System, method, and apparatus for bidirectional DC short-circuit protection

Abstract

A self-triggering bidirectional control electronics component for an electronic switch (50) for current detection and rapid shutoff at selected thresholds for both current flow directions includes a threshold switch having a plurality of selectable shutoff thresholds for both current flow directions, the threshold switch coupled to a bidirectional current sensor system (65) disposed within the electronic switch based on sensor sensing on an input side of the threshold switch, and a fast de-energization circuit (53) including a high unloaded circuit voltage for rapid removal of current from the magnetic drive coil (45) on an output side of the threshold switch, the fast de-energization circuit being configured to rapidly remove current from the magnetic drive coil when the bidirectional current sensor system detects a current equal to or greater than a selected one of the plurality of selectable shutoff thresholds.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims priority to U.S. Provisional Patent Application No. 63 / 200,074 (EATN - 2027 - P01), filed on February 12, 2021, entitled "SYSTEM, METHOD, AND APPARATUS FOR BI - DIRECTIONAL DC SHORT - CIRCUIT PROTECTION".

[0002] Each of the aforementioned applications is hereby incorporated by reference in its entirety for all purposes.

[0003] (Field of the Invention) Although not limited to a particular technical field, the present disclosure relates to DC short - circuit protection.

Summary of the Invention

[0004] Aspects of the present disclosure include self - triggering bidirectional control electronic devices, devices, components, circuits, etc. for direct current (DC) switches. Aspects also include methods and systems for using or operating devices, devices, components, circuits, etc. Aspects of the present disclosure include the detection and interruption of current at a selected threshold for either, each, or both current flow directions. Aspects of the present disclosure include having each switching threshold for each current direction. Further, aspects of the present disclosure include applying an off - switch pulse to remove current from a magnetic drive coil when the current exceeds the threshold. The current removal can be fast, high - speed, rapid, etc.

[0005] These and other systems, methods, objects, features, and advantages of the present disclosure will be apparent to those skilled in the art from the following detailed description of the preferred embodiments and the drawings.

[0006] All documents referenced herein are incorporated herein in their entirety by reference. References to singular items should be understood to include plural items unless otherwise specified or evident from the text, and vice versa. Grammatical conjunctions are intended to represent any disjunctive and conjunctive combination of joined clauses, sentences, words, etc., unless otherwise specified or evident from the context. [Brief explanation of the drawing]

[0007] The following detailed description of this disclosure and its specific embodiments can be understood by referring to the following figures. [Figure 1] This example illustrates a DC switching device that utilizes a rapid de-energizing circuit to perform rapid disconnection of a magnetic drive coil. [Figure 2] This shows an exemplary embodiment of a control electronic device for a DC switching device. [Figure 3] This diagram shows a schematic embodiment of a system in which a power distribution unit (PDU) is operably positioned between the power source and the load. [Figure 4] A more detailed embodiment of the system, illustrating the PDU schematically, is shown. [Figure 5] This shows a non-restrictive, illustrative response curve for a fuse. [Figure 6] This shows a non-exclusive, exemplary system for mobile applications such as those for vehicles. [Figure 7] This shows a non-exclusive illustrative system including PDUs. [Figure 8] This shows an apparatus of an embodiment that includes all or part of the PDU. [Figure 9] This shows a non-limiting, exemplary device for providing additional protection against fuse failures and system failures. [Figure 10] This shows an exemplary data embodiment for implementing system response values. [Figure 11]This shows a non-exclusive, exemplary fuse circuit that may exist on a PDU. [Figure 12] This shows an embodiment of a fuse circuit having a contactor. [Figure 13] An embodiment of a fuse circuit including multiple fuses is shown. [Figure 14] This shows a fuse circuit with a contactor and a fuse in parallel. [Figure 15] This shows exemplary data illustrating the fuse response to the vehicle's drive cycle. [Figure 16] This shows a non-limiting, exemplary system including a power supply and a load having a fuse electrically placed between the load and the power supply. [Figure 17] This shows a schematic diagram of a vehicle equipped with a PDU (Power Unit). [Figure 18] A schematic diagram of a circuit breaker / repeater and a precharge repeater is shown. [Figure 19] A schematic diagram of a circuit breaker / repeater and a suppressor is shown. [Figure 20] This shows a schematic diagram of the power bus protection configuration. [Figure 21] This shows details of an embodiment of a circuit breaker / repeater component. [Figure 22] This shows details of an embodiment of a circuit breaker / repeater component. [Figure 23] This shows details of an embodiment of a circuit breaker / repeater component. [Figure 24] This shows current plots for contactors, fuses, and circuit breakers / relays. [Figure 25] A flowchart of an embodiment for current protection is shown. [Figure 26] A flowchart of an embodiment for current protection is shown. [Figure 27] A flowchart of an embodiment for current protection is shown. [Figure 28] A flowchart of an embodiment for current protection is shown. [Figure 29] This diagram shows a schematic representation of the power protection configuration between the battery and the inverter. [Figure 30] It shows a schematic diagram of the power protection configuration between the battery and the inverter. [Figure 31] It shows a schematic diagram of the power protection configuration between the battery and the load. [Figure 32] It shows a schematic diagram of the power protection configuration. [Figure 33] It shows a schematic diagram of the power protection configuration between the battery and the load. [Figure 34] It shows a schematic diagram of the power protection configuration between the battery and the load. [Figure 35] It shows a schematic diagram of the power protection configuration between the battery and the load with a depiction of the current path. [Figure 36] It shows a schematic diagram of the power protection configuration between the battery and the load with a depiction of the current path. [Figure 37] It shows a schematic diagram of the power protection configuration between the battery and the load with a depiction of the current path. [Figure 38] It shows a schematic diagram of the power protection configuration between the battery and the load with a depiction of the current path. [Figure 39] It shows the details of an embodiment of the circuit breaker / repeater component. [Figure 40] It shows a schematic diagram of the power bus protection configuration. [Figure 41] It shows the details of an embodiment of the contacts of the circuit breaker / repeater component. [[ID=3​​​​​​​​​​​​​​​​ [Figure 48] This document describes how to operate a self-triggering bidirectional electronic device. [Figure 49] This document describes how to operate a self-triggering bidirectional electronic device. [Figure 50] This shows a self-triggering bidirectional control circuit for an electronic switch. [Figure 51] This shows the system for operating the contactors of a circuit breaker / relay. [Modes for carrying out the invention]

[0008] Power distribution in many applications, particularly in the case of high DC currents, is subject to several challenges. Applications with high variable loads, high power throughput, high voltage ratings, and / or distinct protection characteristics depending on the direction of power flow (e.g., different sensitivity of protected components depending on power flow value, duty cycle, and / or power flow direction) present specific challenges. Certain applications, including but not limited to mobile applications, grid operations, and / or power supply operations, have high costs due to high current damage to components and / or application downtime. High costs may arise due to damage to high-power battery packs, external costs due to loss of service (e.g., for data centers, medical facilities, grids, minigrids, etc.), and costs related to the type of application (e.g., failures in mobile applications and / or remotely located locations may increase the time until service or response is available, increasing both the cost of repairs and the time until access by service personnel, which could otherwise minimize ongoing damage to the application). Certain applications have highly variable power throughput requirements depending on the direction of power flow and may also have distinct sensitivity to current flow depending on the direction of power. For example, a mobile application may have very specific power ratings (e.g., nominal voltage, power throughput, and / or rated current) depending on whether power, regenerative power, and / or fast-charging power are flowing through the system. In further examples, a mobile application may have separate power electronics, specific components that are exposed to power only under specific operating conditions (e.g., during charging, power operation, regeneration, etc.), and / or power control components such as diodes that have a clear sensitivity to current depending on the direction of power. Similarly, applications such as power grid support systems and / or power supply operations may have different power flow ratings depending on the operating conditions, time of day, and where the power is flowing (e.g., from grid to battery).The flow of electricity from batteries and / or power generators such as wind turbines to the grid flows through the batteries, grid, loads, or a combination thereof.

[0009] In another example, the high-voltage battery of an electric vehicle is typically charged with a relatively constant current. If a short circuit occurs during charging, the resulting short-circuit current is significantly lower than that of a complete short circuit with a fully charged battery during operation. Therefore, to minimize problems fundamentally related to short circuits, such as those caused by exceeding the switching capacity of switching devices in a DC circuit or by thermal overload of the charging cable, it is desirable in many DC applications to differentiate thresholds for switching off the short-circuit current according to the direction of current flow and / or to optimize the short-circuit current to suit each application.

[0010] Exemplary energy storage and DC networks include combinations of contactors and repeaters (e.g., circuit breakers / repeaters) for routing and switching in normal operation, combined with separate fuse elements for rapid interruption in emergencies such as short circuits. This is particularly true for so-called "high-voltage automotive networks" in the field of electrical mobility, which use nominal voltages of 400V or higher and DC currents that can exceed 100A during operation. In such applications, combined with the formation of DC arcs, currents of several kiloamperes can be generated in the event of a short circuit, which, without adequate protection, can cause considerable destruction within milliseconds.

[0011] Referencing International Publication No. 2020 / 016179 (filed July 15, 2019, “SWITCHING DEVICE AND SWITCHING ARRANGEMENT” which is incorporated herein by reference in its entirety for all purposes), a DC switching device suitable for high-voltage networks such as those in electric vehicles is described. Conventionally known DC switching devices operate independently of the direction of current flow, utilizing the same threshold for both drive and charge modes, for example, with the direction of current flow reversed. In nominal operation, DC currents of several hundred amperes can be generated for rapid charging of energy storage in larger electric vehicles. During operation, the vehicle's power electronics ensure that the switched current is limited to approximately 30 amperes, which allows the switching device to have a long electrical life of more than 100,000 switching operations under load. On the other hand, when a short circuit occurs in a DC network, typically with a current in the range of >1000A, the switch opens the switching contacts very quickly, ensuring that the resulting switching arc is always rapidly removed from the contact tips by the magnetic field force, regardless of the direction of current flow, due to the extremely high temperature, to prevent damage to the switching elements. The switching arc is moved towards the arc chamber, where it is extinguished, so the short-circuit current is turned off within milliseconds.

[0012] Short-circuit detection is provided by a current sensor element placed very close to the fixed contacts, for example in the form of a Hall effect sensor. If a specified threshold is exceeded, for example, which can correspond to a multiple of the nominal current, the coil voltage of the electromagnetic switching drive is immediately shut off by a controlled electronic device that is turned off, so that the switching contacts within a time typically less than 2 milliseconds and remains open indefinitely (e.g., open to prevent re-contact of the contact element). In the case of a short circuit, damage to electrical components can occur very quickly. In the case of a high short-circuit current, the switching contacts may initially be open due to dynamic current forces (e.g., due to the Lorentz force), resulting in the immediate formation of a high-energy arc. In the case of a magnetic drive coil that has not yet completely discharged (e.g., a magnetic drive coil that controls the contact of a contactor element), the contact compression spring force may still be acting during the opening operation, and as the Lorentz force decreases, it can drive the contacts to reconnect. The contact compression spring force that may still be acting during the opening operation may be due to a dynamic contact force that acts much faster than the mechanical contact opening, which can be driven by the simultaneous de-energization of the reverse contact spring and the magnetic drive coil. Reconnecting the contactor immediately after initial opening can result in serious damage and / or welding of the switching contacts heated by the arc. Exemplary DC switching devices utilize a rapid de-energized circuit to perform rapid disconnection of the magnetic drive coil (see, e.g., Figure 1). The exemplary de-energized circuit utilizes a switch-off pulse to initiate a connection of a high freewheeling countervoltage to the magnetic coil circuit, ensuring rapid discharge of the coil current. An example in Figure 1 is further described in '179 literature.

[0013] It should be understood that determining whether a coil current discharge is fast, rapid, quick, etc. depends on the discharge event and system conditions, such as how quickly a component fails or how robust the protected component is against high-current events. In certain embodiments, fast, rapid, quick, etc. can be a speed faster than nominal deceleration, such as faster than a few milliseconds (e.g., faster than 2 ms). Those skilled in the art can readily determine whether a coil current discharge characteristic is fast, rapid, quick, etc. for a particular system, taking advantage of the benefits of this disclosure. Specific considerations for those skilled in the art in determining whether a coil current discharge characteristic is fast, rapid, quick, etc. include, but are not limited to any other aspect of this disclosure, the capacitance of the energizing coil, the capacitance of the power supply circuit on which the energizing coil operates, the ability of the protected device to withstand high-current events, capital versus operating cost considerations (e.g., component cost versus operating cost to keep the current within the margin), the dynamics of the power supply circuit when open under transient and power supply events, and / or the dynamics of the power supply components.

[0014] Referring to Figure 1, an illustrative list of the illustrated components includes: • 50DC switch • 50A switch main circuit • 50b auxiliary switch • 51 Overvoltage protection ·52 reverse polarity protection ·53 high-speed de-energized circuits • 54 magnetic drive coils • 55 Power-Up Driver 56 Inbound Filters • 57 Threshold switch input voltage • 58 timer • 59 Switch-on Link • 60 Switch-on Voltage Control Circuit • 61 filter circuit 62DC-DC Step-Down Converter 63 Decoupling • 64 threshold switch control voltage • 65 current sensor • 66 Current detection threshold switch • 67 Overvoltage protection external emergency shutoff • 68 External emergency shutdown threshold switch

[0015] In the exemplary switch-controlled electronic device shown in Figure 1, there is no distinction based on the direction of current flow for switch-off control, including turning off a short-circuit current. Examples in this disclosure refer to DC circuits and switching for the purposes of this specification. However, embodiments of switch-controlled electronic devices described herein are useful for switching direct current (DC) circuits and / or alternating current (AC) circuits.

[0016] An exemplary DC switching device of this disclosure includes a control / release electronic device that provides bidirectional short-circuit detection having different levels of switch-off thresholds for two current flow directions, including rapid de-energization of a magnetic drive. In a particular embodiment, the bidirectional switch-off threshold may be based on one or more current characteristics for each direction, such as: the value of the current flowing; the rate of change of the current value; the time-based value of the current; the relative position of the current value with respect to the threshold; the rate of change of the relative position of the current value with respect to the threshold; and / or a combination thereof. In a particular embodiment, both the threshold and / or current characteristics considered for switching may vary depending on the direction of current flow.

[0017] A current-direction-dependent cutoff threshold can be implemented, for example, using a parallel arrangement of two comparators. A signal arriving from a current sensor, preferably in the form of a Hall sensor, positioned immediately adjacent to the main current path, is a measure of the amount of current flowing at that moment and proceeds simultaneously to one of the inputs of both comparators. In current flow mode, the Hall voltage signal is compared to a fixed reference signal for each of the two inputs of the two comparators. The level of the reference signal is dimensioned relative to the current sensor signal such that, in the nominal operating case for both current directions, the output signals of both comparators are in a non-operating state of fast de-excitation downstream of the magnetic drive coil for switching the DC load off. If the load current reaches a threshold in one direction of current, and / or another threshold as specified herein, e.g., a value corresponding to a short circuit, and / or any other condition indicating that immediate power cutoff should be performed, the modified Hall voltage level has the effect of changing the state of the output signal of one of the two comparators so that a fast de-energizing circuit is activated. However, in the other comparator, the altered Hall voltage due to the reference voltage simultaneously applied therein does not cause an input voltage difference that results in a change in the state of the output signal. When the short-circuit current threshold is reached in the case of current flow in the other direction, which may be different from the threshold for the reverse polarity, a change in the state of the signal output of the second comparator occurs, while there is no change in the first comparator.

[0018] Such a signal constellation can be advantageously implemented in that the Hall signal is applied to an inverted signal input to one of the two comparators and to a non-inverted signal input to the other comparator. The desired value or reference voltage can be implemented using a voltage divider that divides the control voltage of the control electronics accordingly. Such a voltage divider can be, for example, via a series connection of ohmic resistors that specify a fixed constellation of reference voltages applied to the two comparators. In applications where a variable threshold is useful for turning off a short-circuit current, the voltage divider can also be designed as a chain of variable resistors, such as B in the form of a potentiometer or Zener diode configuration. Other threshold types (e.g., rate of change of current, integral of current value, and / or comparison of current value with threshold) can be implemented by appropriate analog or digital electronics (e.g., capacitors, inductors, reference voltage and / or current value coupled to the circuit, solid components, and / or control electronics) integrated with the DC switching device circuit.

[0019] Referring to Figure 2, an illustrative list of the components depicted includes: • 10 DC switch • 10a main circuit switch • 10b auxiliary switch • 15-hole sensor ·21 comparator K1 ·22 comparator K2 30-minute voltage divider • 35 Overvoltage Protection ·36 reverse polarity protection ·40 rapid de-energizing circuits 45 drive coil

[0020] Figure 2 shows an exemplary embodiment of a control electronics unit for a DC switching device. The operating modes are described using the following exemplary embodiment. The current to be monitored is measured by a bipolar Hall sensor 15 mounted on the DC switching device 10 immediately adjacent to the main current path 12. When de-energized, a Hall voltage UH-0 is present at the sensor output, which in this example is 50% of the supply voltage Vcc. As the DC current increases, the Hall voltage also increases in one direction of the current, and decreases for currents increasing in the opposite direction. The Hall voltage is supplied as an input signal to two comparators 21 (e.g., inverting) and 22 (e.g., non-inverting) arranged in parallel with the comparator section 20 of the control electronics unit. In this example, one comparator is the inverting input and the other comparator is the non-inverting input. For each of the other signals, a reference signal is set for both directions of the current, having a threshold for activating the rapid de-energization circuit 40 of the magnetic drive unit in the event of a short circuit. In this example, the two reference voltage values ​​are derived from a power supply voltage Vcc that is always applied via a voltage divider 30 provided with a permanently selected ohmic resistor. It will be understood that the voltage divider 30 may include a variable resistor to adjust, for example, a current threshold for opening a contactor. Additionally or alternatively, the Hall voltage values ​​provided to and / or from each comparator may be adjusted and / or connected in parallel with adjustments to utilize other types of thresholds such as rate of change, cumulative time-current value, and / or for comparison with a reference value (for example, to determine whether the current value is approaching a threshold). For example, a resistance constellation with R1=R2=15kΩ, R3=20kΩ, and a power supply voltage Vcc of 5V is voltage-divided so that a reference voltage of 3.5V is applied to the non-inverting input of comparator K1 21 and a voltage of 2.0V is applied to the inverting input of comparator K2 22. Therefore, the Hall sensor signal in comparator K1 becomes both the inverting and non-inverting input to comparator K2. As long as the monitored DC current is below the trigger threshold (e.g., short-circuit current, or another selected threshold), the input voltage difference is always greater than zero for both comparators. In the example in Figure 2, when the rapid de-energization circuit 40 is not activated and the voltage difference is greater than zero, the output signal has the state "HI".However, when the Hall voltage reaches 3.5V for one current flow direction having a given exemplary value, and this corresponds to the threshold for a specified short circuit in this current direction, the voltage difference across comparator K1 becomes zero and the output signal jumps to state "LO". In this example, due to the reference voltage value of 2.0V in K2, the voltage difference across comparator K2 is still greater than zero, so the output signal from comparator K2 remains in state "HI", but the parallel arrangement of the two comparators causes the rapid de-energization circuit 40 to activate immediately and the corresponding response of the magnetic drive coil 45 of the switching device.

