A single large-current DC contactor with four movable contact pieces and a preparation method thereof

Abstract

The application discloses a single large-current DC contactor with four movable contact pieces and a preparation method thereof, relates to the technical field of contactors, and specifically discloses a single large-current DC contactor with four movable contact pieces, which comprises an iron cup and an upper cover, a positive copper bar and a negative copper bar are arranged above the upper cover, and a static contact is arranged on the upper cover and used for electrically connecting the positive copper bar and the negative copper bar. Through the cooperation of the contact piece assembly, the elastic force assembly, the supporting assembly and the pushing assembly, the four movable contact pieces are formed, the large current can be shared, the heat generated by the continuous large current is low, the first movable contact piece and the second movable contact piece on the two sets of contact piece assemblies can be synchronously disconnected from the two sets of static contacts, the four movable contact pieces are equally divided before breaking, for example, 2000A current is equally divided into 500A, the four points are synchronously disconnected at the breaking moment, the risk that the last breaking contactor bears the whole voltage and breaking current is reduced, and the breaking failure is avoided and the breaking life is ensured.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of contactors, in particular to a single large-current DC contactor with four moving contact pieces and a preparation method thereof. BACKGROUND

[0002] A contactor is an automatic electric appliance for realizing circuit on-off by using electromagnetic control principle, and the core function is to quickly turn on or turn off a large-current circuit (from several amperes to thousands of amperes) under the driving of a control signal (such as coil power-on / power-off), and the contactor is widely used in load control in the fields of electric power, industrial control, new energy and the like.

[0003] A large-current contactor on the market, such as a 1000A contactor, is a twin structure formed by two independent and complete contactors in parallel, but the contactors in parallel structure have the problem of asynchronous breaking, and when turned on, the current is divided to a certain extent, for example, 1000A is divided into 500A on one side, but when broken, the contactor that breaks last bears all the voltage and breaking current, which is easy to cause breaking failure or extremely low breaking life, therefore, the application provides a single large-current DC contactor with four moving contact pieces and a preparation method thereof. SUMMARY

[0004] The application aims to provide a single large-current DC contactor with four moving contact pieces and a preparation method thereof, so as to solve the problems in the background.

[0005] To achieve the above-mentioned purpose, the application provides the following technical scheme: a single large-current DC contactor with four moving contact pieces, comprising an iron cup and an upper cover, a positive copper bar and a negative copper bar are arranged above the upper cover, static contact pieces for electrically connecting with the positive copper bar and the negative copper bar are arranged on the upper cover, and the single large-current DC contactor with four moving contact pieces further comprises:

[0006] A partition plate is arranged in the interior of the iron cup and is detachably connected to the interior of the iron cup in a threaded manner, and the interior of the iron cup is divided into a driving cavity and an operating cavity by the partition plate, and the driving cavity is located below the operating cavity.

[0007] A contact piece assembly is arranged in the interior of the operating cavity for conducting a circuit, four groups of static contact pieces are uniformly distributed on the upper cover, adjacent two groups of the static contact pieces are electrically connected with the positive copper bar and the negative copper bar respectively, two groups of the contact piece assemblies are symmetrically arranged in the interior of the operating cavity, first moving contact pieces and second moving contact pieces for abutting and contacting with two groups of the static contact pieces on the positive copper bar or the negative copper bar are arranged on the contact piece assemblies, an elastic assembly for elastically pushing the first moving contact pieces and the second moving contact pieces is arranged on the operating cavity, and an arc extinguishing assembly for extinguishing arc in an operation process is arranged on the upper cover.

[0008] And, a pushing assembly arranged between the driving cavity and the operating cavity and used for pushing the contact piece assembly, an inside of the driving cavity is provided with a driving assembly used for driving the pushing assembly, and the partition plate is provided with a supporting assembly used for assisting in supporting during transmission of the pushing assembly.

[0009] Preferably, the contact piece assembly further comprises a mounting rod, the first movable contact piece and the second movable contact piece are respectively provided with a first circular hole and a second circular hole, the first circular hole has a larger diameter than the second circular hole, the first movable contact piece and the second movable contact piece are sleeved on the mounting rod under the action of the first circular hole and the second circular hole, the first movable contact piece has a U-shaped structure, the second movable contact piece has a strip-shaped structure and is attached to the upper side of the first movable contact piece, and the mounting rod is provided with a positioning assembly used for positioning the first movable contact piece and the second movable contact piece.

[0010] Preferably, the positioning assembly comprises a U-shaped positioning frame, the U-shaped positioning frame is provided with a mounting hole, the U-shaped positioning frame is sleeved on the outside of the mounting rod under the action of the mounting hole, the first movable contact piece and the second movable contact piece are located on the inside of the U-shaped positioning frame and abut against each other, and the mounting rod is threadedly connected with a nut used for pushing the sleeved U-shaped positioning frame.

[0011] Preferably, the elastic assembly comprises a mounting sleeve fixed to the outside of the mounting rod, the outside of the mounting sleeve is fixed with a mounting ring, the outside of the mounting rod is sleeved with a first spring and a second spring, the first spring is located in the inside of the first circular hole, and the two ends of the first spring are respectively arranged in abutment with the second movable contact piece and the end of the mounting sleeve, the second spring is located on the outside of the first spring, and the two ends of the second spring are respectively arranged in abutment with the mounting ring and the first movable contact piece.

