Contactor device, high-voltage power supply system and method for controlling contactor device

Abstract

The invention relates to a contactor device and a high-voltage power supply system comprising the same. The contactor arrangement (100) comprises a contact arrangement comprising at least one movable bus bar (106, 108) and at least one fixed bus bar (102, 104), where the at least one movable bus bar (106, 108) has a first contact area and the at least one fixed bus bar (102, 104) has a second contact area, and at least one actuation element (118), where the at least one movable bus bar (106, 108) has a second contact area and the at least one fixed bus bar (102, 104) has a third contact area. The actuating element is configured to change at least a state of the contactor device (100) from an open state to a closed state, in which the first contact region is electrically isolated from the second contact region, and in which the first contact region is conductively coupled to the second contact region, and from the closed state to the open state. The contact device also includes a first current sensing element (152) having a first predetermined resistance that is integrally formed with one of the bus bars (102, 104, 106, 108) included in the contact device.

Description

Technical Field

[0001] The present disclosure relates to a contactor device, a high-voltage power supply system including the contactor device, and a corresponding method for controlling the contactor device. Background Art

[0002] The use of contactor devices to connect and disconnect electronic circuits in power systems is known in the art. With the advancement of electric vehicles (EVs) or hybrid electric vehicles (HEVs), high-voltage (HV) power systems are becoming increasingly common in vehicles. Because such high-voltage systems currently provide voltages in a typical range of 400V to 1kV, and may even be able to provide higher voltages in future applications, these high-voltage power systems pose a greater risk of electric shock than traditional power systems. Therefore, it is crucial for these systems to prevent safety hazards and overcurrent protection. For example, in the event of a failure in the high-voltage power system or a vehicle accident that affects the electronic circuits of the power system, it is very important to ensure the safety of vehicle passengers, roadside responders, or maintenance personnel.

[0003] Therefore, safety requirements for power supply systems and contactor devices used to control current in power supply systems are increasing, especially when the power supply system is used to store energy to drive a vehicle. Figure 14 shows a typical arrangement of a power supply system 10, for example for an electric vehicle.

[0004] To provide high voltages ranging from 400V to at least 1kV to the motors of EV or HEV vehicles during driving, multiple battery modules (or battery packs) are electrically connected to form a high-voltage battery 11. Each battery pack typically includes multiple battery cells electrically connected in series and / or in parallel. Thus, for example, approximately 80 to 100 battery cells can be electrically connected to form a single high-voltage battery pack.

[0005] In the event that operating conditions in the power supply system become unsafe, for example due to an overcurrent or fault in an electronic circuit of the power supply system, or due to an accident in a vehicle driven by electricity stored in the power supply system, the current in the power supply system should be immediately and permanently interrupted. For this purpose, it is known to connect an additional overcurrent protection device 12 in series to the high-voltage battery 11. An example of such an overcurrent protection device 12 is a fuse, which uses a metal wire or strip that melts when an overcurrent occurs. Recently, the use of thermoelectric devices (also called pyrotechnic fuses) has also been established as overcurrent protection devices 12, which are activated by triggering a thermoelectric charge to cut off a bus bar installed in the power supply line of the power supply system. The overcurrent protection device 12 can be located at the positive terminal of the battery 11, the negative terminal of the battery 11, in the battery 11, or at several locations in the HV power supply system 10.

[0006] In order to connect or disconnect the battery 11 at the positive and negative terminals to a DC bus that connects the battery to an external load (or charger), a positive main contactor 13 and a negative main contactor 14 are electrically connected in series with the terminals of the battery 11. The external load may include a high-voltage component such as a motor inverter (DC-AC converter), a DC-DC converter or a charger (A-DC converter), a heater, an auxiliary load, or other high-voltage components. Conventional contactor devices are capable of reversibly changing state between a closed state, in which current can flow through the contactor device, and an open state, in which current is prevented from flowing through the contactor device, typically by moving at least one movable contact.

[0007] To measure the battery current supplied by the battery, the power system 10 typically also includes one or more current sensors, typically in the form of a dedicated shunt resistor 15, which is electrically connected in series with the HV battery 11. The power system 10 contains electronics for measuring the voltage drop across the shunt resistor 15. Typically, these electronics are part of a battery management system (BMS, not shown), which monitors the operation of the power system 10. The battery management system also often controls the actuation of the positive main contactor 13 and the negative main contactor 14, and controls and diagnoses the function of the fuse or pyrotechnic fuse 12.

[0008] Therefore, in conventional power systems, for example, when assembling an HV battery power system 10 or a subassembly of an HV battery (such as an HV battery junction box or an HV battery disconnect unit or an HV battery distribution unit), it is necessary to interconnect various individual components in the HV power system. To connect the various components of the power system 10, copper or aluminum busbars are typically used. The interfaces between the individual components are mostly bolted or completed via connectors. In rare cases, when individual components provide welded interfaces rather than bolted interfaces, welding may also be applied. Therefore, depending on the type of interconnection, the interfaces between the battery 11 and the fuse 12, between the fuse 12 and the positive main contactor 13, between the battery 11 and the shunt current sensor 15, and between the shunt current sensor 15 and the negative main contactor 14 all introduce additional ohmic resistance in the main battery current path. Depending on the interconnection technology, these interfaces can become a major source of energy loss and unintended heat generation. Particularly in high-power applications, such as fast charging, this issue becomes a system-level limitation, which limits the charging current applicable to the power system and may extend charging time. Furthermore, the BMS of the power system 10 needs to provide dedicated control and monitoring functions for each component included in the power system 10 , and thus the structure of the BMS may become complicated. Summary of the Invention

[0009] In this regard, the inventors of the present invention have recognized that there is still a need for a contactor device that can provide a higher level of functional integration and / or can reduce the required interconnections in the power supply system. Therefore, the object of the present invention is to provide an improved contactor device for high-voltage applications, a high-voltage energy storage system including a contactor device, and a corresponding method for controlling a contactor device, which can provide a higher level of functional integration and / or can reduce the necessary interconnections and the associated interconnection resistance in the power supply system. Furthermore, the object of the present invention is to provide a space- and weight-saving and economical solution.

[0010] At least one of these objects is solved by the subject matter of the independent claims. Advantageous aspects of the disclosure are subject matter of the dependent claims.

[0011] Specifically, the present disclosure provides a contactor device comprising a contact device and at least one actuating element, the contact device comprising at least one movable busbar and at least one fixed busbar, wherein the at least one movable busbar has a first contact region and the at least one fixed busbar has a second contact region, the actuating element being configured to at least change the state of the contactor device from an open state to a closed state and from a closed state to an open state, wherein in the open state, the first contact region is electrically isolated from the second contact region, and in the closed state, the first contact region is electrically coupled to the second contact region. The contact device comprises a first current sensing element having a first predetermined resistance, wherein the first current sensing element is integrally formed with one of the busbars included in the contact device.

[0012] By integrating the current sensing element into the contactor device, the need to provide an external shunt resistor in the HV power system can be eliminated, thereby reducing the number of interconnections required for the HV power system. This allows for faster and more cost-effective assembly of the HV power system or battery pack. By integrally forming the current sensing element with one of the bus bars of the contactor device as a shunt resistor, the two components can be combined into a single component or manufactured as a single component. As a result, energy losses and unintended heat generation at the interconnection interface of the HV power system can be reduced. Here, the term "integrally formed" should clearly include that the two components formed integrally cannot be separated from each other without destroying at least one of the two components.

[0013] According to a second example, the contactor device may include a contactor housing that at least partially houses the first bus bar and the second bus bar, wherein the first current sensing element is disposed within the contactor housing. In an alternative embodiment, the contactor housing is a sealed housing, which further helps suppress arc formation because the sealed housing can be filled with a vacuum and / or an electronegative gas.