[0021] In this example, an increase in the current intensity of the current flowing in the reverse direction is associated with a decrease in the Hall voltage. In this example, when the decreasing voltage reaches 2.0V, which corresponds to a specified short-circuit threshold for the opposite current direction, the input to comparator K2 drops to a voltage difference of zero, and the output signal of comparator K2 jumps to state "LO". In this example, the voltage difference in comparator K1 remains positive due to a higher reference voltage, and the output of comparator K1 remains "HI", but the parallel arrangement of the two comparators causes the rapid de-energization circuit 40 to activate immediately and the corresponding response of the magnetic drive coil 45 of the switching device.

[0022] An exemplary switching device includes implementing a control electronics unit using, for example, a microcontroller-based configuration and / or a controller as shown with reference to Figure 9. exemplified input variables for such a control electronics unit include a Hall voltage as a measure of the instantaneously flowing load current, and / or a comparison of its processing value, such as a rate of change, a cumulative time-current value, and / or any one or more of these thresholds.

[0023] Control electronics can also be implemented using a microcontroller-based configuration. The input variable for such control electronics is the Hall voltage, which is a measure of the instantaneous load current flowing.

[0024] In nominal operation, the applied Hall voltage varies within a voltage interval, and the upper and lower limits of the voltage interval correspond to the switch-off thresholds in the event of a short circuit in both current directions. While these threshold levels can be set differently in principle, they are fixed for a given application. When these thresholds are exceeded or fallen below, respectively, the microcontroller output sends an activation signal to the rapid de-excitation circuit 40 of the drive coil 45, similar to the comparator-based embodiment described in relation to Figure 2. The use of control electronics also ensures that the load current to the drive coil 45 is quickly switched off, avoiding a contactor reconnection event.

[0025] Illustrative features of the present disclosure are described below, any one or more of which may be present in a particular embodiment. An exemplary system includes a self-triggering bidirectional control electronic device for a DC switch for detecting and rapidly interrupting current at a selected threshold (e.g., short-circuit current) for both current flow directions, comprising a threshold switch having different selectable interruption thresholds for both current directions in the form of a parallel arrangement of two comparators, and / or utilizing the control electronic device to couple a bidirectional current sensor system located on the input-side DC switch based on a bipolar Hall sensor with an output-side high-speed de-energizing circuit having a high unloaded circuit voltage for rapid removal of current from the magnetic coil of the switch driver. The self-triggering bidirectional control electronic device may alternatively be described as a component, apparatus, device, assembly, circuit, or system. An exemplary system includes a bidirectional adjustable current interruption threshold (e.g., short-circuit current) on the input side of the comparator circuit in the form of a voltage divider with fixed and / or adjustable ohm resistance, as a variable-adjustable potentiometer configuration and / or equivalent Zener diode circuit. An exemplary system includes a self-triggering bidirectional control electronic device for a DC switch that utilizes control electronics such as a microcontroller circuit to provide rapid recognition of bidirectional high-current events, and rapid deactivation of a magnetic coil that operates the contacts of a switching device (e.g., a circuit breaker / repeater). In some embodiments of the self-triggering bidirectional control electronic device, a high-speed de-energized circuit is operable when there is no selectable interruption threshold. In some embodiments, the self-triggering bidirectional control electronic device may be useful for detecting and rapidly interrupting current at a selected threshold (e.g., short-circuit current) for one direction of bidirectional current. Various embodiments of bidirectional switching include having different switching thresholds for each current direction, having the same switching threshold for both directions, and having a switching threshold for only one current direction and no switching threshold for the other current direction.

[0026] Specific descriptions refer to switching means for operating a threshold switch and current rejection means for operating a high-speed de-energized circuit. Embodiments shown in Figures 1 and 2 illustrate non-limiting examples of switching means and current rejection means.

[0027] Specific further exemplary embodiments are described below. In further examples, but not limited to, components such as contactors and / or circuit breakers / repeaters may be implemented using a switching device having bidirectional switching control as described above with reference to Figure 2. Without limiting to any aspect of this disclosure, the operation described in relation to detected current values, current thresholds, etc., may be implemented as a bidirectional current response, including having the same or distinct operation for each current direction.

[0028] Referring to Figure 48, a method 4800 for operating a self-triggering bidirectional controlled electronic device is shown. The method 4800 for operating a self-triggering bidirectional controlled electronic device for an electronic switch for detecting and interrupting current at selected thresholds for both current flow directions includes: operating a threshold switch coupled to a bidirectional current sensor system located within the electronic switch, based on detection by a sensor on the input side of the threshold switch, having a first interruption threshold related to a first current flow direction and a second interruption threshold related to a second current flow direction 4802; and operating a de-energizing circuit to apply a switch-off pulse to the output side of the threshold switch, including a high no-load circuit voltage for removing current from a magnetic drive coil, the de-energizing circuit is configured to remove current from the magnetic drive coil when the bidirectional current sensor system detects a current greater than or equal to a selected threshold among the first and second interruption thresholds 4804. Figure 49 shows a method 4900 further including operating the de-energizing circuit to apply a high freewheeling counter voltage for removing current from the magnetic drive coil 4902.

[0029] Figure 50 shows a self-triggered bidirectional control circuit 5002 for an electronic switch. The circuit 5002 may also include switching means 5004 for operating a threshold switch having a first cutoff threshold related to a first current flow direction and a second cutoff threshold related to a second current flow direction, the threshold switch being coupled to a bidirectional current sensor system located within the electronic switch based on detection by a sensor on the input side of the threshold switch. Embodiments of the switching means 5004 are shown and described with reference to at least the embodiments shown in Figures 1 and 2. The circuit 5002 may also include current removal means 5008 for operating a fast de-energizing circuit to apply a switch-off pulse to the output side of the threshold switch, the fast de-energizing circuit including a high no-load circuit voltage for rapidly removing current from the magnetic drive coil, the fast de-energizing circuit rapidly removing current from the magnetic drive coil when the bidirectional current sensor system detects a current above a selected threshold among the first and second cutoff thresholds. Embodiments of the current removal means 5008 are shown and described with reference to at least the embodiments shown in Figures 1 and 2. It should be understood that the bidirectional control circuit 5002 may include both the switching means 5004 and the current removal means 5008, and either one may be omitted.

[0030] Figure 51 shows a system 5100 for operating the contactor of a circuit breaker / repeater 5102, the system comprising the circuit breaker / repeater 5102 as described herein and a self-triggering bidirectional control electronic device component 5110 for an electronic switch within the circuit breaker / repeater 5102 for detecting and rapidly interrupting current at thresholds selected for both current flow directions. The component 5110 may include a threshold switch 5104 having a first interruption threshold related to a first current flow direction and a second interruption threshold related to a second current flow direction, as illustrated and described with reference to the embodiments shown in Figures 1 and 2, the threshold switch is coupled to a bidirectional current sensor system located within the electronic switch based on detection by a sensor on the input side of the threshold switch. Component 5110 may also include a fast de-energizing circuit 5108 configured to apply a switch-off pulse to the output side of the threshold switch, as illustrated and described with reference to the embodiments shown in Figures 1 and 2, the fast de-energizing circuit including a high no-load circuit voltage for rapidly removing current from the magnetic drive coil, and the fast de-energizing circuit 5108 is configured to rapidly remove current from the magnetic drive coil when the bidirectional current sensor system detects a current above a selected threshold from among first and second cutoff thresholds. It should be understood that component 5110 may include both the threshold switch 5104 and the de-energizing circuit 5108, or one of them may be omitted.

[0031] An exemplary device is a self-triggered bidirectional controlled electronic device for an electronic switch for detecting and interrupting current at selected thresholds for both current flow directions, comprising: a threshold switch having a first interruption threshold related to a first current flow direction and a second interruption threshold related to a second current flow direction, coupled to a bidirectional current sensor system located within the electronic switch based on detection by a sensor on the input side of the threshold switch; and a de-energized circuit to apply a switch-off pulse to the output side of the threshold switch, including a high no-load circuit voltage for removing current from a magnetic drive coil, wherein the de-energized circuit is configured to remove current from the magnetic drive coil when the bidirectional current sensor system detects a current greater than or equal to a selected threshold among the first and second interruption thresholds.

[0032] Specific further embodiments of the exemplary apparatus are described below, any one or more of which may be present in a particular embodiment. The exemplary apparatus further includes a non-energized circuit further configured to remove current from the magnetic drive coil by applying a high freewheeling counter voltage. The exemplary apparatus further includes the high freewheeling counter voltage comprising a flyback diode. The exemplary apparatus further includes a threshold switch comprising two comparators, each of the first and second cutoff thresholds comprising a bidirectionally adjustable current cutoff threshold on the input side of the two comparators. The exemplary apparatus further includes a threshold switch comprising a controller control output. The exemplary apparatus further includes one or more of the first and second cutoff thresholds corresponding to a short-circuit current value. The exemplary apparatus further includes a voltage divider electrically coupled to a sensor in the threshold switch on the first side of the voltage divider, which is a bipolar Hall sensor, and to two comparators in the threshold switch on the second side of the voltage divider. An exemplary apparatus further includes a voltage divider comprising at least one component selected from components comprising a fixed ohm resistor, an adjustable ohm resistor, a variable adjustable potentiometer configuration, or a Zener diode circuit. An exemplary apparatus further includes a first side of the voltage divider being the input side and a second side of the voltage divider being the output side. An exemplary apparatus further includes an electronic switch comprising a direct current (DC) switch.

[0033] An exemplary method includes operating a self-triggering bidirectional control electronic device for an electronic switch for detecting and interrupting current at selected thresholds for both current flow directions, wherein the method includes operating a threshold switch coupled to a bidirectional current sensor system located within the electronic switch, based on detection by a sensor on the input side of the threshold switch, having a first interruption threshold related to a first current flow direction and a second interruption threshold related to a second current flow direction; and operating a de-energizing circuit to apply a switch-off pulse to the output side of the threshold switch, including a high no-load circuit voltage for removing current from a magnetic drive coil, wherein the de-energizing circuit is configured to remove current from the magnetic drive coil when the bidirectional current sensor system detects a current greater than or equal to a selected threshold among the first and second interruption thresholds.

[0034] Specific further embodiments of the exemplary method are described below, any one or more of which may be present in a particular embodiment. The exemplary method further includes operating a de-energized circuit to apply a high freewheeling counter voltage to remove current from a magnetic drive coil. The exemplary method further includes the high freewheeling counter voltage comprising a flyback diode. The exemplary method further includes the threshold switch comprising two comparators. The exemplary method further includes each of the first and second cutoff thresholds comprising a bidirectionally adjustable current cutoff threshold on the input side of the two comparators. The exemplary method further includes the threshold switch comprising a control output of a controller. The exemplary method further includes one or more of the first and second cutoff thresholds corresponding to a short-circuit current value. The exemplary method further includes a voltage divider electrically coupled to a sensor in the threshold switch on the first side of the voltage divider, which is a bipolar Hall sensor, and to two comparators in the threshold switch on the second side of the voltage divider. An exemplary method further includes the voltage divider comprising at least one component selected from components comprising a fixed ohm resistor, an adjustable ohm resistor, a variable adjustable potentiometer configuration, or a Zener diode circuit. An exemplary method further includes the first side of the voltage divider being the input side and the second side of the voltage divider being the output side. An exemplary method further includes the electronic switch comprising a direct current (DC) switch.

[0035] An exemplary automatic trigger bidirectional control circuit for an electronic switch for detecting and rapidly interrupting current at a selected threshold for both current flow directions includes a threshold switch having a first interruption threshold related to a first current flow direction and a second interruption threshold related to a second current flow direction, and switching means for operating the threshold switch coupled to a bidirectional current sensor system located within the electronic switch based on detection by a sensor on the input side of the threshold switch; and a fast de-energizing circuit for applying a switch-off pulse to the output side of the threshold switch, including a high no-load circuit voltage for rapidly removing current from a magnetic drive coil, wherein the fast de-energizing circuit rapidly removes current from the magnetic drive coil when the bidirectional current sensor system detects a current greater than or equal to a selected threshold among the first and second interruption thresholds, and current removal means for operating the fast de-energizing circuit.

[0036] Specific further embodiments of the exemplary circuit are described below, any one or more of which may be present in a particular embodiment. The exemplary circuit further includes a high-speed de-energized circuit further configured to rapidly remove current from the magnetic drive coil by applying a high freewheeling counter voltage. The exemplary circuit further includes a high freewheeling counter voltage comprising a flyback diode. The exemplary circuit further includes a threshold switch comprising two comparators. The exemplary circuit further includes a selected threshold comprising a bidirectionally adjustable current-cut threshold on the input side of the two comparators. The exemplary circuit further includes a threshold switch comprising a control output of a controller. The exemplary circuit further includes a selected threshold corresponding to a short-circuit current value. The exemplary circuit further includes a voltage divider electrically coupled to a sensor in the threshold switch on the first side of the voltage divider, which is a bipolar Hall sensor, and to two comparators in the threshold switch on the second side of the voltage divider. The exemplary circuit further includes the voltage divider comprising at least one component selected from components comprising a fixed ohm resistor, an adjustable ohm resistor, a variable adjustable potentiometer configuration, or a Zener diode circuit. The exemplary circuit further includes the first side of the voltage divider being the input side and the second side of the voltage divider being the output side. The exemplary circuit further includes the electronic switch comprising a DC switch.

[0037] An exemplary system for operating the contacts of a circuit breaker / repeater includes a circuit breaker / repeater comprising: a fixed contact electrically coupled to a power bus; a movable contact selectively electrically coupled to the fixed contact; an armature coupled to the movable contact, configured to move to contact the fixed contact to allow current to flow through the power bus; a relay section including a coil and a magnetic core, configured such that the coil acts the relay such that when the coil is energized, the armature is attracted to the magnetic core; and a breaker section comprising a plurality of splitter plates adjacent to the body of the circuit breaker / repeater; and a permanent magnet system surrounding one or more of the arc paths between the plurality of splitter plates and the contact gap and the plurality of splitter plates, wherein the body of the circuit breaker / repeater cooperates with the splitter plates using the magnetic field provided by the permanent magnet system to break the arc while the movable contact is engaged or disengaged when the power bus is energized. The circuit breaker / repeater includes a breaker section configured to dissipate current, and the self-triggering bidirectional control electronic device component for an electronic switch within the circuit breaker / repeater, comprising a threshold switch having a first break threshold related to a first current flow direction and a second break threshold related to a second current flow direction for detecting and rapidly interrupting current at selected thresholds for both current flow directions, the threshold switch coupled to a bidirectional current sensor system located within the electronic switch based on detection by a sensor on the input side of the threshold switch, and a high-speed de-energizing circuit configured to apply a switch-off pulse to the output side of the threshold switch, comprising a high no-load circuit voltage for rapidly removing current from a magnetic drive coil, the high-speed de-energizing circuit configured to rapidly remove current from the magnetic drive coil when the bidirectional current sensor system detects a current above a selected threshold among the first and second thresholds.

[0038] Specific further embodiments of the exemplary system are described below, any one or more of which may be present in a particular embodiment. The exemplary system further includes a high-speed de-energized circuit further configured to rapidly remove current from the magnetic drive coil by applying a high freewheeling counter voltage. The exemplary circuit further includes the high freewheeling counter voltage comprising a flyback diode. The exemplary circuit further includes a threshold switch comprising two comparators. The exemplary circuit further includes a selected threshold corresponding to a short-circuit current value. The exemplary circuit further includes an electronic switch comprising a direct current (DC) switch.

[0039] An exemplary system for operating the contactors of a circuit breaker / repeater is a circuit breaker / repeater comprising: a fixed contact electrically coupled to a power bus; a movable contact selectively electrically coupled to the fixed contact; an armature coupled to the movable contact, configured to move to contact the fixed contact to allow current to flow through the power bus; a relay section including a coil and a magnetic core, configured such that when the coil is energized, the armature is attracted to the magnetic core, thereby activating the relay; and a breaker section comprising a plurality of splitter plates adjacent to the body of the circuit breaker / repeater; and a permanent magnet system surrounding one or more of the arc paths between the plurality of splitter plates and the contact gap and the plurality of splitter plates. A circuit breaker / repeater, including a breaking section, the body of the circuit breaker / repeater, configured to cooperate with a splitter plate using a magnetic field provided by a permanent magnet system to extinguish an arc while the movable contacts are engaged or disengaged when the power bus is energized; and a self-triggering bidirectional control electronic device component for an electronic switch within the circuit breaker / repeater, comprising a threshold switch having a first interruption threshold related to a first current flow direction and a second interruption threshold related to a second current flow direction, for detection and rapid interruption of current at thresholds selected for both current flow directions, the threshold switch being coupled to a bidirectional current sensor system located within the electronic switch, based on detection by a sensor on the input side of the threshold switch.

[0040] Specific further embodiments of the exemplary system are described below, any one or more of which may be present in a particular embodiment. The exemplary system further includes a threshold switch comprising two comparators. The exemplary system further includes a selected threshold corresponding to a short-circuit current value. The exemplary system further includes an electronic switch comprising a direct current (DC) switch.

