Switchable Electric Fuse Element for Arc Prevention

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Solution Overview

Problem

High voltage levels in motor vehicle systems pose challenges for fuse elements, requiring increased isolation currents and dielectric strength while minimizing error probability and power loss, and ensuring safe disconnection to prevent electrical arcs and battery short circuits.

Innovation Solution

A switchable fuse element with a load path and a fuse path that are mechanically connected to ensure safe disconnection, where the load path is actively opened and the fuse path is closed during faults, using a combination of active and passive components to minimize power dissipation and prevent arcs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a melt fuse is used in the load path, then reliable disconnection is achieved, but power loss increases due to internal resistance

Engineering Contradiction:

Improvereliable disconnectionVSAvoidpower loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The fuse element is divided into two separate paths: a load path with low resistance for normal current flow and a fuse path with high resistance for fault protection. This segmentation allows each path to be optimized for its specific function, resolving the contradiction between reliable disconnection and power loss.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fuse path is pre-configured with high resistance and kept isolated during normal operation. In the event of a fault, the load path is opened and current is redirected to the pre-positioned fuse path, which then trips the fuse. This preliminary arrangement ensures reliable disconnection without affecting normal power flow.

Inventive Principle:

Principle #10Preliminary action

2Speed

If an active disconnector is used, then fast separation is achieved, but arc formation risk increases

Engineering Contradiction:

Improveseparation speedVSAvoidarc formation

Core Design Contradiction:

SpeedVSObject-affected harmful factors

Solution Approach 1:

The fuse path acts as an intermediary during the switching process. When the load path is opened, the fuse path provides a controlled alternative route for current, preventing direct arcing across the open load path contacts. The fuse element itself serves as a mediator that safely interrupts the current.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The potential harmful arc is converted into a beneficial protective mechanism. The fuse path is designed to intentionally create a controlled arc at the fuse element, which safely interrupts the current and protects the main disconnector from damage. The harmful arc energy is directed and contained within the fuse path.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Loss of energy

If the fuse path is closed during normal operation, then low resistance path is provided, but battery short circuit risk increases

Engineering Contradiction:

Improvepower dissipationVSAvoidshort circuit prevention

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The fuse path is dynamically switched between open and closed states based on operational conditions. During normal operation, the fuse path is open to prevent short circuiting the battery. Upon detection of a fault condition, the system dynamically transitions the fuse path to closed state to provide a low-resistance current path for fuse operation.

Inventive Principle:

Principle #15Dynamics

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 ensures reliable disconnection of the battery from the vehicle electrical system with minimal power loss and arc prevention, maintaining safety by commutating current to the fuse path and tripping the fuse, thus disconnecting the load from the battery.

Implementation Method 1

a fuse arranged in the fuse path trips at the moment of closing of the fuse path

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

Active fuse elements are disconnectors that cut a line driven by a drive

Methodology Applied

Scientific EffectMechanical separation: Mechanical Force

Data Source

PatentUS11239039B2Electric fuse element, and method for operating an electric fuse element

Publication Date: 2022.02.01 AUTO KABEL MANAGEMENT GMBH

AI summary

Electrical fuse element 12 comprising a switchable load path 22 and a switchable fuse path 36, wherein the load path 22 and the fuse path 36 are short-circuited with their respective inputs 14. The load path 22 and the fuse path 36 are in mechanical connection with each other in such a way that an electrical opening of the load path 22 causes an electrical closing of the fuse path 36 and that a melting fuse 38 arranged in the fuse path 36 is triggered at the moment of closing of the fuse path 36.