Fuses – How It’s Made

Fuses are available from 90th century. It came with various size and rating. But main purpose of electrical fuse is same as today. Till now we are using fuses from Power Plant to Grid Line and Home Appliance to Mobile Device. Fuses protect our electrical system or circuit when there is a strong power surge happens. It designs to blow for any kind of power surge. This action stops the flow of electricity and prevents further damage. In this post we will learn “Fuses – How Its Made?”

Choosing a fuse is always depending on your requirement. Because you cannot use a transmission line fuse to your home appliance. So selecting a fuse is really important.

Fuses, How it’s Made:

Making a high voltage fuse at first we need a long silver wire. A machine press on the silver wire and make some notch on it. This notch will help this fuse to blow when there is any surge. Then worker melt a soft metal on the notched point and later it will be the point where fuse will blow. Then they weld this silver wire to the top of a ceramic fuse core. After that they attached silver wire with the ceramic core by winding around it.

Another worker slides the element core inside the fuse casing. Then they bend the support metal which will stay attached with the casing. After that they seal everything together by soldering technique. This soldering technique known as brazing.

Now come to the fuse ignition system. They use brass washers by winding ignition wire around it. There is a sticker pin that indicates the blown fuse. It also shut down the power during surge by separating fuse from load. Then they press the sticker pin on washer and complete the assembly of this part.

After that they add some explosive powder inside the sticker pin from bottom section. Then they press a rubber stopper at bottom and make a seal. After this step they press the complete setup of sticker pin in a brass capsule. This arrangement will perform the explosion and by supporting of brass capsule, sticker will come out and make fuse separate from load.

But amount of force generate from the ignition system is very impotent. Because it should have enough force to separate the fuse during surge. For this reason fuse manufacturer run several test of this ignition system.

Then they use a metal eyelet with the sticker pin and attached it with the coil. After that they pull the complete assembly of sticker pin into the fuse. They attached the end of the coil with the fuses cap. After this step the press the outer cap on the inner cap and complete one side of fuse. From other side of fuse they fill up the fuse with specific type of sand.

This sand will absorb the explosion energy. Then they compact the sand by automated taping rod. When it’s done then they lubricate the fuse outer cap and press it on inner to outer section of the fuse. A machine creates a group on the fuse cap and tight the joint. Then a worker seals the joint section and makes it air tight.

Now come to the testing section. Because this fuse must need to work in its first surge. They test each one of those fuse by current and check voltage that it’s having its rated capacity or not. When it passes from the quality department then they attached the safety information and they also stab some electrical specification on cap. This fuse will use in an electrical substation and it will protect substation from any sudden surge.

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