[0014] According to a third example, each of the at least one movable busbar includes a deflectable contact region that is resiliently deflectable between a disconnected position, in which each of the at least one movable busbar is electrically isolated from each of the at least one fixed busbar, and a second position, in which each of the at least one movable busbar is electrically coupled to one of the at least one fixed busbars. In this manner, the switching force provided by the at least one actuating element to change the state of the contactor device can be efficiently transmitted without requiring the second busbar to be moved as a whole. However, in alternative embodiments, the movable busbars can be moved as a whole between the first and second positions.

[0015] According to a fourth example, the first current sensing element and a busbar of the contact device are formed of the same conductive material, and the first current sensing element is formed integrally with the busbar. This configuration can simplify the manufacture of the integrated first current sensing element because the corresponding busbar can be directly manufactured into an integral body with the current sensing element. Therefore, the resistance of the interconnection interface can be further reduced because no additional interface resistance is required. Alternatively, the first current sensing element and the busbar can be formed of different conductive materials, and the first current sensing element can be interconnected with the busbar by welding, soldering, brazing, or any other suitable interconnection method, which only introduces a small interface resistance.

[0016] According to a fifth example, the contact device includes a second current sensing element having a second predetermined resistance, wherein the second current sensing element is integrally formed with one of the busbars included in the contact device. In an optional embodiment of the fifth example, the second current sensing element and one of the busbars of the contact device are formed from the same conductive material, and the second current sensing element is integrally formed with the busbar. This allows for redundant measurement of the contactor current by providing two independent voltage detection signals, both of which are proportional to the contactor current. In this way, a single-point failure in one of the detection lines used to detect the voltage drop across one of the first and second current sensing elements only affects one of the two detection signals, and the contactor current can continue to be determined.

[0017] According to a sixth example, the first current sensing element and the second current sensing element are integrally formed with the same bus bar included in the contact device. In this way, redundancy can be introduced in the contactor current measurement by replacing only a single bus bar in a conventional contactor device.

[0018] According to a seventh example, the first current sensing element and the second current sensing element are integrally formed with different busbars included in the contact device. This allows redundancy in contactor current measurement to be introduced for different busbars of the contact device, and also allows the contactor current to be determined at different locations along the current-carrying path of the contact device.

[0019] According to the eighth example, the first current sensing element and the second current sensing element are formed of the same conductive material. In this way, since both current sensing elements can be manufactured by the same process, the manufacturing of the bus bar including the first current sensing element and the second current sensing element can be simplified.

[0020] Alternatively, according to a ninth example, the first current sensing element and the second current sensing element may be formed of different conductive materials.

[0021] According to a tenth example, the contactor device may further include at least one second actuator, which, when activated, is configured to irreversibly prevent current from flowing through the contact device. The integration of the second actuator also allows the functionality of the overcurrent protection device to be integrated into the contactor device. In an optional embodiment of the third example, the second actuator is a pyrotechnic actuator, but the second actuator may also be a mechanical actuator. In another optional embodiment of the third example, the second actuator is configured to irreversibly displace or irreversibly cut off one or more of the at least one movable bus bar, and / or the second actuator is configured to irreversibly displace or irreversibly cut off one or more of the at least one fixed bus bar.

[0022] According to the eleventh example, at least a portion of the first current sensing element defines a weak point that supports the second actuator when a bus bar is cut, and the first current sensing element is formed integrally with the bus bar. In an optional embodiment of the eleventh aspect, at least a portion of the second current sensing element also defines a (second) weak point that supports the second actuator when a bus bar is cut, and the second current sensing element is formed integrally with the bus bar. In this way, the first current sensing element and / or the second current sensing element can integrate two functions and can support the breaking or bending of the bus bar after the second actuator is activated. Therefore, there is no need to specially design a weak point in the bus bar in which the first current sensing element and / or the second current sensing element are integrated.

[0023] According to a twelfth example, the weak point is formed as a predetermined breaking region, so that the corresponding bus bar is configured to break in the predetermined breaking region in response to activation of the second actuator. With this embodiment, the first current sensing element and / or the second current sensing element can support the second actuator when disconnecting the corresponding bus bar.

[0024] According to a thirteenth example, the weak point is formed as a hinge flexure, so that the corresponding bus bar can bend about the hinge flexure in response to activation of the second actuator. With this embodiment, the first current sensing element and / or the second current sensing element can support the second actuator when bending or displacing the corresponding bus bar.

[0025] According to a fourteenth example, the contact device includes a pair of movable busbars and a pair of fixed busbars, each movable busbar having a movable contact area, and each fixed busbar having a fixed contact area, wherein at least one actuating element is configured to simultaneously move the pair of movable busbars when changing the state of the contactor device from the open state to the closed state and from the closed state to the open state, so that the movable contact area is electrically isolated from the fixed contact area in the open state, and the movable contact area is conductively coupled with the fixed contact area in the closed state. This embodiment allows the current shunt to be integrated into a 2-pole combination contactor that provides the functions of two single contactor devices. In this way, the functional integration of the contactor device can be further enhanced and system integration can be simplified.

[0026] The present disclosure also relates to a high voltage power supply system comprising at least one battery and a contactor arrangement.

[0027] In this application, the term "terminal" refers to the point where a conductor from an electronic device, circuit, or electronic component ends, as well as a point provided for electrically connecting an external electronic device, external circuit, or external electronic component to that conductor. The term "node" can refer to a point where the terminals of one or more circuit components intersect, or it can refer to an entire conductor that conductively couples the terminals of one or more circuit components. In addition, the terms "electrically connect" and "conductively couple" describe establishing an electrical connection between at least two electronic devices, electronic components, or electrical conductors, thereby allowing current to flow. Therefore, electrical connection should not be limited to the direct coupling of terminals of at least two electronic devices, electronic components, or electrical conductors, but other electronic devices, electronic components, or electrical conductors can be coupled between them. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The accompanying drawings are incorporated into and form a part of the specification to illustrate several examples of the present disclosure. These drawings, together with the description, serve to explain the principles of the present disclosure. The drawings are only used to illustrate how to make and use the preferred and alternative examples of the present disclosure and should not be interpreted as limiting the present disclosure to only the examples shown and described. In addition, according to the present disclosure, several aspects of these examples can form solutions alone or in different combinations. Therefore, the examples described below can be considered alone or in any combination thereof. Further features and advantages will become apparent from the following more detailed description of various examples of the present disclosure, as shown in the accompanying drawings, in which like numbers refer to like elements, and in which:

[0029] Figure 1 shows a schematic perspective view of a first exemplary contactor device;

[0030] Figure 2shows a schematic side view of a first exemplary contactor device in an open state;

[0031] Figure 3 shows a schematic side view of a first exemplary contactor device in a closed state;

[0032] Figure 4 shows a schematic top view of a first exemplary contactor device;

[0033] Figure 5 shows another schematic top view of a first exemplary contactor device;

[0034] Figure 6 shows another schematic top view of a first exemplary contactor device;

[0035] Figure 7 is a schematic circuit diagram of a first exemplary contactor;

[0036] Figure 8 shows a schematic perspective view of a first exemplary bus bar;

[0037] Figure 9 shows another schematic perspective view of a first exemplary bus bar;

[0038] Figure 10 shows a schematic perspective view of a second exemplary bus bar;

[0039] Figure 11 shows a schematic circuit diagram of a second exemplary contactor device;

[0040] Figure 12 shows a schematic circuit diagram of an exemplary pre-charge circuit;

[0041] Figure 13 shows a schematic circuit diagram of an exemplary leakage resistance detection circuit;

[0042] FIG14 shows a schematic circuit diagram of an exemplary conventional high-voltage power supply system. DETAILED DESCRIPTION

[0043] The present disclosure will now be further explained with reference to the accompanying drawings, first referring to Figure 1 . Figure 1 A schematic perspective view of a first exemplary contactor device 100 is shown. In the exemplary application scenarios described below, the contactor device 100 can be used in a power supply system of an electric vehicle to control the power supply to an electric load, such as an electric motor, which is supplied with a predetermined high voltage. However, the contactor device 100 can also be used in other application scenarios that require the storage and / or supply of high-voltage energy in one or more high-voltage batteries, such as energy storage systems used in power grids.

