Direct-current power relay capable of quickly alarming

Abstract

The invention discloses a direct-current power relay capable of rapidly giving an alarm, and belongs to the technical field of power system alarm. Comprising a quick plug type electromagnetic driving module and a composite function base, and when the relay is in overvoltage, overcurrent, overheating, gas-liquid invasion or abnormal pressure intensity, a dry contact is output within 20ms-2s by utilizing a sliding-pressing-touching mechanism, bimetallic linkage, expansion triggering and phase change-corrugated pipe coupling, and an EMS / PLC / sound-light alarm is driven; repeating / fusing dual-mode protection is ensured through a low-friction sliding pair, elastic automatic reset and a replaceable low-melting-point alloy gasket, direct-current systems such as energy storage and charging piles are compatible, the size is not changed, and reliability is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of power system alarms, and in particular to a DC power relay capable of rapid alarming. Background Art

[0002] In application scenarios such as renewable energy power generation, energy storage, and DC fast charging, the DC bus voltage level continues to increase (800V, 1000V, and even 1500V), and the power density continues to increase, which puts higher requirements on the safety and reliability of DC power relays.

[0003] Traditional electromagnetic relays or solid-state relays usually only have a single main contact on-off function. Their protection action relies on external fuses, Hall sensors or software algorithms, and they have the following common problems. Existing relays lack the ability to self-sensing and self-alarm for multiple faults such as overvoltage, overcurrent, overheating, gas and liquid intrusion, and increased internal pressure. They must rely on distributed sensor networks, which are complex, costly, and have many fault points. After overload action, manual on-site reset or replacement of the fuse is required, and unmanned scenarios such as charging piles and energy storage containers have long downtime.

[0004] To shorten response time, some manufacturers have adopted magnetic blowout combined with permanent magnet arc extinguishing, dual-breakpoint, or bridge contact structures. However, these solutions only improve the main contact's breaking capacity and fail to address the issues of fault detection and alarm speed. Another solution involves connecting an electronic fast-acting fuse (Pyro-Fuse) in parallel with the relay, using a gunpowder explosion to push a piston to cut the busbar. This can operate within 1-3ms, but it is costly, disposable, and non-resettable. Therefore, a DC power relay with rapid alarm has been proposed. Summary of the Invention

[0005] The purpose of the present invention is to solve the shortcomings of the prior art and to propose a DC power relay capable of rapid alarm.

[0006] In order to achieve the above object, the present invention adopts the following technical solutions:

[0007] A DC power relay capable of rapid alarming comprises a quick-plug electromagnetic drive module and a composite functional base. One end of the quick-plug electromagnetic drive module is laterally inserted into the composite functional base. The composite functional base comprises a main terminal block and a gas-liquid intrusion alarm module arranged away from one end of the quick-plug electromagnetic drive module. An overheating alarm module is inserted into one side of the gas-liquid intrusion alarm module, and an overvoltage / overcurrent alarm module is inserted into the bottom of the overheating alarm module.

[0008] Preferably, the main terminal seat includes a terminal body and an insert slot arranged on one side end face of the terminal body, and a locking hole is arranged on the side end face of the terminal body.

[0009] Preferably, the gas-liquid intrusion alarm module comprises two sets of air slits opposite to each other, an expansion cavity is provided between the two sets of air slits, and a micro-trigger plate is provided at the bottom of the inner end surface of the air slit;

[0010] Two sets of oppositely opened slit-type ventilation slits are located on the side walls of the gas and liquid intrusion alarm module. The slit width is 0.05-0.1mm, which can block large particles such as sand and dust, but allow gas or liquid to penetrate into the inner cavity, achieving the detection premise of "allowing entry but not blocking";

[0011] The expansion chamber is located between two sets of breathable slits and is filled with highly liquid / gas absorbing polymer expansion strips. When encountering water, oil or specific gases such as SF6 leakage or hydrogen, the expansion strips will increase in volume by 3-5 times within 1-3 seconds, generating a thrust of 1-2N.

[0012] The micro-trigger strip slotted at the bottom of the vent slit acts as an elastic cantilever, with one end fixed inside the vent slit and the other end extending into the expansion chamber. When the expansion strip increases in volume, it pushes the micro-trigger strip downward by 0.2mm, causing its end to close with the alarm contact below, outputting a dry contact signal.

[0013] The closed circuit can directly drive the fast-closing contacts or be connected in parallel to remote monitoring to achieve "instant alarm for gas-liquid intrusion." The expansion strip changes color from blue to red after absorbing moisture / air, providing visual secondary confirmation, allowing operation and maintenance personnel to quickly locate the source of the leak.

[0014] Through the cascade action of "the permeable slit to the expansion chamber sensing causes the micro-trigger piece to close", in gas or liquid.