[0041] An exemplary device is a self-triggered bidirectional controlled electronic device for a direct current (DC) switch for detecting and interrupting current at selected thresholds for both current flow directions, comprising: a DC switch; a threshold switch having a first interruption threshold related to a first current flow direction and a second interruption threshold related to a second current flow direction, coupled to a bidirectional current sensor system located within the DC switch based on detection by a sensor on the input side of the threshold switch; and a de-energized circuit to apply a switch-off pulse to the output side of the threshold switch, including a high no-load circuit voltage for removing current from a magnetic drive coil, wherein the de-energized circuit is configured to remove current from the magnetic drive coil when the bidirectional current sensor system detects a current greater than or equal to a selected threshold among the first and second interruption thresholds.

[0042] An exemplary device is a self-triggered bidirectional controlled electronic device for an electronic switch for detecting and interrupting current at selected thresholds for both current flow directions, and includes a bidirectional current sensor system; a threshold switch having a first interruption threshold related to a first current flow direction and a second interruption threshold related to a second current flow direction, coupled to the bidirectional current sensor system located within the electronic switch based on detection by a sensor on the input side of the threshold switch; and a de-energized circuit to apply a switch-off pulse to the output side of the threshold switch, including a high no-load circuit voltage for removing current from a magnetic drive coil, wherein the de-energized circuit is configured to remove current from the magnetic drive coil when the bidirectional current sensor system detects a current greater than or equal to a selected threshold among the first and second interruption thresholds.

[0043] An exemplary device is a self-triggered bidirectional controlled electronic device for an electronic switch for detecting and interrupting current at selected thresholds for both current flow directions, comprising: a magnetic drive coil; a threshold switch having a first interruption threshold related to a first current flow direction and a second interruption threshold related to a second current flow direction, coupled to a bidirectional current sensor system located within the electronic switch based on detection by a sensor on the input side of the threshold switch; and a de-energized circuit to apply a switch-off pulse to the output side of the threshold switch, including a high no-load circuit voltage for removing current from the magnetic drive coil, wherein the de-energized circuit is configured to remove current from the magnetic drive coil when the bidirectional current sensor system detects a current greater than or equal to a selected threshold among the first and second interruption thresholds.

[0044] An exemplary device is a self-triggered bidirectional controlled electronic device for an electronic switch for detecting and interrupting current at selected thresholds for both current flow directions, comprising: a threshold switch having a first interruption threshold related to a first current flow direction and a second interruption threshold related to a second current flow direction, coupled to a bidirectional current sensor system located within the electronic switch based on detection by a sensor on the input side of the threshold switch and the detected current; and a de-energized circuit to apply a switch-off pulse to the output side of the threshold switch, including a high no-load circuit voltage for removing current from a magnetic drive coil, wherein the de-energized circuit is configured to remove current from the magnetic drive coil when the detected current is greater than or equal to a selected threshold among the first and second interruption thresholds.

[0045] Referring to Figure 3, an exemplary system 100 is schematically shown, which includes a power distribution unit (PDU) 102 operably positioned between a power source 104 and a load 106. The power source 104 may be of any type, including at least a battery, a generator, and / or a capacitor. The power source 104 may include multiple power sources or power lines, which may be distributed according to the type of power (e.g., a battery input separated from a generator input) and / or according to the device being powered (e.g., auxiliary and / or accessory power separated from the main load power such as moto power, and / or division within accessories, division within moto power, etc.). The load 106 may be of any type, including one or more power loads (e.g., individual drive wheel motors, global power drive motors, etc.) and one or more accessories (e.g., on-board accessories such as steering, fans, lights, cab power, etc.). In certain embodiments, the PDU 102 facilitates the integration of the electrical system in an application including system 100 by utilizing uniform input and output access, and by grouping all power distributions into a single box, a single area, and / or a single logically integrated group of components. In certain embodiments, the PDU 102 provides protection for the electrical system, including the fusion and / or connection or disconnection (manual and / or automatic) of the electrical system or individual aspects of the electrical system. In certain embodiments, one or more power supplies 104 may be high voltage (e.g., 96V, 230V-360V, 240V, 480V, or any other value) or low voltage (e.g., 12V, 24V, 42V, or any other value). In certain embodiments, one or more power supplies 104 may be direct current (DC) power supplies or alternating current (AC) power supplies including multiphase (e.g., three-phase) AC power. In certain embodiments, the PDU 102 is a pass-through device and, for example, only when affected by sensing and other operations from the PDU 102 that are not provided for power configuration, it supplies power to the load 106 as configured by the power supply 104. In certain embodiments, the PDU 102 may include power electronics such as rectification, voltage regulation, and noisy power cleanup to provide the load 106 with selected power characteristics.

[0046] Referring to Figure 4, a more detailed schematic diagram of an exemplary PDU 102 is schematically shown. The exemplary PDU 102 includes a main power supply 202 (e.g., high voltage, main load power, power, etc.) which may be supplied by one or more power supplies 104, and an auxiliary power supply 204 (e.g., auxiliary, accessory, low voltage, etc.) which may be supplied by one or more power supplies 104. Although the exemplary PDU 102 shows a single main power supply 202 and a single auxiliary power supply 204, a given application may include one or more main power supplies 202, separate auxiliary power supplies 204, and / or omit the auxiliary power supplies 204.

[0047] An exemplary PDU 102 further includes a coolant inlet 206 and a coolant outlet 208. Supplying coolant to the PDU 102 is optional and may not be included in any particular embodiment. The coolant may be any type available in this application, including, for example, available on-board coolants (e.g., engine coolant, transmission coolant, coolant flow associated with other power components such as auxiliary devices or power supply 104), and / or a coolant specifically for the PDU 102. Where present, the amount of cooling provided by the coolant may be variable by changing the amount of coolant flowing through the coolant loop through the PDU 102, for example, by operating hardware within the PDU 102 (e.g., valves or limiters), or by providing a coolant flow rate request to another device in the system.

[0048] An exemplary PDU 102 further includes a main power outlet 210 and an auxiliary power outlet 212. As previously stated, the PDU 102 may include multiple main power outlets 210 and / or divided, multiple, multiplexed, and / or omitted auxiliary power outlets 212. The exemplary PDU 102 is a pass-through power supply unit in which the power outlets 210, 212 have substantially the same electrical characteristics as the corresponding power inlets 202, 204, except for the impact on power due to sensing and / or active diagnostics. However, the PDU 102 may include power electronics (solid-state or otherwise) for configuring power in any desired manner.

[0049] An exemplary PDU 102 further includes a controller 214 configured to functionally perform specific operations of the PDU 102. The controller 214 includes, and / or is communicatively coupled to, one or more sensors and / or actuators in the PDU 102 to determine, for example, current values, voltage values, and / or temperatures of any power supplies or inputs, fuses, connectors, or other devices in the PDU 102. Additionally or alternatively, the controller 214 is communicatively coupled to a system 100 including the PDU 102, which includes, for example, a vehicle controller, engine controller, transmission controller, application controller, and / or network devices or servers (e.g., fleet computer, cloud server, etc.). The controller 214 may be coupled to an application network (e.g., CAN, data link, private or public network, etc.), an external network, and / or another device (e.g., operator's portable device, in-cab computer for vehicle, etc.). For illustrative purposes, the controller 214 is schematically shown as a single standalone unit. It will be understood that the controller 214 and / or embodiments of the controller 214 may be distributed across multiple hardware devices to perform one or more operations of the controller 214, may be contained within another hardware device (e.g., a controller for a power supply, load, vehicle, application, etc.), and / or may be configured as a hardware device, logic circuit, etc. The PDU 102 is schematically shown as a device in a single enclosure, but may be in a single enclosure and / or distributed in two or more locations within the application. In certain embodiments, containing the PDU 102 in a single enclosure offers particular advantages for integration, footprint reduction, and / or interface simplification. Additionally or alternatively, it is intended herein to include the PDU 102 in multiple locations within the application and / or to include multiple PDU 102s within the application.

[0050] An exemplary PDU 102 includes a main contactor 216 that selectively controls the main power throughput of the PDU 102. In this example, the main contactor 216 is communicatively coupled to a controller 214 and controlled by the controller. The main contactor 216 may be additionally manually controllable, and / or other main contactors 216 may be inline for manually controllable main power. An exemplary main contactor 216 includes a solenoid (or other coil-based) contactor that, when energized, provides connected main power (e.g., normally open, or power disconnected when not energized), and / or provides disconnected main power (e.g., normally closed, or power connected when not energized). Characteristics of the system 100, including design choices regarding whether the power supply should be activated when the power supply to the controller 214 fails, predetermined service plans, regulations and / or policies, the consequences of power loss in the system 100, the voltage normally carried by the mains power supply, and the availability of a positive manual disconnection option, may inform or instruct the decision of whether the main contactor 216 is normally open or normally closed. In certain embodiments, the main contactor 216 may be a solid-state device such as a solid-state repeater. If there are multiple main contactors 216, the different contactors may include the same or different hardware (e.g., one is a solenoid and one is a solid-state repeater) and / or the same or different logic for being normally open or normally closed. The main contactor 216 may be further controllable by an external device of the PDU 102, such as a key switch lockout, another controller in the system 100 having access to control the main contactor 216, and / or the controller 214 may respond to external commands to open and close the main contactor 216, and / or an additional inline contactor for the main power supply may respond to an external device of the PDU 102.

[0051] An exemplary PDU 102 includes an auxiliary contactor 218 that selectively controls the auxiliary power throughput of the PDU 102. In this example, the auxiliary contactor 218 is communicably coupled to a controller 214 and controlled by the controller. The auxiliary contactor 218 may be additionally manually controllable, and / or other auxiliary contactors 218 may be inline for manually controllable auxiliary power. An exemplary auxiliary contactor 218 includes a solenoid (or other coil-based) contactor that, when energized, provides connected auxiliary power (e.g., normally open, or power disconnected when not energized), and / or provides disconnected auxiliary power (e.g., normally closed, or power connected when not energized) when the solenoid is energized. The characteristics of system 100 include design choices regarding whether the power supply should be activated when the power supply of controller 214 fails, predetermined service plans, regulations and / or policies, the consequences of power loss in system 100, the voltage typically carried by the auxiliary power supply, the availability of a positive manual disconnection option, etc., which may inform or instruct the decision of whether the auxiliary contactor 218 is properly open or properly closed. In certain embodiments, the auxiliary contactor 218 may be a solid-state device such as a solid-state repeater. The auxiliary contactor 218 may be further controllable by an external device of PDU 102, such as a key switch lockout, another controller in system 100 having access to control the auxiliary contactor 218, and / or controller 214 may respond to external commands to open and close the auxiliary contactor 218, and / or an additional in-line contactor for the auxiliary power supply may respond to an external device of PDU 102. In certain embodiments, the auxiliary contactors 218 may be provided for each auxiliary line, a subset of auxiliary lines (for example, four auxiliary power inputs having two, three, or four auxiliary contactors 218 each), etc.

[0052] An exemplary PDU 102 includes a current source 220, which may be an AC power source and / or provided as a solid-state electronic circuit on a controller 214. The current source 220 can provide a selected current injection into the mains power supply across the mains fuse 222, for example, as an AC current, a DC current, and / or a controllable current over time. For example, the PDU 102 may include sensors such as voltage and / or current sensors on the mains power supply, and the current source 220 provides an electrical connection to a power supply (which may be an external power supply and / or supplied via a controller) in a manner configured to inject a desired current into the mains power supply. The current source 220 may include feedback to ensure that the desired current is injected, for example, in response to system noise, variability, and aging, and / or a nominal electrical connection may be applied to inject the current, and the controller 214 determines the sensor input to determine the current actually injected into the mains power supply. The exemplary PDU 102 shows a current source 220 associated with the main fuse 222, but the PDU 102 may further include one or more current sources 220 associated with one or more of the fuses 222, 224 in the PDU 102, including individually, within a subset, or across all fuses (affected by power compatibility on the fuses, for example, simultaneous current injection across electrically coupled fuses should generally be avoided). Including additional current sources 220 provides greater resolution in injecting current across individual fuses and managing fuse variations over time, while including fewer current sources 220 reduces system cost and complexity. In certain embodiments, the current sources 220 are configured to selectively inject current across each fuse in the PDU 102 and / or across each target fuse in sequence or on schedule and / or as required by the controller 214.

[0053] An exemplary PDU 102 includes a main fuse 222 and an auxiliary fuse 224. One or more main fuses 222 are associated with the main power supply, and the auxiliary fuse 224 is associated with the auxiliary power supply. In certain embodiments, the fuses are thermal fuses, such as resistive devices that exhibit heating, and are intended to fail when a given current profile is exceeded in the associated power line. Referring to Figure 5, a typical and non-limiting exemplary response curve of a fuse is shown. Curve 302 represents the applied damage curve, showing the current-time space at which several aspects of the application are damaged when the curve is exceeded. For example, in the exemplary application damage curve 302, damage to several aspects of the application occurs when the 10 × rated current is exceeded by approximately 50 milliseconds. The application may include many components, and it will be understood that the components may differ in the application damage curve 302. Furthermore, each fuse 222, 224 may be associated with a separate component having a different damage curve than the other components. Curve 304 represents the control space, and in a particular embodiment, the controller 114 provides control protection to prevent the system from reaching the applied damage curve 302 in the event of a fuse failure or out-of-nominal operation. The applied damage curve 302 may be a specified value, for example, a system requirement to be met, and exceeding the applied damage curve 302 means that the system requirement is not met, but actual damage to the components may be experienced at some other value in the current time space. Curve 306 represents the fuse blow line of an exemplary fuse. At the location of the fuse blow line 306, the fuse temperature exceeds the fuse design temperature, and the fuse blows. However, the fuse continues to conduct for a period after the start of blowing (for example, due to conduction through the fused material before the connection is broken, arc discharge, etc.), as indicated by the fuse conduction line 308. When the time current space reaches the fuse conduction line 308, the fuse is no longer conducting on the power line, and the line is broken.It will be understood that specific system dynamics, inter-fuse variations, fuse aging (e.g., induced mechanical or thermal degradation, changes in composition or oxidation, etc.), the exact nature of the current experienced (e.g., current rise time), and other real-world variables affect the precise timing of both fuse blowing and fuse disconnection. However, even with nominal fuses as shown in Figure 5, at very high currents, it can be seen that the nominal fuse conduction wire 308, and even the fuse blowing wire 306, may cross the applied damage curve 302 because, for example, the specific dynamics of the fuse disconnection operation are unresponsive (in the time domain) or unresponsive to currents applied at very high current values.

[0054] An exemplary PDU 102 further includes a conductive layer 226 associated with auxiliary power and a conductive layer 228 associated with main power. The conductive layers 226, 228 include power coupling to the fuse of the power line. In certain embodiments, the conductive layers 226, 228 are simply wires or other conductive couplings between the fuse and the power connection to the PDU 102. Additionally or alternatively, the conductive layers 226, 228 may include flat or laminated portions having, for example, punched or formed conductive layers to provide power connections within the PDU 102, and / or portions of the conductive layers 226, 228 may include flat or laminated portions. Without limiting to other disclosures provided herein, the use of flat or laminated portions provides manufacturing flexibility, installation flexibility, and / or a reduction in the footprint of the conductive layers 226, 228, and / or provides a larger contact area between the conductive layers 226, 228 and portions of the PDU 102, for example, between the conductive layers 226, 228 and fuses, controllers, contactors, or other devices within the PDU 102 where thermal and / or electrical contact between the conductive layers 226, 228 and other devices is desired. While exemplary conductive layers 226, 228 are shown in relation to fuses, conductive layers 226, 228 may additionally or alternatively be associated with controllers 214 (e.g., power coupling, internal or external communication of the PDU 102, coupling to actuators, coupling to sensors, and / or thermal coupling), contactors 216, 218, and / or any other devices within the PDU 102.

[0055] Referring to Figure 6, the exemplary system 400 is a mobile application such as a vehicle. The exemplary system 400 includes a high-voltage battery 104 electrically coupled to a high-voltage load 106 via a PDU 102. In the exemplary system 400, an auxiliary prime mover, such as an internal combustion engine 402 (and associated conversion electronic devices such as a generator, motor generator, and / or inverter), is further coupled to the PDU 102. It is understood that the high-voltage battery 104 and / or auxiliary prime mover 402 may function as a power source or load during certain operating conditions of the system 400, and furthermore, the high-voltage load 106 (e.g., an electric motor or motor generator coupled to a wheel) may function as a load or power source during certain operating conditions. The descriptions of the load 106 and the power source 104 herein are non-limiting, and refer only to nominal operation, normal operation, and / or operating conditions selected for conceptual explanation, even if the described load 106 and / or power source 104 often operate in modes other than those named herein, usually or always. For example, the high-voltage battery 104 may operate as a power source during powered operation in which net energy is drawn from the battery, and / or as a load during charging operation, such as during powered operation in which wheels or an auxiliary motor are charging the battery.

[0056] The exemplary system 400 further includes a powertrain controller 404 for controlling the operation of the powertrain, which may be associated with other components within the system 400 and / or some of the other controllers within the system (e.g., a vehicle controller, a battery controller, a motor or motor-generator controller, and / or an engine controller). The exemplary system 400 further includes a charger 406 coupled to a high-voltage battery 404 via a PDU 102, and a low-voltage load (the “12V autoload” in the example of Figure 6) representing auxiliary and accessory loads within the system 400. Those skilled in the art will recognize the system 400 as including a serial hybrid powertrain for a vehicle, for example, if the auxiliary power (e.g., an internal combustion engine) interacts only with the electrical system to recharge the battery and / or provide additional real-time power during operation, but does not mechanically interact with the drive wheels. Additionally or alternatively, the system may include a parallel hybrid system, in which the auxiliary power can mechanically interact with the drive wheels and / or interact with the electrical system (either or both). Additionally or alternatively, the system may be a fully electric system in which auxiliary power is absent and / or where auxiliary power is present but does not interact with a high-voltage / power system (e.g., an alternative power unit for driving auxiliary equipment, refrigerators, etc., the power of which may be transmitted via PDU102 but may be isolated from the power-electric system). In certain embodiments, power systems such as vehicles experience very transient load cycles, for example, during acceleration, deceleration, stop-and-go traffic, and emergency operations, and therefore power management in such systems is complex, and certain devices such as fuses may be vulnerable to very transient load cycles. Additionally or alternatively, loss of vehicle operation may result in the cost of system downtime, loss or premature delivery of cargo, and / or significant operational risks due to failure (e.g., operator and / or vehicle overturning, loss of operation in traffic, loss of operation on a highway, etc.).In certain embodiments, other systems, which may be hybrid electric and / or fully electric, are subject to highly variable duty cycles and / or certain vulnerabilities to operational interruptions such as pumping operations, process operations for larger processes (e.g., chemical, refining, drilling, etc.), power generation operations, and mining operations. System failures of these and other operations may include externalities such as losses associated with process failures that exceed the downtime of a particular system, and / or such system downtime may result in significant costs.

