Intelligent dc connection line with overcurrent protection

Abstract

This invention discloses an intelligent DC connection cable with overcurrent protection, belonging to the field of DC connection cable technology. It includes a cable with a positive and a negative core wire. A measuring unit is installed on the cable to monitor the current value of the DC line. Both the positive and negative core wires have a current-breaking unit, which includes an insulating and heat-conducting cylinder. Conductive terminals are symmetrically fixed on the insulating and heat-conducting cylinder, and conductive rods are slidably mounted on the conductive terminals. Utilizing the anomalous properties of bismuth-based alloys—solidification expansion and melting contraction—the solid state pushes the contacts to engage and conduct. During overcurrent, the melted volume shrinks, and the spring energy releases, causing the contacts to separate and disconnect the power. Independent current-breaking units are installed on both the positive and negative core wires, and both poles disconnect synchronously during overcurrent, achieving complete physical isolation between the load and the power supply. This completely eliminates the residual leakage path in the negative circuit under single-pole protection and prevents secondary safety accidents caused by insulation damage, reverse polarity, etc.

Description

Technical Field

[0001] This invention relates to the field of DC connection technology, and in particular to intelligent DC connection with overcurrent protection. Background Technology

[0002] In existing DC power supply systems, the DC connection line serves as a critical power transmission channel between the power source and the load, and its overcurrent protection capability directly affects the safety and reliability of equipment operation. Existing overcurrent protection technologies include two main types: one is fuse-based protection, which utilizes the Joule heating of a molten metal element to permanently disconnect the circuit when the current is too high. However, this is a one-time protection element, requiring manual replacement after a failure, which can cause prolonged equipment downtime in continuous operation or field scenarios, and it cannot achieve automatic recovery after fault resolution. The other type is resettable protection based on electronic switches. While it can monitor overcurrent and automatically recover, its normal operation requires continuous power consumption, resulting in conduction voltage drop and static power consumption issues. Furthermore, electronic components have poor tolerance to harsh environments such as high temperature, high humidity, and vibration, making reliability difficult to guarantee in industrial and heavy equipment applications. Therefore, this invention provides an intelligent DC connection line with overcurrent protection. Summary of the Invention

[0003] This invention addresses the shortcomings of existing technologies by providing an intelligent DC connection line with overcurrent protection, overcoming the problems of unresettable traditional fuses and high static power consumption and poor reliability of electronic switches.

[0004] To achieve the above objectives, the present invention provides the following technical solution: an intelligent DC connection line with overcurrent protection, comprising a cable, a positive core wire and a negative core wire disposed within the cable, a measuring unit disposed on the cable for monitoring the current value of the DC line, a current interruption unit disposed on both the positive and negative core wires, the current interruption unit comprising an insulating heat-conducting cylinder, conductive terminals symmetrically fixedly disposed on the insulating heat-conducting cylinder, conductive slide rods slidably mounted on the conductive terminals, circular conductive sliders fixedly disposed on the conductive slide rods, a bismuth-based alloy block disposed between the conductive slide rod and the corresponding circular conductive slider, a conductive contact block fixedly disposed at the end of the conductive slide rod, the bismuth-based alloy block being used to control the engagement of the corresponding two conductive contact blocks, the current interruption unit being used to control the connection of the corresponding positive and negative core wires, and heat dissipation units symmetrically disposed on the insulating heat-conducting cylinder, each heat dissipation unit comprising a linkage gear ring rotatably mounted on the insulating heat-conducting cylinder, an annular impeller fixedly disposed inside the linkage gear ring, the heat dissipation unit being used to cool the bismuth-based alloy block.

[0005] Furthermore, a power plug and a load plug are respectively provided at both ends of the cable, the measuring unit is located between the current-cutting unit and the power plug, and an insulation layer is provided on both the positive and negative core wires.

[0006] Furthermore, the cable is equipped with two protective housings, each of which is movably fitted with a cover housing. Trapezoidal limit blocks and clearance grooves are symmetrically arranged between the cover housings and the protective housings. The trapezoidal limit blocks and clearance grooves are used to lock the cover housings and the corresponding insulation layers.

