Saving type electromechanical contactor

Abstract

Apparatuses, methods, and computer program products for savory electromechanical contactors are disclosed. In a particular embodiment, an electromechanical contactor includes a movable contact configured for switching between a non-actuated position and an actuated position by an actuator assembly. The electromechanical contactor also includes two or more fixed contacts configured to engage with the movable contact when the movable contact is in the actuated position and to disengage from the movable contact when the movable contact is in the non-actuated position. In this embodiment, the electromechanical contactor also includes a motion sensor configured to detect motion of the electromechanical contactor and provide information about the motion of the electromechanical contactor to the controller.

Description

Background Art

[0001] Electromechanical switching devices, such as contactors and relays, are designed to carry a certain amount of current for a certain period of time. Such devices are particularly important in electric vehicles. Some of these devices use movable contacts that, when in a closed or actuated position, engage and electrically couple two fixed contacts. The movable contact is held in the closed position by a holding force provided by an actuator assembly. In some examples, the actuator assembly is actuated by an electromagnetic field generated by a solenoid. In the open or non-actuated position, the holding force is removed or substantially reduced such that the movable contact is biased away from the fixed contact.

[0002] In some applications, such as in electric vehicle applications, electromechanical switching devices may be exposed to shock or vibratory motion that may potentially cause the movable contact to prematurely disengage from the fixed contact, which may potentially cause damage to the connected components. To address this issue, it is provided that the electromechanical switching device utilize a holding force that is sufficient to avoid the worst-case scenario of premature disengagement of the movable contact. However, this worst-case scenario is not often encountered, and powering the solenoid to generate such a high holding force when a low holding force is sufficient would waste energy. Summary of the Invention

[0003] Devices, methods, and computer program products for a frugal electromechanical contactor are disclosed, where a motion sensor is employed to identify conditions where high or low holding force is needed. When it is determined that a low holding force is sufficient, the low holding force is applied, and thus the excess power required to maintain the high holding force can be conserved.

[0004] In a specific embodiment, the frugal electromechanical contactor includes an electromechanical contactor having a movable contact configured to switch between a non-actuated position and an actuated position by an actuator assembly. The electromechanical contactor also includes two or more fixed contacts configured to engage the movable contact when the movable contact is in the actuated position and to disengage from the movable contact when the movable contact is in the non-actuated position. In this embodiment, the electromechanical contactor further includes a motion sensor configured to detect the motion of the electromechanical contactor and provide information about the motion of the electromechanical contactor to a controller.

[0005] In another embodiment, a controller for a frugal electromechanical contactor is disclosed, the controller being configured to control the current supplied to a solenoid of the electromechanical contactor. The controller is further configured to determine, based on information from a motion sensor of the electromechanical contactor, that the motion of the electromechanical contactor has exceeded a threshold. In response to determining that the motion of the electromechanical contactor has exceeded the threshold, the controller increases the current supplied to the solenoid of the electromechanical contactor.

[0006] In another embodiment, a method for a cost-saving electromechanical contactor is disclosed, the method including controlling the current supplied to a solenoid of the electromechanical contactor by a cost-saving controller. The method further includes determining by the cost-saving controller that the movement of the electromechanical contactor has exceeded a threshold based on information from a motion sensor of the electromechanical contactor. In this embodiment, the method further includes increasing, by the cost-saving controller in response to determining that the movement of the electromechanical contactor has exceeded the threshold, the current supplied to the solenoid of the electromechanical contactor.

[0007] In another embodiment, a method for a cost-saving electromechanical contactor is disclosed, the method including detecting the movement of the electromechanical contactor by a motion sensor. The method further includes providing, by the motion sensor, information related to the movement of the electromechanical contactor to a controller.

[0008] The foregoing and other objects, features, and advantages of the present invention will be apparent from the following more particular description of exemplary embodiments of the invention as illustrated in the accompanying drawings, in which like reference numerals generally represent like parts of the exemplary embodiments of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a cross-sectional view of a cost-saving electromechanical contactor configured for illustration according to at least one embodiment of the present disclosure.

[0010] Figure 2 is a schematic diagram of an example system for a cost-saving electromechanical contactor according to at least one embodiment of the present disclosure.

