Zero-crossing contactor and method of operation

Abstract

A contactor device and a method for operating a contactor device can include a contactor assembly, where a contactor coil is operably coupled to a contactor switch. One or more sensors can be disposed in the contactor assembly, the one or more sensors adapted to measure one or more aspects of the contactor assembly. Based on the measured aspects, a controller can initiate operation of the contactor switch to effectively switch the contactor switch at a zero crossing point along an alternating current waveform.

Description

[0001] This application is a divisional application of the invention patent application filed on April 24, 2019, with application number 201910333980.X and invention title "Zero-crossing contactor and operating method".

[0002] Cross-reference to related applications

[0003] This application claims priority and benefit to UK Patent Application No. 1806782.7, filed on April 25, 2018. Technical Field

[0004] This disclosure relates to a method of operating a contactor, and more specifically to initiating at least one of disconnecting or connecting a power supply via a contactor. Background Technology

[0005] In power systems, it is typically necessary to connect and disconnect the power system or parts thereof. In alternating current (AC) systems, the current periodically reverses direction, varying between positive and negative voltages in a sinusoidal cycle. The voltage is zero when the current changes direction. Traditional AC contactors switch at any point during the AC cycle, regardless of current or voltage. Switching contactors in this way can lead to voltage or current spikes, voltage surges, contact wear and other stresses, noise, arcing, and arc deposits. Summary of the Invention

[0006] In one aspect, this disclosure relates to a method of operating a contactor, comprising: receiving, in a controller module, an electrical signal representing an alternating current (AC) waveform of a power source; receiving, in the controller module, a temperature value representing the temperature of a contactor coil; receiving, in the controller module, operating characteristics of the contactor coil; in the controller module, determining a disconnection time delay for disconnecting the power source via the contactor, the disconnection time delay being a sum of a set of delay times based on the electrical signal, the temperature value, and the coil operating characteristics; and initiating the disconnection of the power source via the contactor by a start time prior to a zero-crossing voltage of the AC waveform, wherein the start time predicts the zero-crossing voltage based on the disconnection time delay.

[0007] In another aspect, the present invention relates to a method of operating a contactor, comprising: receiving an alternating current (AC) waveform of a power supply in a controller module; receiving a temperature of a contactor coil, the contactor coil being energized to disconnect the power supply from an electrical load in the controller module; receiving characteristics of the contactor coil energizing source in the controller module; determining a total disconnection time delay defined by a timing estimate in the controller module based on the temperature of the contactor coil and the contactor coil energizing source characteristics, to operably disconnect the power supply from the electrical load; determining a disconnection initiation time based on the total disconnection time delay and the AC waveform of the power supply, such that the cutoff of the total disconnection time delay coincides with the zero-crossing voltage of the AC waveform; and initiating the disconnection of the power supply via the contactor at the disconnection initiation time through the controller module.

[0008] In another aspect, this disclosure relates to a contactor assembly including a contactor switch selectively connecting an input to an output. A contactor coil is operatively coupled to the contactor switch and configured to drive the contactor switch. A contactor coil temperature sensor is configured to measure the temperature of the contactor coil. A contactor coil operating characteristic sensor is configured to measure the operating characteristics of the contactor coil. An input AC waveform sensor is configured to measure the AC waveform of the input power supply. A controller module is configured to: receive a first electrical signal representing the AC waveform from the input AC waveform sensor; receive a second electrical signal representing the temperature of the contactor coil from the contactor coil temperature sensor; receive a third electrical signal representing the operating characteristics of the contactor coil from the contactor coil operating characteristic sensor; determine a disconnection time delay based on the first, second, and third electrical signals as a sum of a set of delay timings; and initiate the disconnection of the input and output via the contactor switch at a start time prior to the zero-crossing voltage of the AC waveform, wherein the start time is based on the disconnection time delay. Attached Figure Description

[0009] In the attached diagram:

[0010] Figure 1 This is a top-view schematic diagram of the aircraft and power distribution system based on the aspects described in this article.

[0011] Figure 2 It is based on the formation of the aspects described in this article. Figure 1 A schematic diagram of a circuit for a portion of a power distribution system, which includes a contactor assembly.

[0012] Figure 3 It is to draw the aspects described in this article. Figure 2 A graph of the AC waveform of the circuit, including the total delay before the zero crossing.

[0013] Figure 4 This demonstrates the operation of the aspects described herein. Figure 2 A block diagram of the methods for the contactor component. Detailed Implementation

[0014] This disclosure relates to a zero-crossing contactor assembly and method of operation, which, for example, can be used in the power distribution system of an aircraft. Although the description is primarily directed to the power distribution system of an aircraft, it is also applicable to any environment utilizing an alternating current system, such as any power distribution system in non-aircraft embodiments.

[0015] As used herein, the term "upstream" refers to movement toward the inlet or starting position, or to a component that is relatively closer to the inlet or starting position compared to another component. The term "downstream" refers to movement toward the outlet or ending position, or to a component that is relatively closer to the outlet or ending position compared to another component. Furthermore, the terms "upstream" or "downstream" can be used as a reference to the direction of current relative to an AC circuit, which can periodically reverse direction, defining the meaning of the terms "upstream" or "downstream" based on the direction of current in the circuit. Additionally, as used herein, the term "group" or a "set" of elements can be any number of elements, including a single element.

