Pyrotechnic High-Voltage Switch with Levitation Detection
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Solution Overview
Problem
Conventional high-voltage switches in electric vehicles require complex and costly designs with coordinated fuse and relay combinations to ensure reliable tripping during faults, and lack a trip signal in all necessary locations, leading to inefficiencies and safety concerns.
Innovation Solution
A high-voltage switch with a pyrotechnic drive and passive measuring circuit that uses levitation-induced voltage drops to automatically trigger the drive, separating the bridge contact from the fixed contacts without external control lines, ensuring reliable disconnection of high currents during faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a combination of fuse and relay is used for high-voltage switching, then reliable tripping in the event of a short circuit is ensured, but the device complexity and cost increase significantly
Solution Approach 1:
The patent combines the fuse and relay into a single integrated high-voltage switch unit. The bridge contact serves dual functions: as a switching element during normal operation and as a fuse element during short circuits. The pyrotechnic drive is integrated within the same housing, eliminating the need for separate fuse and relay components while maintaining reliable tripping functionality.
Solution Approach 2:
The bridge contact is designed to perform multiple functions: it acts as a conductive path during normal operation, serves as a fuse element during short circuits, and can be actuated by the pyrotechnic drive for emergency disconnection. This multi-functionality reduces the number of separate components needed in the system.
2Reliability
If coordinated fuse and relay design is implemented, then safe shutdown in the event of a short circuit is achieved, but manufacturing effort and coordination requirements increase
Solution Approach 1:
By integrating the fuse and relay functions into a single unit with common components (housing, bridge contact, pyrotechnic drive), the patent eliminates the need for separate manufacturing and coordination processes. The single-unit design simplifies manufacturing while ensuring safe shutdown through the integrated pyrotechnic drive that can rapidly disconnect the bridge contact during short circuits.
3Reliability
If additional cabling and control lines are added for trip signals, then adequate security and control are provided, but the device complexity and cost increase
Solution Approach 1:
The pyrotechnic drive is designed to be self-activating through overcurrent detection. When a short circuit occurs, the excessive current directly triggers the pyrotechnic drive without requiring external control signals or additional cabling. This self-service mechanism maintains security while eliminating complex control wiring.
Solution Approach 2:
The patent replaces electrical control signaling with a direct electrical-mechanical-trip mechanism. The overcurrent detection unit senses the short circuit condition and directly activates the pyrotechnic drive, which mechanically separates the bridge contact. This substitution eliminates the need for external control lines and complex signaling systems.
4Power
If conventional fuse and relay combinations are used, then high-voltage switching is achieved, but the system requires multiple components increasing overall system complexity
Solution Approach 1:
The patent merges the fuse, relay, and high-voltage switching functions into a single integrated unit. The bridge contact serves as the common element for all three functions, and the pyrotechnic drive provides unified actuation. This consolidation maintains high-voltage switching capability while reducing the component count from multiple separate devices to one integrated assembly.
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
This solution provides reliable and cost-effective disconnection of high-voltage systems during normal operation and faults, eliminating the need for additional wiring and external control signals, enhancing safety and reducing complexity.
Implementation Method 1
A high-voltage switch with a pyrotechnic drive and passive measuring circuit that uses levitation-induced voltage drops to automatically trigger the drive
Implementation Method 2
uses levitation-induced voltage drops to automatically trigger the drive, separating the bridge contact from the fixed contacts
Data Source
Figure 1a~1b
Figure 1c~2
AI summary
The invention relates to a high-voltage switch having a first terminal contact (6a) connected to a first fixed contact (4a), a second terminal contact (6b) connected to a second fixed contact (4b), a bridge contact (8) arranged between the first fixed contact and the second fixed contact and connecting the first fixed contact to the second fixed contact, wherein the bridge contact is pressed against at least one of the fixed contacts by a pressing force and can be released from at least one of the fixed contacts by a pull-off force, and a drive (18) acting on the bridge contact in the direction of the pull-off force. According to the invention, a measuring circuit senses a voltage drop between the fixed contacts in the case of a levitation between at least one fixed contact and the bridge contact and, depending on the sensed voltage drop, controls the drive such that the drive acts on the bridge contact by means of a force in the direction of the pull-off force. The drive (18) according to the invention is preferably a pyrotechnical drive.