Results in Engineering 22 (2024) 102238

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Computational study of the effect of the number of splitter plates

considering blow-out coil voltage in arc chamber of moulded case
circuit breaker
Pravin Katare a, b, *, Meenakshi Tumane c, Ajay Ingle d, Prashant Thakre c, Choon Kit Chan e
a
Research Fellow, INTI International University, Nilai, Negeri Sembilan, Malaysia
b
Department of Mechanical Engineering, Marathwada Mitra Mandal’s College of Engineering, Pune, India
c
Department of Electrical Engineering, Tulsiramji Gaikwad Patil College of Engineering and Technology, Nagpur, India
d
Department of Electrical Engineering, Marathwada Mitra Mandal’s College of Engineering, Pune, India
e
Faculty of Engineering and Quantity Surveying, INTI International University, Persiaran Perdana BBN, 71800, Nilai, Negeri Sembilan, Malaysia

A R T I C L E I N F O A B S T R A C T

Keywords: To attain current limitation in low voltage circuit breaker (LVCB) apparatus, the approach involves elevating the
Reliable electricity arc voltage. This improvement is realised primarily in the arc chamber’s splitter plates because of the higher drop
Smart micro-grid voltages at the anode and cathode sheath areas. One of the most crucial ways to better describe arc behaviour in
Circuit breaker
LVCB is to account for voltage in the vicinity of the electrodes. To reduce the current, LVCB works by raising the
Moulded case
arc voltage. Voltage is raised in several ways, including increase in losses, elongating the arc, and multiplying the
Splitter plates
Blow out coil voltage splitter plates. The aim of this research is to present readers with an additional technique for analysing electric
arcs in moulded case circuit breaker (MCCB) which is one of the types of low voltage circuit breakers which is
used to prevent overload and short circuit in electrical systems. 2-D model of MCCB with splitter plate has been
developed and simulated using ANSYS software. Simulation results with the effect of increase in the number of
Splitter plates considering blow-out coil voltage in arc chamber has been discussed. Modelling and simulation
technologies provide the mechanism through which this understanding may be attained.

1. Introduction overload and short circuit in electrical systems. MCCBs are versatile
circuit breakers that may be programmed to trip at a variety of voltages
A circuit breaker is a switch that may be operated manually or and frequencies. Their current rating goes up to 2500 A. These circuit
automatically to prevent damage to an electrical circuit in the event of breakers are substituted for MCBs in large-scale PV systems to provide
an overload or short circuit. High, medium, and low voltage circuit isolation and reliability.
breakers are the common designations for the three categories of circuit Zhengjun Liu and Li Wang [1] were compared CEA curves over a
breaker used in various electrical installations. In electric power net­ range of supply voltages and power factors to determine the impact of
works, Low Voltage Circuit Breakers (LVCBs) serve a crucial role in arc voltage on breaking current, and an arc erosion model was devel­
ensuring the safety of electrical equipment and humans by regulating oped to account for arc voltage. The LVCB’s electrical life was modelled
the flow of electricity. A safety mechanism such as a moulded case cir­ using Monte Carlo analysis to determine the distribution of electrical life
cuit breaker, which operates in low voltage conditions, serves to across various operational scenarios. From the accumulated informa­
disconnect electrical power during instances of overloads or short cir­ tion, it tends to be induced that the electrical existence of the LVCB
cuits, ensuring protection. Whenever a defect or overcurrent scenario is decreases as the stockpile voltage builds, meanwhile keeping the power
detected, power is immediately shut off, protecting the electrical system factor steady. For the mix of two boundaries, explicitly (220 V, 0.95) and
from potential harm. The MCCB is a versatile device that may be utilised (660 V, 0.65), the divergence in electrical life for the LVCB can reach up
in both low-voltage and high-voltage systems. A moulded case circuit to 21.4 %. The technique addresses the issue of poor accuracy in life
breaker (MCCB) is a kind of electrical protection device used to prevent evaluation of LVCBs in a variety of operational settings. In power

* Corresponding author. Research Fellow, INTI International University, Nilai, Negeri Sembilan, Malaysia.
E-mail address: pravinkatare10@[Link] (P. Katare).