[0016] All directional references (e.g., radial, axial, proximal, distal, up, down, upward, downward, left, right, side, front, rear, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, front, rear, etc.) are used for identification purposes only to aid the reader's understanding of this disclosure and do not impose limitations, particularly regarding the location, orientation, or use of aspects of this disclosure described herein. Unless otherwise indicated, connection references (e.g., attachment, joint, connection, and link) should be interpreted broadly and may include intermediate members between sets of elements and relative movement between elements. Therefore, a connection reference does not necessarily imply that two elements are directly connected and fixed to each other. Exemplary figures are for illustrative purposes only, and the dimensions, positions, orders, and relative sizes reflected in the figures may vary.

[0017] Additionally, while terms such as “voltage,” “current,” and “electricity” may be used herein, it will be apparent to those skilled in the art that these terms may be interchangeable when describing aspects of a circuit or its operation.

[0018] Similarly, as used herein, while a sensor may be described as “sensing” or “measuring” a corresponding value, sensing or measuring may include determining a value that indicates or is associated with the corresponding value, rather than directly sensing or measuring the value itself. The sensed or measured value may then be provided to additional or separate components. This determination may be provided as a signal, such as an electrical signal, to the aforementioned additional or separate components. For example, the measured value may be provided to a controller module or processor, which may process the value to determine a representative value or electrical characteristic represented by the value.

[0019] As used herein, a “system” or “controller module” may include at least one processor and memory. Non-limiting examples of memory may include random access memory (RAM), read-only memory (ROM), flash memory, or one or more different types of portable electronic storage, such as discs, DVDs, CD-ROMs, etc., or any suitable combination of these types of memory. The processor may be configured to run any suitable program or executable instructions designed to perform various methods, functions, processing tasks, calculations, etc., to enable or implement the technical operations or actions described herein. The program may include a computer program product that may include a machine-readable medium for carrying or having machine-executable instructions or data structures stored thereon. Such a machine-readable medium may be any available medium that can be accessed by a general-purpose or special-purpose computer or other machine having a processor. Typically, such a computer program may include routines, programs, objects, components, data structures, etc., that have the technical effect of performing a particular task or implementing a particular abstract data type.

[0020] As used herein, a controllable switching element or "switch" is an electrical device that can controllably switch between a first operating mode and a second operating mode, wherein the switch is "closed" meaning that current is transferred from the switch input to the switch output, and wherein the switch is "open" meaning that current is prevented from transferring between the switch input and the switch output. In a non-limiting example, connection or disconnection, such as a connection enabled or disabled by a controllable switching element, can be selectively configured to provide, enable, disable, etc., electrical connections between various elements.

[0021] This disclosure can be implemented in any circuit environment having switches, electrical switches, or switching elements. Non-limiting examples of circuit environments that may include aspects of this disclosure include an aircraft electrical system architecture capable of generating electricity from at least one spool of a turbine engine, preferably a gas turbine engine, and delivering that electricity to a set of electrical loads. In one non-limiting example, the electrical switch or switching element may include at least one solid-state switch, such as a solid-state power controller (SSPC) switching device. A non-limiting example of an SSPC may include a high-power switch based on silicon carbide (SiC) or gallium nitride (GaN). SiC or GaN can be selected based on their solid-state material construction, their ability to handle high voltage and high power levels in a smaller and lighter form factor, and their high-speed switching capability to perform electrical operations very quickly. Additional switching devices or additional silicon-based electrical switches may be included.

[0022] like Figure 1As shown, aircraft 10 is illustrated as having at least one gas turbine engine, shown as a left engine system 12 and a right engine system 14. Alternatively, aircraft 10 may have fewer or additional engine systems. The left engine system 12 and right engine system 14 may be substantially identical and may also include at least one generator, such as generator 18. Aircraft 10 is also shown as including multiple power-consuming components or electrical loads 20, such as actuator loads, flight-critical loads, and non-flight-critical loads. The electrical loads 20 are electrically connected to at least one generator 18 via a power distribution system 22.

[0023] In aircraft 10, the left and right engine systems 12 and 14 generate mechanical energy, which can be extracted via spools to provide driving force for generator 18. Generator 18, in turn, delivers electricity to electrical load 20 via power distribution system 22 for load operation. Additional power sources, such as emergency power supplies, ram air turbine systems, or starters / generators, can be envisioned for supplying power to electrical load 20. It should be understood that while power distribution system 22 is shown in an aircraft environment, it is not limited to general applications in electrical systems used in non-aircraft applications, such as other mobile and non-mobile industrial, commercial, and residential applications.

[0024] Now for reference Figure 2 Circuit 30 can form at least a portion of the power distribution system 22 having contactor assembly 32. It should be understood that circuit 30 is merely one example aspect of the electrical network or power distribution system 22 or its sub-components for ease of understanding. Other non-limiting examples of this disclosure may include or be incorporated as part of a printed circuit board, a field-programmable gate array (FPGA), etc.

