FORM 2
The Patents Act 1970
(39 of 1970)
&
The Patent Rules 2003
COMPLETE SPECIFICATION
(See Section 10 and rule 13)
TITLE OF THE INVENTION:
A COMPOSITE SWITCH ASSEMBLY FOR A MOULDED CASE CIRCUIT
BREAKER
APPLICANT: LARSEN & TOUBRO LIMITED
L&T House, Ballard Estate, P.O. Box No. 278,
Mumbai, 400 001. Maharashtra
INDIA.
PREAMBLE OF THE DESCRIPTION:
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED

A) TECHNICAL FIELD
[0001] The present invention generally relates to a molded case circuit breakers and particularly to a circuit breakers of thermo-magnetic or electronic type. The present invention more particularly relates to a composite switch assembly for circuit breakers with arrangements for simultaneously indicating the ON, OFF or TRIP condition of the circuit breaker visually and mechanically.
B) BACK GROUND OF THE INVENTION
[0002] Circuit breakers are the mechanical switching devices capable of making, carrying and breaking currents under normal circuit conditions and also making, carrying for a specified time and breaking currents under specified abnormal conditions. A circuit breaker basically consists of a pair of separable contacts and an interrupting medium. The function of the contacts is to conduct the electrical current when the breaker is closed and to withstand the arcs while interrupting. Generally, the electrical contacts have a stationary part and a moving part. By bringing the moving contact to touch the stationary contact, electric current flows and the breaker is closed. By driving the moving contact away from the stationary contact, an electrical arc is developed and by quenching it, the current flow is stopped and the breaker is opened.
[0003] In the existing technique, a spring-loaded plunger that contacts the circuit breaker operating mechanism is used at one end and extends a signal flag at an opposite end to provide a local indication as to the status of the circuit breaker contacts. A switch arrangement provides a remote indication over a pair of electrical conductors. One problem with such bell alarm indicating devices is the difficulty in resetting the bell alarm plunger once the circuit breaker contacts have been reset.

[0004] In the alternative method, the molded case circuit breakers used for residential and light commercial or industrial is provided with an auxiliary and trip alarm switch having only electrical contacts. Adding an auxiliary and trip alarm switch with mechanical indication in addition to electrical indication to such small circuit breakers is made difficult by the fact that such breakers typically have very limited space which are configured to be mounted in a standardized load center or panel board.
[0005] Hence there exists a need to develop a composite switch assembly with an visual and mechanical indicators for the ON. OFF, TRIP status for a molded case circuit breaker.
[0006] The above mentioned shortcomings, disadvantages and problems are addressed herein and which will be understood by reading and studying the following specification.
C) OBJECT OF THE PRESENT INVENTION
[0007] The primary object of the present invention is to provide a composite switch assembly with an auxiliary and trip alarm contact for a molded case circuit breaker.
[0008] Another object of the present invention is to provide a composite switch assembly with an auxiliary and trip alarm contact with mechanical ON or OFF indication in a stored energy electrical operating mechanism of a molded case circuit breaker,

[0009] Yet another object of the present invention is to provide a composite switch assembly which gives electrical as well as mechanical ON. OFF or TRIP indications for a molded case circuit breaker.
[0010] Yet another object of the present invention is to provide a compact switch assembly with minimal number of components to provide both electrical as well as mechanical outputs.
[0011] Yet another object of the present invention is to provide a compact switch assembly such that all electrical as well as mechanical indications and tripping mechanism of molded case circuit breaker other than normal trip button are uniquely combined in a composite assembly.
D) SUMMARY OF THE INVENTION
[0012] The various embodiments of the present invention provide a composite switch assembly with an auxiliary and trip alarm contact for a molded case circuit breaker. The present invention provides a circuit breaker which electrically indicates whether the circuit breaker has been switched ON, OFF or TRIP by activating an electrical auxiliary contact switch, trip alarm switch at such time and to simultaneously provide a visual, mechanical indication of ON or OFF. The composite switch assembly of the present invention is inserted into the cover cavity of a molded case circuit breaker. The composite switch gives electrical ON. OFF or TRIP as well as mechanical ON or OFF indication.
[0013] According to one embodiment of the present invention, the composite switch assembly for a molded case circuit breaker comprises a housing and an electrical auxiliary switch is provided in the housing. The composite switch assembly further comprises a trip alarm contact, an actuator assembly and a linkage