[0011] Figure 3 is a schematic diagram of a cost-saving electromechanical contactor configured for another example according to at least one embodiment of the present disclosure.

[0012] Figure 4 is a flowchart of an example method of a controller of a cost-saving electromechanical contactor according to at least one embodiment of the present disclosure.

[0013] Figure 5 is a flowchart of another example method of a motion sensor of a cost-saving electromechanical contactor according to at least one embodiment of the present disclosure.

[0014] Figure 6 is a flowchart of another exemplary method of a controller of a cost-saving electromechanical contactor according to at least one embodiment of the present disclosure. DETAILED DESCRIPTION

[0015] For the purpose of describing particular examples, the terms used herein are not intended to limit other examples. Whenever the singular forms such as "a", "an", and "the" are used and only a single element is neither explicitly nor implicitly defined as being mandatory, other examples may also use plural elements to achieve the same function. Similarly, when a function is subsequently described as being implemented using multiple elements, further examples may use a single element or processing entity to achieve the same function. It will be further understood that the terms "comprises", "comprising", "includes", and / or "including", when used, specify the presence of the stated features, integers, steps, operations, processes, acts, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, processes, acts, elements, components, and / or any groups thereof.

[0016] It will be understood that when an element is referred to as being "connected" or "coupled" to another element, these elements can be directly connected or coupled or connected or coupled via one or more intermediate elements. If two elements A and B are combined using "or", this should be understood to disclose all possible combinations, i.e., only A, only B, and A and B. An alternative wording for the same combination is "at least one of A and B". This also applies to combinations of more than two elements.

[0017] Accordingly, while additional examples are capable of various modifications and alternative forms, certain specific examples thereof are shown in the drawings and will subsequently be described in detail. However, this detailed description does not limit other examples to the specific forms described. Other examples may cover all modifications, equivalents, and alternatives falling within the scope of the present invention. Throughout the description of the drawings, the same reference numerals represent the same or similar elements, which may be implemented identically or in a modified form when compared to each other, while providing the same or similar functions.

[0018] Some examples of electromechanical contactors use a solenoid to actuate a movable contact assembly that forms a contact between two fixed contacts, thereby allowing current to flow. For example, the solenoid includes a coil of wound conductive material (copper, aluminum) having a hollow center. At the center, a plunger can be actuated by applying a current through the coil. The minimum current through the coil is determined by the holding force required to hold the high-voltage movable assembly in place. Excessively reducing this current may cause an unexpected disconnection of the line powering the connected load, resulting in a serious safety risk in a vehicle. For this reason, the holding current is set high enough so as not to pose a risk of unexpected disconnection. This holding current level is high enough to prevent disconnection even in the most extreme shock scenarios.

[0019] However, while the current level is set high enough so that even the most likely shock scenario will not cause an accidental disconnection, these events rarely occur. Therefore, power is wasted by keeping the coil at a high current level. Reducing the current supplied to the coil and thus reducing the holding ability of the high-voltage electromechanical connector assembly is immaterial for 99% of the contactor's mission profile. However, during 1% of the mission profile, it can be catastrophic. If the contactor could "know" whether it is subject to those rare but catastrophic shock forces, the contactor could (temporarily) increase the power to the coil. This would temporarily ensure a higher holding force and prevent accidental disconnection. The controller should be able to raise the current within a few milliseconds, so a low-inductance coil is required.

[0020] According to an embodiment of the present disclosure, a motion sensor is associated with the electromechanical contactor and measures the level of acceleration / vibration / shock experienced by the contactor. In a specific embodiment, an accelerometer disposed in or on the contactor measures the acceleration level in the plunger direction. When the accelerometer detects an acceleration higher than a threshold (Ath), the accelerometer will record this trigger and communicate a signal to a microcontroller, which will in turn increase the current to the coil. The threshold can be application-specific and should be set such that it is low enough to prevent unintentional disconnection but high enough to avoid erratic triggering.

