Circuit Breaker

Light pipe indicator assembly for a stored energy circuit breaker operator assembly

Circuit Breaker Abstract
A motor operated stored energy assembly for use with a circuit breaker assembly having a light pipe indicator assembly for indicating a status of the stored energy assembly, the motor operated stored energy assembly comprising a housing assembly; a movable element having at least two positions so that each of the positions corresponds to a state of the motor operated stored energy assembly, wherein each of the positions has a corresponding shading indicator; at least one light pipe mounted with respect to the housing assembly so that a first end of the light pipe faces the shading indicator and a second end opposite to the first end faces outwardly with respect to the housing assembly so that the light pipe indicates the shading indicator corresponding to a position of the movable element.

Circuit Breaker Claims
What is claimed:

1. A status indicator for a motor operated stored energy assembly comprising:

a motor operated stored energy assembly;

a housing assembly thereof;

a light pipe mounted with respect to said housing assembly, having a first end and a second end visible from an exterior portion of said housing assembly;

a movable element, optically coupled to the first end of said light pipe, having at least first and second positions corresponding to respective first and second states of said motor operated stored energy assembly; and

a shading indicator coupled to said moveable element and optically coupled to said first end of said light pipe when said moveable element is in at least one of said positions.

2. The motor operated stored energy assembly of claim 1, wherein said shading indicator comprises a light background for said first position of said movable element and a darker background for said second position of said movable element.

3. The motor operated stored energy assembly of claim 2, wherein said light pipe is generally cylinder shaped.

4. The motor operated stored energy assembly of claim 2, wherein said light pipe is generally rectangular shaped.

5. The motor operated stored energy assembly of claims 3 or 4, wherein said light pipe comprises acrylic plastic.

6. The motor operated stored energy assembly of claim 5, wherein said light pipe is optically clear so that said shading indicator is visible through said second end of said light pipe.

7. The motor operated stored energy assembly of claim 6, wherein said movable element is an operator gear.

8. The motor operated stored energy assembly of claim 7, wherein said shading indicator has a lighter portion and a darker portion, said lighter portion facing said first end of said light pipe when said operator gear is in one of said first and second positions and said darker portion facing said one end of said light pipe when said operator gear is in the other of said first and said second positions.

9. The motor operated stored energy assembly of claim 8, wherein said lighter portion is essentially white and said darker portion is essentially black.

10. The motor operated stored energy assembly of claim 9, wherein said shading indicator is mounted on said operator gear.

11. The motor operated stored energy assembly of claim 10, wherein said shading indicator is a circle shaped indicator having said lighter portion associated with one area of said operator gear and said darker portion associated with another area of said operator gear.

12. The motor operated stored energy assembly of claim 11, wherein said first position corresponds to a charged energy state of said motor operated stored energy assembly and said second position corresponds to a discharged energy state of said motor operated stored energy assembly.

13. A status indicator for a motor operated stored energy assembly comprising:

a motor operated stored energy assembly;

a housing assembly thereof;

first and second light pipes mounted with respect to said housing assembly each having respective first ends and respective second ends visible from an exterior portion of said housing assembly;

a movable element optically coupled to said respective first ends of said light pipes, having at least first and second positions corresponding to respective first and second states of said motor operated stored energy assembly; and

a shading indicator coupled to said movable element and optically coupled to said respective first ends of said light pipes when said movable element is in at least one of said positions.

14. The motor operated stored energy assembly of claim 13, wherein said shading indicator comprises a light background for said first position of said movable element and a darker background for said second position of said movable element.

15. The motor operated stored energy assembly of claim 14, wherein at least one of said light pipes is generally cylinder shaped.

16. The motor operated stored energy assembly of claim 14, wherein at least one of said light pipes is generally rectangular shaped.

17. The motor operated stored energy assembly of claims 15 or 16, wherein at least one of said light pipes comprises acrylic plastic.

18. The motor operated stored energy assembly of claim 17, wherein at least one of said light pipes is optically clear so that said corresponding shading indicator is visible through said second end of each of said light pipes.

19. The motor operated stored energy assembly of claim 18, wherein said movable element is an operator gear.

20. The motor operated stored energy assembly of claim 19, wherein said shading indicator has a lighter portion and a darker portion, said lighter portion facing said first end of said first light pipe when said operator gear is in one of said first and second positions and said darker portion facing said one end of said second light pipe when said operator gear is in one of said first and second positions.

21. The motor operated stored energy assembly of claim 20, wherein said lighter portion is essentially white and said darker portion is essentially black.

22. The motor operated stored energy assembly of claim 21, wherein said shading indicator is mounted on said operator gear.

23. The motor operated stored energy assembly of claim 22, wherein said shading indicator is a circle shaped indicator having said lighter portion associated with one area of said operator gear and said darker portion associated with another area of said operator gear.

24. The motor operated stored energy assembly of claim 23, wherein said first position corresponds to a charged energy state of said motor operated stored energy assembly and said second position corresponds to a discharged energy state of said motor operated stored energy assembly.

Circuit Breaker Description
interior housing 511. Extension springs 516a and 516b each have top and bottom hooked ends 516c, 516d and 516e, 516f, respectively. Bottom or lower extension spring hooked ends 516e, 516f fit into slotted spring apertures 504a and 504b, respectively, of first and second vertical side flanges 504c and 504d of drive connector 504, respectively. Upper extension spring hooked ends 516c and 516d fit into first and second notchback dips 511aa and 511bb, respectively.