[0044] The contactor device 100 includes two fixed busbars 102 and 104 and two movable busbars 106 and 108, which form a contact arrangement of the contactor device 100. In this way, the contactor device 100 can be used as a 2-pole combination contactor that acts as a 2-pole single-break contactor.

[0045] Advantageously, the design of the contact arrangement of contactor device 100 allows one of the fixed busbars 102 and 104 and one of the movable busbars 106 and 108 to function as a first main contactor, while the other of the fixed busbars 102 and 104 and the other of the movable busbars 106 and 108 can function as a second main contactor, thereby integrating the functionality of two main contactors into the contactor device. However, the number of two movable busbars and two fixed busbars is not essential for the functionality of contactor device 100. Contactor device 100 may include more than two movable busbars and more than two fixed busbars, or may include only one movable busbar and one fixed busbar. Furthermore, it is also conceivable that the number of movable busbars differs from the number of fixed busbars. For example, the principles of the present disclosure may also be applied to a contactor device that includes two fixed busbars and one movable busbar, with the movable busbar being configured to reversibly connect the two fixed busbars.

[0046] Back to Figure 1 , schematically illustrates that movable bus bars 106 and 108 can be in a closed position, wherein each of movable bus bars 106 and 108 is conductively coupled to one of fixed bus bars 102 and 104, thereby placing the contactor device in a closed state. Thus, the closed state allows current to flow between a first terminal 110 integrally formed with movable bus bar 106 and a second terminal 112 integrally formed with fixed bus bar 102, as well as between a third terminal 114 integrally formed with movable bus bar 108 and a fourth terminal 116 integrally formed with fixed bus bar 104. Alternatively, movable bus bars 106 and 108 can be in an open position, wherein each of movable bus bars 106 and 108 is electrically isolated from fixed bus bars 102 and 104, thereby placing the contactor device in an open state. Thus, the open state interrupts current flow through the contact devices of contactor device 100.

[0047] In order to reversibly connect and disconnect the current path through the contactor device 100, the contactor device 100 includes an electromagnetic actuator 118 as an example of an actuating element. The electromagnetic actuator 118 is configured to reversibly move the movable bus bars 106 and 108 between a closed position and an open position to change the state of the contactor device 100 from the closed state to the open state and from the open state to the closed state.

[0048] In order to facilitate the reversible transition between the open position and the closed position, the movable bus bars 106 and 108 are formed in such a manner that they are able to elastically deflect between the open position and the closed position in a deflectable bus bar region 120, which constitutes at least a portion of the movable bus bars 106 and 108. To this end, the movable bus bars 106 and 108 can be formed from a multilayer structure that includes, for example, 10 to 15 layers of copper, aluminum, or other suitable conductive materials. In addition, each of the movable bus bars 106 and 108 can include a protrusion 122 for supporting the deflection capability of the movable bus bars 106 and 108. The protrusion 122 can also help to apply a preload to the movable bus bars 106 and 108, which pushes the movable bus bars 106 and 108 toward the open position.

[0049] The electromagnetic actuator 118 is configured to hold the movable bus bars 106 and 108 in the closed position when energized. To this end, the deflectable bus bar region 120 of the movable bus bars 106 and 108 can be individually moved by the electromagnetic actuator 118, for example, via a shaft 124 disposed on the top side of the movable bus bars 106 and 108 in the deflectable bus bar region 120. Additional spring elements can be disposed around the shaft 124, which help absorb small misalignments or imbalances between the movable bus bars 106 and 108 during operation of the contactor device 100, thereby preventing such misalignments from affecting the electromagnetic actuator 118 or significantly affecting the forces applied between the fixed bus bars 102 and 104 and the movable bus bars 106 and 108. In this way, tolerances between the fixed bus bars 102 and 104 and the movable bus bars 106 and 108 introduced during the manufacturing process of the contactor device 100 can be better compensated. Additionally, a retaining spring 126 may be located beneath, i.e., on the bottom side of, each of the movable bus bars 106 and 108 so as to bias the movable bus bars 106 and 108 to the disconnected position when no force is applied by the shaft 124, i.e., when the electromagnetic actuator 118 is not energized.

[0050] Figure 2The contactor device 100 is shown in an unpowered state, wherein the electromagnetic actuator 118 is de-energized and, therefore, the movable busbars 106 and 108 are simultaneously in the open position. Consequently, the contact elements 128 of the movable busbars 106 and 108 are electrically isolated from the contact elements 128 of the fixed busbars 102 and 104 by a spatial gap, thereby interrupting the current flowing through the contact arrangement of the contact device 100. To reduce contact resistance, the contact elements 128 can be made, for example, of silver or any silver alloy and can be attached to the fixed busbars 102 and 104 and the movable busbars 106 and 108 by welding, soldering, or brazing. Each busbar can include one or more contact elements, each forming a contact point that collectively constitutes a contact area of ​​the busbar for electrically contacting another busbar of the contact arrangement. Of course, other suitable conductive materials or interconnection technologies can also be used to form the contact elements 128 on the busbars of the contact device 100.

[0051] Figure 3 The contactor device 100 is shown in an energized state, with the movable bus bars 106 and 108 in a closed position such that the contact points 128 of the movable bus bars 106 and 108 are conductively coupled with the contact points 128 of the fixed bus bars 102 and 104 .

[0052] In order to move the movable bus bars 106 and 108 from the open position to the closed position, the armature of the electromagnetic actuator 118 applies a closing force to the movable bus bars 106 and 108, for example through the shaft 124, thereby pushing the movable bus bars 106 and 108 in the direction of the closing force, that is, in the direction toward the fixed bus bars 102 and 104.

[0053] As an alternative to the electromagnetic actuator 118, the contactor device 100 can be equipped with a linear motor actuator as an actuating element, and the movable bus bars 106 and 108 can be moved in the disconnected position (e.g., Figure 2 as shown) and closed position (as shown) Figure 3 (as shown). In this configuration, the shaft 124 moves only when the linear motor actuator is energized, such that the movable bus bars 106 and 108 remain in their previous positions when the linear motor actuator is not energized. Thus, the linear motor actuator can be used as a bistable actuator, which allows the introduction of an open state and a closed state of the contactor device 100 as bistable states of the contactor device 100 that change only when the linear motor actuator is energized. Thus, with this configuration, when the linear motor actuator experiences a loss of power, such as due to a damage event or due to a communication loss, the contactor device 100 can remain in the closed state (or open state).

[0054] Return Reference Figure 1The contactor device 100 may also advantageously include a pyrotechnic actuator 130, which is configured to permanently displace the fixed busbars 102 and 104 to the ignition position after the pyrotechnic actuator 130 is triggered (activated). In the ignition position, the fixed busbars 102 and 104 are permanently electrically isolated from the movable busbars 106 and 108. Therefore, the fixed busbars 102 and 104 can be displaced as a whole, or can be displaced only in the displacement area 132 of the fixed busbars 102 and 104 including the contact element 128. In this way, it is prevented that the movable busbars 106 and 108 can still be electrically coupled to the fixed busbars 102 and 104 after the pyrotechnic actuator 130 is activated. Therefore, after the pyrotechnic actuator 130 is activated, the current flowing through the contact device of the contactor device 100 is permanently interrupted.

[0055] The pyrotechnic actuator 130 may include two or more pyrotechnic pins 134 that ignite a pyrotechnic charge in response to an electrical control signal. The pyrotechnic charge may be an explosive that is directly ignited by the electrical control signal, or a gas generator charge that expands suddenly upon receiving the electrical control signal. Alternatively, the pyrotechnic charge may have a multi-charge structure, including, for example, an initiator charge and a secondary gas generator charge.

[0056] Alternatively, pyrotechnic pin 134 may be connected to an internal controller of contactor device 100, as will be described later, or may be connected to an external controller, such as a battery management system of a high-voltage battery, an ECU of a vehicle, or a crash sensor. The electrical control signal for triggering pyrotechnic actuator 130 may be issued by the internal or external controller, for example, in response to a detected anomaly or fault in any other circuit component of the circuit to which contactor device 100 is conductively coupled, or in response to detection of a vehicle accident.

