Pyrotechnic Busbar Bridging for Fast Multi-Phase Short-Circuit Switching
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Solution Overview
Problem
The increasing use of high-capacity electrical batteries and fuel cells in applications like electric vehicles and photovoltaic systems poses a greater risk of short circuits and associated hazards such as fires and explosions, which can hinder firefighting efforts and cause significant damage to electrical systems.
Innovation Solution
An electrical emergency switching device with a pyrotechnic trigger and a connecting element that establishes an electrically conductive connection between multiple contact arrangements, allowing for simultaneous switching of several phases and achieving short response times while reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple contact arrangements are switched simultaneously using conventional devices, then the response time increases and material requirements increase, but the risk of short circuits and associated hazards remains high
Solution Approach 1:
The connecting element is divided into multiple segments, each corresponding to a different phase conductor. Each segment can independently establish contact with its respective busbar, allowing simultaneous switching of multiple phases through a single pyrotechnic trigger event rather than requiring multiple separate switching operations
Solution Approach 2:
Multiple contact arrangements are combined into a single integrated connecting element that simultaneously contacts multiple busbars. The pyrotechnic trigger mechanism is merged with the connecting element, so that a single ignition event propels the entire multi-segment connecting element to establish all necessary electrical connections at once, achieving simultaneous multi-phase switching
2Productivity
If multiple contact arrangements are switched simultaneously using conventional devices, then the response time increases and material requirements increase, but the complexity of the device increases
Solution Approach 1:
The connecting element serves multiple functions simultaneously: it acts as the structural support for contact arrangements, the electrical conductor for multiple phases, and the moving component actuated by the pyrotechnic trigger. The single pyrotechnic trigger mechanism provides universal actuation for all contact arrangements, eliminating the need for multiple separate actuation systems
Solution Approach 2:
The contact arrangements are nested within the connecting element structure, with each contact arrangement integrated into a segment of the connecting element. The pyrotechnic trigger mechanism is nested within the housing, which contains all components in a compact arrangement. This nested structure reduces overall device complexity while enabling simultaneous multi-phase switching
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 enables rapid and simultaneous switching of multiple phases, effectively managing short circuits and reducing the risk of fires and explosions, while minimizing material requirements for secure electrical systems.
Implementation Method 1
the pyrotechnic trigger comprises at least one propellant charge
Implementation Method 2
The piston absorbs the pressure of the combustion gases when the propellant charge is ignited
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to an electrical emergency switching device with a connecting element for establishing an electrically conductive connection between at least two contact arrangements. It comprises a pyrotechnic release for moving the connecting element from a standby position, in which the contact arrangements are electrically isolated from one another, to an operating position, in which the contact arrangements are electrically connected to one another, with the connecting element contacting a contact surface of each contact arrangement. The release, the connecting element, and the contact surfaces are arranged in a housing. The contact arrangements are each formed on a busbar that extends through a tunnel formed in the housing, the tunnels being arranged parallel to one another.In a special embodiment of the switching device, it can be mounted on existing busbars.