[0015] Preferably, the overheat alarm module includes a thermally sensitive frame and bimetallic cavities respectively provided in the middle of the end surfaces on both sides of the thermally sensitive frame, thermal trigger sliders are installed on both sides of the inner cavity of the thermally sensitive frame, and the overheat alarm contacts are inserted in the gap between the two groups of thermal trigger sliders;

[0016] The thermistor skeleton is directly mounted on the coil or conductive bar, and uses the high thermal conductivity metal to quickly absorb the Joule heat generated by overvoltage and high current, so that the overall temperature rise can be sensed within 1~2 seconds;

[0017] The bimetallic strip cavity is opened on both sides of the thermal frame, and the bimetallic strip is clamped inside. As the temperature rises, the bimetallic strip arches outward, providing mechanical thrust, converting the temperature signal into a controllable displacement.

[0018] The thermal trigger sliders are installed on both sides of the inner cavity of the thermal frame. After being pushed by the bimetallic strip, they move inward synchronously along the guide groove of the bimetallic strip cavity, forming a "top-to-top" action, ensuring that the thrust direction is completely coaxial with the overheating alarm contact to avoid lateral jamming;

[0019] The overheat alarm contact is inserted between two sets of thermal trigger sliders. When the sliders move inward, the overheat alarm contact is pressed down and closes with the lower static contact, forming an independent overheat alarm circuit. This circuit can be connected in parallel with the overvoltage alarm circuit of the overvoltage / overcurrent alarm module to achieve "temperature-pressure" dual redundant alarm. It can also independently drive the temperature indicator light or fan, facilitating rapid on-site fault location.

[0020] Through the cascade action of "rapid heat conduction of the thermal skeleton causes the bimetallic spring to deform, thereby triggering the thermal trigger slider to push the overheating alarm contact to close", when overvoltage and high current cause the coil or busbar to heat up abnormally, a dry contact signal is output within 2 seconds to realize overheating alarm, avoiding secondary faults such as insulation aging and coil burning.

[0021] Preferably, the overvoltage / overcurrent alarm module includes a main contact and a buzzer chamber arranged on a side end surface of the main contact, a sliding guide rail is horizontally arranged on one side of the buzzer chamber, and slider contact arms are slidably arranged on both sides of the side end surface of the sliding guide rail. Slider contact arms are installed at one end of multiple groups of slider contact arms arranged in a row, and two groups of slider contact arms arranged opposite to each other are connected in series through an elastic linkage member, and the gap between the two groups of elastic linkage members is connected in series through a quick closing contact;

[0022] When the relay detects an overvoltage or overcurrent condition, the overload current passes through one end of the slider contact arm and moves in the opposite direction with the sliding guide rail as the sliding path; during the movement, the two sets of oppositely opened slider contact arms squeeze the elastic linkage parts inward, causing the quick closing contacts to move downward and contact directly above the sliding guide rail, thereby forming a closed circuit and triggering an alarm signal.

[0023] The sliding guide rail provides stable sliding support for the slider contact arm, ensuring that it can move along the predetermined trajectory when subjected to force, thereby maintaining the accuracy of the alarm action; when an overload current passes through, the slider contact arm slides along the sliding guide rail due to electromagnetic or mechanical force, receives the overload signal through one end of itself, and converts this signal into mechanical motion, transmitting it to subsequent components; multiple groups of slider contact arms are interconnected and connected in series with elastic linkage parts to form a mechanical and electrical linkage structure, jointly participating in the transmission of alarm signals.

[0024] After the overvoltage / overcurrent signal is triggered, the overvoltage / overcurrent alarm module completes the circuit closure within tens of milliseconds through the three steps of "slide, press, and touch", significantly shortening the response time of traditional relays.

[0025] The sliding guide rail and the slider contact arm sliding pair adopt a low-friction design to prevent jamming. The elastic linkage is made of elastic material and is naturally stretched in the initial state. When the slider contact arm is squeezed inward, the elastic linkage is elastically deformed and provides rebound force. It can automatically reset after the action to ensure that repeated triggering will not fail.

[0026] The quick-closing contacts and the sliding guide rails are in surface-to-surface contact, with low contact resistance and resistance to welding; the buzzer alarm mechanism is built into the buzzer cavity and shares the same composite functional base with the main circuit of the relay; the quick-closing contacts can be connected in parallel to remote monitoring, PLC or sound and light alarms, and are suitable for various scenarios such as DC power distribution, new energy storage, and charging piles.

[0027] The main contacts of the relay are connected in series between the busbar and the energy storage converter, and the fast closing contact terminals are connected in parallel to the DI port of the EMS energy management system and the on-site sound and light alarm;

[0028] Overload current enters the sliding guide rail through the slider contact arm and slides in the opposite direction. At this time, the elastic linkage is compressed to close the quick-closing contact and the sliding guide rail. The EMS receives the dry contact signal within 20ms, automatically reduces the load of the photovoltaic inverter and disconnects the energy storage charging circuit. The on-site buzzer simultaneously alarms, and the operation and maintenance personnel arrive at the site for confirmation within 30s. The busbar overvoltage duration is shortened from the traditional 300ms to <50ms, avoiding overvoltage breakdown of the IGBT module.

