Circuit Breaker with Movable Plug-in for Semiconductor Switch Reliability
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Solution Overview
Problem
Controllable power semiconductor switches in vehicle electrical systems are not absolutely fail-safe, leading to potential overcurrent or short-circuit issues that can result in either constant switching off or on of loads, necessitating a solution for reliable operation even in defective states.
Innovation Solution
A circuit breaker system with a controllable switch and an additional circuit breaker that can switch between series and parallel positions, providing overcurrent protection and a bypass path to ensure load power supply in case of switch failures, utilizing a thermal release element and BUS interface for control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a controllable power semiconductor switch is used to switch loads, then switching control capability is improved, but reliability deteriorates due to potential failure modes (interruption or breakdown)
Solution Approach 1:
The circuit breaker is designed with a movable plug-in unit that can dynamically change its connection mode between series connection (for overcurrent protection) and parallel connection (for bypass functionality). This dynamic reconfiguration allows the system to adapt to different fault conditions and maintain reliability while preserving the electronic switch's control capability.
Solution Approach 2:
The circuit breaker changes its electrical connection parameters (series vs. parallel) based on operational needs. In series connection mode, it provides overcurrent protection; in parallel connection mode, it creates a bypass path. This parameter change enables the system to maintain reliability without compromising the electronic switch's automated control function.
2Reliability
If overcurrent protection is added to protect against switch breakdown, then reliability is improved, but device complexity increases
Solution Approach 1:
The circuit breaker is designed to perform multiple functions through a single device: overcurrent protection in series connection mode and bypass path provision in parallel connection mode. This multi-functionality reduces the need for separate protection devices, thereby limiting the increase in device complexity while maintaining reliability.
Solution Approach 2:
The circuit breaker incorporates a thermal release element that automatically detects overcurrent conditions and triggers the tripping mechanism without external intervention. This self-service capability simplifies the control system and reduces complexity by eliminating the need for additional sensing and control circuitry.
3Reliability
If a bypass path is provided for load power supply during switch failure, then reliability is improved, but device complexity increases
Solution Approach 1:
The bypass path is implemented through a dynamic reconfiguration of the circuit breaker's connection mode. The movable plug-in unit can switch between series and parallel connections, creating the bypass path only when needed. This dynamic approach avoids the complexity of permanently installed bypass circuitry while ensuring load power supply reliability during switch failures.
Solution Approach 2:
The bypass functionality is merged into the same circuit breaker device that provides overcurrent protection. By combining multiple functions (overcurrent protection and bypass path) into a single integrated device with a movable plug-in unit, the design reduces overall system complexity compared to having separate protection and bypass devices.
4Adaptability or versatility
If the circuit breaker can switch between series and parallel positions, then versatility is improved, but ease of operation deteriorates
Solution Approach 1:
The circuit breaker incorporates automatic position detection and configuration capabilities. The control unit automatically determines the appropriate connection mode (series or parallel) based on system conditions and fault detection, eliminating the need for manual operator intervention. This self-service approach maintains ease of operation while providing versatile connection options.
Solution Approach 2:
The system uses feedback from the control unit to automatically adjust the circuit breaker's connection mode. Sensors and control logic monitor system conditions and automatically reconfigure the circuit breaker between series and parallel positions as needed, providing versatility without requiring complex manual operation or operator judgment.
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 reliable switching and overcurrent protection, allowing the load to remain powered even during switch failures by providing a bypass path and enabling communication for error reporting through the BUS interface, thus enhancing safety and operational reliability in critical applications.
Implementation Method 1
the circuit breaker, which then acts as an overcurrent circuit breaker, is thermally tripped above a definable current threshold by opening the bimetal to open the overlapping position with the corresponding flat plug
Implementation Method 2
a controllable switch, in particular in the form of a power semiconductor, which is connected between a voltage input and a load output for switching a load within a current path
Data Source
Figure 1
AI summary
Circuit breaker system (1) having a switch (2), in particular in the form of a controllable power semiconductor, which is connected between a voltage input (5) and a load output (6) for the purpose of switching a load (7) within a current path (4), and having a circuit breaker (9), which can be repositioned between a first plug-in position (13) forming a series circuit with the switch (2) and a second plug-in position (15) forming a parallel circuit with the switch (2).