[0007] Furthermore, the measurement unit includes a sampling resistor, a differential amplifier, a microcontroller, and an analog-to-digital converter. The sampling resistor is connected in series on the positive core wire, and the sampling resistor, differential amplifier, microcontroller, and analog-to-digital converter are fixedly installed inside the corresponding cover housing.

[0008] Furthermore, symmetrical support circular plates are fixedly installed on the protective shell, and the two ends of the insulating heat-conducting cylinder are fixedly connected to the corresponding support circular plates respectively. The conductive terminals are connected to the corresponding positive and negative core wires respectively, and an insulating spring is installed between the two circular conductive sliders on the same insulating heat-conducting cylinder.

[0009] Furthermore, when the bismuth-based alloy block is in a normal solidified state, the two circular conductive sliders corresponding to the same insulating and heat-conducting cylinder are in a joined state, so that the corresponding positive or negative electrode core wire is in a conductive state; when the bismuth-based alloy block is in an overcurrent heated liquefaction state, the two circular conductive sliders corresponding to the same insulating and heat-conducting cylinder are disjointed, so that the corresponding positive or negative electrode core wire is in a non-conductive state.

[0010] Furthermore, the insulating heat-conducting cylinder is symmetrically provided with guide cylinders, and there is an annular guide chamber between the guide cylinder and the corresponding insulating heat-conducting cylinder. The annular guide chamber is used to accommodate the airflow movement generated by the annular impeller. The guide cylinders are respectively fixedly installed on the corresponding support circular plates. A guide circular plate is also fixedly installed in the middle position of the insulating heat-conducting cylinder. Arc-shaped chamfer blocks are provided on both sides of the guide circular plate and between the insulating heat-conducting cylinder.

[0011] Furthermore, a linkage assembly is provided between the two annular impellers on the same insulating heat-conducting cylinder. Each linkage assembly includes a drive shaft, two linkage gears, and two linkage gear rings.

[0012] Furthermore, fan-shaped heat dissipation holes are evenly arranged on the support circular plate, and strip-shaped heat dissipation holes are evenly arranged on the cover shell.

[0013] The beneficial effects of this invention compared with the prior art are as follows: (1) This invention utilizes the anomalous characteristics of solidification expansion and melting contraction of bismuth-based alloys. When solid, it pushes the contacts to engage and conduct. After melting due to overcurrent, the volume shrinks, and the spring energy is released to separate the contacts and cut off the power. (2) This invention sets independent current-breaking units on both the positive and negative core wires. When there is an overcurrent, both poles disconnect synchronously, achieving complete physical isolation between the load and the power supply. It completely eliminates the residual leakage path in the negative circuit under single-pole protection and prevents secondary safety accidents caused by insulation damage, reverse polarity, etc. (3) This invention sets a heat dissipation unit, which can controllably restore conduction after the fault is cleared. It can achieve overcurrent protection and avoid the inconvenience of replacing traditional fuses after one use. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0015] Figure 2 This is a schematic diagram of the structure of the protective shell of the present invention.

[0016] Figure 3 This is a schematic diagram of the internal structure of the protective shell of the present invention.

[0017] Figure 4 for Figure 3 A magnified view of a portion of point A in the middle.

[0018] Figure 5 This is a schematic diagram of the structure inside the housing of the present invention.

[0019] Figure 6 This is a schematic diagram of the structure of the conductive slide bar of the present invention.

[0020] Figure 7 This is a front view of the structure at the conductive slide bar of the present invention.

[0021] Figure 8 This is a schematic diagram of the internal structure of the insulating and heat-conducting cylinder of the present invention.

[0022] Figure 9 This is a front view of the internal structure of the insulating and heat-conducting cylinder of the present invention.

[0023] Figure 10 This is a schematic diagram of the structure of the insulating and heat-conducting cylinder of the present invention.

[0024] Figure 11 for Figure 10 A magnified view of a portion of point B in the middle.