[0029] The main contact of the relay is connected in series to the output end of the charging pile, and the fast closing contact terminal is connected to the CAN bus alarm node of the charging pile main control board;

[0030] The vehicle's BMS abnormally draws a load of 300A (rated at 250A). The contacts close quickly within 30ms, and the main control board immediately reduces the power to 150A. At the same time, it alerts the owner through a CAN message. After the fault is eliminated, the elastic linkage automatically resets and the relay resumes full power output, avoiding fuse blowing, reducing shutdown times by 90%, and improving the availability of charging piles.

[0031] Preferably, the quick-plug electromagnetic drive module includes an insulating shell and a moving iron core guide rod inserted into the inner cavity of the insulating shell. Side locks are installed on both sides of the edge of the insulating shell, and the pressure-overheat alarm is vertically inserted into the groove of the side lock.

[0032] Preferably, the locking hole penetrates and is inserted into the inner cavity of the movable iron core guide rod, so that the quick-plug electromagnetic drive module and the composite functional base are combined into a whole.

[0033] Preferably, the pressure-overheat alarm includes a bellows and a heat-conducting sleeve installed on the outer ring of the bellows, the outer ring of the heat-conducting sleeve is sleeved with a phase-change thermistor cavity, bimetallic discs are installed on both sides of the outer ring of the phase-change thermistor cavity, and the other end of the bimetallic disc is sleeved with a linkage push rod, the inner cavity of the bellows is connected to the main cavity of the relay, and the internal air pressure change is sensed in real time. The heat-conducting sleeve synchronously converts the deformation displacement of the bellows into a change in the heat conduction area, and the phase-change thermistor cavity is filled with a low-boiling-point phase-change liquid with a boiling point of ≈85°C; when the internal pressure increases and causes the bellows to expand, the contact area between the heat-conducting sleeve and the phase-change thermistor cavity increases, the phase-change liquid quickly vaporizes and absorbs heat, and the cavity temperature rises sharply;

[0034] The bimetallic disc is fixed on the top of the phase change thermistor cavity; when the temperature rises suddenly, the bimetallic disc jumps suddenly, the upper end of the linkage push rod is pushed by the bimetallic disc, and the lower end passes through the phase change thermistor cavity and enters the center hole of the pressure-overheat alarm.

[0035] Preferably, the linkage push rod comprises a conductive disk and elastic contact fingers mounted on both side end walls of the conductive disk, and a low melting point alloy gasket is clamped between the two sets of elastic contact fingers;

[0036] When the linkage push rod is pushed downward by the bimetallic disc, the conductive disc and the elastic contact finger close, forming a dry contact alarm; if the temperature continues to rise to the melting point of the low-melting-point alloy gasket, the low-melting-point alloy gasket melts, the conductive disc is permanently pressed down, and the elastic contact finger is locked and closed, realizing a "fuse-lock" alarm;

[0037] The two sets of elastic contact fingers are connected in series through the series output terminal, which can directly drive the internal buzzer, remote PLC or SCADA system, realizing the closed loop of "excessive pressure leads to excessive heat, thus providing immediate alarm";

[0038] The pressure-overheat alarm utilizes a three-stage coupling of "bellows-phase change thermistor cavity-bimetallic disc". When an abnormal increase in internal pressure causes heat accumulation, it completes "sense-trigger-alarm" within 2-3 seconds. It also takes into account both recoverable and irreversible protection requirements through two modes: "repeatable jump" or "one-time fusing", significantly improving the safety of relays in closed, high-voltage DC systems.

[0039] Level 1 resettable alarm: The bimetallic disc suddenly jumps, causing the linkage push rod to move downward, driving the conductive disc and elastic contact finger to close. At this time, the dry contact immediately outputs and drives the on-site buzzer / remote PLC; when the pressure drops, the bimetallic disc automatically rebounds, the circuit is disconnected, and the system can be used again.

[0040] Secondary fuse lockout alarm: If the pressure continues to rise and the temperature exceeds the set threshold, the low-melting-point alloy gasket melts, causing the conductive disk to lose its support and permanently press down, causing the elastic contact fingers to be mechanically locked and remain permanently closed. At this time, regardless of whether the pressure is restored, the alarm signal continues to output until the low-melting-point alloy gasket is manually replaced to prevent the risk of repeated failures.

[0041] Preferably, the two groups of elastic contact fingers are connected in series through a series output terminal, and the two groups of elastic contact fingers are connected in series through the series output terminal to form a redundant circuit; if the connector in any series output terminal fails, the other group can still be turned on, and the output end can be directly connected to SCADA, realizing a complete closed loop of "excessive pressure leading to excessive heat, thereby immediately and continuously alarming".

[0042] Compared with the prior art, the present invention has the following beneficial effects:

[0043] 1. Extremely short response time: The overvoltage / overcurrent alarm module adopts a three-step cascade of "slide-press-touch", completing the circuit closure within tens of milliseconds. The busbar overvoltage duration is shortened from the traditional 300ms to <50ms, significantly reducing the risk of overvoltage breakdown of power devices such as IGBTs.

[0044] 2. Mechanical-electrical integrated linkage: The slider contact arm, elastic linkage parts and quick closing contacts form a low-friction, low-lateral-force surface-to-surface contact structure with low movement resistance, reliable rebound, and no failure in repeated triggering, reducing maintenance cycles by more than 90%.

