Modular Pyrotechnic Circuit Protection for Arc Mitigation
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Solution Overview
Problem
Conventional pyrotechnic circuit protection devices are limited to low voltage and current applications, require external actuation sources and monitoring systems, lack arc mitigation elements, and are not compatible with existing circuit protection accessories, restricting their widespread use and increasing costs.
Innovation Solution
The development of modular pyrotechnic circuit protection devices and control modules that can be easily configured with standard fuses and terminals, providing a scalable and cost-effective solution for various circuit protection needs, including arc mitigation through optional high-voltage fuses, and enabling remote operation and monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pyrotechnic circuit protection devices are used, then quick and reliable operation is achieved, but the devices are limited to low voltage and current applications
Solution Approach 1:
The pyrotechnic circuit protection device is divided into separate modular components: a pyrotechnic disconnect module containing the pyrotechnic charge and circuit breaker mechanism, and a separate control module containing electronics and sensors. This segmentation allows each module to be optimized independently and enables versatile configuration for different voltage and current applications by combining multiple modules in series or parallel.
Solution Approach 2:
The control module is designed with universal functionality to work with multiple pyrotechnic disconnect modules through standardized electrical connectors. The control module can detect fault conditions and activate one or more pyrotechnic disconnects in various configurations, making the system adaptable to different circuit protection needs across a wide range of voltage and current applications.
2Reliability
If conventional pyrotechnic circuit protection devices are used, then circuit isolation is achieved, but external actuation sources and monitoring systems are required
Solution Approach 1:
The control module integrates multiple functions into a single unit: fault detection through embedded sensors, signal processing electronics, and activation control for one or more pyrotechnic disconnect modules. This merging eliminates the need for separate external actuation sources and monitoring systems, reducing overall system complexity while maintaining reliable circuit isolation capability.
3Reliability
If conventional pyrotechnic circuit protection devices are used, then fault protection is achieved, but arc mitigation elements are lacking
Solution Approach 1:
An arc mitigation element is introduced as an intermediary component between the pyrotechnic disconnect module and the circuit being protected. When the pyrotechnic disconnect opens the circuit, the arc mitigation element provides a controlled path for arc energy dissipation, preventing uncontrolled arcing from damaging surrounding components while maintaining the effectiveness of the fault protection.
4Reliability
If conventional pyrotechnic circuit protection devices are used, then pyrotechnic disconnection is achieved, but compatibility with existing circuit protection accessories is lost
Solution Approach 1:
The pyrotechnic disconnect module incorporates universal electrical connectors and standardized mounting interfaces that are compatible with existing circuit protection accessories such as breaker panels, distribution boards, and circuit breaker mounts. This universality allows the reliable pyrotechnic disconnection mechanism to be integrated into existing electrical infrastructure without requiring custom accessories for each application.
5Speed
If conventional pyrotechnic circuit protection devices are used, then rapid shutdown is achieved, but installation complexity increases
Solution Approach 1:
The device is segmented into self-contained modular units with all necessary components (pyrotechnic charge, circuit breaker mechanism, electrical connectors, and mounting hardware) pre-assembled and tested. This segmentation allows installers to simply plug the modules into existing circuit breaker positions without complex assembly procedures, maintaining rapid shutdown capability while greatly simplifying installation.
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 enables the use of pyrotechnic disconnection features in a wide range of applications, reducing costs, simplifying installation, and improving the reliability and efficiency of circuit protection systems by allowing for lower resistance and cooler operation, while facilitating management of multi-phase power systems and compliance with regulatory requirements such as rapid shutdown in solar photovoltaic systems.
Implementation Method 1
a pyrotechnic disconnect feature that releases energy to disconnect the terminals inside the device. The pyrotechnic disconnect feature may include stored chemical, electrical or mechanical energy that is released via actuation of a pyrotechnic charge to sever an electrical connection between the terminals of the device.
Data Source
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AI summary
A pyrotechnic circuit protection system includes a first connection terminal (404), a second connection terminal (406) and a plurality of pyrotechnic modules (100) connected between the first and second connection terminals. Each of the pyrotechnic modules includes a nonconductive housing (102) and electrical connectors (124,126) facilitating plug-in connection of the pyrotechnic modules to one another. A single control module (402) may control and coordinate a plurality of pyrotechnic disconnect modules.