mechanism. The electrical auxiliary switch is activated to provide a visual indication and a mechanical indication of ON. OFF or TRIP conditions simultaneously, when the molded case circuit breaker is switched to ON, OFF or TRIP conditions.
[0014] According to one embodiment of the present invention, the composite switch assembly of the present invention is also used as an external accessory for a molded case circuit breaker which when inserted into the cavity of the circuit breaker, gives an electrical ON, OFF or TRIP indication as well as a mechanical ON or OFF indication by way of popping out of a lever. The composite switch is assembled in the cavity of a molded case circuit breaker along with a stored energy electrical operating mechanism. The mechanical translational output of the actuator assembly is converted into an oscillatory movement to indicate an actual condition of the molded case circuit breaker. This oscillatory movement is shown on the front fascia of an electrical operating mechanism indicating the state of the circuit breaker i.e. ON or OFF.
[0015] According to one embodiment of the present invention, the present invention also relates to the electrical ON, OFF or TRIP indication of composite switch by means of two micro-switches. The first micro-switch has Closed (C), Normally Open (NO) and Normally Closed (NC) terminals which indicate ON or OFF states of the circuit breaker. This is referred to as an Auxiliary contact of the composite switch. Similarly the second micro-switch which senses the TRIP position of the circuit breaker which is referred to as a Trip Alarm Contact of the composite switch.
J00.16] According to one embodiment of the present invention, the composite switch assembly for a molded case circuit breaker is provided with a driveshaft for holding the electrical moving contacts of the molded case circuit breaker. The composite switch assembly also includes a movable lever, attached to the auxiliary

contact switch through the drive shaft to provide a mechanical indication of an actual position of the electrical contacts of the molded case circuit breaker. The actuator assembly further includes a first lever for receiving a mechanical ON or OFF indication from a rotational motion of the drive shaft and a second lever for receiving a mechanical TRIP indication from the molded case circuit breaker. The actuator assembly also includes a slider and a spring mechanism for receiving a mechanical input from the first lever. The slider and the spring mechanism give a mechanical ON or OFF indication as an output.
[0017] According to one embodiment of the present invention, a spring is discharged and keeps the first lever in the downward position during the OFF position of the molded case circuit breaker. However, during ON position, the force exerted on the slider by the driveshaft (through the first lever) compresses the spring and the slider pops out to show ON position.
[0018] According to one embodiment of the present invention, the composite switch assembly for a molded case circuit breaker further comprises a first pin to mount and hinge the first lever and second lever on the actuator assembly, two second pins to mount the plurality of micro-switches and a stored energy electrical operating mechanism in the cavity of the molded case circuit breaker.
[0019) According to one embodiment of the present invention, the mechanical translational output of the actuator assembly is converted into an oscillatory movement to indicate an actual condition of the molded case circuit breaker. The trip alarm contact and the spring give a tripping command to a release assembly to TRIP the molded case circuit breaker. During the ON condition of the molded case circuit breaker, the spring is in discharge state and the spring is compressed while giving tripping command.

[0020] According to one embodiment of the present invention, all electrical as well as mechanical indications and tripping mechanism of molded case circuit breaker other than normal trip button are uniquely combined in a composite assembly such that all electrical as well as mechanical indications and tripping mechanism of molded case circuit breaker other than normal trip button are arranged in the same housing.
[0021] These and other objects and advantages of the present invention will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings.
E) BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which:
[0023] FIG. 1 illustrates a front perspective view of the composite switch assembly for a molded case circuit breaker, according to one embodiment of the invention.
[0024] FIG. 2 illustrates an exploded perspective view of the composite switch
assembly for a molded case circuit breaker, according to one embodiment of the invention.
[0025] FIG. 3 illustrates a side view of a molded case circuit breaker with composite switch assembly in OFF position, according to one embodiment of the invention.

[0026] FIG. 4 illustrates a side view of a molded case circuit breaker with composite switch assembly in ON position, according to one embodiment of the invention.
[0027] Although the specific features of the present invention are shown in some drawings and not in others. This is done for convenience only as each feature may be combined with any or all of the other features in accordance with the present invention.
F) DETAILED DESCRIPTION OF THE INVENTION
[0028] In the following detailed description, a reference is made to the
accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that the logical, mechanical and other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense.
[0029] The various embodiments of the present invention provide a composite
switch assembly with an auxiliary and trip alarm contact for a molded case circuit breaker. The composite switch assembly electrically indicates whether the circuit breaker has been switched to ON, OFF or TRIP positions by activating an electrical auxiliary contact switch and trip alarm switch at such time and to simultaneously provide a visual and mechanical indication.
[0030] According to one embodiment of the present invention, the composite switch assembly for a molded case circuit breaker comprises the housing and the electrical auxiliary switch is provided in the housing. The composite switch assembly