[0045] 3. Multi-scenario plug-and-play: The quick-closing contacts can be directly connected in parallel to external systems such as EMS, PLC, CAN, SCADA, and sound and light alarms without the need for additional drive circuits. It is suitable for diverse working conditions such as DC power distribution, new energy storage, charging piles, and high-voltage closed systems.

[0046] 4. Temperature-pressure dual redundant protection: The overheat alarm circuit composed of the thermal skeleton 231-bimetallic strip-heat trigger slider is output in parallel with the overvoltage / overcurrent alarm circuit, and the dry contact is output within 2s to avoid secondary faults such as insulation aging and coil burning caused by single detection failure.

[0047] 5. Instant alarm for gas-liquid intrusion: "Admittable but not blocked" detection is achieved between the vent slit, expansion cavity and micro-trigger piece. Leakage detection and dry contact output are completed within 1-3 seconds. The color change of the expansion bar provides visual secondary confirmation, improving reliability in outdoor and chemical environments.

[0048] 6. Pressure-overheat coupling self-protection: The three-level coupling between the bellows, phase-change thermistor cavity and bimetallic disc can complete "sense-trigger-alarm" within 2-3 seconds, and has two-level protection of resettable jump and one-time fuse lock, taking into account the requirements of resumable operation and irreversible safety shutdown. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Figure 1 This is a schematic diagram of the three-dimensional structure of a DC power relay capable of rapid alarm proposed by the present invention;

[0050] Figure 2 This is a schematic diagram of the structure of a composite functional base of a DC power relay capable of rapid alarm proposed by the present invention;

[0051] Figure 3 This is a schematic diagram of the main terminal block structure of a DC power relay capable of rapid alarm proposed by the present invention;

[0052] Figure 4 This is a structural diagram of a gas-liquid intrusion alarm module of a DC power relay capable of rapid alarm proposed by the present invention;

[0053] Figure 5 This is a structural schematic diagram of an overheat alarm module of a DC power relay capable of rapid alarm proposed by the present invention;

[0054] Figure 6 This is a structural diagram of an overvoltage / overcurrent alarm module of a DC power relay capable of rapid alarming proposed by the present invention;

[0055] Figure 7 This is a schematic diagram of the internal structure of an overvoltage / overcurrent alarm module of a DC power relay capable of rapid alarming proposed by the present invention;

[0056] Figure 8 This is a structural schematic diagram of a quick-plug electromagnetic drive module for a DC power relay capable of rapid alarm proposed by the present invention;

[0057] Figure 9 This is a schematic diagram of the structure of the moving iron core guide rod of a DC power relay capable of rapid alarm proposed by the present invention;

[0058] Figure 10 This is a schematic structural diagram of a pressure-overheat alarm for a DC power relay capable of rapid alarming proposed by the present invention;

[0059] Figure 11 This is a schematic diagram of the linkage push rod structure of a DC power relay capable of rapid alarm proposed by the present invention.

[0060] Figure: 1. Quick-plug electromagnetic drive module; 11. Insulating housing; 12. Moving iron core guide rod; 13. Lateral lock; 14. Pressure-overheat alarm; 141. Bellows; 142. Thermal sleeve; 143. Phase-change thermistor cavity; 144. Bimetallic disc; 145. Linkage ejector; 1451. Conductive disc; 1452. Elastic contact finger; 1453. Low-melting-point alloy gasket; 146. Series output terminal; 2. Composite function base; 21. Main terminal block; 211. Terminal body; 212 , insert slot; 213, locking hole; 22, gas-liquid intrusion alarm module; 221, ventilation slit; 222, expansion chamber; 223, micro-trigger plate; 23, overheating alarm module; 231, thermal skeleton; 232, bimetallic cavity; 233, thermal trigger slider; 234, overheating alarm contact; 24, overvoltage / overcurrent alarm module; 241, main contact; 242, buzzer cavity; 243, sliding guide rail; 244, slider contact arm; 245, elastic linkage; 246, quick closing contact. DETAILED DESCRIPTION

[0061] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0062] Reference Figures 1-10 , Example 1, a DC power relay capable of rapid alarm, includes a quick-plug electromagnetic drive module 1 and a composite functional base 2, one end of the quick-plug electromagnetic drive module 1 is horizontally inserted into the composite functional base 2, the composite functional base 2 includes a main terminal seat 21 and a gas-liquid intrusion alarm module 22 arranged away from one end of the quick-plug electromagnetic drive module 1, an overheating alarm module 23 is inserted into one side of the gas-liquid intrusion alarm module 22, and an overvoltage / overcurrent alarm module 24 is inserted into the bottom position of the overheating alarm module 23.

[0063] The main terminal seat 21 includes a terminal body 211 and an inserting slot 212 arranged and opened on one side end surface of the terminal body 211 . The side end surface of the terminal body 211 is arranged and opened with a locking hole 213 .

