Pyrotechnic Busbar Bridging for Fast Battery Emergency Switching
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Solution Overview
Problem
Existing electrical emergency switches face challenges in achieving a short enough response time and minimizing material usage while ensuring the safety of firefighters and preventing damage to electrical systems during short circuits in high-capacity batteries.
Innovation Solution
An electrical emergency switching device with a pyrotechnic trigger and a connecting element that moves from a standby to an operating position, establishing an electrically conductive connection between contact arrangements on power rails, thereby achieving rapid short-circuiting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a conventional short-circuit switching device is used, then the response time is reduced, but the device complexity and material usage increase
Solution Approach 1:
The device is divided into separate functional modules: a housing containing the pyrotechnic trigger, a connecting element with pin, and contact arrangements on busbars. This segmentation allows each component to be optimized independently while maintaining overall simplicity and rapid response.
Solution Approach 2:
The pyrotechnic trigger is extracted as a separate ignition system that can be activated independently to initiate the short-circuiting action. This extraction allows for a simpler overall device structure while achieving extremely fast response times through chemical ignition.
2Loss of time
If a conventional short-circuit switching device is used, then the response time is reduced, but the material usage increases
Solution Approach 1:
The connecting element uses a thin pin structure that penetrates through holes in the busbars, creating electrical contact with minimal material. This thin-film approach reduces material usage while maintaining effective electrical conductivity for the short-circuit path.
Solution Approach 2:
The pin of the connecting element is nested through coaxial holes in multiple busbars, creating simultaneous electrical connections through a single moving component. This nesting approach minimizes the number of materials required while achieving comprehensive short-circuiting of multiple conductors.
3Device complexity
If the busbars are arranged parallel to each other, then the device complexity is reduced, but the area occupied increases
Solution Approach 1:
The busbars are arranged in a three-dimensional configuration within the housing, with holes positioned at different depths and locations. This dimensional arrangement allows parallel busbars to be compacted into a smaller footprint while maintaining the simplicity of the parallel arrangement for the connecting element.
4Loss of time
If the connecting element moves rapidly to establish connection, then the response time is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The pin of the connecting element is positioned asymmetrically relative to the busbar holes, with an offset that ensures reliable electrical contact is made before complete penetration. This asymmetric design provides a tolerance buffer that reduces manufacturing precision requirements while maintaining rapid response capability.
Solution Approach 2:
The holes in the busbars are pre-positioned with specific dimensions and tolerances to accommodate the pin's movement path. This preliminary preparation of the contact paths allows the connecting element to move rapidly without requiring extremely tight manufacturing tolerances on the moving components themselves.
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 device achieves a significantly shorter response time and reduces material usage while ensuring effective electrical isolation and rapid connection of power rails, mitigating risks associated with short circuits in high-capacity batteries.
Implementation Method 1
an electrically controllable, pyrotechnic trigger for moving the connecting element from a standby position to an operating position
Implementation Method 2
in the operating position the contact arrangements are electrically conductively connected to each other by the connecting element
Data Source
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AI summary
The invention relates to an electrical emergency switching device with a connecting element for establishing an electrically conductive connection between two contact arrangements. The device includes an electrically controlled, pyrotechnic trigger for moving the connecting element from a standby position to an operating position. In the standby position, the contact arrangements are electrically isolated from one another. In the operating position, the contact arrangements are electrically connected to one another by the connecting element, such that the connecting element makes contact with the contact arrangements. The trigger, the connecting element, and the contact arrangements are arranged in a housing, preferably one that is dust- and liquid-tight.The connecting element comprises a mandrel aligned in one direction of movement, and the contact arrangements are formed on a busbar extending through the housing. Each contact arrangement includes a hole extending through the busbar, the holes being coaxial with each other and aligned with the mandrel of the connecting element.