EP-4736286-A1 - END OF LIFE MONITORING FOR A SOLID-STATE CIRCUIT BREAKER

Abstract

A solid-state circuit breaker comprises an air gap, at least one counter and/or a timer, a memory, a radio and a microprocessor to: retrieve saved health data, alert data and counter, timer data from the memory, determine a status of a heath rating by data and comparing the heath rating to a threshold, if it is poor, send a message via a smart phone application (APP) and start a counter or timer, determine if the counter is at a predefined value and/or the timer is expired, if the counter is at a predefined value and/or the timer is expired, turn OFF the breaker and inhibit from being turned on, send a breaker OFF/disabled alert message using the radio to an end user/a customer via the APP, and if the counter is not at a predefined value and/or the timer is not expired, increment/decrement the counter and/or the timer.

Inventors

• KINSEL, HUGH T.
• Janakiraman, Arthi Sudhakar
• TURNER, SCOTT

Assignees

• Siemens Industry, Inc.

Dates

Publication Date

20260506

Application Date

20240723

Claims (1)

1. 202301241 What is claimed is: 1. A solid-state circuit breaker comprising: an air gap and at least one semiconductor switching device disposed in series between an input electrical conductor and an output electrical conductor; at least one counter and/or a timer; a memory; a radio; and a microprocessor that is configured to: retrieve saved health data, alert data and the at least one counter and/or the timer data from the memory, determine a status of a heath rating of the solid-state circuit breaker being based on the health data, the alert data and the at least one counter and/or the timer data by comparing the heath rating to a threshold, if the health rating determined to be poor, send a poor health rating message using radio to an end user/a customer via a smart phone application (APP) and start a counter or timer, determine if the at least one counter is at a predefined value and/or the timer is expired, if the at least one counter is at a predefined value and/or the timer is expired, turn OFF the solid-state circuit breaker and inhibit from being turned on, send a solid-state circuit breaker OFF/disabled alert message using the radio to an end user/a customer via a smart phone application (APP), and if the at least one counter is not at a predefined value and/or the timer is not expired, increment and/or decrement the at least one counter and/or the timer. 202301241 2. The solid-state circuit breaker of claim 1, further comprising: a current sensor; a temperature sensor; a power supply/driver; a Light Emitting Diode (LED); and an overvoltage protection device being a Metal Oxide Varistor (MOV) for protecting the microprocessor. 3. The solid-state circuit breaker of claim 1, wherein the solid-state circuit breaker OFF/disabled alert message alerts the end user that the solid-state circuit breaker’s electronic performance has been affected by overuse which results in degraded performance and potentially an erratic behavior such as random trips which lead to random incidents of a sudden loss of power. 4. The solid-state circuit breaker of claim 1, wherein the microprocessor determines the status of the heath rating of the solid-state circuit breaker by monitoring and logging at least one of items or parameters associated with operational use of the solid-state circuit breaker to determine health of the solid-state circuit breaker. 5. The solid-state circuit breaker of claim 4, wherein the at least one of items or parameters associated with the operational use of the solid-state circuit breaker include: (a) an amount of time that the solid-state circuit breaker has been operating, (b) an amount of time that the solid-state circuit breaker has been conducting current over a predetermined amplitude, 202301241 (c) an amount of time that the solid-state circuit breaker has been operating with an internal temperature over a predetermined temperature, (d) a number of overload trips (for example – 135% to 800% of rated current overload), (e) a number of high interrupting capacity (HIC) trips (for example -- >800% of rated current/short circuit current), and (f) a number of mechanical operations of the air gap. 6. The solid-state circuit breaker of claim 1, wherein the solid-state circuit breaker disables itself from turning power ON within a predetermined elapsed time after sending alerts to the end user, wherein the microprocessor alerts the end user that the solid-state circuit breaker will be disabled in the predetermined elapsed time. 7. The solid-state circuit breaker of claim 1, wherein the solid-state circuit breaker sends out alerts repeatedly and periodically until the solid-state circuit breaker is replaced. 8. The solid-state circuit breaker of claim 1, wherein the solid-state circuit breaker in response to a first interrupt for a request for health data using the radio sends latest health data using the radio to the end user/the customer via the smart phone application (APP). 