Rapid fusing device for self-adaptive overload protection

Abstract

The invention discloses a rapid fusing device for adaptive overload protection, and belongs to the technical field of overload protection. Comprising a multi-dimensional monitoring module used for collecting circuit current, environment temperature and humidity and equipment operation parameters in real time; the intelligent processing module is internally provided with a self-adaptive algorithm unit, and dynamically calculates and adjusts a multi-stage fusing threshold value based on real-time acquired data; the rapid execution module comprises a composite fusing structure and an arc extinguishing unit, and the composite fusing structure executes overload early warning, graded fusing or complete cutting action according to the multi-stage fusing threshold value; and the communication interaction module is used for realizing device state remote monitoring, threshold parameter remote configuration and fault information uploading. Parameters such as current, temperature and humidity are collected in real time through the multi-dimensional monitoring module, a multi-stage fusing threshold value is dynamically adjusted in combination with a self-adaptive algorithm of the intelligent processing module, the limitation that the threshold value of a traditional fuse is fixed is broken through, load fluctuation and environment change can be accurately adapted, and mistaken fusing or protection lag is avoided.

Description

Technical Field

[0001] The present invention relates to the technical field of overload protection, and more particularly to a fast-blow fuse device for adaptive overload protection. Background Art

[0002] With the rapid development of modern industry, new energy, and smart grids, power systems are placing higher demands on real-time, precise, and intelligent overload protection. Traditional fusing devices (such as fuses and circuit breakers) are no longer able to meet the protection needs of complex scenarios due to their fixed thresholds, delayed response, and lack of adaptive capabilities. For example, the high-voltage platforms of new energy vehicles (800V and above) require extremely high transient response for circuit protection. Traditional fuses lack the required breaking capacity under high current surges, which can easily lead to equipment damage or even safety accidents. Furthermore, in industrial power distribution systems, fixed-threshold circuit breakers cannot dynamically adapt to load fluctuations, potentially causing over-tripping or malfunctioning, impacting system stability.

[0003] Traditional fuses rely on the thermal effects of physical materials for protection. Their melting thresholds are determined by the properties of the fuse element and cannot be dynamically adjusted based on real-time load or environmental changes. For example, low-voltage fusible disconnect switches require manual replacement of the fuse link, resulting in high maintenance costs and slow response times, making them incapable of handling sudden short-circuit faults. To address this issue, we propose a fast-acting fuse device with adaptive overload protection. Summary of the Invention

[0004] The purpose of the present invention is to provide a fast-acting fuse device with adaptive overload protection to solve the problems raised in the above background technology: To achieve the above object, the present invention provides the following technical solutions: A fast-blow fuse device with adaptive overload protection, including a multi-dimensional monitoring module for real-time acquisition of circuit current, ambient temperature and humidity, and equipment operating parameters; The intelligent processing module is electrically connected to the multi-dimensional monitoring module and has a built-in adaptive algorithm unit that dynamically calculates and adjusts multi-level fuse thresholds based on real-time collected data; The fast execution module is electrically connected to the intelligent processing module and includes a composite fusing structure and an arc extinguishing unit. The composite fusing structure performs overload warning, graded fusing or complete disconnection according to the multi-level fusing threshold. The communication interaction module is connected to the intelligent processing module to realize remote monitoring of device status, remote configuration of threshold parameters and uploading of fault information.

[0005] Preferably, the multi-dimensional monitoring module includes: Hall current sensor, used to collect real-time current signals of the circuit; Temperature and humidity sensor, used to collect temperature and humidity data of the environment in which the device is located; Voltage sensor, used to monitor circuit input and output voltage; The sampling frequency of the multi-dimensional monitoring module is ≥10kHz, ensuring high-frequency updates of real-time data.