[0021] For further explanation, Figure 1 A cross-sectional view of an exemplary electromechanical contactor 100 in accordance with at least one embodiment of the present disclosure is shown. The electromechanical contactor 100 includes a housing 102 having an upper portion 104 and a lower portion 106 separated by a separator 108. At least one movable contact 110 and at least one fixed contact 112 are disposed within the upper portion 104 of the housing 102. As Figure 1 shown, the electromechanical contactor 100 includes two fixed contacts 112, and when the electromechanical contactor 100 is in an actuated state, the movable contact 110 engages the fixed contacts 112 to allow current to pass through the movable contact 110 through the fixed contacts 112. In Figure 1 the example, the fixed contacts 112 are electrically coupled to one or more external terminals 114 on the housing 102 for connection to electrical components. When the electromechanical contactor 100 is actuated, the movable contact 110 is driven towards the fixed contacts 112 by an actuator assembly 116 described in more detail below and remains in contact with the fixed contacts 112.

[0022] The lower portion 106 of the housing includes a solenoid 118. For example, the solenoid 118 can be a metal coil wound around a coil bobbin. The solenoid 118 surrounds an actuator cavity 120 that houses at least a portion of the actuator assembly 116. For example, the actuator cavity 120 can be defined within the center of the coil bobbin. The actuator assembly 116 includes a metal plunger 122 attached to a plunger shaft 124. The plunger 122 is disposed within the actuator cavity 120. The plunger shaft 124 extends from the plunger 122 within the actuator cavity 120 through a separator 108 to the upper portion 104 of the housing 102, where the plunger shaft 124 engages a movable contact 110. In some examples, the plunger shaft 124 is attached to the movable contact 110. The actuator assembly 116 further includes a plunger spring 126 disposed between the plunger 122 and the separator 108.

[0023] In the non-actuated state, the movable contact 110 is in a non-actuated position in which the movable contact 110 is separated from the fixed contact 112. That is, the movable contact is held in a position non-contact with the fixed contact 112. For example, the plunger spring 126 can apply a biasing force to the plunger 122 and the separator 108 to keep the movable contact 110 from contacting the fixed contact 112 in the non-actuated state. In the actuated state, current is applied to the solenoid 118, and the solenoid 118 generates an electromagnetic field that actuates the plunger 122 toward the separator 108, thereby overcoming the biasing force applied by the plunger spring 126. The movement of the plunger 122 drives the plunger shaft 124 toward the fixed contact 112 and, thus, drives the movable contact 110 toward the fixed contact 112 until the movable contact 110 contacts the fixed contact 112.

[0024] In the actuated state, the strength of the electromagnetic field and the resulting force (holding force) applied by the plunger shaft on the movable contact 110 must be sufficient to keep the movable contact 110 in contact with the fixed contact 112, even if the electromechanical contactor is subjected to vibrations due to sudden movements; otherwise, circuit interruption can cause damage to the electrical components. However, as discussed above, such vibrational movements can be rare. Thus, a large amount of energy is wasted by applying a large amount of current within the solenoid 118 when anticipating such rare events. However, the risk of damaging the electrical components may be unacceptable.

[0025] To address this issue, the electromechanical contactor 100 further includes a motion sensor 130 disposed on or within the housing 102 of the electromechanical contactor 100. The motion sensor 130 detects the force with which the electromechanical contactor 100 moves along the axis of the plunger shaft 124. For example, the motion sensor 130 can be an accelerometer, a shock sensor, etc. The motion sensor 130 can be a microelectromechanical (MEM) sensor that generates an electrical signal proportional to the magnitude of the detected acceleration. When the magnitude of the acceleration detected along the axis of the plunger shaft 124 exceeds a specific threshold, the current flowing through the solenoid 118 is increased to apply a greater force on the plunger / plunger shaft, which in turn provides a greater force on the movable contact 110 to keep the movable contact 110 in contact with the fixed contact 112. In some examples, the motion sensor 130 is coupled to a microcontroller that controls the amount of electrical current flowing through the solenoid 118. When the microcontroller detects that the voltage of the signal from the motion sensor 130 is higher than the target threshold, the microcontroller increases the current in the solenoid 118. Thus, the electromechanical contactor 100 can generally employ a lower holding force during standard operation as compared to the higher holding force employed in the compensation operation where the motion sensor 130 detects that the electromechanical contactor 100 is undergoing violent vibrational movement. By selectively applying a higher holding force, the amount of energy required to hold the electromechanical contactor 100 in the actuated state is lower because the current applied to the solenoid is smaller.