[0057] After activation, the pyrotechnic actuator 130 can drive the displacement element 136 via the piston structure 138 under the impetus of the pyrotechnic charge ignition to push the fixed bus bars 102 and 104 into the fired position, in which the fixed bus bars 102 and 104 are electrically isolated from the movable bus bars 106 and 108. For example, studs or bolts driven by the energy of the piston structure 138 to move or support the fixed bus bars 102 and 104 can be used as the displacement element 136.

[0058] In order to facilitate the displacement of the fixed bus bars 102 and 104, a weak point (or weak point area) can be formed in each of the fixed bus bars 102 and 104. The weak point can be formed, for example, in the form of a hinge flexure 140. In the example shown, the hinge flexure 140 is formed by a cutout in the bus bar. The position of the cutout forming the hinge flexure 140 can be adjusted to change the swing radius of the displacement area 132 of the fixed bus bars 102 and 104. In this way, when the fixed bus bars 102 and 104 are moved to the ignition position, the movement path of the fixed bus bars 102 and 104, or at least the movement path of the displacement area 132 of the fixed bus bars 102 and 104, can be well defined.

[0059] Alternatively, the weak point may be formed by a cutout or notch in the corresponding bus bar that defines a predetermined fracture region. In this way, the weak point facilitates severing or breaking the corresponding bus bar in the predetermined fracture region in response to activation of the pyrotechnic actuator 130.

[0060] An exemplary operation of the pyrotechnic actuator 130 is as follows: Figure 4 and Figure 5 , each of which shows a schematic top view of a contactor device 100 . Figure 4 The contactor assembly 100 is shown in a closed state prior to activation of the pyrotechnic actuator 130. In this example, a retaining force 142 directed toward the page holds the movable bus bars 106 and 108 in electrical contact with the fixed bus bars 102 and 104.

[0061] Figure 5A top view of contactor assembly 100 is shown with pyrotechnic actuator 130 activated. While only fixed busbar 104 is shown in the firing position, fixed busbar 102 can also be simultaneously moved to the firing position upon activation of pyrotechnic actuator 130. The pyrotechnic force drives displacement element 136 to irreversibly move fixed busbars 102 and 104 to the firing position, thereby electrically isolating fixed busbars 102 and 104 from movable busbars 106 and 108. As indicated by arrow 144, fixed busbars 102 and 104, or displacement regions 132 of fixed busbars 102 and 104, rotate about hinge flexure 140, which, in this example, defines a weak point for fixed busbars 102 and 104. This rotational movement preferably occurs in a plane perpendicular to the direction of retaining force 142 applied by electromagnetic actuator 118 to movable busbars 106 and 108. However, in not all cases does the plane in which the fixed bus bars 102 and 104 or the displacement regions 132 of the fixed bus bars 102 and 104 move to the ignition position necessarily have to be perpendicular to the direction of the retaining force 142. Instead, the plane may simply enclose a predetermined angle with the direction of the retaining force 142, such that the direction of movement of the fixed bus bars 102 and 104 or the displacement regions 132 of the fixed bus bars 102 and 104 at least includes an angle relative to the direction of movement of the movable bus bars 106 and 108 between the open position and the closed position.

[0062] In this manner, it is possible to ensure that fixed bus bars 102 and 104 can be moved to the firing position without interfering with the actuation mechanism used to move and hold movable bus bars 106 and 108 in the closed position. Similarly, the movement of fixed bus bars 102 and 104 into the firing position is prevented from being affected by the actuation mechanism used to move and hold movable bus bars 106 and 108 in the closed position because the force generated by pyrotechnic actuator 130 is transmitted to fixed bus bars 102 and 104 in such a manner that it does not oppose the force generated by electromagnetic actuator 118. Similarly, the movement of fixed bus bars 102 and 104 or displacement region 132 into the firing position is not limited to rotational motion, but can follow a linear motion path.

[0063] It is noteworthy that the same principles as described above can be applied to the movable bus bars 106 and 108, such that the pyrotechnic actuator 130 may not permanently displace or sever the fixed bus bars 102 and 104, but rather displace or sever the movable bus bars 106 and 108. Alternatively, a second pyrotechnic actuator may be provided for the contactor device 100, such that the fixed bus bars 102 and 104 are permanently displaced or severed by a dedicated pyrotechnic actuator, respectively, and the movable bus bars 106 and 108 are permanently displaced or severed by a dedicated pyrotechnic actuator, respectively. Furthermore, instead of using the energy of one or more pyrotechnic actuators to sever and / or displace one or more bus bars of the contactor device 100, the energy of one or more mechanical actuators may be used. The mechanical actuator may be, for example, a biasing spring configured to permanently sever and / or displace one or more bus bars of the contactor device 100 upon triggering (activation) of the mechanical actuator, for example, by releasing the biasing spring.

[0064] In another alternative, upon activation of the pyrotechnic actuator 124, rather than mechanically moving one or more busbars of the contactor device 100 to the firing position (or disconnecting one or more busbars), the fixed busbars 102 and 104 can be irreversibly separated from the movable busbars 106 and 108 by actuating at least one isolating cap formed of an electrically insulating material to completely surround the end regions of the fixed busbars 102 and 104. In this manner, the isolating cap interrupts the current flowing through the contact device of the contactor device 100 while suppressing the formation of an arc. Details of this activation mode are further explained in Figures 23 and 24 of European Patent Application EP 22177000.1, which is incorporated herein by reference.

[0065] Figure 6 The contactor assembly 100 is shown along with an optional contactor housing 146 that houses significant portions of the internal components of the contactor assembly 100. In this example, only the terminals 112 and 116 of the fixed busbars 102 and 104 and the terminals 110 and 114 of the movable busbars 106 and 108 are not enclosed by the contactor housing 146. However, the terminals 110, 112, 114, and 116 may be formed by connectors, and the connectors may be integrated into the contactor housing 146. The contactor housing 146 may be a sealed enclosure that may be filled with a vacuum or an electronegative gas to suppress arc formation when the movable contacts 106 and 108 are opened. However, the specific design of the movable busbars 106 and 108, already exposed to normal atmosphere, can provide sufficient electrical isolation between the movable busbars 106 and 108 and the fixed busbars 102 and 104. Therefore, it is not necessary to seal the contactor housing 146 or use a vacuum or an electronegative gas. Furthermore, although terminals 110, 112, 114 and 116 are Figures 1 to 6A bolted interface is shown, but a welded interface or connectors may also be used, for example, which are provided as part of the connector housing 146.

[0066] Figure 7 A schematic circuit diagram of a contactor device 100 conductively coupled to a high-voltage battery 500 is shown. In the example shown, a first terminal 110 of the contactor device 100 is electrically connected to the positive terminal of the HV battery 500. A second terminal 112 can be electrically connected to the positive voltage side of a high-voltage DC bus powered by the electricity of the HV battery 500. Similarly, a third terminal 114 is electrically connected to the negative terminal of the HV battery 500. The second terminal 112 can be electrically connected to the negative voltage side of the HV DC bus. Thus, in the example shown, the fixed bus bar 102 and the movable bus bar 106 serve as a positive main contactor (schematically shown by reference numeral 148), which can be opened and closed to control the electrical connection between the battery 500 and the positive side of the HV DC bus. Similarly, the fixed bus bar 104 and the movable bus bar 108 function as a negative main contactor (schematically shown by reference numeral 150 ), which can be opened and closed to control the electrical connection between the battery 500 and the positive side of the HV DC bus.

[0067] As mentioned above, Figure 7 As shown, the two movable bus bars 106 and 108 are moved by the same actuating element 118 to change the state of the contactor device 100 from a closed state to an open state, and from an open state to a closed state, in which the HV DC bus is disconnected from the HV battery 500 and in which the HV DC bus is connected to the HV battery 500.