[0006] Preferably, the intelligent processing module includes: Microprocessor unit, using a microprocessor unit, using ARM Cortex-M4 and above architecture, integrated digital signal processing function; The adaptive algorithm unit includes: The environmental compensation algorithm module dynamically corrects the initial fuse threshold based on temperature and humidity data. The correction formula is: T′=T0×(1+k1ΔT+k2ΔH); where T0 is the initial threshold, ΔT is the temperature offset, ΔH is the humidity offset, and k 1~ k2 is the environmental impact coefficient; Multi-level circuit breaker strategy module, preset at least three levels of circuit breaker thresholds, each level of threshold meets T 预警阈值 <T 限流阈值 <T 切断阈值 , and match different action response times.

[0007] Preferably, the composite fuse structure of the fast execution module includes: Two conductive connection components are arranged opposite to each other and are electrically connected to achieve circuit conduction; The trigger mechanism is electrically connected to the intelligent processing module and drives the two conductive connection components to quickly separate after receiving the fuse instruction; The arc extinguishing units are arranged on both sides of the trigger mechanism.

[0008] Preferably, it further comprises a housing, wherein the conductive connection assembly, the trigger mechanism, and the arc extinguishing unit are all arranged in the housing, and an outer end of the conductive connection assembly extends to the outside of the housing; A connecting plate is sleeved on the conductive connecting assembly, and the connecting plate is slidably matched with the inner wall of the shell. A plurality of spring telescopic rods are provided near the outer surface of the connecting plate, and the other ends of the spring telescopic rods are connected to the inner wall of the shell; The trigger mechanism includes a mounting frame, an insulating sheet is provided on the inner side of the mounting frame, and an electromagnetic component is provided below the mounting frame; The arc extinguishing unit includes two sets of arc extinguishing corals, which are respectively arranged on both sides of the insulating sheet.

[0009] Preferably, the electromagnetic assembly includes a first electromagnet and a second electromagnet that are arranged opposite to each other, the first electromagnet is installed at the bottom of the mounting frame, and the second electromagnet is installed at the bottom of the shell.

[0010] Preferably, a limit frame is provided at the lower end of the mounting frame, the upper end of the limit frame is located above the first electromagnet, and the first electromagnet and the second electromagnet are both located between the inner walls on both sides of the limit frame.

[0011] Preferably, a conical guide sleeve is sleeved on one inner end of each of the two conductive connection components, and the inclined ends of the two conical guide sleeves are arranged opposite to each other.

[0012] Preferably, limit rails are provided on both sides of the mounting frame, the mounting frame and the limit rails are slidably matched, and the limit rails are installed on the inner wall of the shell.

[0013] Preferably, it also includes: A self-recovery module is electrically connected to the intelligent processing module, and automatically resets the fast execution module to a standby state when it detects that the fault is cleared and the real-time current is ≤ 0.8 times the rated current for 5 minutes; Human-machine interaction interface, integrated OLED display and buttons, supports local threshold configuration, historical fault query and manual test functions.

[0014] Compared with the prior art, the present invention has the following beneficial effects: (1) The present invention uses a multi-dimensional monitoring module to collect parameters such as current, temperature and humidity in real time, and combines the adaptive algorithm of the intelligent processing module to dynamically adjust the multi-level fuse threshold, breaking through the limitations of the fixed threshold of traditional fuses. It can accurately adapt to load fluctuations and environmental changes, avoid false melting or protection lag, and significantly improve the accuracy and reliability of circuit protection. The fast execution module adopts a composite fuse structure and arc extinguishing unit to achieve microsecond response, which can quickly cut off the circuit in extreme situations such as short circuits. Compared with traditional fuses, it greatly shortens the action time and effectively reduces the risk of equipment damage due to overcurrent. The multi-level fuse strategy module presets three-level thresholds of warning, current limiting, and cutting, and cooperates with different action logics (such as warning current limiting, partial melting, and complete cutting) to achieve hierarchical protection of the circuit, which can not only prevent minor faults from causing power outages of the entire system, but also quickly isolate in the event of serious faults to ensure the safety of core equipment.

