Parallel Pyroswitch DC Interrupting Assembly for Arc-Free High Current Cutoff
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Solution Overview
Problem
Existing direct current electric circuit switch assemblies struggle to reliably interrupt high current values above 400 A without forming electric arcs, especially in dynamic and varying DC electric circuits, and require external sensor dependencies for actuation, making them unreliable in critical situations like vehicle crashes.
Innovation Solution
A direct current interrupting switch assembly with parallel branches, including an electric fuse and a pyroswitch, where the pyroswitch is activated by an explosive chemical reactant, allowing for independent operation and reliable interruption of high current circuits without external sensor dependency, using multiple pyroswitches and an actuator connected in series with an irreversible thermal fuse and electromagnetic reed switch for enhanced reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional switch assembly is used to interrupt DC electric circuits, then the structure is simple and cost-effective, but it cannot reliably interrupt high current values above 400 A without forming electric arcs
Solution Approach 1:
The switch assembly is divided into multiple independent pyroswitches connected in parallel, each capable of interrupting high current. This segmentation allows the system to handle currents above 400 A by distributing the load across multiple interrupting members, preventing electric arc formation that would occur in a single-point interruption system.
Solution Approach 2:
Pyroswitches with pyrotechnic actuators serve as intermediary devices between the electrical circuit and the interruption action. The pyrotechnic mechanism provides a reliable, sensor-independent actuation method that can trigger circuit interruption under all conditions including critical situations like vehicle crashes, eliminating the need for external sensors while ensuring reliable operation.
2Reliability
If external sensors are used to trigger circuit interruption, then the control can be precise, but the system becomes dependent on external devices and unreliable in critical situations
Solution Approach 1:
The switch assembly incorporates pyroswitches with integrated pyrotechnic actuators that can autonomously trigger circuit interruption without requiring external sensors. The pyrotechnic mechanism is self-contained and can be activated by simple electrical impulses, making the system independent of external sensing devices while maintaining reliable operation in critical situations.
Solution Approach 2:
The system includes redundant pyroswitches connected in parallel, providing a backup interruption path. This redundancy ensures that if one pyroswitch fails or is insufficient for the current load, other pyroswitches can still perform the interruption function, cushioning against failure and ensuring reliable autonomous operation.
3Reliability
If multiple pyroswitches are used in parallel to handle high current, then the current interruption capability is improved, but the device complexity increases
Solution Approach 1:
Multiple pyroswitches are combined in a single integrated switch assembly housing, sharing common structural elements, mounting interfaces, and electrical connections. This merging approach allows the system to handle high currents through parallel pyroswitches while minimizing the increase in overall device complexity by consolidating components into a unified assembly.
Solution Approach 2:
The pyroswitch assembly is designed as a universal module that can be configured in different numbers and arrangements depending on the required current handling capability. The same basic pyroswitch design serves multiple functions: circuit interruption, current distribution, and redundant backup, reducing the need for specialized components for each function.
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
Enables prompt and reliable interruption of high current direct voltage electric circuits without arcing, ensuring complete isolation of electric loads from sources, even in critical situations, and withstands dynamic current variations and temperature changes, maintaining reliability and safety.
Implementation Method 1
an actuator (52), which is capable of activating said pyroswitch assembly (5) due to the interruption of said second branch (112) of the primary electric conductor (11) by means of explosion of at least one chemical reactant contained therein
Implementation Method 2
at least one electromagnetic reed switch (525) with an interrupting member (525'), which is during regular operation of the switch assembly (1) interrupted and is closed i.e. set into uninterrupted state only when a pre-determined value of the electric current within the switch assembly (1) is exceeded
Implementation Method 3
at least one irreversible thermal electric fuse (524) with a contact member (524'), which is during the regular operation of the switch assembly (1) interrupted and is closed i.e. set into uninterrupted state only when an electric overload occurs
Data Source
AI summary
A direct current electric circuit interrupting switch assembly is disclosed that comprises a pyroswitch assembly, which comprises at least two pyroswitches, which are connected in parallel with each other and are each per se integrated in its respective electrically conductive branch together forming a second branch of the primary electric conductor the switch assembly, with a first, preceding pyroswitch and a second, subsequent, or last pyroswitch. Each of said pyroswitches comprises an interrupting member, by means of which each circuit with each of the pyroswitches is either connected during normal operation or is interrupted by displacing each corresponding interrupting member into another position, when a pre-determined condition is met.