Claims:
1. A system for testing an electrical life of one or more circuit breakers, the system comprising:
a controller device, having one or more contactor modules adapted to connect with the one or more circuit breakers, for generating one or more test criteria for testing of the one or more circuit breaker, and an extraction module adapted to extract one or more features associated with the electrical life of the one or more circuit breakers when subjected to the one or more test criteria;
at least a remote controller device having display unit, communicably coupled with the controller device, adapted to fetch the one or more features, and analyze the one or more features to determine the electrical life of one or more circuit breakers for displaying on the display unit.
2. The system as claimed in claim 1, wherein the electrical life of one or more circuit breaker is determined based on one or more faults associated with the one or more circuit breaker retrieved based on the one or more features.
3. The system as claimed in claim 1 is characterized by detecting one or more faults associated with the one or more circuit breaker selected from any or combination of an Electric Charging Device (ECD) charging cycle fault when micro switch (MSW) is present or absent, Real Time Counter(RTC) fault when micro switch (MSW) is present or absent, circuit breaker closing faults, current reset fault, R-Y-B-N (terminal) continuity fault, auxiliary (AUX) contacts normally open (NO) faults and/or normally close (NC) faults, a circuit breaker trip/open cycle faults, Shunt Release(SR) faults, and Fault Sensing Device(FSD) faults.
4. The system as claimed in claim 1 provides an automated process of endurance testing of electrical life of air circuit breaker.
5. The system as claimed in claim 1, wherein the remote controller device generates one or more tripping graphs for analysis purpose.
6. The system as claimed in claim 1, wherein the controller device enables dynamic updates of one or more settings associated with the one or more circuit breakers.
7. A device having display unit for testing an electrical life of one or more circuit breakers, the device comprising:
a controller device, having one or more contactor modules adapted to connect with the one or more circuit breakers, for generating one or more test criteria for testing of the one or more circuit breaker, and an extraction module adapted to extract one or more features associated with the electrical life of the one or more circuit breakers when subjected to the one or more test criteria; and
at least a remote controller device, communicably coupled with the controller device, adapted to fetch the one or more features, and analyze the one or more features to determine the electrical life of one or more circuit breakers for displaying on the display unit.
, Description:
TECHNICAL FIELD
[0001] The present disclosure generally relates to the field of monitoring equipment. In particular, it pertains to, but not by way of limitation, a circuit breaker electrical life of diagnostic systems.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Endurance testing involves testing a system with a significant load extended over a significant period of time, to discover how the system behaves under sustained use. The goal is to discover how the system behaves under sustained use. That is, to ensure that the throughput and/or response times after some long period of sustained activity are as good as or better than at the beginning of the test.
[0004] Earlier, endurance test of air circuit breaker was done by a programmable logic controller (PLC). Total number of ON+OFF cycles was counted by Digital Counter. However, such system use to get stopped when RYBN Continuity fault occurred, and the operator used to find the faults manually. Also, the conventional systems were unable to find out other critical errors like Closing Release (CR) faults, Shunt Release (SR) Faults, Under Voltage (UV) Faults, Electric Charging Device (ECD) Faults, Auxiliary (AUX) normally open (NO)- normally close (NC) and Micro-switches. Also, there was no data acquisition facility for off line investigation of these faults. Furthermore, the present method is time consuming and very difficult to monitor.
[0005] Apart from the above issues, the existing mechanisms also have some other issues of limitations in fault detection, few of them are limitations to select tripping operation (UVR or SR), manual faults recording, limitations of setting different time like ECD Charging Delay, CR on Delay, No current measurement mechanisms, and No measurement on closing and tripping time.
[0006] The aforementioned limitations of the existing monitoring mechanism of circuit breaker electrical life diagnostic are recognized by the inventors hereof and some or all of these limitations have been addressed by various embodiments of the current invention.
[0007] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0008] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0009] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0010] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0011] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

SUMMARY
[0012] The aforementioned limitations of the existing monitoring mechanism of circuit breaker electrical life diagnostic are recognized by the inventors hereof and some or all of these limitations have been addressed by the current invention by providing an automated process of endurance testing of electrical life of air circuit breaker.