[Link]
Received 4 March 2024; Received in revised form 13 April 2024; Accepted 6 May 2024
Available online 11 May 2024
2590-1230/© 2024 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY license ([Link]
P. Katare et al. Results in Engineering 22 (2024) 102238

distribution systems, it facilitates more effective LVCB overhaul and current (AC) is the most useful approach. However, the material that
maintenance. Arc erosion takes place each time the circuit breaker is was studied did not clearly differentiate between the uses of DC and AC
switched both on and off. The electric arc causes permanent damage to power networks and the various circuit breakers. The DC circuit brea­
the contact’s surface, which manifests as permanent deformation and kers, which include mechanical, solid-state, and hybrid breakers, are
the evaporation of material. As the electric arc temperature increases, used for the protection of electrical equipment in both residential and
there is a corresponding increase in material loss on the contact surface commercial settings that utilise DC current, most notably in high-voltage
of the circuit breaker. This research introduces a methodology for DC (HVDC) network systems. Alternating current (AC) circuit breakers
examining and assessing the arc extinguishing chamber of a circuit may be split into two distinct categories: high voltage and low voltage.
breaker, considering the condition of the arc contact, the nozzle, and the Miniature and moulded case circuit breakers are the building blocks of
SF6 gas. These three critical parameters significantly influence the the low voltage CB, both of which find widespread use in residential and
electrical longevity of the chamber. commercial settings. High voltage circuit breakers may be further cat­
Xiaopo Mao [2] presented the study of gradual accumulation of egorised as either oil-based or oil-free. The oil-free CB is constructed
breaking current leads to an increase in average contact resistance and a from circuit breakers that use air, vacuum, and sulphur hexafluoride
decrease in the effective contact displacement between arc contacts. (SF6) instead of oil. High voltage circuit breakers are usually utilised in
When the kinetic energy of the breaking process is increased, the high voltage and additional high voltage transmission frameworks to
effective contact displacement drops rapidly. If carbonaceous chemicals guarantee the assurance of force framework gear and electrical ma­
are introduced into the system, the CF4 concentration may be utilised to chinery. This usage is aimed at safeguarding the integrity of the elec­
characterise the discharge decomposition degree of SF6 as well as the trical infrastructure. Young-Maan Cho and Kun-A Lee [6] was
discharge ablation on the surface of the nozzle insulating material. The performed a splitter plate swap experiment, and the circuit breaker’s
results of the experiment indicated that a concentration of 600 l/l of CF4 dielectric recovery voltage measuring system employed to enhance the
is an appropriate benchmark for determining whether the arc extin­ interrupt performance against re-ignition. Modifying the splitter plate in
guishing chamber requires servicing. The arc extinguishing chamber of two ways—by switching up the material and the quantity of its bottom
other SF6 circuit breakers may also be evaluated for working condition plates—permits for two distinct tests to be conducted. The thermal
using this procedure. Qiwen He [Link]. [3] studied the shift in energy conductance is considered while analysing the potential impact of a
distribution because of gas arc extinguishing using a computer simula­ splitter plate material change. Both the number of plates and the dis­
tion. The extinction of a gas arc in a two-dimensional axisymmetric tance between them in a splitter plate’s bottom half are adaptable. Re­
module was modelled using energy balance theories. Subsequent testing sults from an experiment measuring the dielectric recovery voltage
results validated the initial simulation outcomes. Consequently, a testing demonstrate that copper plates perform best, with a value that is 102.1
platform for lightning impulse current, compliant with the IEC standard, % higher than normal, while aluminium plates perform somewhat
was established. Curves were generated by utilizing both experimental lower, at 59.8 % higher than usual, in the first phase. The warm con­
data and simulation calculations, enabling a comparison of the two ductivity of the three terminal materials is directly proportional to these
datasets across a voltage range spanning from 20 kV to 70 kV. The ca­ enhancements. Increases of 84.5 % and 36.1 %, respectively, are shown