[0025] Contactor assembly 32 may form part of circuit 30, located between power input 34 (e.g., generator 18 (not shown)) and power output 36, which is connected to a power-consuming device, such as electrical load 20 (not shown). In a non-limiting example, power input 34 may include a voltage input, and power output 36 may include a voltage output. Contactor assembly 32 may also include contactor 38, schematically shown as including switch 40 and contactor coil 42. Switch 40 may be configured to move between a first open condition or state and a second closed condition or state. In the open condition, contactor 38 or switch 40 prevents, disconnects, or otherwise disables current conduction between power input 34 and power output 36, while in the closed condition, contactor 38 or switch 40 permits, enables, connects, or otherwise enables current conduction between power input 34 and power output 36. By selectively energizing contactor coil 42, switch 40 may operate between the first open condition and the second closed condition. For example, applying voltage or power to the coil can effectively or operably close the switch, while the lack of voltage or power to the coil can effectively or operably open the switch. A non-limiting example of the contactor assembly 32 may include a solenoid, and any suitable element or component configured to actuate or be energized to actuate the switch 40 within the contactor 38 is contemplated.

[0026] Circuit 30 may further include a coil switch 48 connected to a first end 44 of the contactor coil 42. The coil switch 48 is operable between a first open condition or state and a second closed condition or state, in which the first open condition prevents, disconnects, or otherwise disables voltage or power on the coil switch 48, and in the second closed condition permits, enables, connects, or otherwise enables power or voltage on the coil switch 48. In a non-limiting example, the contactor coil excitation source 50 may include a power supply or power source electrically and selectively coupled to the coil switch 48, selectively supplying voltage or power to the coil switch 48. Circuit 30 may further include a ground 52 disposed at a second end 46 of the contactor coil 42, opposite the coil switch 48, electrically grounding the contactor coil 42.

[0027] The contactor assembly 32 may also include a controller module 60 electrically connected within the circuit 30. The controller module 60 may include at least one processor 64 and a memory 66, and may be configured to run any suitable program or executable instructions designed to perform operations on the circuit 30, the contactor assembly 32, or portions thereof. The controller module 60 may be controllably connected to the coil switch 48 such that the controller module 60 can generate, send, or otherwise provide control signals 54 (as indicated by the dashed arrow) to selectively control the switching between first and second states of the coil switch 48.

[0028] Command controller 62 may be further communicatively coupled to controller module 60 and may be configured to provide commands, such as instructions to open or close a switch, or to operate part of circuitry 30. Command controller 62 may also include at least one processor and memory (not shown) and may be configured to run any suitable program or executable instructions. Although shown near controller module 60, command controller 62 may be located remotely from controller module 60 and is adapted to send signals or instructions to controller module 60 relating to contactor assembly 32 or circuitry 30.

[0029] Sensor group 70 may be included in contactor assembly 32 and may include contactor coil operating characteristic sensor 72, waveform sensor 74, and temperature sensor 78. Sensor group 70 may be communicatively and operatively coupled to controller module 60 such that the group of electrical signals may be generated, provided, supplied, or otherwise received by controller module 60. Contactor coil operating characteristic sensor 72 may be configured to generate signals representing voltage, current, or other parameters that may represent the operating characteristics of contactor coil excitation source 50. For example, non-limiting examples of operating characteristics may include an "on" or "off" characteristic, and in other non-limiting examples, "active," "inactive," "closed," or "open." Additionally, sensor group 70 is further shown including an optional output voltage sensor 76. Although four sensors are shown, it is contemplated that sensor group 70 may include additional or fewer sensors. Contactor coil operating characteristic sensor 72 may be coupled to circuitry 30 between contactor coil excitation source 50 and coil switch 48. In one non-limiting example, waveform sensor 74 may be coupled to circuit 30 between power input 34 and switch 40, and may be configured or adapted to sense or measure the waveform frequency of the AC current flowing through switch 40 from power input 34 to power output 36. Waveform sensor 74 may be configured to generate a signal representing the AC waveform provided by power input 34. This waveform may be substantially sinusoidal, representing the reverse current direction over a period of time. In another non-limiting example, output voltage sensor 76 may be coupled to circuit 30 between switch 40 and power output 36, and may be configured or adapted to sense or measure the voltage downstream of switch 40 between contactor assembly 32 and power output 36. Output voltage sensor 76 may be configured to generate a signal representing a voltage, such as the voltage transmitted through contactor assembly 32 when switch 40 is in a second closed position. Temperature sensor 78 may be positioned to measure the temperature of contactor coil 42 and is configured to produce a signal representing the temperature of contactor coil 42.

[0030] During operation, contactor assembly 32 or contactor 38 operates to selectively enable or disable the conduction of power supplied to power input 34 to power output 36. This selective enabling or disabling can be operably or effectively controlled by controller module 60. In a non-limiting example, command controller 62 or another control component can supply or provide a demand, expectation, or instruction to controller module 60 to connect or disconnect power output 36 from power input 34 via contactor coil 42, coil switch 48, control signal 54, and contactor coil excitation source 50, or a combination thereof. Such instructions can be based on a schedule or can be on demand. Based on said instruction, controller module 60 operably or effectively supplies control signal 54 to coil switch 48, instructing or controlling coil switch 48 to switch to a closed state, energizing contactor coil 42 with contactor coil excitation source 50. Thus, the operation of switch 40 of contactor 38 is controlled by selectively supplying power to contactor coil 42 in response to control signal 54 from controller module 60. Therefore, controller module 60 can effectively operate contactor assembly 32.