As shown in FIGS. 30 and 31, the drive connector 504, which is preferably made of steel but which may be made of any suitably appropriate material, comprises first and second upper and lower drive connector flanges 504e, 504g and 504f, 504h, respectively, as well as first and second side drive connector flanges 504i, 504j, which further have corresponding first and second side vertical side flanges 504c, 504d having slotted spring apertures 504a, 504b. Upper and lower flanges 504e, 504f and 504g, 504h have upper and lower guide rod apertures 504k, 504l and 504m, 504n respectively, which receive nylon bushings 508a, 508b and 508e, 508d. Toggle slide plate 522 comprises toggle operator handle slide aperture 522t, first and second upper and lower guide rod members 522b, 522d and 522c, 522f, respectively, and first and second overtoggle springs 524a, 524b, fit between the first and second upper and lower guide members, respectively. Spring centering washers 523a, 523b, 523c and 523d fit between the left and right overtoggle springs 524a, 524b and the plastic/nylon slide bushings 508a, 508b, 508c and 508d, which fit in the first and second upper flange apertures 504e and 504f and the first and second lower flange apertures 504g and 504h, respectively, in first and second lower flanges 504e and 504f. The first and second overtoggle springs 524a and 524b are believed to limit at least to some extent the force that the toggle slide plate 522 and drive connector 504 exert against the circuit breaker toggle handle 103.

A simplified perspective view of toggle slide plate 522 is also shown in FIGS. 34A and 34B. As discussed, the circuit breaker handle 103 of circuit breaker assembly 100 fits through toggle aperture 501t of adapter base 501 and into drive plate toggle aperture 522t of toggle drive plate 522. As shown in FIGS. 34A and 34B, toggle slide plate 522, which is molded from plastic, has left and right upper guide rod members 522b and 522 having guide rod apertures 522k, 522l, respectively, and further has left and right lower guide rod members 522d and 522e having guide rod apertures 522m, 522n, respectively. As can be seen, upper and lower left guide rod members 522b and 522d slide along left slide shaft 503a, while upper and lower guide rod members 522c and 522e slide along right slide shaft 503b so as to vertically move toggle handle 103 of the circuit breaker assembly 100 to its ON or OFF position.

Side views of the main subassembly 400 are shown in FIGS. 9 to 18. In particular, FIGS. 9 to 18 show the first or front motor mount subassembly plate or upper gear housing 512 and the second or middle subassembly plate or 510 lower gear housing of the main subassembly 400. FIG. 14 shows the main internal housing or third subassembly mounting plate 511 of the main subassembly 400. As discussed, second or middle subassembly plate or lower gear housing 510 is attached, secured to or otherwise appropriately fastened to third or main subassembly mounting plate or upper gear housing 511 using five screws 591 and five lockwashers 596, which are inserted through middle plate subassembly fastening apertures 510h, 510i, 510j, 510k and 510ii and third or main plate subassembly fastening apertures 511h, 511i, 511j, 511k and 511ii.

Also shown in FIGS. 11, 16 and 18 is a side view of a charging handle/gear block pinion shaft 513, one end 513b of which fits a pinion shaft bearing 520a and which also has three grooves (not shown) to receive wave and circumferential backup washers 571 and 572 and backup washer 583. Another end 513a also fits pinion shaft bearing 520c. The washers 571, 572 and 583 are made of steel, but may also be made of any other suitably appropriate material. A pinion gear carrier 536 is retained between the pinion shaft bearing 520c positioned at one end portion 513a of the pinion shaft 513 and the washers 571, 572 and 583 and gear carrier retainer ring 600. Triangular shaped gear carrier block 536 has a pinion shaft aperture 536a so that it may fit onto or over the one end 513a of charging handle/pinion gear shaft 513, together with wave washer 571, backup washer 572, which also receives driver pinion gear 518a, fiber washer 583 and pinion shaft bearing 520c. As shown, charge carrier gear block 536 has an idler pinion gear aperture 536s for receiving idler pinion gear 518s, using idler gear bearing 570, idler gear roller 569 and idler gear shaft 568.

A gear carrier stop 557 having a larger diameter stop end 557a and a smaller diameter end 557b uses larger diameter stop end 557a to stop movement of tapered or triangular end 536c of gear carrier 536. The larger end 537a fits through gear carrier stop aperture 512a of upper gear housing 512 and gear carrier stop aperture 510a so that larger diameter stop end 557b extends towards the interior of main internal housing 511 so as to interfere with movement of the pinion gear carrier 536. In this way, it may stop or limit movement of the triangular end 536c of gear carrier 536.

As shown in FIGS. 16, 17 and 18, the pinion shaft 513, which is part of pinion gear assembly 630, which comprises pinion gear carrier 536 and pinion gears 518, fits into pinion shaft bearing 520a, which fits into pinion shaft aperture 510b of lower gear housing 510. The pinion shaft 513 also fits into worm gear 507 and unidirectional clutch 519a, both of which reside between the lower and upper gear housings 510 and 512. Additionally, pinion shaft 513 extends through pinion shaft aperture 512b of upper gear housing 512, as well as operator gear handle 537, retainer 600, backup washer 572, handle hub 565, unidirectional clutch 519b and pinion shaft bearing 520b, all of which at least partially sit outside the outer surface of upper gear housing 512. Handle hub 565 has a protruding hexagonal portion 565a on which operator handle 537 is easily mounted. Handle hub 565 also has a recessed portion 565c and a slotted portion 565b. The recessed portion 565c allows limited rotational movement with respect to upper gear housing flange 512cc.

