disposed on opposite ends of the insulated sleeve 218 and contain a pair of inwardly facing rectangular slots 188. The pair of inwardly facing slots 188 are used to receive the rollers 198 of the cam roll pin 176. The oppositely disposed plate portions 220 and 222 are also provided with a pair of aligned apertures 226. The apertures 226 are aligned with apertures 228 in the pivotal bracket 132. A pin 230 is secured in the apertures to provide a pivotal connection between the rotatable bracket 132 and the integrally formed insulated sleeve assemblies 218.

The spacing between the oppositely disposed plate portions 220 of the insulated sleeves 218 is such that it captures the pivotally mounted bracket 132. Thus, any magnetic repulsion forces generated between the contact arm assemblies due to overcurrent conditions will cause the contact arm assemblies 109 to repel and, in turn, cause the insulated sleeve portions 218 to be forced off the shaft 206. Since the magnetic repulsion forces can cause movement of the crossbar plates 68 along the shaft 206, these crossbar plates 68 are welded to the shaft 206. The insulated sleeve assemblies 218 may be either molded on the shaft 206 or molded separately and affixed to the shaft 206 with an adhesive, such as epoxy, and pinned to the shaft 206 by way of one or more metal pins 232 inserted transversely in apertures in the sleeves 218 and the shaft 206 to prevent axial movement of the sleeves 218 with respect to the shaft 206. The metal pins 232 are inserted 1/8 inch below apertures (not shown) in the insulated sleeves 218 and may be covered with an electrically insulating material.

A rubber stop assembly 234 (shown in FIGS. 4 and 5) is provided on each of the outside poles to prevent damage to the cover 24 of the circuit breaker when the contact assemblies 109 are separated from the fixed main contact 32. During relatively high overcurrent conditions, particularly when the contact arm assembly 109 is blown open by the magnetic repulsion member 118, considerable force is generated. In conventional circuit breakers shock absorbing materials are glued to the inside of the cover to stop or prevent the contact assembly 109 from striking the cover 24. However, in some circumstances, damage to the cover 24 still results. An important feature of circuit breaker 20 relates to the rubber stop assemblies 234 for outside poles used to prevent the contact assemblies 109 from striking the cover 24. The robber stop assembly 234 includes a shock absorber 236, spaced away from the cover 24 of the circuit breaker housing 21. By spacing the shock absorber 236 away from the cover 234, damage to the cover 24 is prevented.

An important aspect of the rubber stop assembly 234 is that it includes a dual purpose bracket 238 with two parallel sets of spaced apart depending arms 240 and 242. The relatively longer set of arms 240 contain aligned apertures 243 at the free end 244 for receiving a pin 246. The shock absorber 236 is generally cylindrical in shape having a center bore with a diameter to allow it to be slidingly received on the pin 246. The pin 246 is slightly longer than the cylindrical shock absorber such that the ends of the pin extends outwardly from the arms 240. This extending portion of the pin is received in integrally molded bores 248 formed in the molded base 28 to provide additional support for the rubber stop assembly 234. The relatively shorter set of extending arms 242 are used to provide a pivotal connection for the crossbar assembly 42.

A portion 219 of the bracket 238 is provided with apertures 250. A barrier plate 252 having a pair of extending ears 254 is provided with a pair of apertures 256 which are aligned with the apertures 250 in the bracket 238. The apertures 250 and 256 receive fasteners (not shown) to fasten the rubber stop assembly 234 to the frame of the circuit breaker.

Because the operating mechanism 58, including the toggle assembly 60, is adjacent the center pole, a different rubber stop assembly 257 is used for the center pole. More particularly, an elongated metal bar 258 for carrying a shock absorber 260 is provided. The shock absorber 260 is generally an elongated U-shaped member, secured to the elongated metal bar 258. The length of the elongated metal bar is such that it extends beyond the shock absorber 260 and are received in slots (not shown) in oppositely disposed sideplates 262, disposed adjacent the center pole, rigidly fastened to the frame 28. The mounting of the center pole assembly 257 is such that it is spaced apart from the operating mechanism 58 to prevent the center pole contact assembly 109 from contacting it.