[0025] Reference numerals: 101-Cable; 102-Power plug; 103-Load plug; 104-Protective housing; 105-Insulation layer; 106-Cover housing; 107-Conductive slide bar; 108-Positive core wire; 109-Negative core wire; 110-Conductive contact block; 111-Baffle plate; 112-Conductive terminal; 113-Guide tube; 114-Trapezoidal limit block; 115-Relieving groove; 116-Cooling motor; 117-Strip-shaped heat dissipation hole; 118- Sampling resistor; 119-Differential amplifier; 120-Microcontroller; 121-Analog-to-digital converter; 122-Drive shaft; 123-Insulated heat-conducting cylinder; 124-Flow guide plate; 125-Chamfered arc block; 126-Support plate; 127-Linkage gear; 128-Linkage gear ring; 129-Annular impeller; 130-Fan-shaped heat dissipation hole; 131-Bismuth-based alloy block; 132-Circular conductive slider; 133-Insulating spring; 134-Annular flow guide chamber. Detailed Implementation

[0026] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0027] Example: Reference Figures 1-11 The intelligent DC connection cable with overcurrent protection includes a cable 101. A power plug 102 and a load plug 103 are respectively provided at both ends of the cable 101. A positive core wire 108 and a negative core wire 109 are provided inside the cable 101. An insulation layer 105 is provided on both the positive core wire 108 and the negative core wire 109. A measuring unit is provided on the cable 101. The measuring unit is located between the current-breaking unit and the power plug 102. The measuring unit is used to monitor the current value of the DC line.

[0028] The measurement unit includes a sampling resistor 118, a differential amplifier 119, a microcontroller 120, and an analog-to-digital converter 121. The sampling resistor 118 is connected in series with the positive core wire 108. Two protective housings 104 are also provided on the cable 101, positioned opposite each other. Each protective housing 104 has a movable cover housing 106. Trapezoidal limit blocks 114 and clearance grooves 115 are symmetrically arranged between the cover housings 106 and the protective housings 104. The trapezoidal limit blocks 114 and clearance grooves 115 are used to lock the cover housing 106 to the corresponding insulation layer 105. The sampling resistor 118, differential amplifier 119, microcontroller 120, and analog-to-digital converter 121 are fixedly installed inside the corresponding cover housing 106. The differential amplifier 119 measures the voltage across the sampling resistor 118, and the microcontroller 120 and analog-to-digital converter 121 work together to obtain the current value of the DC line.

[0029] The trapezoidal limiting block 114 is fixedly installed inside the cover housing 106, and the clearance groove 115 is installed on the protective housing 104. When the trapezoidal limiting block 114 and the corresponding clearance groove 115 are engaged, the cover housing 106 and the corresponding protective housing 104 are in a fixed state. When it is necessary to remove the cover housing 106 from the protective housing 104, press the trapezoidal limiting block 114 on the cover housing 106, so that the trapezoidal limiting block 114 can be pulled out from the clearance groove 115 on the protective housing 104.

[0030] Both the positive electrode core wire 108 and the negative electrode core wire 109 are equipped with current-breaking units. These units control the connection of the corresponding positive electrode core wire 108 and negative electrode core wire 109. Each current-breaking unit includes an insulating heat-conducting cylinder 123. Supporting circular plates 126 are symmetrically fixedly mounted on the protective shell 104. Both ends of the insulating heat-conducting cylinder 123 are fixedly connected to the corresponding supporting circular plates 126. The axes of the insulating heat-conducting cylinder 123 and the two corresponding supporting circular plates 126 are on the same straight line. The conductive terminals 112 are symmetrically fixed on the 23. One end of the conductive terminal 112 is located inside the insulating heat-conducting cylinder 123, and the other end of the conductive terminal 112 is located outside the insulating heat-conducting cylinder 123, outside the protective housing 104, that is, in the area between the protective housing 104 and the cover housing 106. The conductive terminals 112 are respectively connected to the corresponding positive core wire 108 and negative core wire 109. The conductive terminal 112 corresponding to the sampling resistor 118 is connected to the sampling resistor 118.

[0031] A conductive slide rod 107 is slidably mounted on the conductive terminal 112. A circular conductive slider 132 is fixedly mounted on the conductive slide rod 107. A bismuth-based alloy block 131 is disposed between the conductive slide rod 107 and the corresponding circular conductive slider 132. A conductive contact block 110 is also fixedly mounted at the end of the conductive slide rod 107. The bismuth-based alloy block 131 is used to control the engagement of the two corresponding conductive contact blocks 110. An insulating spring 133 is disposed between the two circular conductive sliders 132 on the same insulating heat-conducting cylinder 123.