With respect to the pinion shaft 513 and outer handle hub unidirectional clutch assembly 519b and inner gear carrier unidirectional clutch assembly 519a, if unidirectional clutch assembly 519b rotates, then unidirectional clutch 519a slips in one direction and the pinion gear assembly 507 does not rotate. Likewise, when electric motor 521 operates to rotate the worm gear 507 through worm 517, unidirectional clutch 519b slips in one direction so that operator handle 537 does not move or rotate, but the worm gear 507 rotates so as to rotate the pinion gear carrier assembly 630. Both unidirectional clutches 519a and 519b are oriented in the same way or direction so that they slip unidirectionally in the same direction.

As discussed, cam operated roller arm limit switch 531a operates as operator gear cam surface 515c rotates on operator gear shaft 514. In particular, when the roller arm switch 531a is up as it traverses upper roller arm surface 515a, the switch 531 is on, and when the roller switch 531a is down as it traverses the operator gear cam surface 515c, the switch 531 is off. The cam operated limit switch 531 is mounted on the inside surface of lower gear housing 510 in cam operated limit switch mounting apertures 510l and 510m using motor switch spacers 567, two flat screws 592 and two lockwashers 603.

Operator gear 515 receives operator gear bushing 575 for mounting on operator gear shaft 514. Additionally, latch plate 574 is mounted to the smaller diameter operator gear face 515b using back-up washer 572, retainer 600 and six flat screws 606 and six latch plate mounting apertures 515d and six latch plate apertures 574d. Also, cam follower 542 is mounted using mounting post 542a and washer 588 in a cam follower mounting aperture (not shown) on the inner face of operator gear 515. The cam follower 542 rotates with operator gear 515 and moves laterally through slotted cam follower aperture or guide 504m of drive connector 504 so as to move the drive connector 504 and the toggle slide 522 vertically so as to allow charging or discharging of the main springs 516.

As is shown in FIGS. 10, 14, 18 and 30, the main subassembly 400 comprises a third or main internal subassembly plate or housing 511, first and second charging springs 516a and 515b, respectively, toggle slide shafts 503a and 503b, toggle slide 522, drive connector plate 504 and overtoggle springs 523a and 523b. In particular, the main internal housing 511 comprises an upper support flange 511e having upper mounting flange 511, a lower support flange 511f having lower mounting flange 511p and first and second side support flanges 511c and 511d, each having side mounting flanges 511o and 511q, respectively, a lower center circuit breaker toggle handle aperture or opening 511t.

As shown in FIGS. 8, 9, 11, 16, 23 and 24, trip rod 553 has an OFF button end 553d, a trip end 553e and a step bend 553b. Referring to the referenced Figures, when OFF/TRIP button 609 is depressed it actuates trip rod 553 by contacting OFF button end 553d of short upper trip rod member 553, which is integrally associated with OFF/TRIP end 553e and corresponding long lower trip rod member 553c by integrally associated perpendicular connecting member 553b, which contacts or is otherwise associated with an OFF/TRIP actuation structure (not shown) on the circuit breaker assembly 100 so as to set the circuit breaker assembly 100 to its OFF or tripped position. In particular, button end 553a passes through aperture 512d of the upper gear housing 512, while trip end 553b passes through aperture 510e of the lever gear housing an aperture 511t of the housing 511.

As is further shown in FIGS. 1, 2, 8, 9, 11, 17, 19 and 20, the main subassembly 400 comprises the operator reset/charging handle 537, which may be manually rotated or ratcheted clockwise approximately 90 degrees from main external housing surface 534p to surface 543m, and is then returned by handle return spring 566, which sits in spring slot 565b of handle hub 565. Also, roll pin 595 fits in roll pin aperture 565d of handle hub 565 to provide an attachment point for handle return spring 566. The handle rotation action drives a pinion gear carrier block shaft 513 through associated overrunning unidirectional clutch 519b so as to rotate pinion gear carrier block 536 clockwise about pivot point or shaft aperture 536a until a tapered or triangular end 536c meets and is stopped by a pinion gear carrier block stop 557 mounted in lower and upper housing 510 and 512. If the stored energy main springs 516a and 516b are not fully charged, the gear carrier block 536 carries or moves driver/pinion gear 518s and idler/pinion gear 518a into contact with the main charging operator gear 515. When actuated, the pinion gears 518 rotate the main charging operator gear 515 clockwise so as to move cyclically and clockwise the pin cam follower 542 within a pin or cam follower aperture 504m on the drive connector plate 504 so as to charge the springs 516.

As shown in FIG. 15, the main charging operator gear 515 only has missing gear teeth 515t through in the order of about more than one-half of its circumference so that the idler/pinion gear 518a cooperating with the driver/pinion gear 518s only drives, moves or rotates the pin or cam follower 542 on the order of about a few degrees past a position that is top dead center. In particular, teeth 515t on the main charging operator gear 515 only cover on the order of about one-half of the operator gear circumference. In the specific embodiment, the operator gear 515 comprises twenty adjacent or contiguous operator gear teeth that fit in a thirty-two gear tooth pattern. That is, twelve gear teeth are missing from the thirty-two gear tooth pattern so that on the order of about sixty-two and one-half percent (62.5%) of the operator gear 515 has operator gear teeth so that there is almost a thirty-two and one-half percent (32.5%) gap. Also, further rotating the manual reset/charging handle 537 rotates the pinion gear carrier block 536 no more than the driver/pinion gear 518s. To indicate that the charging action is complete, the force required to operate the manual operator reset/charging handle 537 is noticeably

reduced. When the main charging gear 515 has been driven as far as possible by the driver/pinion gear 518s, the force of the main charging springs 516a and 516b causes the main charging gear 515 to continue to rotate until its rotation is stopped by the D-shaped cylindrical latch assembly 640. By moving in pin cam follower aperture 504m on the drive connector plate 504, the cyclic motion of the pin cam follower 542 causes the drive connector plate 504 and the slide plate 522 to move linearly as guided by the guide or toggle slide shafts 503a and 503b. The linear motion of the drive connector plate 504 moves the circuit breaker toggle handle 103 so as to open the main contacts (not shown) of the circuit breaker assembly 100, thereby driving the motor operated stored energy circuit breaker assembly 200 into its reset and ready to close position. The linear motion of the drive connector plate 504 and the slide plate 522 also stretches or charges the operating springs 516a and 516b which are secured between the drive connector plate 504 and the main internal housing 511, as previously discussed. In this way, the energy stored in the operating springs 516a and 516b may later be used to quickly close the main contacts of the circuit breaker assembly 100.