[0057] Referring to Figure 7, an exemplary system including a PDU 102 is shown. The exemplary PDU 102 has several auxiliary power connections (e.g., in this example, charging, power steering, vehicle accessories, and load return for current sensing) and a main power / tow power connection. The exemplary system 500 includes two high-voltage contactors, one on the high-side and one on the low-side of the battery, in this example the two high-voltage contactors are controllable by the system control board, but may be additionally or alternatively manual (e.g., an operator-accessible switch). Furthermore, the system control board can control a master disconnection that can disconnect all power through the PDU 102. System 500 further illustrates a power fuse bypass 502 controllable by the system control board that supports the specific operations of this disclosure described throughout. Although system 500 illustrates a power fuse bypass 502, it may additionally or alternatively include one or more of the auxiliary fuses, any subset of the auxiliary fuses, and / or all of the auxiliary fuses collectively as auxiliary bypasses. The exemplary system 500 includes an optional coolant supply and return coupling. The battery coupling in system 500 is shown as 230V to 400V battery coupling, but the high-voltage coupling may be of any value. The system control board is shown as being communicatively coupled to a 12V CAN network, but the communication coupling to applications or systems around the system control board may be any network or multiple networks understood in the art (e.g., vehicle, engine, powertrain, private, public, OBD, etc.), and / or may be, or include, wireless network connections.

[0058] Referring to Figure 8, an exemplary apparatus 1300 is shown, which may include all or part of the PDU 102. Descriptions relating herein to the interaction between the main fuse 222 and the lamination layers 226 / 228 may, additionally or alternatively, contemplate the interaction between any fuses and / or connectors in apparatus 1300 and / or any other components of the PDU 102 described throughout this disclosure. The exemplary apparatus 1300 includes a contactor 216 / 218, which may be a high-voltage contactor and / or may be associated with various fuses 222, 224 in apparatus 1300. Apparatus 1300 includes lamination layers 226 / 228, which may include conductive layers for particular embodiments of conductive circuits in apparatus 1300. Lamination layers 226 / 228 may, additionally or alternatively, provide rigidity and / or structural support for various components in apparatus 1300. The lamination layers 226 / 228 may be configured to interact with any components in a manner desired to support the functions of the lamination layers 226 / 228, including structural functions, heat transfer functions, and / or electrical conductivity functions. While the exemplary lamination layers 226 / 228 interact with all contactors and fuses in the device 1300, the lamination layers 226 / 228 can be easily configured to interact with selected contactors and / or fuses, and / or other components in the device, for example, in a manner similar to printed circuit board (PCB) design. The exemplary device 1300 is mounted on an L-bracket, which may be the final configuration and / or the test configuration. In certain embodiments, the device 1300 is enclosed in a dedicated housing and / or a housing for another device in the system 100, such as a battery housing. In certain embodiments, the device 1300 includes a removable housing portion (e.g., top, lid, etc.) for service and / or maintenance access to components of the device. An exemplary device 1300 includes, for example, a connector 1302 for providing power, data link access, connection to power supply 104, connection to load 106, connection to a sensor (not shown), and / or any other type of connection to system 100, etc.

[0059] Referring to Figure 9, an exemplary device 1900 for providing additional protection against fuse failures and system failures is described. For example, an exemplary device 1900 implemented on a controller 214 includes a current event determination circuit 1902 that determines that a current event 1904 is active or is expected to occur, where the current event includes a component that is experiencing (or is about to experience) a wear event, such as a current value that causes thermal and / or mechanical stress on the component but may not cause an immediate failure or observable damage. The exemplary component includes a fuse, but may be any other component in the system, including a battery cell, a switch or connector, a motor, etc. Another exemplary current event includes a system failure value, e.g., a current value that may cause or is expected to cause a system failure (e.g., a cable failure, a connector failure, etc.).

[0060] The apparatus 1900 further includes a response determination circuit 1906 that determines a system response value 1910 for a current event 1904. Exemplary and non-limiting responses include notifying the operator to reduce power, reducing power, notifying the system controller that a current event 1904 is present or imminent, opening a contactor on the circuit associated with the event, delaying circuit protection, monitoring the cause of the event and response delay and responding later, and / or scheduling a response according to the operating state in the system. The apparatus 1900 further includes a response implementation circuit 1908 that determines communication and / or actuator responses according to the system response value 1910 and provides network communication 1912 and / or actuator commands 1914 to implement the system response value 1910. Exemplary and non-limiting actuator responses include operating a contactor, operating an active coolant actuator to regulate heat conduction away from the fuse, and the like.

[0061] Referring to Figure 10, exemplary data 2000 for implementing the system response value 1910 is shown. The exemplary data 2000 includes thresholds 2002, e.g., current, temperature, index parameters, or other values ​​where component wear and / or system failure is expected to occur, and is used as thresholds by the current event determination circuit 1902 under specific operating conditions at least at some point in the system. It is understood that the current event determination circuit 1902 may utilize multiple thresholds and / or dynamic thresholds, as described throughout this disclosure. Curve 2004 represents nominal system performance, e.g., current, temperature, index parameters, etc., that the system would experience if the device 1900 were not operating. In this example, the response determination circuit 1906 determines that the threshold 2002 is crossed and, within the time to avoid the crossing of the threshold 2002, instructs the contactor to increase heat conduction away from the fuse, taking into account the contactor disconnection time 2008 (and / or the response time of the effective coolant loop). Exemplary data 2000 shows the resulting system response curve 2006, where the resulting system performance is maintained below threshold 2002. The system may experience alternative response trajectories (e.g., the resulting system response curve 2006 may fall far below threshold 2002 depending on the system dynamics, how long the contactor remains open, etc.). Nevertheless, additionally or alternatively, the response decision circuit 1906 may enable exceeding threshold 2002, for example, according to any operation or decision described throughout this disclosure. In certain embodiments, the response decision circuit 1906 enables exceeding threshold 2002, but the lower peak values ​​of the response and / or the area under the response curve above threshold 2002 are smaller than in the absence of operation by the response decision circuit 1906.

[0062] Exemplary procedures that may be performed by a device such as device 1900 include actions that determine whether a current event (or other response event) exceeds or is expected to exceed a wear threshold, and / or whether a current event exceeds or is expected to exceed a system fault value. In response to the determination that a current event exceeds or is expected to exceed either value, the procedure includes actions to perform mitigation measures. Components of the wear threshold may be fuses (e.g., fuses that have experienced or are expected to experience a current event causing mechanical stress, thermal stress, or high use of the fuse life), components in the system (e.g., contactors, cables, switches, battery cells, etc.), and / or nominally determined defined thresholds (e.g., calibration of values ​​expected to be related to the likelihood of damage to a component, without necessarily being tied to a specific component). In certain embodiments, the wear threshold and / or system fault value are compensated for aging or wear conditions of the system or components in the system (e.g., the threshold decreases and / or the response increases as the system ages).

[0063] The non-limiting mitigation action, which may have a system response value of 1910, may include, non-limitingly, 1) disconnecting a circuit having wear components (e.g., a fuse, system component, and / or a specific power line experiencing an event); 2) notifying the operator to reduce power requirements; 3) notifying the vehicle or powertrain control device of a current event; 4) adjusting or limiting the available power to the operator; and 5) allowing components within the system to experience underlying wear and / or fault events, in situations (e.g., traffic, moving vehicles, type of application, where continuous operation is required). 6) Delaying circuit protection (disconnection and / or power reduction) in response to notifications from operators such as the operator; 7) Continuing to monitor and disconnect (or reduce power, etc.) the circuit if the event persists and subsequent conditions permit; 8) Scheduling responses according to the system's operating mode (e.g., sports, economic, emergency, fleet operator (and / or policy), owner / operator (and / or policy), geographic policy, and / or regulatory policy); and / or 9) Bypassing wear components (e.g., bypassing current around a fuse as a response action).

[0064] In certain embodiments, the operation to determine whether a current event exceeds a wear threshold and / or a system fault value is based on calculations such as: 1) determining that the current through the circuit exceeds a threshold (e.g., an ampere value); 2) determining that the rate of change of the current through the circuit exceeds a threshold (e.g., amperes / second value); and / or 3) determining that an exponential parameter exceeds a threshold (e.g., accumulated amperes-seconds; amperes / second-seconds; counting exponent for periods above a threshold or periods above more than one threshold; counting exponent weighted by instantaneous current values; integrated current, heat transfer, and / or power values; and / or exponents including counting down or resetting these based on current operating conditions).

[0065] In certain embodiments, the operation determining whether a current event exceeds a wear threshold and / or a system fault value includes: 1) a trip curve (e.g., a power-time or current-time trajectory, and / or an operating curve on a dataset or table as shown in Figure 5); 2) a fuse temperature model including a first or second derivative of temperature and one or more temperature thresholds for a scheduled response and / or an escalating response; 3) a measured battery voltage (e.g., the current value may increase as the battery voltage decreases, and / or the dynamic response of the current may change, causing changes in the wear threshold, system fault value, and / or current event determination); 4) first derivatives of current, temperature, power demand, and / or index parameters; 5) second derivatives of current, temperature, power demand, and / or index parameters; 6) information from the battery management system (e.g., voltage, current, charge) 7) Determination and monitoring of contactor disconnection times, and consideration of contactor disconnection times when determining responses to current events; 8) Using auxiliary system information to adjust responses (e.g., power requests from operations expected to generate future changes, open contactors (power disconnection); 8) Activating / deploying supplemental restraint systems - keeping contactors closed for maximum system control; and / or antilock braking systems and / or traction control systems are active and keeping contactors closed for maximum system control), including, or being adjusted based on, one or more of the following: In certain embodiments, the degree of activation may also be considered and / or the system status may be communicated to the PDU, for example, the system may report critical operations that require power for as long as possible, or interruption operations that require disconnection as quickly as possible.

[0066] Referring to Figure 11, an exemplary fuse circuit 2100 that may exist on the PDU 102 is shown. The exemplary fuse circuit 2100 may be associated with a main fuse, an auxiliary fuse, and / or a group of fuses or a subset of a group of fuses. The fuse circuit 2100 comprises a contactor (C1) in parallel with a fuse (F1). During normal operation, the contactor is open and current in the fuse circuit 2100 passes through the fuse. In certain embodiments, the contactor may include a physical component (e.g., a solenoid and / or a coil-based switch or repeater), and / or the contactor may be a solid-state repeater. In certain embodiments, the contactor may be normally open (e.g., applied power closes the contactor) or normally closed (e.g., applied power opens the contactor). The exemplary fuse circuit 2100 allows the contactor to selectively bypass the fuse circuit, for example, according to the operation of the device 1900 (see Figure 9 and the corresponding disclosure).

[0067] Referring to Figure 12, another embodiment of the fuse circuit 2200 is disclosed in which a contactor (C1) is in series with a second fuse (F2), and C1-F2 branches in parallel with a first fuse F1. The fuse circuit 2200 provides additional flexibility and several additional features for the operation of the device 1900. For example, the contactor may be closed, and the current may be divided between F1 and F2 (by the resistance ratio of the two fuses) to perform normal operation. One example includes a fuse F2 having a low current threshold set such that the divided current causes fuse F2 to fail if the system design current exceeds a design amount (e.g., 135% to 300% of the system design current, but any value is intended herein). Fuse F1 may be set to a very high value, allowing the opening of the contactor to temporarily increase the blowing capacity of the circuit but still blow. Additionally or alternatively, fuse F2 may be a relatively inexpensive and / or accessible fuse, and being at a lower current threshold F2 may be subject to greater mechanical and thermal fatigue and may act as a point of failure in the fuse circuit 2200, which can significantly extend the life of the more expensive and / or less accessible fuse F1. Additionally or alternatively, normal operation may be performed with the contactor open, and fuse F1 defines the normal blowout of the circuit. In the event of a high transient or other current event, the contactor closes, and branches C1-F2 share the current load, keeping fuse F1 within normal or lower wear operating conditions. In certain embodiments, fuses F1 and F2 may be similar in size, for example, to allow fuse F2 to act as a backup fuse, and to maintain similar fault conditions in place for F1 and F2. Alternatively, fuse F2 may be smaller than fuse F1, allowing for the alternative operation described, intermittent use of the C1-F2 circuit to draw some current to protect fuse F1, and / or backup blowing of F1 which can reduce the system's power limit when fuse F2 is small (e.g., as an unrated operating mode and / or a limp-home operating mode).Alternatively, fuse F2 may be larger than fuse F1, for example, to allow fuse F2 to manage very high transient current conditions where continued operation is desired. The use of the fuse circuit 2200 enables advanced control of the blowing system, protecting the power system during nominal operation and still providing advanced capability during fault modes, non-nominal operation, and / or transient operation. In certain embodiments, a resistor may be provided in the C1-F2 branch to control the current sharing load between F1 and F2 when contactor C1 is closed, for example.

[0068] Referring to Figure 13, the fuse circuit 2300 includes a plurality of fuses F1, F2, F3, and F4 shown in parallel, with corresponding contactors in series with each. While the exemplary fuse circuit 2300 is for auxiliary fuses, the fuse circuit 2300 can be any fuse, including a main fuse. The exemplary fuse circuit 2300 allows either removing a fuse from operation if, for example, one of the fuses is experiencing a transient event, or adding a fuse in case of a high transient event to share a current load. In certain embodiments, one or more of the fuses in the fuse circuit 2300 do not have associated contactors and are primary load-bearing fuses for the fuse circuit 2300. The relative sizes of the fuses in the fuse circuit 2300 may follow any selected value and depend on the purpose of the fuse circuit 2300 (e.g., to provide limp-home functionality, to provide additional capacity, to function as a backup, and / or to allow the disconnection of individual fuses in the system). Additionally or alternatively, one or more fuses in the fuse circuit 2300 may be placed in series with a resistor, for example, to control current load distribution. In certain embodiments, fuses F1, F2, F3, F4 are not in parallel, and / or one or more fuses are not in parallel. Therefore, opening a contactor for such a fuse does not cause current to be diverted to another fuse. Exemplary embodiments include separate contactors for fuses to allow for the interruption of specific system capabilities (e.g., due to faults, high transients, etc.) without interrupting all system capabilities (e.g., a fuse supporting braking may remain active even in high transient events, while accessory fuses for less critical systems may be opened to protect the fuse and / or the system).

[0069] Referring to Figure 14, a fuse circuit 2400 is shown that is similar to fuse circuit 2300 except that each fuse has a contactor in parallel, allowing a short circuit of a particular fuse while maintaining the current flowing through the fuse's path. In certain embodiments, the parallel path of each fuse may include additional fuses and / or resistors so that the load across each fuse circuit remains at least partially balanced when the fuses are connected in parallel. Embodiments in Figures 11 to 14 may also be referred to as current protection circuits, and embodiments such as those shown in Figures 11 to 14 allow for selectable configurations of the current protection circuit, as and / or as described. Selectable configurations of the current protection circuit may include runtime operation (e.g., reconfiguring the current protection circuit in response to an event or operating condition) and / or design-time operation (e.g., allowing the same hardware device to support multiple power ratings, electrical connection configurations, and / or service events or upgrade changes).

[0070] Referring to Figure 15, exemplary data 2500 showing the fuse response to a vehicle drive cycle is shown. In this example, the fuse current (e.g., the lower dashed curves at 12 and 25 units of time) and the fuse temperature (e.g., the upper solid curves at 12 and 25 units of time) are shown. It will be understood that other parameters describing fuse performance and / or limits may be used, including at least any of the values ​​described in the section referring to Figure 10. The operation of the drive cycle, in this example, shows a high transient event where the fuse temperature is expected to exceed the “fuse temperature avoidance limit,” e.g., a temperature or temperature transient at which the fuse is subjected to mechanical stress. The device 1900 may consider several thresholds for the fuse, e.g., a light wear threshold, a heavy wear threshold, and a potential failure threshold which may be set to a separate value of the fuse performance indicator being used (e.g., temperature). In certain embodiments, multiple types of thresholds may be used, e.g., a temperature threshold or set of thresholds, a second threshold or set of thresholds that changes with temperature over time (e.g., dT / dt), etc. In this example, the device 1900 may perform a mitigation action at the transient, for example, by briefly bypassing the corresponding fuse to avoid the transient and / or controlling the rate of the transient experienced by the fuse.

[0071] Referring to Figure 16, the exemplary system 2600 includes a power supply 104 and a load 106, with a fuse (F1) electrically positioned between the load 106 and the power supply 104. The operator provides a power request (accelerator pedal input), and the device 1900 may determine that the load request exceeds the fuse threshold (for example, current demand exceeding a temperature limit, or according to some other determination), but further determine that the transient event does not exceed the system operating condition limits. In this example, the device 1900 commands the contactor (C3) to close for a period before or during the transient event in order to protect the fuse. System 2600 shows high-side (C1) and low-side (C3) high-voltage contactors (e.g., 216, 218 from system 100) distinct from the fuse bypass contactor C3.