[0032] When the two supporting circular plates 126 on the insulating heat-conducting cylinder 123 corresponding to the positive electrode core wire 108 are engaged, the positive circuit between the power plug 102 and the load plug 103 is in a conductive state under the action of the positive electrode core wire 108, the conductive terminal 112, the sampling resistor 118, the circular conductive slider 132, the conductive slider 107, and the conductive contact block 110; when the two supporting circular plates 126 on the insulating heat-conducting cylinder 123 corresponding to the negative electrode core wire 109 are engaged, the negative circuit between the power plug 102 and the load plug 103 is in a conductive state under the action of the positive electrode core wire 108, the conductive terminal 112, the circular conductive slider 132, the conductive slider 107, and the conductive contact block 110.

[0033] When the bismuth-based alloy block 131 is in a normal solidified state, the two circular conductive sliders 132 corresponding to the same insulating heat-conducting cylinder 123 are in a engaged state, and the insulating spring 133 is in a compressed state, so that the corresponding positive electrode core wire 108 or negative electrode core wire 109 is in a conductive state; when the bismuth-based alloy block 131 is in an overcurrent heated liquefaction state, the two circular conductive sliders 132 corresponding to the same insulating heat-conducting cylinder 123 disengage, and the insulating spring 133 returns to its initial state and is not compressed, so that the corresponding positive electrode core wire 108 or negative electrode core wire 109 is in a non-conductive state.

[0034] In the initial state, the bismuth-based alloy blocks 131 are all in a solid state. At this time, under the action of the bismuth-based alloy blocks 131, the two conductive contact blocks 110 in the same insulating heat-conducting cylinder 123 are located at the closest position and the two conductive contact blocks 110 are in contact. That is, at this time, the positive circuit on the positive electrode core wire 108 and the negative circuit on the negative electrode core wire 109 are both in a conductive state.

[0035] When the current in the DC line is too high, i.e., exceeding the rated current, the temperature of the conductive terminal 112, the circular conductive slider 132, and the conductive slide bar 107 will rise, causing the bismuth-based alloy block 131 to reach its melting point and liquefy. After liquefaction, the volume of the bismuth-based alloy block 131 will decrease, thereby releasing the push on the corresponding circular conductive slider 132. Under the action of the insulating spring 133, the two circular conductive sliders 132 move away from each other, thereby causing the corresponding two conductive contact blocks 110 to disengage, thus interrupting the current in the positive electrode core wire 108 or the negative electrode core wire 109, and putting the positive or negative circuit in an unconducted state, thereby achieving overcurrent protection for the DC line.

[0036] The insulating heat-conducting cylinder 123 is also symmetrically equipped with heat dissipation units. Each heat dissipation unit includes a linkage gear ring 128 rotatably mounted on the insulating heat-conducting cylinder 123. An annular impeller 129 is fixedly mounted on the inner side of the linkage gear ring 128. The heat dissipation units are used to cool the bismuth-based alloy block 131. The insulating heat-conducting cylinder 123 is also symmetrically equipped with a flow guide cylinder 113. The flow guide cylinder 113 is fixedly mounted on the corresponding support circular plate 126. There is an annular flow guide chamber 134 between the flow guide cylinder 113 and the corresponding insulating heat-conducting cylinder 123. The annular flow guide chamber 134 is used to accommodate the airflow movement generated by the annular impeller 129. A flow guide circular plate 124 is also fixedly mounted in the middle of the insulating heat-conducting cylinder 123. Arc-shaped chamfered blocks 125 are provided on both sides of the flow guide circular plate 124 and between the insulating heat-conducting cylinder 123.