As is shown in FIGS. 2, 8, 9, 11, 12 and 15 to 22, 28A and 28B, the second or middle subassembly or lower gear housing 510 has a worm gear shaft receiving section 510u, which further comprises first and second worm gear shaft flanges 510c and 510d. The first and second worm gear shaft flanges 510c and 510d respectively have worm gear shaft apertures 510ee and 510ff in their midsection. Also, the second or right worm gear shaft flange 510d also has a cluster gear mounting aperture 510r for receiving a first or left mounting end 527a of motor standoff shaft 527, which is used to support cluster gear 530 of a reduction gear assembly 630 which comprises final reduction gear 528, motor gear 529 and cluster gear 530. Similarly, motor mounting plate 580 has a cluster gear mounting aperture 580c (on motor mounting surface 580e) for receiving a second or right mounting end 527b of motor standoff shaft 527, which is also used to support cluster gear 530.

In particular, and as is shown in FIGS. 2, 6 to 12, 16 to 18 and 26 to 28, electric motor 521 drives motor shaft 521a, which receives and drives motor gear 529. Motor gear 529 drives first larger diameter cluster gear 530a, which further drives associated second cluster gear 530b, which drives first and second smaller diameter cluster gears 530a and 530b, both of which are mounted on cluster gear motor standoff shaft 527. A first or left end 527a of cluster gear motor standoff shaft 527 is movably or rotateably mounted in middle or second or lower gear housing 510 at cluster gear drive motor standoff shaft aperture 510r and a second or right end 527b of cluster gear motor standoff shaft 527 is movably or rotateably mounted in front or upper gear housing 512 at cluster gear motor standoff shaft aperture 580c. Smaller diameter cluster gear 530b drives final reduction gear 528 and corresponding worm gear drive shaft 525 and worm 517, which drives worm gear 507, using flange bearings 526, which are mounted at aperture 510ee and 510ff of worm gear shaft flanges 510c and 510d. Worm shaft 525 receives worm 517. Another or left worm end 517a of worm 517 is movably mounted using worm gear spacer 579 and flange bearing 526a.

In particular, worm gear shaft 525 has two securing apertures 525a and 525b, each of which receive securing roll pins 595 so that each end of each of the securing roll pins 595 protrudes outwardly from each end of the work shaft securing apertures 525a and 525b and fit into worm gear apertures 517a and 517b and final reduction gear apertures 528a and 528b, which is directly opposite final reduction gear aperture 528a, respectively. Similarly, motor shaft 521a has securing aperture 521b, which receives securing roll pin 595 so that each end of the securing roll pin 595 protrudes outwardly from each end of the motor shaft securing aperture 521b so as to fit in motor gear apertures 529a and 529b.

Button switch 541c, which is mounted in lower gear housing 510 as button switch mounting flange 510bb using two screws 592 and two lockwashers 603, is used to detect when the main housing 543 has been opened. Also, straight lever switch 614 is mounted on straight lever switch bracket 549 using two screws 592 and two lockwashers 603 is operated by trip rod 553 as shown in FIGS. 6 and 7. Switch bracket 549 is mounted on the lower front surface of lower gear housing 510 using two screws 591 and two lockwashers 596. Worm gear housing member 510u also has first or left flange 510c and second or right flange 510d each having fastening flanges 510f and 510q, respectively, which are insertedly fitted into fastening flange apertures 512dd and 512ee, respectively, of upper gear housing 512 so as to facilitate assembly of the lower gear housing 510 and the upper gear housing 512.

Additionally, the second or right side of lower housing 510 has two indicator light pipe rear apertures 510n and 510o and upper gear housing 512 has two indicator light pipe front apertures 512n and 512o, where apertures 510n and 512n and apertures 510o and 512o are aligned with one another, respectively. The light pipe apertures are designed to receive and support two indicator light pipes 534a and 534b. The indicator light pipes 534a and 534b indicate OFF/CHARGED and ON/DISCHARGED, respectively.

An indicator plate or wheel 616, which is mountedly aligned with latch plate 574 and operator gear 515, is used to provide the indicator status of indicator light pipe 534a (ON/DISCHARGED) and 534b (OFF/CHARGED.

Also, latch plate hasp aperture 574e of latch plate 574 is aligned with indicator wheel hasp aperture 616e of indicator wheel 616. With respect to the indicator wheel structure, it comprises mounting aperture 616f, inner ON/DISCHARGED ring 616c (white) and 616d (black) and outer OFF/CHARGED ring 616a (white) and 616b (black). Thus, as the latch plate 574 and indicator wheel 616 rotate together with operator gear 515, when the black ON/DISCHARGED ring 616d is positioned behind light indicator pipe 534a, the circuit breaker assembly is ON and the main springs 516 are discharged, and when the black OFF/CHARGED ring 616b is positioned behind light indicator pipe 534b, the circuit breaker assembly is OFF and the main springs 516 are charged. An optical indicator for an enclosed operating mechanism is shown in U.S. Pat. No. 3,916,133.