[0012] Preferably, the pushing assembly comprises a connecting block arranged in the inside of the operating cavity, two groups of the contact piece assemblies are arranged in a symmetrical state on the connecting block, the mounting rod is detachably mounted on the connecting block in a threaded manner, the partition plate is provided with a connecting hole, the connecting hole is slidably connected with a pushing shaft, and one end of the pushing shaft is fixed with the connecting block.

[0013] Preferably, the driving assembly comprises a coil holder fixed to the inside of the driving cavity, the outside of the coil holder is wound with a coil, the inside of the coil holder is fixed with a magnetic conducting sleeve, the inside of the magnetic conducting sleeve is fixed with a shaft bushing, the inside of the shaft bushing is slidably connected with a movable iron core, the pushing shaft is detachably fixed on the movable iron core in a threaded manner, the outside of the pushing shaft is sleeved with a third spring, and the two ends of the third spring are respectively arranged in abutment with the partition plate and the movable iron core.

[0014] Preferably, the support assembly includes a mounting ring, which is detachably mounted to the upper end of the partition by means of threads, and the mounting ring is concentrically arranged with the push shaft. The inner side of the mounting ring is connected to multiple sets of arc-shaped support plates through a pressure assembly. The multiple sets of arc-shaped support plates are arranged in a circular array. The arc-shaped support plates are provided with arc-shaped grooves. The inner side of the arc-shaped grooves is rotatably connected to ball bearings through spherical grooves. Under the action of the pressure assembly, the ball bearings in the arc-shaped grooves of each set of arc-shaped support plates abut against the outer side of the push shaft. The lower end of the arc-shaped support plate is provided with an inclined surface for abutting against the end of the push shaft for transmission.

[0015] Preferably, the pressure assembly includes multiple sets of sleeves fixed inside the mounting ring, with a sliding rod slidably connected to each sleeve. One end of the sliding rod is fixed to an arc-shaped support plate, and a pressure spring is sleeved on the outside of each sleeve. The two ends of the pressure spring are respectively abutted against the inside of the mounting ring and the arc-shaped support plate.

[0016] Preferably, the upper cover includes a cover body and an isolation cover fixed inside the cover body, one end of the stationary contact is inside the isolation cover, and a sealing ring for sealing against the inner wall of the iron cup is sleeved and fixed on the outer side of the cover body;

[0017] The arc-extinguishing assembly is disposed inside the isolation cover. The arc-extinguishing assembly includes a first frame and a second frame disposed on both sides of the stationary contact. A magnet is placed inside the first frame and the second frame. The first frame and the second frame are fixed inside the isolation cover. A ceramic arc-extinguishing plate is disposed between the first frame and the second frame. The ceramic arc-extinguishing plate is installed inside the isolation cover. An isolation frame is fixed between two adjacent sets of stationary contacts. The interior of the isolation frame is filled with epoxy resin.

[0018] A method for manufacturing a single high-current DC contactor with four moving contacts includes the following steps:

[0019] S1: The magnetic sleeve, the coil frame with the coil wound on it, the bushing and the moving iron core are installed in sequence inside the iron cup. During the installation process, the magnetic sleeve is fitted inside the coil frame, the bushing is fixed inside the magnetic sleeve, and the moving iron core is slidably connected to the inside of the bushing. During the installation of the moving iron core, a push shaft is pre-installed on the moving iron core and a third spring is fitted on the push shaft.

[0020] S2: The partition is installed inside the iron cup by means of threads. The partition divides the iron cup into a driving cavity and an operating cavity. During the installation of the partition, the push shaft on the moving iron core passes through the connecting hole and is located inside the operating cavity. In addition, during the installation of the partition, the front end of the push shaft abuts against the inclined surface of each set of arc-shaped support plates on the inner side of the mounting ring on the partition. During the abutting process, the arc-shaped support plates are pushed to move away from each other and contract. After the push shaft passes through each set of arc-shaped support plates, the pressure component pushes the balls of the arc grooves on each set of arc-shaped support plates to abut against the outer side of the push shaft to support the push shaft.

[0021] S3: After the partition is installed, install the connecting block on the push shaft. After the connecting block is installed, install the two sets of contact plate assemblies symmetrically on the connecting block in sequence. During the installation process, install one end of the mounting rod on the connecting block by means of thread. During the installation process, make the bottom of the mounting ring abut against the upper end of the connecting block to assist in the positioning of the mounting rod during the installation process.

[0022] S4: After the mounting rod is installed, the first spring and the second spring are sleeved on the outside of the mounting rod. After the sleeves are installed, the second movable contact piece and the first movable contact piece are sleeved on the mounting rod from the other end of the mounting rod through the second round hole and the first round hole. After the sleeves are installed, the U-shaped positioning frame is sleeved on the mounting rod through the mounting hole. During the sleeve installation process, the second movable contact piece and the first movable contact piece are located inside the U-shaped positioning frame. The U-shaped positioning frame is used to position the second movable contact piece and the first movable contact piece after the sleeves are connected.