[0013] An object of the present disclosure is to provide automated process of endurance testing of electrical life of air circuit breaker.
[0014] An aspect of the present disclosure a system for testing an electrical life of one or more circuit breakers. The system includes a controller device, having one or more contactor modules adapted to connect with the one or more circuit breakers, for generating one or more test criteria for testing of the one or more circuit breaker, and an extraction module adapted to extract one or more features associated with the electrical life of the one or more circuit breakers when subjected to the one or more test criteria; and at least a remote controller device having display unit, communicably coupled with the controller device, adapted to fetch the one or more features, and analyze the one or more features to determine the electrical life of one or more circuit breakers for displaying on the display unit.
[0015] In an aspect, the electrical life of one or more circuit breaker is determined based on one or more faults associated with the one or more circuit breaker retrieved based on the one or more features.
[0016] In an aspect, the system is characterized by detecting one or more faults associated with the one or more circuit breaker selected from any or combination of an Electric Charging Device (ECD) charging cycle fault when micro switch (MSW) is present or absent, Real Time Counter(RTC) fault when micro switch (MSW) is present or absent, circuit breaker closing faults, current reset fault, R-Y-B-N (terminal) continuity fault, auxiliary (AUX) contacts normally open (NO) faults and/or normally close (NC) faults, a circuit breaker trip/open cycle faults, Shunt Release(SR) faults, and Fault Sensing Device(FSD) faults.
[0017] In an aspect, the remote controller device generates one or more tripping graphs for analysis purpose.
[0018] In an aspect, the controller device enables dynamic updates of one or more settings associated with the one or more circuit breakers.
[0019] An aspect of the present disclosure relates to a device having display unit for testing an electrical life of one or more circuit breakers. The device includes a controller device, having one or more contactor modules adapted to connect with the one or more circuit breakers, for generating one or more test criteria for testing of the one or more circuit breaker, and an extraction module adapted to extract one or more features associated with the electrical life of the one or more circuit breakers when subjected to the one or more test criteria; and at least a remote controller device, communicably coupled with the controller device, adapted to fetch the one or more features, and analyze the one or more features to determine the electrical life of one or more circuit breakers for displaying on the display unit.
[0020] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components

BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0022] FIG. 1A illustrates an exemplary block diagram of the proposed machine, in accordance with an embodiment of the present disclosure.
[0023] FIG. 1B illustrates an exemplary images of the proposed machine while testing, in accordance with an embodiment of the present disclosure.
[0024] FIG. 2A and 2B illustrates an exemplary software screen and timing cycles for Closing-ECD Charge-Tripping Timing Cycle during testing, in accordance with an embodiment of the present disclosure.
[0025] FIG. 3 illustrates an exemplary timing cycles for Closing-Tripping-ECD Charge Timing Cycle during testing, in accordance with an embodiment of the present disclosure.
[0026] FIG. 4 illustrates an exemplary screenshot on occurrence of CR fault, in accordance with an embodiment of the present disclosure.
[0027] FIG. 5 illustrates an exemplary screenshot on occurrence of RYBN close fault, in accordance with an embodiment of the present disclosure.
[0028] FIG. 6 illustrates an exemplary screenshot on occurrence of RYBN open fault, in accordance with an embodiment of the present disclosure.
[0029] FIG. 7 illustrates an exemplary flowchart for testing an electrical life of one or more circuit breakers, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0030] The following is a detailed description of embodiments of the disclosure illustrated in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0031] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0032] Endurance testing involves testing a system with a significant load extended over a significant period of time, to discover how the system behaves under sustained use. The goal is to discover how the system behaves under sustained use. That is, to ensure that the throughput and/or response times after some long period of sustained activity are as good as or better than at the beginning of the test.
[0033] The aforementioned limitations of the existing monitoring mechanism of circuit breaker electrical life diagnostic are recognized by the inventors hereof and some or all of these limitations have been addressed by the current invention by providing an automated process of endurance testing of electrical life of air circuit breaker.
[0034] An object of the present disclosure is to provide automated process of endurance testing of electrical life of air circuit breaker.
