Stacked Circuit Breaker Modules for Scalable High-Voltage Switching
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Solution Overview
Problem
Existing high-voltage circuit breakers are not economical in production and lack scalability for varying voltage ratings, as they often require complex and costly designs with multiple switch types and low mass production efficiency.
Innovation Solution
A circuit breaker comprising a stack of identical breaker modules with mechanical, semiconductor, and arrester assemblies arranged in series, allowing for modular design with parallel electrical connections, enabling efficient switching of high voltages and scalable voltage ratings through module stacking, and utilizing a galvanically insulated power feeder to reduce costs and improve modularity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high-voltage circuit breaker uses complex designs with multiple switch types, then it can achieve high-voltage switching capability, but production costs increase and manufacturing efficiency decreases
Solution Approach 1:
The circuit breaker is divided into multiple identical breaker modules, each capable of independent operation. Each module contains a mechanical switch and semiconductor switch arranged in parallel, allowing the system to achieve high-voltage capability through series connection of modules while maintaining standardized, cost-effective individual module production
Solution Approach 2:
Each breaker module is designed as a universal unit that can function independently or in combination with other identical modules. The standardized design with common components (mechanical switch, semiconductor switch, surge arrester) enables mass production and reduces manufacturing complexity while maintaining high-voltage switching capability
2Reliability
If a circuit breaker is designed for high-voltage applications, then it can handle large voltages, but it lacks scalability for varying voltage ratings
Solution Approach 1:
The circuit breaker system is segmented into modular units that can be configured in series to achieve different voltage ratings. By varying the number of breaker modules in the stack, the system can be adapted to different voltage requirements while maintaining the same standardized module design
Solution Approach 2:
The circuit breaker configuration is made dynamic and adaptable through the ability to stack varying numbers of identical modules in series. This allows the voltage rating to be scaled up or down by simply adding or removing modules, providing versatility without requiring redesign
3Ease of manufacture
If identical breaker modules are used in large numbers, then mass production techniques can be exploited to reduce costs, but the circuit breaker requires complex switching coordination between mechanical and semiconductor switches
Solution Approach 1:
The complex switching coordination problem is resolved by segmenting the system into identical modular units, each with its own mechanical and semiconductor switches. The control system can manage each module independently, simplifying the overall coordination task while enabling mass production of standardized modules
Solution Approach 2:
A control unit acts as an intermediary to manage the switching coordination between mechanical and semiconductor switches across multiple modules. The control unit receives switching commands and distributes appropriate control signals to individual modules, abstracting the complexity from the mass production aspect
Data Source
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AI summary
A circuit breaker comprises a plurality of stacked breaker modules (3) arranged in series. Each breaker module (3) comprises in parallel a mechanical switching assembly (8), a semiconductor switching assembly (10) and an arrester assembly (12). The circuit breaker can easily be adapted to a larger number of applications and voltage ranges by varying the number of breaker modules (3).