A high-voltage direct-current contactor capable of prewarning service life

Abstract

The application discloses a high-voltage direct-current contactor capable of prewarning service life, which comprises an upper shell and a lower shell, output sheets fixed on the two sides of the upper shell and the lower shell respectively, and wiring terminals arranged on the output sheets; a pair of auxiliary lead-out heads and a pair of coil lead-out heads are fixed on the two sides of the middle part of the upper shell; lead-out ends are fixed on the bottom of the output sheets; a prewarning device is arranged between the two lead-out ends below the upper shell; a push rod is arranged right below the prewarning device; and a movable spring sheet matched with the lead-out ends is fixed on the push rod. The prewarning device is used for monitoring the abrasion condition of the lead-out ends, and when the lead-out ends are abraded greatly, the user is reminded to replace the contactor.

Description

Technical Field

[0001] This invention relates to a high-voltage DC contactor capable of providing early warning of its service life. Background Technology

[0002] Contactors are used in control circuits to connect and disconnect electrical loads from power sources, and are commonly used in the field of automatic control.

[0003] During use, contactors will gradually wear down. After prolonged use, excessive wear can cause the contactor to malfunction. If the contactor is not replaced in time, it may cause significant losses and pose a very serious safety hazard.

[0004] To address the above issues, relying on manual periodic inspections would not only incur significant labor costs, but also result in many contactors being replaced while still in normal working order, failing to maximize their lifespan and wasting resources. Summary of the Invention

[0005] To address the aforementioned problems, this invention provides a high-voltage DC contactor capable of providing early warning of its service life, effectively solving the problems mentioned in the background art.

[0006] The technical solution adopted in this invention is:

[0007] A high-voltage DC contactor capable of providing early warning of service life includes an upper housing and a lower housing, and output plates respectively fixed on both sides of the upper and lower housings. The output plates are provided with wiring terminals. A pair of auxiliary leads and a pair of coil leads are respectively fixed on both sides of the middle part of the upper housing. A lead end is fixed at the bottom of the output plate. An early warning device is provided between the two leads at the bottom of the upper housing. A push rod is provided directly below the early warning device. A moving spring matching the lead end is fixed on the push rod.

[0008] Preferably, the warning device includes a circuit board, the bottom of which is provided with an auxiliary contact head and an auxiliary spring, the top center of which is provided with an auxiliary spring groove, an auxiliary spring is provided in the auxiliary spring groove, an auxiliary bracket is fixed to the top of the auxiliary spring, and the top of the circuit board is provided with two auxiliary contacts that are respectively connected to the auxiliary bracket and the auxiliary contact head, and the two auxiliary contacts are respectively connected to two auxiliary leads.

[0009] Preferably, the interior of the lower outer casing is divided into a contact chamber and a lifting chamber by an exhaust pipe assembly. The push rod extends downward into the lifting chamber, and a moving iron core is fixed at the bottom of the push rod. A metal shell fixed to the exhaust pipe assembly is provided inside the lifting chamber. The moving iron core slides up and down inside the metal shell. A return spring is provided on the outside of the push rod between the moving iron core and the exhaust pipe assembly, and a pressure spring is provided between the exhaust pipe assembly and the moving spring. A coil assembly and a U-shaped yoke are arranged sequentially from the inside to the outside of the metal shell in the lifting chamber. The coil assembly is connected to the coil lead. The upper end of the push rod and the moving spring are located inside the contact chamber. A ceramic cover is provided above the exhaust pipe assembly in the contact chamber.

[0010] Preferably, the top of the exhaust pipe assembly is provided with an insulating cover directly below the moving spring.

[0011] An insulating cover is used to isolate the moving spring from the exhaust pipe assembly.

[0012] Preferably, the contact chamber has a magnet between the side of the ceramic cover and the lower outer shell, and the magnet is fixed to the lower outer shell by a magnetic steel frame.

[0013] Preferably, the coil assembly includes a holding coil and a starting coil, and an energy-saving plate is provided on the lower housing. The holding coil, the starting coil, and the coil leads are all connected to the energy-saving plate.