[0072] Referring to Figure 10, exemplary data 2000 for implementing a system response value 1910 is shown. The exemplary data 2000 includes a threshold 2002 (e.g., a current, temperature, exponential parameter, or other value at which fuse wear and / or failure is expected to occur) which is used as a threshold by the current event determination circuit 1902 under specific operating conditions at least at some point in the system. It is understood that the current event determination circuit 1902 may utilize multiple thresholds and / or dynamic thresholds, as described throughout this disclosure. Curve 2004 represents nominal system performance, e.g., the current, temperature, exponential parameter, etc., that the fuse would experience if the device 1900 were not operating. In this example, the response determination circuit 1906 determines that the threshold 2002 has been crossed and instructs the contactor to connect or disconnect in time to avoid crossing the threshold 2002, taking into account the contactor's connect / disconnect time 2008 (e.g., to bypass the fuse, engage a second fuse branch, and / or close a more vulnerable fuse branch). Additionally or alternatively, the response decision circuit 1906 may nevertheless allow the threshold 2002 to be exceeded, for example, in accordance with any operation or decision described throughout this disclosure, such as when a more important system parameter requires the fuse to remain connected and allows the fuse to experience wear and / or a fault event.

[0073] In certain embodiments, the operation to determine whether a current event exceeds a wear threshold and / or fuse fault value is based on calculations such as: 1) determining that the current through the fuse exceeds a threshold (e.g., an ampere value); 2) determining that the rate of change of the current through the fuse exceeds a threshold (e.g., amperes / second value); and 3) determining that an exponential parameter exceeds a threshold (e.g., accumulated amperes-seconds; amperes / second-seconds; counting exponent for periods above a threshold or periods above more than one threshold; counting exponent weighted by instantaneous current values; integrated current, heat transfer, and / or power values; and / or exponents including counting down or resetting these based on current operating conditions).

[0074] In certain embodiments, the operation determining whether a current event exceeds a wear threshold and / or a fuse fault value includes: 1) a trip curve (e.g., a power-time or current-time trajectory, and / or an operating curve on a dataset or table as shown in Figure 5); 2) a fuse temperature model including a first or second derivative of temperature and one or more temperature thresholds for a scheduled response and / or an escalating response; 3) a measured battery voltage (e.g., the current value may increase as the battery voltage decreases, and / or the dynamic response of the current may change, causing changes in the wear threshold, system fault value, and / or current event determination); 4) first derivatives of current, temperature, power demand, and / or indicator parameters; 5) second derivatives of current, temperature, power demand, and / or indicator parameters; 6) information from the battery management system (e.g., voltage, current, charge state, health state, and the rate of change of any of these, where these parameters are current value, expected current) 7) the rate of change which may affect the dynamic response of the value and / or current value and cause changes in the wear threshold, fuse fault value and / or current event determination; 8) the determination and monitoring of the contactor connection or disconnection time and consideration of the contactor connection or disconnection time when determining the response to current events; 9) the use of auxiliary system information to adjust the response (e.g., activating a collision avoidance system, causing a fuse to fail and / or bypassing a fuse to allow potential damage to the system and maintain the flow of power; 10) the use of an auxiliary system information which includes or is adjusted based on one or more of the following:

[0075] Referring to Figure 9, an exemplary apparatus 1900 for reducing or preventing fuse damage and / or fuse failure is shown. The exemplary apparatus 1900 includes a current event determination circuit 1902 which may determine that a current event 1904 indicates that a fuse threshold (wear, failure, fatigue, or other threshold) has been exceeded or is expected to be exceeded. The current event 1904 may be, for example, current, temperature, or any other parameter as described in relation to Figures 10, 15, and 16. The exemplary apparatus 1900 further includes a response determination circuit 1906 which determines a system response value 1910, for example, a response determination circuit which opens or closes one or more contactors in a fuse circuit (e.g., 2100, 2200, 2300, 2400, or any other fuse circuit or current protection circuit). The apparatus 1900 further includes a response implementation circuit 1908 which provides network communication 1912 and / or actuator commands 1914 in response to the system response value 1910. For example, the system response value 1910 may decide to close one or more contactors, and the actuator command 1914 provides the selected contactors with a command in response to the actuator command 1914.

[0076] In certain embodiments, the operation to bypass and / or engage one or more fuses is performed in coordination with the vehicle battery management system and / or accelerator pedal input (or other load request indicator) to time the inrush current experienced at the fuse in order to provide the battery management system or other vehicle power system with an indication that a momentary non-fuse operation is about to occur and / or that a higher fuse limit is readily applicable. In certain embodiments, during a non-fuse operation and / or a higher fuse limit operation, the device 1900 may operate a virtual fuse, for example, if the experienced current is higher than expected (e.g., it was expected to exceed the fuse wear limit but not the system fault limit, but in reality it appears to exceed the system fault limit), the device 1900 may operate to open the main high-voltage contactor, re-engage the fuse, or perform another system adjustment to protect the system in the absence of a normally available fuse-fuse operation.

[0077] Referring to Figure 17, an example of a conventionally known system having a combination of contactors and fuses is shown. For illustrative purposes, the exemplary system is provided as part of a power distribution unit (PDU) 6402 for an electric vehicle or a partially electric vehicle. The system includes an electrical storage unit (e.g., a battery) and a motor that powers the vehicle. The electrical storage (or power storage) device may be of any type, including batteries, fuel cells, and / or capacitors (e.g., supercapacitors or hypercapacitors), and combinations thereof (e.g., capacitors included in the circuit to assist in peak power generation or transient operation management). In certain embodiments, the electrical storage device is rechargeable (e.g., any rechargeable battery technology such as lithium-ion, nickel metal hydride, or nickel-cadmium) or recoverable (e.g., a chemical-based fuel cell with reversible chemistry for restoring charge generation capability). In the exemplary system, the battery operates as a DC device and the motor operates as an AC device, with an inverter positioned between them to regulate the motor's power. The exemplary system includes a filter capacitor 6404 that provides regulation of the mains power circuit. The exemplary system includes a low-side contactor and a high-side contactor. The high-side contactor is in series with a fuse 6410 that provides overcurrent protection to the circuit. The exemplary system further includes a pre-charge circuit, indicated as a pre-charge repeater 6408 and a pre-charge resistor 6406. In certain embodiments, the pre-charge repeater 6408 is engaged before the high-side contactor is engaged, allowing the capacitive elements throughout the circuit to be energized through the pre-charge resistor 6406, limiting inrush current or other charging artifacts during system startup. Overcurrent protection is provided by the system via the fuse 6410, and it is found that the characteristics of the fuse 6410 set the overcurrent protection for the drive circuit via the PDU. Furthermore, the contactors are exposed to connection and disconnection events, including arcing, heating, and other wear.

[0078] Referring to Figure 18, an exemplary PDU 6402 of this disclosure is schematically shown. The exemplary PDU 6402 is available in a system such as that shown in Figure 17. The exemplary PDU in Figure 18 includes a circuit breaker / repeater 6502 component on the high side. The exemplary configuration in Figure 18 is not limiting, and any configuration of the circuit breaker / repeater 6502 that provides overcurrent protection for a system using any of the principles described throughout this disclosure is contemplated herein. The exemplary PDU 6402 in Figure 18 utilizes the circuit breaker / repeater 6502 for overcurrent protection and omits the contactor and fuse in series. Any circuit breaker / repeater 6502 described throughout this disclosure may be available in a system such as that shown in Figure 18. The PDU 6402 in Figure 18 further utilizes a precharge repeater 6408 and a precharge resistor 6406, similar to that shown in Figure 17. In the example shown in Figure 18, the circuit breaker / repeater 6502 is in parallel with the precharge circuit, and the relay portion of the circuit breaker / repeater 6502 may be engaged after the system has been charged via the precharge circuit. As described throughout this specification, the circuit breaker / repeater 6502 provides continuous and selectable overcurrent protection while providing full-rated operation over the entire range of the system's design operating current. In previously known systems, the contactor / fuse device always provides a gap within the operating range, either by pushing the fuse activation at least partially within the operating current range or by moving the fuse activation outward from the rated range, providing a gap for overcurrent protection above the system's rated current. Furthermore, as described throughout this disclosure, the circuit breaker / repeater 6502 can provide multiple current protection regimes, selectable current protection based on operating conditions, and reduces wear on the contact elements of the circuit breaker / repeater compared to previously known contactors. Thus, a system like the one shown in Figure 18 can provide more reliable, responsive, and recoverable overcurrent protection compared to previously known systems.

[0079] Referring to Figure 19, an exemplary PDU 6402 is schematically shown. The exemplary PDU 6402 is available in a system such as the one shown in Figure 1 and has features that can be added to or replaced with the features described with respect to Figure 18. The example in Figure 19 shows an external input to a circuit breaker / repeater 6502 (suppressor, by schematic diagram of key switch input 6504 in the example). The circuit breaker / repeater 6502 responds to external signals in a configurable manner. For example, a key switch-on operation may be used to energize the circuit breaker / repeater 6502 directly (e.g., by wiring a key switch circuit through the coil of the circuit breaker / repeater) or indirectly (e.g., by receiving a network value representing the key switch position, or by receiving a voltage signal representing the key switch position), thereby charging the power circuit. In another example, a key switch-off operation may be used to de-energize the circuit breaker / repeater 6502, thereby removing power from the power circuit. External signals may be of any type or a number of types, including external commands generated from any part of the system, calculated values ​​indicating whether power should be supplied or cut off (e.g., service events, maintenance events, accident indicators, emergency stop commands, vehicle controller requests, device protection requests for any device on the vehicle, calculations indicating that temperature, voltage, or current values ​​have exceeded a threshold, etc.). External signals may be supplied as hardwired signals (e.g., electrical connections to voltages representing signal values) and / or as communications (e.g., data links or network communications), which may be wired or wireless, and may be generated on or by an external controller (e.g., a vehicle controller, a power management controller, etc.) on the PDU6402. For ease of explanation, the example in Figure 19 does not show a precharge circuit, but embodiments such as those shown in Figure 18 or Figure 19 may have a precharge circuit or omit one, depending on the characteristics of the system, the design goals and requirements of the system, etc.

[0080] Referring to Figure 20, an exemplary schematic block diagram of a circuit breaker / repeater is shown. The exemplary circuit breaker / repeater in Figure 20 includes a power bus 6702 (e.g., high voltage, power, load power, etc.) that operates high voltage throughput and is connected or disconnected via the contacts schematically shown. The voltage that is “high voltage” on the power bus may be any value and depends on the load being driven and other selection parameters of the system. In certain embodiments, high voltage is any voltage above 42V, above 72V, above 110V, above 220V, above 300V, and / or above 360V. The voltage range may differ for power loads versus auxiliary loads (e.g., PTO devices, pumps, etc.) and may be higher or lower than these ranges. In this example, the standard on / off 6504 or control voltage is shown on the left (shown as 12V, but any value such as 6V, 12V, 24V, 42V, etc. may be available). The standard voltage 6504 is shown for illustrative purposes, but the standard voltage may additionally or alternatively be a data link or network input communicating with the circuit breaker / repeater controller (e.g., if the circuit breaker / repeater has independent access to control power). In certain embodiments, the standard voltage 6504 is the same voltage experienced by the vehicle controller in the key switch by auxiliary (e.g., non-powered or non-loaded) components in the system. In certain embodiments, the standard voltage 6504 is the key switch 6504 signal. The standard voltage 6504 may be configured to be received via input control isolation 6710.

[0081] Furthermore, the example in Figure 20 shows an auxiliary off-isolation 6708 that provides inputs for auxiliary control of the circuit breaker / repeater. In certain embodiments, the auxiliary off-isolation 6708 is coupled to an electrical input 6704, such as a selectable input at a standard voltage, or an output from a controller (e.g., the controller provides power to the auxiliary off-isolation as an output of the selected voltage). In certain embodiments, the auxiliary off-isolation 6708 may utilize a data link or network input. For example, in certain embodiments where the circuit breaker / repeater has an internal controller, the standard on / off 6504 and the auxiliary off-isolation input 6704 may be the same physical input, such as a data link input, a network input, and / or a controllable electrical signal (e.g., a controlled voltage value) that provides the circuit breaker / repeater with information to determine the current requested state of the circuit breaker / repeater. In certain embodiments, the circuit breaker / repeater is a hardware-only device that accepts a first voltage value for the standard on / off position, a second voltage value for the auxiliary off position, and responds by performing a selected operation via the circuit breaker / repeater's hardware configuration.

[0082] In the example in Figure 20, the standard on / off input 6504 and auxiliary off input 6704 include circuit protection components such as surge protection and polarity protection (e.g., isolation 6708, 6710). The exemplary circuit breaker / repeater includes logic circuits that energize the repeater (close the contacts on the power bus) when the standard on / off input 6504 is high, and deenergize the repeater (open the contacts on the power bus) when the standard on / off input 6504 is low or the auxiliary off input 6704 is low. In the example in Figure 20, the logic circuits are shown schematicly and may be implemented as hardware elements within the circuit breaker / repeater. Additionally or alternatively, a controller within the circuit breaker / repeater may interpret input voltages, data link signals, and / or network communications to implement the logic and determine whether to open or close the repeater. The logic of this system is shown as a "normally open" repeater that closes (contacts) using power, but the circuit breaker / repeater may be configured as "normally closed", latched, or any other logic configuration. Additionally or alternatively, the standard on / off input 6504 and / or auxiliary off input 6704 may utilize logic high or logic low to implement the operation of the circuit breaker / repeater.

[0083] The exemplary circuit breaker / repeater in Figure 20 further illustrates a current sensing device 6706 ("Current Sensing"), which may be a current sensor on the bus, a calculated current value based on other system parameters, a current value passed to the circuit breaker / repeater, and / or a controller operably coupled to the circuit breaker / repeater, or any other device, mechanism, or method for determining the current value on the bus. In the example in Figure 20, the current sensing device 6706 is coupled to the "trigger level off" portion of the logic circuit and operates to de-energize the repeater when a high current value is detected. The detected high current value may be either a single threshold determined, for example, by hardware in the logic circuit, and / or a selectable threshold determined by the controller based, for example, operating conditions or other values ​​in the system. It can be seen that, via hardware or using the controller, functions of the detected current value, such as rate of change, cumulative current value above a threshold, etc., may be used in addition to or alternative to the single detected current value. It can be seen that a circuit breaker / repeater as shown in Figure 20 provides a controllable opening of the power bus circuit in a selected threshold current value and / or in its function, enabling continuous operation across the entire range of the system's rated current. Furthermore, the circuit breaker / repeater shown in Figure 20 provides controllable disconnection of the power bus for any selected parameter that may not be current-related, such as emergency stop operations, requests from other locations in the system (e.g., vehicle controllers), service or maintenance operations, or any other selected reason. Certain embodiments of the entire disclosure provide additional features of the circuit breaker / repeater, any one or more of which may be included in embodiments such as those shown in Figure 20.

[0084] Referring to Figure 21, an exemplary circuit breaker / repeater is schematically shown in a cross-sectional view. The exemplary circuit breaker / repeater generally includes a switching section 6820 (upper half, or “circuit breaker”) and an operating section 6822 (lower half, i.e., “repeater”). For illustrative purposes, several exemplary components of the circuit breaker / repeater are shown and described. The exemplary circuit breaker / repeater includes a coil 6816 and a magnetic core 6818 in the repeater section. In this example, energizing the coil 6816 activates the repeater, pulling down the armature 6814 to the magnetic core 6818. The armature 6814 is coupled at its upper end to a movable contact 6810, thereby moving to contact a fixed contact 6812, completing the circuit and allowing current to flow through the power bus. In the example in Figure 21, the movable contact 6810 is pressed against the fixed contact 6812 by a contact force which is a biasing spring 6804 of selectable biasing force in the example in Figure 21. The movable contact 6810 can be lifted from the fixed contact 6812 with sufficient force, even when the armature 6814 is in the engaged (downward) position, and can compress the contact force spring 6804. In the example in Figure 21, the movable contact 6810 is open, or the armature 6814 is in the disengaged (upward) position, not in contact with the fixed contact 6812.

[0085] The circuit breaker / repeater's break-off section 6820 includes several splitter plates 6806 adjacent to the main contact body and a permanent magnet system 6802 surrounding the arc path between the splitter plates 6806 and / or the contact gap and the splitter plates 6806. During engagement or disengagement of the movable contact 6810 when the power bus is energized, the main contact body, in the presence of the magnetic field provided by the permanent magnet system 6802, cooperates with the splitter plates 6806 to dissipate and distribute the resulting arc, significantly reducing contact wear, degradation, and damage. The combined configuration of the break-off section has been shown to significantly extend the lifespan of the contacts and switching chamber (for example, due to the low arc heat load over the life of the circuit breaker / repeater).

[0086] The current flowing through the power bus generates a repulsive force between the contacts, i.e., a Lorentz force. The Lorentz force is a complex function of the contact area of ​​the contacts and the value of the current flowing through the power bus. When the current is very high, the Lorentz force between the contacts compresses the contact force spring 6804 sufficiently, causing the movable contact 6810 to lift away from the fixed contact 6812, instantaneously opening the repeater. It has been found that the contact force spring 6804 can be easily adjusted to provide physical disconnection of the contacts at a selectable value. Additionally or alternatively, the contact area between the contacts and other geometric aspects of the contacts can be manipulated to select or adjust the physical disconnection current. However, in certain embodiments, the selection of the contact force spring 6804 provides direct adjustment of the physical disconnection current. In certain embodiments, the selection of the contact force spring 6804 includes changing the spring to change the physical disconnection current. Additionally or alternatively, the contact force spring 6804 can be adjusted in place (e.g., by compressing or releasing the spring axially) to adjust the physical disconnection current.

[0087] In certain embodiments, after a physical disconnection event (for example, when the movable contact 6810 is pushed away from the fixed contact 6812, compressing the contact force spring 6812, while the armature 6814 is in a downward or contact position), the current through the power bus rapidly decreases, the Lorentz force decreases, and the contact force spring 6804 pushes the movable contact 6810 back into the engaged position. In certain embodiments, the current sensor 6706 detects a high-current event, triggering the coil 6816 to de-energize and return the armature 6814 to the disengaged position. Thus, when the movable contact 6810 returns to the engaged position, the armature 6814 has already moved the movable contact so that the movable contact 6810 does not come into contact with the fixed contact 6812 after the physical disconnection event. In certain embodiments, the threshold detected by the current sensor 6706 to disengage the armature 6814 is lower than the physical disconnection current, giving the armature 6814 a "head start" and reducing the likelihood of the movable contact 6810 re-contacting the fixed contact 6812. In many systems, re-contact between the movable contact 6810 and the fixed contact 6812 during very high current events can result in significant damage to the circuit breaker / relay and / or weld of the contacts.