[0031] The operation of the contactor assembly 32 can also be based on multiple operating characteristics. For example, operating characteristics may include at least one of the following: the frequency of the current supplied to the power input 34, coil temperature, coil operating characteristics, error correction, or a combination thereof. The frequency of the circuit may represent the sinusoidal electrical frequency of the alternating current flowing through the power input 34. In a non-limiting example, determining the frequency of the circuit from the power input 34 may include sensing the frequency or frequency characteristics, such as zero-crossing voltage, using a waveform sensor 74, and generating and providing a signal representing the waveform or waveform characteristics to the controller module 60.

[0032] The contactor coil temperature can represent the temperature of the contactor coil 42 when it is energized and de-energized. In a non-limiting example, the coil temperature can be determined by sensing the temperature of the contactor coil 42 using a temperature sensor 78, and a signal representing the temperature of the contactor coil 42 can be generated and provided to the controller module 60.

[0033] Coil operating characteristics may include "on" or "off" characteristics, such as the time taken to turn coil switch 48 on or off. These coil operating characteristics can be determined by sensing the electrical characteristics of coil switch 48 or contactor coil excitation source 50 via contactor coil operating characteristic sensor 72. A signal representing the coil operating characteristics can be generated by contactor coil operating characteristic sensor 72 and provided to controller module 60.

[0034] Error correction may include a measurement that indicates or represents an error measurement of circuit 30, i.e., the difference between the expected operation of circuit 30, contactor 38, or contactor assembly 32 and the actual operation of circuit 30, contactor 38, or contactor assembly 32.

[0035] The controller module 60 may store at least a subset of signals received from the sensor group 70 in the memory 66. The controller module 60 receives or stores electrical signals from the sensor group 70, and the processor 64 may combine these electrical signals into multiple values ​​to initiate the disconnection or connection of power from the power input 34 and the power output 36. Although aspects of this disclosure are described in relation to “disconnecting” power from the power input 34 and the power output 36, it should be understood that this disclosure also applies to any connection of the contactor between disconnection and connection operations, or any switching. More specifically, the controller module 60 may determine disconnection, connection, or contactor time delay based on the values ​​of the electrical signals from the sensor group 70. For example, the temperature value of the contactor coil 42 provided by the temperature sensor 78 may represent a first time delay, such as a coil temperature delay time. As used herein, the temperature delay time of the contactor coil 42 represents a timing delay in the contactor coil 42, which operatively affects the switching of the switch 40 between open and closed states due to the temperature of the contactor coil 42. For example, the temperature of the contactor coil 42 affects the operation of the coil, with higher temperatures typically leading to an increased delay in the switching switch 40, while lower temperatures of the contactor coil 42 typically lead to a decreased delay in the switching switch 40.

[0036] The contactor coil operating characteristics provided by the contactor coil operating characteristic sensor 72 can represent a second time delay, such as a coil operating characteristic delay time, which represents the expected delay in fully energizing the contactor coil 42 through the contactor coil excitation source 50 and the coil switch 48. The contactor coil operating characteristics may include, or at least in part, a time delay based on the supply voltage of the contactor coil source 50, after receiving the control signal 54, operating the coil switch 48, or a combination thereof. The time for providing a signal on circuit 30, based on the specific construction of the circuit signal trace, can represent a third time delay, such as an electrical signal delay time. An error correction value can represent a fourth time delay based on a difference that is the difference between the expected operation of circuit 30, contactor 38, or contactor assembly 32 and the actual operation of circuit 30, contactor 38, or contactor assembly 32. In a non-limiting example, the error correction characteristics may include a voltage sensed or measured at the power supply output 36 by the output voltage sensor 76. In this example, the output voltage sensor 76 may generate and provide a signal representing the voltage to the controller module 60, for example, when the voltage increases, decreases, etc. In response, controller module 60 can compare the actual timing of the signal representing the voltage from output voltage sensor 76 with the expected, estimated, calculated timing of circuit 30 operation. For example, if controller module 60 initiates a "disconnect" or "connect" command to operably switch switch 40 of contactor 38 to disable or enable power supply to power output 36, controller module 60 can receive an indication signal via output voltage sensor 76 when the voltage at power output 36 drops (e.g., when power is disconnected or connected). The difference in the compared or expected timing can result in a defined error correction characteristic. In a non-limiting example, it should be understood that the calculated, compared, or defined error correction characteristic can be expressed as an "error delay time" and considered in the following or subsequent connection or disconnection loops.

[0037] refer to Figure 3Graph 90 includes a plot showing a sinusoidal alternating current (AC) waveform 92, representing the amplitude of the alternating current flowing through circuit 30 over a period of time. In a non-limiting example, AC waveform 92 may represent a signal provided from waveform sensor 74 to controller module 60. AC waveform 92 includes a set of zero-crossings 94, representing zero voltage or current when the alternating current reverses direction. These zero-crossings 94 can be determined by controller module 60 based on the consistent frequency of the current, allowing controller module 60 to accurately predict the timing of future zero-crossings 94. It is advantageous to operate contactor assembly 32 such that the effective connection, disconnection, activation, or deactivation of contactor assembly 32 coincides with the zero-crossings. However, as described above regarding delays, the initial decision or initiation of operation of contactor assembly 32 may not effectively or instantaneously result in the opening or closing of switch 40 because a set of operational delays may be interfered with. Therefore, non-limiting aspects of this disclosure may be included, wherein the controller module 60 can determine the total contactor time delay (i.e., the estimated, predicted, or otherwise determined sum of time delays between initiating a disconnect or connect command, instruction, or control signal, and the actual or effective disconnection or connection of power conducted via contactor 38), and initiate a disconnection or connection such that the effective disconnection or connection coincides with zero crossing 94. While specific examples of initiating a “disconnection” have been described, non-limiting aspects of this disclosure may also be applied and included, wherein the controller module 60 can determine the total contactor time delay and initiate a connection or supply of power conducted via contactor 38 such that the effective connection coincides with zero crossing 94.