Lockout limit switch 541a, which is actuated by manual/auto lockout slide 550, is mounted, using any appropriate fastening or mounting apparatus, such as two screws 592 and two lockwashers 603, on an inside surface of upper gear housing 512 using apertures 512c and 512d. Limit button switch 541a and limit switch 614 are also shown and described in FIGS. 6 and 7.

As shown in FIGS. 1, 2, 13, 15 and 16, a cylinder lock 618 is mounted in the main external housing 543 using recessed cylinder lock aperture 5431. Also, middle cylinder lock member 618c, which receives key 618a, is insertedly fitted through cylinder lock aperture 512s of upper gear housing 512 and secured using cylinder lock arm 613, which is threadedly secured on rear cylinder lock member 618d, while lock base 618b rests inside external housing cylinder lock aperture 543l. In particular, as shown in FIGS. 8 and 13, cylinder lock arm 613 has a tapered end 613u having a lock arm pin aperture 618v, which receives an end 559a of lock arm pin 559. Another end 559b of lock arm pin 559 is insertedly fitted in lifter aperture 552b of vertical lifter mounting member 552a of lifter 552. Also, lifter 552 has a horizontal lifter member 552c, whose surface is perpendicularly oriented with respect to vertical lifter mounting member 552a. Additionally, horizontal lifter member 552c has a wider left end 552d which tapers to a narrower right end 552e, which is integrally formed with vertical lifter mounting member 552a. Horizontal lifter member 552c is insertedly fitted through horizontal lifter aperture 538i of locking hasp member 538e of locking hasp 538. Thus, when a user turns a key 618a so as to rotate clockwise cylinder lock arm 613 from its left oriented horizontal position to a perpendicularly oriented position, the cylinder lock arm 613 rotateably moves lifter 552 upwardly so that horizontal lifter member 552c slides upwardly and transversely from left to right thereby lifting locking hasp member 538e of locking hasp assembly 538 to a locking position with respect to latch plate 574.

As further regards locking hasp 538, it comprises horizontal locking member 538b which is perpendicularly oriented with respect to vertical member 538a, as well as locking hasp securing member 538e, all of which are integrally formed together. Horizontal locking member 538b of locking hasp assembly 538 has a locking hasp aperture 538c for receiving a locking hasp (not shown) so as to resist unauthorized or inadvertent tampering with the circuit breaker assembly. Lockout slide 550 has a locking end 550a that slides into vertical lockout slide aperture 538f of locking hasp securing member 538e when a user slides the lockout slide 550 from its manual (unlocked to allow manual use) position to its automatic (locked to prevent manual use) position. Finally, hasp springs 539a and 539b are secured on each side of locking hasp member using hasp spring pin 538r, which fits in hasp spring pin aperture 538j and which projects from both sides of locking hasp securing member 538e. The other ends of hasp springs 539a and 539b are secured to hasp spring apertures 510s on lower gear housing 510.

As shown in FIGS. 6 to 9, 11, 16, 18 and 24, also mounted at the base of lower gear housing 510 is straight lever switch 614, which is mounted using a straight lever switch bracket 549 and two pozidrive screws 592 and two lockwashers 103 at straight lever switch mounting apertures 510cc and 510dd. The button switch 614a of straight lever switch 614 is positioned adjacent to the vertical member 553b of trip rod 553. When activated, the OFF/TRIP button 609 forces trip rod 553 forward so as to cause trip rod member 553c to actuate a trip button (FIG. 24) on the circuit breaker assembly 100, and vertical member 553b actuates straight lever switch 614 so as to cause the electric motor 521 to drive the circuit breaker assembly to its OFF position, as shown in FIGS. 6 and 7. To avoid actuating the trip button, a screw or other suitably appropriate limit apparatus (not shown) may be mounted adjacent that vertical trip rod member 553b and the button switch 614a of straight lever switch 614 so as to limit movement of the trip rod 553 so as to allow actuation of the local OFF operation using electric motor 521 but prevent tripping of the circuit breaker assembly 100.

A D-shaped latch assembly 640 is shown in FIGS. 8, 9, 11, 16 to 18 and 23 to 25. As shown in the referenced Figures, the assembly 640 comprises D-shaped latch 544, latch lever 545, solenoid link pin 576, roll pin 593, dowel pin 617, latch lever spacer 581, latch bellcrank 561, bellcrank return spring 560, bellcrank pivot bushing 547, bellcrank pivot shaft 562 and push-on retainer 587.

Referring again to the referenced Figures, including FIGS. 25A and 25B, the dowel pin 617 is inserted through dowel pin receiving apertures 545a and 545b of latch lever 545 and further inserted in a dowel pin receiving aperture (not shown) of D-shaped latch 544. The latch 544 has a D-shaped or cylindrical member 544a integrally associated with partial cylindrical member 544b having a flat surface 544c perpendicularly oriented with respect to semi-circular outer end surface 544e of partial cylindrical member 544b and to semi-circular end surface 544d of cylindrical member 544a. A roll pin 593 is also insertedly fitted into a roll pin aperture (not shown) in D-shaped latch 544 and the generally tapered or triangular shaped latch lever end 545e of latch lever 545. The latch lever spacer 581 shown in the referenced Figures fits over the dowel pin 617 so as to space the partially cylindrical latch lever member 544b with respect to the inner surfaces of the upper gear housing 512 and the lower gear housing 510. Latch lever 545 also has a rectangular shaped hasp interfering member 545d, which partially fits in hasp interfering aperture 538l of hasp 538. The hasp interfering member 545d is integrally associated with and is perpendicularly oriented with respect to partially semi-circular latch lever member 545c.