[0026] In Figure 1 the example of, the motion sensor is disposed outside the housing. However, the motion sensor 130 can be located within or on any part of the housing 102 of the electromechanical contactor 100, where the motion sensor 130 detects the motion along the axis of the plunger shaft 124. In some examples, the motion sensor 130 and the microcontroller that controls the current flowing to the solenoid 118 are integrated in the same device.

[0027] For further explanation, Figure 2 FIG. 200 shows a system diagram of a cost - saving electromechanical contactor 202 according to at least one embodiment of the present disclosure. For example, the electromechanical contactor 202 can be similar to Figure 1The electromechanical contactor 100 in []. In some examples, the electromechanical contactor 202 includes a movable contact 210 that contacts a fixed terminal 212 in an actuated position, as discussed above. When the electromechanical contactor 202 is actuated, the fixed terminal and the movable contact electrically couple the power source 206 to the electrical component 208. When the electromechanical contactor 202 is in a non-actuated state, the circuit between the power source 206 and the electrical component 208 is disconnected. In some examples, the electromechanical contactor 202 also includes a solenoid 218 powered by a current source 220, where the solenoid actuates an actuator to move the movable contact. The microcontroller 250 controls the current from the current source 220 to the solenoid, which affects the force applied to the actuator. The microcontroller 250 is also electrically coupled to a motion sensor 230 (e.g., an accelerometer). In some examples, the motion sensor 230 is disposed on or within the electromechanical contactor 202. In other examples, the motion sensor 230 is disposed on a separate structure (not shown) adjacent to the electromechanical contactor 202.

[0028] The microcontroller 250 can be implemented by a variety of devices. In different examples, the microcontroller 250 is an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), a processor coupled to a memory device (e.g., read-only memory (ROM)) that stores processor-executable instructions, or some other semiconductor device that performs the operations described in detail below. The microcontroller 250 is configured to control the flow of current between the current source 220 and the solenoid 218. In standard operation, the microcontroller 250 controls the current according to the amount of current required by the solenoid 218 to generate a magnetic field that is sufficient to actuate the actuator assembly to provide a holding force that holds the movable contact 210 in contact with the fixed terminal 212. In other words, during standard operation, the current I s is proportional to the holding force F provided by the actuator assembly s . In some examples, the microcontroller 250 samples the signal generated by the motion sensor 230. For example, the motion sensor 230 generates a voltage proportional to the force of the motion (e.g., vibration, acceleration, etc.) measured by the motion sensor 230, which is sampled by the microcontroller 250. In other examples, the motion sensor 230 emits a trigger signal in response to detecting a degree of motion (e.g., acceleration) exceeding a threshold level. When the signal from the motion sensor 230 exceeds a threshold (e.g., a threshold voltage) or when the microcontroller receives a trigger signal, the microcontroller 250 controls the current from the current source 220 to the solenoid 218 to increase, which increases the holding force applied by the actuator assembly on the movable contact 210. In other words, during the compensation operation (to counteract the motion force applied to the actuator assembly caused by acceleration or vibration), the increased current I c is proportional to the increased holding force F provided by the actuator assemblyc is proportional, where I c > I s and F c > F s .

[0029] In a specific example, the accelerometer on the contactor 202 measures the acceleration level in the plunger direction. When the accelerometer detects that the acceleration exceeds a threshold, the accelerometer records the event and conveys this information to the microcontroller 250, which in turn increases the current to the solenoid to generate a high holding force. Otherwise, the current in the solenoid is not increased and a low holding force is maintained.

[0030] For further explanation, Figure 3 FIG. shows another example electromechanical contactor 300 according to at least one embodiment of the present disclosure. The example electromechanical contactor 300 includes a high-voltage contact pin 302, a high-voltage moving assembly 304, a plunger 306, an actuator coil 308, and a motion sensor 310.

[0031] For further explanation, Figure 4 FIG. shows a flowchart of an exemplary method for a controller of a frugal electromechanical contactor according to at least one embodiment of the present disclosure. Figure 4 The example method includes controlling 402 the current supplied to the solenoid of the electromechanical contactor by a frugal controller 401. In some examples, the frugal controller 401 receives a signal to actuate the electromechanical contactor. In response, the frugal controller 401 regulates the current flowing from the current source to the solenoid according to a predetermined current level for the low holding force of the electromechanical contactor. The electromagnetic field generated by the solenoid acts on the plunger of the drive actuator assembly, which moves the movable contact to the closed position.