[0038] As described above, the total delay time 80 may include the sum of a set of delay times, including but not limited to the coil temperature delay time 82, the coil operating characteristic delay time 84, the electrical signal delay time 86, and the error delay time 88. As shown, the controller module 60 may determine the total time delay 80 of the aforementioned delays, or determine the individual delay of each corresponding delay, which may be summed in subsequent steps. Additionally, it is conceivable that the aforementioned delay times 82, 84, 86, 88, and any other delay between the initiation of the disconnection or connection of the power supply via contactor 38 at the expected zero-crossing voltage of the AC waveform 92 and the effective disconnection or connection of the power supply, may be used to determine the total delay time 80. Although shown as four delays 82, 84, 86, 88, any number of interventions, determinations, calculations, or comparisons of delays can be expected, as any system component or operating function contributes to the total delay time 80, resulting in the delay time between the command to initiate the opening of switch 40 and the effective disconnection or connection of power input 34 and power output 36. Additionally, although the set of time delays is shown as having approximately the same length of time (e.g., the same time delay), the exemplary delays are for illustrative purposes only, and the time delays or relative delay times used to collect the set of time delays may vary.

[0039] The processor 64 in controller module 60 can calculate the total time delay 80 based on signals received from the contactor coil operating characteristic sensor 72, the output voltage sensor 76, and the temperature sensor 78, or optionally include any other time delays or sensor inputs, and determine a timeline, estimate, prediction, etc., for the subsequent or upcoming zero-crossing of the AC waveform 92 based on signals provided by waveform sensor 74. Controller module 60 can then calculate the start-up time 96. The start-up time 96 can be calculated as the expected zero-crossing 94 minus the total delay time 80. Still referring to... Figure 3 The total delay time 80 is used as the sum of time delays 82, 84, 86, and 88, and the start time 96 is determined before the zero point 94.

[0040] The controller module 60 can initiate the operation of switch 40 at startup time 96 to coincide with the zero-crossing point 94 of the AC waveform 92, so as to effectively disconnect or connect switch 40 at the zero-crossing point 94. In this way, the contactor assembly 32 can utilize the sensor group 70 and the controller module 60 to efficiently calculate the operating delay of the contactor assembly 32, and can operate switch 40 to coincide with the zero-crossing point 94 of the AC waveform.

[0041] Similarly, controller module 60 can utilize output voltage sensor 76 to continuously determine error delay time 88 based on the voltage between switch 40 and power output 36. The term "continuous" as used herein can refer to the operation of contactor assembly 32. Alternatively, output voltage sensor 76 can perform on-demand measurements, such as when the predicted, calculated, determined, or estimated total delay time 80 is found to be outside the expected range or operating threshold (e.g., a predetermined tolerance). If such a measured voltage is not zero, the delay of error delay time 88 can be updated after operation of contactor assembly 32 and input to controller module 60 to update total delay time 80 for future operation of contactor assembly 32. Thus, as contactor assembly 32 changes over time, such as due to aging or other environmental factors, output voltage sensor 76 can provide updated error delay time 88. Therefore, consistent and accurate zero-crossing switching can be achieved, especially over time.

[0042] Now for reference Figure 4At 102, the flowchart illustrates a method 100 for operating contactor 32, which may include receiving an electrical signal in controller module 60 representing an AC waveform 92 of a power supply or power input 34. At 104, method 100 may further include receiving a temperature value in controller module 60 representing the temperature of contactor coil 42. Alternatively, at 104, method 100 may include receiving the temperature of contactor coil 42, which can be energized to disconnect or connect electrical loads and power supplies, in controller module 60. At 106, method 100 may further include receiving contactor coil operating characteristics or contactor coil energizing supply characteristics in controller module 60.

[0043] At 108, method 100 may further include determining, in controller module 60, a total time delay or contactor time delay 80 for disconnecting or connecting power supply 34 via contactor 32, wherein contactor time delay 80 is the sum of a set of delay times 82, 84, 86 based on electrical signals, temperature values, and contactor coil operating characteristics. Alternatively, at 108, method 100 may include determining, in control module 60, a total contactor time delay 80 defined by timing estimation to operatively disconnect or connect power supply 34 and electrical load or power output 36 based on coil temperature delay time 82 and coil operating characteristic delay time 84.

[0044] Optionally, at 110, method 100 may include determining a start-up time or contactor start-up time 96 based on the total contactor time delay 80 and the AC waveform 92 of the power supply, such that the cutoff of the total contactor time delay 80 coincides with the zero-crossing point 94 of the AC waveform 92.

[0045] At 112, method 100 may further include the controller module 60 initiating the disconnection or connection of the power supply 34 via contactor 32 at a start time 96 prior to the zero-crossing point 94 of the AC waveform 92, wherein the start time 96 predicts the zero-crossing point 94 based on the contactor time delay 80. Alternatively, at 112, method 100 may include the controller module 60 initiating the disconnection or connection of the power supply 34 via contactor 32 at the contactor start time 96.