[0014] The starting coil and the holding coil are connected in parallel. The energy-saving board is used to control the on / off state of the starting coil and the holding coil. When the coil assembly is energized, the starting coil and the holding coil are energized at the same time and generate a strong magnetic field. The starting power is about 50W. After 0.2s of starting, the starting coil is de-energized, while the holding coil remains energized, with a holding power of about 10W. Through the on / off control of the energy-saving board, the energy consumption of the coil is reduced to about 50W during starting. After starting, the coil power consumption is reduced to 10W to maintain the closed state of the contactor.

[0015] Preferably, the upper outer casing is provided with mounting holes.

[0016] Mounting holes are used for mounting and securing the contactor.

[0017] Preferably, the lead-out end, the early warning device, and the ceramic cover are supported and fixed together by an inner support frame.

[0018] The internal support frame ensures the stable fixation of the lead-out end, the early warning device, and the ceramic cover.

[0019] Preferably, the ceramic cover, the inner support frame, and the exhaust pipe assembly are sealed by ceramic brazing, and the cavity formed by the ceramic cover, the inner support frame, and the exhaust pipe assembly is filled with inert gas.

[0020] During processing, ceramic brazing and a fully sealed design are used. Finally, inert gas is injected into the inner cavity through the exhaust pipe, and the exhaust pipe is then clamped shut. Injecting inert gas has the following advantages: rapid arc extinguishing, prevention of metal oxidation, and enhanced electrical insulation between metal parts.

[0021] This invention monitors the wear of the lead-out terminals using an early warning device. When the coil assembly is energized, if the wear of the lead-out terminals is minor and can ensure the long-term normal operation of the contactor, the auxiliary bracket at the top of the push rod will not abut against the auxiliary spring. At this time, there is no conductivity between the two auxiliary lead-out terminals, indicating that the contactor does not need to be replaced. If the wear of the lead-out terminals is significant and cannot ensure the long-term normal operation of the contactor, the auxiliary bracket at the top of the push rod will abut against the auxiliary spring and push the auxiliary spring to bend upward. After bending, the auxiliary spring will abut against the auxiliary contact head. At this time, there is conductivity between the two auxiliary lead-out terminals, indicating that the contactor needs to be replaced. Attached Figure Description

[0022] Figure 1 This is a side view of the present invention;

[0023] Figure 2 This is a top view of the structure of the present invention;

[0024] Figure 3 for Figure 2 AA section view;

[0025] Figure 4 A schematic diagram of the structure inside the lower housing when the auxiliary contact head is disconnected from the auxiliary support;

[0026] Figure 5 A schematic diagram of the internal structure of the lower housing when the auxiliary contact head and the auxiliary support are in contact;

[0027] Figure 6 This is a schematic diagram of the side structure of the contact chamber;

[0028] Figure 7 for Figure 6 A top-view structural diagram. Detailed Implementation

[0029] The present invention will now be described in further detail with reference to specific embodiments and accompanying drawings.

[0030] like Figure 1-7As shown, a high-voltage DC contactor capable of providing early warning of its service life includes an upper housing 26 and a lower housing 9, and output plates 1 respectively fixed on both sides of the upper housing 26 and the lower housing 9. To ensure reliable connection, the output plates 1 are made of copper and plated with a silver layer. Terminals 2 are provided on the output plates 1. A pair of auxiliary leads 3 and a pair of coil leads 4 are fixed on both sides of the middle of the upper housing 26. Lead-out ends 5 are fixed at the bottom of the output plates 1. An early warning device 6 is provided between the two leads 5 below the upper housing 26. A push rod 7 is located directly below the early warning device 6, and a moving spring 8 matching the lead-out ends 5 is fixed on the push rod 7.

[0031] The warning device 6 includes a circuit board 61. The bottom of the circuit board 61 is provided with an auxiliary contact head 62 and an auxiliary spring 63. The top center of the push rod 7 is provided with an auxiliary spring groove 64. An auxiliary spring 65 is provided in the auxiliary spring groove 64. An auxiliary bracket 66 is fixed on the top of the auxiliary spring 65. The top of the circuit board 61 is provided with two auxiliary contacts 67 that are respectively connected to the auxiliary bracket 66 and the auxiliary contact head 62. The two auxiliary contacts 67 are respectively connected to two auxiliary leads 3.

