Bucket assemblies for motor control centers (MCC) with disconnect assemblies and related MCC cabinets and methods

Abstract

Circuit breakers with a rotary handle attached to an inwardly oriented shaft that connects to a gear assembly that translates rotational input to linear input also include a trip assist spring in communication with the rack gear so that, in operation, the trip assist spring applies a force to the operator slider and forces the handle to a consistent trip position.

Claims

1. A Motor Control Center (MCC) cabinet with bucket units, the bucket units having a common size external rotary handle that each communicates with a respective internal disconnect assembly that engages a respective toggle or switch of an internal circuit breaker or a fused disconnect switch, wherein different ones of the bucket units can have different frame sizes associated with different amperage ratings, and wherein the rotary handle of each of the bucket units rotate 90 degrees between OFF and ON positions, and wherein the rotary handle of each of the bucket units have a common trip orientation, wherein the bucket units have first and second configurations, with the second configuration being larger than the first configuration, wherein the first configuration is associated with bucket units having frame sizes/amperage ratings in a range of about 125 A to about 250 A, and wherein the second configuration is associated with bucket units having frame sizes/amperage ratings above 250 A, including 400 A and 600 A.

2. The MCC cabinet with bucket units of claim 1, wherein at least one of the bucket units comprises the fused disconnect switch, and wherein the disconnect assembly of the at least one bucket unit with the fused disconnect switch comprises a gear system having a rack gear and disconnect slider that engages the fused disconnect switch.

3. A Motor Control Center (MCC) cabinet with bucket units, the bucket units having a common size external rotary handle that each communicates with a respective internal disconnect assembly that engages a respective toggle or switch of an internal circuit breaker or a fused disconnect switch, wherein different ones of the bucket units can have different frame sizes associated with different amperage ratings, and wherein the rotary handles all rotate 90 degrees between OFF and ON positions and have a common trip orientation, wherein at least one of the bucket units comprises the fused disconnect switch, wherein the disconnect assembly of the at least one bucket unit with the fused disconnect switch comprises a gear system having a rack gear attached to a disconnect slider that engages the fused disconnect switch, and wherein the disconnect slider of the at least one bucket unit with the fused disconnect switch moves vertically up and down in response to rotation of the handle, and wherein the handle is attached to a drive gear that is coupled to the rack gear.

4. The MCC cabinet with bucket units of claim 3, wherein the disconnect assembly of the at least one bucket unit with the fused disconnect switch comprises a pivoting arm that has a lower end portion that extends into a slot or aperture of the slider and a switch contact member or feature that engages the toggle or the switch of the fused disconnect switch.

5. A Motor Control Center (MCC) cabinet with bucket units, the bucket units each having at least one external rotary handle of a common size and each at least one external rotary handle communicates with a respective internal disconnect assembly that engages a respective toggle or switch of an internal circuit breaker or a fused disconnect switch, wherein different ones of the bucket units can have different frame sizes associated with different amperage ratings, and wherein each of the at least one rotary handle rotates 90 degrees between OFF and ON positions and have a common trip orientation, wherein at least one of the bucket units has dual side-by-side external rotary handles aligned in horizontal and vertical directions as the at least one rotary handle, with a load side facing outward and an incoming side between the dual rotary handles facing inward.

6. The MCC cabinet with bucket units of claim 5, wherein the bucket units are provided in different sizes with a plurality of different amperage ratings including at least two of 250 A, 400 A and 600 A.

7. The MCC cabinet with bucket units of claim 1, wherein the bucket units are configured to position the rotary handles aligned along a left hand side of the MCC cabinet.

8. A Motor Control Center (MCC) cabinet with bucket units, the bucket units having a common size external rotary handle that each communicates with a respective internal disconnect assembly that engages a respective toggle or switch of an internal circuit breaker or a fused disconnect switch, wherein different ones of the bucket units can have different frame sizes associated with different amperage ratings, and wherein the rotary handle of each of the bucket units rotate 90 degrees between OFF and ON positions, and wherein the rotary handle of each of the bucket units have a common trip orientation, wherein the bucket units have a substantially common width irrespective of height and the height and/or frame size of the bucket units is provided in modular 6 inch increments in a range of about 6 inches to about 72 inches.

9. The MCC cabinet with bucket units of claim 1, wherein at least one of the bucket units comprises the internal circuit breaker and further comprises a shaft attached to the rotary handle and extending into the bucket unit, wherein the disconnect assembly comprises a gear assembly that engages the shaft and comprises a rack gear that linearly moves an operator slider in communication with the toggle or switch of the circuit breaker, and wherein the disconnect assembly further comprises a trip assist spring that is held on a rod that is parallel to the rack gear, wherein the trip assist spring cooperates with the rack gear to move the external rotary handle to a defined consistent orientation when the circuit breaker trips, and wherein the trip assist spring and rod are parallel to a side of a primary body of the rack gear comprising gear teeth.