[0046] In a non-limiting example, the effective disconnection or connection of the power supply may coincide with the zero-crossing point 94 of the AC waveform 92. In another non-limiting example, the determination is also based on estimating the contactor time delay 80. In yet another example, the determination is also based on predicting the contactor time delay 80. In yet another example, the determination of the contactor time delay 80 is also based on the sum of a set of delay times 82, 84, 86, and an error delay time or error correction value 88 defined by the difference between the effective disconnection or connection of the power supply 34 and the zero-crossing point 94 of the AC waveform 92 of at least one previous contactor 32 disconnection or connection. In yet another non-limiting example, the error correction value 88 is based on the difference between the voltage measured at the effective disconnection or connection of the power supply 34 and the zero value of the voltage. In yet another non-limiting example, the error correction value is also based on the voltage measured at the effective disconnection or connection, and the AC waveform 92 of the power supply 34. In yet another non-limiting example, the start-up also includes energizing the electromagnetic contactor coil 42 with the contactor coil excitation source 50 to operatively disconnect or connect the power supply 34. In yet another non-limiting example, starting also includes closing coil switch 48 to supply contactor coil excitation source 50 to electromagnetic contactor coil 42. In another example, starting may also include energizing contactor coil 42 with contactor coil excitation source 50 at contactor start time 96.

[0047] The order described is for illustrative purposes only and does not imply any limitation on method 100, as it should be understood that parts of the method may be in a different logical order, may include additional or intermediate parts, or the described part of the method may be divided into multiple parts, or parts of the described method may be omitted without departing from the described method.

[0048] Therefore, it should be understood that the contactor assembly 32, as described herein, can provide precise zero-crossing voltage to the switch 40. This precision reduces contact wear on the switch 40 itself, thereby increasing component life and reducing maintenance. Furthermore, it enables a reduction in contact deposition at zero current and voltage. Electromagnetic noise along the power supply is reduced and spikes can be eliminated at a higher level. Stress on upstream and downstream electrical loads can be reduced, and the occurrence of spikes and surges on said electrical loads is reduced. Overall, cleaner power consumption is achieved, which can lead to an overall reduction in power consumption.

[0049] The aspects disclosed herein provide a method and apparatus for operating a contactor assembly. As described herein, the technical effect is that the aforementioned aspects enable the contactor to be disconnected or connected after determining the total contactor time and after initiating the disconnection or connection of the power supply via the contactor at the total contactor time or delay, such that effective disconnection or connection occurs or coincides with the zero-crossing voltage of the input power AC waveform. The circuit and contactor assembly described herein are applicable to different or all types of power supplies, power electronics or circuit boards, or any suitable power distribution system. It should be understood that the contactor assembly provides effective disconnection or connection of the AC circuit at the zero-crossing point, where the current in the AC circuit is at or near zero. Using one or more sensors, the measurement results of the contactor assembly can be provided to a controller module. Upon receiving a command or instruction to do so, the controller module can determine a set of actual, predicted, or estimated time delay values ​​that define the time between when the contactor assembly can operatively connect or disconnect the input and output. As described in this paper, by utilizing a determined time delay, the contactor assembly can initiate the disconnection or connection of the power supply earlier than or as expected before the zero-crossing point on the AC waveform of the AC circuit, thus effectively disconnecting or connecting the power supply at or near the zero-crossing point. Therefore, accurate and consistent disconnection or connection of the power supply at the zero-crossing point can be achieved. Disconnection or connection at the zero-crossing point reduces contact wear and contact deposits, which can increase the life of the contactor assembly and reduce maintenance. Furthermore, it reduces stress on upstream and downstream electrical loads, as well as the occurrence of voltage spikes and surges. Overall power consumption can be cleaner, reducing total power consumption. Noise generated by the contactor assembly is also reduced, and surge spikes can be minimized, further reducing noise.

[0050] Various features, aspects, and advantages of the present invention can also be embodied in the following technical solutions defined in the enumerated clauses:

[0051] 1. A method of operating a contactor, the method comprising:

[0052] The controller module receives the AC waveform of the power supply.

[0053] The controller module receives the temperature of the contactor coil, which can be energized to disconnect the power supply from the electrical load.

[0054] The controller module receives the excitation source characteristics of the contactor coil.

[0055] In the controller module, the total contactor time delay, defined by timing estimation, is determined based on the temperature of the contactor coil and the characteristics of the contactor coil excitation source, so as to operatively disconnect or connect the power supply and electrical load.

[0056] The contactor start-up time is determined based on the total contactor time delay and the AC waveform of the power supply, ensuring that the cutoff of the total contactor time delay coincides with the zero-crossing voltage of the AC waveform; and

[0057] The controller module switches the power supply via the contactor at the contactor start time.

[0058] 2. The method as described in item 1, wherein starting further includes energizing the contactor coil with a contactor coil excitation source at the contactor starting time.

[0059] 3. The method as described in item 1, wherein the effective switching of the power supply coincides with the zero-crossing voltage of the AC waveform.

[0060] 4. The method of claim 1, wherein determining the contactor time delay is further based on the temperature of the contactor coil, the characteristics of the contactor coil excitation source, and an error correction value, the error correction value being defined by the difference between the effective switching of the power supply through the contactor along the AC waveform and the zero-crossing voltage of the AC waveform of at least one previous contactor disconnection or connection.