[0032] Figure 4 The method of also includes determining 404 by the frugal controller 401 that the movement of the electromechanical contactor has exceeded a threshold based on information from a motion sensor of the electromechanical contactor. In some examples, the frugal controller 401 samples a signal (e.g., an acceleration signal) from the motion sensor and compares it to an acceleration threshold of the electromechanical contactor. In other examples, the frugal controller 401 receives a trigger signal from the motion sensor indicating that the detected movement (e.g., acceleration) of the electromechanical contactor has exceeded the threshold.

[0033] Figure 4The method further includes the economy controller 401 increasing 406 the current supplied to the solenoid of the electromechanical contactor in response to determining that the movement of the electromechanical contactor has exceeded a threshold. In some examples, the economy controller 401 regulates the current from the current source to the solenoid according to a predetermined current level for the high holding force of the electromechanical contactor. The increased current flowing to the solenoid increases the holding force applied by the actuator assembly to the movable contact, as described above.

[0034] For further explanation, Figure 5 FIG. shows a flowchart illustrating an example method for a motion sensor of an economy electromechanical contactor according to at least one embodiment of the present disclosure. Figure 5 The method includes detecting 502 the movement of the electromechanical contactor by the motion sensor 501. In different examples, the motion sensor 501 is an accelerometer, a shock sensor, or a vibration sensor. In some examples, detecting the movement includes generating an electrical signal indicative of the amplitude of the movement. In some examples, detecting 502 the movement includes determining whether the amplitude of the movement exceeds a predetermined threshold.

[0035] Figure 5 The method provides 504 information related to the movement of the electromechanical contactor to the controller by the motion sensor 501. In some examples, the motion sensor 501 provides 504 the information to the controller in the form of an electrical signal indicative of the amplitude of the movement. In some examples, the motion sensor 501 provides the information 504 as a trigger signal indicating that the detected movement exceeds the threshold.

[0036] For further explanation, Figure 6 FIG. shows a flowchart 600 that illustrates another example method for a controller of an economy electromechanical contactor according to at least one embodiment of the present disclosure. Figure 6 The method includes a controller that receives a contactor "enable" signal. In response to receiving the contactor "enable signal", the controller fully opens the solenoid coil. The controller then checks the high voltage contact state. If the shrink is engaged, the controller uses a motion detector to measure the acceleration of the electromechanical contactor. If the acceleration is less than the acceleration threshold, the controller sets the coil power to "low holding force". If the acceleration is greater than the acceleration threshold, the controller sets the coil power to "high holding force". The method continues for both results, where the controller continues to measure the acceleration as indicated by the motion detector.

[0037] Some embodiments of the present invention are described largely in the context of a full - function controller. However, those skilled in the art will recognize that the present invention can also be implemented in a computer program product placed on a computer - readable storage medium for use with any suitable data - processing system. Such a computer - readable storage medium can be any storage medium for machine - readable information, including magnetic media, optical media, or other suitable media. Examples of such media include disks in a hard - disk drive or a floppy disk, compact disks for an optical drive, magnetic tape, and other media that would occur to those skilled in the art. Those skilled in the art will immediately recognize that any computer system with a suitable programming device will be able to execute the steps of the method of the present invention as embodied in the computer program product. Those skilled in the art will also recognize that although some of the exemplary embodiments described in this specification are directed to software installed and executed on computer hardware, alternative embodiments implemented as firmware or hardware are also within the scope of the present invention.

[0038] The present invention can be a system, an apparatus, a method, and / or a computer program product. The computer program product may include a computer - readable storage medium (or media) having computer - readable program instructions thereon for causing a processor to execute aspects of the present invention.

[0039] A computer - readable storage medium can be a tangible device that is capable of storing and retaining instructions for use by an instruction - execution device. A computer - readable storage medium can be, by way of example and not limitation, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. A non - exhaustive list of more specific examples of the computer - readable storage medium includes the following: a portable computer disk, a hard disk, a random access memory (RAM), a read - only memory (ROM), an erasable programmable read - only memory (EPROM or flash memory), a static random access memory (SRAM), a portable compact disk read - only memory (CD - ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanical encoding device such as a punched card, or a raised structure in a groove having instructions recorded thereon, and any suitable combination of the foregoing. As used herein, a computer - readable storage medium should not be construed to be a transitory signal per se, such as a radio wave or other freely propagating electromagnetic wave, an electromagnetic wave propagating through a waveguide or other transmission medium (e.g., an optical pulse through an optical fiber cable) or an electrical signal transmitted through a wire.

