Fuses - How It's Made?

General Discussion Electrical & Electronic Engineering.
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Thu Apr 09, 2020 5:17 am

Fuses are available from the 90th century. It came with various sizes and ratings. But the main purpose of the electrical fuse is the 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 the worker melts 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 the 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 is known as brazing.

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

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

But the amount of force generated from the ignition system is very impotent. Because it should have enough force to separate the fuse during the surge. For this reason, the fuse manufacturer runs several tests 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 the 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 the fuse. From another side of the fuse, they fill up the fuse with a specific type of sand.

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

Now come to the testing section. Because this fuse must need to work in its first surge. They test each one of those fuses 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 the cap. This fuse will use in an electrical substation and it will protect substation from any sudden surge.

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