[0061] 5. The method as described in clause 4, wherein the error correction value is based on the difference between the voltage measured when the power supply is effectively disconnected or connected and the zero value of the voltage.

[0062] 6. The method as described in clause 5, wherein the error correction value is further based on the voltage and AC waveform of the power supply measured during effective switching of the power supply through the contactor.

[0063] 7. A contactor assembly, comprising:

[0064] A contactor switch that can selectively connect to an input and an output;

[0065] A contactor coil, which is operatively connected to a contactor switch and configured to drive the contactor switch;

[0066] A contactor coil temperature sensor, which is configured to measure the temperature of a contactor coil;

[0067] A contactor coil operating characteristic sensor, which is configured to measure the operating characteristics of a contactor coil;

[0068] An input AC waveform sensor is configured to measure the AC waveform of an input power supply; and

[0069] The controller module is constructed as follows:

[0070] Receive the first electrical signal representing the AC waveform from the input AC waveform sensor.

[0071] A second electrical signal representing the temperature of the contactor coil is received from the contactor coil temperature sensor.

[0072] A third electrical signal representing the operating characteristics of the contactor coil is received from the contactor coil operating characteristic sensor.

[0073] The contactor time delay is determined based on the first, second, and third electrical signals, and is summed as a set of delay times.

[0074] The start-up time before the zero-crossing voltage of the AC waveform initiates at least one of the disconnection or connection of the input and output via a contactor switch, wherein the start-up time is based on the contactor time delay.

[0075] 8. The contactor assembly as described in clause 7, wherein the controller module is further configured to effectively disconnect or effectively connect at least one of the inputs and outputs when the AC waveform has zero voltage.

[0076] 9. The contactor assembly as described in clause 8 further includes an output voltage sensor configured to measure voltage when at least one of the input and output is effectively disconnected or effectively connected.

[0077] 10. The contactor assembly as described in item 9, wherein the controller module is configured to receive a fourth electrical signal from the output voltage sensor.

[0078] 11. The contactor assembly as described in clause 10, wherein the controller module is further configured to determine the contactor time delay based on the first, second, third, and fourth electrical signals as a sum of a set of delay times.

[0079] Within the scope not described, different features and structures of various characteristics can be combined as needed. The fact that a feature is not shown in all aspects of this disclosure is not to be construed as meaning it cannot be, but is done for the sake of brevity. Therefore, various features of different aspects described herein can be mixed and matched as needed to form new features or aspects thereof, whether or not the new aspects or features are explicitly described. This disclosure covers all combinations or substitutions of the features described herein.

[0080] This written description uses examples to detail the aspects described herein, including best practices, and to enable those skilled in the art to practice the aspects described herein, including making and using any device or system and performing any combined methods. The patentable scope of the aspects described herein is defined by the claims and may include other examples that would occur to those skilled in the art. Such other examples are intended to fall within the scope of the claims if they have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A method of operating a contactor, characterized by, The method comprises: receiving, in a controller module, at least two operating characteristics of the contactor, wherein each operating characteristic represents a delay time; determining, in the controller module, a contactor time delay for at least one of disconnecting or connecting the power source through the contactor, the contactor time delay being based on a summation of a set of delay times of the delay time of each operating characteristic; and initiating, by the controller module, the disconnection or connection of the power source through the contactor at an initiation time prior to a zero crossing voltage of an alternating current, AC, waveform of the power source, wherein the initiation time predicts the zero crossing voltage based on the contactor time delay.

2. The method of claim 1, wherein, wherein the at least two operating characteristics of the contactor include at least two of an electrical signal representing the AC waveform and an electrical signal delay time, a temperature value representing a temperature of a contactor coil and a coil temperature delay time, or a contactor coil operating characteristic delay time representing a contactor coil operating characteristic.

3. The method of claim 1, wherein, wherein the effective disconnection or connection of the power source coincides with the zero crossing voltage of the AC waveform.

4. The method of claim 1, wherein, wherein the determining is based on estimating the contactor time delay.

5. The method of claim 1, wherein, wherein the determining is based on predicting the contactor time delay.

6. The method of claim 1, wherein, wherein determining the contactor time delay is based on the summation of the set of delay times and an error correction value defined by a difference between the effective disconnection or connection of the power source along the AC waveform and the zero crossing voltage of the AC waveform of at least one previous contactor disconnection or connection.

7. The method of claim 6, wherein, wherein the error correction value is based on a difference between a voltage measured at the effective disconnection or connection of the power source and a zero value of the voltage.

8. The method of claim 7, wherein, wherein the error correction value is based on a voltage at the effective disconnection or connection and the AC waveform of the power source.

9. The method of claim 1, wherein, wherein the initiating includes energizing a solenoid coil with a coil power source to operatively disconnect or connect the power source.

10. The method of claim 9, wherein, wherein the initiating includes closing a coil switch to provide the coil power source to the solenoid coil.

