Circuit Breaker Inductor for Magnetic Saturation
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Solution Overview
Problem
Circuit breakers face issues with high primary currents causing magnetic saturation in energy converters, leading to excessive secondary currents and heat dissipation due to the mismatch between source and sink power requirements.
Innovation Solution
Incorporating an inductor between the secondary output of the energy converter and the control unit to compensate for apparent power and reduce heating, with configurations such as a magnetic powder core and low-pass filter to manage magnetic saturation and current harmonics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the energy converter operates with high primary currents, then the control unit receives sufficient power, but magnetic saturation occurs leading to excessive secondary currents and heat dissipation
Solution Approach 1:
The patent introduces an inductor as an intermediary component between the energy converter and the control unit. This inductor compensates for apparent power by creating a reactive power balance, allowing the system to operate with reduced real power losses while maintaining sufficient power supply to the control unit. The inductor effectively mediates the power transfer by storing and releasing energy in magnetic form, reducing the need for high primary currents.
2Reliability
If the primary current amplitude is increased to satisfy secondary-side power requirements, then the control unit operates reliably, but the apparent power of the converter increases linearly
Solution Approach 1:
The patent changes the operating parameters of the energy converter system by introducing reactive power compensation through the inductor. This allows the system to maintain reliable control unit operation while operating at lower apparent power levels. The inductor modifies the power factor and reactive power balance, enabling the converter to deliver the necessary real power without requiring proportionally high apparent power.
3Reliability
If the magnetic core cross section is increased to reduce saturation, then magnetic saturation is delayed, but the device complexity and size increase
Solution Approach 1:
The inductor serves as an intermediary that compensates for apparent power, which indirectly protects the energy converter's magnetic core from saturation. By balancing the reactive power in the circuit, the inductor reduces the stress on the converter's magnetic core, allowing it to operate within safe limits without requiring an oversized core design.
4Use of energy by moving object
If the minimum primary current is set to satisfy the secondary-side power requirement, then the control unit receives adequate power, but excessive heat is generated in the converter
Solution Approach 1:
The patent changes the power factor and reactive power parameters of the system by introducing the inductor. This allows the energy converter to operate at lower primary current levels while still delivering adequate real power to the control unit. The inductor's reactive power compensation reduces the total apparent power requirement, thereby reducing I²R losses and heat generation in the converter.
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
The inductor effectively reduces secondary currents and power losses, minimizing thermal issues and allowing for more efficient energy transfer while maintaining the control unit's operation within safe magnetic limits.
Implementation Method 1
an inductor, connected between a secondary-side output of the energy converter and the at least one control unit
Implementation Method 2
They are based on the principle of magnetically coupled power transfer, as a result of which energy is made available for the control unit
Implementation Method 3
Such high primary currents can occur particularly in the case of high load currents or short-circuit currents. As a consequence, the apparent power of the current converter is exceeded. As a result, the energy converter attains the state of magnetic saturation
Data Source
AI summary
The application relates to a power switch for breaking an electrical circuit when current and/or current time span threshold values are exceeded, including an energy converter, which on the primary side is connected to the electrical circuit, and on the secondary side provides an energy supply for at least one control unit of the power switch. A choke is connected between the secondary-side output of the energy converter and the control unit of the power switch.