[0035] An aspect of the present disclosure a system for testing an electrical life of one or more circuit breakers. The system includes a controller device, having one or more contactor modules adapted to connect with the one or more circuit breakers, for generating one or more test criteria for testing of the one or more circuit breaker, and an extraction module adapted to extract one or more features associated with the electrical life of the one or more circuit breakers when subjected to the one or more test criteria; and at least a remote controller device having display unit, communicably coupled with the controller device, adapted to fetch the one or more features, and analyze the one or more features to determine the electrical life of one or more circuit breakers for displaying on the display unit.
[0036] In an aspect, the electrical life of one or more circuit breaker is determined based on one or more faults associated with the one or more circuit breaker retrieved based on the one or more features.
[0037] In an aspect, the system is characterized by detecting one or more faults associated with the one or more circuit breaker selected from any or combination of an Electric Charging Device (ECD) charging cycle fault when micro switch (MSW) is present or absent, Real Time Counter(RTC) fault when micro switch (MSW) is present or absent, circuit breaker closing faults, current reset fault, R-Y-B-N (terminal) continuity fault, auxiliary (AUX) contacts normally open (NO) faults and/or normally close (NC) faults, a circuit breaker trip/open cycle faults, Shunt Release(SR) faults, and Fault Sensing Device(FSD) faults.
[0038] In an aspect, the remote controller device generates one or more tripping graphs for analysis purpose.
[0039] In an aspect, the controller device enables dynamic updates of one or more settings associated with the one or more circuit breakers.
[0040] An aspect of the present disclosure relates to a device having display unit for testing an electrical life of one or more circuit breakers. The device includes a controller device, having one or more contactor modules adapted to connect with the one or more circuit breakers, for generating one or more test criteria for testing of the one or more circuit breaker, and an extraction module adapted to extract one or more features associated with the electrical life of the one or more circuit breakers when subjected to the one or more test criteria; and at least a remote controller device, communicably coupled with the controller device, adapted to fetch the one or more features, and analyze the one or more features to determine the electrical life of one or more circuit breakers for displaying on the display unit.
[0041] In an exemplary embodiment, the system and/or device according to the present invention is an automation is an integration of following major components/systems:

HARDWARE:
a) Development of Electrical Control Panel with NI Compact RIO Controller- NI cRIO 9075
b) Analog Card. - NI 9227
c) Digital Input Card. NI 9425
d) Digital Output Card. NI 9476
e) Computer.
f) Barcode Scanner.

SOFTWARE:
a) Lab VIEW 2015.
b) SQL Server 2012.

[0042] FIG. 1A illustrates an exemplary block diagram of the proposed machine, in accordance with an embodiment of the present disclosure. As shown in FIG. 1 A, the system 100 for testing an electrical life of one or more circuit breakers 102a and 102b is shown.
[0043] In an embodiment, the system 100 can include a controller device 104 communicably coupled with at least a remote controller device 106. The controller device 104 can include one or more contactor modules 108a, 108b adapted to connect with the one or more circuit breakers 102a and 102b, for generating one or more test criteria for testing of the one or more circuit breaker 102a and 102b, and an extraction module (not shown) adapted to extract one or more features associated with the electrical life of the one or more circuit breakers 102a and 102b when subjected to the one or more test criteria.
[0044] The remote controller device 106 has a display unit and fetches the one or more features, and analyzes the one or more features to determine the electrical life of one or more circuit breakers 102a and 102b for displaying on the display unit.
[0045] FIG. 1B illustrates an exemplary images of the proposed machine while testing, in accordance with an embodiment of the present disclosure. . As shown in FIG. 1 A, the system 100 for testing an electrical life of one or more circuit breakers 102a and 102b is shown.