[0015] (2) The present invention provides a connecting plate on the conductive connection assembly. By providing a spring telescopic rod on the connecting plate, when two conductive connection assemblies need to be connected, the restoring elastic force of the spring telescopic rod can be used to push the two conductive connection assemblies to quickly connect, while ensuring that the conductive connection assemblies always maintain a tight fit and a stable electrical connection. The provision of a conical guide sleeve facilitates the rapid insertion of the insulating sheet between the two conductive connection assemblies when the insulating sheet moves downward, thereby achieving a rapid disconnection of the circuit. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2 is a schematic cross-sectional view of the housing of the present invention; Figure 3 Schematic diagram of the internal structure of the housing of the present invention; Figure 4Schematic diagram of the trigger mechanism of the present invention.

[0017] Explanation of the numbers in the figure: 1. Conductive connection component; 2. Shell; 3. Mounting frame; 4. Insulating sheet; 5. Arc extinguishing coral; 6. First electromagnet; 7. Second electromagnet; 8. Limiting frame; 9. Conical guide sleeve; 10. Limiting rail; 11. Connecting plate; 12. Spring telescopic rod; 13. Base. DETAILED DESCRIPTION

[0018] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0019] Example: See also Figure 1-4 , a fast-acting fuse device with adaptive overload protection, including a multi-dimensional monitoring module for real-time acquisition of circuit current, ambient temperature and humidity, and equipment operating parameters; The intelligent processing module is electrically connected to the multi-dimensional monitoring module and has a built-in adaptive algorithm unit. It dynamically calculates and adjusts the multi-stage fusing thresholds based on real-time collected data. The multi-dimensional monitoring module collects parameters such as current, temperature and humidity in real time, and combines the adaptive algorithm of the intelligent processing module to dynamically adjust the multi-stage fusing thresholds. This breaks through the limitations of fixed thresholds of traditional fuses, can accurately adapt to load fluctuations and environmental changes, avoid false fusing or protection lag, and significantly improve the accuracy and reliability of circuit protection. The fast execution module is electrically connected to the intelligent processing module and includes a composite fuse structure and an arc extinguishing unit. The composite fuse structure performs overload warning, graded fusing or complete cut-off actions according to the multi-level fusing threshold. The fast execution module adopts a composite fuse structure and an arc extinguishing unit to achieve microsecond response, and can quickly cut off the circuit in extreme situations such as short circuits. Compared with traditional fuses, the action time is greatly shortened, effectively reducing the risk of equipment damage due to overcurrent.

[0020] The communication module connects to the intelligent processing module to enable remote monitoring of device status, remote configuration of threshold parameters, and uploading of fault information. Supporting multiple communication methods such as Bluetooth, Wi-Fi, and 4G, the communication module uploads device status and fault information in real time, facilitating remote monitoring and threshold configuration. Combined with the local operation capabilities of the human-machine interface, this significantly improves operation and maintenance efficiency and reduces manual inspection costs.

[0021] In this application, the multi-dimensional monitoring module includes: Hall current sensor, used to collect real-time current signals of the circuit; Temperature and humidity sensor, used to collect temperature and humidity data of the environment in which the device is located; Voltage sensor, used to monitor circuit input and output voltage; The sampling frequency of the multi-dimensional monitoring module is ≥10kHz, ensuring high-frequency updates of real-time data.

[0022] In this application, the intelligent processing module includes: Microprocessor unit, using a microprocessor unit, adopting ARM Cortex-M4 and above architecture, integrating digital signal processing DSP function; The adaptive algorithm unit includes: The environmental compensation algorithm module dynamically corrects the initial fuse threshold based on temperature and humidity data. The correction formula is: T′=T0×(1+k1ΔT+k2ΔH); where T0 is the initial threshold, ΔT is the temperature offset, ΔH is the humidity offset, and k 1~ k2 is the environmental impact coefficient; Multi-level circuit breaker strategy module, preset at least three levels of circuit breaker thresholds, each level of threshold meets T 预警阈值 <T 限流阈值 <T 切断阈值 , and matching different action response times. The environmental compensation algorithm automatically adjusts the fuse threshold based on temperature and humidity. Combined with the impact-resistant structure and flame-retardant housing design, the device ensures stable operation in extreme environments such as -40°C to +60°C and humidity ≤95% RH, broadening its application scenarios.