Solenoid link pin 576 is used to rotateably connect or link the tapered end of latch lever 545 to an end 533a (having a solenoid link pin aperture) of solenoid link 533. Another end 533b (having a solenoid plunger connecting aperture 533d) is operably connected or linked to a slotted aperture (not shown) at end 532g to solenoid cylindrical plunger 532 using a roll pin 594 and solenoid roll pin aperture 532e. A solenoid end 532f is designed to fit within a solenoid plunger 532a receiving aperture (not shown) of solenoid 532b. Solenoid spring 578 operates to apply force to the solenoid plunger 532a so that it moves outwardly from solenoid 532b and to its original position. The ON push-button switch 548, which is used to actuate the D-latch assembly 640 and the solenoid 532, is also returned to its original position by the force of solenoid plunger spring 578. The solenoid 532 is mounted at an appropriate angle on the outside surface of lower gear housing 512 using solenoid mounting apertures 532h and 532i and appropriate fastening apparatus, such as screws 607 and spacer 532s, and lower gear solenoid mounting apertures 510x and 510w.

The D-shaped latch assembly 640 operates as follows: when the operator pushes the ON push button switch 548, it depresses push button rod 564 through push button rod aperture 512u of upper gear housing 512 so as to actuate latch bell crank 561, thereby rotating D-shaped latch 544 which releases latch plate 574 so as to allow operator gear 515 to rotate, thereby allowing the charged main springs 516 to release so as to force drive connector 504 and slide plate 522 upwardly so as to move the toggle handle 103 of the circuit breaker assembly 100 from its OFF position to its ON position.

In particular, the latch bellcrank 561 comprises a mounting surface 561a and two perpendicular rectangular flanges, namely a push button rod flange 561b and a solenoid link pin flange 561c, as well as a rotateable bellcrank latch mounting pin aperture (not shown), which receives bellcrank lath pivot bushing 547, bellcrank return spring 560 and bellcrank latch pivot shaft 562, which is secured on the bellcrank latch mounting flange 512hh of upper gear housing 512 using push-on retainer 587.

As discussed, the push button rod 564 pushes the push button flange 561b of bellcrank latch 561 so that it pivots about pivot bushing 547, pivot shaft 562 as well as bellcrank return spring 560 which resists the clockwise rotation of bellcrank latch 561. As the bellcrank latch rotates clockwise, solenoid link pin flange 561c pushes solenoid link pin 576, located in the tapered end 545e of latch lever 545 so as to rotate clockwise latch 544, dowel pin 617 and spacer 581. In this way, the D-shaped latch member 544b of latch 544 also rotates clockwise so that it no longer interferes with latch stop 574l on latch plate 574. As a result, the latch plate 574 and the operator gear 515 may rotate, as discussed above and as shown in FIGS. 23 to 25.

Also, when the ON push button switch 548 is actuated so as to depress ON button rod 564 and partially rotate clockwise D-shaped latch assembly 640, rectangular shaped hasp interfering member 545 rotates into slotted aperture 538l of hasp 538. In this way, hasp 538 is prevented from being removed while the stored energy circuit breaker assembly 200 moves the toggle handle 103 of the circuit breaker assembly 100 to its ON position.

As discussed, and as is shown in FIGS. 8, 9, 11, 14 to 22, is a pinion gear assembly comprising pinion gear carrier 536, which is used to mount driver/pinion gear 518s and idler/pinion gear 518a. Operator handle/pinion shaft aperture 510b in lower gear housing plate 510 is used to receive the operator handle/pinion shaft 513. Pinion gear carrier post or stop 557 projects perpendicularly from the inside surface of lower gear housing 510 towards main housing 511, and is used to limit rotational movement of charge gear carrier 536, as is discussed further below. The main operator gear 515 has a kickout cam or latch plate 574 and a cam following pin or post structure 542, which fits within cam following aperture 504m of drive connector 504. Cam following pin or post structure 542 moves horizontally within cam following aperture 504 of drive connector or slide plate 504 so as to cause the drive connector or slide plate 504 to move linearly and vertically.

Also shown in FIGS. 2, 3, 6, 8, 9, 11, 15 and 16 are a manual/auto lockout slide plate 550 having a locking extension member 550a. As discussed, locking hasp vertically slotted apertures 510t and 512t receives locking hasp 538. Manual/auto lockout slide plate 550 has a lockout slide retainer 555 which is secured by placing securing end 555b in lock slide retainer

aperture 550b using retainer 597 fitted in circumferential slot 555c so that button end 555a projects outwardly through generally oval shaped lock slide retainer aperture 512w of upper gear housing 512. A manual/auto lockout slide handle 546 (secured by retainer 597), which a user may grasp and slide horizontally to move the manual/auto slide plate 750 between its left or manual and right or automatic positions, is secured by using retainer 597 to retain securing end 546b in lockout slide handle aperture 550e and allowing handle end 546a to project through upper gear housing lockout slide handle aperture 512ff and main external housing lockout slide handle aperture 543g. Both lockout slide retainer 555 and manual auto lockout slide handle 546 are securely associated with lockout slide plate 550 using shoulder rivets or any other suitably appropriate securing apparatus. If the manual/auto lockout slide handle 546 is in its manual position, a user may operate OFF button 609 and ON button 548. If the manual/auto lockout slide handle 546 is in its automatic position, then a user cannot actuate OFF button 609 or ON button 548, which are blocked by the "automatic" position of the manual/auto lockout slide handle 550.