[0046] In an embodiment, the present invention can be utilized for the testing of occurrence of one or more faults in the circuit breaker. In an exemplary implementation, Faults Detection of ECD charging cycle can be detected using the below two conditions:
a. ECD micro switch (MSW) is present (selected in micro switch selection on test screen)
i. ECD MSW does not change over from NO to NC, ECD charging fault will be displayed.
b. ECD MSW not present (Not selected in micro switch selection on test screen)
i. No ECD charging fault will be displayed
[0047] In an exemplary implementation, RTC Fault can be detected using the below two conditions:
a. RTC MSW is present (Selected in micro switch selection on test screen)
i. If RTC MSW does not change over from NO to NC after ACB fully charged and in ACB healthy condition, RTC fault will be displayed.
b. RTC MSW not present (Not selected in micro switch selection on test screen)
i. No RTC fault will be displayed
[0048] FIG. 2A and 2B illustrates an exemplary software screen and timing cycles for Closing-ECD Charge-Tripping Timing Cycle during testing, in accordance with an embodiment of the present disclosure. FIG. 2A shows fault detection during ACB Cycle and FIG. 2B shows a timing diagram associated with the same. FIG. 3 illustrates an exemplary timing cycles for Closing-Tripping-ECD Charge Timing Cycle during testing, in accordance with an embodiment of the present disclosure. FIG. 3 shows timing diagram associated with the fault detection during Closing-Tripping-ECD Charge Timing Cycle during testing.
[0049] In an exemplary implementation, ACB closing cycle faults can be determined based on below analysis:
CR Fault: RYBN- No continuity and no change over from NO-NC, CR fault will be displayed. FIG. 4 illustrates an exemplary screenshot on occurrence of CR fault, in accordance with an embodiment of the present disclosure.
RTC Fault:
a. RTC MSW is present (Selected in micro switch selection on test screen)
i. If RTC MSW does not change over from NO to NC after ACB fully charged and in ACB healthy condition, RTC fault will be displayed.
b. RTC MSW not present (not selected in micro switch on test screen)
i. No RTC fault will be displayed.
AUX NC Contact Fault:
a. RTC MSW is present
i. RTC MSW- NC to NO, RYBN- Continuity OK, AUX NC- NO change over from NC-NO: AUX NC Contact Fault will be displayed.
b. RTC MSW is not present
i. RYBN - Continuity OK, AUX NC- NO change over from NC-NO: AUX NC Contact Fault will be displayed. FIG. 5 illustrates an exemplary screenshot on occurrence of RYBN close fault, in accordance with an embodiment of the present disclosure.
AUX NO Contact Fault:
a. RTC MSW is present
i. RTC MSW- NC to NO, RYBN-Continuity ok, AUX NO- No change over from NO-NC: AUX NC Contact Fault will be displayed.
b. RTC MSW is not present
i. RYBN- Continuity OK, AUX NO- No change over from NO-NC: AUX NO Contact Fault will be displayed.
RYBN Closing Fault:
a.RTC MSW is present
i. RTC MSW-NC to NO RYBN- Continuity not OK: NO RYBN Continuity Fault but CR Fault will be displayed
b. RTC MSW is not present
i. RYBN Continuity not OK: RYBN Closing Fault will be displayed.
[0050] In an exemplary implementation, ACB trip/open cycle faults can be analyzed using:
Condition 1: Tripping with UV selected –
UV Fault:
a. UV MSW is present
i. UV MSW- NO to NC change over: No UV Fault
ii. UV MSW-No change over: UV fault
b. UV MSW is not present
i. No UV Fault
RYBN Opening Fault:
a. UV MSW is present
i. UV MSW –NO to NC change over, RYBN continuity ON: RYBN opening fault will be displayed.
b. UV MSW is not present
i. RYBN Continuity ON: RYBN opening Fault will be displayed. FIG. 6 illustrates an exemplary screenshot on occurrence of RYBN open fault, in accordance with an embodiment of the present disclosure.
SR Fault:
a. SR MSW is present
ii. SR MSW- NO to NC change over: SR fault will be displayed.
4). FSD Fault:
a. FSD MSW is present
i. FSD MSW- NC to NO change: FSD Fault will be displayed.
5). AUX NC Contact Fault:
a. If UV fault is not there
i. AUX NC- No change over from NO-NC: AUX NC contact fault will be displayed.
b. If UV fault is there
i. AUX NC contact fault will be displayed.
