Levitation Fuse Contact Separation for Fast Overcurrent Tripping
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Solution Overview
Problem
Conventional fuse devices lack efficient mechanisms for overcurrent protection, particularly in advanced electrical systems like electrical automobiles, which can lead to device malfunction and safety hazards such as electrical fires, and require modern solutions for improved convenience and efficiency in triggering mechanisms.
Innovation Solution
The integration of a levitation actuator in fuse devices that causes separation between contacts at a predetermined current level, increasing resistance and activating a pyro feature to break the circuit, thereby preventing further current flow, using ferromagnetic components to generate magnetic fields that overcome holding forces and separate the contacts, and incorporating pyrotechnic devices for automatic tripping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fuse devices are used for overcurrent protection, then the device structure remains simple, but the response speed and reliability of overcurrent protection are insufficient
Solution Approach 1:
The levitation actuator is pre-positioned to separate contacts when excessive current flows, before the pyrotechnic device activates. This preliminary action initiates the circuit breaking process early, improving response speed and protection reliability without requiring complete structural redesign
Solution Approach 2:
The levitation actuator serves as an intermediary mechanism between the current-carrying contacts and the pyrotechnic device. It translates electrical current into mechanical separation force, providing a controlled intermediate step that enhances overall system reliability while maintaining manageable structural complexity
2Speed
If a levitation actuator is integrated to separate contacts at threshold current, then the response speed improves, but the device complexity increases
Solution Approach 1:
The levitation actuator replaces traditional mechanical trip mechanisms with an electromagnetic field-based system. Current flowing through the actuator generates a magnetic field that levitates the movable contact, achieving rapid separation without complex mechanical linkages or moving parts in the triggering mechanism
Solution Approach 2:
The actuator utilizes changes in electrical current parameters (magnitude and threshold) to trigger contact separation. When current exceeds the predetermined threshold, the resulting electromagnetic force automatically actuates the levitation, providing speed-dependent protection response without additional mechanical complexity
3Reliability
If pyrotechnic devices are used for automatic tripping, then the circuit breaking reliability improves, but the manufacturing complexity increases
Solution Approach 1:
The pyrotechnic device is extracted as a separate, self-contained module within the fuse assembly. This modular approach allows the pyrotechnic component to be manufactured and tested independently, then integrated into the final device, simplifying the overall manufacturing process while maintaining high circuit breaking reliability
Solution Approach 2:
The pyrotechnic device is pre-positioned and pre-charged within the fuse housing during manufacturing. This preliminary preparation ensures that when the levitation actuator initiates contact separation, the pyrotechnic device is immediately ready to provide the final circuit breaking action, enhancing reliability without requiring complex real-time manufacturing processes
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 provides reliable and predictable overcurrent protection, automatically tripping the fuse at a desired threshold current level, minimizing contact rotation and friction, and ensuring safe and efficient operation by breaking the conductive path and preventing electrical fires.
Implementation Method 1
The levitation actuator may include a ferromagnetic component that generates a magnetic field that overcomes a holding force
Implementation Method 2
The levitation actuator causes separation between the movable contact and at least one of the fixed contacts when the movable contact is in the first position and a threshold current passes through the fixed contacts and the movable contact
Implementation Method 3
The current activates the pyro feature, which causes the contacts to separate and puts the fuse device in 'fuse blown' condition
Data Source
AI summary
Fuse devices and electrical systems using the fuse devices are disclosed, with the fuse devices having internal components to cause a fuse blown event when the pre-determined current level is reached through the contacts. The internal components can comprise a levitation actuator that causes separation between one or more of the contacts as the current level approaches the predetermined level. This causes contact levitation and arcing, which increases the resistance at the contact being separated. This in turn causes the current through the contacts to seek another path that in the embodiments herein is a path to a pyro feature. The current activates the pyro feature, which causes the contacts to separate and puts the fuse device in “fuse blown” condition where currents can no longer flow through the contacts.