[0068] Figure 7 The first aspect of the present disclosure is further illustrated by the integration of a (first) current sensing element 152 (which may also be denoted as a shunt resistor or a shunt current sensor) into the contactor device 100. The current sensing element 152 is formed integrally with one of the busbars of the contactor device 100, here for example with the movable busbar 108. In this way, it is no longer necessary to connect a separate shunt current sensor in series with the contactor device 100 and the HV battery 500. Thus, the integration of the first current sensing element 152 within the contactor device 100 allows the elimination of a (bolted) interconnection between the current sensing element 152 and one of the main contactors 148 and 150 formed by the contact device of the contactor 100.

[0069] Thus, the movable bus bar 108 includes a current sensing element 152 having a predefined resistance and can be used to measure the battery current provided by the HV battery 500. Since the battery current corresponds to the current flowing through the contactor device, it is also denoted as "contactor current" in this application. In order to measure the voltage drop across the first current sensing element 152, the contactor device 100 includes detection nodes 154 and 156. The battery management system of the battery 500 or another external controller of the HV power system using the contactor 100 can be electrically connected to the detection nodes 154 and 156, for example, via a wiring harness or a flexible circuit. The BMS or external controller can then determine the battery current I bat for

[0070]

[0071] Among them, V Res describes the detected voltage drop across the first current sensing element 152, and R describes the predefined resistance of the first current sensing element 152. In addition to the voltage drop across the first current sensing element 152, the BMS or external controller can also determine the temperature of the first current sensing element 152 and correct the resistance value by taking into account the temperature coefficient of resistance (TCR). In this way, the temperature dependence of the resistance of the first current sensing element can be taken into account, so that the battery current can be determined more accurately.

[0072] Figures 8 to 10 The first current sensing element 152 is schematically shown to be integrated into one of the busbars of the contact arrangement of the contactor 100. Figure 7 In the example of FIG, the movable bus bar 108 arranged on the negative output side of the HV battery 500 is shown as an example of a bus bar of the contactor device 100, and the bus bar is integrally formed with the first current sensing element 152. However, the first current sensing element may be integrally formed with the fixed bus bar 104 instead. Figure 7 In the example of FIG. 5 , the fixed bus bar 104 is arranged on the negative output side of the HV battery 500 or is formed integrally with one of the movable bus bar 106 or the fixed bus bar 102. Figure 7 In the example of , they are arranged on the positive output side of the HV battery 500. Figures 8 to 10 , the sizes and shapes of exemplary busbars are shown schematically only, and it should be noted that the inventive concepts described with respect to these figures may be particularly applied to one or more of the movable busbars 106 and 108 and the fixed busbars 102 and 104 of the contactor device 100, as described with reference to FIG. Figures 1 to 5 Shown and described.

[0073] Figure 8A removable bus bar 108 in an interconnected tri-band form is shown, comprising a first bus bar portion 108(1), a second bus bar portion 108(2), and a current sensing element 152 disposed between the first bus bar portion 108(1) and the second bus bar portion 108(2). As described above, the first bus bar portion 108(1) and the second bus bar portion 108(2) may be formed from copper, aluminum, or any other suitable conductive material known in the art. In the example shown, the current sensing element 152 is preferably formed as a manganese copper strip that is fixedly connected to the first bus bar portion 108(1) and the second bus bar portion 108(2) at interconnection interfaces 158 and 160 by welding the manganese copper strip to the first bus bar portion 108(1) and the second bus bar portion 108(2).

[0074] In addition to manganese copper, current sensing element 152 may also be formed from Isotan, Isabellin, or constan, or from another copper alloy containing copper, manganese copper, and / or nickel. However, other suitable materials known in the art that allow for the manufacture of current sensing element 152 with a well-defined resistance are also contemplated. Instead of welding, current sensing element 152 may be interconnected to first bus bar portion 108(1) and second bus bar portion 108(2) by brazing or brazing, or any other suitable interconnection method, which introduces only a small resistance at interconnection interfaces 158 and 160.

[0075] Alternatively, the current sensing element 152 can be formed directly from the movable bus bar 108 and can therefore be formed from the same material as the current sensing element. In this exemplary embodiment, the predetermined resistance of the current sensing element 152 can be defined as an area of ​​the first bus bar 108 having a specific geometry, so that the area in which the current sensing element 152 is formed has a predefined resistance. For example, a constriction having a predetermined width and / or thickness in a direction transverse to the main direction of the current flow can be formed in the movable bus bar 108 to serve as the current sensing element 152. As a technique for forming the current sensing element 152 from the movable bus bar 108, stamping or punching can be used, for example. Alternatively, it is also conceivable to cut certain parts of the prefabricated bus bar in order to integrate the current sensing element 152 into the bus bar.

[0076] By directly forming the current sensing element 152 from the busbar of the contactor device 100 , the corresponding busbar with the current sensing element can be directly manufactured as one piece. Therefore, the resistance of the interconnection interfaces 158 and 160 can be further reduced because no additional interface resistance needs to be introduced.

[0077] Figure 9 The first current sensing element 152 is shown between the contact element 128 of the movable bus bar 108 and the third terminal 114 ( Figure 8 1 ), the third terminal is formed integrally with the movable bus bar 108. Here, the second bus bar portion 108(2) may, for example, include a deflectable bus bar region 120 such that the current sensing element 152 is arranged within a static region of the movable bus bar 108 that is not affected by actuation of the electromagnetic actuator 118. Thus, changes in the state of the contactor device are prevented from affecting the detection of the battery current, for example due to a change in the resistance of the current sensing element 152.

[0078] In another advantageous configuration, the current sensing element 152 can be arranged in one of the busbars of the contactor 100 as a weak point, which facilitates the displacement or disconnection of the corresponding busbar. For example, the current sensing element 152 can be arranged as a hinge flexure 140, such as Figures 1 to 5 As shown, the current sensing element 152 is located in one of the busbars of the contactor device 100 and allows displacement of the corresponding busbar. Alternatively, the current sensing element 152 can define a predetermined breaking area, which helps to cut or break the corresponding busbar in the predetermined breaking area in response to activation of the pyrotechnic actuator 130, similar to the above, especially with respect to Figure 4 and Figure 5 As described.

[0079] Figure 10 Another advantageous configuration of the movable bus bar 108 is shown. In addition to the (first) current sensing element 152, the movable bus bar 108 may also include a (second) current sensing element 162. Like the first current sensing element 152, the second current sensing element 162 may be formed as a manganese copper strip that is fixedly connected to the second bus bar portion 108 (2) and the third bus bar portion 108 (3) at interconnection interfaces 164 and 166 by welding the manganese copper strip to the first bus bar portion 108 (1) and the second bus bar portion 108 (2). However, other manufacturing techniques and interconnection techniques described above for integrating the first current sensing element 152 may also be used to integrate the second current sensing element 162 into the movable bus bar 108 or any bus bar of the contactor device 100. Thus, each of the first and second current sensing elements 152 and 162 may be formed from the same conductive material, or the first and second current sensing elements 152 and 162 may be formed from different conductive materials.

[0080] The integration of the second current sensing element allows for redundant measurement of the battery current because a voltage drop across each of the first and second current sensing elements 152 and 162 can be measured separately, thereby providing two independent voltage detection signals, both of which are proportional to the battery current. In this way, a single point failure in one of the detection lines used to detect the voltage drop across each of the first and second current sensing elements 152 and 162 affects only one of the two detection signals, and the battery current can continue to be determined.

[0081] Obviously, the first current sensing element 152 and the second current sensing element 162 are not necessarily arranged in the same bus bar of the contactor device 100, but can be arranged in different bus bars of the contactor device. Figure 7 In the example of FIG. 5 , the first current sensing element 152 may be part of one of the fixed bus bar 104 and the movable bus bar 108 , which are electrically connected to the negative output side of the HV battery 500 , while Figure 7 In the example of FIG, the second current sensing element 162 may be part of one of the fixed bus bar 102 and the movable bus bar 106, which are electrically connected to the positive output side of the HV battery 500. In addition, more than two current sensing elements may be integrally formed with the bus bar of the contactor device 100.

