In electronics and electrical engineering, a fuse is an electrical safety device that operates to provide overcurrent protection of an electrical circuit. Its essential component is a metal wire or strip that melts when too much current flows through it, thereby stopping or interrupting the current. It is a sacrificial device; once a fuse has operated, it is an open circuit, and must be replaced or rewired, depending on its type. Fuses have been used as essential safety devices from the early days of electrical engineering. Today there are thousands of different fuse designs which have specific current and voltage ratings, breaking capacity, and response times, depending on the application. The time and current operating characteristics of fuses are chosen to provide adequate protection without needless interruption. Wiring regulations usually define a maximum fuse current rating for particular circuits. A fuse can be used to mitigate short circuits, overloading, mismatched loads, or device failure. When a damaged live wire makes contact with a metal case that is connected to ground, a short circuit will form and the fuse will melt. A fuse is an automatic means of removing power from a faulty system, often abbreviated to ADS (automatic disconnection of supply). Circuit breakers have replaced fuses in many contexts, but have significantly different characteristics, and fuses are still used when space, resiliency or cost are significant factors.
History
Louis Clément François Breguet recommended the use of reduced-section conductors to protect telegraph stations from lightning strikes; by melting, the smaller wires would protect apparatus and wiring inside the building. A variety of wire or foil fusible elements were in use to protect telegraph cables and lighting installations as early as 1864. A fuse was patented by Thomas Edison in 1890 as part of his electric distribution system.
Construction A fuse consists of a metal strip or wire fuse element, of small cross-section compared to the circuit conductors, mounted between a pair of electrical terminals, and (usually) enclosed by a non-combustible housing. The fuse is arranged in series to carry all the charge passing through the protected circuit. The resistance of the element generates heat due to the current flow. The size and construction of the element is (empirically) determined so that the heat produced for a normal current does not cause the element to attain a high temperature. If too high of a current flows, the element rises to a higher temperature and either directly melts, or else melts a soldered joint within the fuse, opening the circuit. The fuse element is made of zinc, copper, silver, aluminium, or alloys among these or other various metals to provide stable and predictable characteristics. The fuse ideally would carry its rated current indefinitely, and melt quickly on a small excess. The element must not be damaged by minor harmless surges of current, and must not oxidize or change its behavior after possibly years of service. The fuse elements may be shaped to increase heating effect. In large fuses, current may be divided between multiple strips of metal. A dual-element fuse may contain a metal strip that melts instantly on a short circuit, and also contain a low-melting solder joint that responds to long-term overload of low values compared to a short circuit. Fuse elements may be supported by steel or nichrome wires, so that no strain is placed on the element, but a spring may be included to increase the speed of parting of the element fragments. The fuse element may be surrounded by air, or by materials intended to speed the quenching of the arc. Silica sand or non-conducting liquids may be used.
Characteristics
Rated current IN A maximum current that the fuse can continuously conduct without interrupting the circuit.
Time vs current characteristics The speed at which a fuse blows depends on how much current flows through it and the material of which the fuse is made. Manufacturers can provide a plot of current vs time, often plotted on logarithmic scales, to characterize the device and to allow comparison with the characteristics of protective devices upstream and downstream of the fuse. The operating time is not a fixed interval but decreases as the current increases. Fuses are designed to have particular characteristics of operating time compared to current. A standard fuse may require twice its rated current to open in one second, a fast-blow fuse may require twice its rated current to blow in 0.1 seconds, and a slow-blow fuse may require twice its rated current for tens of seconds to blow. Fuse selection depends on the load's characteristics. Semiconductor devices may use a fast or ultrafast fuse as semiconductor devices heat rapidly when excess current flows. The fastest blowing fuses are designed for the most sensitive electrical equipment, where even a short exposure to an overload current could be damaging. Normal fast-blow fuses are the most general purpose fuses. A time-delay fuse (also known as an anti-surge or slow-blow fuse) is designed to allow a current which is above the rated value of the fuse to flow for a short period of time without the fuse blowing. These types of fuse are used on equipment such as motors, which can draw larger than normal currents for up to several seconds while coming up to speed.
The I2t value
The I2t rating is related to the amount of energy let through by the fuse element when it clears the electrical fault. This term is normally used in short circuit conditions and the values are used to perform co-ordination studies in electrical networks. I2t parameters are provided by charts in manufacturer data sheets for each fuse family. For coordination of fuse operation with upstream or downstream devices, both melting I2t and clearing I2t are specified. The melting I2t is proportional to the amount of energy required to begin melting the fuse element. The clearing I2t is proportional to the total energy let through by the fuse when clearing a fault. The energy is mainly dependent on current and time for fuses as well as the available fault level and system voltage. Since the I2t rating of the fuse is proportional to the energy it lets through, it is a measure of the thermal damage from the heat and magnetic forces that will be produced by a fault end.
Breaking capacity
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