[0023] Specifically, the action logic of the multi-level circuit breaker strategy module is as follows: When the real-time current exceeds the warning threshold, a warning signal is sent through the communication interaction module, and the current limiting strategy is activated at the same time (such as limiting the output power to 80% of the rated value); When the real-time current exceeds the current limit threshold and the duration is ≥100ms, partial fusing is triggered (such as disconnecting non-critical load branches); When the real-time current exceeds the cut-off threshold or a short-circuit signal is detected, the electromagnetic trigger mechanism acts instantaneously, completely cuts off the main circuit and locks the state.

[0024] In this application, the communication interaction module includes: The Bluetooth 5.0 / Wi-Fi dual-mode communication unit supports the 2.4GHz / 5GHz frequency bands; the 4G / NB-IoT remote communication unit has a built-in eSIM card and supports the MQTT protocol; the status data uploaded in real time by the communication interaction module includes: real-time current, fuse threshold, number of operations, fault codes and environmental parameters.

[0025] In this application, the composite fuse structure of the fast execution module includes: Two conductive connection components 1 are arranged opposite to each other and are electrically connected to achieve circuit conduction; The trigger mechanism is electrically connected to the intelligent processing module and drives the two conductive connection components 1 to separate quickly after receiving the fuse instruction; The arc extinguishing units are arranged on both sides of the trigger mechanism.

[0026] In a possible embodiment, a state feedback sensor is further included to detect the opening and closing state of the fuse and feed back the signal to the intelligent processing module to realize closed-loop monitoring of the fuse state. The present application also includes a housing 2, in which the conductive connection component 1, the trigger mechanism, and the arc extinguishing unit are all arranged, and an outer end of the conductive connection component 1 extends to the outside of the housing 2; A connecting plate 11 is sleeved on the conductive connection component 1, and the connecting plate 11 is slidably matched with the inner wall of the shell 2. A plurality of spring telescopic rods 12 are provided near the outer surface of the connecting plate 11, and the other end of the spring telescopic rod 12 is connected to the inner wall of the shell 2; through the setting of the connecting plate 11 and the spring telescopic rod 12, after the two conductive connection components 1 are moved outward and disconnected, the spring telescopic rod 12 is compressed. When the two conductive connection components 1 need to be connected, the recovery elastic force of the spring telescopic rod 12 can be used to push the two conductive connection components 1 to be quickly connected, while ensuring that the conductive connection components 1 always remain tightly fitted to maintain a stable electrical connection.

[0027] The trigger mechanism includes a mounting frame 3, an insulating sheet 4 is provided on the inside of the mounting frame 3, and an electromagnetic component is provided under the mounting frame 3; the electromagnetic component is used to drive the insulating sheet 4 to move vertically, so that the insulating sheet 4 separates the two conductive connection components 1. When the circuit exceeds the preset value, the insulating sheet 4 is used to disconnect the two conductive connection components 1.

[0028] The arc extinguishing unit includes two sets of arc extinguishing shrouds 5, which are respectively arranged on both sides of the insulating sheet 4. The arrangement of the arc extinguishing shrouds 5 can limit the arc and help it extinguish quickly when the two conductive connection components 1 are disconnected, thereby avoiding or reducing the arc burning of the contacts of the conductive connection component 1, extending the service life of the contacts, and ensuring the normal operation of the electrical equipment.

