Integrated Breaker-Relay PDU With Arc Suppression for Mobile Power
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Solution Overview
Problem
Electrical power distribution in mobile applications faces challenges due to highly variable loads, thermal and mechanical stresses on fuses, complex electrical systems, and limited space and weight constraints, leading to integration difficulties, increased downtime, and reduced system flexibility.
Innovation Solution
A mobile application with a power distribution unit (PDU) incorporating a breaker/relay system that includes a fixed and moveable contact, an armature, and a biasing member to control power flow, along with an arc suppression assembly, to manage current thresholds and prevent arc formation, enhancing system flexibility and reducing component size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate breaker and relay components are used, then circuit protection and power distribution functions are provided, but device complexity and component count increase
Solution Approach 1:
The patent combines a breaker and relay into a single integrated device with shared housing, contacts, and actuation mechanisms. The breaker portion provides overcurrent protection while the relay portion enables controlled power distribution, both functions operating within one physical component rather than requiring separate devices.
2Adaptability or versatility
If multiple separate components are used for power distribution, then functional requirements are met, but weight and space requirements increase
Solution Approach 1:
The integrated breaker-relay device consolidates multiple power distribution functions into a single component, reducing the cumulative weight of separate breakers, relays, and associated mounting hardware. The shared structural elements and common actuation system further minimize overall weight while maintaining full functional capability.
Solution Approach 2:
The single device performs multiple functions: overcurrent protection, controlled circuit opening/closing, and power distribution routing. This multi-functionality eliminates the need for multiple specialized components, directly reducing total system weight while maintaining adaptability for various power distribution scenarios.
3Adaptability or versatility
If multiple separate components are used for power distribution, then functional requirements are met, but integration difficulty increases
Solution Approach 1:
The patent integrates the breaker and relay mechanisms into a single manufactured unit with shared housing, contact assemblies, and actuation systems. This consolidation reduces the number of separate components that must be sourced, tested, and assembled, significantly simplifying the integration process while maintaining full power distribution functionality.
4Adaptability or versatility
If rapid power throughput swings occur, then variable load requirements are met, but thermal and mechanical stress on components increases
Solution Approach 1:
The integrated breaker-relay device features shared structural components and common mounting points that distribute mechanical stresses across a unified structure. The coordinated operation of the breaker and relay portions allows for smoother power transitions, reducing thermal cycling and mechanical shock that would otherwise occur with separate components operating independently.
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 PDU system provides efficient power management, reduces component size and weight, improves integration, and enhances system reliability by minimizing failure points and downtime, while accommodating variable loads and duty cycles.
Implementation Method 1
along with an arc suppression assembly, to manage current thresholds and prevent arc formation
Data Source
AI summary
A mobile application includes a breaker/relay that includes a plurality of fixed contacts electrically coupled to a power bus, a plurality of corresponding moveable contacts that are selectively electrically coupled to the plurality of fixed contacts, allowing power flow through the power bus when electrically coupled to the fixed contacts and preventing power flow when not electrically coupled, an armature operationally coupled to at least one of the moveable contacts, such that the armature prevents electrical coupling between the at least one of the moveable contacts and the corresponding one of the fixed contacts when in a first position and allows electrical coupling when in a second position, a first biasing member biasing the armature into the first position or the second position; and an arc suppression assembly structured to guide and disperse an opening arc between each of the plurality of moveable contacts and the corresponding fixed contacts.