[0064] The gas-liquid intrusion alarm module 22 comprises two sets of oppositely disposed vent slits 221 , an expansion chamber 222 is provided between the two sets of oppositely disposed vent slits 221 , and a micro-trigger plate 223 is provided at the bottom of the inner end surface of the vent slit 221 ;

[0065] Two sets of oppositely opened slit-type channel ventilation slits 221 are located on the side wall of the gas and liquid intrusion alarm module 22. The slit width is 0.05-0.1mm, which can prevent large particles such as sand and dust, but allow gas or liquid to penetrate into the inner cavity, achieving the detection premise of "allowing entry but not blocking";

[0066] The expansion chamber 222 is located between the two sets of air-permeable slits 221 and is filled with a highly liquid / gas-absorbing polymer expansion strip. When encountering water, oil, or specific gases such as SF6 or hydrogen, the expansion strip increases in volume by 3-5 times within 1-3 seconds, generating a thrust of 1-2N.

[0067] The micro-trigger strip 223 slotted at the bottom of the vent slit 221 acts as an elastic cantilever, with one end fixed to the inside of the vent slit 221 and the other end extending into the expansion chamber 222. The expansion strip increases in volume, pushing the micro-trigger strip 223 downward by 0.2 mm, causing its end to close with the alarm contact below, outputting a dry contact signal.

[0068] The closed loop can directly drive the fast closing contact 246, or be connected in parallel to remote monitoring to achieve "instant alarm for gas-liquid intrusion"; the expansion strip changes color from blue to red after absorbing moisture / air, providing visual secondary confirmation, making it easier for operation and maintenance personnel to quickly locate the source of the leak. Through the cascade action of "the air permeable slit 221 to the expansion cavity 222 sensing and causing the micro-trigger piece 223 to close", when gas or liquid accidentally enters the relay cavity, an alarm will be issued within seconds to prevent insulation degradation, corrosion or short circuit failures, thereby improving the reliability of the device in humid, outdoor and chemical environments.

[0069] In Example 2, the overheat alarm module 23 includes a thermally sensitive frame 231 and bimetallic cavities 232 respectively provided in the middle of the end surfaces of the thermally sensitive frame 231. Thermal trigger sliders 233 are installed on both sides of the inner cavity of the thermally sensitive frame 231. An overheat alarm contact 234 is inserted between the two sets of thermal trigger sliders 233.

[0070] The thermal skeleton 231 is directly mounted on the coil or conductive bar, and uses the high thermal conductivity metal to quickly absorb the Joule heat generated by overvoltage and high current, so that the overall temperature rise can be sensed within 1 to 2 seconds;

[0071] The bimetallic strip cavity 232 is formed on both sides of the thermal frame 231 and holds the bimetallic strip inside. As the temperature rises, the bimetallic strip arches outward, providing mechanical thrust and converting the temperature signal into a controllable displacement.

[0072] The thermal trigger sliders 233 are installed on both sides of the inner cavity of the thermal frame 231. When pushed by the bimetallic strip, they move inward along the guide groove of the bimetallic strip cavity 232, forming a "top-to-top" action, ensuring that the thrust direction is completely coaxial with the overheating alarm contact 234 to avoid lateral jamming.

[0073] The overheat alarm contact 234 is inserted between the two sets of thermal trigger sliders 233. When the sliders move inward, the overheat alarm contact 234 is pressed down and closes with the lower static contact, forming an independent overheat alarm circuit. This circuit can be connected in parallel with the overvoltage alarm circuit of the overvoltage / overcurrent alarm module 24 to achieve "temperature-pressure" dual redundant alarm. It can also independently drive the temperature indicator light or fan to facilitate rapid on-site fault location.

[0074] Example 3, through the cascade action of "rapid heat conduction of the thermal skeleton 231 causing the bimetallic spring to deform, thereby triggering the thermal trigger slider 233 to push the overheating alarm contact 234 to close", when overvoltage and large current cause the coil or busbar to heat up abnormally, a dry contact signal is output within 2 seconds to realize overheating alarm, thereby avoiding secondary faults such as insulation aging and coil burning.

[0075] In Example 4, the overvoltage / overcurrent alarm module 24 includes a main contact 241 and a buzzer chamber 242 disposed on a side end surface of the main contact 241. A sliding guide rail 243 is disposed transversely on one side of the buzzer chamber 242. Slider contact arms 244 are slidably disposed on both sides of the side end surfaces of the sliding guide rail 243. Slider contact arms 244 are mounted on one end of a plurality of groups of slider contact arms 244 arranged in a row. Two opposing groups of slider contact arms 244 are connected in series via an elastic linkage 245. The gap between the two groups of elastic linkages 245 is connected in series via a quick-closing contact 246.

[0076] When the relay detects an overvoltage or overcurrent condition, the overload current passes through one end of the slider contact arm 244 and moves in the opposite direction with the sliding guide rail 243 as the sliding path; during the movement, the two sets of relatively open slider contact arms 244 squeeze the elastic linkage 245 inward, thereby causing the quick closing contact 246 to move downward and contact directly above the sliding guide rail 243, thereby forming a closed circuit and triggering an alarm signal.