pacity of long-gap gas arcs to self-extinguish decreases with increasing in the first phase at the point when the quantity of lower plates on the
voltage and increases with increasing distance, as shown by both splitter plate is changed from the standard design of 7 plates. A large
simulation and experiment. Moreover, when operating within the number of plates obviously prevents heat from escaping. As expected
acceptable range of conditions, enhancing the chamber’s length, rather from research focusing on early-stage performance enhancement, the
than reducing it, contributes to a more efficient and rapid arc extin­ results show little variation in the latter stages. This agrees with what
guishment. While renewable energy sources like wind and solar power was found in the lab. The strength of dielectric recovery after a
can help cut down on carbon emissions and bring us closer to our low-voltage circuit breaker is experimentally established. Researchers
"emission peak and carbon neutral" goal, having so much of it available hope this will aid their efforts to enhance circuit breakers’ dielectric
to us at once will encourage a change in the structure of the electric recovery capabilities. Khaled Alharbi et. al [7] provided a report about
power grid. The incorporation of artificial intelligence into electricity circuit breakers protection devices, such as Circuit breakers, which cut
infrastructure is a future trend that cannot be stopped. In a power dis­ off electricity during faults, are essential to any electrical system to
tribution system, miniature circuit breakers serve as essential protective prevent damage from harmful fault currents.
components. Therefore, the power IoT system mandates certain fea­ J. Lua [Link]. [8] used experimental and simulated methods to
tures, such as superior breaking performance, remote control capabil­ investigate the dynamics of arc voltage using a simple design made up of
ities, and a digital sensing platform. Jianning Yin et al. [4] investigated two rails and either one or two splitter plates. To represent the arc
remote control technology, digital monitoring of operational status, and motion and arc splitting, a single 3D magneto hydrodynamic model was
advanced AC and DC general switching technology. To improve the created. Experiments were conducted to check for discrepancies be­
capability to interrupt a short circuit, we introduced an innovative DC tween the model and the data. A plasma chamber powered by a filament,
non-polar breaking technique. Utilizing these previously mentioned which possesses plasma attributes that correspond to those found in the
methods, we successfully developed a prototype, which underwent arc chamber of NBI ion sources, has been successfully constructed. B.J.
testing for its ability to interrupt a DC 1000 V/10 kA short circuit. Crowley [9] presented the results of early research on the most preva­
Expanding upon this groundwork, we have devised an intelligent circuit lent failure. The disappointment system saw during helium procedure on
breaker incorporating functionalities such as remote on/off control, DIII-D outcomes from the electrical breakdown of the protecting mate­
constant temperature checking, energy utilization following, and rial that isolates the fiber plates from the anode. Possible solutions are
shortcoming location and cautioning. Moreover, we have laid out a presented, and the flaw is shown using a benchtop experiment that
computerized condition observing and controller program. This shares crucial characteristics with the DIII-D NBI ion source. J
research carries significant importance for advancing the field of the Quéméneur et al. [10] investigated arc behaviour in basic low-voltage
Internet of Things (IoT) in the realm of power, encompassing both circuit breaker designs. Fast camera and a magneto hydrodynamic
theoretical and practical dimensions. P. I. Obi [Link]. [5] provided an model are used to explore both experimental and theoretical techniques.
overview of how circuit breakers (CB) may be used in the distribution Two theoretical approaches, the Mean Electrical Conductivity Method
and transmission of electrical power. Circuit breakers may be broadly (MECM) and the Global Current Resolution Method (GCRM), have been
categorised as either direct current (DC) or alternating current (AC) devised to describe the arc’s motion. The two models provide findings
devices. It demonstrates that categorising circuit breakers according to that accord well with the data from experiments. Although the GRCM is
whether they are designed to handle direct current (DC) or alternating more difficult to build in complicated geometries, it does a better job of

