Battery Circuit Breaker With Visual Reset and Arc Suppression
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Solution Overview
Problem
Existing current disconnect devices for high-voltage batteries in motor vehicles do not automatically trip in case of faults and lack visual indicators for confirming current interruption, requiring manual replacement and lacking visual confirmation of activation.
Innovation Solution
A circuit breaker with a movable member, actuator, and reset mechanism that automatically triggers to a disarmed position upon fault detection, featuring a visual indicator and a mechanism to reset from outside, along with a fluid compression system to limit electric arcs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual disconnect devices are used to open power circuits for battery charging and discharging, then current interruption is achieved, but automatic fault detection and visual indication capabilities are lacking
Solution Approach 1:
The disconnect device automatically detects faults through an actuator that senses abnormal conditions (overcurrent, short circuit, etc.) and autonomously triggers the movable member to transition to the disarmed position, eliminating the need for manual intervention while maintaining device reliability
Solution Approach 2:
A visual indicator system is integrated into the device that changes its state (e.g., color or position) to clearly indicate whether the device is in the armed or disarmed position, providing immediate visual confirmation of the current circuit state without requiring complex diagnostic equipment
2Reliability
If disconnect devices require access to battery modules for replacement after activation, then current interruption is ensured, but ease of operation and maintenance are reduced
Solution Approach 1:
The disconnect device is designed with separable functions: the actuator and movable member are integrated within the battery module for reliable current interruption, while the reset mechanism is positioned externally or accessible through a dedicated access point, allowing operators to reset the device without requiring module disassembly or specialized access
Solution Approach 2:
A reset mechanism serves as an intermediary component that enables the transition from disarmed to armed position without requiring direct access to the movable member or actuator inside the battery module, simplifying the reset operation while maintaining the integrity of the current interruption function
3Device complexity
If disconnect devices lack visual indicators of activation, then device simplicity is maintained, but verification of current interruption becomes difficult
Solution Approach 1:
A visual indicator is integrated into the disconnect device structure that provides clear visual feedback about the device's state (armed or disarmed), enabling operators to immediately verify current interruption status without adding significant complexity to the device
Solution Approach 2:
The visual indicator provides immediate feedback about the device's operational state, allowing operators to confirm whether the circuit is currently open or closed, thereby eliminating information loss and ensuring safe operation
4Object-affected harmful factors
If fluid compression systems are added to limit electric arcs, then arc suppression is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The fluid compression system is integrated with the existing movable member and chamber structure of the disconnect device, combining arc suppression functionality with the current interruption mechanism to reduce overall device complexity and simplify manufacturing
Solution Approach 2:
A compression chamber filled with compressible fluid (such as air or gas) is incorporated into the device, where the fluid is compressed during the movable member's transition to the disarmed position, and this compressed fluid is then released to suppress electric arcs forming in the blowing zone, providing effective arc suppression through pneumatic principles
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures automatic fault detection with visual confirmation and easy external reset, while minimizing electric arcs during current interruption.
Implementation Method 1
to cut an electric arc forming during the transition from the armed position to the disarmed position
Data Source
Figure 1~2
Figure 3
AI summary
A circuit breaker for an electric current, said device comprising a movable member (2) provided with an electrical conductor (4), said device being configured to move said movable member (2) between a first position, referred to as armed, allowing current to flow in the conductor (4), and a second position, referred to as disarmed, interrupting said current flow, said device further comprising an actuator (12), configured to trigger a transition of the movable member (2) from the armed position to the disarmed position in the event of a fault on an electrical circuit in which said device is integrated, said device further comprising a reset member (36) having a manual actuation zone (38), configured to move the movable member (2) from the disarmed position to the armed position, thereby also triggering a reset of the actuator (12), said actuation zone (38) forming a visual indicator of a disarmed state of said device.