[0040] The computer-readable program instructions for performing the operations of the present invention may be assembly instructions, instruction set architecture (ISA) instructions, machine instructions, machine-related instructions, microcode, firmware instructions, state-setting data, or source code or object code written in any combination of one or more programming languages, including object-oriented programming languages (such as Smalltalk, C++, etc.) and conventional procedural programming languages (such as the "C" programming language or similar programming languages). In some embodiments, an electronic circuit, including, for example, a programmable logic circuit, a field-programmable gate array (FPGA), or a programmable logic array (PLA), can execute the computer-readable program instructions by personalizing the electronic circuit using the state information of the computer-readable program instructions to perform aspects of the present invention.

[0041] Aspects of the present invention are described herein with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It should be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer-readable program instructions.

[0042] These computer-readable program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions executed via the processor of the computer or other programmable data processing device create a means for implementing the functions / acts specified in the flowchart and / or block diagram or in a block thereof. These computer-readable program instructions can also be stored in a computer-readable storage medium that causes a computer, a programmable data processing device, and / or other devices to operate in a particular manner, so that the computer-readable storage medium storing the instructions includes a manufacture comprising instructions implementing aspects of the functions / acts specified in the flowchart and / or block diagram or in a block thereof.

[0043] The computer-readable program instructions can also be loaded onto a computer, other programmable data processing device, or other device to cause a series of operational steps to be performed on the computer, other programmable device, or other device to produce a computer-implemented process, such that the instructions executed on the computer, other programmable device, or other device implement the functions / acts specified in the flowchart and / or block diagram or in a block thereof.

[0044] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of the possible implementations of systems, devices, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagram may represent a module, segment, or portion of instructions, which includes one or more executable instructions for implementing the specified logical function. In some alternative implementations, the functions noted in the blocks may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It should also be noted that each block of the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or combinations of special purpose hardware and computer instructions.

[0045] All orientations and arrangements of the components shown herein are used by way of example only. Further, those of ordinary skill in the relevant art will understand that in alternative embodiments, the functions of several elements may be performed by fewer elements or a single element. Similarly, in some embodiments, any functional element may perform fewer or different operations than those described with respect to the illustrated embodiments. Also, functional elements shown for purposes of illustration may be incorporated within other functional elements in a particular implementation.

[0046] Although the subject matter technology has been described with respect to embodiments, those skilled in the art will readily appreciate that various changes and / or modifications can be made to the subject matter technology without departing from the spirit or scope of the subject matter technology. For example, each claim may depend from any or all of the other claims in a multiple dependent manner, even if such claims were not originally claimed as dependent.

[0047] The advantages and features of the present disclosure can be further described by the following statements:

[0048] 1. An electromechanical contactor, comprising: a movable contact configured to be switched between a non-actuated position and an actuated position by an actuator assembly; two or more fixed contacts configured to engage the movable contact when the movable contact is in the actuated position and to disengage from the movable contact when the movable contact is in the non-actuated position; and a motion sensor configured to detect the motion of the electromechanical contactor and to provide information about the motion of the electromechanical contactor to a controller.

[0049] 2. The electromechanical contactor according to statement 1, further comprising a solenoid; wherein the actuator assembly is moved along an axis by an electromagnetic field generated by the solenoid.

[0050] 3. The electromechanical contactor as described in statement 1 or 2, wherein the movement is detected along an axis.

[0051] 4. The electromechanical contactor as described in any one of statements 1 - 3, wherein the motion sensor is at least one of an accelerometer, a vibration sensor, and a shock sensor.

[0052] 5. The electromechanical contactor as described in any one of statements 1 - 4, wherein the information includes an electrical signal indicating the amplitude of the detected movement.

[0053] 6. The electromechanical contactor as described in any one of statements 1 - 5, wherein the information includes an electrical signal indicating a threshold level at which movement has been detected.