[0082] Figure 11 A schematic circuit diagram of a second exemplary contactor device 200 conductively coupled to a high voltage battery 500 is shown. Therefore, elements of the second exemplary contactor device 200 corresponding to elements of the first exemplary contactor device 100 are indicated by corresponding reference numerals. The second exemplary contactor device 200 benefits from the second aspect of the present disclosure, namely, the integration of assembly circuitry, which allows at least a portion of the functionality of a battery management system of the battery 500 to be transferred to the contactor device 200, or allows the contactor device 200 to integrate the battery management system of the battery 500 so that the contactor device can operate more independently. As described below, the integration of assembly circuitry can be performed without integrating the reference numerals. Figures 7 to 11 This is done with or can be done with the integration of the at least one current sensing element 152 described for the first exemplary contactor device 100 .

[0083] The assembly circuit 268 includes a control circuit configured to control the operation of the electromagnetic actuator 118 to open and close the positive main contact 148 formed by the movable bus bar 106 and the fixed bus bar 102, and the negative main contact 150 formed by the movable bus bar 108 and the fixed bus bar 104, as shown. Figure 11270, 272, and 274. In this manner, the control circuitry of the assembled circuit 268 can directly override the control of the actuator 118, thereby eliminating the need to implement the control functionality of the actuator 118 in the battery management system of the HV battery 500 or in another external controller of the HV power system including the HV battery 500.

[0084] The control circuitry can control the operation of electromagnetic actuator 118 based on an operating parameter determined by the processing circuitry of the assembled circuit. The operating parameter can be a control command received by the processing circuitry from an external controller (such as a battery management system (BMS) of battery 500, which is located external to contactor device 200) or a vehicle ECU, for changing the state of contactor device 100 by operating electromagnetic actuator 118, or a control command received by the processing circuitry from an external entity for activating a pyrotechnic actuator. Alternatively, the operating parameter can be a measured value, either determined directly by the processing circuitry or determined by an external controller and communicated to the processing circuitry. The measured value can be one of the battery current, the contactor voltage indicating a voltage drop between first terminal 110 and second terminal 112, or a voltage drop between third terminal 114 and fourth terminal 116, or a leakage path resistance between a ground terminal (or voltage reference terminal) of the assembled circuitry and at least one busbar of contactor device 200.

[0085] The assembly circuit 268 may also include a plurality of peripheral circuits, such as a communication circuit, which enables communication between the processing circuit and one or more external controllers, so that the processing circuit can receive and / or transmit control commands from and to the one or more external controllers, thereby monitoring the operation of the contactor device 200. Communication between the communication circuit and the external controller can be performed, for example, by using a CAN (Controller Area Network) bus and a CAN protocol, by using an isoSPI (Isolated Serial Port Interface) interface and an isoSPI protocol, or by using Ethernet. However, other known in-vehicle networks and industrial communication protocols may also be used.

[0086] For example, the peripheral circuit may also include a power supply unit that supplies power to the circuits of the assembled circuit 268. Thus, the assembled circuit 268 may be powered directly by the HV battery 500. However, another (external) power source for supplying power to the assembled circuit 268 is also conceivable.

[0087] The various circuits of the assembled circuit 268 can be mounted on a single component carrier to form the assembled circuit as an integrated assembly. Therefore, the term integrated assembly specifically refers to the fact that all components of the assembled circuit are packaged together as a single compact assembly. For example, a printed circuit board (PCB) can be used as a component carrier, and by mounting the assembled circuit 268 on the PCB, the PCB becomes a printed circuit board assembly (PCBA).

[0088] To further improve the integration, for example, the assembled circuit 268 mounted on a PCB to form a PCBA can be arranged in the contactor housing 146 (eg, Figure 6 ). For example, the connector housing may allow for providing specific housing portions for the assembly circuit 268 and / or may provide specific cooling channels to effectively cool the assembly circuit 268. The connection interface necessary to allow a wired connection between the assembly circuit 268 and an external controller may be provided in the form of a connector that is integrated into the contactor housing 146. However, it is also conceivable that the communication circuit of the assembly circuit 268 allows for wireless communication with external circuits.

[0089] Furthermore, the contactor assembly 200 may not be housed in the contactor housing 146. In this case, the PCBA with the assembled circuit 268 mounted thereon may be secured to the contactor assembly 200, for example, by screws or welding. In such an embodiment, protection of the PCBA may be provided, for example, by a protective coating or by overmolding the PCBA.

[0090] In addition to receiving measurements from an external controller, the level of integration of the contactor device 200 may be further increased by implementing additional detection functionality in the assembled circuitry, thereby allowing the assembled circuitry to directly detect and / or determine at least one of the battery current, contactor voltage, or leakage path resistance.

[0091] In the first example, the assembly circuit 268 includes a first detection circuit configured to detect a first detection voltage indicative of a battery current (or a contactor current). To this end, the contactor device 200 may further include an integrated current sensing element 152 that is integrally formed with one of the busbars of the contactor 200. The current sensing element 152 may be designed in any manner that has been described with reference to the first exemplary contactor device 100, with particular reference to the embodiment of the present invention. Figures 8 to 10 To measure the voltage drop across the current sensing element 152, the first detection circuit can be electrically connected to the detection nodes 254 and 256 of the busbar (in this example, the movable busbar 108) via detection lines 276 and 278, with the current sensing element 152 being formed using these detection nodes. As described above, more than one current sensing element can be integrally formed with the busbar of the contactor device 200. In this case, the first detection circuit can be electrically connected to each current sensing element individually via a detection line, and the voltage drop across each current sensing element can be individually measured.

[0092] It is worth noting that the integrated current sensor element is not necessarily formed integrally with the contactor device 200, but the first detection circuit can also be electrically connected to at least one external shunt resistor (such as the shunt resistor 15 shown in Figure 14) through external wiring. In this case, the first detection circuit detects the voltage drop across the at least one external shunt resistor as the first detection voltage.

[0093] Based on the detected voltage drop, the processing circuit is configured to determine the contactor current by using the above equation (1), wherein the detected first detection voltage is used as the detected voltage drop VRes, and the resistance of the corresponding current sensing element (or external shunt) is used as the predefined resistance R. Alternatively, in order to determine the contactor current, the processing circuit may transmit the detected first detection voltage to an external controller, and the external controller may calculate the contactor current and transmit the calculation result back to the processing circuit.

[0094] Based on the determination of the contactor current, the control circuit controls the operation of the electromagnetic actuator 118 and may also optionally control the activation of a pyrotechnic actuator or an external fuse (e.g., fuse 12 shown in FIG14 ). For example, due to electromagnetic forces, when the contactor current (or battery current) exceeds a predetermined current threshold, it may be impossible to separate the movable contacts 106 and 108 from the fixed contacts 102 and 104. Therefore, if the control circuit determines that the determined contactor current is greater than or equal to the predetermined current threshold, the control circuit does not actuate the electromagnetic actuator 118, but instead issues an activation signal to activate the pyrotechnic actuator or external fuse. However, in some exemplary configurations, the activation signal may be issued by the external controller if the external controller determines that the control circuit is unable to interrupt the contactor current by actuating the electromagnetic actuator 118.

[0095] In a second example, the assembly circuit 268 includes a second detection circuit configured to detect a second detection voltage indicative of the contactor voltage. To this end, the second detection circuit can determine the voltage drop across the negative main contactor 150, i.e., the voltage drop between the movable bus bar 108 and the fixed bus bar 104. To detect the voltage drop between the movable bus bar 108 and the fixed bus bar 104, the second detection circuit can be electrically connected to the detection node 254 of the movable bus bar 108 via a detection line 276 and to the detection node 286 of the fixed bus bar 104 via a detection line 280.

[0096] Alternatively, or in addition, the second detection circuit can determine the voltage drop across the positive main contactor 148, i.e., the voltage drop between the movable bus bar 106 and the fixed bus bar 102. To detect the voltage drop between the movable bus bar 106 and the fixed bus bar 102, the second detection circuit can be electrically connected to a detection node 288 of the fixed bus bar 102 via a detection line 282 and to a detection node 290 of the movable bus bar 106 via a detection line 284.