10. The MCC cabinet with bucket units of claim 9, wherein the trip assist spring and rod are both held in a fixed lateral orientation over their respective lengths, wherein the fixed lateral orientation is parallel to a long side of the side of the primary body as the side of the primary body comprising gear teeth, and wherein the rod extends through the trip assist spring and has a length that is greater than the trip assist spring, and wherein the trip assist spring is in a compressed state when the toggle or the switch is in the ON and OFF positions to be able to bias the operator slider to a center of its travel path.

11. The MCC cabinet with bucket units of claim 9, wherein the trip assist spring is held above the rack gear in a fixed horizontal orientation on the rod, wherein the rod has a length that is greater than the trip assist spring, and wherein the trip assist spring extends over a sub-length of the rod in a compressed configuration and applies a force to bias the operator slider to reside at a location that is at a medial position of its sliding travel path.

12. A Motor Control Center (MCC) cabinet with bucket units, the bucket units having a common size external rotary handle that each communicates with a respective internal disconnect assembly that engages a respective toggle or switch of an internal circuit breaker or a fused disconnect switch, wherein different ones of the bucket units can have different frame sizes associated with different amperage ratings, and wherein the rotary handle of each of the bucket units rotate 90 degrees between OFF and ON positions, and wherein the rotary handle of each of the bucket units have a common trip orientation, wherein the disconnect assembly of at least one of the bucket units comprises a slider that engages the toggle or the switch and moves vertically up and down in response to rotation of the rotary handle.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1A is a front perspective, partial cutaway view of an exemplary bucket assembly/unit according to embodiments of the present invention.

(2) FIG. 1B is a partially exploded view of FIG. 1A according to embodiments of the present invention.

(3) FIG. 2 is a front perspective view of the bucket assembly shown in FIG. 1A without the front cover according to embodiments of the present invention.

(4) FIG. 3A is a front perspective view of the bucket assembly of FIGS. 1A and 2, but shown without the front cover and without the door that holds the rotary handle according to embodiments of the present invention.

(5) FIG. 3B is a partial exploded view of the door lock assembly shown in FIG. 3A according to embodiments of the present invention.

(6) FIG. 4 is a front perspective view of the bucket assembly shown in FIG. 1A with the drive shaft and door interlock components omitted to illustrate the breaker mechanism with drive shaft portal integrally mounted to the breaker bucket assembly according to embodiments of the present invention.

(7) FIG. 5 is a front perspective view of the bucket assembly shown in FIG. 1A illustrating the breaker rotary to linear translating operating mechanism according to embodiments of the present invention.

(8) FIG. 6 is an exploded view of the rotary to linear translating operating mechanism according to embodiments of the present invention.

(9) FIG. 7A is a front view of a unit illustrating exemplary ON and OFF rotary positions according to embodiments of the present invention.

(10) FIG. 7B is a front view of a unit with a dual feeder configuration with tandem mounted rotary handles according to embodiments of the present invention.

(11) FIG. 8 is a front view of an exemplary Motor Control Center cabinet according to embodiments of the present invention.

(12) FIG. 9A is a front perspective view of a bucket assembly (with part of the housing removed) that has a fuse disconnect assembly according to embodiments of the present invention.

(13) FIG. 9B is a partial exploded, front perspective view of the bucket assembly shown in FIG. 9A.

(14) FIG. 9C is a left-side perspective, partially exploded view of the bucket assembly shown in FIG. 9A.

(15) FIG. 9D is a left-side perspective, partially exploded view of the bucket assembly shown in FIG. 9A.

(16) FIG. 10A is left-side, partially exploded view of the bucket assembly shown in FIG. 9B illustrating the primary drive gear apart from the rack gear and slider according to embodiments of the present invention.

(17) FIG. 10B is an enlarged view of the slider and gear components shown in FIG. 10A.

(18) FIGS. 11A, 11B and 11C are side perspective views of small breakers of increasing frame size that each include a substantially common operator mechanism configuration (with the units oriented 90 degrees from a normal operative position) according to embodiments of the present invention.

(19) FIGS. 12A and 12B are side perspective views of large breakers of increasing frame size that each include a substantially common operator mechanism configuration (with the units oriented 90 degrees from a normal operative position) according to embodiments of the present invention.

(20) FIG. 12C is a perspective view of a circuit breaker with a trip unit module according to embodiments of the present invention.

(21) FIG. 12D is a perspective view of an example of a trip unit module according to embodiments of the present invention.

(22) FIG. 13 is an exploded view of a handle mechanism illustrating an exemplary detent configuration according to embodiments of the present invention.

(23) FIG. 14 is a front perspective view of an exemplary fused switch disconnect arrangement according to embodiments of the present invention.