9. The solid-state circuit breaker of claim 1, wherein the solid-state circuit breaker in response to a second interrupt of overload current high interrupting capacity (HIC) fault turn OFF the solid-state circuit breaker, save fault event (monitored parameter), update and save the health data, the alert data and the at least one counter and/or the timer data to the 202301241 memory, send trip alert message using the radio to the end user/the customer via the smart phone application (APP), and trip the solid-state circuit breaker (open airgap). 10. The solid-state circuit breaker of claim 1, wherein the solid-state circuit breaker in response to a third interrupt of user opening the air gap, turn OFF the solid-state circuit breaker and update and save the health data (monitored parameter), the alert data and the timer data to the memory. 11. A method of end of life monitoring for a solid-state circuit breaker, the method comprising: providing an air gap and at least one semiconductor switching device disposed in series between an input electrical conductor and an output electrical conductor; providing at least one counter and/or a timer; providing a memory; providing a radio; and providing a microprocessor that is configured to: retrieve saved health data, alert data and the at least one counter and/or the timer data from the memory, determine a status of a heath rating of the solid-state circuit breaker being based on the health data, the alert data and the at least one counter and/or the timer data by comparing the heath rating to a threshold, if the health rating determined to be poor, send a poor health rating message using radio to an end user/a customer via a smart phone application (APP) and start a counter or timer, 202301241 determine if the at least one counter is at a predefined value and/or the timer is expired, if the at least one counter is at a predefined value and/or the timer is expired, turn OFF the solid-state circuit breaker and inhibit from being turned on, send a solid-state circuit breaker OFF/disabled alert message using the radio to an end user/a customer via a smart phone application (APP), and if the at least one counter is not at a predefined value and/or the timer is not expired, increment and/or decrement the at least one counter and/or the timer. 12. The method of claim 11, further comprising: providing a current sensor; providing a temperature sensor; providing a power supply/driver; providing a Light Emitting Diode (LED); and providing an overvoltage protection device being a Metal Oxide Varistor (MOV) for protecting the microprocessor. 13. The method of claim 11, wherein the solid-state circuit breaker OFF/disabled alert message alerts the end user that the solid-state circuit breaker’s electronic performance has been affected by overuse which results in degraded performance and potentially an erratic behavior such as random trips which lead to random incidents of a sudden loss of power. 14. The method of claim 11, wherein the microprocessor determines the status of the heath rating of the solid-state circuit breaker by monitoring and logging at least one of 202301241 items or parameters associated with operational use of the solid-state circuit breaker to determine health of the solid-state circuit breaker. 15. The method of claim 14, wherein the at least one of items or parameters associated with the operational use of the solid-state circuit breaker include: (a) an amount of time that the solid-state circuit breaker has been operating, (b) an amount of time that the solid-state circuit breaker has been conducting current over a predetermined amplitude, (c) an amount of time that the solid-state circuit breaker has been operating with an internal temperature over a predetermined temperature, (d) a number of overload trips (for example – 135% to 800% of rated current overload), (e) a number of high interrupting capacity (HIC) trips (for example -- >800% of rated current/short circuit current), and (f) a number of mechanical operations of the air gap. 16. The method of claim 11, wherein the solid-state circuit breaker disables itself from turning power ON within a predetermined elapsed time after sending alerts to the end user, wherein the microprocessor alerts the end user that the solid-state circuit breaker will be disabled in the predetermined elapsed time. 17. The method of claim 11, wherein the solid-state circuit breaker sends out alerts repeatedly and periodically until the solid-state circuit breaker is replaced. 202301241 18. The method of claim 11, wherein the solid-state circuit breaker in response to a first interrupt for a request for health data using the radio sends latest health data using the radio to the end user/the customer via the smart phone application (APP). 19. The method of claim 11, wherein the solid-state circuit breaker in response to a second interrupt of overload current high interrupting capacity (HIC) fault turn OFF the solid-state circuit breaker, save fault event (monitored parameter), update and save the health data, the alert data and the at least one counter and/or the timer data to the memory, send trip alert message using the radio to the end user/the customer via the smart phone application (APP), and trip the solid-state circuit breaker (open airgap). 20. The method of claim 11, wherein the solid-state circuit breaker in response to a third interrupt of user opening the air gap, turn OFF the solid-state circuit breaker and update and save the health data (monitored parameter), the alert data and the timer data to the memory.