further comprises the trip alarm contact, the actuator assembly and the, linkage mechanism. The electrical auxiliary switch is activated to provide a visual indication and a mechanical indication of ON, OFF or TRIP conditions simultaneously, when the molded case circuit breaker is switched to ON, OFF or TRIP conditions.
[0031] According to one embodiment of the present invention, the housing storing the electrical auxiliary switch and the actuator assembly is inserted inside a cover cavity of the molded case circuit breaker.
[0032] According to one embodiment of the present invention, the electrical auxiliary switch is activated by an actuator and the actuator is pivoted to engage with the auxiliary switch during a collapse of the linkage mechanism by engage the linkage mechanism with the actuator, but not during manual movement of the mechanism between the ON and OFF positions.
[0033] According to one embodiment of the present invention, the composite switch assembly further comprises a plurality of micro-switches for indicating an electrical ON, OFF or TRIP indication of the composite switch assembly, A first micro-switch indicates the ON or OFF indication and a second micro-switch indicates a TRIP indication. The first micro-switch indicating ON or OFF indication of the molded case circuit breaker is an auxiliary contact switch and the second micro-switch indicating a TRIP indication of the molded case circuit breaker is the trip alarm contact.
[0034] According to one embodiment of the present invention, the composite switch assembly further comprises a driveshaft for holding the electrical moving contacts of the molded case circuit breaker.

[0035] According to one embodiment of the present invention, a movable lever is attached to the auxiliary contact switch through the drive shaft to provide a mechanical indication of an actual position of the electrical contacts of the molded case circuit breaker. The actuator assembly comprises a first lever for receiving a mechanical ON or OFF indication from a rotational motion of the drive shaft and a second lever for receiving a mechanical TRIP indication from the molded case circuit breaker.
[0036] According to one embodiment of the present invention, the actuator assembly further comprises a slider and a spring mechanism for receiving a mechanical input from the first lever. The slider and the spring mechanism give a mechanical ON or OFF indication as an output. When the molded case circuit breaker is switched to the OFF position, the spring is discharged to keep the first lever in the downward portion. When the molded case circuit breaker is switched to the ON position, the spring is in discharge state and the spring is compressed to give the tripping command.
|0037] According to one embodiment of the present invention, the spring is compressed, when the driveshaft exerts a force on the slider through the first lever and the slider pops out to show an ON position of the molded case circuit breaker.
[0038] According to one embodiment of the present invention, the composite switch assembly further comprises a first pin to mount and hinge the first lever and second lever on the actuator assembly, two second pins to mount the plurality of micro-switches and a stored energy electrical operating mechanism in the cavity of the molded case circuit breaker.

[0039] According to one embodiment of the present invention, the mechanical translational output of the actuator assembly is converted into an oscillatory movement to indicate an actual condition of the molded case circuit breaker.
[0040] According to one embodiment of the present invention, the trip alarm contact and the spring, gives a tripping command to a release assembly of the molded case circuit breaker.
[0041] According to one embodiment of the present invention, all electrical as well as mechanical indications and tripping mechanism of molded case circuit breaker other than normal trip button are uniquely combined in a composite assembly such that all electrical as well as mechanical indications and tripping mechanism of molded case circuit breaker other than normal trip button are arranged in the same housing.
[0042] FIG. 1 illustrates a front perspective view of the composite switch assembly for a molded case circuit breaker, according to one embodiment of the invention, while FIG. 2 illustrates an exploded perspective view of the composite switch assembly for a molded case circuit breaker, according to one embodiment of the invention. With respect to FIG.l and FIG.2, the composite switch assembly 100 includes a cover 101, an accessory housing 109, a trip arm 102, a micro-switch sub assembly 201, levers 103-104. pins 105-106, conical spring 107. a slider 108 and a spring 202 as shown in FIG. 1 and FIG.2. The levers 103-104 are connected to the accessory housing 109 by aligning the holes and inserting the first pin 105 into the holes provided on the levers 103-104 and the accessory housing 109.
[0043] The first pin 105 is used to mount and hinge the first lever 103 and
second lever 104 on the actuator assembly 203 as shown in FIG. 1. The set of two second pins 106 are used to mount the first micro-switch and the second micro-switch (micro-switch sub assembly 201) and a stored energy electrical operating mechanism