(24) FIG. 15 is a top perspective view of a fused switch arrangement with a fuse and a load-end fuse clip connection according to embodiments of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(25) The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. Like numbers refer to like elements and different embodiments of like elements can be designated using a different number of superscript indicator apostrophes (e.g., 10, 10, 10, 10).

(26) In the drawings, the relative sizes of regions or features may be exaggerated for clarity. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

(27) It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present invention.

(28) Spatially relative terms, such as beneath, below, lower, above, upper and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as below or beneath other elements or features would then be oriented above the other elements or features. Thus, the exemplary term below can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

(29) The term about refers to numbers in a range of +/20% of the noted value.

(30) As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms includes, comprises, including and/or comprising, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. It will be understood that when an element is referred to as being connected or coupled to another element, it can be directly connected or coupled to the other element or intervening elements may be present. As used herein, the term and/or includes any and all combinations of one or more of the associated listed items.

(31) Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

(32) The term escutcheon refers to a cover residing about the operator handle.

(33) The terms operating mechanism and operator mechanism are used interchangeably and refer to an assembly for opening and closing separable main contacts in a circuit breaker and/or for turning power ON and OFF using a switch associated with a fuse (e.g., a fused disconnect). The circuit breaker can be for a motor starter unit or feeder unit, for example.

(34) The terms bucket assembly, bucket and unit are used interchangeably and refer to a structure (typically a protective metal shell) that contains either a fuse or a circuit breaker for turning power ON and OFF to a motor, or feeder circuit, typically for controlling power to motor starters. As is well known, the bucket can be, for example, a feeder unit or a starter unit. The bucket assembly can include other components such as a power transformer, a motor starter to control a single motor and PLCs (programmable logic controllers), drives and the like. The bucket assembly can be configured as a modular device to allow the internal components to be assembled as a unit that can be easily installed into a Motor Control Center (MCC) compartment. As is well known, the bucket can have power stabs in the back that connect to vertical bus bars that carry power (current) to the compartments of a vertical section in an MCC cabinet. The vertical bus bars are connected to the larger horizontal bus bars that bring power to the vertical sections. The horizontal bus bars are usually in the top, but some MCC designs may have them in the center or bottom. MCCs usually have a wire way for wires to the motors and other loads and control wires.

(35) MCCs can be configured in many ways. Each compartment can have a different height to accept different frame sizes of respective bucket assemblies or units 10, typically in about 6-inch increments. The vertical bus can be omitted or not run through the full height of the section to accommodate deeper buckets for larger items like variable frequency drives. The MCC can be a modular cabinet system for powering and controlling motors or feeder circuits. Several may be powered from main switchgear which, in turn, gets its power from a transformer attached to the incoming line from the power company.

(36) A typical MCC cabinet is an enclosure with a number of small doors arranged in rows and columns along the front and flat, mostly featureless, back and sides. The buckets can be provided in varying sizes. For starter units, the size can be based on the size of the motor they are controlling. The bucket assembly can be configured to be relatively easily removable for repair, service or replacement. MCCs can have, for example, regular starters, reversing starters, soft start, and variable frequency drives. MCCs can be configured so that sections can be added for expansion if needed.

(37) The term compact refers to bucket units 10 (also known as buckets) in a very condensed configuration (package) relative to conventional units/buckets. The MCC structure or cabinet 100 (FIG. 8) can be designed to receive multiple bucket units 10 ranging in various defined sizes. The units 10 can be provided in package or frame sizes of about 6 inches to about 72 inches (tall) with substantially common depth and width dimensions, known as 1X (6 inches) to 12X (72 inches) sizes. The sizes can be in single X increments, from 1X, 2X, 3X, 4X, 5X, 6X, 7X, 8X, 9X, 10X, 11X and 12X. Thus, a 5X MCC unit 10 can be about 30 inches tall. The frame sizes can be provided for a plurality of amperages, including a plurality of: 125 A, 150 A, 225 A, 250 A, 400 A, 600 A, 1200 A and 2000 A, for example.

(38) Referring now to the figures, FIGS. 1A and 1B illustrate and example of a bucket assembly or unit 10. The bucket assembly can be configured for DC (direct current) and/or AC (alternating current) operation. The bucket assembly 10 can include a front cover 10c. The bucket assembly can include at least one door 22 under the front cover. The bucket assembly 10 can have a metal frame or housing 11.

(39) In some embodiments, the bucket assembly 10 can comprise a molded case circuit breaker. Molded case circuit breakers are well known to those of skill in the art, as exemplified by U.S. Pat. Nos. 4,503,408 and 5,910,760, the contents of which are incorporated herein by reference as if recited in full herein. In other embodiments, the bucket assembly 10 can be configured to house a fuse disconnect with a fuse disconnect switch to turn power on and off (FIGS. 9A-9D, for example). In some embodiments, the MCC cabinet 100 can hold both type bucket units 10 (e.g., 10F and 10C) and each can have a standardized rotary handle 20h that controls the internal components for power on/off operation (FIG. 8).

