PPSE Circuit Breaker with Inductor for Short-Circuit Protection

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Solution Overview

Problem

Conventional programmable power switching systems and elements fail to protect energy sources and switching elements from high current surges during short circuit conditions, leading to potential damage or failure due to delayed disconnection and high internal resistance of power sources like batteries.

Innovation Solution

A programmable power switching element (PPSE) comprising a series of transistors, gate drivers, a high-speed microcontroller, and a charge storage capacitor, which rapidly isolates the energy source from the load branch upon detecting a short circuit, using an inductor and capacitor to limit high current flow and disconnect transistors within 200 ns, thereby preventing damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional electronic fuses are used to detect and disconnect short circuits, then the system can isolate the load from the voltage source, but the MOSFET and power source are exposed to high current surges during the delay period before disconnection

Engineering Contradiction:

Improvesystem reliabilityVSAvoidhigh current surge damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent implements preliminary protective action by placing an inductor in series with the power source before the short circuit can occur. This inductor is pre-configured to limit current surge automatically when a short circuit happens, acting before the electronic fuse detection and disconnection process completes. The inductor's magnetic field builds up gradually, naturally restricting the rate of current increase and protecting the MOSFET from instantaneous high current damage.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies beforehand cushioning by introducing an inductor that acts as a current-limiting element in the power circuit. This inductor serves as a protective cushion that absorbs and limits the harmful current surge during short circuit conditions, preventing direct exposure of the MOSFET and power source to destructive current levels while the electronic fuse performs its detection and disconnection sequence.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Speed

If the disconnection delay is reduced to protect the MOSFET, then the protection speed increases, but the system complexity and cost increase due to additional protective components

Engineering Contradiction:

Improvedisconnection speedVSAvoidcircuit complexity

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The patent introduces an inductor as an intermediary component between the power source and the load/MOSFET. This inductor mediates the current flow by automatically limiting surge current through its inductive reactance, providing passive protection without requiring complex active control circuits or ultra-fast switching mechanisms. The inductor serves as a simple yet effective mediator that protects the system during the inherent delay of electronic detection and disconnection.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 PPSE effectively reduces or prevents damage to transistors and increases system reliability by rapidly isolating the energy source from high currents, ensuring the protection of both the energy source and switching elements during short circuit conditions.

Implementation Method 1

using an inductor and capacitor to limit high current flow

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

using an inductor and capacitor to limit high current flow

Methodology Applied

Scientific EffectCapacitance: Capacitance

Data Source

PatentUS10291011B2Automatic, highly reliable, fully redundant electronic circuit breaker that reduces or prevents short-circuit overcurrent

Publication Date: 2019.05.14 REDLER TECH LTD

AI summary

A programmable power (PPSE) switching element including a front power transistor, a main switching transistor, and at least one reverse current blocking transistor in series, a gate of each of which is connected to a gate driver; an inductor and a shunt resistor connected in series with the transistors; a charge storage capacitor connected between ground and a junction located between the inductor and the shunt resistor; a high-speed NPN transistor, a collector of which is connected to the front power transistor and an emitter of which is connected to an output of the main switching transistor via the shunt resistor; a current measurement element in parallel to the shunt resistor; a voltage amplifier; and a high-speed MCU.