[0097] Based on the detected one or more voltage drops, the processing circuit is configured to determine the contactor voltage as a voltage drop across one of the primary contactors 148 and 150 or an average of these voltages. Similarly, the determination of the contactor voltage can include the processing circuit transmitting the detected second detection voltage to an external controller, and the external controller calculating the contactor voltage and transmitting the calculated result back to the processing circuit. By implementing the detection of the contactor voltage as a function of the assembly circuit 268, the status of the contactor device 200 can be confirmed by the assembly circuit 268 and / or by an external controller monitoring the operation of the contactor device 200, thereby enabling the determination of contactor health and wear.

[0098] Based on the determination of the contactor voltage, the control circuit controls the operation of the electromagnetic actuator 118. For example, due to possible current spikes that could damage components electrically connected to the HV DC bus, such as DC link capacitors, the control circuit may only actuate the electromagnetic actuator 118 to place the movable bus bars 106 and 108 in the closed position if the determined contactor voltage is equal to or less than a predetermined voltage threshold, but will not actuate the electromagnetic actuator 118 if the determined contactor voltage is greater than the predetermined voltage threshold.

[0099] In order to reduce the contactor voltage before changing the state of the contactor device 100 , the assembled circuit may further include a pre-charge circuit 301 , which may be electrically connected in parallel to one of the main contactors 148 and 150 . Figure 12 A schematic circuit diagram of an exemplary pre-charge circuit 301 is shown, which is electrically connected in parallel with the positive main contactor 148 by electrically connecting the pre-charge circuit to a node 303 provided on the movable busbar 108 and a node 305 provided on the fixed busbar 102, for electrically connecting the pre-charge circuit to the respective busbars. The pre-charge circuit includes at least one pre-charge resistor 307 and at least one pre-charge switch 309, which are electrically coupled in series between nodes 303 and 305. In this way, the pre-charge circuit 301 allows the main contactor 148 formed by the contact points of the movable busbar 108 and the fixed busbar 102 to be optionally bypassed to short-circuit the terminals 110 and 112 of the contactor device when the pre-charge switch 309 is closed.

[0100] The resistance of the pre-charge resistor 307 can be selected according to the application scenario to limit the maximum current flowing through the pre-charge circuit 301, thereby avoiding dangerous current peaks when the pre-charge switch 309 is closed. The pre-charge switch 309 can be a semiconductor switch, such as a metal oxide semiconductor field effect transistor or an insulated gate bipolar transistor (IGBT), which can be easily integrated into the assembly circuit 268. However, another type of pre-charge relay can also be used.

[0101] The opening and closing of the pre-charge switch 309 can be controlled by the control circuitry of the assembly circuit 268, or it can be controlled by an external controller based on the contactor voltage. For example, if the contactor voltage is determined to be greater than a predetermined voltage threshold, the electromagnetic actuator 118 is not actuated, but the pre-charge switch 309 is closed. Once the contactor voltage reaches or drops below the predetermined voltage threshold, the electromagnetic actuator 118 can be actuated to place the movable contacts 106 and 108 in the closed position, thereby allowing current to flow through the main contactors 148 and 150. In this way, the contactor device 200 only enters the closed state when the contactor voltage is equal to or less than the predetermined voltage threshold, significantly reducing the risk of dangerous current spikes generated after closing the movable contacts 106 and 108. Because the pre-charge circuit 301 is an integral part of the assembly circuit 268, it is directly integrated into the contactor device 200, eliminating the need to connect an external pre-charge circuit to the contactor device 200.

[0102] In a third example, the assembled circuit 268 includes a third detection circuit configured to detect a third detection voltage that indicates a leakage path resistance between one of the bus bars of the contactor device 200 and a ground potential (or a reference potential), which may correspond to the potential of the vehicle chassis, for example. To detect the leakage path resistance, the third detection circuit may be part of a leakage path resistance detection circuit. A circuit diagram of an exemplary leakage path resistance detection circuit 311 is shown in FIG. Figure 13 The leakage path resistance detection circuit 311 is conductively coupled here, for example, to the movable bus bar 108 at a node 313 and to a ground terminal 317 of a contactor device at a node 315, which may be electrically connected to the chassis of the vehicle or another reference potential.

[0103] The leakage path resistance detection circuit 311 includes at least a first leakage path resistance detection resistor 319 and a second leakage path resistance detection resistor 321, which are conductively coupled in series with a node 323 between the movable bus bar 108 and the ground terminal 317. A leakage path resistance detection switch 323 is conductively coupled in parallel with the first leakage path resistance detection resistor 319 so as to selectively bypass (short-circuit) the first leakage path resistance detection resistor 319 when the leakage path resistance detection switch 323 is closed. The leakage path resistance detection switch 323 can be a semiconductor switch, such as a metal oxide semiconductor field effect transistor or an insulated gate bipolar transistor (IGBT), which can be easily integrated into the assembled circuit 268. However, another type of relay can also be used.

[0104] The third detection circuit (see Figure 13 The third detection circuit is conductively coupled to a node 323 between the first leakage path resistance detection resistor 319 and the second leakage path resistance detection resistor 321 (reference numeral 325 in FIG). The third detection circuit is configured to detect a first leakage path resistance detection voltage V across the second leakage path resistance detection resistor 321 when the leakage path resistance detection switch 323 is open. leak,1 , and when the leakage path resistance detection switch 323 is closed, the second leakage path resistance detection voltage V across the second leakage path resistance detection resistor 321 is detected. leak,2 .

[0105] Based on the detected leakage path resistance, the voltage V leak,1 and V leak,2 , the processing circuit is configured to determine the leakage path resistance of the contact arrangement of the contactor by using the following equation (2),

[0106]

[0107] Where V bat is the voltage of battery 500, R ST1 is the resistance of the leakage path resistance detection circuit 311 when the leakage path resistance detection switch 323 is closed. For a more detailed description of the leakage path resistance determination, reference may be made to European patent application EP18 209 536.4. Figure 1 More details of the possible leakage path resistance detection circuit 311 can be found in European patent application EP 18 209 536.4 Figure 2 and Figure 3Of course, the circuit and method disclosed in European Patent Application EP 18 209 536.4 can also be used for leakage path resistance detection of assembly circuit 268. However, other known leakage path resistance circuits and detection methods can also be implemented for leakage path resistance detection of assembly circuit 268.

[0108] Instead of electrically connecting the leakage path resistance detection circuit 311 to the movable bus bar 108, the leakage path resistance detection circuit 311 can be electrically connected to another bus bar of the contactor 200. Furthermore, the leakage path resistance detection can be performed on multiple bus bars of the contactor 200. In particular, it is particularly advantageous to perform the leakage path resistance detection on one bus bar that is part of the positive main contactor 148 and one bus bar that is part of the negative main contactor 150.

[0109] Likewise, the determining of the leakage path resistance may include the processing circuit transmitting the detected third detection voltage to the external controller, and the external controller may calculate the leakage path resistance of the contact assembly and transmit the calculation result back to the processing circuit.

[0110] Based on the determination of the leakage path resistance, the control circuit controls the operation of the electromagnetic actuator 118 or may activate the pyrotechnic actuator 130. Specifically, if the control circuit determines that the leakage path resistance of the assembled circuit (i.e., any busbar of the assembled circuit) is equal to or less than a predetermined resistance threshold, the control circuit may be configured to control the electromagnetic actuator 118 to change the state of the contactor device 200 to the open state. If the movable contact can no longer be moved, for example, because the contactor current is above a predetermined current threshold, the control circuit is configured to activate the pyrotechnic actuator 130 to permanently interrupt the current flow through the contactor device. Alternatively, in some exemplary configurations, if the external controller determines that the leakage path resistance of the assembled circuit is equal to or less than the predetermined resistance threshold, the command to open the movable contacts 106 and 108 or the activation signal to activate the pyrotechnic actuator may be issued by the external controller and processed by the processing circuitry and control circuitry of the assembled circuit.