(40) The unit 10 includes a handle mechanism 20 with a rotary handle 20h. For the circuit breaker unit 10C, the unit 10 includes a shaft 25 that communicates with the handle 20h can be rotated through defined translations of rotation from circuit breaker conduction to circuit breaker non-conduction. Typically, there is about a 90 rotation from conduction to non-conduction (OFF to ON) but other defined rotational stroke distances may be used including, for example, about 45 degrees, about 120 degrees, or about 180 degrees. The handle 20h can be configured to turn about 90 degrees in all different breaker sizes in a single MCC cabinet 100 (FIG. 8) that can provide standardized visual output of on/off and can allow for standardized components between different assemblies 10.

(41) The rotary handle 20h can be attached to an inwardly extending shaft 25 (FIG. 3A) that is keyed to a drive gear 42, 42 (FIG. 5, FIG. 9B). The drive gears 42, 42 can have the same configuration (e.g., be the same component) or may have different dimensions or configurations. In some embodiments, the drive gear for the operator mechanism 42 as well as the drive gear 42 for the fuse mechanism 260 can have gear teeth that extends less than a full circumference of the respective gear, typically the gear teeth 42t extend for between about 9-180 degrees, more typically about 90 degrees of the circumference of the drive gear 42, 42.

(42) In operation, the orientation of the rotary handle 20h can provide a visual indication of the conduction status of the operator disconnect, e.g., breaker 60 (FIG. 1A) or ON/OFF switch for the fuse disconnect switch 260 (FIGS. 9A-9D).

(43) If the handle 20h is in a generally horizontal position, i.e., with the nose, lever or thumb knob straight across the front of the circuit breaker as shown in FIG. 1A, this orientation can be the OFF position and can be visually used as an indication that the contacts of the circuit breaker are open and that current is blocked. If the handle 20h is rotated from the orientation shown in FIG. 1A, e.g., rotated 90 degrees (typically clockwise from the orientation in FIG. 1A) as illustrated by the broken line position and arrow direction in FIG. 7A, to be parallel with the long longitudinal axis of the circuit breaker and/or the handle position in FIG. 9A, then an indication is given that the circuit contacts are closed and current is being conducted. The breaker trip position can be at about 45 degrees mid-point between ON and OFF.

(44) The handle 20h can be circular with a protruding thumb or finger segment 21 and/or a T shaped member or feature (e.g., an insert) 23 residing substantially inside the circular profile with the small cross-end of the T on the outer perimeter as shown in FIG. 1A or may comprise a rotating lever type as is known to those of skill in the art.

(45) The handle can have a rectangular lever or arm and this end can be oriented to reside on the handle 20h to provide a clean visual indicator of handle position (e.g., ON and OFF) readily visible from a distance (e.g., 5-20 feet away) in a room holding the MCC 100 (FIG. 8) with the unit(s) 10.

(46) FIG. 2 illustrates the unit 10 without the outer front cover 11c. FIGS. 3A and 3B illustrate the unit 10 with the door 22 and front cover 10c omitted. FIG. 2 illustrates that the handle mechanism 20 can be fixed the front panel door 22. The door 22 may optionally be hingeably attached to the frame 11f of the housing 11. The unit 10 can include an external door defeat interlock 22i.

(47) FIGS. 11A-11C, 12A and 12B illustrate that the units 10 can be circuit breaker units 10C provided in different frame sizes. The orientation of the units 10C shown in FIGS. 11A-11C is rotated 90 degrees from the typical operative position shown in FIG. 1A, for example.

(48) As is shown in FIGS. 3A and 3B, the unit 10 can include an internal automated interlock assembly 30. As is also shown, the assembly 30 can include a bolt 31 and a biasing member 33 to urge the latch 35 into a locked configuration to extend through door bracket 222 and engage the interlock bracket 44. The latch 35 can releasably engage an inwardly facing primary surface 44s of the bracket 44 to lock the door shut. The bracket 222 can be attached to a rear primary surface of the door 22r (proximate the aperture 22a for the sliding latch 35) as shown in FIG. 1B.

(49) FIG. 1B also illustrates that the unit 10 can include a divider pan 14 with associated apertures 14a that can cooperate with interlocks 14a.sub.1 and/or pin locks 14a.sub.2, for example.

(50) The biasing member 33 is shown as a coil spring, but other biasing members may also be used including, for example, a leaf spring, belleville or stacked dome washers and elastic plugs or combinations of the same. The door 22 can include a hinge 22h that attaches to the frame 11f of the housing and supports the bolt 31 and biasing member 33.

