Reliable fault management remains a critical challenge as electric vehicles push toward more efficient and higher voltage architectures. Automakers require protection devices that can react quickly and consistently to high magnitude fault events to protect the vehicle and its occupants.
Addressing the challenge is the new FaultBreak contactor from Sensata Technologies. The device is a high voltage switching and protection solution engineered to improve fault clearing performance, enhance safety and simplify electric vehicle power systems. Passive and resettable fuse function enables robust protection against high magnitude fault currents, reducing system cost, weight, and complexity while enhancing vehicle safety and serviceability.
The device delivers market leading fault clearing capability validated up to 16 kA at 1 kV and operates with low contact resistance for minimal power loss, says the company, helping OEMs protect their systems against dangerous faults including full battery short circuit conditions. The passive fuse functionality interrupts faults without reliance on external detection electronics. For applications that require an added level of protection, the contactor can be paired in a dual configuration to create system level redundancy and support higher reliability targets.
By combining the functions of a fuse and a contactor, it also reduces component count, weight and thermal losses compared to conventional contactor and fuse solutions. Eliminating pyrofuses, busbars, and low voltage harnesses simplifies the architecture and lowers total system cost.
Key features include:
- Fast Response: The magnetic field generated by a fault current is directed though the actuator, allowing rapid opening only in fault conditions, which is faster than traditional fuses, allowing it to clear 16 kA faults at 1 kV.
- Arc Management: The design utilizes magnetic blowout techniques, dielectric gas environment, to handle arc extinguishing during a fault.
- Resettable Design: Unlike pyrofuses, the magnetic actuator allows the device to be reset after a fault in cases when determined acceptable, increasing vehicle uptime.
“Our FaultBreak contactor represents an important advancement in high voltage protection,” said Markus Schwabe, EVP, Automotive for Sensata. “It helps our customers build electric vehicles that are safer, more dependable, and more economical to produce and maintain.” See www.sensata.com.
