Integrated Circuit Breaker-Switch Layout for Fast EV Fault Isolation
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Solution Overview
Problem
Existing circuit breakers and switches in electric vehicles require a large number of parts, leading to complexity and increased costs, and there is a need for a more efficient and cost-effective solution that can quickly respond to overcurrent and short-circuit conditions.
Innovation Solution
A circuit breaker and switch arrangement where the circuit breaker serves as the master, controlling a slave switch to manage power flow, with simultaneous de-energization of their magnetic drive assemblies upon fault detection, and coordinated opening and closing of paths to minimize part count and simplify operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate circuit breaker and switch components are used in electric vehicles, then reliable overcurrent protection and power flow control are achieved, but the number of parts increases leading to complexity and increased costs
Solution Approach 1:
The patent combines the circuit breaker and switch into a single integrated unit called a 'comb breaker'. This merging of two separate protective devices into one component reduces the total number of parts, simplifies the device structure, and lowers costs while maintaining the reliable overcurrent protection function that would otherwise require separate components.
2Reliability
If traditional circuit breaker and switch arrangements are used, then adequate protection is provided, but fabrication costs and part count increase
Solution Approach 1:
By merging the circuit breaker and switch functions into a single comb breaker component, the patent reduces the number of separate manufacturing processes, assembly steps, and individual parts that need to be produced and assembled. This integration directly lowers fabrication costs while preserving the adequate protection capability through the coordinated operation of the breaker and switch elements within the unified structure.
3Ease of operation
If circuit breaker and switch operate independently, then individual control is possible, but response time to faults increases
Solution Approach 1:
The comb breaker incorporates a feedback mechanism where the circuit breaker and switch are electromagnetically coupled through a common magnetic drive assembly. When overcurrent is detected, the feedback signal simultaneously triggers both the breaker to open and the switch to de-energize, ensuring coordinated operation and minimizing fault response time while maintaining individual control functions during normal operation.
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
This arrangement reduces part count, lowers fabrication costs, and ensures rapid and coordinated response to faults, providing efficient protection for both driving and charging paths in electric vehicles.
Implementation Method 1
after detection of a fault of the arrangement, a magnetic drive assembly of the circuit breaker and a magnetic drive assembly of the switch are de-energized simultaneously or approximately simultaneously
Data Source
AI summary
Some embodiments relate to an arrangement including a circuit breaker, a switch, a first signal line, a first current connection line and a first power port. The circuit breaker can include a first and a second breaker terminal. The switch is realized as a disconnector or a contactor and comprises a first and a second contact terminal. The first signal line is coupled to the circuit breaker and to the switch. The first current connection line is coupled to the first breaker terminal and to the first contact terminal. The first power port is coupled to the first current connection line.