(51) The interlock assembly 30 can be integrated in the operator envelope or operator mechanism 40 and can be an automated mechanism. Thus, the interlock assembly 30 can reside inside the operator mechanism envelope 40 that comprises a laterally extending spring 33 residing over a door interlock bolt 31 configured so that the bolt can be electronically directed to automatically slidably extend to lock the door bracket 44.

(52) In some embodiments, the circuit breaker 10 can include a handle escutcheon 227 (FIG. 3A) that communicates with the spring-loaded door lock assembly 30 that locks the door 22 shut when the circuit is energized. The door 22, latch 35 and door catch configuration 44 can be configured so as to avoid requiring manual adjustment for proper assembled alignment using the biasing member 33.

(53) Referring to FIGS. 3A and 3B, the handle escutcheon 227 can interact with an upwardly extending arm 225 with a horizontally oriented slot 228 that slidably engages a stationary shaft 229 as a safety lock for the door.

(54) FIGS. 3A and 3B also illustrate that the rotary handle 20h can engage an inwardly extending drive shaft 25 that extends into the unit housing through the door 22 or other housing frames 11f via a path or portal 25p.

(55) The circuit breaker unit 10C also includes a rotary to linear translating operator mechanism 40. The operator mechanism 40 can be integrally and/or permanently mounted to the unit housing or body 11.

(56) As shown in FIG. 6, the operator mechanism 40 can include a drive gear 42, a pinion gear 144, and an operator rack gear 46. Generally summarized, the handle 20h via shaft 25 is keyed to interface with the rotary drive gear 42. Drive gear 42 interacts mechanically with pinion gear 144. Pinion gear 144 also interacts with the linearly translationally moveable rack 46. Consequently, as the handle 20h rotates, because it is interlocked with the drive gear 42, the drive gear 42 rotates on its axis, thus rotating the pinion gear 144, which then linearly moves the rack 46. The rack 46 then moves the operator slider 52 which moves to trip lever 90 as the handle 20h moves.

(57) Referring to FIGS. 4-6, the operator mechanism 40 can include an operator base 50 and the slider 52. The operator base 50 can be stationary and affixed to the inner housing 11h (FIG. 6). The base 50 can have a horizontally oriented elongate slot 50s that is aligned with a smaller slot 52s in the operator slider 52. The slots 50s, 52s cooperate to hold lever 90 (toggle) and when the operator slider with slot 52s moves to the right (based on rotation of the handle 20h, for example), this moves the lever 90 to the right along the path defined by slot 50s.

(58) It is noted that the lever 90 (also known as a toggle) can move laterally as shown or the circuit breaker or fuse switch may be oriented to move vertically.

(59) FIGS. 9A-9D illustrate an exemplary fuse bucket 10F with the drive gear 42 in communication with a rack gear 46 that moves up and down or orthogonal to the rack gear 46 of the operating mechanism 40 shown in FIGS. 1A-5, for example. This movement can engage and move a fuse switch lever or input up and down for ON/OFF operation (FIG. 15 illustrates an exemplary arrangement of a fuse and load end fuse clip).

(60) For units with circuit breakers 60, the operating mechanism 40 can also include a trip assist spring 43 that is in communication with the rack gear 46 to assist the handle 20h to move to a consistent OFF position when the circuit breaker is tripped.

(61) As shown in FIG. 5, the spring 43 is typically compressed in operative position. As also shown in FIGS. 5 and 6, the rack gear 46 can have an outwardly extending arm 47 (extending in a direction toward the door 22) with an opening 48. The opening 48 can receive a guide rod 41 that can be held in the trip assist spring 43 to provide a controlled lateral travel path for the trip assist spring 43. Where used, the arm 47 can have an open or closed end (forming a through aperture or an outward facing open ended slot) to hold the guide rod 41 and cooperate with outer member 49 to compress the spring 43 (or other biasing member). The spring 43 typically resides between the end frame of the housing and an arm 47 or other support member that can cooperate with the spring 43 to provide the desired compression.

(62) The spring 43 can spring bias the operating mechanism 40 to a consistent trip position, independent of a breaker toggle trip position. That is, in the past, if tripped, the lever or breaker toggle 90 will move to a TRIP position with little force. Unfortunately, this may not be sufficient force to move the lever 90 to a consistent trip orientation/position.

(63) The spring 43 can be configured to provide a suitable trip-assist force. The spring 43 can be configured with a length and and/or k-factor such that the slider 52 is biased to a center of its travel path between ON and OFF positions. The length of the spring 43 can vary depending on the type or size lever 90 and/or associated breaker 60. Although shown as one spring 43, more than one spring can be used, alone or with other cooperating members, e.g., an elastically resilient plug, belleville washers, stacked resilient dome washers and the like, to provide a desired spring force and/or biasing action. In addition, the spring 43 may be omitted in favor of one or more different resilient members to provide a suitable trip assist force.