6). AUX NO Contact Fault:
a. If UV fault is not there
i. AUX NC- No change over from NC-NO: AUX NO contact fault will be displayed.
ii. AUX NO contact fault will be displayed.

Condition 2: Tripping with SR selected.
UV Fault (If UV is present)
a. UV MSW is present
i. UV MSW- NO to NC change over: UV Fault
ii. UV MSW-No change over: No UV fault
b. UV MSW is not present
i. No UV Fault
RYBN Opening Fault:
a. SR MSW is present
i. SR MSW –NO to NC change over, RYBN continuity ON: RYBN opening fault will be displayed.
b. SR MSW is not present
i. RYBN Continuity ON: RYBN opening Fault will be displayed
SR Fault:
a. SR MSW is present
i. SR MSW- No change over: SR fault will be displayed.
b. SR MSW is not present
i. No SR Fault
FSD Fault:
a. FSD MSW is present
i. FSD MSW- NC to NO change: FSD Fault will be displayed.
AUX NC Contact Fault:
a. If SR fault is not there
i. AUX NC- No change over from NO-NC: AUX NC contact fault will be displayed.
b. If SR fault is there
i. AUX NC contact fault will be displayed.
AUX NO Contact Fault:
a. If SR fault is not there
i. AUX NC- No change over from NC-NO: AUX NO contact fault will be displayed.
b. If SR fault is there
i. AUX NO contact fault will be displayed.
[0051] FIG. 7 illustrates an exemplary flowchart for testing an electrical life of one or more circuit breakers, in accordance with an embodiment of the present disclosure. In an embodiment, upon initiation of the testing process using the proposed system and/or device, an ESD charging is passed for analysis at step 702. If a delay is detected by the proposed system and/or device at step 704, a closing command is provided by the proposed system and/or device at step 706.
[0052] At step 708, the fault is detected and analyzed by the the proposed system and/or device and if the fault is determined the same is displayed on the display unit at step 710. However, if the fault is not detected, and still there is any delay at step 712, a trip command is issued at step 714.
[0053] Upon issuing of the trip command, at step 716 the fault is detected and analyzed by the proposed system and/or device and if the fault is determined the same is displayed on the display unit at step 718. However, if the fault is not detected, and still there is any delay at step 720, a ECD charging torque and force measurement are performed by the by the proposed system and/or device at step 722, and the measurements are displayed on the display unit at step 722.
[0054] At last the proposed system and/or device at step 726 checks if the entire test are complete and if completed then end the testing and displays the final results on the display unit and if the testing is not completed the above steps are repeated again.
[0055] Although the preferred embodiments have been described, it should be pointed out that changes are possible and attainable without departing from the scope of the present invention.
[0056] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0057] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
[0058] The present disclosure provides a provision to test 2 ACB in 2 stations simultaneously. (Improvement in Productivity)
[0059] The present disclosure provides a software controlled recipe selection. (Case A or Case B)
[0060] The present disclosure provides a software controlled – trip selection (UV trip or shunt trip).
[0061] The present disclosure provides a closing time and tripping time detection.
[0062] The present disclosure provides a current measurement (peak + rms) of ECD charging for each cycle.
[0063] The present disclosure provides Indication of UV Delays. (Instantaneous/1S/2S/5S).
[0064] The present disclosure provides software Controlled-ACB Cycle. (Timing Settings for ECD Charging, Closing Time and Tripping Time.)
[0065] The present disclosure provides an AUX NO-NC Faults which will be displayed (with specific ferule number + Operation Cycle Number).
[0066] The present disclosure provides a specific counter for AUX NC and AUX NO.
[0067] The present disclosure provides an indication of UV Delay switch settings (To change in UV Release Settings).
[0068] The present disclosure provides an ECD graph for entire endurance test (to check performance of ECD Motor).
[0069] The present disclosure provides a shunt/UVR Tripping Graph for better understanding.
[0070] The present disclosure provides a live settings update. (No need to stop the Program and restart).
[0071] The present disclosure provides a program which will be resumed from last operations automatically even power supply is cut off. Software can be installed to initiator PC to view real time scenario.