[0029] In the present application, the electromagnetic assembly includes a first electromagnet 6 and a second electromagnet 7 arranged opposite to each other. The first electromagnet 6 is installed at the bottom of the mounting frame 3, and the second electromagnet 7 is installed at the bottom of the housing 2. When the two conductive connection components 1 need to be disconnected, the first electromagnet 6 and the second electromagnet 7 are energized respectively to generate opposite magnetism, thereby generating an attractive force between the two first electromagnets 6 and the second electromagnet 7. Since the second electromagnet 7 is fixed, the first electromagnet 6 will move downward. The first electromagnet 6 is fixed to the mounting frame 3, so the first electromagnet 6 will drive the mounting frame 3 to move downward, thereby driving the insulating sheet 4 and the arc extinguishing shroud 5 to move downward, so that the insulating sheet 4 and the arc extinguishing shroud 5 are inserted between the two conductive connection components 1, thereby disconnecting the circuit. When the two conductive connection components 1 need to be connected, the magnetism of the second electromagnet 7 is changed to make it have the same magnetism as the first electromagnet 6, thereby generating a repulsive force, causing the mounting frame 3 to move upward, so that the two conductive connection components 1 are restored to connection.

[0030] In this application, a limit frame 8 is provided at the lower end of the mounting frame 3, the upper end of the limit frame 8 is located above the first electromagnet 6, and the first electromagnet 6 and the second electromagnet 7 are both located between the inner walls on both sides of the limit frame 8. The limit frame 8 limits the movement trajectory of the first electromagnet 6.

[0031] In a possible embodiment, springs are provided at the bottom of both sides of the mounting frame 3 , and the springs are connected to the bottom of the housing 2 . The mounting frame 3 can move upward quickly by utilizing the restoring elastic force of the springs.

[0032] In this application, a conical guide sleeve 9 is provided at one end of the inner side of each of the two conductive connection components 1, and the inclined ends of the two conical guide sleeves 9 are arranged opposite to each other. The arrangement of the conical guide sleeve 9 facilitates the insertion of the insulating sheet 4 between the two conductive connection components 1 when it moves downward.

[0033] In this application, limiting rails 10 are provided on both sides of the mounting frame 3. The mounting frame 3 slides with the limiting rails 10. The limiting rails 10 are installed on the inner wall of the shell 2. The setting of the limiting rails 10 limits the moving trajectory of the mounting frame 3.

[0034] In a possible embodiment, it further includes: The self-recovery module is electrically connected to the intelligent processing module. When it detects that the fault has been cleared and the real-time current is ≤0.8 times the rated current for 5 minutes, it automatically resets the fast execution module to the standby state. The reset condition of the self-recovery module also includes the ambient temperature and humidity returning to the normal operating range (temperature -40°C to +60°C, humidity ≤95% RH without condensation) to avoid erroneous recovery in faulty or harsh environments. Human-machine interaction interface, integrated OLED display and buttons, supports local threshold configuration, historical fault query and manual test functions.

[0035] The above shows and describes the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions are merely preferred examples of the present invention and are not intended to limit the present invention. Various changes and improvements may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and improvements fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

Claims

1. A fast-blow fuse device with adaptive overload protection, characterized in that: include: Multi-dimensional monitoring module for real-time collection of circuit current, ambient temperature and humidity, and equipment operating parameters; An intelligent processing module, electrically connected to the multi-dimensional monitoring module, having a built-in adaptive algorithm unit, dynamically calculating and adjusting multi-level fuse thresholds based on real-time collected data; a fast execution module, electrically connected to the intelligent processing module, comprising a composite fuse structure and an arc extinguishing unit, wherein the composite fuse structure performs overload warning, graded fusing or complete disconnection according to the multi-stage fusing threshold; The communication interaction module is connected to the intelligent processing module for remote monitoring of the device status, remote configuration of threshold parameters and uploading of fault information.

2. The fast-blow fuse device for adaptive overload protection according to claim 1, characterized in that: The multi-dimensional monitoring module includes: Hall current sensor, used to collect real-time current signals of the circuit; Temperature and humidity sensor, used to collect temperature and humidity data of the environment in which the device is located; Voltage sensor, used to monitor circuit input and output voltage; The sampling frequency of the multi-dimensional monitoring module is ≥10kHz, ensuring high-frequency updates of real-time data.