[0088] Referring to Figure 22, an exemplary circuit breaker / repeater is shown illustrating the relative motion between the armature and the movable contact. In this example, the upper armature biases the movable contact away from the fixed contact, resulting in the disconnection of the power bus. The lower armature pulls the movable contact downward, engaging it with the fixed contact, resulting in the connection of the power bus. The operating arrow 6904 in Figure 22 illustrates the movement of the armature that occurs when the armature moves from the open to the closed position after energizing the coil. Throughout this disclosure, references to “up” or “down” are for illustrative purposes only and do not refer to the actual vertical relationships of any component of the circuit breaker / repeater. The circuit breaker / repeater may be positioned such that the movement of the armature is along any axis, including up and down, down and up, horizontal orientation, and / or any other orientation. In certain embodiments, the armature returns to the upper or disengaged position using passive elements such as a biasing spring or reversing spring (e.g., located between the armature and the permanent magnet, and / or in one or more housings thereof), resulting in the "normally open" logical operation of the circuit breaker / repeater. The biasing spring or reversing spring is not visible in the schematic cross-sectional view of Figure 22. As described throughout this disclosure, the circuit breaker / repeater may be normally open, normally closed, latched, or any other logical configuration, with hardware and / or control elements appropriately tuned to provide such configurations.

[0089] Referring to Figure 23, an exemplary circuit breaker / relay is shown in the closed position. In the example in Figure 23, the armature is lowered, and the movable contact 6810, together with the armature 6814, is lowered further to the engagement position with the fixed contact, closing the circuit and allowing power to pass through the power bus. The contact force spring 6804 is compressed in the position shown in Figure 23, providing a contact force to the movable contact 6810 against the fixed contact. It can be seen that there is space for movement in the movable contact, and a force sufficient to overcome the contact force 6804 is allowed by the spring to lift the movable contact 6810 away from the fixed contact, thereby opening the circuit and preventing power from passing through the power bus.

[0090] Referring to Figure 24, schematic diagrams of conventionally known contactor-fuse systems and circuit breaker / repeater systems consistent with embodiments of the present disclosure are shown. In the example of Figure 24, the operating current bar is shown on the left and has two common operating regimes: operation within the rated current value (e.g., within the system's designed current limits, such as regions 7004 and 7006) and operation above the rated current value (e.g., region 7008). Furthermore, in the example of Figure 24, operation within the rated current is subdivided into lower region 7004 and upper region 7006. In the example of Figure 24, lower region 7004 and upper region 7006 are exemplary examples for showing operating modes within the rated current region; for example, lower region 7004 may be associated with low-power operations such as auxiliary equipment operation, and upper region 7006 may be associated with high-power operations such as power or lifting. Regions 7004 and 7006 provide a conceptual distinction between operating conditions, and the actual operations occurring within the lower region 7004 and upper region 7006 are not important for the explanation of Figure 24. For example, the upper region 7006 for one exemplary system may be power for moving a vehicle (e.g., if the lower region 7004 has another function such as communication or power to accessories), and the lower region 7004 for another exemplary system may be power for moving a vehicle (e.g., if the upper region 7006 has another function such as charging or high-performance power).

[0091] In the example in Figure 24, the operating region of the contactor-fuse system is shown in the center. The contactor provides full operation up to the rated power. Design choices allow the contactor to provide operation slightly above the rated power (e.g., when system risk is acceptable to provide higher capability) or slightly below the rated power (e.g., when system performance is compromised to protect system components). The contactor-fuse system further includes the operating region of the fuse, which operates at a selected current value. An operating gap 7002 occurs, and the fuse does not operate because the current value is low, but the contactor also does not support operation in the gap 7002 region. The gap 7002 can only be closed by overlapping operation of the contactor and / or fuse, which inevitably compromises the system risk profile or performance. If the fuse region is extended further down, rated operation under a particular duty cycle may result in fuse events and loss of mission. Furthermore, when contactors and fuses experience wear or degradation, the operating area of ​​the contactor-fuse system shifts, leading to inconsistent system performance, loss of protection, and / or unnecessary fuse events. Additionally, fuse failure modes, due to the fuse blow-out period and the arc discharge time through the fuse during activation, result in the system being exposed to high current for extended periods. Finally, contactor operation in the upper range of the contactor operating area leads to undesirable overheating and degradation of the contactor.

[0092] The example in Figure 24 shows the operating region of a circuit breaker / repeater consistent with a particular embodiment of this disclosure. The circuit breaker / repeater provides smooth, selectable functionality across the entire operating current bar. The circuit breaker / repeater provides high-performance contacts that do not operate near the upper region of its current capacity, reducing overheating and degradation from operation within high rating ranges such as the upper region 7006. Furthermore, current sensors and associated disconnection operations enable selectable disconnection when operation exceeds the system's rated current. In addition, a physical disconnection current is available that provides immediate disconnection of the power bus at very high current values ​​(see, for example, Figure 21 and related disclosures). In certain embodiments, the arc discharge mechanism of the circuit breaker / repeater further provides a faster and less damaging disconnection event than that experienced by conventionally known contactor-fuse configurations. Furthermore, the circuit breaker / repeater provides recoverable disconnection operation, where a simple command to the circuit breaker / repeater provides connection again without a service event. Therefore, if a system fault causing a high-current event is resolved or coincides with a restart, the system can immediately resume operation by the circuit breaker / repeater as needed, without the need to diagnose the fuse event or replace the fuse.

[0093] Referring to Figure 25, an exemplary procedure 7100 for disconnecting the power bus is shown. The exemplary procedure 7100 includes an operation 7102 for detecting a current value, for example, using a current sensor (see Figure 21). The procedure 7100 further includes an operation 7104 for determining whether an overcurrent event has been detected. For example, the detected current value, its function, or a calculated parameter determined in response to the current value can be compared to a threshold to determine whether an overcurrent event has been detected. The exemplary procedure 7100 further includes an operation 7106 for commanding the contacts to open, for example, by de-energizing a coil, thereby moving the armature to a position where the contacts are open. The overcurrent threshold may be any value and may be changed in real time and / or according to operating conditions. The value of the overcurrent threshold depends on the application and components in the system. Exemplary and non-limiting overcurrent values ​​include 100A, 200A, 400A, 1kA (1,000 amperes), 1.5kA, 3kA, and 6kA.

[0094] Referring to Figure 26, an exemplary procedure 7200 for performing a physical disconnection is shown. The exemplary procedure 7200 includes an operation 7202 to accept the current throughput, for example, as the current passing through the coupled contacts in a power bus. The exemplary procedure 7200 further includes an operation 7204 to determine whether the current resulting force (e.g., a Lorentz force between the movable and fixed contacts) exceeds the contact force (e.g., as provided by a contact force spring). The exemplary procedure 7200 further includes an operation 7206 to open the contacts by a physical response, such as a Lorentz force that overcomes the contact force spring and moves the movable contact away from the fixed contact. The physical disconnection current may be any value and depends on the application and the components in the system. Exemplary and non-limiting physical disconnection currents include 400A, 1kA, 2kA, 4.5kA, 9kA, and 20kA.

[0095] Referring to Figure 27, an exemplary procedure 7300 for opening contacts in response to an overcurrent event and / or in response to any other selected parameter is shown. The exemplary procedure 7300 includes an operation 7302 for turning on the system power, for example, via a key switch or other circuitry and / or via recognition of the key switch ON state. Procedure 7300 further includes an operation 7304 for determining whether the contact-enabling condition is met, for example, immediately after the key switch is ON, after a selected period, after it is determined that a system precharge event has been completed, and / or according to any other selected condition. In a particular embodiment in which operation 7304 determines that the contact-enabling condition is not met, procedure 7300 holds operation 7304 until the contact-enabling condition is met. Any other response to operation 7304 determining that the contact-enabling condition is not met is contemplated herein and includes requesting permission to enable the contact condition, setting a fault code, and so on. In response to operation 7304, which determines that the contact conditions are met, procedure 7300 further includes operation 7306, which closes the contacts (e.g., energizes the coils to move the armature), and operation 7202, which accepts the current throughput. An exemplary procedure 7300 further includes operation 7200, which performs a physical disconnection if the allowable current is sufficiently high, and proceeds to operation 7102 to detect the current value through the power bus. Procedure 7300 further includes operation 7104, which determines whether an overcurrent event has been detected (in a particular embodiment, operation 7104 may be set to a current value lower than the physical disconnection current tested in operation 7200). In response to operation 7104, which determines that an overcurrent event has been detected, procedure 7300 includes operation 7312, which commands the contacts to open. In response to operation 7104, which determines that no overcurrent event is detected, procedure 7300 includes operation 7308, which detects an auxiliary command (e.g., auxiliary off input), and operation 7310, which determines whether an auxiliary command for opening a contact exists (e.g., logical high, logical low, specified value, absence of specified value, etc.). In response to operation 7310, which determines that an auxiliary command for opening a contact exists, procedure 7300 includes operation 7312, which commands the contact to open.In response to operation 7310 determining that there is no auxiliary command to open the contact (for example, in the example in Figure 27, the branch is "continue operation"), the procedure returns to operation 7306.

[0096] Referring to Figure 28, an exemplary procedure 7400 for restoring the operation of a circuit breaker / repeater after a contact opening event is shown. The exemplary procedure 7400 includes an operation 7300 to open the contacts of the circuit breaker / repeater, e.g., an operation in which the contacts open due to a physical disconnection, overcurrent detection, and / or an auxiliary off command. The procedure 7400 further includes an operation 7402 to determine whether a contact reset condition exists. Exemplary and non-limiting operations 7402 include determining that a contact-enabling condition is met, determining that a fault code value has been reset, determining that a system controller has requested a contact reset, and / or any other contact reset condition. The procedure 7400 further includes an operation 7404 to close the contacts, e.g., by supplying power to a coil to move an armature.

[0097] Referring to Figure 29, an example of a conventionally known mobile power supply circuit is shown. The exemplary mobile power supply circuit is similar to the mobile power supply circuit shown in Figure 17. The example in Figure 29 includes a junction box housing a precharge circuit, a high-side repeater, and a low-side repeater. In certain embodiments, the precharge circuit and high-side repeater are housed within a housing in the junction box. In the example in Figure 29, a fuse 6410 provides overcurrent protection on the high side and is housed in the PDU housing 7500 together with the main repeater and precharge resistor 6406.

[0098] Referring to Figure 30, an exemplary mobile power supply circuit includes a circuit breaker / repeater 6502 located in the high-side circuit and a second circuit breaker / repeater 6502 located in the low-side circuit. In certain embodiments, each circuit breaker / repeater 6502 provides continuous overcurrent control throughout the operating range of the mobile application, as described throughout this disclosure. Furthermore, the low-side circuit breaker / repeater 6502 provides overcurrent protection under all operating conditions, including during pre-charge operation in which the high-side circuit breaker / repeater 6502 can be bypassed, and as a result, the mobile power supply circuit can be pre-charged via the pre-charge resistor 6406. In certain embodiments, both the high-side and low-side circuit breaker / repeater 6502 provide additional advantages such as rapid arc dispersion, low wear during connection and disconnection events, and improved heating characteristics within the rated range during high-current operation of the mobile circuit.

[0099] Referring to Figure 31, an exemplary power distribution configuration for a mobile application is shown. The embodiment in Figure 31 is similar to the embodiment in Figure 30, having a high-side circuit breaker / repeater 6502 and a low-side circuit breaker / repeater 6502. Four operating regimes of the embodiment in Figure 31 are described herein, including pre-charge operation (e.g., when the mobile application's system is powered on), power supply operation for a load (e.g., providing power or auxiliary power to the mobile application), regenerative operation (e.g., recovering power from a power load or auxiliary load), and charging operation (e.g., connecting a dedicated charger to the system). In the example in Figure 31, the low-side circuit breaker / repeater 6502 has an associated current sensor 6706. In the example in Figure 31, the low-side circuit breaker / repeater 6502 is in the loop during all operations and can provide current protection for any operating conditions. To save costs, the current sensor of the high-side circuit breaker / repeater 6502 can be omitted. In certain embodiments, for the protection of the circuit breaker / repeater contacts 6502, a local current sensor may be included for each circuit breaker / repeater 6502 to provide action to protect the contacts in the event of a physical current interruption (see, for example, Figure 24). For example, it can be seen that additional contactors and / or circuit breakers / repeaters beyond those shown may be provided to isolate the charging circuit, route power through one of a selected power load and / or auxiliary load, and / or prevent the flow of power through an inverter (not shown) during charging operation. Additionally or alternatively, certain components shown in Figure 31 may not be present in certain embodiments. For example, a low-side contactor on the charging circuit may not be present, and one or more of either a power load (traction motor drive) or an auxiliary load may not be present. During pre-charge operation, the pre-charge contactor 7702 may be closed while the high-side circuit breaker / repeater 6502 is open, and the low-side circuit breaker / repeater 6502 provides current protection during pre-charge operation (in addition to or instead of the pre-charge fuse). During charging, the low-side circuit breaker / repeater 6502 provides current protection, while the high-side circuit breaker / repeater 6502 is bypassed by the charging circuit.

[0100] Referring to Figure 32, an exemplary power distribution management for a mobile application is shown. The embodiment in Figure 32 is similar to the embodiment in Figure 31, except that the high-side circuit breaker / repeater 6502 is in the loop during all operations, and the low-side circuit breaker / repeater 6502 is not in the loop during charging operations. In the example in Figure 32, the high-side circuit breaker / repeater 6502 may include a current sensor associated with it to protect the contacts during physical current disconnection. In a particular embodiment, depending on the circuit dynamics of the mobile application, the current sensor 6706 shown on the low side may be sufficient to protect the contacts of the high-side circuit breaker / repeater 6502 without a dedicated current sensor for the high-side circuit breaker / repeater 6502. During pre-charge operations in the embodiment in Figure 32, current protection is either absent or provided by a pre-charge fuse. During charging operations in the embodiment in Figure 32, current protection is provided by the high-side circuit breaker / repeater 6502.

[0101] Referring to Figure 33, an exemplary power distribution management for a mobile application is shown. The embodiment in Figure 33 is similar to the embodiment in Figure 31, except that the high-side circuit breaker / repeater 6502 is replaced with a standard contactor. In the example in Figure 33, the low-side circuit breaker / repeater 6502 provides current protection during all operating conditions, otherwise the system would use conventional components. In certain embodiments, improved current protection capability is desirable, but contactor wear may not be a major concern, and the trade-off with an inexpensive contactor located elsewhere in the mobile power circuit away from the low-side circuit breaker / repeater 6502 may be an acceptable solution. Furthermore, the presence of the low-side circuit breaker / repeater 6502 in the circuit for all operating conditions can reduce wear on conventional contactors in the mobile power circuit through connection timing, as the low-side circuit breaker / repeater 6502 reduces the number of connection and disconnection events of other contactors while the system is charging.

[0102] Referring to Figure 34, an exemplary power distribution management for a mobile application is shown. The embodiment in Figure 34 is similar to the embodiment in Figure 32, except that the low-side circuit breaker / repeater is replaced with a contactor and the low-side charging circuit is routed through the low-side contactor. The low-side charging circuit, as in the embodiment in Figure 32, may, in certain embodiments, bypass the low-side contactor. In Figure 34, it can be seen that when the high-side circuit breaker / repeater 6502 is bypassed, there is a circuit path through the pre-charge circuit without short-circuit protection during pre-charge operation unless protection is provided by a pre-charge fuse. In certain embodiments, a fuse in the pre-charge circuit (not shown) may be provided to provide short-circuit protection during pre-charge operation, and / or unprotected pre-charge operation may be an acceptable risk. In any of the embodiments shown throughout this disclosure, a fuse may be included potentially in series with the circuit breaker / repeater 6502, depending on the benefits required from the circuit breaker / repeater 6502 for a particular embodiment. In certain embodiments, the included fuse with the circuit breaker / repeater 6502 may be configured to operate at very high current values ​​that are expected to be higher than the physical disconnection current of the circuit breaker / repeater 6502, for example as redundant protection of the circuit, and / or to provide a long-life fuse that is expected to last over a selected period, such as the service life of an electric mobile application.

[0103] Referring to Figure 35, an exemplary power distribution management for a mobile application is shown, consistent with the embodiment shown in Figure 31. The power flow during pre-charge operation is schematically shown in Figure 35, with arrows indicating the path of the power flow. The operation described in relation to Figure 35 can be understood in the context of any of the embodiments described throughout this disclosure. During pre-charge operation, the pre-charge contactor 7702 is closed, the low-side circuit breaker / repeater 6502 is closed, and power is supplied through the mobile circuit and the pre-charge resistor 6406. Pre-charge operation allows the capacitive elements of the mobile circuit to be charged before the high-side circuit breaker / repeater 6502 is closed. During pre-charge operation in the embodiment of Figure 35, the low-side circuit breaker / repeater 6502 provides overcurrent protection for the circuit. After the pre-charge operation, which can be determined by an open-loop method (e.g., using a timer) or a closed-loop method (e.g., detecting a voltage drop across battery terminals or detecting current flowing through the circuit) is completed, the high-side circuit breaker / repeater 6502 is closed and the pre-charge contactor 7702 may be opened.

