Levitation Fuse Contacts With Pyro Triggered Overcurrent Interruption
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Solution Overview
Problem
Existing electrical systems, particularly in advanced devices like electrical automobiles, require improved overcurrent protection mechanisms to prevent device malfunction, permanent damage, and safety hazards such as electrical fires, while ensuring predictable and efficient triggering of fuse devices.
Innovation Solution
The implementation of levitation actuators in fuse devices that cause contact separation at a predetermined current level, utilizing ferromagnetic components to generate magnetic fields that separate contacts, increasing resistance and activating a pyrotechnic feature to break the circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fuse devices are used with simple melting mechanisms, then the device complexity is low, but the reliability and predictability of tripping at threshold current levels is insufficient
Solution Approach 1:
The fuse device is divided into distinct functional modules: levitation actuators for contact separation, pyrotechnic features for rapid interruption, and magnetic field generation components. This segmentation allows each component to perform its specific function reliably, improving overall tripping predictability while managing complexity through modular design
Solution Approach 2:
The levitation actuators are pre-positioned and pre-charged with magnetic field generation capability before the overcurrent event occurs. When threshold current is reached, the magnetic field is already prepared to actuate the levitation, ensuring immediate and predictable response without delay, thereby improving reliability
2Speed
If simple contact melting mechanisms are used, then the device structure is simple, but the speed of circuit interruption is insufficient for modern electrical systems
Solution Approach 1:
The conventional thermal-mechanical melting process is replaced with an electromagnetic field-based levitation system. When overcurrent occurs, the magnetic field generated by the levitation actuators rapidly separates the contacts, and pyrotechnic features provide instantaneous circuit interruption, achieving much higher speed than traditional melting mechanisms
Solution Approach 2:
The triggering mechanism utilizes changes in current parameters (threshold detection) to activate the levitation actuators, which then change the physical state of contacts from closed to separated position. This parameter-based triggering provides predictable and rapid response to overcurrent conditions
3Extent of automation
If external signals are required to trigger fuse devices, then the automation level is low, but the ease of operation and installation is improved
Solution Approach 1:
The fuse device monitors its own operating conditions through the levitation actuators that detect threshold current levels automatically. When overcurrent is detected, the system self-actuates through magnetic field generation and contact levitation without requiring external signals, achieving complete automation while maintaining straightforward installation
Solution Approach 2:
The levitation actuators continuously monitor the current flowing through the contacts and provide feedback on the electrical state. When the threshold is reached, this feedback triggers the magnetic field generation and contact separation, creating an automatic closed-loop control system that eliminates the need for external triggering signals
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 automatic and predictable tripping of fuse devices at a desired threshold current level, minimizing contact rotation and friction, and ensuring reliable overcurrent protection without external signals, enhancing safety and efficiency.
Implementation Method 1
utilizing ferromagnetic components to generate magnetic fields that separate contacts
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
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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.