[0032] The interior of the lower outer casing 9 is divided into a contact chamber 11 and a lifting chamber 12 by an exhaust pipe assembly 10. The push rod 7 extends downward into the lifting chamber 12, and a moving iron core 13 is fixed to the bottom of the push rod 7. A metal shell 14 fixed to the exhaust pipe assembly 10 is provided inside the lifting chamber 12. The moving iron core 13 slides up and down inside the metal shell 14. A return spring 15 is provided on the outside of the push rod 7 between the moving iron core 13 and the exhaust pipe assembly 10. A return spring 15 is provided between the exhaust pipe assembly 10 and the moving spring 8. A pressure spring 16 is provided between the layers. The lifting chamber 12 is provided with a coil assembly 17 and a U-shaped yoke 18 arranged sequentially from the inside to the outside of the metal shell 14. The coil assembly 17 is connected to the coil lead-out head 4. The upper end of the push rod 7 and the moving spring 8 are located in the contact chamber 11. The contact chamber 11 is provided with a ceramic cover 19 above the exhaust pipe assembly 10. The auxiliary contact 67 is located above the ceramic cover 19. The existing space layout is reasonably utilized, which facilitates the welding and wiring of the auxiliary lead-out head 3.

[0033] An insulating cover 20 is provided on the top of the exhaust pipe assembly 10 directly below the moving spring 8.

[0034] The contact chamber 11 has a magnet 21 between the side of the ceramic cover 19 and the lower outer shell 9, and the magnet 21 is fixed to the lower outer shell 9 by a magnetic steel frame 22.

[0035] The coil assembly 17 includes a holding coil and a starting coil. An energy-saving plate 23 is provided on the lower housing 9. The holding coil, the starting coil, and the coil lead-out head 4 are all connected to the energy-saving plate 23.

[0036] The upper outer shell 26 is provided with mounting holes 24.

[0037] The lead-out end 5, the early warning device 6, and the ceramic cover 19 are supported and fixed together by an inner support frame 25.

[0038] The ceramic cover 19, the inner support frame 25 and the exhaust pipe assembly 10 are sealed by ceramic brazing, and the cavity formed by the ceramic cover 19, the inner support frame 25 and the exhaust pipe assembly 10 is filled with inert gas.

[0039] During assembly, the output piece 1 and the lead-out end 5 are first reliably fixed by M8 combination screws, and then the output piece 1 is connected to the load end by M10 bolts / nuts on the outside. This connection method can effectively reduce contact resistance and prevent product overheating or even burnout caused by poor contact.

[0040] The coil lead 4 is connected to a DC voltage source. The voltage can be either 12V or 24V, both of which can reliably engage the device. The coil is started by a dual-coil parallel connection, consisting of a starting coil and a holding coil. The on / off control is achieved through the energy-saving board 23, which achieves energy saving and consumption reduction. The coil energy consumption is around 50W during startup, and after startup, the coil power consumption is reduced to 10W to maintain the contactor's closed state.

[0041] The auxiliary lead-out head 3 is used to detect the wear condition of the contactor's lead-out end 5. During installation and use, it can be connected to an alarm to remind the user: when the contactor is open and not working, there is no conductivity between the two auxiliary leads-out heads 3. When the contactor is working and closed, if the wear of the lead-out end 5 is small, the auxiliary bracket 66 will not move upward to abut against the auxiliary spring 63. At this time, there is no conductivity between the two auxiliary leads-out heads 3. If the wear of the lead-out end 5 is large, the auxiliary bracket 66 will move upward to abut against the auxiliary spring 63. After the auxiliary spring 63 bends upward, it will contact the auxiliary contact head 62. At this time, there is conductivity between the two auxiliary leads-out heads 3, prompting the user that the contactor needs to be replaced.