OFF button 609 receives and actuates trip rod 553 through trip rod aperture 512d of upper gear housing 512. ON button 548 receives and actuates ON button rod 564 through ON button rod aperture 512u. Also, the ON button legs 548x and 548xx fit in ON button leg apertures 512x and 512xx of upper gear housing 512 to allow ON button 548 to be depressed in the manual position when ON button leg lockout slide aperture 550c is aligned with ON button leg aperture 512x of upper gear housing 512. When the manual/auto lockout slide plate 550 is in its first or left manual position, then the ON button 548 and the OFF button 609 cannot be depressed because the lockout slide plate 550 interferes with the depression of those buttons since the lockout slide button apertures are not aligned with the corresponding apertures in the upper gear housing 512. When the manual/auto lockout slide is moved to the right so that it is in its automatic position, button switch flange 550g depresses an actuation button (not shown) of button switches 535a and 535b (see FIG. 6) which are also switches S2A and S2B of the electrical schematics shown in FIGS. 6 and 7. Thus, switches 535a (S2A) and 535b (S2B) are open when the manual/auto lockout slide 550 is in its manual position, and they are closed for automatic operation when the manual auto lockout slide 550 is in its automatic position.

Finally, the manual/auto lockout slide 550 is biased or restrained in either its manual or automatic position using two lockout slide spring pins 563, lockout slide toggle pin 554 and lockout slide toggle spring 558. In particular, lockout slide spring pins fit in lower and upper lockout slide spring pin apertures 512y while lockout slide toggle pin 554 fits in lockout slide toggle pin aperture 550z of lockout slide 550 and further projects through oval-shaped upper gear housing lockout slide pin aperture 512z. Also, each lockout slide spring pin 563 fit into lockout upper and lower slide pin spring aperture 558y and lockout slide toggle pin 554 fits in middle lockout slide toggle pin spring aperture 558z. In this way, the lockout slide 550 is biased into either its manual or automatic positions using the lockout slide toggle spring.

When the charging springs 516a and 516b are fully charged, the main contact of the circuit breaker assembly 100 may be either manually or electrically closed as follows. As discussed, pressing ON button 548 causes the D-latch assembly 544 to rotate clockwise so that latch 574l of latch plate 574 is free to rotate clockwise past the flat surface of D-latch 544. As discussed, this allows the main operator gear 515 to rotate and the drive connector or slide plate 504 to move relatively rapidly in an upward direction so as to force the toggle handle 103 of the circuit breaker assembly 100 to its ON position using toggle handle slide 522.

When the charging springs 516a and 516b are not fully charged, electrical operation is as follows:

When electric power is applied, an electric motor 510 is used to drive a reduction gear assembly 630, which rotates a worm 517 and corresponding worm gear 507, which drives handle/pinion shaft 513 through unidirectional clutches 519a and 519b as previously discussed. The shaft 513 rotates until charge gear carrier 536 is stopped by the charge gear block stop 557a. The charge gear carrier 536 carries driver/pinion gear 518s and idler/pinion gear 518a into contact with a main charging or operator gear 515 if the stored energy operating mechanism or charging springs 516a and 516b are not fully charged. The idler/pinion gear 518a then rotates the main charging gear 515 clockwise so as to carry the pin/cam follower 542 in a cyclic motion, which is translated into linear motion of the drive connector or slide plate 504. The main charging gear 515 has twelve teeth 515t missing out of a thirty-two gear tooth pattern so that the idler/pinion gear 518a is only able to drive the main charging gear 515 to a point or position where the pin/cam follower 542 has been carried a few degrees past the position of top dead center of the main operator gear 515 or in the proper overcenter position. This also allows the electric motor 521 to coast to its resting position so that it is not necessary to electrically or mechanically brake the electric motor 521.

When the main charging gear 515 has been driven as far as the idler/pinion and driver/pinion gears 518a 518s may drive it, the force of the operating springs 516a and 516b causes it to continue to rotate until the latch 574l of latch plate 574 catches D-latch 544 so as to stop its rotation. By moving laterally in a horizontal slot operator 504m in the drive connector or slide plate 504, the cyclic motion of the pin/cam follower 542 causes the drive connector 504 and the toggle handle slide 522 to move linearly as guided by the guide rods or slide shafts 503a and 503b. The linear motion of the drive connector 504 moves the toggle handle 103 of the circuit breaker assembly 100 so as to open the main contacts of the circuit breaker assembly 100. The linear motion of the drive connector 522 also stretches or charges the charging springs 516a and 515b, which are attached, secured or otherwise fastened between slotted apertures of drive connector 504 and anchor points of main housing assembly plate 511 as previously discussed. In this way, the energy stored in the charging operating springs 516 may be used to close relatively rapidly the main contacts of the circuit breaker assembly 100 by forcing the circuit breaker toggle handle 101 to its ON position.

While the present invention has been described in connection with what are believed to be the most practical and preferred embodiments as currently contemplated, it should be understood that the present invention is not limited to the disclosed embodiments. Accordingly, the present invention is intended to cover various modifications and comparable arrangements, methods and structures that are within the scope of the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a drawing of one embodiment of the apparatus and system of the present invention showing the motor operated stored energy circuit breaker system.

FIG. 2 is an exploded view of some assemblies of the motor operated stored energy assembly and circuit breaker assembly.

FIG. 3 is an embodiment of the front panel of the motor operated stored energy assembly for a 630 Ampere rated circuit breaker assembly.

FIG. 4 is an embodiment of the front panel of the motor operated stored energy assembly for a 125 or 250 Ampere rated circuit breaker assembly.

FIG. 5 illustrates the stored energy operator positions, including the automatic/remote, manual/unlocked and manual/locked positions.

FIG. 6 is a schematic view of the circuitry of the motor operated stored energy assembly with a control module.