in the cavity of the molded case circuit breaker. Then the micro-switch sub assembly 201 is connected to the accessory housing 109 by aligning and inserting the second two pins 106 through the set of holes provided in the micro-switch sub assembly 201 and the accessory housing 109.
[0044] The cover 101 is placed over the accessory housing 109. The spring 202 is adopted within the slider 108 and the slider 108 is inserted through the accessory housing 109, the micro-switch sub assembly and the cover 101. The trip arm 102 along with the conical spring 107 is connected to the accessory housing 109 over the cover 101. The composite switch assembly 100 is an external accessory to a molded case circuit breaker which when inserted into the cavity of such a circuit breaker. gives electrical ON, OFF or TRIP indication as well as mechanical ON or OFF indication by way of popping out of a first lever 103,
[0045] The arrangement for electrically indicating the electrically tripped open condition of the molded case circuit breaker contacts includes an electrical auxiliary switch located within the accessory housing 109 of a composite switch assembly 100 and activated by a pivotal actuator. The actuator is pivoted into an engagement with the auxiliary switch during the collapse of the molded case circuit breaker linkage mechanism by the engagement of the linkage mechanism with the actuator, but not during the manual movement of the mechanism between the on and off positions or vice versa.
[0046] The composite switch 100 is assembled in the cavity of a molded case circuit breaker along with a stored energy electrical operating mechanism. The mechanical translational output of the actuator assembly is converted into an oscillatory movement to indicate an actual condition of the molded case circuit breaker. This oscillatory movement is shown on the front fascia of an electrical operating mechanism indicating the state of the circuit breaker i.e. ON or OFF.

|0047] The micro-switch sub assembly 201 further includes two micro-switches. The first micro-switch has Closed (C), Normally Open (NO) and Normally Closed (NC) terminals which indicate ON or OFF states of the circuit breaker. This is referred to as an Auxiliary contact of the composite switch. Similarly the second micro-switch which senses the TRIP position of the circuit breaker which is referred to as a Trip Alarm Contact of the composite switch 100.
[0048] FIG. 3 illustrates a side view of a molded case circuit breaker with a composite switch assembly in OFF position according to one embodiment of the present invention, while FIG. 4 illustrates a side view of a molded case circuit breaker with a composite switch assembly in ON position. The composite switch assembly 100 is placed inside the molded case circuit breaker. The composite switch assembly 100 includes a drive shaft 301. a cover for a molded case circuit breaker 302, a release assembly 303, an indicator module assembly 304 and housing for a circuit breaker 305. The driveshaft 301 holds the electrical moving contacts of the molded . case circuit breaker 302.
(0049] The composite switch assembly 100 also includes a movable lever, attached to the auxiliary contact switch through the drive shaft 301 to provide a mechanical indication of an actual position of the electrical contacts of the molded case circuit breaker 302. The actuator assembly further includes a first lever 103 for receiving a mechanical ON or OFF indication from a rotational motion of the drive shaft 301 and a second lever 104 for receiving a mechanical TRIP indication from the molded case circuit breaker 302. The actuator assembly also includes the slider 108 and the spring 202 mechanism for receiving a mechanical input from the first lever 103. The slider 108 and the spring 202 mechanism give a mechanical ON or OFF indication as an output,

[0050] During the OFF position of the molded case circuit breaker 302 as shown in FIG. 3, the spring 202 is discharged and keeps the first lever 103 in the downward position. However, during ON position as shown in FIG. 4. the force exerted on the slider 108 by the driveshaft 30! (through the first lever 103) compresses the spring 202 and the slider 108 pops out to show ON position.
[0051] The mechanical translational output of the actuator assembly 203 is converted into an oscillatory movement to indicate an actual condition of the molded case circuit breaker 302. The trip arm 102 and the conical spring 107 give a tripping command to a release assembly 303 to TRIP the molded case circuit breaker 302. Under normal ON condition of circuit breaker 302, the spring 107 is in discharge state; however, it is compressed while giving tripping command.
G) ADVANTAGES OF THE INVENTION
[0052] The composite switch assembly for a molded case circuit breaker of the present invention is a compact assembly and easy to assemble with fewer no of components.
[0053] The composite switch assembly for a molded case circuit breaker of the present invention gives electrical as well as mechanical indications for ON, OFF or TRIP conditions in a single composite assembly.
[0054] The composite switch assembly for a molded case circuit breaker of the
present invention gives an accurate electrical as well as mechanical indications of ON, OFF or TRIP states of the circuit breaker since the actuations are derived from the driveshaft of the circuit breaker.

[0055] The composite switch assembly of the present invention is an additional means of tripping the circuit breaker other than normal trip button and by pushing the trip arm provided on top of the composite assembly, the circuit breaker can be tripped.
[0056] Although the invention is described with various specific embodiments, it will be obvious for a person skilled in the art to practice the invention with modifications. However, all such modifications are deemed to be within the scope of the claims.
[0057] it is also to be understood that the following claims are intended to cover all of the generic and specific features of the present invention described herein and all the statements of the scope of the invention which as a matter of language might be said to fall there between.