(64) In some embodiments, the spring 43 can have a length that is about 50% to about 100% of a length of the travel path of the operator slider 52 between ON and OFF positions.

(65) The spring 43 can reside between a mounting member 55 and the operator base 50. The mounting member 55 can be formed integral with the base member 50 or be provided as a separate component that can attach to the operator base 50. The mounting member 55 can hold the guide rod 41 above the lever 90. The mounting member 55 can include an end portion that turns inwardly to be substantially orthogonal to a primary surface 55p of the mounting member. The end portion 55e can include a slot, channel or aperture 55a that allows the rod 41 to extend through to support the rod. However, the mounting member 50 can hold the rod inside its body and does not require the aperture 55a. The mounting member 55 can be a monolithic member with a formed end portion 55e or may include attached cooperating components.

(66) The operator base 50 and be in communication with the rack gear 46 to can provide sufficient force to move the handle 20h to a consistent TRIP position/orientation.

(67) The handle 20h can be detented when the operating mechanism 40 is in the spring-biased TRIP position to be in an externally visible consistent TRIP position. The ON and OFF positions can be separated by about 90 degrees.

(68) While the circuit breaker bucket 10C is shown with the operating mechanism 40 having a guide rod 41 in the figures, it is contemplated that other configurations or components can be used to provide the desired controlled lateral path for the compression of the spring 43 and/or other biasing members and proper movement of the sliding base 52 and/or rack 46 to provide the desired trip assistance.

(69) In operation, the breaker 60 with the spring 43 can bias/force the slider 52 to move to a position at or proximate a center of a travel length. The spring 43 can be sized and configured to move the handle 20h to a middle position, e.g., about 45 degrees.

(70) FIG. 13 illustrates the handle 20h and an underlying base 20b that slidably (rotatably) holds the external handle 20h. The base 20b can include visual indicial 20i of handle operational position, e.g., the On/OFF/TRIP/RESET position text and/or color-coded features at appropriate locations about an outer perimeter. Alternatively or additionally, the exterior cover 10c may include this visual indicia. As shown, the handle 20h can include an inwardly extending plunger 20p that cooperates with surface features or members on the base 20b. As shown, the base 20b can include a projecting feature or member configured as a detent 20d that resides in line with a trip position of the handle 20h between the ON and OFF positions. The plunger 20p can reside inside a spring 20s or cooperate with other biasing members to facilitate the movement. Thus, the handle 20h can be detented in the spring biased trip position to the trip position to provide a visually consistent handle 20h trip position.

(71) The guide rod 41, where used, can have a length that is greater than the length of the trip assist spring 43 and may have a length that is about the same as a long side width of the operator base 50. In some embodiments, the trip assist spring 43 can have a length that is between about 30-80% less than a length of a guide rod 43 extending therethrough.

(72) In some embodiments, the rear surface of the rotary handle 20h resides a distance d1 (FIG. 3) that is within about 0.25 inches to about 1 inch, more typically from a distance that is about to about inch, from the front surface of the operator base 50 (in a depth direction) with the drive gear 42, pinion gear 144, rack gear 46, and trip assist spring 43 therebetween.

(73) FIGS. 4 and 5 illustrate that opposing ends of the guide rod 41 can be held by the mounting member 55 so that the guide rod 41 and spring 43 reside above the rack gear teeth 46t. In some particular embodiments, the guide rod 41 can be held in place using one or more attachment members 53 to inhibit or prevent lateral translation of the guide rod 41. The attachment member 53 can comprise a lock washer. In other embodiments, the attachment members 53 can have other configurations. The attachment member 53 can have threads for a threaded engagement, e.g., a threaded nut. In other embodiments, the rod 41 end portion can be configured to threadably engage a threaded insert held in the aperture 55a. In yet other embodiments, the rod 41 can include a radially extending aperture that resides outside the aperture 55a and can engage a locking pin or other suitable attachment feature/member.

(74) The mounting member 55 can have a primary upwardly extending surface 55s that is substantially planar and can include a cutout or shape that provides an open space 55o for the toggle or lever 90 and a portal and/or path 55p for the drive shaft 25. FIGS. 4-6 illustrate that the member 55 can be attached to the operator base 50 and each member 50, 55 can be stationary and attached to the circuit breaker 60 via standoffs 58.

(75) In some embodiments, the mounting member 55 resides a distance d2 (FIG. 4) that is within about 0.1 inches to about 0.5 inches from the front surface of the operator base 50 (in a depth direction) with the drive gear 42, pinion gear 144, rack gear 46, and trip assist spring 43 therebetween, typically about 0.25 inches.

(76) The operating mechanism 40 can include a blocking member 49 that resides about the rod 41 and that traps the spring to the left of the right half of the rod 41 and compresses at least a portion of the spring 43 as the rack gear 46 translates in one direction (e.g., toward the left).