[0104] Referring to Figure 36, an exemplary power distribution management for a mobile application is shown, consistent with the embodiment shown in Figure 31. The power flow during load power supply operation is shown in Figure 36, with arrows indicating the path of the power flow. The operation described in relation to Figure 36 can be understood in the context of any of the embodiments described throughout this disclosure. During load power supply operation, in this example, the precharge contactor 7702 is open, and power flows through the high-side circuit breaker / repeater 6502 and the low-side circuit breaker / repeater 6502. The embodiment in Figure 36 shows a traction motor load being powered, but additionally or alternatively, one or more auxiliary loads may be powered in a similar manner. During load power supply operation, both the high-side circuit breaker / repeater 6502 and the low-side circuit breaker / repeater 6502 provide overcurrent protection. In certain embodiments, the high-side circuit breaker / repeater 6502 and the low-side circuit breaker / repeater 6502 may have the same or different current ratings. For example, if one of the high-side circuit breakers / repeaters 6502 or the low-side circuit breakers / repeaters 6502 is easier or less expensive to maintain, that one of the circuit breakers / repeaters 6502 may have a lower overall current rating to provide a system in which one of the circuit breakers / repeaters 6502 is predictable to fail first. Additionally or alternatively, certain operations on the system may have a higher current rating, for example, a charging operation in which the charging circuit is routed through only one of the circuit breakers / repeaters 6502 (e.g., the low-side circuit breaker / repeater in the embodiment of Figure 36), and therefore one of the circuit breakers / repeaters 6502 may have a higher current rating than the other. In certain embodiments, the current rating of the circuit breaker / repeater 6502 may be reflected by the contact material of the movable and fixed contacts, the contact surface area of ​​the movable and fixed contacts, the threshold setting of controlled operation in response to the detected current, the number or arrangement of splitter plates, the material and geometry of the splitter plates, the magnetic strength and geometry of the permanent magnet system around the splitter plates, the contact force of the contact force springs, and / or the Lorentz force on the contacts, as well as circuit breaker / repeater design elements (e.g., contact surface area and contact spring force) that determine the physical disconnection current.

[0105] Referring to Figure 37, an exemplary power distribution management for a mobile application is shown, consistent with the embodiment shown in Figure 31. The power flow during regenerative operation is shown in Figure 37, with arrows indicating the flow path. Regenerative operation from a power load is shown, for example, as can be experienced during regenerative braking, but any regenerative operation from any load in the system is intended herein. During regenerative operation, the high-side circuit breaker / repeater 6502 and the low-side circuit breaker / repeater 6502 are closed, and the pre-charge contactor 7702 may be open. Thus, both the high-side circuit breaker / repeater 6502 and the low-side circuit breaker / repeater 6502 provide overcurrent protection during the regenerative operation of the system.

[0106] Referring to Figure 38, an exemplary power distribution management for a mobile application is shown, consistent with the embodiment shown in Figure 31. The power flow during a charging operation is shown in Figure 38, with arrows indicating the flow path. Charging may be by an external charger and may include a high-current fast-charging operation that can provide current operation higher than that associated with the load's rated power. In the operation shown in Figure 38, the low-side circuit breaker / repeater 6502 is closed, the contacts in the charging circuit are closed, and the power flow path as shown is provided. In certain embodiments, the high-side circuit breaker / repeater 6502 and the pre-charge repeater 7702 may be opened, for example, to isolate an inverter (not shown) from the circuit during a charging operation. In certain embodiments, for example, if isolation of the inverter during a charging operation is not required and / or if rapid operation without a pre-charge cycle after charging may be desired, the high-side circuit breaker / repeater 6502 may be closed. During a charging operation, the low-side circuit breaker / repeater 6502 provides overcurrent protection in the example of Figure 38.

[0107] Referring to Figure 39, another broken schematic diagram of a circuit breaker / repeater is shown. In the example in Figure 39, the circuit breaker side 6820 shows the circuit breaker and connection components, and the repeater side 6822 shows the contactor operating components. The illustrated circuit breaker / repeater is an example and shows a single-pole single-throw circuit breaker repeater. Additionally or alternatively, the circuit breaker / repeater may be dual-pole (e.g., operating two separate circuits, a parallel path for one of the circuits to provide additional current capacity, and / or one pole providing high-side coupling and the other pole providing low-side coupling). In certain embodiments, a circuit breaker / repeater having two or more poles may have poles that are controlled independently, or they may operate together using the same armature. In certain embodiments, both poles have arc diffusion protection provided by the same splitter plate or by a separate set of splitter plates. In certain embodiments, both poles have arc diffusion protection provided by the same permanent magnet system or by separate permanent magnet systems.

[0108] Referring to Figure 40, another example of a schematic logic diagram of a circuit breaker / repeater is shown. The example in Figure 40 includes an emergency input or auxiliary input 8602 handled by input isolation 8604. The emergency input or auxiliary input 8602 may replace or add to any other auxiliary inputs and provide the ability of a particular application to control the operation of the circuit breaker / repeater for a selected response to any desired mode of the system, including, but not limited to, enabling disconnection guarantees in service, in emergency, and / or by any desired control logic.

[0109] Referring to Figure 41, a detailed cross-sectional view of the contact area of ​​an exemplary circuit breaker / repeater is shown. The contact area in Figure 41 shows an example configuration of the contact surfaces of the movable contact 6810 and the fixed contact 6812. The contact configuration is part of the system that contributes to the physical opening force of the contact and can be configured by any shape or area to provide a desired response to the high currents generated in the associated circuit.

[0110] Referring to Figure 42, an exemplary circuit breaker / repeater is shown with a portion of the housing removed for illustrative purposes. The exemplary circuit breaker / repeater includes two movable contacts that engage with two fixed contacts. In the example in Figure 42, the movable contacts are coupled and operated by the same armature 6814 by a contact force provided by a contact spring 6804. In the example in Figure 42, each contact is electrically connected via a busbar 8802. In this example, the busbar 8802 transitions directly between the contacts and is not largely exposed to the energized portion of the busbar containing the fixed contacts. In certain embodiments, the busbar 8802 may include a trajectory that exposes a portion of the busbar 8802 in close proximity to the energized member of the fixed contacts, thereby contributing to a Lorentz force that provides physical disconnection of the circuit breaker / repeater. In certain embodiments, both the area of ​​the busbar 8802 exposed to the fixed contact current carrier portion and the degree of proximity of the busbar 8802 to the fixed contact current carrier portion are design elements that enable the configuration of the Lorentz force response.

[0111] Referring to Figure 43, an exemplary power management configuration for a mobile application is shown. The example in Figure 43 includes a circuit breaker / repeater 6502 located on the high side of the power supply circuit, and a pre-charge contactor, resistor, and fuse coupled in parallel to the high-side circuit breaker / repeater 6502. In the example in Figure 43, the circuit breaker / repeater 6502 is, for example, a two-pole circuit breaker / repeater 6502 to provide additional current capacity through contacts for the power supply circuit. The example in Figure 43 shows a controller 8902 that performs control functions for the circuit breaker / repeater 6502 and the power management device. For example, the controller 8902 responds to high-current events by receiving a key switch input, performing a pre-charge operation, operating the circuit breaker / repeater to close, and opening the contacts of the circuit breaker / repeater. In another example, the controller 8902 performs a tripping operation of the power management device, such as opening the circuit breaker / repeater, after the key switch is turned off, or in response to an auxiliary input, emergency input, or other input requesting power cut-off.

[0112] Referring further to Figure 43, an exemplary power distribution management system for a mobile application is schematically shown, which can be used in whole or in part with any other system or aspect of the present disclosure. The exemplary power distribution management system includes a two-pole circuit breaker / repeater, and the example in Figure 43 includes a two-pole circuit breaker / repeater having a single magnetic drive unit (e.g., a magnetic actuator) (e.g., using one set of contacts per pole). In certain embodiments, both contacts are mechanically coupled to open and close each other (e.g., operating as a two-pole single-throw contactor). In certain embodiments, the contactor may share one or more arc suppression modes (e.g., splitter plates and / or permanent magnets) and / or have individual arc suppression modes. In certain embodiments, the arc suppression modes may be partially shared (e.g., several splitter plates adjacent to both contacts) and / or partially separate (e.g., several splitter plates adjacent to only one or the other of the contacts). In certain embodiments, various features of the contactor may be shared, and other features of the contactor, such as control commands or operation (e.g., two-pole double-throw configuration), arc suppression modes, and / or housing, may be supplied separately. An example in Figure 43 further illustrates a separate contactor (e.g., the lower left of the three contacts shown) that can be controlled separately to provide contact management for a pre-charge circuit for a power distribution management system. In certain embodiments, the pre-charge contactor may be integrated with the dual-pole contacts, for example, in the same housing as the dual-pole contacts and / or together with a pre-charge coupling provided as one of the dual-pole contacts. An example in Figure 43 illustrates a fuse on the pre-charge circuit and a further overall fuse on the battery low side. The presence of the illustrated fuse is optional and non-limiting, and the fuse may be located elsewhere, may be omitted, and / or replaced (e.g., by a circuit breaker / repeater as described throughout this disclosure and / or as a pole on a two-pole or multi-pole circuit breaker / repeater).In certain embodiments, the precharge circuit may be housed in a separate power distribution unit from the circuit breaker / repeater, and / or housed in the circuit breaker / repeater, as a solid-state precharge circuit, and / or as a mechanical / electrical circuit located elsewhere in the system and / or within the circuit breaker / repeater housing.

[0113] The electrical arrangement of poles in Figure 43 is a schematic example and is not limited to the arrangement of the system for a particular embodiment. In a particular embodiment, each pole of a two-pole circuit breaker / repeater (and / or each pole or subset of poles of a multi-pole circuit breaker / repeater) may provide selectable electrical coupling to the same circuit, separate circuits, and / or selected circuits (e.g., using switches or connectors controllable elsewhere in the system not shown). In a particular embodiment, the power distribution management system further includes high-resolution current sensors and / or current sensing in two or more poles of a two-pole or multi-pole circuit breaker / repeater. In a particular embodiment, a controller is communicatively coupled to one or more high-resolution current sensors and utilizes one or more high-resolution current sensors for any operation described throughout this disclosure (e.g., to command one or more of the contacts to the open position to avoid re-contact after opening), and / or communicates information determined from the current sensors (e.g., current, or other information derived therefrom) to another controller in the system, such as a vehicle controller. In certain embodiments, each contactor of a two-pole or multi-pole circuit breaker / repeater includes a configuration configured to open in a Lorentz force response resulting from a large current through the contactor circuit, as described throughout this disclosure. In certain embodiments, one contact is configured to open in a Lorentz force response, and the other contactor opens due to a mechanical coupling with the responding contactor. In certain embodiments, each contact is configured to open in a Lorentz force response, for example to provide redundancy for circuit protection. In certain embodiments, each contact is configured to open in a Lorentz force response, each contact has a separately configured threshold for the opening response, and / or each contact is separably controllable (e.g., using a separate magnetic actuator or other controlled actuator).

[0114] Referring to Figure 44, an exemplary circuit breaker / repeater 9302 is schematically shown in context 9300. The exemplary context 9300 includes, for example, a regulatory interface 9304 that includes legal or industry regulations, policies, or other enforceable frameworks that the circuit breaker / repeater 9302 is responsible for maintaining certain performance characteristics. The exemplary regulatory interface 9304 may represent one or more design-time considerations made during the selection, installation, repair, maintenance, and / or replacement of the circuit breaker / repeater 9302 that are not physically apparent during the runtime operation of the application having the circuit breaker / repeater 9302, such as network communications, calibration values ​​for responses, and the selection of sizing of components of the circuit breaker / repeater 9302.

[0115] An exemplary context 9300 further includes a command and / or control interface 9306 which may include network couplings where signals, voltages, electrical couplings, and / or commanded functions (e.g., connector open commands or connector close commands) are received by the circuit breaker / repeater 9302. In certain embodiments, the circuit breaker / repeater 9302 includes only electromechanical components and, for example, does not include a microprocessor, controller, printed circuit board, or other “intelligent” mechanism. In certain embodiments, the circuit breaker / repeater 9302 includes several function controllers locally on the circuit breaker / repeater 9302 and other function controllers in other locations on the application having the circuit breaker / repeater 9302 on it, for example, a battery management system controller, a vehicle controller, a power electronics controller, and / or other function controllers having a distributed configuration across one or more controllers. In certain embodiments, certain commands or control modes are provided as physical or electrical commands, while other commands or control modes are provided as communication elements (e.g., data link or network commands) and / or as intelligent modes of the circuit breaker / repeater 9302 determined according to programmed logic in response to parameters detected or otherwise determined during runtime operation.

[0116] An exemplary context 9300 further includes an environmental interface 9308, such as vibration, temperature events, shocks, and other environmental parameters that the circuit breaker / repeater 9302 is subjected to. Aspects of the environmental interface 9308 may manifest physically in the circuit breaker / repeater 9302, for example, through the selection of material design, the size and placement of components, the selection of connectors, and the selection of active or passive cooling. Additionally or alternatively, planned or experienced duty cycles, power throughput, etc., may also be part of the environmental interface 9308 of the circuit breaker / repeater 9302.

[0117] An exemplary context 9300 further includes coupling to a high-voltage interface 9310, for example, a high-voltage battery of the system, a system load, a charger, etc. In certain embodiments, the high-voltage interface 9310 physically appears on the circuit breaker / repeater 9302, for example, by voltage rating, size of components, rating of current sensors (if any), material selection, etc. Any exemplary features of a circuit breaker / repeater as described throughout this disclosure, including but not limited to arc extinguishing features, contactor design elements, connector contact forces affecting the manner, etc., may be included herein for an exemplary circuit breaker / repeater 9302. Any manner of context 9300 may be included or omitted, and the described manner of context 9300 is not limited to the assumed context 9300 of a particular circuit breaker / repeater 9302. Furthermore, while the configuration of the aspects of context 9300 is an example to clarify the explanation, it will be understood that certain aspects 9304, 9306, 9308, and 9310 may be omitted, separated, and / or present in other aspects 9304, 9306, 9308, and 9310 in certain embodiments. For example, voltage limits, response time limits, etc., may be understood to arise from the regulatory interface 9304 in one embodiment, from the command / control interface 9306 in another embodiment, and from both interfaces 9304 and 9306 in yet another embodiment.

[0118] Referring to Figure 45, an exemplary circuit breaker / repeater architecture 9400 is shown. The exemplary circuit breaker / repeater 9302 includes all electronically controlled functions located away from the circuit breaker / repeater 9302, with only the electromechanical hardware remaining in the circuit breaker / repeater 9302. The exemplary circuit breaker / repeater 9302 includes a contactor 9402 that is movable by a coil 9404, for example, a high-voltage contactor that is normally open or normally closed, and power to the coil 9404 provides switching force to the contactor 9402. In certain embodiments, the contactor 9402 is normally open, and power to the coil 9404 closes the contactor 9402. The exemplary architecture 9400 further includes a high-voltage circuit 9406 that is switched by the contactor 9402, and a pair of input signals, for example, input A 9408 and input B 9410, but any number and type of input signals are construed herein. Figure 47 shows an exemplary system demonstrating exemplary operation of electronic devices for controlling an exemplary circuit breaker / repeater 9302 (magnetic drive unit 2302 in the depiction in Figure 47). The exemplary architecture 9400 further includes an external controller 9412, e.g., a battery management controller, a vehicle controller, or other controller present on the application, the external controller 9412 including an electronic device portion and a management portion. In the exemplary architecture 9400, the electronic device portion schematically represents a controller configured to manage direct switching control of the circuit breaker / repeater 9302 and to communicate diagnostic information relating to the circuit breaker / repeater 9302. The management portion schematically represents supplying external commands to the circuit breaker / repeater 9302 for, for example, commanding the circuit breaker / repeater 9302 to turn on or off, implementing overcurrent protection, and / or implementing auxiliary or safety protection (e.g., crash signals, service event signals, etc.). Although the electronic devices and control components are shown in configurations for clarity, it is understood that the configurations of the electronic devices and control components may be distributed throughout the system, and / or some of the electronic devices may be located on the circuit breaker / repeater 9302.

[0119] Referring to Figure 46, an exemplary system 9500 is shown, illustrating specific voltage, amperage, and time-based values ​​for an exemplary system. The exemplary system 9500 includes a switch-on signal with specific electrical characteristics and a hold signal with specific electrical characteristics, these being non-limiting examples. The exemplary system 9500 corresponds to a specific embodiment of architecture 9400 shown in Figure 45. The exemplary circuit breaker / repeater corresponding to the specific embodiment of the system in Figure 46 responds to a switch-on voltage of 8.2V, a hold voltage of 1.5V, and includes a 3-ohm resistor in the operating coil.

[0120] Referring to Figure 47, for illustrative purposes, the operation of an exemplary electronic component of architecture 9400 as shown in Figure 45 is illustrated. It will be understood that the components of the system as shown in Figure 47 may be implemented in hardware, software, and logic circuits, and / or coupled or distributed around the system. The exemplary electronic component includes a switch-on response in which a control voltage of 12V is applied to the module. The actual drive coil of the circuit breaker / repeater can be switched to the control voltage via a de-energized circuit and driver. The switch-on driver 9702 is controlled to approximately 65% ​​of the minimum nominal voltage (e.g., <70% or 8.2V) for 100ms. The timing, voltage, and switching logic of the switch-on operation are non-limiting examples. During the switch-on operation, the drive coil is energized with a pull current, and as a result, the drive can be switched on.

[0121] An exemplary electronic device includes an adjustment response. The exemplary adjustment response includes, for example, using a control circuit (adjustment) to linearly adjust the voltage during the switch-on process and a linkage mechanism over the duration of the switch-on process (e.g., 100 ms) thereby applying a selected operating voltage to the drive coil.

[0122] An exemplary electronic device includes a hold response. The exemplary hold response includes disabling the driver after a switch-on period and providing the drive coil with a hold signal (e.g., 1.5V) that remains on at all times, and / or a diagnostic interruption (e.g., see schematic voltage graph 9708).

[0123] In certain embodiments, non-energized transistors are checked at selected intervals (e.g., fault-tolerant time intervals, regulatory or policy intervals, and / or intervals of interest). If a non-energized transistor is faulty (e.g., permanently conductive), the circuit breaker / repeater relies on turning off the 1.5V power supply to de-energize the magnetic drive. The system can still be turned off, but operation with a faulty non-energized repeater may be slower than expected and / or too slow for the circuit breaker / repeater to comply. In certain embodiments, frequent blanking pulses (or diagnostic interruptions) bring a cutoff voltage peak (freewheeling level, about 180V in the exemplary system) to the coil connection. If the voltage peak remains off, the non-energized transistor can be diagnosed as faulty. In certain embodiments, the blanking pulses are kept short, thereby keeping the energy in the freewheeling circuit low, reducing wasted energy and heating, and keeping the holding energy low to reduce noise emission. In certain embodiments, a 100-microsecond blanking pulse is sufficient. In certain embodiments, faster or slower blanking pulses may be used. In certain embodiments, diagnostics of unenergized repeaters and / or system responses (e.g., a more conservative shutoff to account for a slower response) may be used in the electronic device, control, or elsewhere in the system.