CLAIMS
What is claimed is:
1) A composite switch assembly for a molded case circuit breaker comprising: a housing;
an electrical auxiliary switch provided in the housing; a trip alarm contact; an actuator assembly; and a linkage mechanism:
wherein the electrical auxiliary switch is activated to provide a visual indication and a mechanical indication of ON, OFF or TRIP conditions simultaneously, when the molded case circuit breaker is switched to ON, OFF or TRIP conditions.
2) The composite switch assembly for a molded case circuit breaker according to claim 1. wherein the housing storing the electrical auxiliary switch and the actuator assembly is inserted inside a cover cavity of the molded case circuit breaker.
3) The composite switch assembly for a molded case circuit breaker according to claim 1, wherein the electrical auxiliary switch is activated by an actuator and the actuator is pivoted to engage with the auxiliary switch during a collapse of the linkage mechanism by engage the linkage mechanism with the actuator, but not during manual movement of the mechanism between the ON and OFF positions.
4) The composite switch assembly for a molded case circuit breaker according to claim 1, further comprises a plurality of micro-switches for indicating an electrical ON. OFF or TRIP indication of the composite switch assembly.
5) The composite switch assembly for a molded case circuit breaker according to claim 1, wherein a first micro-switch indicates the ON or OFF indication.

6) The composite switch assembly for a molded case circuit breaker according to claim 1. wherein a second micro-switch indicates a TRIP indication.
7) The composite switch assembly for a molded case circuit breaker according to claim I, wherein the first micro-switch indicating ON or OFF indication of the molded case circuit breaker is an auxiliary contact switch.
8) The composite switch assembly for a molded case circuit breaker according to claim 1, wherein the second micro-switch indicating a TRIP indication of the molded case circuit breaker is the trip alarm contact.
9) The composite switch assembly for a molded case circuit breaker further comprises a driveshaft for holding the electrical moving contacts of the molded case circuit breaker.
10) The composite switch assembly for a molded case circuit breaker according to claim 1. wherein a movable lever is attached to the auxiliary contact switch through the drive shaft to provide a mechanical indication of an actual position of the electrical contacts of the molded case circuit breaker.
11) The composite switch assembly for a molded case circuit breaker according to claim 1, wherein an actuator assembly comprises a first lever for receiving a mechanical ON or OFF indication from a rotational motion of the drive shaft and a second lever for receiving a mechanical TRIP indication from the molded case circuit breaker.
12) The composite switch assembly for a molded case circuit breaker according to claim 1, wherein the actuator assembly further comprises a slider and a spring mechanism for receiving a mechanical input from the first lever.

13) The composite switch assembly for a molded case circuit breaker according to claim 1, wherein the slider and the spring mechanism gives a mechanical ON or OFF indication as an output.
14) The composite switch assembly for a molded case circuit breaker according to claim 1. wherein the spring is discharged to keep the first lever in the downward position, when the molded case circuit breaker is a switched to the OFF position.
15) The composite switch assembly for a molded case circuit breaker according to claim 1. wherein the spring is compressed, when the driveshaft exerts a force on the slider through the first lever and the slider pops out to show an ON position of the molded case circuit breaker.
16) The composite switch assembly for a molded case circuit breaker according to claim 1, further comprises a first pin to mount and hinge the first lever and second lever on the actuator assembly.
17) The composite switch assembly for a molded case circuit breaker according to claim 1, further comprises two second pins to mount the plurality of micro-switches.
18) The composite switch assembly for a molded case circuit breaker according to claim 1, further comprises a stored energy electrical operating mechanism in the cavity of the molded case circuit breaker.
19) The composite switch assembly for a molded case circuit breaker according to claim I, wherein the mechanical translational output of the actuator assembly is

converted into an oscillatory movement to indicate an actual condition of the molded case circuit breaker.
20) The composite switch assembly for a molded case circuit breaker according to claim 1, wherein the trip alarm contact and the spring, gives a tripping command to a release assembly of the molded case circuit breaker,
21) The composite switch assembly for a molded case circuit breaker according to claim I, wherein the spring is in discharge state and the spring is compressed while giving tripping command, when the molded case circuit breaker is under switched ON condition.
22) The composite switch assembly for a molded case circuit breaker according to claim 1, wherein all electrical as well as mechanical indications and a tripping mechanism of the molded case circuit breaker other than a normal trip button are arranged in the same housing.