[0042] The installation method of this invention is vertical installation, which is reliably fixed by M5 bolts through four mounting holes 24. It is particularly noteworthy that the outer shell is made of plastic, and the mounting holes 24 on the outer shell are embedded with knurled studs, which can effectively enhance the installation strength and ensure that the product is installed firmly and reliably.

[0043] The contact portion of this invention is sealed with ceramic brazing, and the outer shell is encapsulated with epoxy resin, achieving a protection level of IP67.

[0044] Working principle of the invention:

[0045] The working principle of the contactor is as follows: When the coil assembly 17 is energized, it generates magnetic force, and the electrical energy is converted into mechanical energy, which pushes the moving spring 8 of the contactor to close with the lead-out terminal 5, realizing the conduction of the contactor. When the coil assembly 17 is de-energized, the magnetic force also disappears. Under the reaction force of the return spring 15, the moving spring 8 is separated from the lead-out terminal 5, returning to the open state.

[0046] The coil assembly 17 of this contactor can use a 12V or 24V DC power supply. The ampere-turn ratio of both coils can reach over 2100. The power supply method of the coil is adjusted by the energy-saving board 23. When the coil assembly 17 is energized, the starting coil and the holding coil are energized at the same time, generating a strong magnetic field. At this time, the starting power reaches about 50W. After starting for about 0.2s, the starting coil is de-energized, while the holding coil is continuously energized, with a holding power of about 10W.

[0047] When the coil assembly 17 is energized, a magnetic field is formed. The direction of the current and the direction of the magnetic field lines can be determined by the right-hand rule. After the magnetic field is formed, it magnetizes the U-shaped yoke 18, the metal shell 14, and the moving iron core 13, forming a magnetic circuit. Under the action of the strong magnetic force, the moving iron core 13 overcomes the reaction force of the return spring 15 and moves upward along the metal shell 14. The moving iron core 13 is fixed together with the moving spring 8 through the push rod 7, which also causes the moving spring 8 to close with the lead end 5, so that the contactor is closed and energized. After the coil assembly 17 is de-energized, the magnetic force disappears. Under the action of the reaction force of the return spring 15, the moving spring 8 separates from the lead end 5 and returns to the open state.

[0048] The working principle of the warning device 6 is as follows: The warning device 6 is installed on one side of the lead-out end 5, with its auxiliary spring 63 facing the push rod 7. The push rod 7 is equipped with an auxiliary bracket 66. The push rod 7 drives the auxiliary bracket 66, so that when the contactor is open, the two auxiliary leads 3 are not connected. When the contactor is closed, if the wear of the lead-out end 5 is small and the stroke of the moving spring 8 is less than or equal to 1 / 2, the auxiliary bracket 66 will not move upward to abut against the auxiliary spring 63. At this time, there is no connection between the two auxiliary leads 3. If the wear of the lead-out end 5 is large and the stroke of the moving spring 8 is greater than 1 / 2, the auxiliary bracket 66 moves upward to abut against the auxiliary spring 63. After the auxiliary spring 63 bends upward, it contacts the auxiliary contact head 62. At this time, there is connection between the two auxiliary leads 3, prompting the user that the contactor needs to be replaced.

[0049] Finally, it should be noted that the above examples are merely specific embodiments of the present invention. Obviously, the present invention is not limited to the above embodiments and many variations are possible. All variations that can be directly derived or conceived by those skilled in the art from the disclosure of this invention should be considered within the scope of protection of this invention.

