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Breaktor circuit protection for electric vehicles

Breaktor is a resettable, high-voltage (HV) circuit protection device that integrates switching, circuit protection, and fault detection into a single unit. It is designed for battery electric vehicle OEMs, Tier 1 suppliers, and high-voltage (HV) system designers developing advanced EV architectures.

As battery electric vehicle systems move to higher voltages, higher currents, and faster DC fast charging, circuit protection must address a wider range of operating conditions. Circuit protection systems must support normal driving, DC fast charging, overloads, short circuits, and crash events while helping maintain vehicle and occupant safety.

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What protection challenges does Breaktor address in high-voltage (HV) EV systems?

  • Reduces coordination complexity between contactors, fuses, and pyro fuses
  • Improves fault response time under high fault currents
  • Simplifies circuit protection design for high-voltage (HV) EV systems and DC fast charging architectures
  • Reduces dependency on multiple devices with different response times
  • Supports consistent protection performance across operating conditions

Integrated circuit protection for high-voltage (HV) EV systems

Conventional EV circuit protection architectures rely on multiple components. This includes contactors, fuses, and pyro fuses, coordinated through the battery management system. As high-voltage (HV) system power levels increase, these architectures become more complex to manage.

Because protection functions are distributed across devices with different response times, fault handling often requires coordination between the contactor, fuse, and pyro fuse. This can introduce:

  • Complex system integration
  • Tight timing dependencies
  • Increased risk of miscoordination under high fault currents

In high-voltage (HV) battery electric vehicles, these challenges can impact response time, system coordination, and overall circuit protection design.

Conventional EV circuit protection architectures vs Breaktor

Conventional systems Breaktor
Multiple components  Single integrated device
Coordinated response required Autonomous circuit protection response
Non-resettable Resettable 

How Breaktor simplifies circuit protection design

Breaktor combines switching, circuit protection, and fault detection into a single device. This reduces component count, simplifies system integration, and supports faster, more predictable fault response in high-voltage (HV) EV systems.

Key capabilities and outcomes

Breaktor EV circuit protection cutaway

Faster, simpler fault response

  • Integrated switching and circuit protection: Combines switching and circuit protection in one device to reduce component count and timing dependencies

Improved system safety and reliability

  • Integrated fault detection: Enables autonomous tripping and supports external crash-triggered response
  • Mirror contact feedback: Provides position feedback to support functional safety monitoring (ASIL-D)

Designed for next-generation EV power levels

  • DC fast charging support: Supports systems up to 1 MW
  • Active current limiting: Limits fault current in real time to support system protection
  • Resettable, bidirectional operation: Supports operation in both current directions for driving and DC fast charging
  • Splitter plate technology: Supports controlled arc extinguishing
  • Driver coil: Actuates Breaktor with low-voltage current
  • Driver electronics: Supports Breaktor actuation with ASIL-D capability

Why Breaktor matters for EV system design

Breaktor supports the transition to higher-voltage EV architectures by simplifying protection strategies and reducing system complexity. By integrating multiple protection functions into a single device, it enables more scalable and repeatable system designs for battery electric vehicles.
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
E_Breaktor_infographic_updated_0424_032724_1013am_Font_Change

    Produits associés

    Breaktor infographic
    Spécifications

    General Specifications

    Max. operating voltage 900V 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 35kA  
    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
    Functional safety ASIL-D  

    General Specifications

    Rated insulation voltage Tbd* max 4000m ASL*
    Maximum operating voltage 500V / 480V max 2000m ASL / max 4000m ASL
    Contact configuration 1 NO  
    Rated current (continuous load, thermal) 350A <125°C at HV terminals, 120mm2 busbars
    Maximum short time current tbd 10min*  
    Mechanical lifespan operations >=106 switching operations* 300 ops per hour @no switch-on load*

    *Values shown apply when a cooling system is used. Specifications depend on system parameters and are subject to change. Other models and configurations are available. Contact Eaton for application-specific details.

    **Two poles switch at the same time.

    * Breaktor 500 One Pole Generic, Technical Data, specifications estimation, final value may differ. Other models and configurations available including 900-volt. Consult Eaton for more details.
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