[0077] The sliding guide rail 243 provides stable sliding support for the slider contact arm 244, ensuring that it can move along the predetermined trajectory when subjected to force, thereby maintaining the accuracy of the alarm action; when an overload current passes through, the slider contact arm 244 slides along the sliding guide rail 243 due to the action of electromagnetic force or mechanical force, receives the overload signal through one end of itself, and converts this signal into mechanical motion, which is transmitted to subsequent components; multiple groups of slider contact arms 244 are interconnected and connected in series with the elastic linkage part 245 to form a mechanical and electrical linkage structure, and jointly participate in the transmission of the alarm signal.

[0078] In Example 5, after the overvoltage / overcurrent signal is triggered, the overvoltage / overcurrent alarm module 24 completes the circuit closure within tens of milliseconds through the three steps of "slide, press, and touch", significantly shortening the response time of traditional relays.

[0079] The sliding pair of the sliding guide rail 243 and the slider contact arm 244 adopts a low-friction design to prevent jamming. The elastic linkage member 245 is made of elastic material and is naturally stretched in the initial state. When the slider contact arm 244 is squeezed inward, the elastic linkage member 245 elastically deforms and provides a rebound force. After the action, it can automatically reset to ensure that repeated triggering will not fail.

[0080] The core of this embodiment is that the quick closing contact 246 and the sliding guide rail 243 are in face-to-face contact, with low contact resistance and resistance to welding; the buzzer alarm mechanism is built into the inner cavity of the buzzer chamber 242 and shares the same composite functional base 2 with the main circuit of the relay; the quick closing contact 246 can be connected in parallel to remote monitoring, PLC or sound and light alarm, and is suitable for various scenarios such as DC power distribution, new energy storage, and charging piles.

[0081] In order to distinguish from the above embodiment 5, a different embodiment is proposed: the relay main contact 241 is connected in series between the busbar and the energy storage converter, and the fast closing contact 246 terminal is connected in parallel to the EMS energy management system DI port and the on-site sound and light alarm;

[0082] The overload current enters the sliding guide rail 243 through the slider contact arm 244 and slides in the opposite direction. At this time, the elastic linkage 245 is compressed to close the quick-closing contact 246 and the sliding guide rail 243. The EMS receives the dry contact signal within 20ms, automatically reduces the load of the photovoltaic inverter and disconnects the energy storage charging circuit. The on-site buzzer simultaneously alarms, and the operation and maintenance personnel arrive at the site for confirmation within 30s. The busbar overvoltage duration is shortened from the traditional 300ms to <50ms, avoiding overvoltage breakdown of the IGBT module.

[0083] The main contact 241 of the relay is connected in series to the output end of the pile body, and the quick-closing contact 246 terminal is connected to the CAN bus alarm node of the charging pile main control board. The vehicle BMS abnormally pulls 300A and the rated load is 250A. The quick-closing contact 246 closes within 30ms, and the main control board immediately reduces the power to 150A, and at the same time reminds the owner through the CAN message; after the fault is eliminated, the elastic linkage 245 automatically resets, and the relay resumes full power output, avoiding fuse blowing, reducing the number of shutdowns by 90%, and improving the availability of the charging pile.

[0084] Example 6, the quick-plug electromagnetic drive module 1 includes an insulating shell 11 and a moving iron core guide rod 12 inserted into the inner cavity of the insulating shell 11, and lateral locks 13 are installed on both sides of the edge of the insulating shell 11. The pressure-overheat alarm 14 is vertically inserted into the groove of the lateral lock 13, and the locking hole 213 is inserted through the inner cavity of the moving iron core guide rod 12, so that the quick-plug electromagnetic drive module 1 and the composite functional base 2 are combined into a whole.

[0085] The pressure-overheat alarm 14 includes a bellows 141 and a heat-conducting sleeve 142 mounted on the outer ring of the bellows 141. The outer ring of the heat-conducting sleeve 142 is sleeved with a phase-change thermistor cavity 143. Bimetallic discs 144 are mounted on both sides of the outer ring of the phase-change thermistor cavity 143. The other end of the bimetallic disc 144 is sleeved with a linkage push rod 145. The inner cavity of the bellows 141 is connected to the main cavity of the relay, sensing the internal air pressure changes in real time. The heat-conducting sleeve 142 synchronously converts the deformation displacement of the bellows 141 into a change in the heat conduction area. The phase-change thermistor cavity 143 is filled with a low-boiling-point phase-change liquid with a boiling point of ≈85°C. When the internal pressure increases and the bellows 141 expands, the contact area between the heat-conducting sleeve 142 and the phase-change thermistor cavity 143 increases, the phase-change liquid rapidly vaporizes and absorbs heat, and the cavity temperature rises sharply.

[0086] The bimetallic disc 144 is fixed on the top of the phase change thermistor cavity 143; when the temperature rises suddenly, the bimetallic disc 144 jumps suddenly, and the upper end of the linkage push rod 145 is pushed by the bimetallic disc 144, and the lower end passes through the phase change thermistor cavity 143 and enters the center hole of the pressure-overheat alarm 14.