Description

202301241 END OF LIFE MONITORING FOR A SOLID-STATE CIRCUIT BREAKER BACKGROUND 1. Field [0001] Aspects of the present invention generally relate to end-of-life monitoring for a solid-state circuit breaker to determine the health of the solid-state circuit breaker. 2. Description of the Related Art [0002] Solid-state circuit breakers use power electronics as switching components instead of contacts as in traditional thermal-magnetic circuit breakers, and the switching process is arc free. Therefore, solid state circuit breakers show promising aspects for use in both AC and DC systems. Circuit breakers typically allow the flow of a load current a little over the rated current and follow a trip curve to identify unsafe current conditions before the breaker is tripped on overload. However, there is a certain window of load current between the rated current and safety threshold that the user can run current where tripping would not be initiated. Although this gives a buffer for the end user, it puts strain and increases wear on the electronic hardware inside the breaker, especially a solid-state circuit breaker where the load current passes through a solid-state (semiconductor) switching device. Over a period of time the breaker performance is degraded, becoming less efficient, generating more heat, and the breaker may trip at inopportune random times or no longer continue to function (power on) even though there are no safety concerns. Breaker contacts degrade over time based on arcing and electronic components degrade over time and temp. Contacts should not be subjected to arcing in a solid-state breaker. [0003] Therefore, there is a need for an improved functionality for a solid-state circuit breaker. 202301241 SUMMARY [0004] Briefly described, aspects of the present invention relate to a solid-state circuit breaker for end-of-life monitoring. The invention solves the problem by monitoring / logging at least one of the following items or parameters listed below to determine the health of the solid-state circuit breaker. This health rating would be available through a mobile App for the end user to view at any time. The breaker will send out alerts to the end user through the mobile App when the determined health rating has reached a predetermined value indicating poor health, warning the end user that the breaker is approaching its end of life and to replace the breaker at their earliest convenience. [0005] Another feature of the invention is the solid-state circuit breaker disables itself from turning power on within a predetermined elapsed time after sending alerts to the end user, also alerting the user that the breaker will be disabled in predetermined elapsed time (for example, in 30 days). [0006] In addition, the breaker sends out alerts repeatedly and periodically until the breaker is replaced. The invention monitors/logs at least one of the following items or parameters but not limited to: [0007] Amount of time that breaker has been operating. [0008] Amount of time that breaker has been conducting current over a predetermined amplitude. [0009] Amount of time that breaker has been operating with an internal temperature over a predetermined temperature. 202301241 [0010] Number of overload trips (for example – 135% to 800% of rated current overload) [0011] Number of HIC trips (for example -- >800% of rated current/short circuit current). [0012] Number of mechanical operations of the air gap. [0013] The health rating of the above items and parameters is based upon statistical test data and analysis such as the calculation of MTBF (mean time between failure) to predict an end of life of various components of the solid-state circuit breaker. [0014] The health rating can be a hybrid of any combination of these above items. [0015] A sample Health score: Health Rating A Overloads 5% reduction per overload B HIC Faults 10% reduction per Fault C 85°C Temp flag 40% reduction D Mechanical Ops 0.03% reduction per operation E Hours of 0.03% reduction per 24 hrs Operation Health Rating = 100%-(5*A+10*B+20*C+.03*D+.03*(E/24)) [0016] In accordance with one illustrative embodiment of the present invention, a solid- state circuit breaker is provided. It comprises an air gap and at least one semiconductor 202301241 switching device disposed in series between an input electrical conductor and an output electrical conductor. It further comprises at least one counter and/or a timer, a memory, a radio and a microprocessor that is configured to: [0017] retrieve saved health data, alert data and the at least one counter and/or the timer data from the memory, [0018] determine a status of a heath rating of the solid-state circuit breaker being based on the health data, the alert data and the at least one counter and/or the timer data by comparing the heath rating to a threshold, [0019] if the health rating determined to be poor, send a poor health rating message using radio to an end user/a customer via a smart phone appl