11. A method of operating a contactor, characterized by, The method comprises: receiving, in a controller module, at least two operating characteristics of the contactor, wherein each operating characteristic represents a delay time; determining, in the controller module, a contactor time delay for at least one of disconnecting or connecting the power source through the contactor, the contactor time delay being based on a summation of a set of delay times of the delay time of each operating characteristic; and initiating, by the controller module, the disconnection or connection of the power source through the contactor at an initiation time prior to a zero crossing voltage of an alternating current, AC, waveform of the power source, wherein the initiation time predicts the zero crossing voltage based on the contactor time delay. wherein the at least two operating characteristics of the contactor include at least two of an electrical signal representing the AC waveform and an electrical signal delay time, a temperature value representing a temperature of a contactor coil and a coil temperature delay time, or a contactor coil operating characteristic delay time representing a contactor coil operating characteristic.

12. The method of claim 11, wherein, wherein the effective disconnection or connection of the power source coincides with the zero crossing voltage of the AC waveform. wherein the determining is based on estimating the contactor time delay. wherein the determining is based on predicting the contactor time delay. wherein determining the contactor time delay is based on the summation of the set of delay times and an error correction value defined by a difference between the effective disconnection or connection of the power source along the AC waveform and the zero crossing voltage of the AC waveform of at least one previous contactor disconnection or connection. wherein the error correction value is based on a difference between a voltage measured at the effective disconnection or connection of the power source and a zero value of the voltage. wherein the error correction value is based on a voltage at the effective disconnection or connection and the AC waveform of the power source. wherein the initiating includes energizing a solenoid coil with a coil power source to operatively disconnect or connect the power source. wherein the initiating includes closing a coil switch to provide the coil power source to the solenoid coil. The method comprises: receiving, in a controller module, at least two operating characteristics of the contactor, wherein each operating characteristic represents a delay time; determining, in the controller module, a contactor time delay for at least one of disconnecting or connecting the power source through the contactor, the contactor time delay being based on a summation of a set of delay times of the delay time of each operating characteristic; and initiating, by the controller module, the disconnection or connection of the power source through the contactor at an initiation time prior to a zero crossing voltage of an alternating current, AC, waveform of the power source, wherein the initiation time predicts the zero crossing voltage based on the contactor time delay. wherein the at least two operating characteristics of the contactor include at least two of an electrical signal representing the AC waveform and an electrical signal delay time, a temperature value representing a temperature of a contactor coil and a coil temperature delay time, or a contactor coil operating characteristic delay time representing a contactor coil operating characteristic. wherein the effective disconnection or connection of the power source coincides with the zero crossing voltage of the AC waveform. wherein the determining is based on estimating the contactor time delay. wherein the determining is based on predicting the contactor time delay. wherein determining the contactor time delay is based on the summation of the set of delay times and an error correction value defined by a difference between the effective disconnection or connection of the power source along the AC waveform and the zero crossing voltage of the AC waveform of at least one previous contactor disconnection or connection. wherein the error correction value is based on a difference between a voltage measured at the effective disconnection or connection of the power source and a zero value of the voltage. wherein the error correction value is based on a voltage at the effective disconnection or connection and the AC waveform of the power source. wherein the initiating includes energizing a solenoid coil with a coil power source to operatively disconnect or connect the power source. wherein the initiating includes closing a coil switch to provide the coil power source to the solenoid coil.

13. The method of claim 11, wherein, The starting process includes energizing the contactor coil with a contactor coil excitation source at the contactor start time, and wherein the effective switching of the power supply coincides with the zero-crossing voltage of the AC waveform.

14. The method of claim 11, wherein, The contactor time delay is determined based on the contactor coil temperature, contactor coil excitation source characteristics, and an error correction value, which is defined by the difference between the effective switching of the power supply through the contactor along the AC waveform and the zero-crossing voltage of the AC waveform at least one previous contactor disconnection or connection.

15. The method of claim 14, wherein, The error correction value is based on the difference between the voltage measured when the power supply is effectively disconnected or connected and the zero value of the voltage.

16. A contactor assembly comprising: include: A contactor switch, which can be selectively connected to an input and an output; A contactor coil, operatively connected to and configured to drive the contactor switch; At least two sensors, the at least two sensors being configured to measure the operating characteristics of the contactor assembly; and The controller module is configured as follows: At least two electrical signals are received from the at least two sensors, wherein each electrical signal represents a delay time; The contactor time delay is determined based on the at least two electrical signals, as a sum of a set of delay times, and The start-up time prior to the zero-crossing voltage of the AC waveform of the power supply initiates at least one of the disconnection or connection of the input and the output via the contactor switch, wherein the start-up time is based on the contactor time delay.

17. The contactor assembly of claim 16, wherein, The at least two sensors include at least two of the following: a contactor coil temperature sensor configured to measure the temperature of the contactor coil; a contactor coil operating characteristic sensor configured to measure the operating characteristics of the contactor coil; or an input AC waveform sensor configured to measure the AC waveform from the input power supply.

18. The contactor assembly of claim 17, wherein, The contactor coil temperature sensor represents the coil temperature delay time, the input AC waveform sensor represents the electrical signal delay time, and the contactor coil operating characteristic sensor represents the operating characteristic delay time.

19. The contactor assembly of claim 16, wherein, The controller module is configured to effectively disconnect or effectively connect at least one of the input and the output when the AC waveform has zero voltage.

20. The contactor assembly of claim 17, wherein, One of the at least two sensors includes an output voltage sensor configured to measure voltage when at least one of the input and the output is effectively disconnected or effectively connected, wherein the controller module is configured to receive a fourth electrical signal from the output voltage sensor.

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