[0087] In Example 7, the linkage push rod 145 includes a conductive plate 1451 and elastic contact fingers 1452 mounted on both side walls of the conductive plate 1451 , with a low-melting-point alloy gasket 1453 clamped between the two sets of elastic contact fingers 1452 ;

[0088] When the linkage push rod 145 is pushed downward by the bimetallic disc 144, the conductive disc 1451 and the elastic contact finger 1452 close, forming a dry contact alarm; if the temperature continues to rise to the melting point of the low-melting-point alloy gasket 1453, the low-melting-point alloy gasket 1453 melts, the conductive disc 1451 is permanently pressed downward, and the elastic contact finger 1452 is locked and closed, realizing a "fuse-lock" type alarm;

[0089] The two sets of elastic contact fingers 1452 are connected in series through the series output terminal 146, which can directly drive the internal buzzer, remote PLC or SCADA system, and realize the closed loop of "excessive pressure leads to excessive heat, thereby providing an immediate alarm";

[0090] The pressure-overheat alarm 14 utilizes a three-stage coupling of "bellows 141 - phase change thermistor cavity 143 - bimetallic disc 144". When an abnormal increase in internal pressure causes heat accumulation, it completes "sense-trigger-alarm" within 2-3 seconds. It also takes into account both recoverable and irreversible protection requirements through two modes: "repeatable jump" or "one-time fusing", significantly improving the safety of relays in closed, high-voltage DC systems.

[0091] In order to distinguish the above embodiment 7, the following parallel distinguishing embodiments are proposed:

[0092] Level 1 resettable alarm: The bimetallic disc 144 suddenly jumps, causing the linkage push rod 145 to move downward, driving the conductive disc 1451 and the elastic contact finger 1452 to close. At this time, the dry contact immediately outputs, driving the on-site buzzer / remote PLC; when the pressure drops, the bimetallic disc 144 automatically rebounds, the circuit is disconnected, and the system can be used again.

[0093] Secondary fuse lockout alarm: If the pressure continues to rise and the temperature exceeds the set threshold, the low-melting-point alloy gasket 1453 melts, causing the conductive disk 1451 to lose its support and be permanently pressed down, causing the elastic contact finger 1452 to be mechanically locked and remain permanently closed. At this time, regardless of whether the pressure is restored, the alarm signal continues to be output until the low-melting-point alloy gasket 1453 is manually replaced, preventing the risk of missing due to repeated failures.

[0094] In Example 8, two sets of elastic contact fingers 1452 are connected in series via a series output terminal 146. The two sets of elastic contact fingers 1452 are connected in series via the series output terminal 146 to form a redundant circuit. If a connector in any series output terminal 146 fails, the other set can still conduct. The output end can be directly connected to SCADA, achieving a complete closed loop of "excessive pressure leading to excessive heat, thereby providing immediate and continuous alarm."

[0095] In summary, when overvoltage / overcurrent occurs at the DC bus or charging pile output, slider contact arm 244 slides in the opposite direction on guide rail 243 and compresses elastic linkage 245, closing quick-close contact 246 within 20-30ms. The dry contact signal is directly fed to the EMS or charging pile main control board, enabling load derating, main circuit disconnection, and on-site / remote alarms. The duration of busbar overvoltage is reduced from 300ms to <50ms, reducing charging pile downtime by 90%.

[0096] Overvoltage current causes the coil or busbar to heat up. Thermistor frame 231 transmits the thermal signal to bimetallic cavity 232 within 1-2 seconds. The bimetallic strip arches and pushes thermal trigger slider 233, closing overheat alarm contact 234. This independently outputs dual redundant "temperature and pressure" alarms, or directly drives a fan / indicator light to prevent coil burnout.

[0097] When external water vapor, oil, or SF6 enters the expansion chamber 222 through the vent slit 221, the volume of the polymer expansion strip increases instantly, pushing the micro-trigger piece 223 to bend downward by 0.2 mm, triggering the alarm contact to close; the expansion strip changes color for secondary confirmation, and the leakage alarm is completed within seconds to avoid insulation degradation, corrosion or short circuit.

[0098] The internal pressure of the relay increases, the bellows 141 expands, the contact area between the heat-conducting sleeve 142 and the phase-change thermistor cavity 143 increases, the phase-change liquid vaporizes and absorbs heat, the bimetallic disc 144 jumps suddenly, and the linkage push rod 145 moves downward.

[0099] Level 1: The conductive disk 1451 and the elastic contact finger 1452 are closed, and the alarm can be reset;

[0100] Level 2: The low-melting-point alloy gasket 1453 melts, the elastic contact finger 1452 is permanently locked, and output continues until manually reset.

[0101] "Perception-triggering-alarm" is completed within 2-3 seconds, which is suitable for closed high-voltage DC systems and realizes recoverable or irreversible dual protection.

[0102] The above is the entire working principle of the present invention.

[0103] In the present invention, the installation method, connection method or setting method of all the components mentioned above are common mechanical methods, and the specific structures, models and coefficient indicators of all its components are its own technology. As long as it can achieve its beneficial effects, it can be implemented, so it will not be elaborated on.