[0037] A linkage assembly is provided between two annular impellers 129 on the same insulating heat-conducting cylinder 123. Each linkage assembly includes a drive shaft 122, two linkage gears 127, and two linkage gear rings 128. The linkage gear rings 128 are fixedly mounted on the corresponding annular impellers 129. The drive shaft 122 is rotatably mounted on the protective housing 104. The two linkage gears 127 are fixedly mounted at both ends of the drive shaft 122. The linkage gears 127 and the corresponding linkage gear rings 128 mesh to form a gear pair. Two cooling motors 116 are fixedly mounted on the protective housing 104 closest to the measuring unit. The cooling motors 116 are fixedly connected to the corresponding drive shafts 122. Starting the cooling motors 116 drives the corresponding drive shafts 122 to rotate, which causes the corresponding two linkage gears 127 to rotate synchronously, the corresponding two linkage gear rings 128 to rotate synchronously, and thus the corresponding two annular impellers 129 to rotate synchronously.

[0038] A baffle plate 111 is provided between the two guide circular plates 124. The guide circular plates 124 are fixedly connected to the baffle plate 111. The baffle plate 111 and the guide circular plates 124 have the same thickness. There is a gap between the protective shell 104 and the baffle plate 111. The protective shell 104 and the baffle plate 111 are used to accommodate the airflow discharge in the annular guide chamber 134. Under the action of the baffle plate 111, the airflow between the two annular guide chambers 134 arranged opposite to each other is blocked from convection.

[0039] The supporting circular plate 126 is uniformly provided with fan-shaped heat dissipation holes 130, and the cover housing 106 is uniformly provided with strip-shaped heat dissipation holes 117. Airflow enters the cavity between the protective housing 104 and the cover housing 106 through the strip-shaped heat dissipation holes 117 on the cover housing 106. Under the action of the annular impeller 129, the airflow in the cavity between the protective housing 104 and the cover housing 106 enters the corresponding annular guide chamber 134 through the fan-shaped heat dissipation holes 130. The airflow moves along the annular guide chamber 134 towards the guide circular plate 124 and finally exits through the gap between the protective housing 104 and the guide circular plate 124. The airflow is guided by the arc-shaped chamfered block 125. Under the action of the airflow in the annular flow guiding chamber 134, the bismuth-based alloy block 131 cools down from the farthest end of the flow guiding circular plate 124 to the closest end of the bismuth-based alloy block 131 to the flow guiding circular plate 124. The end of the bismuth-based alloy block 131 farthest from the flow guiding circular plate 124 cools down the fastest, that is, the end of the bismuth-based alloy block 131 farthest from the flow guiding circular plate 124 solidifies first, thereby pushing the two circular conductive sliders 132 to move closer to each other. After the circular conductive sliders 132 are completely solidified, the two conductive contact blocks 110 are in a connected state.

[0040] Working principle: When the current is too high, the current-cutting units on the positive electrode core wire 108 and the negative electrode core wire 109 are activated. Under the action of the bismuth-based alloy block 131, the overheated positive or negative circuit is interrupted, thereby achieving overheat protection for the DC line. After the side unit detects that the current value has returned to normal, the microcontroller 120 controls the cooling motor 116 to rotate, thereby causing the cooling unit to cool and solidify the bismuth-based alloy block 131, thus restoring the conduction of the positive or negative circuit.

[0041] This invention is not limited to the specific embodiments described above. Any modifications made by those skilled in the art based on the above concept without creative effort are within the protection scope of this invention.

Claims

1. An intelligent DC connection cable with overcurrent protection, comprising a cable (101), wherein a positive core wire (108) and a negative core wire (109) are disposed within the cable (101), characterized in that: A measuring unit is provided on the cable (101) for monitoring the current value of the DC line. Both the positive core wire (108) and the negative core wire (109) are provided with a current interruption unit. The current interruption unit includes an insulating and heat-conducting cylinder (123). Conductive terminals (112) are symmetrically fixed on the insulating and heat-conducting cylinder (123). A conductive slide rod (107) is slidably installed on the conductive terminal (112). A circular conductive slider (132) is fixedly installed on the conductive slide rod (107). A bismuth-based alloy block (131) is provided between the conductive slide rod (107) and the corresponding circular conductive slider (132). The end of the conductive slide bar (107) is also fixedly provided with a conductive contact block (110). The bismuth-based alloy block (131) is used to control the connection of the corresponding two conductive contact blocks (110). The current interruption unit is used to control the connection of the corresponding positive electrode core wire (108) and negative electrode core wire (109). The insulating heat-conducting cylinder (123) is also symmetrically provided with heat dissipation units. Each heat dissipation unit includes a linkage gear ring (128) rotatably mounted on the insulating heat-conducting cylinder (123). An annular impeller (129) is fixedly provided on the inner side of the linkage gear ring (128). The heat dissipation unit is used to cool down the bismuth-based alloy block (131).

