Pluggable Surge Protector Synchronous Tripping via Low-Melting Alloy
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Solution Overview
Problem
Existing surge protection devices face issues with synchronous tripping of multiple Metal Oxide Varistors (MOVs) and limited protection level and leakage capacity, leading to potential overheating, misindications, and risks of device damage due to asynchronous tripping and limited MOV connections.
Innovation Solution
A pluggable surge protection device design featuring a base with a micro switch and pluggable modules, where nonlinear protection elements are connected in parallel with a gas discharge tube in series, utilizing a low-melting-point alloy for reliable tripping and a positioning mechanism for secure assembly, ensuring synchronous tripping and accurate state indication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pluggable modules are used for ease of installation, then the ease of operation is improved, but the connection stability deteriorates
Solution Approach 1:
The patent applies different connection qualities to different parts of the pluggable module. The MOVs themselves are securely fixed to the printed circuit board using stable solder joints and mechanical mounting, ensuring strong local connections. The entire module uses a pluggable design with contacts and sockets for easy installation and removal. This local quality approach allows the critical internal connections to be stable while the overall module remains easily replaceable.
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 enables safe and reliable synchronous tripping of multiple nonlinear elements, providing accurate fault indication and enhanced protection against high-energy waveform impacts, while ensuring secure module alignment and preventing loose connections.
Implementation Method 1
The intermediate conductor and the second pin are connected through a low-melting-point alloy. When the non-linear protection element works abnormally and causes a rise in temperature, the low-melting-point alloy is softened
Implementation Method 2
The releasing lever is connected to a first spring. When the low-melting-point alloy is softened, the first spring is released and pushes the releasing lever and the intermediate conductor to move
Implementation Method 3
The indication component is connected to a second spring. The second spring is mounted between the indication component and the shell. The second spring is released and pushes the indication component to move away from the position of the indication window
Data Source
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AI summary
A pluggable surge protection device comprising: a base (114) and at least one pluggable module (105). The base comprises a pressing plate (107) and a micro switch (108). The pluggable module is mounted to the base via a positioning mechanism. The pluggable module comprises: a shell (118), a first contact piece (110), a second contact piece (112), a non-linear protection element (109), a releasing lever (106) and an indication component (101). An indication window (133) is provided on the top of the shell. A first pin (109b) of the non-linear protection element is connected directly to the first contact piece. A second pin (109a) of the non-linear protection element is connected to the second contact piece via a U-shaped bracket (131) and a flexible connection piece (132). The U-shaped bracket and the flexible connection piece are made of a conductive material, to which the second pin is connected by means of a low-melting-point alloy. The releasing lever is mounted within the U-shaped bracket. The indication component (101) is mounted on the top of the shell and is capable of moving horizontally. A lower extension portion (106a) of the releasing lever is mounted on the bottom of the U-shaped bracket and is provided with a downward projection. The pressing plate is arranged at the bottom the shell, the micro switch is arranged below the shell and is aligned with the pressing plate.