Intelligent Fuse Holder with Solid-State Sensing for Predictive Maintenance
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Solution Overview
Problem
Existing circuit protection systems, such as those using fuses, fail to provide timely warnings for impending overload or failure, leading to costly downtime and potential safety hazards, as they often require manual inspection and do not diagnose underlying issues.
Innovation Solution
An intelligent circuit protection system that employs solid-state sensing circuits to monitor current, voltage, and temperature, providing real-time data to processors for predictive maintenance, automatic alerts, and diagnostic capabilities, allowing for remote monitoring and proactive replacement of faulty components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fuses are used for circuit protection, then the load is protected from overload and short circuit damage, but the system cannot provide advance warning of impending failure and requires manual inspection
Solution Approach 1:
The patent implements feedback mechanisms through intelligent fuse holders with microprocessors that continuously monitor fuse conditions and provide real-time status information to the control system. The system sends alerts when fuses are approaching failure or have opened, enabling proactive maintenance and reducing unplanned downtime.
Solution Approach 2:
The patent replaces manual inspection and mechanical fuse replacement with automated electronic monitoring systems. Solid-state sensing circuits and communication interfaces automatically detect fuse status, eliminate the need for manual checking, and enable remote diagnostics and replacement scheduling.
2Productivity
If fuses are replaced immediately after opening, then the load can be restored quickly, but the underlying cause of the failure may not be identified and preventive measures not taken
Solution Approach 1:
The patent implements preliminary diagnostic actions by continuously monitoring load conditions, current, and temperature before fuse failure occurs. The system identifies trends and anomalies that precede fuse opening, allowing maintenance personnel to investigate and address root causes before they lead to equipment damage or safety incidents.
Solution Approach 2:
The intelligent fuse holder acts as an intermediary between the fuse and the control system, providing diagnostic information about the failure cause. It monitors parameters such as current, temperature, and fuse integrity, and communicates this information to the control system for analysis and decision-making.
3Reliability
If intelligent monitoring systems are added to fuses, then advance warning of failure and diagnostic information become available, but the system complexity and cost increase
Solution Approach 1:
The patent segments the monitoring function into a separate intelligent fuse holder module that interfaces with existing control systems. This modular approach allows the monitoring capabilities to be added independently without redesigning the entire circuit protection system, reducing implementation complexity.
Solution Approach 2:
The intelligent fuse holder is designed with multi-functionality, serving both as a traditional fuse holder and as a monitoring station. It integrates solid-state sensing circuits, microprocessors, and communication interfaces into a single device that performs both protection and diagnostics functions.
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 system effectively prevents catastrophic failures by predicting and alerting maintenance personnel to potential issues, reducing downtime and enhancing safety through remote monitoring and diagnostic capabilities.
Implementation Method 1
a first sensing circuit configured to sense a temperature-indicating value across the fuse
Implementation Method 2
sense a temperature-indicating value across the fuse
Implementation Method 3
provides a solid state switch output via optical coupling with the sense circuitry
Data Source
AI summary
A circuit protection device includes: (i) a housing configured to hold a fuse; (ii) a first contact configured to connect the fuse to a power source; (iii) a second contact configured to connect the fuse to a load; and (iv) a sensing circuit placed in parallel with the fuse, the sensing circuit configured to operate on a leakage current running through the circuit after the fuse opens.