[0054] 7. The electromechanical contactor as described in any one of statements 1 - 6, wherein the motion sensor is configured to compare the current level of movement detected by the motion sensor with a threshold.

[0055] 8. The electromechanical contactor as described in any one of statements 1 - 7, wherein the motion sensor is disposed within the housing of the electromechanical contactor.

[0056] 9. The electromechanical contactor as described in any one of statements 1 - 8, wherein the motion sensor is disposed on the surface of the housing of the electromechanical contactor.

[0057] 10. The electromechanical contactor as described in any one of statements 1 - 9, wherein the actuator assembly includes a plunger, a plunger shaft, and a plunger spring.

[0058] 11. A controller for an energy - saving electromechanical contactor, the controller being configured to: control the current supplied to the solenoid of the electromechanical contactor; determine that the movement of the electromechanical contactor has exceeded a threshold based on information from the motion sensor of the electromechanical contactor; and increase the current supplied to the solenoid of the electromechanical contactor in response to determining that the movement of the electromechanical contactor has exceeded the threshold.

[0059] 12. The controller as described in statement 11, wherein determining that the movement of the electromechanical contactor has exceeded the threshold is based on a sampled signal generated by the motion sensor.

[0060] 13. The controller as described in statement 11 or 12, wherein determining that the movement of the electromechanical contactor has exceeded the threshold is based on a trigger signal generated by the motion sensor indicating that the threshold has been exceeded.

[0061] 14. The controller as described in any one of statements 11 - 13, wherein the information from the motion sensor is acceleration information measured along the movement axis of the movable contact of the electromechanical contactor.

[0062] 15. The controller according to any one of statements 11 - 14, wherein the controller adjusts the current based on a first current level for low holding force and a second current level for high holding force.

[0063] 16. A method for an energy - saving electromechanical contactor, the method comprising: controlling, by an energy - saving controller, the current supplied to a solenoid of the electromechanical contactor; determining, by the energy - saving controller, based on information from a motion sensor of the electromechanical contactor, that the motion of the electromechanical contactor has exceeded a threshold; and in response to determining that the motion of the electromechanical contactor has exceeded the threshold, increasing, by the energy - saving controller, the current supplied to the solenoid of the electromechanical contactor.

[0064] 17. The method according to statement 16, wherein determining that the motion of the electromechanical contactor has exceeded the threshold is based on a sampled signal generated by the motion sensor.

[0065] 18. The method according to statement 16 or 17, wherein determining that the motion of the electromechanical contactor has exceeded the threshold is based on a trigger signal generated by the motion sensor indicating that the threshold has been exceeded.

[0066] 19. The method according to any one of statements 16 - 18, wherein the information from the motion sensor is acceleration information measured along the movement axis of a movable contact of the electromechanical contactor.

[0067] 20. The method according to any one of statements 16 - 19, wherein the controller adjusts the current based on a first current level for low holding force and a second current level for high holding force.

[0068] 21. A method for an energy - saving electromechanical contactor, the method comprising: detecting, by a motion sensor, the motion of the electromechanical contactor; and providing, by the motion sensor, information related to the motion of the electromechanical contactor to a controller.

[0069] 22. The method according to statement 21, wherein the information includes an electrical signal indicating the amplitude of the detected motion.

[0070] 23. The method according to statement 21 or 22, wherein the information includes an electrical signal indicating a threshold level of motion that has been detected.

[0071] One or more embodiments may be described herein by way of method steps that illustrate the performance of specific functions and their relationships. For ease of description, the boundaries and order of these functional building blocks and method steps have been arbitrarily defined herein. Alternative boundaries and orders can be defined so long as the specific functions and relationships are performed appropriately. Accordingly, any such alternative boundaries or orders are within the scope and spirit of the claims. In addition, for ease of description, the boundaries of these functional building blocks have been arbitrarily defined. Alternative boundaries can be defined so long as certain important functions are performed appropriately. Similarly, flowchart blocks may also be arbitrarily defined herein to illustrate certain important functions.

[0072] To the extent used, the flowchart block boundaries and order may be defined otherwise and still perform certain important functions. Accordingly, such alternative definitions of functional building blocks and flowchart blocks and order are within the scope and spirit of the claims.