(77) The operating mechanism 40 can be configured so that the spring 43 has a compressed configuration when in use, e.g., when the lever is in both the OFF and ON position to be able to bias the slider 52 to a center of its travel path. Stated differently, the spring 43 is configured to have a compressed configuration irrespective of the position of the rack gear 46 and lever 90.

(78) The blocking member 49 can be a washer, nut, sleeve or other sufficiently rigid member and/or a protrusion on the outer surface of the rod itself that provides suitable obstruction with a cooperating component or feature on the rack gear 46 so as to compress the spring 43 and provide the desired biasing force.

(79) As shown, the blocking member 49 can contact the upper end portion 46u (e.g., arm 47) of the rack gear 46. The blocking member 49 and arm 47 thus cooperate to trap one end of the spring to thereby compress the spring 43.

(80) Embodiments of the invention provide circuit breakers 10 with a rotary position of the rotary handle 20h positioned on a centerline of the breaker 60, in-line with a corresponding center pole.

(81) As shown in FIG. 7B, embodiments of the invention can provide units 10 with symmetrically positioned disconnect operator handles 20h on an MCC allowing a panel board, mounted tandem (line to line), dual feeder breakers 60.sub.1, 60.sub.2, in a compact unit 10 with both handles 20h aligned (e.g., laterally spaced apart but residing at about the same height or at the same height. The breakers 601, 602 can be oriented so that respective load sides 300L are on respective left hand and right hand outer ends and the incoming or feed circuit or path 300I can be shared along a center of the unit as shown.

(82) FIGS. 9A-9D, 10A and 10B illustrate a bucket unit 10 which is an example of a fuse based unit 10F. The unit 10 can include a housing or unit body 11 with a housing frame 11f and external cover 11c and optional door 22. The handle 20h can reside over on side of the cover 11c, located closer to a left side of the unit (for single units at a single level). The frame 11f can include at least one planar laterally extending interior frame member 11i that can include a portal 25p for an inwardly extending shaft 25 that attaches to the handle 20h and is keyed to the drive gear 42 as discussed with respect to the embodiment shown in FIG. 1A. As shown in FIG. 9D, the interior frame member 11i can include cooperating first and second members 11i.sub.1 and 11i.sub.2, each with a shaft portal 25p.

(83) As shown, the unit 10 includes a fuse body or fuse assembly frame 250 with a fused switch 260. FIGS. 14, 15 illustrate an exemplary fused switch unit 10F with a fuse and load-end fuse clip arrangement according to embodiments of the present invention. FIG. 15 is a front perspective view of a fused switch arrangement with a line end 263Li fuse clip connection 263c and a load-end 263Lo fuse clip connection 263c that hold respective fuses 263 according to embodiments of the present invention. The fused switch 260 can be provided as two separate components that fit into the MCC unit 10 to allow for connection to different size fuses 263. The fuses 263 can vary in length A and width B and still attach to the fuse connectors 263c. Exemplary fuses are FUSETRON 600V Class RK5 fuses (BU-SB13729) available from Cooper Bussmann Company, St. Louis, Mo. However, the design is flexible and can accommodate other fuses including those in different classes.

(84) The unit 10 also includes a fuse disconnect assembly 140 that includes a primary drive gear 42 and a rack gear 46 that are in communication with the rotary handle 20h. The rack gear 46 can be attached to a slider 52 that translates to move a switch 260 in communication with a pivoting arm 262. The arm 262 includes an end portion 262e that extends through a slot 52s or opening in the slider 52. As shown, the pivoting arm 262 also includes a mounting end portion 265 which may optionally be substantially circular. The mounting end portion 265 can include an aperture that receives an attachment member to be pivotably attached to a fuse body frame and/or housing or housing frame. The arm 262 can also include a projection member 264 (which can be a discrete member or a monolithic shaped feature and/or portion of the arm) that contacts the switch 260 to force the switch between ON and OFF positions. In the embodiment shown, the projection feature/member 264 is inclined in an upward direction as it extends a distance above the arm primary body.

(85) The bucket unit 10F can be configured to have a visually similar appearance to the bucket unit 10C with the same handle 20h and exterior housing layout/appearance although the internal ON/OFF circuit components are different.

(86) FIGS. 11A, 11B and 11C illustrate smaller size breakers 60 which have the same operating mechanism 40 but may include different size components of the mechanism 40. The operating mechanism 40 can be configured to work with a plurality of different breaker levers or toggles 90 of different sizes. Different components of the operator 40 and/or features of the different components of the operator 40 may be sized or configured differently to accommodate the different size or layout of members of the different size breakers 60 and associated circuit breaker frames 60f (FIGS. 11A-C, 12A, and 12B, for example). For example, the base 50 and slider 52 can have a different size for each size unit, particularly to accommodate different size levers 90 or a different position or travel path length of the lever 90.