[0104] The above embodiments are preferred implementation modes of the present invention, but the implementation modes of the present invention are not limited to the above embodiments. Any other changes, modifications, substitutions, combinations, and simplifications that do not deviate from the spirit and principles of the present invention should be considered as equivalent replacement methods and are included in the scope of protection of the present invention.

[0105] In the present invention, unless otherwise specified, directional words contained in terms such as "up, down, left, right, front, back, inside, outside, and vertical, horizontal" only represent the orientation of the term in normal use, or are common names understood by those skilled in the art, and should not be regarded as limitations on the term. At the same time, number series nouns such as "first", "second" and "third" do not represent specific quantities and orders, but are merely used to distinguish names. Moreover, the terms "include", "comprise" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or apparatus that includes a series of elements includes not only those elements, but also other elements that are not explicitly listed, or also includes elements inherent to such process, method, article or apparatus.

Claims

1. A DC power relay capable of rapid alarm, comprising a quick-plug electromagnetic drive module (1) and a composite functional base (2), characterized in that: One end of the quick-plug electromagnetic drive module (1) is laterally inserted into the composite functional base (2), the composite functional base (2) comprising a main terminal seat (21) and a gas-liquid intrusion alarm module (22) arranged at one end away from the quick-plug electromagnetic drive module (1), an overheating alarm module (23) is inserted into one side of the gas-liquid intrusion alarm module (22), and an overpressure / overcurrent alarm module (24) is inserted into the bottom of the overheating alarm module (23).

2. A DC power relay capable of rapid alarm according to claim 1, characterized in that: The main terminal seat (21) comprises a terminal body (211) and an insert slot (212) arranged and opened on one side end face of the terminal body (211), and a locking hole (213) is arranged and opened on the side end face of the terminal body (211).

3. A DC power relay capable of rapid alarm according to claim 1, characterized in that: The gas-liquid intrusion alarm module (22) comprises two groups of air-permeable slits (221) that are opened opposite to each other, an expansion cavity (222) is opened between the two groups of air-permeable slits (221), and a micro-trigger plate (223) is opened at the bottom of the inner end surface of the air-permeable slit (221).

4. A DC power relay capable of rapid alarm according to claim 1, characterized in that: The overheat alarm module (23) comprises a heat-sensitive frame (231) and bimetallic cavities (232) respectively provided at the middle positions of the end surfaces on both sides of the heat-sensitive frame (231). Heat-triggering sliders (233) are installed at the positions on both sides of the inner cavity of the heat-sensitive frame (231), and an overheat alarm contact (234) is inserted into the gap between the two sets of heat-triggering sliders (233).

5. A DC power relay capable of rapid alarm according to claim 1, characterized in that: The overvoltage / overcurrent alarm module (24) comprises a main contact (241) and a buzzer chamber (242) arranged on a side end surface of the main contact (241); a sliding guide rail (243) is transversely arranged on one side of the buzzer chamber (242); slider contact arms (244) are slidingly arranged on both sides of the side end surface of the sliding guide rail (243); a slider contact arm (244) is installed at one end of a plurality of groups of slider contact arms (244) arranged in a row; two groups of slider contact arms (244) arranged opposite to each other are connected in series via an elastic linkage member (245); and the interval between the two groups of elastic linkage members (245) is connected in series via a quick closing contact (246).

6. A DC power relay capable of rapid alarm according to claim 2, characterized in that: The quick-plug electromagnetic drive module (1) comprises an insulating shell (11) and a moving iron core guide rod (12) inserted into the inner cavity of the insulating shell (11); side lock buckles (13) are installed on both sides of the edge of the insulating shell (11); and a pressure-overheat alarm (14) is vertically inserted into the groove of the side lock buckle (13).

7. A DC power relay capable of rapid alarm according to claim 6, characterized in that: The locking hole (213) penetrates and is inserted into the inner cavity of the moving iron core guide rod (12), so that the quick-insertion electromagnetic drive module (1) and the composite functional base (2) are combined into a whole.

8. A DC power relay capable of rapid alarm according to claim 6, characterized in that: The pressure-overheat alarm (14) includes a bellows (141) and a heat-conducting sleeve (142) installed on the outer ring of the bellows (141), the outer ring of the heat-conducting sleeve (142) is sleeved with a phase-change thermosensitive cavity (143), bimetallic discs (144) are installed at both sides of the outer ring of the phase-change thermosensitive cavity (143), and the other end of the bimetallic disc (144) is sleeved with a linkage push rod (145).

9. A DC power relay capable of rapid alarm according to claim 8, characterized in that: The linkage push rod (145) comprises a conductive disk (1451) and elastic contact fingers (1452) mounted on both side end walls of the conductive disk (1451), with a low melting point alloy gasket (1453) clamped between the two sets of elastic contact fingers (1452).

10. A DC power relay capable of rapid alarm according to claim 9, characterized in that: The two groups of elastic contact fingers (1452) are connected in series via a series output terminal (146).

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