Pyrotechnic Fuse With Magnetic Triggering for High-Current Isolation
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Solution Overview
Problem
High current circuits require effective isolation and safety measures to prevent hazardous voltage exposure, with existing solutions like circuit breakers and fuses having limitations in efficiency and cost-effectiveness.
Innovation Solution
A system comprising a magnetic concentrator, pyrotechnic actuator, and adjustable magnetic switch that concentrates magnetic flux to activate a pyrotechnic actuator when a threshold current is reached, breaking the circuit and using a low-capacity fuse to manage residual current and arcing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high-capacity fuse is used to protect against high current circuits, then the circuit safety is improved, but the cost and complexity of the fuse increases
Solution Approach 1:
The system divides the protection function into two separate components: a low-capacity fuse for handling residual current and a pyrotechnic actuator for breaking the main high-current circuit. This segmentation allows each component to be optimized independently, using a simpler, cheaper low-capacity fuse instead of requiring a complex high-capacity fuse.
Solution Approach 2:
The pyrotechnic actuator serves as an intermediary device between the low-capacity fuse and the high-current circuit. When the fuse blows, it triggers the pyrotechnic actuator which then mechanically breaks the busbar, providing the necessary circuit interruption capability without requiring the fuse itself to handle the full high current.
2Measurement precision
If a magnetic switch with adjustable angle is used, then the threshold current precision is improved, but the device complexity increases
Solution Approach 1:
The magnetic switch's threshold current is adjusted by changing its angular position relative to the magnetic concentrator. This parameter change approach allows precise tuning of the threshold current without requiring complex electronic controls or multiple components, as the geometric angle directly determines the magnetic flux coupling and thus the trigger current.
3Reliability
If a pyrotechnic actuator is used to break the busbar, then the circuit breaking capability is improved, but the manufacturing complexity increases
Solution Approach 1:
The pyrotechnic actuator is designed as a disposable component that is replaced after each use. This approach simplifies manufacturing requirements compared to designing for multiple uses, as the actuator can be produced as a simple, standardized component without needing to withstand repeated thermal and mechanical stress cycles.
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 efficient and cost-effective isolation of high current flows with a low-capacity fuse, ensuring safety and reliability by automatically disconnecting the circuit at a predetermined current level.
Implementation Method 1
a magnetic concentrator positioned near the busbar or power line, wherein the magnetic concentrator is configured to concentrate and/or direct the magnetic flux to a magnetic switch
Implementation Method 2
a pyrotechnic actuator configured to break the busbar. Thus, when the pyrotechnic fuse is activated, the pyrotechnic actuator may break the current flow between the first end and the second end of the busbar
Data Source
AI summary
Systems and methods described herein are directed to a pyrotechnic fuse comprising a magnetic concentrator configured to partially surround at least a portion of a busbar, wherein the magnetic concentrator may comprise an aperture, a pyrotechnic actuator (which may be coupled to the busbar and configured to stop electrical flow in the busbar when the pyrotechnic actuator is activated), and a magnetic switch (which may be located within or near the aperture). The magnetic switch may be configured to activate the pyrotechnic actuator when a current through the busbar reaches a threshold current. An angle of the magnetic switch relative to the aperture may determine the threshold current.