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P. Katare et al. Results in Engineering 22 (2024) 102238

Fig. 1. Simple 2-D model of arc chamber.

representing stagnation periods than the MECM, and it can be imple­ such as circuit quantities, distances, and depths.
mented more quickly. As can be seen from the outcomes, the exhaust
description is equally crucial to the arc’s behaviour. A. Iturregi [Link]. 2. Finite element method
[11] was developed the simulation model with the help of the com­
mercial programme ANSYS CFX, which implements the finite-volume In the realm of engineering problem-solving, the finite element
approach. The model’s three-dimensional geometry is composed of method (FEM), which is also recognized as finite element analysis (FEA),
densely structured hexahedral meshes, the P1 radiation model, and stands as a computational technique employed to produce an approxi­
thermal plasma properties, along with transport coefficients of hot air mation for addressing a boundary value problem as [15]. In mathe­
characteristics. The model is used to mimic an LVCB’s operation at 50, matics, a boundary value issue is posed when one or more dependent
100, and 200 A with a variety of arc ignition positions and splitter plate variables are required to fulfil a differential equation in all regions of a
configurations. When the number of splitter plates is increased, the arc given domain of independent variables, as well as meet certain re­
lengthens and the arc voltage rises. Increased expansion and diffusion at quirements on the domain’s border. issues with boundaries are some­
high input currents and quicker arcs at high ignition zones have also times known as field issues. In most cases, the field is meant to represent
been achieved. The accuracy of these simulation outcomes has been a real-world structure as the focus of investigation. As the variables
confirmed. The numerical inaccuracies have been determined using the controlled by the differential equation, the field variables are of rele­
lattice intermingling record and the Courant-Friedrichs-Lewis number, vance. Boundary conditions are the values of the field variables (or
and the confirmation procedure is complete. The validation procedure associated variables, such derivatives), as defined at the field’s borders.
was completed by doing actual practical tests in the lab, demonstrating
that the simulation model yields findings that are very comparable to
those seen in real life. Three of the most popular brands of circuit 2.1. Element attributes
breakers had their short circuit performance tested experimentally.
Circuit breakers with current ratings of 16 A, 20 A, 25 A, and 32 A from The characteristics of the finite element model depend upon element
time-current curve classes B and C were utilised. Based on the findings attributes. These attributes must be set before meshing the solid models.
from experimentation by Aleksejs Gedzurs et. al. [12] it is clear that There are three main element attributes that are given below.
thorough analysis is required before using circuit breakers from various
manufacturers in a series connection to ensure selectivity and the • Element type
appropriate functioning of the safety system. • Real constants
A. Iturregi [13] explained the electric arc phenomenon in LVCBs • Material properties
and outlined the mathematical, physical, and software requirements for
modelling and simulating the arc. Yi Wu [Link]. [14] was conducted the Selection of appropriate element type is an important step in the
three-dimensional modelling of the arc chamber in a low-voltage circuit analysis process because the accuracy of result mainly depends on it.
breaker, wherein the electric and magnetic fields were computed. Real constants are used to define the geometric properties of those ele­
Simultaneously, the electric potential and flow thickness of the bend ments that are not defined by the element geometry (node locations).
plasma were ascertained, considering the plasma flow field influenced The area, thickness, internal and external diameters, etc., are all ex­
predominantly by temperature. Furthermore, we employed the potential amples of real constants. It is also necessary to define element type
vector technique to ascertain the attractive motion thickness and Lor­ before applying real constants.
entz force impacted by the splitter plates. I. Diahovchenko et al. [15] In the process of analysis, it is necessary to provide material char­
presented a fuzzy logic-based method to estimate the reliability of acteristics to the geometry that was either built or imported. For
high-voltage SF6 circuit breakers and to set priorities for the mainte­ example, permittivity, permeability, resistivity, density, specific heat,
nance schedule. In this method a realistic mathematical model was thermal conductivity, emissivity, friction coefficient, and so on. Based
combined with a fuzzy inference system, and its effectiveness was tested on the analysis type and variation in material properties, it can be linear
with a MATLAB-Simulink model. Based on the simulation results, a or non-linear. Linear material qualities are those that do not change with
preventive maintenance strategy for high-voltage SF6 circuit breakers time or space, such as those that are constant or temperature dependant
proposed for particular operational states and conditions. R.M. Arias in three dimensions. Nonlinear characteristics are those of a material
Velasquez [16] employed advanced finite element methods with that change over time and space, such as magnetic field data, stress-
Composition, Environmental, Structure, and Mechanism (CESM) and strain data, etc.
mathematical modeling to enhance existing procedures defined by in­
ternational standards like IEC 60287, 60502, and 60228. The primary 3. Result and discussion
parameter of interest was the thermal influence of subterranean XLPE
(cross-linked polyethylene) current capacity, considering various factors Modelling and simulation of arc chamber for 2-D model has been
described in this paper. Electric, potential analysis is carried out on 2-D

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P. Katare et al. Results in Engineering 22 (2024) 102238

Table 1 3.1. Simple 2-D model of arc chamber and its limitations
Material properties of MCCB components.
Sr. Part of MCCB Material Used Permeability Permittivity Fig. 1 shows the simple 2-D model explained in paper [14]. In this
No figure the cathode present at the top of chamber represents the fixed
1 Arc splitter plates Ferromagnetic 8.1 × 10− 4
10 contact and anode at the bottom of chamber represents the moving
Materials contact. The two ferromagnetic splitter plates are present at the right
2 Fixed and Moving Silver alloy 1.2566 × 1 side of the arc chamber. The space between anode, cathode and fixed
Contacts 10− 6 contact is filled with natural air.
6
3 Blow out coil Copper 1.27 × 10− 1
4 Air – 1 8.85 ×
The arc chamber model shown in Fig. 1 is very compact due to which
10− 12 it is very difficult to apply the load conditions. In this arc chamber
model, the arc splitter plates are restricted to two due to the compact
size of arc chamber.
model of arc chamber. MCCB ratings considered as.

• Operating voltage 500 V 3.2. Properties of arc chamber components

• Number of poles 3
• Rated current 100–800 A This MCCB has breaking capacity of 65 kA at 500 V. At the very left
• Breaking current 65 kA of the diagram is the cathode, which is a stationary contact, and at the
• Breakers operating time 1 ms very right is the anode, which represents a mobile one. Both the top and
• Rated frequency 50 Hz bottom of the arc chamber have two blowout coils and four arc splitter
plates. Connectors, splitter plates, and coils all have natural air between
them. The electrolytic copper or silver alloy is used for both the fixed

Fig. 2. 2-D mesh model with load voltage.

