Abstract: Thermal-mechanical fatigue assessment systems and methods include a controller operable to estimate a temperature of the conductor having a non-linear resistance based on an ambient temperature input and a current input for current flow through the conductor when connected to an energized electrical power system. A state of fatigue of the conductor may be assessed in view of an estimated first temperature differential between the conductor and an arc extinguishing medium surrounding the conductor, an estimated temperature differential between the temperature of the arc quenching medium and the ambient temperature, and the estimated temperature of the conductor.

Abstract: Systems and methods for estimating a thermal-mechanical fatigue in an electrical conductor in a thermal-mechanical fatigue assessment system include an electrical conductor having a cold resistance and a non-linear resistance when connected to an electrical power system, and a controller receiving temperatures of the conductor as inputs, wherein the controller is operable to estimate a service life of the conductor based on at least the input temperatures of the conductor and the cold resistance of the conductor.

Abstract: A circuit protection system including at least one fuse including a fuse element, at least one inductive heating element operable to heat the fuse element, at least one control module in communication with the inductive heating element, and at least one current detection device coupled to said control module. The control module is configured to operate the inductive heating element and cause the fuse element to open in response to a predetermined current condition.

Abstract: Power fuses having filler material including hydrated zeolite material facilitates increasing power density of electrical fuses in reduced package sizes. The hydrated zeolite material releases water to cool and suppress electrical arcing conditions experienced in higher power circuitry.

Abstract: A mobile application includes a motive power circuit having a power storage device and an electrical load, where the power storage device and the electrical load are selectively electrically coupled through a power bus. The application includes a power distribution unit (PDU) electrically interposed between the power storage device and the electrical load, where the PDU includes a breaker/relay positioned on one of a high side and a low side of the power storage device. The breaker/relay includes a fixed contact and a moveable contact selectively electrically coupled to the fixed contact, where the moveable contact allows power flow through the power bus when electrically coupled to the fixed contact, and prevents power flow through the power bus when not electrically coupled to the fixed contact. The breaker/relay includes an armature coupled to the moveable contact, and capable to open or close the motive power circuit.

Abstract: A compact fusible disconnect switch device includes a magnetic arc deflection assembly including pairs of magnets disposed about a mechanical switch contact assembly. The magnetic arc deflection assembly facilitates reliable connection and disconnection of DC circuitry operating at a voltage well above 125 VDC with reduced arcing intensity and duration. The pairs of magnets may apply magnetic fields in directions opposing one another to deflect electrical arcs in different directions at different locations in the mechanical switch contact assembly to facilitate high voltage DC switching operation.

Abstract: A thermal limiter system for an electric motor includes a thermal limiter fuse having a hollow contact element anchored by solder to at least one of first and second terminals of the fuse. A coaxial spring element causes the hollow contact element to slidably release and separate from one of the first and second terminals due to overheating of the solder that is not caused by a flow of electrical current. The system also includes stator mounting blocks and a stator cooling jacket for a motor to be thermally protected.

Abstract: A compact fusible disconnect switch device includes a magnetic arc deflection assembly including pairs of magnets disposed about a mechanical switch contact assembly. The magnetic arc deflection assembly facilitates reliable connection and disconnection of DC circuitry operating at a voltage well above 125 VDC with reduced arcing intensity and duration. The pairs of magnets may apply magnetic fields in directions opposing one another to deflect electrical arcs in different directions at different locations in the mechanical switch contact assembly to facilitate high voltage DC switching operation.

Abstract: A system include a vehicle having a motive electrical power path and a power distribution unit (PDU). The PDU includes a current protection circuit disposed in the motive electrical power path, the current protection circuit including a thermal fuse and a contactor in a series arrangement with the thermal fuse, and a high voltage power input coupling having a first electrical interface for a high voltage power source. The high voltage power output coupling includes a second electrical interface for a motive power load. The current protection circuit electrically couples the high voltage power input to the high voltage power output, and the current protection circuit is at least partially disposed in a laminated layer of the PDU. The laminated layer includes an electrically conductive flow path disposed between two electrically insulating layers.