Claims

1. A high-voltage DC contactor capable of predicting service life, characterized in that, It includes an upper outer shell (26) and a lower outer shell (9), and output plates (1) fixed on both sides of the upper outer shell (26) and the lower outer shell (9) respectively. The output plates (1) are provided with terminals (2). A pair of auxiliary leads (3) and a pair of coil leads (4) are fixed on both sides of the middle part of the upper outer shell (26) respectively. The bottom of the output plate (1) is fixed with a lead end (5). A warning device (6) is provided between the two leads (5) at the bottom of the upper outer shell (26). A push rod (7) is provided directly below the warning device (6). A moving spring (8) matching the lead end (5) is fixed on the push rod (7). The warning device (6) includes a circuit board (61), the bottom of which is provided with an auxiliary contact head (62) and an auxiliary spring (63). The top center of the push rod (7) is provided with an auxiliary spring groove (64), the auxiliary spring groove (64) is provided with an auxiliary spring (65), the top of the auxiliary spring (65) is fixed with an auxiliary bracket (66), the top of the circuit board (61) is provided with two auxiliary contacts (67) that are respectively connected to the auxiliary bracket (66) and the auxiliary contact head (62), and the two auxiliary contacts (67) are respectively connected to two auxiliary leads (3). The warning device (6) is installed on one side of the lead-out end (5), with its auxiliary spring (63) facing the push rod (7). The push rod (7) is equipped with an auxiliary bracket (66). The push rod (7) drives the auxiliary bracket (66) so that when the contactor is disconnected, the two auxiliary lead-out heads (3) are not connected. When the contactor is closed, if the wear of the lead-out end (5) is small and the stroke of the moving spring (8) is less than or equal to 1 / 2, the auxiliary bracket (66) will not move upward to abut against the auxiliary spring (63). At this time, the two auxiliary lead-out heads (3) are not connected. If the wear of the lead-out end (5) is large and the stroke of the moving spring (8) is greater than 1 / 2, the auxiliary bracket (66) moves upward to abut against the auxiliary spring (63). After the auxiliary spring (63) bends upward, it contacts the auxiliary contact head (62). At this time, the two auxiliary lead-out heads (3) are connected, prompting the user that the contactor needs to be replaced.

2. A high-voltage DC contactor capable of predicting service life according to claim 1, characterized in that, The interior of the lower outer casing (9) is divided into a contact chamber (11) and a lifting chamber (12) by an exhaust pipe assembly (10). The push rod (7) extends downward into the lifting chamber (12). A moving iron core (13) is fixed at the bottom of the push rod (7). A metal shell (14) fixed to the exhaust pipe assembly (10) is provided inside the lifting chamber (12). The moving iron core (13) slides up and down inside the metal shell (14). The outer side of the push rod (7) is between the moving iron core (13) and the exhaust pipe assembly (10). A return spring (15) is provided, and a pressure spring (16) is provided between the exhaust pipe assembly (10) and the moving spring (8). The lifting chamber (12) is provided with a coil assembly (17) and a U-shaped yoke (18) in sequence from the inside to the outside of the metal shell (14). The coil assembly (17) is connected to the coil lead (4). The upper end of the push rod (7) and the moving spring (8) are located in the contact chamber (11). The contact chamber (11) is provided with a ceramic cover (19) above the exhaust pipe assembly (10).

3. A high-voltage DC contactor capable of predicting service life according to claim 2, characterized in that, The top of the exhaust pipe assembly (10) is provided with an insulating cover (20) directly below the moving spring (8).

4. A high-voltage DC contactor capable of predicting service life according to claim 3, characterized in that, The contact chamber (11) has a magnet (21) between the side of the ceramic cover (19) and the lower outer shell (9), and the magnet (21) is fixed to the lower outer shell (9) by a magnetic steel frame (22).

5. A high-voltage DC contactor capable of predicting service life according to claim 4, characterized in that, The coil assembly (17) includes a holding coil and a starting coil. An energy-saving plate (23) is provided on the lower housing (9). The holding coil, the starting coil and the coil lead (4) are all connected to the energy-saving plate (23).

6. A high-voltage DC contactor capable of predicting service life according to claim 5, characterized in that, The upper outer shell (26) is provided with mounting holes (24).

7. A high-voltage DC contactor capable of predicting service life according to claim 6, characterized in that, The lead-out end (5), the early warning device (6) and the ceramic cover (19) are supported and fixed by an inner support frame (25).

8. A high-voltage DC contactor capable of predicting service life according to claim 7, characterized in that, The ceramic cover (19), the inner support frame (25) and the exhaust pipe assembly (10) are sealed by ceramic brazing, and the cavity formed by the ceramic cover (19), the inner support frame (25) and the exhaust pipe assembly (10) is filled with inert gas.

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