Fig. 3. Electric potential distribution without blowout coil effect.

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P. Katare et al. Results in Engineering 22 (2024) 102238

Fig. 4. Electric potential distribution with blowout coil effect.

Fig. 5. Time verses voltage graph at center node four splitter plates arc chamber.

and movable contacts. Both the splitter plates and the blowout coils are 3.3. Blow out coil voltage effect on arc elongation
built of ferromagnetic materials, whereas copper is used for the latter.
Table 1at voltage at center node increases 1 shows material properties of The simulations are carried out with and without blowout coil
MCCB. voltage to find out the electrical potential distribution within the arc
An electric arc is formed when current flows from a stationary con­ chamber. The distribution of electric potential beneath a defect is seen in
tact to a moving one during the fault. Potential of 500 V developed at Fig. 3. The moving contact receives no potential whereas the stationary
cathode (fixed) contact and ground (zero) potential developed at anode. contact receives 500 V. The voltage on the blowout coil is maintained at
2-D mesh arc chamber MCCB model with load voltage is shown in Fig. 2. a constant 0 V.

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P. Katare et al. Results in Engineering 22 (2024) 102238

Fig. 6. Graph of blow out coil verses potential at third splitter plate.

Fig. 7. Potential distribution with ten splitter plates.

The electric potential distribution during a fault state is seen in Fig. 4. the voltage at the specified node is also increases linearly.
Initially 20 V is applied to blowout coils. Voltage to blow out coils is varied and its effect on arc potential at the
In this scenario, the electrical arc is characterized by the distribution third splitter plate is observed. Different blowout coils voltage verses
of electric potential within the chamber. Utilizing the magnetic field potential at third splitter plate is shown in Fig. 6. As the blow out coil
generated by the blowout coils, the electric arc is guided toward the arc voltage is increased the potential at the third splitter plate varies line­
splitter [Link] electric potential distribution during a fault is seen in arly. This demonstrates the arc’s rapid approach to the splitter plates
Fig. 4. Fig. 4 shows a far more rapid drop in electric potential from the and subsequent extinguishment.
stationary contact to the moving contact than Fig. 3, which shows the
same phenomenon without the application of a blowout coil voltage.
After increasing the blowout coil voltage the electric potential at center 3.4. Effect of number of splitter plates on arc elongation
node goes on increasing, this shows fast extinction of electric arc.
The circuit breaker fault clearing time considered for analysis is 1 ms. The optimum numbers of splitter plates are calculated from
The voltage at ceneter node is observed for different interval of time Ref. [14].
(0.0001sec–0.001sec) in 10 steps. Fig. 5 shows that as the time increases
Ua = N x UAC + [L - (N x e)] x UL (1)

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P. Katare et al. Results in Engineering 22 (2024) 102238

Fig. 8. Time verses voltage graph at Center node with ten splitter plates.

Fig. 9. Graph of number of splitter plates verses potential at end splitter plate.

Where Ua = stabilized arc voltage = 500 V. plates increases the arc get elongated much faster. Time verses voltage
N = number of splitter plates. graph at center node is shown in Fig. 8 Fig. It shows that voltage at
UAC = Anode - cathode voltage at each elementary arc = 30 V. center node increases from starting time (0.0001sec) to end time
UL = Arc voltage per centimeter = 60 V/cm (0.001sec). The increase voltage at each interval of time shows the fast
e = plate width = 2 mm. extinction of arc as compare to the arc chamber with less number of arc
L = length of arc chamber = 55 mm. splitter plates.
As per the specification of selected model, using equation (1) the The maximum nodal voltage at center node in case of four arc splitter
number of spliter plates caluculated as ten. The circuit breaker model plate at the end time is 64 V whereas in case of ten splitter splitter plate
with ten splitter plates is developed. maximum nodal voltage is 73 V. This shows that as number of arc
Fig. 7 shows the potential distribution within the arc chamber con­ splitter plate increases the voltage at specified node also increases
sisting of ten arc splitter plates. This shows that as the number of splitter linearly.

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P. Katare et al. Results in Engineering 22 (2024) 102238

Table 2 interests or personal relationships that could have appeared to influence

Comparison ofoperating parameters. the work reported in this paper.
Sr. Parameters Current methods Proposed methods
No. Data availability
1 Number of splitter 4 10
plates No data was used for the research described in the article.
2 Blow out coil No blow out coil Blow out coil voltage
voltage voltage applied (20v) References

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Declaration of competing interest (2023) 101552.

The authors declare that they have no known competing financial