Interference-Fit Fuse Link for Low-Resistance HV Disconnection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical fuse devices face challenges in achieving low ohmic resistance and reliable, permanent disconnection of high-voltage electrical connections in motor vehicles, with issues such as increased resistance due to tapered breaking points and potential re-establishment of connections due to elastic restoring forces.
Innovation Solution
An electrical fuse device with an interference fit between conductive metal components, featuring a housing with non-conductive materials, a connecting element in an interference fit between connection lugs, and an actuator for controlled separation, ensuring low contact resistance and irreversible disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single conductor with a tapered breaking point is used, then the conductor can be broken at a predetermined point, but the taper reduces the cross-section and increases electrical resistance
Solution Approach 1:
The fuse device is divided into two separate conductive elements (first and second conductive elements) connected by a connecting element. This segmentation allows each element to maintain its full cross-section and low resistance while the connecting element serves as the sacrificial component for permanent disconnection.
2Reliability
If a connecting element is used between conductors, then electrical connection is established, but the contact resistance remains high due to reliance on elastic restoring force alone
Solution Approach 1:
The connecting element is pre-compressed between the two conductive elements before operation. This preliminary compression action creates a strong interference fit that ensures low contact resistance and reliable electrical connection, eliminating the need to rely solely on elastic restoring force during operation.
3Reliability
If high forces are applied to break through and bend conductor materials, then separation is achieved, but the forces required are very high
Solution Approach 1:
The fuse device is divided into two separate conductive elements (first and second conductive elements) connected by a connecting element. This segmentation allows each element to maintain its full cross-section and low resistance while the connecting element serves as the sacrificial component for permanent disconnection.
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 provides a low-resistance, reliable, and permanent disconnection of high-voltage electrical connections, minimizing ohmic losses and preventing re-contacting, thus ensuring efficient energy transmission and safety in motor vehicles.
Implementation Method 1
the contact between the connector and the conductors was usually secured by the elastic restoring force of the connecting element alone
Implementation Method 2
An interference fit of two metal components can significantly reduce the electrical contact resistance between the metal components compared to a clearance fit
Implementation Method 3
an actuator for controlled separation, ensuring low contact resistance and irreversible disconnection
Data Source
AI summary
A fuse device comprising a housing, at least two connection lugs, a connecting element between the connection lugs, and an actuator. The actuator moves the connecting element from a closed position, in which it connects the connection lugs, to an open position, in which it is disconnected from at least one of the connection tabs. A particularly well-conducting connection between the connection lugs and the connecting element, which can nevertheless be easily disconnected by the actuator, is achieved by the connecting element being interference-fitted between the connection lugs.