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High-voltage power distribution and protection

Breaktor circuit protection

As vehicle electrification becomes more prevalent, the demand for increased power levels and charging rates also grows. With these changes and advancements in technology come new vehicle safety implications and challenges.

Electric vehicle (EV) systems must safely and reliably protect people and components during all load situations including short circuits, overloads and collision events, as well as quick charging and normal driving scenarios. Eaton’s all-new Breaktor® circuit protection is the complete solution.

Intelligently safe
Self- and external triggering device can sense current spikes to interrupt the circuit
Reliable
Switching and protection function in one unit, with consistent reaction time and no fatigue
Ease of service
Resettability means no device replacements required
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Pacepilot 2022 Innovation to Watch

 

Core features

  • Simplified electrical architecture. Switching and protection function in one device, reducing components and solving coordination challenges for up to900V battery pack applications
  • Resettable and bidirectional. Breaktor can be reset after a fault, and is independent of the current direction for both charging and duty use
  • Embedded short circuit sensing. Can be self-triggered in an over currentevent, and also externally triggered in case of a crash event
  • Quick driver coil disconnection after overcurrent event helps to eliminate contactor welding
  • Device is current limiting in event of a short circuit, improving system level protection 
  • Integrated mirror contact for higher functional safety level requirements
  • Enables up to 1 MW DC fast charging 
Breaktor EV circuit protection cutaway
  • Permanent magnet system: Helps control location of arcing
  • Splitter plates: Split the arcing into smaller, lower voltage arcs to help with extinguishing
  • Current sensor: Senses unsafe overcurrent conditions and communicates to on-board PCBA
  • Driver electronics: Powers Breaktor® actuation and deenergizes coil during overcurrent event
  • Driver coil: Actuates Breaktor® with low voltage current
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    Specifications

    General Specifications

    Max. operating voltage 2 x 450/425V d.c. or 900V/850V d.c. max. 2000m ASL / max. 4500m ASL
    Contact configuration 1 NO or 2 NO  
    Rated current (continuous load, thermal) 350- 750A* based on generic load profile, bidirectional
    Max. switch on current Approx. 1,7kA(+/-20%) current sensor threshold, adjustable
    Max. overload switch off current 25kA  
    Overload switch off time

    up to 4kA < 7ms

    4 – 10kA < 6ms

    10 – 25kA < 4ms

    includes sensing, triggering, and arcing time; load and time constant depending
    * When cooling system is leveraged. All specified values are dependent on system parameters and subject to change. Other models and configurations are available; consult Eaton for details.
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