3. The fast-blow fuse device for adaptive overload protection according to claim 1, characterized in that: The intelligent processing module includes: Microprocessor unit, using a microprocessor unit with ARM Cortex-M4 and above architecture and integrated digital signal processing (DSP) functions; The adaptive algorithm unit includes: The environmental compensation algorithm module dynamically corrects the initial fuse threshold based on temperature and humidity data. The correction formula is: T′=T0×(1+k1ΔT+k2ΔH); where T0 is the initial threshold, ΔT is the temperature offset, ΔH is the humidity offset, and k 1~ k2 is the environmental impact coefficient; Multi-level circuit breaker strategy module, preset at least three levels of circuit breaker thresholds, each level of threshold meets T 预警阈值 <T 限流阈值 <T 切断阈值 , and match different action response times.

4. The fast-blow fuse device for adaptive overload protection according to claim 1, characterized in that: The composite fuse structure of the fast execution module includes: Two conductive connection components (1) arranged opposite to each other, the two conductive connection components (1) are electrically connected to achieve circuit conduction; A trigger mechanism is electrically connected to the intelligent processing module and drives the two conductive connection components (1) to quickly separate after receiving a fuse instruction; The arc extinguishing units are arranged on both sides of the trigger mechanism.

5. The fast-blow fuse device for adaptive overload protection according to claim 4, characterized in that: It also includes a housing (2), wherein the conductive connection component (1), the trigger mechanism, and the arc extinguishing unit are all arranged in the housing (2), and an outer end of the conductive connection component (1) extends to the outside of the housing (2); The conductive connection assembly (1) is provided with a connecting plate (11), the connecting plate (11) is slidably engaged with the inner wall of the shell (2), and a plurality of spring telescopic rods (12) are provided near the outer surface of the connecting plate (11), and the other ends of the spring telescopic rods (12) are connected to the inner wall of the shell (2); The trigger mechanism comprises a mounting frame (3), an insulating sheet (4) is provided on the inner side of the mounting frame (3), and an electromagnetic component is provided below the mounting frame (3); The arc extinguishing unit comprises two groups of arc extinguishing chalices (5), and the two groups of arc extinguishing chalices (5) are respectively arranged on both sides of the insulating sheet (4).

6. The fast-blow fuse device for adaptive overload protection according to claim 5, characterized in that: The electromagnetic assembly comprises a first electromagnet (6) and a second electromagnet (7) which are arranged opposite to each other, wherein the first electromagnet (6) is mounted on the bottom of the mounting frame (3), and the second electromagnet (7) is mounted on the bottom of the housing (2).

7. The fast-blow fuse device for adaptive overload protection according to claim 6, characterized in that: A limiting frame (8) is provided at the lower end of the mounting frame (3), the upper end of the limiting frame (8) is located above the first electromagnet (6), and the first electromagnet (6) and the second electromagnet (7) are both located between the inner walls on both sides of the limiting frame (8).

8. The fast-blow fuse device for adaptive overload protection according to claim 5, characterized in that: A conical guide sleeve (9) is sleeved on one inner end of each of the two conductive connection components (1), and the inclined ends of the two conical guide sleeves (9) are arranged opposite to each other.

9. The fast-blow fuse device for adaptive overload protection according to claim 5, characterized in that: Limit rails (10) are provided on both sides of the mounting frame (3), the mounting frame (3) and the limit rails (10) are slidably matched, and the limit rails (10) are installed on the inner wall of the shell (2).

10. The fast-blow fuse device for adaptive overload protection according to claim 1, characterized in that: Also includes: A self-recovery module, electrically connected to the intelligent processing module, automatically resetting the fast execution module to a standby state when detecting that the fault is cleared and the real-time current is ≤ 0.8 times the rated current for 5 minutes; Human-machine interaction interface, integrated OLED display and buttons, supports local threshold configuration, historical fault query and manual test functions.

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