2. The intelligent DC connection cable with overcurrent protection according to claim 1, characterized in that: The cable (101) is provided with a power plug (102) and a load plug (103) at both ends, the measuring unit is located between the current interruption unit and the power plug (102), and the positive core wire (108) and the negative core wire (109) are provided with an insulation layer (105).

3. The intelligent DC connection cable with overcurrent protection according to claim 1, characterized in that: The cable (101) is also provided with two protective shells (104), and each protective shell (104) is movably provided with a cover shell (106). Trapezoidal limiting blocks (114) and clearance grooves (115) are symmetrically provided between the cover shells (106) and the protective shells (104). The trapezoidal limiting blocks (114) and clearance grooves (115) are used to lock the cover shells (106) and the corresponding insulation layers (105).

4. The intelligent DC connection cable with overcurrent protection according to claim 3, characterized in that: The measurement unit includes a sampling resistor (118), a differential amplifier (119), a microcontroller (120), and an analog-to-digital converter (121). The sampling resistor (118) is connected in series with the positive core wire (108), and the sampling resistor (118), differential amplifier (119), microcontroller (120), and analog-to-digital converter (121) are fixedly installed inside the corresponding cover housing (106).

5. The intelligent DC connection cable with overcurrent protection according to claim 3, characterized in that: The protective shell (104) is symmetrically fixed with support circular plates (126). The two ends of the insulating heat-conducting cylinder (123) are respectively fixedly connected to the corresponding support circular plates (126). The conductive terminals (112) are respectively connected to the corresponding positive electrode core wire (108) and negative electrode core wire (109). An insulating spring (133) is provided between the two circular conductive sliders (132) on the same insulating heat-conducting cylinder (123).

6. The intelligent DC connection cable with overcurrent protection according to claim 5, characterized in that: When the bismuth-based alloy block (131) is in a normal solidified state, the two circular conductive sliders (132) corresponding to the same insulating heat-conducting cylinder (123) are in a connected state, so that the corresponding positive electrode core (108) or negative electrode core (109) is in a conductive state; when the bismuth-based alloy block (131) is in an overcurrent heated liquefaction state, the two circular conductive sliders (132) corresponding to the same insulating heat-conducting cylinder (123) are disconnected, so that the corresponding positive electrode core (108) or negative electrode core (109) is in a non-conductive state.

7. The intelligent DC connection cable with overcurrent protection according to claim 6, characterized in that: The insulating heat-conducting cylinder (123) is also symmetrically provided with a flow guide cylinder (113). There is an annular flow guide chamber (134) between the flow guide cylinder (113) and the corresponding insulating heat-conducting cylinder (123). The annular flow guide chamber (134) is used to accommodate the airflow movement generated by the annular impeller (129). The flow guide cylinder (113) is fixedly installed on the corresponding support circular plate (126). The middle position of the insulating heat-conducting cylinder (123) is also fixedly provided with a flow guide circular plate (124). Arc-shaped chamfered blocks (125) are provided on both sides of the flow guide circular plate (124) and between the insulating heat-conducting cylinder (123).

8. The intelligent DC connection cable with overcurrent protection according to claim 7, characterized in that: A linkage group is provided between two annular impellers (129) on the same insulating heat-conducting cylinder (123). Each linkage group includes a drive shaft (122), two linkage gears (127), and two linkage gear rings (128).

9. The intelligent DC connection cable with overcurrent protection according to claim 8, characterized in that: The supporting circular plate (126) is uniformly provided with fan-shaped heat dissipation holes (130), and the cover shell (106) is uniformly provided with strip-shaped heat dissipation holes (117).

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