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The new technology project, funded by a $3.3 million award from ARPA-E's BREAKERS programme, could use innovations in power electronics, piezoelectric actuators, and new insulation materials to make high-power DC circuit breakers feasible. "The transition from AC to DC, which is already happening, will open up a new paradigm for efficiently and controllably managing power in future electrical systems and military platforms," said Michael Steurer, a research faculty member at FSU's Center for Advanced Power Systems. "This will be enabled by the amazing developments that have happened over the past two decades in power electronics."

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The hybrid circuit breaker under development by the research team will use stacks of very large transistors to switch off the DC when necessary. Semiconductors are less efficient at conducting current than conventional mechanical switches, so under ordinary conditions, the current will flow through mechanical switches. But when the power must be turned off, the current will be briefly routed through the power electronics until the mechanical breakers can be opened. "We need to be extremely fast," Graber said. "We have to separate the contacts within 250 microseconds and to completely break the current within 500 microseconds — just half a millisecond. For that reason, we cannot use spring-loaded or hydraulic actuators common to AC breakers. Devices that rely on the piezoelectric effect can do that for us."

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'Hybrid Breakers' to make DC Practical in High Power Applications

The Georgia Tech and FSU researchers have developed intellectual property for components of the proposed DC breakers and will work together to combine the technologies. The project is known as Efficient DC Interrupter with Surge Protection (EDISON). The researchers expect to build a prototype that will be tested at FSU's five-megawatt test facility "within three years". The development and testing will be done in collaboration with a team of industrial partners who will ultimately transition the DC breakers to commercial use.

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The move towards renewable energy, away from primary fuelled electricity, is threatening to make large parts of Germany's AC based power grid increasingly redundant. More and more devices are now using DC-based photovoltaic (PV) systems on rooftops. This is in addition to DC-based electric cars and charging stations for cell phones. And new types of circuit breakers are now required to protect them. "The Federal Government's goal is to increase the share of electricity based on renewable energies significantly and at the same time, reduce energy losses in transport and consumption. Both the systems for generating renewable energies, such as photovoltaic systems and many consumer devices such as PCs, TVs or LED lighting are already based on direct current. Therefore, the switch from conventional AC to DC networks for households and industry is the order of the day," explain the project partners. 

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Last year ABB announced a technological breakthrough in the form of a solid-state circuit breaker, which the company claims will enhance the performance of renewable energy solutions, industrial battery storage solutions and so-called edge grids. With power losses 70 percent lower than comparable solutions, the technology is said to be 'vital' for the electrification of sustainable transport. It will enable savings of up to $200,000 in a ferry and up to $1 million in a cruise liner over ten years. The product is to be made available this year. The ABB solid-state breaker concept works by replacing the traditional moving parts of an electro-mechanical circuit breaker with power electronics and advanced software algorithms that control the power and can interrupt extreme currents faster than ever before. 

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TU Ilmenau Researching New Circuit Breakers

Developed in Italy at ABB's Bergamo Electrification business R&D Center, the ABB breaker concept is the first of its kind to use a patented integrated gate-commutated thyristor (IGCT) semiconductor technology. This technological breakthrough is combined with new embedded predictive power management software, protection algorithms and higher levels of connectivity. "This development is going to strengthen the weakest link in next-generation electricity infrastructure. Our 21st Century circuit breaker technology can better meet the demands of renewables, the electrification of transport and modern edge grids as today's offerings," said Giampiero Frisio, the head of ABB's Smart Power business line.

The race is on to develop a new range of mechanical Direct Current (DC) circuit breakers. While the significant power users depend on alternating current (AC), which cycles on and off 60 times per second, DC is used to power devices such as flashlights, smartphones and electric cars. DC has inherent advantages over AC, among them higher efficiency and the ability to carry more power over longer distances. However, unlike alternating current that can be safely shut down when the power level hits zero during a cycle - the basis for breakers that protect modern power systems - switching off the DC for even just a few microseconds or milliseconds, is fraught with difficulty. Several projects are now underway that seeks to address this problem.

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By Paul Whytock | 16-10-2018

16-06-2020 |   |  By Nnamdi Anyadike