Fuse Module Terminal Layout for Ampacity Rejection
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Solution Overview
Problem
Conventional fuse modules lack the ability to selectively reject fuses with higher ampacity, leading to potential damage or safety hazards, and often rely on user discretion for proper ampacity matching, which can result in inadequate overcurrent protection.
Innovation Solution
The design of fuse holders and fuses with specific ampacity ratings, where the configuration of fuse terminals and slots ensures that only fuses with the correct or lower ampacity are accepted, preventing installation of fuses with higher ampacity through physical compatibility, including offset and staggered terminal configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a fuse holder accepts multiple fuse sizes, then ease of operation is improved, but safety deteriorates due to risk of incorrect ampacity installation
Solution Approach 1:
The fuse holder employs asymmetric terminal configurations where the position and orientation of terminals vary based on the fuse ampacity rating. This asymmetry creates a unique geometric signature for each ampacity level, allowing the holder to accept only fuses with matching terminal patterns. The asymmetric design enables automatic ampacity verification during installation, preventing incorrect fuses from being installed while maintaining ease of operation through intuitive fit.
Solution Approach 2:
Different regions of the fuse holder are designed with locally optimized terminal configurations tailored to specific ampacity requirements. Each local area (corresponding to different ampacity ratings) has uniquely positioned and oriented terminals that match only the appropriate fuse type. This local quality approach allows the holder to provide targeted acceptance criteria for each ampacity level without affecting other regions, ensuring safety while maintaining operational simplicity.
2Reliability
If a fuse holder is designed for a specific ampacity rating, then reliability is improved, but adaptability deteriorates as it cannot accept fuses with different ratings
Solution Approach 1:
The fuse holder is designed with multiple sets of terminals that can accommodate different fuse ampacity ratings within a single device. Each set of terminals is configured with specific positions and orientations corresponding to different ampacity levels. The holder can selectively engage with fuses of various ratings by activating the appropriate terminal set, providing multi-functionality that maintains reliable protection across different applications while adapting to various fuse types.
Solution Approach 2:
The fuse holder incorporates dynamic terminal configurations that can be selectively engaged based on the installed fuse's ampacity rating. The terminal positions and orientations are designed to dynamically match the specific fuse type installed, allowing the holder to adapt its acceptance criteria in real-time. This dynamic approach enables a single holder design to reliably support multiple ampacity ratings while maintaining proper protection characteristics for each.
3Manufacturing precision
If fuse terminals are positioned to match a specific ampacity, then manufacturing precision is improved, but device complexity increases due to multiple terminal configurations
Solution Approach 1:
The fuse holder's terminal structure is segmented into distinct modular groups, each corresponding to a specific ampacity rating. Each segment contains terminals positioned and oriented for a particular fuse type. This segmentation allows for standardized manufacturing of individual terminal modules with high precision, while the modular nature reduces overall complexity by breaking down the complex multi-configuration requirement into manageable, repeatable units that can be manufactured and assembled systematically.
Data Source
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AI summary
A fuse and fuse module that facilitate ampacity rejection based on electrical contact location is disclosed. A configuration of electrical contacts in the fuse and a corresponding configuration of fuse slots in the fuse holder permit fuses within an acceptable range of ampacities to be installed in the fuse holder while at the same time preventing fuses within an unacceptable range of ampacities from being installed in the fuse holder.