Programmable Fuse Trip Mechanism with Mechanical Severing
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Solution Overview
Problem
Existing fuse technologies, particularly electronically controlled fuses, are costly due to the need for expensive high-speed switches, and they require complex systems to manage overcurrent conditions effectively.
Innovation Solution
A trip mechanism for fuses that includes a processor and an actuator within an elongated housing, allowing the fuse to be programmable for different current ratings without the need for a separate high-speed switch, using a chemical firing mechanism or cutting mechanism to sever the fuse element directly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electronically controlled fuse technology is used with high-speed switches, then overcurrent protection can be achieved, but manufacturing cost increases significantly
Solution Approach 1:
The patent extracts the expensive high-speed switch from the system by using a traditional fuse element that can be directly actuated by a motor-driven cutting mechanism. The switch function is eliminated and replaced with direct mechanical severing of the fuse element, thereby removing the costly component while maintaining overcurrent protection capability
Solution Approach 2:
The patent employs a disposable fuse element that is inexpensive compared to high-speed switches. The fuse element is designed to be severed mechanically rather than electronically controlled, using a motor-driven cutter that activates a one-time mechanical separation instead of requiring expensive electronic switching components
2Reliability
If high-speed switches are used to shunt current, then circuit interruption can be achieved, but device complexity increases
Solution Approach 1:
The patent removes the high-speed switch and associated electronic control circuitry from the system. Instead of using electronic components to shunt and interrupt current, the invention uses a direct mechanical cutting mechanism that severs the fuse element, thereby eliminating the complex electronic switching subsystem
Solution Approach 2:
The patent replaces the electronic-mechanical hybrid system (processor, high-speed switch, current sensors) with a purely mechanical interruption system. A motor-driven cutting mechanism physically severs the fuse element, substituting complex electronic control with a simpler mechanical action that achieves the same circuit interruption function
3Ease of manufacture
If traditional current-limiting fuses are used, then manufacturing cost is reduced, but adaptability to different applications is limited
Solution Approach 1:
The patent introduces a programmable processor that can dynamically adjust the trip current threshold and timing characteristics of the fuse. This allows the same physical fuse device to be adapted to different application requirements by software configuration rather than hardware redesign, providing versatility while maintaining low manufacturing costs
Solution Approach 2:
The patent enables change of operational parameters (trip current threshold, trip timing) through software programming rather than physical modification. The processor can be configured with different trip profiles to suit various applications, allowing a single fuse design to serve multiple purposes by changing control parameters instead of manufacturing different hardware variants
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 solution reduces manufacturing costs by eliminating the need for expensive high-speed switches while maintaining high-speed performance and enabling the same fuse to be used in various applications with different current ratings.
Implementation Method 1
The processor is adapted to monitor electrical current
Implementation Method 2
The actuator may comprise a cutting mechanism for cutting the fuse element
Implementation Method 3
and a biasing member for biasing the cutting mechanism toward the fuse element
Implementation Method 4
the actuator may be a chemical firing mechanism, wherein the chemical firing mechanism severs the fuse directly
Data Source
AI summary
A trip mechanism for a fuse includes a trip unit disposed within an elongated housing of the fuse, and a processor. The trip unit includes a fuse element and an actuator for severing the fuse element. The processor is in electrical communication with the trip unit, and is adapted to monitor electrical current. Responsive to the processor detecting a predetermined prescribed electrical current, the processor is adapted to signal the actuator to sever the fuse element. The processor is programmable to selectively adjust the predetermined prescribed electrical current, thereby enabling the fuse to have a plurality different current ratings.