FIG. 7 is a schematic view of the motor control circuit of the motor control module.

FIG. 8A is a full component front view of the apparatus showing the charging springs in a charged position.

FIG. 8B is a partial component front view of the apparatus showing the charging springs in a charged position.

FIG. 9A is a partial component side through view of the apparatus.

FIG. 9B is a partial component side view of the apparatus.

FIG. 10 is a side view of the motor operated stored energy assembly external casing or housing and its main internal housing.

FIG. 11 is a side view of same components associated with the lower and upper gear housings of the motor operated stored energy assembly.

FIG. 12 is a side view of the motor assembly and related gearing assemblies of the motor operated stored energy assembly.

FIG. 13 is a side view of the hasp assembly, cylinder lock assembly, solenoid assembly and OFF switch button.

FIG. 14 is another side view of the external housing, the main internal housing and adapter base, as well as the main charging springs of the motor operated stored energy assembly, including the operator gearing and the operator handle.

FIG. 15 is a front view of the main operator gear, the hasp and cylinder lock assemblies, the solenoid, the operator handle hub and the upper gear housing of the motor operated stored energy assembly.

FIG. 16 is a side view of the upper and lower gear housings of the motor operated stored energy assembly, including the operator gearing and the operator handle and other associated components.

FIG. 17 is a front and side view of the motor operated stored energy assembly's electric motor and associated gearing, the gearing and operator handle and the lower gear housing.

FIG. 18 is a side view of some components of the motor operated stored energy assembly, including the lower gear housing, main operator gear drive connector, slide plate and other associated components.

FIG. 19 is a front view of some components of the motor operated stored energy assembly, including the upper gear housing, main operator gear, gear carrier and operator handle.

FIG. 20 is a side view of some components of the motor operated stored energy assembly, including the upper gear housing, main operator gear, gear carrier and operator handle.

FIG. 21 is a front view of some components of the motor operated stored energy assembly, including the operator handle components and the main operator gear.

FIG. 22A is a solid side view of some components of the motor operated stored energy assembly, including the operator handle components and the main operator gear.

FIG. 22B is a solid side view of some components of the motor operated stored energy assembly, including the operator handle components and the main operator gear, as well as the main internal housing and the adapter plate.

FIG. 23A is a front through view of some components of the motor operated stored energy assembly, including the upper and lower gear housings, latch plate, D-latch assembly, solenoid assembly and the OFF and ON switch buttons.

FIG. 23B is a front solid view of some components of the motor operated stored energy assembly, including the upper and lower gear housings, latch plate, D-latch assembly, solenoid assembly and the OFF and ON switch buttons.

FIG. 23C is a front solid view of some components of the motor operated stored energy assembly, including the upper and lower gear housings, latch plate, D-latch assembly, solenoid assembly and the OFF and ON switch buttons, as well as the automated manual slide plate.

FIG. 24 is a side view of some components of the motor operated stored energy assembly, including the upper and lower gear housings, latch plate, D-latch assembly, solenoid assembly and the OFF and ON switch buttons.

FIGS. 25A and 25B are a front and side view of the D-latch assembly.

FIGS. 26A and 26B are front and side views of some components of the motor operated stored energy assembly, including the lower gear housing, electric motor and its gearing and the worm assembly.

FIGS. 27A and 27B are through views of FIGS. 26A and 26B.

FIGS. 28A and 28B are enlarged views of FIGS. 27A and 27B.

FIGS. 29A and 29B are front and side views of some components of the motor operated stored energy assembly, including the upper and lower gear housings, the indicator light pipes and the circular indicator light pattern wheel.

FIG. 30A is a solid front view of the main internal housing of the motor operated stored energy assembly, including the drive connector plate, toggle slide plate and charging springs.

FIG. 30B is a solid front view of the main internal housing of the motor operated stored energy assembly, including the drive connector plate, toggle slide plate and charging springs, including some additional detail.

FIG. 31 is a front view of the main internal housing of the motor operated stored energy assembly, including the drive connector plate, toggle slide plate and charging springs.

FIG. 32 is a side view of the main internal housing of the motor operated stored energy assembly, including the drive connector plate, toggle slide plate and charging springs.

FIG. 33 is a solid side view of the main internal housing and movable adapter base of the motor operated stored energy assembly.

FIG. 34A is a simplified front perspective view of the toggle slide.

FIG. 34B is a simplified rear perspective view of the toggle slide.

FIG. 35A is a solid front view of the movable adapter base for the motor operated stored energy assembly.

FIG. 35B is a solid side view of the movable adapter base for the motor operated stored energy assembly.

FIG. 36A is a front view of the movable adapter base for the motor operated stored energy assembly.

FIG. 36B is a side view of the movable adapter base for the motor operated stored energy assembly.

FIG. 37A is a top view of the trip arm assembly for the movable adapter base of the motor operated stored energy assembly.

FIG. 37B is a side view of the trip arm assembly for the movable adapter base of the motor operated stored energy assembly.

FIG. 38A is a simplified frontal view of the motor operated stored energy apparatus with the circuit breaker contacts open and the springs charged.

FIG. 38B is a simplified side view of the motor operated stored energy apparatus with the circuit breaker contacts open and the springs charged.

FIG. 39A is a simplified frontal view of the motor operated stored energy apparatus with the contacts closed and the springs discharged.

FIG. 39B is a simplified side view of the motor operated stored energy apparatus with the contacts closed and the springs discharged.

FIG. 40A is a simplified frontal view of the motor operated stored energy apparatus with the main operator gear engaged to charge the springs.

FIG. 40B is a simplified side view of the motor operated stored energy apparatus with the main operator gear engaged to charge the springs.