Magnetically Latching Solenoid Bypass for Power Cell Faults
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Solution Overview
Problem
In multi-cell power supplies, when a power cell fails in an open-circuit mode, the current through all power cells in the phase-group goes to zero, leading to operational cessation, and existing bypass solutions may not effectively prevent further damage to the failed cell due to slow fuse action during low fault currents.
Innovation Solution
A bypass device with a magnetically latching solenoid and added insulating material, allowing voltage between the solenoid and power cell output terminals to exceed the output terminal voltage, enabling quicker bypass and reduced damage by creating a shunt path around the failed power cell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bypass device is implemented to quickly divert current around a failed power cell, then the damage to the failed cell is minimized and operational continuity is improved, but the device complexity increases due to the need for additional components like magnetically latching solenoids and insulating materials
Solution Approach 1:
The bypass device is pre-configured with magnetically latching solenoids and insulating materials positioned between the solenoid and power cell output terminals. When a power cell fails, the bypass contacts are already in place and can be quickly activated by energizing the solenoid, eliminating the need for complex real-time decision-making or multiple switching stages. This preliminary preparation enables rapid bypass activation while maintaining a relatively simple overall device structure.
Solution Approach 2:
The magnetically latching solenoid acts as an intermediary component that bridges the control signal and the bypass contact activation. The solenoid converts electrical control signals into mechanical motion to close the bypass contacts, while the insulating material serves as an intermediary that allows voltage between the solenoid and power cell output terminals to exceed the output terminal voltage. This intermediary approach simplifies the direct connection requirements and reduces the complexity of high-voltage switching design.
2Reliability
If existing bypass solutions are used with slow fuse action, then the bypass function is achieved, but further damage to the failed cell occurs due to delayed current diversion
Solution Approach 1:
The invention replaces the traditional thermal-mechanical fuse action with an electromagnetic field-based magnetically latching solenoid system. When a power cell fails, the control system can immediately detect the fault and energize the solenoid to close the bypass contacts, diverting current almost instantaneously. This electromagnetic actuation is significantly faster than fuse melting and breaking, which requires thermal buildup and mechanical separation. The result is rapid bypass activation that prevents further damage to the failed cell while maintaining system reliability.
3Adaptability or versatility
If added insulating material is positioned between the solenoid and power cell output terminals to allow higher voltage, then the bypass device can operate at elevated voltages safely, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The insulating material is positioned specifically and locally between the solenoid and the power cell output terminals, rather than requiring comprehensive insulation throughout the entire bypass device. This localized insulation approach provides the necessary voltage handling capability at the critical high-voltage interface while keeping the rest of the device structure simple and easy to manufacture. The insulating material can be integrated into the solenoid mounting structure or as a separate component during assembly, minimizing the impact on manufacturing complexity.
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 solution allows for rapid bypass of failed power cells, minimizing damage and ensuring continued operation of the multi-cell power supply by quickly diverting current, even during low fault conditions.
Implementation Method 1
A bypass device with a magnetically latching solenoid and added insulating material, allowing voltage between the solenoid and power cell output terminals to exceed the output terminal voltage
Data Source
AI summary
A bypass device for bypassing a power cell of a multi-cell device. The bypass device includes a stationary portion of a first set of contacts connected to at least first and second output terminals of a power cell, a magnetically latching solenoid that, when energized, moves a moving portion of the first set of contacts from a first position to a second position or from the second position to the first position, and at least one added insulating material positioned between the solenoid and the first set of contacts, and configured to allow a voltage between the magnetically latching solenoid and the first and second output terminals of the power cell to exceed a voltage between said output terminals.