Evaluation of Novel Hybrid Protection Based on Pyroswitch and Fuse Technologies

In battery applications, a DC contactor is usually used in series with a current-limiting fuse to clear respectively low and high fault currents. However, classic protection devices have operation limits due to maximum and minimum breaking capacities of each device. In this paper, the self-triggered pyrofuse (Xp-ST) based on conventional fuses and pyroswitch is introduced. This protection solution can be installed as a standalone device. The Xp-ST has an advantage of selectivity. The selectivity is more easily tunable by using a low voltage fuse for the trigger fuse. As an experimental result under the DC condition of 1000 V with 15.6 kA fault current, the proposed self-triggered pyrofuse cleared the fault in 1.5 ms and has limited the current to 7 kA. Furthermore, reliability of the Xp-ST is validated by simulations and aging tests for cycling performances. The cycling performances of the Xp-ST can satisfy the requirements from the EV application with up to 1000 V.