[0111] The sense lines 276, 278, 280, 282, and 284 that electrically connect the various sense circuits to the various sense nodes, as well as other lines that electrically connect the components of the assembled circuit (such as the pre-charge circuit 301 and the leakage path resistance sense circuit 311) to one or more bus bars of the contactor device 200, can be provided in the form of a wiring harness or as conductors on a flexible PCB. For example, the latter option allows the assembled circuit to be directly integrated on the flexible PCB, further improving the level of integration of the contactor device 200.

[0112] It is worth noting that the function of each circuit of the assembled circuit 268 can be implemented by software, hardware, or software in cooperation with hardware. In addition, each circuit of the assembled circuit 268 can be implemented as an application-specific integrated circuit, and the application-specific integrated circuits are assembled to form the assembled circuit. Alternatively, the function of each circuit can be integrated into a common integrated circuit forming the assembled circuit. Alternatively, one or more circuits of the assembled circuit can be implemented by using a programmable general-purpose processor, a dedicated processor, or an FPGA (field programmable gate array).

[0113] Furthermore, the voltage detection circuit of the assembled circuit may be formed of a dedicated analog-to-digital converter (ADC converter), or may be formed of a single ADC converter that performs the individual voltage detections described above in serial order.

[0114] The present disclosure also relates to a high-voltage power supply system, which includes the first exemplary contactor device 100 or the second exemplary contactor device 200 and a battery 500. The HV power supply system may further include an external controller, such as the battery management system (BMS) of the battery 500 or the vehicle ECU, which controls the operation of the battery 500. As described above, the external controller can control the operation of the contactor device alone (for the contactor device 100) or in interaction with the internal controller (assembly circuit 268) of the contactor (contactor device 200). Thus, the internal controller can override at least some of the functions of the external controller and thus can at least partially control the contactor device independently of the external controller. In particular, the internal controller in the form of assembly circuit 268 can even replace the battery management system (BMS) of the battery 500. In addition, the contactor devices 100 and 200 can allow the contactor device 100 or 200 to be directly electrically connected to the HV battery 500 without the need for an external bus bar to be connected therebetween. This can be achieved by extending the length of the bus bars of the contact assembly on the battery side, such as the movable bus bars 106 and 108 in the described example. This reduces the possibility of a short circuit occurring during assembly of the HV power system or in the event of a vehicle collision. In addition, by connecting only two conductive elements, the contactor devices 100 and 200 can be installed within a battery pack formed by the HV battery 500.

[0115] As is apparent from the foregoing description, the concepts of the first and second aspects of the present disclosure can be used individually or in combination to improve the level of integration of the contactor device and facilitate the provision of an inexpensive, space-saving, and weight-saving contactor device. However, it should be noted that integrating the current sensing element into the contactor device is not essential for achieving the second aspect of the present disclosure, and similarly, integrating the assembly circuit into the contactor device is not essential for achieving the first aspect of the present disclosure.

[0116] Reference Mark

[0117]

[0118]

Claims

1. A contactor device (100), comprising: A contact arrangement comprising at least one movable busbar (106, 108) and at least one fixed busbar (102, 104), wherein the at least one movable busbar (106, 108) has a first contact area and the at least one fixed busbar (102, 104) has a second contact area; at least one actuating element (118) configured to change at least the state of the contactor device (100) from an open state to a closed state and from a closed state to an open state, wherein in the open state the first contact region is electrically isolated from the second contact region and in the closed state the first contact region is electrically conductively coupled to the second contact region; Wherein, the contact device comprises a first current sensing element (152) having a first predetermined resistance; The first current sensing element (152) is formed integrally with one of the bus bars (102, 104, 106, 108) included in the contact device.

2. The contactor device (100) of claim 1, further comprising a contactor housing (146) at least partially housing the at least one movable bus bar (106, 108) and the at least one fixed bus bar (102, 104), and wherein The first current sensing element (152) is disposed within the contactor housing (146); Optionally, the contactor housing (146) is a sealed housing.

3. The contactor device (100) according to claim 1 or 2, wherein: Each of the at least one movable bus bar (106, 108) includes a deflectable contact area (120) that is resiliently deflectable between a disconnected position in which the at least one movable bus bar (106, 108) is electrically isolated from the at least one fixed bus bar (102, 104) and a second position in which the at least one movable bus bar (106, 108) is electrically coupled to the at least one fixed bus bar (102, 104).

4. The contactor device (100) according to one of claims 1 to 3, wherein The first current sensing element (152) and a bus bar (102, 104, 106, 108) of the contact device are formed of the same conductive material, and the first current sensing element (152) is formed integrally with the bus bar.

5. The contactor device (100) according to one of claims 1 to 4, wherein The contact device includes a second current sensing element (162) having a second predetermined resistance; wherein the second current sensing element (162) is integrally formed with one of the bus bars (102, 104, 106, 108) included in the contact device; and Optionally, the second current sensing element (162) and a bus bar (102, 104, 106, 108) of the contact device are formed of the same conductive material, and the second current sensing element (162) is formed integrally with the bus bar.

6. The contactor device (100) according to claim 5, wherein The first current sensing element (152) and the second current sensing element (162) are integrally formed with the same bus bar (102, 104, 106, 108) included in the contact arrangement.

7. The contactor device (100) according to claim 5, wherein The first current sensing element (152) and the second current sensing element (162) are formed integrally with different bus bars (102, 104, 106, 108) included in the contact device.

8. The contactor device (100) according to one of claims 5 to 7, wherein The first current sensing element (152) and the second current sensing element (162) are formed of the same conductive material.

9. The contactor device (100) according to one of claims 5 to 7, wherein The first current sensing element (152) and the second current sensing element (162) are formed of different conductive materials.

10. The contactor arrangement (100) according to one of claims 1 to 9, further comprising at least one second actuator (130) which, when activated, is configured to irreversibly prevent the flow of current through the contact arrangement; Optionally, wherein The second actuator (130) is a pyrotechnic actuator; Optionally, wherein the second actuator (130) is a mechanical actuator; Optionally, wherein the second actuator (130) is configured to irreversibly displace or irreversibly disconnect one or more of the at least one movable bus bar (106, 108); and Optionally, the second actuator (130) is configured to irreversibly displace or irreversibly cut one or more of the at least one fixed bus bar (102, 104).

11. The contactor device (100) according to claim 10, wherein At least a portion of the first current sensing element (152) defines a weak point (140) that supports the second actuator (130) when one bus bar (102, 104, 106, 108) is severed, the first current sensing element (152) being integrally formed with the bus bar. Optionally, at least a portion of the second current sensing element (162) defines a weak point (140) that supports the second actuator (130) when one bus bar (102, 104, 106, 108) is severed, and the second current sensing element (162) is integrally formed with the bus bar.

12. The contactor device (100) according to claim 11, wherein The weak point (140) is formed as a predetermined breaking area, so that the corresponding bus bar (102, 104, 106, 108) is configured to break in the predetermined breaking area in response to activation of the second actuator (130).

13. The contactor device (100) according to claim 11, wherein The weak point (140) is formed as a hinge flexure, enabling the corresponding bus bar (102, 104, 106, 108) to bend about the hinge flexure in response to activation of the second actuator (130).

14. The contactor device (100) according to one of claims 1 to 13, wherein The contact device includes a pair of movable bus bars (106, 108) and a pair of fixed bus bars (102, 104), each movable bus bar having a movable contact area and each fixed bus bar having a fixed contact area. The at least one actuating element (118) is configured to simultaneously actuate the pair of movable bus bars (106, 108) when changing the state of the contactor device (100) from the open state to the closed state and from the closed state to the open state, so that the movable contact area is electrically isolated from the fixed contact area in the open state and the movable contact area is conductively coupled to the fixed contact area in the closed state.

15. A high voltage power supply system comprising at least one battery (500) and a contactor device (100) according to any one of claims 1 to 14.

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