Abstract: Systems and methods for detecting thermal-mechanical strain fatigue in an electrical fuse include a controller configured to monitor at least one fuse fatigue parameter over a period of time while the fuse is connected to an energized electrical power system, and based on the monitored at least one fuse fatigue parameter, the controller is further configured to determine at least one of a consumed service life of the fuse element or a service life remaining of the fuse element.

Abstract: Fuse assemblies in the form of fuse blocks and fuse holders include embedded permanent magnet arc suppression features that facilitate higher voltage operation of fusible circuit protection without increasing the size of the fuse assemblies. The embedded magnets apply an external magnetic field upon an overcurrent protection fuse and produce an arc deflection force to enhance arc quenching capability of the fuse without increasing its form factor.

Abstract: A compact fusible disconnect switch device includes a magnetic arc deflection assembly including at least a pair of magnets disposed about a switch contact assembly. The magnetic arc deflection assembly facilitates reliable connection and disconnection of DC voltage circuitry well above 125 VDC with reduced arcing intensity and duration. Multiple pairs of magnets may apply magnetic fields in directions opposing one another to deflect electrical arcs in different directions at more than one location in the switch contact assembly to facilitate high voltage DC operation.

Abstract: Electrical current sensing and monitoring methods include connecting sensing a voltage across a conductor having a non-linear resistance such as a fuse element. The current flowing in the conductor is calculated based on at least a first detected state of the sensed voltage and a thermal equilibrium characterization of the conductor.

Abstract: An embodiment of a fuse module has been disclosed. The fuse module includes a housing and a fuse element assembly contained within the housing. The fuse element assembly includes at least one fuse element unit having a plurality of trigger mechanisms and a perforated strip electrically connected to the trigger mechanisms. Increased ampacity ratings in a more compact arrangement provides for fuse modules having increased current protection capability that, in turn, provides for improved disconnect switching capabilities.

Abstract: Systems and methods for detecting thermal-mechanical strain fatigue in an electrical fuse include a controller configured to monitor at least one fuse fatigue parameter over a period of time while the fuse is connected to an energized electrical power system, and based on the monitored at least one fuse fatigue parameter, the controller is further configured to determine at least one of a consumed service life of the fuse element or a service life remaining of the fuse element.

Abstract: Systems and methods for detecting thermal-mechanical strain fatigue in an electrical fuse include a controller configured to monitor at least one fuse fatigue parameter over a period of time while the fuse is connected to an energized electrical power system, and based on the monitored at least one fuse fatigue parameter, the controller is further configured to determine at least one of a consumed service life of the fuse element or a service life remaining of the fuse element.

Abstract: Fuse assemblies in the form of fuse blocks and fuse holders include embedded permanent magnet arc suppression features that facilitate higher voltage operation of fusible circuit protection without increasing the size of the fuse assemblies. The embedded magnets apply an external magnetic field upon an overcurrent protection fuse and produce an arc deflection force to enhance arc quenching capability of the fuse without increasing its form factor.

Abstract: A compact fusible disconnect switch device includes a magnetic arc deflection assembly including at least a pair of magnets disposed about a switch contact assembly. The magnetic arc deflection assembly facilitates reliable connection and disconnection of DC voltage circuitry well above 125 VDC with reduced arcing intensity and duration. Multiple pairs of magnets may apply magnetic fields in directions opposing one another to deflect electrical arcs in different directions at more than one location in the switch contact assembly to facilitate high voltage DC operation.

Abstract: Fuse assemblies in the form of fuse blocks and fuse holders include embedded permanent magnet arc suppression features that facilitate higher voltage operation of fusible circuit protection without increasing the size of the fuse assemblies. The embedded magnets apply an external magnetic field upon an overcurrent protection fuse and produce an arc deflection force to enhance arc quenching capability of the fuse without increasing its form factor.

Abstract: A compact fusible disconnect switch device includes a magnetic arc deflection assembly including at least a pair of magnets disposed about a switch contact assembly. The magnetic arc deflection assembly facilitates reliable connection and disconnection of DC voltage circuitry well above 125 VDC with reduced arcing intensity and duration. Multiple pairs of magnets may apply magnetic fields in directions opposing one another to deflect electrical arcs in different directions at more than one location in the switch contact assembly to facilitate high voltage DC operation.