Electromechanical Circuit Breaker with Integrated Common Mode Choke
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Solution Overview
Problem
Existing electromechanical circuit breakers for high-voltage applications in electric vehicles suffer from coupling attenuation, which allows interference to spread and negatively impacts electromagnetic compatibility.
Innovation Solution
Incorporating a common mode choke within the circuit breaker's housing, positioned between the coil and external terminals, to reduce parasitic currents and interference emissions, while maintaining a compact design suitable for automotive applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a common mode choke is integrated inside the circuit breaker housing, then electromagnetic compatibility is improved and parasitic currents are reduced, but device complexity increases
Solution Approach 1:
The patent integrates the common mode choke directly inside the circuit breaker housing, merging two separate components (circuit breaker and common mode choke) into a single integrated device. This eliminates the need for separate mounting of the common mode choke and reduces the overall number of discrete components in the system.
Solution Approach 2:
The common mode choke is nested within the existing housing structure of the circuit breaker. The choke is positioned in the available internal space between the coil and external terminals, utilizing the existing structural envelope without requiring additional external mounting space.
2Object-affected harmful factors
If the common mode choke is positioned close to the coil (conductor length < 5 cm), then interference filtering is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by positioning the common mode choke at a specific location close to the coil (within 5 cm conductor length) where the electromagnetic interference is most problematic. This targeted placement maximizes the filtering effect on parasitic currents generated by the coil while minimizing the conductor length through which interference can propagate.
3Power
If the circuit breaker is designed for high-voltage applications (up to 800 V), then switching performance is improved, but safety risks increase
Solution Approach 1:
The common mode choke acts as an intermediary component between the high-voltage coil and the external control circuitry. It provides galvanic isolation and filters high-frequency voltage spikes and parasitic currents, thereby protecting the control device from high-voltage transients while allowing the circuit breaker to maintain its high-voltage switching capability.
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 solution effectively filters out parasitic currents and improves electromagnetic compatibility, reducing interference and maintaining high switching performance for voltages up to 800 V and currents of 2000 A, while occupying minimal installation space.
Implementation Method 1
A common mode choke may be arranged inside the housing of the circuit breaker. The common mode choke may be positioned between the coil and one of the external terminals of the electromechanical circuit breaker, such that the common mode choke is electrically connected to the coil.
Implementation Method 2
a coil with an armature in a housing to switch a high-voltage load circuit by a movement of the armature
Data Source
AI summary
Embodiments of the present disclosure provide an electromechanical circuit breaker for a battery distribution box of a motor vehicle. The electromechanical circuit breaker comprises a housing having a coil arranged therein. To switch the electromechanical circuit breaker, the coil is actuated via a control terminal. The electromechanical circuit breaker includes a common load choke arranged inside the housing.