The CT quick change assembly 264 (FIG. 13) allows the main current transformer 54 to be replaced rather quickly and easily either in the factory or in the field. The CT quick change assembly 264 simplifies replacement of the current transformer 54 without requiring extensive dismantling of the circuit breaker. One reason for replacing the current transformer 54 is failure of the current transformer 54. Another reason for replacing the current transformer 54 is the change from one rating to the other rating of a dual rating circuit breaker, such as, in a circuit breaker that has a rating of 1600/2000 amperes. More specifically, a current transformer 54 used with the circuit breaker at the 1600 ampere rating would not be suitable for use at the 2000 ampere rating.

The CT quick change assembly 264 includes the main current transformer 54 disposed about a load side conductor 46 and a removable plate 266. The current transformer 54 is a donut-type current transformer which utilizes the load side conductor 46 as its primary winding.

The main current transformer 54 is disposed in an integrally formed cavity 267 in the frame 28 open on one side to allow removal from the housing 21. The load side conductor is disposed in an integrally formed cavity 269 in the frame 28 to allow the load side conductor 46 to be removed from the housing 21 in a direction parallel to its longitudinal axis. In order to remove the current transformer 54 from the housing 21, the removable plate 266 is removed. After the plate 266 is removed, it is necessary to unscrew six fasteners 48 to uncouple the load side conductor 46. After these bolts are removed, four more fasteners 49 have to be removed to uncouple the stab 50 from the load side conductor 46. Once the stab 50 is uncoupled from the load side conductor 46, the conductor 46 can be slid out in a direction parallel to its longitudinal axis. After the conductor 46 is removed, the current transformer 54 can then be removed from the circuit breaker housing 21 and replaced with a different current transformer. To replace the current transformer 54, the steps are simply reversed. Thus, it should be clear that a quick change CT assembly has been disclosed which allows for a quick and easy replacement of current transformers in the field.

A combination barrier and auxiliary current transformer board 268 is provided (FIGS. 14, 15 and 16). This board 268 has several purposes. One purpose is to provide a barrier to prevent contact with the circuit breaker internal components. More specifically, the board 268 closes an open portion 271 of the housing 21. Another purpose is to provide means for mounting auxiliary transformers 270. A third purpose is to provide a means to connect the auxiliary transformers 270 to the main current transformer 54 and the electronic trip unit. Lastly, the combination barrier and auxiliary CT board 268 provides means for venting of the heat generated within the circuit breaker 20 to the atmosphere.

The combination barrier and auxiliary CT board 268 is comprised of an E-shaped printed circuit board 272. The printed circuit board 272 is received in oppositely disposed slots 274 formed in the side walls 276 of the base 22. The bottom of the printed circuit board 272 rests on top of a vertically standing leg 278 portion of the frame 28. The E-shaped printed circuit board 272 is disposed between the latch assembly 82 and the open portion 271 of the housing 21. The printed circuit board 272 contains a pair of spaced apart slots 282 which define its E-shape. The slots 282 are adapted to receive vertically standing side walls 284 formed in the frame 28.

Three auxiliary transformers 270 are provided; one for each pole. The auxiliary transformers 270 have full primary and full secondary windings and are used to step down the current applied to the electronic trip unit. More specifically, the secondary winding of each of the main current transformers 54 is applied to the primary winding of a corresponding auxiliary current transformer 270. The secondary windings of the auxiliary transformers 270 are then applied to the electronic trip unit.

The printed circuit board 272 is used to replace a wiring harness between the auxiliary transformers 272 and the electronic trip unit. More particularly, an electric circuit is provided on the printed circuit board 270 for the electrical connections required between the primary windings of the auxiliary transformers 272 and the secondary windings of the main current transformer 54. The electric circuit is formed on the printed circuit board 272 in a conventional manner. A main connector 286 is provided in the upper right hand corner of the printed circuit board 272. This connector 286 is electrically connected to the secondary windings of the auxiliary current transformers 272 by way of the electric circuitry formed on the printed circuit board 272. A wiring harness having a connector at both ends (not shown) is then used to connect the printed circuit board 272 to the electronic trip unit. The auxiliary transformers 270 are mounted directly to the printed circuit board 272. Secondary connectors 288 are disposed adjacent each of the auxiliary transformers 270 on the printed circuit board 272. These secondary connectors 288 are connected to the primary windings of the auxiliary transformers 270. In order to connect each of the primary windings of the auxiliary transformers 270 to the secondary windings of the main auxiliary transformers 54, another cable (not shown) is provided having a connector at one end connects the main current transformers 54 to the board 270.