[0073] It will be understood from the foregoing description that modifications and changes may be made in the different embodiments of the present invention without departing from the true spirit thereof. The description in this specification is for illustrative purposes only and should not be construed as restrictive. The scope of the present invention is limited only by the language of the appended claims.

Claims

1. An electromechanical contactor, comprising: a movable contact configured to be switched between a non-actuated position and an actuated position by an actuator assembly; two or more fixed contacts configured to engage with the movable contact when the movable contact is in the actuated position and to disengage from the movable contact when the movable contact is in the non-actuated position; and a motion sensor configured to detect the motion of the electromechanical contactor and to provide information about the motion of the electromechanical contactor to a controller.

2. The electromechanical contactor according to claim 1, further comprising a solenoid; wherein the actuator assembly is moved along an axis by an electromagnetic field generated by the solenoid.

3. The electromechanical contactor according to claim 2, wherein, the motion is detected along the axis.

4. The electromechanical contactor according to claim 1, wherein, the motion sensor is at least one of an accelerometer, a vibration sensor, and a shock sensor.

5. The electromechanical contactor according to claim 1, wherein, the information includes an electrical signal indicating the amplitude of the detected motion.

6. The electromechanical contactor according to claim 1, wherein, the information includes an electrical signal indicating a threshold level of motion that has been detected.

7. The electromechanical contactor according to claim 6, wherein, the motion sensor is configured to compare the current level of motion detected by the motion sensor with a threshold.

8. The electromechanical contactor according to claim 1, wherein, the motion sensor is disposed within the housing of the electromechanical contactor.

9. The electromechanical contactor according to claim 1, wherein, the motion sensor is disposed on the surface of the housing of the electromechanical contactor.

10. The electromechanical contactor according to claim 1, wherein, the actuator assembly includes a plunger, a plunger shaft, and a plunger spring.

11. A controller for an energy-saving electromechanical contactor, the controller being configured to: control the current supplied to the solenoid of the electromechanical contactor; determine, based on information from the motion sensor of the electromechanical contactor, that the motion of the electromechanical contactor has exceeded a threshold; and increase the current supplied to the solenoid of the electromechanical contactor in response to determining that the motion of the electromechanical contactor has exceeded the threshold.

12. The controller according to claim 11, wherein, determining that the motion of the electromechanical contactor has exceeded a threshold is based on a sampled signal generated by the motion sensor.

13. The controller according to claim 11, wherein, determining that the motion of the electromechanical contactor has exceeded a threshold is based on a trigger signal generated by the motion sensor indicating that the threshold has been exceeded.

14. The controller according to claim 11, wherein, the information from the motion sensor is acceleration information measured along the axis of movement of the movable contact of the electromechanical contactor.

15. The controller according to claim 11, wherein, The controller adjusts the current according to a first current level for low holding force and a second current level for high holding force.

16. A method for an energy-saving electromechanical contactor, the method comprising: controlling, by an energy-saving controller, the current supplied to a solenoid of the electromechanical contactor; determining, by the energy-saving controller, based on information from a motion sensor of the electromechanical contactor, that the motion of the electromechanical contactor has exceeded a threshold; and increasing, by the energy-saving controller in response to determining that the motion of the electromechanical contactor has exceeded the threshold, the current supplied to the solenoid of the electromechanical contactor.

17. The method according to claim 16, wherein determining that the motion of the electromechanical contactor has exceeded the threshold is based on a sampled signal generated by the motion sensor.

18. The method according to claim 16, wherein determining that the motion of the electromechanical contactor has exceeded the threshold is based on a trigger signal generated by the motion sensor indicating that the threshold has been exceeded.

19. The method according to claim 16, wherein the information from the motion sensor is acceleration information measured along a movement axis of a movable contact of the electromechanical contactor.

20. The method according to claim 16, wherein the controller adjusts the current according to a first current level for low holding force and a second current level for high holding force.

21. A method for an energy-saving electromechanical contactor, the method comprising: detecting, by a motion sensor, the motion of the electromechanical contactor; and providing, by the motion sensor, information related to the motion of the electromechanical contactor to a controller.

22. The method according to claim 21, wherein the information includes an electrical signal indicating the amplitude of the detected motion.

23. The method according to claim 21, wherein the information includes an electrical signal indicating a threshold degree of the detected motion.

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