[0124] The exemplary electronic device includes a switch-off and / or de-energized response. In this example, the holding voltage of 1.5V is used to switch off approximately 4.5V (nominal <50%). * The non-energized circuit is deactivated when the trigger voltage exceeds Urated = 6V.

[0125] Certain operations described herein include interpreting, receiving, and / or determining one or more values, parameters, inputs, data, or other information ("receiving data"). Receiving data operations include, but are not limited to, receiving data via user input, receiving data via any type of network, reading data values ​​from memory locations communicating with a receiving device, using default values ​​as received data values, estimating, calculating, or deriving data values ​​based on other information available to the receiving device, and / or updating any of these in response to subsequently received data values. In certain embodiments, data values ​​may be received by a first operation as part of receiving data values ​​and subsequently updated by a second operation. For example, if communication is down, intermittent, or interrupted, the first receiving operation may be performed, and if communication is restored, the updated receiving operation may be performed.

[0126] To illustrate aspects of this disclosure, specific logical groups of operations, e.g., methods or procedures, are provided herein. The operations described herein are described and / or illustrated schematically, and the operations may be combined, divided, rearranged, added, or removed in a manner consistent with the disclosure herein. The context of the operation descriptions may require ordering for one or more operations, and / or the order for one or more operations may be explicitly disclosed, but the order of operations should be broadly understood, and it should be understood that any equivalent grouping of operations to provide equivalent results of operations is specifically contemplated herein. For example, if a value is used in one operation step, the determination of the value may be required before that operation step in certain contexts (e.g., when a time delay of data for an operation is important to achieve a particular effect), but not before that operation step in other contexts (e.g., when using a value from a previous execution cycle is sufficient for those purposes). Accordingly, in certain embodiments, the sequence and grouping of operations described herein are explicitly intended, and in certain embodiments, rearrangement, subdivision, and / or different grouping of operations are explicitly intended herein.

[0127] Although only a few embodiments of this disclosure have been shown and described, it will be apparent to those skilled in the art that many modifications and changes can be made without departing from the spirit and scope of this disclosure as set forth in the following claims. All patent applications and patents, both foreign and domestic, and all other publications referenced herein are incorporated herein to the maximum extent permitted by law.

[0128] The programmed methods and / or instructions described herein may be deployed in part or in whole through a machine that executes computer instructions, program code, and / or instructions on one or more processors on a computer-readable medium. As used herein, “processor” is synonymous with multiple “processors,” and the two terms may be used interchangeably unless the context clearly indicates otherwise. A processor may be part of a server, client, network infrastructure, mobile computing platform, fixed computing platform, or other computing platform. A processor may be any type of computing or processing device capable of executing program instructions, code, binary instructions, etc. A processor may be a signal processor, digital processor, embedded processor, microprocessor, or any variation thereof such as a coprocessor (e.g., numerical coprocessor, graphics coprocessor, communications coprocessor) that can directly or indirectly facilitate the execution of program code or program instructions stored therein, or may include such coprocessors. Furthermore, a processor may enable the execution of multiple programs, threads, and code. Threads may run concurrently to improve processor performance and facilitate the simultaneous operation of applications. As an implementation, the methods, program code, program instructions, etc. described herein may be implemented in one or more threads. Threads may spawn other threads to which they may be assigned associated priorities. The processor may execute these threads based on priority or any other order based on instructions provided in the program code. The processor may include memory for storing methods, code, instructions, and programs as described herein and elsewhere. The processor may access storage media through interfaces that can store methods, code, and instructions as described herein and elsewhere.A storage medium associated with a processor for storing methods, programs, code, program instructions, or other types of instructions executable by a computing or processing device may include, but is not limited to, one or more of the following: CD-ROMs, DVDs, memory, hard disks, flash drives, RAM, ROMs, caches, etc.

[0129] The processor may include one or more cores that can improve the speed and performance of the multiprocessor. In embodiments, the process may be a dual-core processor, a quad-core processor, or other chip-level multiprocessor that combines two or more independent cores (called dies).

[0130] The methods and systems described herein may be deployed in part or in whole via servers, clients, firewalls, gateways, hubs, routers, or other machines that execute computer-readable instructions on such computer and / or network hardware. Computer-readable instructions may be associated with servers, which may include file servers, print servers, domain servers, internet servers, intranet servers, and other variations such as secondary servers, host servers, and distributed servers. A server may include one or more interfaces that allow it to access other servers, clients, machines, and devices via memory, processors, computer-readable media, storage media, ports (physical and virtual), communication devices, and wired or wireless media. Methods, programs, or code described herein and elsewhere may be executed by a server. Furthermore, other devices necessary for executing methods such as those described herein may be considered part of the infrastructure associated with the server.

[0131] The server may provide interfaces to other devices, including, but not limited to, clients, other servers, printers, database servers, print servers, file servers, communication servers, and distributed servers. Furthermore, this coupling and / or connection may facilitate the remote execution of programs over the network. Some or all of the networking of these devices may, without exceeding the scope, facilitate the parallel processing of programs or methods at one or more locations. Furthermore, any device attached to the server via the interface may include at least one storage medium capable of storing methods, programs, code, and / or instructions. A central repository may provide program instructions to be executed on different devices. In this implementation, remote repositories may function as storage mediums for program code, instructions, and programs.

[0132] Computer-readable instructions may be associated with clients, which may include file clients, print clients, domain clients, internet clients, intranet clients, and other variations such as secondary clients, host clients, and distributed clients. A client may include one or more interfaces that allow it to access other clients, servers, machines, and devices via memory, processors, computer-readable media, storage media, ports (physical and virtual), communication devices, and wired or wireless media. Methods, programs, or code described herein and elsewhere may be executed by a client. Furthermore, other devices necessary for executing methods such as those described in this application may be considered part of the infrastructure associated with the client.

[0133] The client may provide interfaces to other devices, including, but not limited to, servers, other clients, printers, database servers, print servers, file servers, communication servers, and distributed servers. Furthermore, this coupling and / or connection may facilitate the remote execution of programs over the network. Some or all of the networking of these devices may, without exceeding the scope, facilitate the parallel processing of programs or methods at one or more locations. Furthermore, any device attached to the client via the interface may include at least one storage medium capable of storing methods, programs, applications, code, and / or instructions. A central repository may provide program instructions to be executed on different devices. In this implementation, remote repositories may function as storage mediums for program code, instructions, and programs.

[0134] The methods and systems described herein may be deployed partially or entirely through a network infrastructure. The network infrastructure may include elements such as computing devices, servers, routers, hubs, firewalls, clients, personal computers, communication devices, routing devices, and other active and passive devices, modules, and / or components known in the art. Computing devices and / or non-computing devices associated with the network infrastructure may include, apart from other components, storage media such as flash memory, buffers, stacks, RAM, and ROM. The processes, methods, program code, and instructions described herein and elsewhere may be executed by one or more of the network infrastructure elements.

[0135] The methods, program code, and instructions described herein and elsewhere may be implemented on a cellular network having multiple cells. The cellular network may be either a frequency division multiple access (FDMA) network or a code division multiple access (CDMA) network. The cellular network may include mobile devices, cell sites, base stations, repeaters, antennas, towers, etc. The cell network may be GSM, GPRS, 3G, 4G, LTE, EVDO, mesh, or other network types.

[0136] The methods, programs, code, and instructions described herein and elsewhere may be implemented on or via a mobile device. A mobile device may include navigation devices, vehicle remote network access devices, selfies, mobile phones, personal digital assistants, laptops, palmtops, netbooks, pagers, e-book readers, music players, and the like. These devices may include, apart from other components, storage media such as flash memory, buffers, RAM, ROM, and one or more computing devices. Computing devices associated with a mobile device may be capable of executing program code, methods, and instructions stored therein. Alternatively, a mobile device may be configured to execute instructions in cooperation with other devices. A mobile device may communicate with a base station that is interfaced with a server and configured to execute program code. A mobile device may communicate over a peer-to-peer network, a mesh network, or other communication network. The program code may be stored in storage media associated with the server and executed by a computing device embedded within the server. A base station may include computing devices and storage media. The storage devices may store program code and instructions executed by computing devices associated with the base station.

[0137] Computer instructions, program code, and / or instructions may be stored and / or accessed in computer components, devices, and recording media that hold digital data used in calculations over time intervals; semiconductor memory known as random access memory (RAM); mass storage devices, typically for more persistent storage, such as optical discs, hard disks, tapes, drums, cards, and other types of magnetic storage devices; processor registers, cache memory, volatile memory, non-volatile memory; optical storage devices such as CDs and DVDs; removable media such as flash memory (e.g., USB sticks or keys), floppy disks, magnetic tape, paper tape, punch cards, standalone RAM disks, Zip drives, removable mass storage, and offline storage; and other computer memories such as dynamic memory, static memory, read / write storage, variable storage, read-only, random access, sequential access, location-addressable, file-addressable, content-addressable, network-attached storage, storage area networks, barcodes, and magnetic ink.

[0138] The methods and systems described herein may transform physical and / or intangible items from one state to another. The methods and systems described herein may also transform data representing physical and / or intangible items from one state to another.

[0139] Elements described and depicted herein, including procedural descriptions, methods, flowcharts, and block diagrams, imply logical boundaries between elements. However, any operation described herein may be divided in whole or in part, combined in whole or in part, rearranged in whole or in part, and / or certain operations may be omitted in certain embodiments. Accordingly, descriptions and / or explanations of the order of various steps should not be understood as requiring a specific execution order of those steps unless required by a particular application, or unless explicitly stated or evident from the context. The operations described herein may be implemented by a computing device accessing computer executable instructions stored on a computer-readable medium, and the computing device performs one or more aspects of the operations described herein by executing the instructions. Additionally or alternatively, the operations described herein may be performed by hardware configurations, logic circuits, and / or electrical devices configured to perform one or more aspects of the operations described herein. Examples of specific computing devices include, but are not limited to, one or more controllers located in or associated with vehicles, engines, transmissions, and / or PTO device systems, personal digital assistants, laptops, personal computers, mobile phones, other handheld computing devices, wired or wireless communication devices, transducers, chips, calculators, satellites, tablet PCs, ebooks, gadgets, electronic devices, devices with artificial intelligence, networking equipment, servers, routers, etc. Accordingly, while the aforementioned drawings and descriptions illustrate functional aspects of the disclosed systems, the descriptions herein are not limited to specific arrangements of computer instructions, hardware devices, logic circuits, etc., for implementing the operations, procedures, or methods described herein, unless expressly stated otherwise or evident from the context.

[0140] The methods and / or processes described above, and their steps, may be implemented for a particular application in hardware, instructions stored in a computer-readable medium, or any combination thereof. Hardware may include general-purpose computers, dedicated computing devices or specific computing devices, logic circuits, hardware configurations configured to perform the described operations, any type of sensor, and / or any type of actuator. Aspects of the processes performed on a computing device may be implemented in one or more microprocessors, microcontrollers, embedded microcontrollers, programmable digital signal processors, or other programmable devices, along with internal and / or external memory. The processes may also, or instead, be implemented in application-specific integrated circuits, programmable gate arrays, programmable array logic, or any other devices or combinations of devices that can be configured to process electronic signals. It will be further understood that one or more of the processes may be implemented as computer-executable code that can be executed on a machine-readable medium.

[0141] Accordingly, in one embodiment, each of the methods and combinations thereof described above may be embodied in computer executable code that performs those steps when executed on one or more computing devices. In another embodiment, the method may be embodied in a system that performs its steps, may be distributed across devices in several ways, or all of the functionality may be integrated into a dedicated standalone device or other hardware. In yet another embodiment, the means for performing the steps associated with the aforementioned processing may include any of the aforementioned hardware and / or computer-readable instructions. All such substitutions and combinations are intended to fall within the scope of this disclosure.

[0142] While the methods and systems described herein are disclosed in relation to specific exemplary embodiments shown and described in detail, various modifications and improvements will readily become apparent to those skilled in the art. Therefore, the spirit and scope of the methods and systems described herein should not be limited by the examples given herein, but should be understood in the broadest sense permitted by law.

[0143] The examples described above are provided for illustrative and explanatory purposes only. They are not intended to be comprehensive or to limit the disclosure. Individual elements or features of a particular example are generally not limited to that particular example, are interchangeable as needed, and may be used in selected examples, even if not specifically illustrated or described. The same may be modified in many ways. Such modifications should not be considered deviations from this disclosure, and all such modifications are intended to be within the scope of this disclosure.

Claims

1. A threshold switch having a first cutoff threshold related to a first current flow direction and a second cutoff threshold related to a second current flow direction, the threshold switch coupled to a bidirectional current sensor system for an electronic switch, An apparatus comprising: a de-energized circuit for a magnetic drive coil that controls the electronic switch, the de-energized circuit being coupled to the output of the threshold switch and configured to apply a switch-off pulse to the output of the threshold switch so as to remove the current from the magnetic drive coil in accordance with the output of the threshold switch when the bidirectional current sensor system detects a current exceeding a selected threshold among the first and second cutoff thresholds.

2. The apparatus according to claim 1, wherein the non-energized circuit is further configured to apply a high freewheeling counter voltage to the output of the threshold switch in order to remove the current from the magnetic drive coil.

3. The apparatus according to claim 2, wherein the high freewheeling counter voltage comprises a flyback diode for applying the high freewheeling counter voltage.

4. The apparatus according to claim 1, wherein the threshold switch comprises two comparators.

5. The apparatus according to claim 4, wherein each of the first and second cutoff thresholds includes a bidirectionally adjustable current cutoff threshold on the input side of the two comparators.

6. The apparatus according to claim 1, wherein one or more of the first and second interruption thresholds correspond to the short-circuit current value.

7. The apparatus according to claim 6, further comprising a voltage divider electrically coupled to the threshold switch, wherein the voltage divider provides reference values ​​for the first cutoff threshold and the second cutoff threshold.

8. The apparatus according to claim 7, wherein the voltage divider comprises at least one component selected from components consisting of a fixed ohm resistor, an adjustable ohm resistor, a variable adjustable potentiometer configuration, or a Zener diode circuit.

9. The apparatus according to claim 1, further comprising the bidirectional current sensor system.

10. The apparatus according to claim 9, wherein the bidirectional current sensor system includes a bipolar Hall sensor.

11. The apparatus according to claim 1, wherein the electronic switch comprises a direct current (DC) switch.

12. The apparatus according to claim 1, further comprising the electronic switch, wherein the electronic switch is electrically coupled to a power bus.

13. The apparatus according to claim 1, wherein the electronic switch is a contact of a circuit breaker / repeater.

14. A circuit breaker / repeater, The electronic switch, as a fixed contact electrically coupled to the power bus, A movable contact selectively electrically coupled to the fixed contact, An armature coupled to the movable contact, wherein the armature is configured to move so as to contact the fixed contact, thereby enabling current to flow through the power bus; A relay unit comprising a coil and a magnetic core, wherein the coil is configured to operate the relay unit such that when the coil is energized, the armature is attracted to the magnetic core, It is a blocking section, Multiple splitter plates located close to the main body of the circuit breaker / repeater, A blocking section comprising the plurality of splitter plates and a permanent magnet system surrounding one or more of the arc paths between the contact gap and the plurality of splitter plates, The apparatus according to claim 1, further comprising a circuit breaker / repeater, wherein the body of the circuit breaker / repeater is configured to cooperate with the splitter plate using the magnetic field provided by the permanent magnet system to extinguish an arc while the movable contact is engaged or disengaged when the power bus is energized.

15. A fixed contact electrically coupled to the power bus, A movable contact selectively electrically coupled to the fixed contact, An armature coupled to the movable contact, wherein the armature is configured to move so as to contact the fixed contact, thereby enabling current to flow through the power bus; A repeater comprising a coil and a magnetic core, wherein the coil is configured to operate the repeater such that when the coil is energized, the armature is attracted to the magnetic core, A circuit breaker comprising a plurality of splitter plates adjacent to the body of the circuit breaker, and a permanent magnet system surrounding one or more of the arc paths between the plurality of splitter plates and the contact gap and the plurality of splitter plates, wherein the body of the circuit breaker is configured to cooperate with the splitter plates to extinguish the arc using the magnetic field provided by the permanent magnet system when the movable contact is engaged or disengaged while the power bus is energized, A bidirectional current sensor system for detecting the current of the power bus, A threshold switch coupled to the bidirectional current sensor system, having a first cutoff threshold related to a first current flow direction and a second cutoff threshold related to a second current flow direction, The system includes a non-energized circuit for a magnetic drive coil that controls the movable contact, The threshold switch comprises two comparators, each of which receives the output of the bidirectional current sensor system and reference values ​​for the first and second cutoff thresholds from a voltage divider electrically coupled to the threshold switch. The non-energized circuit is coupled to receive the output of the threshold switch, thereby being configured to apply a switch-off pulse to the output of the threshold switch so as to remove the current from the magnetic drive coil when the bidirectional current sensor system detects a current greater than or equal to a selected threshold among the first and second cutoff thresholds.

16. Control electronic device for DC switching device, A bidirectional current sensor system for power buses, A threshold switch comprising two comparators, each of which receives the output of the bidirectional current sensor system, wherein the threshold switch has a first cutoff threshold related to a first current flow direction and a second cutoff threshold related to a second current flow direction. A voltage divider electrically coupled to the threshold switch, which provides reference values ​​for the first and second cutoff thresholds to the two comparators; Control electronic device comprising: a de-energized circuit for a magnetic drive coil that controls the DC switching device, the de-energized circuit being coupled to receive the output of the threshold switch, and thereby configured to apply a switch-off pulse to the output of the threshold switch so as to remove the current from the magnetic drive coil when the bidirectional current sensor system detects a current greater than or equal to a selected threshold among the first and second cutoff thresholds.

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