Venting holes 290 are provided in the extending leg portions 292 of the printed circuit board 270. These vent holes allow venting of heat generated in the housing 21 to be vented to the atmosphere.

The combination barrier and auxiliary CT board 268 thus simplifies assembling of a circuit breaker thus reducing manufacturing costs and simplifies the internal wiring of the circuit breaker 20.

A modular option deck assembly is provided which facilitates attachment of various options, such as an undervoltage release mechanism, shunt trip and various other options to the circuit breaker. An undervoltage release mechanism functions to open the main contacts 30 automatically when the line voltage falls below a predetermined value. This is done to prevent certain loads, such as motors, from operating at a reduced voltage which can cause overheating of the motor. An example of an undervoltage release mechanism is disclosed in U.S. Pat. No. 4,489,295, assigned to the same assignee as the present invention and hereby incorporated by reference. A shunt trip device (not shown) is essentially comprised of a solenoid having a reciprocally mounted plunger disposed adjacent the trip bar 98. The shunt trip device allows the circuit breaker 20 to be tripped from a remote location. Neither the undervoltage release mechanism nor the shunt trip device are required for all circuit breakers 20. These items are custom items and are generally factory installed. In order to reduce the manufacturing time and cost of adding such custom items to the circuit breakers 20 during fabrication, an option deck assembly 294 is provided. The option deck assembly 294 (FIGS. 17, 18) includes a rectangular plate disposed under the circuit breaker cover 24 carried by the frame 28 having an aperture 296 to allow communication with the trip bar 98. The plate 294 also includes a plurality of sets of slots 298 for receiving a plurality of downwardly extending L-shaped arms 300 integrally formed with a bracket 302. A plurality of sets of slots 98 in the bracket 302 for receiving the arms 300 allow cooperation with the L-shaped arms 300 allow the various options to be secured to the rectangular plate 294 to prevent movement in a direction perpendicular to the plane of the plate 294 and alignment with the trip bar 98. The L-shaped arms 300 are provided on diametrically opposite portions of the bracket 302. The bracket 302 is adapted to be received into any set of diametrically opposite slots 304, 306 or 308 to allow up to three options, for example, to be provided in a given circuit breaker 20.

The bracket 302 is provided with a plurality of apertures 310 to allow the options to be attached to the bracket 302 by way of a plurality of fasteners (not shown). Grooves 312 are provided in the plate 294, aligned with the apertures 310 in the bracket 302. These grooves 312 provide space for the fasteners used to attach the option to the bracket 302 to allow the bracket 302 to be slidingly received onto the plate 294.

The various options each have a downwardly extending lever (not shown) adapted to engage the trip bar 98 to cause the circuit breaker 20 to trip. After the option is assembled to the bracket 302, the downwardly extending levers extend downwardly from the rear edge of the bracket 302 through the aperture 296 to communicate with the trip bar 95. The brackets 302 are then secured in place. Thus, it should be clear that the option deck assembly allows the customizing of a circuit breaker rather easily and quickly.

FIG. 19 shows a plate designed to fulfill the role of the upper toggle link 62 with a projection, or nose 501.

FIG. 20 is like FIG. 19 but the plate has here been so designed as to possess two such projections, or noses (501, 501') symmetrically disposed about a common axis (76-66). With such a design, the same plate can be used in a circuit breaker wherein a mirror image of the projection, or nose 501 would be required. With such a plate only one nose is used, the other not hampering the overall operation of the toggle mechanism.

Whereas particular embodiments of the invention have been described for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details may be made without departing from the invention as defined in the appended claims.