Diode-Actuated Reverse Connection Lockout for Circuit Breakers
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Solution Overview
Problem
Existing power supply and distribution systems face safety risks and increased costs due to reverse connections between storage batteries and circuit breakers, which can cause short-circuits and device damage, and current solutions involving magnetic contactors and voltage sampling circuits are costly and voluminous.
Innovation Solution
A reverse power connection preventing circuit using a diode and actuation unit connected in series with a circuit breaker, which prevents closure during reverse connections and provides an alarm prompt, and optionally includes a current limiting resistor and fuse to reduce power consumption and protect components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic contactor and voltage sampling circuits are added to prevent reverse connection, then reverse connection prevention capability is improved, but device complexity, cost, volume, and heat dissipation requirements increase
Solution Approach 1:
The patent extracts the reverse connection detection function from the complex magnetic contactor and voltage sampling circuit system, implementing it through a simple diode connected in parallel with the battery. The diode's inherent unidirectional conduction property provides reverse connection detection without requiring additional complex components, thereby reducing device complexity while maintaining prevention capability
Solution Approach 2:
The diode serves dual functions: it provides reverse connection detection and simultaneously acts as the indication element. The diode's natural property of conducting in one direction and blocking in the other direction is utilized to both detect reverse connections and provide visual indication, eliminating the need for separate detection circuits and indication lights, thus reducing overall system complexity
2Reliability
If magnetic contactor and voltage sampling circuits are added to prevent reverse connection, then reverse connection prevention capability is improved, but cost increases
Solution Approach 1:
The patent replaces expensive magnetic contactors and voltage sampling circuits with a simple, inexpensive diode. The diode is a low-cost component that can be easily manufactured and replaced if needed, significantly reducing the overall cost of the reverse connection prevention system while maintaining its protective function
Solution Approach 2:
The diode performs multiple functions simultaneously: reverse connection detection, indication of connection status, and protection against reverse polarity damage. This multi-functionality eliminates the need for separate components for each function, reducing both component count and overall manufacturing cost
3Reliability
If magnetic contactor and voltage sampling circuits are added to prevent reverse connection, then reverse connection prevention capability is improved, but volume increases
Solution Approach 1:
The patent extracts the essential reverse connection detection function from the bulky magnetic contactor and voltage sampling circuit assembly, implementing it through a compact diode that occupies minimal space. This extraction dramatically reduces the volume required for reverse connection prevention functionality
4Reliability
If magnetic contactor and voltage sampling circuits are added to prevent reverse connection, then reverse connection prevention capability is improved, but heat dissipation requirements increase
Solution Approach 1:
The diode is a component with excellent thermal characteristics and low power consumption. Compared to magnetic contactors and voltage sampling circuits, the diode generates minimal heat and has no active cooling requirements, significantly reducing heat dissipation requirements while maintaining reverse connection prevention 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 prevents short-circuit accidents, ensures safety, reduces volume and costs, and simplifies the structure compared to conventional technologies by using a diode and actuation unit to prevent reverse power connections, while also providing early warnings and protecting against overcurrents.
Implementation Method 1
A diode and an actuation unit that are connected in series... A positive electrode of the diode points to the negative wiring terminal of the circuit breaker, and a negative electrode of the diode points to the positive input terminal of the circuit breaker. When a power supply is forward connected to the circuit breaker, the diode is cut off... When the power supply is reversely connected to the circuit breaker, the diode is conducted
Data Source
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AI summary
This application provides a reverse power connection preventing circuit, a power distribution apparatus, and a power supply and distribution system. The reverse power connection preventing circuit includes a diode and an actuation unit that are connected in series between a positive input terminal and a negative input terminal of a circuit breaker. A positive electrode of the diode points to the negative wiring terminal of the circuit breaker, and a negative electrode of the diode points to the positive input terminal of the circuit breaker. When a power supply is forward connected to the circuit breaker, the diode is cut off, there is no current on the actuation unit, and the reverse power connection preventing circuit is in a power-off state. When the power supply is reversely connected to the circuit breaker, the diode is conducted, and the actuation unit is configured to prevent closing of the circuit breaker, and/or the actuation unit is configured to perform an alarm prompt, to perform an early warning. Therefore, a short-circuit accident caused by the reverse connection of the power supply is completely prevented. In addition, the reverse power connection preventing circuit provided in this application is simple in structure, so that a volume and costs can be reduced compared with the conventional technology.