(87) In some embodiments, one or more of the gears 42, 144, 46 of the operator mechanism 40 can be provided in different configurations, e.g., as first and second configurations, e.g., a small and larger version to work with bucket units having frame sizes/amperages from about 125 A, 225 A, 250 A, 400 A and 600 A, for example. The small version refers to circuit breakers rated between about 125 A and about 250 A. The larger bucket units 10 can have circuit breakers rated above 250 A, including 400 A and 600 A.

(88) FIGS. 11A-C illustrate a molded case circuit breaker configuration with the metal frame configured to allow access to the breaker trip adjustment setting and a push-to-trip button, which may be arranged differently in each frame 60f. Each type/size breaker can have a unique trip switch (e.g., lever or button) location. FIGS. 11A-C illustrate exemplary trip button access feature locations 60T for respective frames 60f.

(89) FIGS. 11C, 12A and 12B illustrate that some bucket units 10 can have a base 50 that provides the trip switch or trip button access features 60T. FIG. 12C illustrates an exemplary breaker 60 with an access window 210 for the trip switch 210s (e.g., lever or button). The access window 210 can be the same or different sizes in these units 10. The 250 A, 400 A and 600 A breakers 60 (FIGS. 11C, 12A, 12B) can be configured with interchangeable trip unit modules 60M such as shown in FIG. 12D. This trip unit module 60M shown in FIG. 12B is can be for the 600 A breaker. The access window 210 can be configured to allow access to this module. The trip unit modules 60M can have several configurations including, for example, TM (thermal-magnetic), being bimetal overload, ETU (electronic trip unit), and MCP (motor control protection) with only an instantaneous trip function.

(90) The trip unit module 60M is typically installed prior to the operating mechanism 40 and can be used only for adjustment access.

(91) The base 50 and cooperating slider 52 can be provided in different sizes with different length and width slots 50s to accommodate smaller and larger toggles or switches 90 associated with frames of different sizes/amperage rating. In some embodiments, when mounted in the MCC cabinet 100, the handles 20h can all substantially, if not totally, vertically align and have the same trip and/or ON/OFF positions.

(92) Similarly, an MCC cabinet 100 can be configured so the bucket units 10 all have the same handle 20h in the same position when mounted in the MCC cabinet 100 and the units 10 can have the same ON/OFF operative positions for both fuse and circuit breaker units 10F, 10C, respectively (FIG. 8).

(93) In some embodiments, as shown in FIGS. 11A-11C, 12A, 12B the guide rod 41, where used, can have a different length for some or all the different sizes of the circuit breakers 60.

(94) Each unit 10 with a circuit breaker 60 can have a mounting member 55 that has a rod support end 55e that extends inwardly away from the rotary handle 20h, away from the primary surface 55s as discussed above with respect to FIGS. 3 and 4, for example. FIGS. 11A-11C, 12A, and 12B show examples of the mounting members 55 which can have different curvilinear shapes along one long side 55c to form the open space 55o to accommodate the different size/arrangements of the levers 90.

(95) FIG. 8 illustrates an example of an MCC cabinet 100 that can support multiple units 10 of various types 10F, 10C and/or of various defined sizes, typically from between 1X to 12X. Thus, the units 10 can have a compact, visually aesthetic or clean appearance provided by aligned handles 20h irrespective of breaker or fuse type 10C, 10F and irrespective of frame size (breaker size). The same handle 20h can be configured to accommodate different size gears 40, sliders 52 and different size frames (different size toggles or switches 90) while providing an external similar aesthetic visual appearance with a common look of the OFF and ON positions of the handles 20h of units 10 of various types.

(96) The units 10 can have visual indicia 20v (FIG. 9A) that indicates whether it is a fuse switch or circuit breaker type unit 10F, 10C, respectively. The visual indicia can include a label, icon, color, and the like. In some embodiments, handles 20h can have visual indicia 20v that distinguishes the type and/or size (rating) of the unit. The visual indicia 20v can be provided with a stripe or different contrast colors for a protruding lever, knob, handle or T or the underlying portion of the handle that is externally visible.

(97) Embodiments of the invention provide a handle detent to assist in positioning the handle to the defined tripped configuration, typically with the handle in a vertical orientation. Embodiments of the invention can include one or more of the below claims presented in this section of the application as an alternate claim listing although not formally presented in a claim section of the application at filing of the original application.

(98) A bucket assembly with a trip assist spring that cooperates with a rack gear and operator slider that communicate with an internal circuit breaker to move the external rotary handle to a defined consistent orientation when the circuit breaker trips.

(99) A bucket assembly with an automated latch assembly integrated into the operator system.

(100) The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention. Therefore, it is to be understood that the foregoing is illustrative of the present invention and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the invention.