[0023] S5: After the U-shaped positioning frame is connected, the nut is threaded onto the mounting rod and abuts against the U-shaped positioning frame. During the abutting process, the U-shaped positioning frame is pushed towards the connecting block. During the movement, the first spring and the second spring are compressed and deformed to generate elastic force. Through the elastic force of the first spring and the second spring, the U-shaped positioning frame, the first moving contact piece, and the second moving contact piece are pushed into an abutting state. During the abutting process, the upper ends of the first moving contact piece and the second moving contact piece are in a flush state, completing the installation of the contact piece assembly. In addition, during the installation process, the position of the U-shaped positioning frame is adjusted by the pushing action of the nut on the U-shaped positioning frame, so that the U-shaped positioning frames on the two sets of contact piece assemblies are flush, ensuring subsequent synchronous contact and synchronous separation.

[0024] S6: After the internal components of the iron cup are installed, the top cover with the pre-installed static contact, positive copper busbar and negative copper busbar is installed. During the installation process, the ceramic arc extinguishing plate and magnet are installed in the designated positions inside the isolation cover in sequence, and epoxy resin is filled inside the isolation frame to complete the installation of the top cover.

[0025] S7: After the top cover is installed, install the top cover inside the iron cup. During the installation process, push the top cover toward the inside of the iron cup. During the pushing process, make the isolation cover abut against the partition. In addition, during the pushing process, make the sealing ring on the outside of the cover abut against the inside of the iron cup. At this time, an annular cavity is formed between the inner wall of the iron cup, the sealing ring and the outside of the cover. Inject the external epoxy resin into this position to seal the iron cup and the top cover after installation, and complete the preparation and installation of the single high-current DC contactor with four moving contacts.

[0026] Compared with the prior art, the beneficial effects of the present invention are:

[0027] This invention achieves a four-moving-contact conductive operation through the cooperation of contact components, elastic components, support components, and pushing components. This allows for the distribution of larger currents, ensuring low heat generation during continuous high-current operation. It also enables the first and second moving contacts on the two sets of contact components to simultaneously disconnect from the two sets of stationary contacts. Before disconnection, the four moving contacts evenly distribute the large current, such as dividing a 2000A current into 500A. At the moment of disconnection, the four points disconnect simultaneously, reducing the risk that the last contactor to disconnect will bear the entire voltage and disconnection current, avoiding disconnection failure, and ensuring disconnection life. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the overall external structure of the present invention;

[0029] Figure 2 This is a schematic diagram of the upper cover structure of the present invention;

[0030] Figure 3 This is a schematic diagram of the internal structure of the upper cover of the present invention;

[0031] Figure 4 This is a schematic diagram of the internal structure of the iron cup of the present invention;

[0032] Figure 5 This is a schematic diagram of the structure of the driving component and the push component of the present invention;

[0033] Figure 6 This is a schematic diagram of the support component structure of the present invention;

[0034] Figure 7 This is a schematic diagram of the pressure component structure of the present invention;

[0035] Figure 8 This is a schematic diagram of the contact assembly and positioning assembly of the present invention;

[0036] Figure 9 This is a schematic diagram of the elastic component structure of the present invention;

[0037] Figure 10This is a schematic diagram of the iron cup and its lid after installation according to the present invention;

[0038] Figure 11 This is a schematic diagram of the contact assembly before the circuit is turned on, according to the present invention.

[0039] Figure 12 This is a schematic diagram of the state of the contact assembly after the circuit is turned on, according to the present invention.

[0040] In the diagram: 101-Iron cup; 102-Top cover; 1021-Lid body; 1022-Isolation cover; 1023-Sealing ring; 103-Positive copper busbar; 104-Negative copper busbar; 105-Static contact; 2-Baffle plate; 301-Mounting rod; 302-First moving contact piece; 303-Second moving contact piece; 304-First round hole; 305-Second round hole; 401-U-shaped positioning bracket; 402-Mounting hole; 403-Nut; 501-Mounting sleeve; 502-Mounting ring; 503-First spring ; 504-Second spring; 601-Connecting block; 602-Connecting hole; 603-Push shaft; 604-Third spring; 701-Coil frame; 702-Magnetic sleeve; 703-Bearing bushing; 704-Moving iron core; 801-Mounting ring; 802-Arc support plate; 803-Arc groove; 804-Sloping surface; 901-Sleeve; 902-Slide rod; 903-Compression spring; 1001-First frame; 1002-Second frame; 1003-Ceramic arc extinguishing plate; 1004-Isolation frame. Detailed Implementation

[0041] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0042] Example 1: Please refer to Figures 1-12 The diagram shows a single-unit high-current DC contactor with four moving contacts, comprising:

[0043] The iron cup 101 and the upper cover 102 are provided. A positive copper busbar 103 and a negative copper busbar 104 are provided on the upper cover 102. A static contact 105 for electrical connection with the positive copper busbar 103 and the negative copper busbar 104 is provided on the upper cover 102.

[0044] It should be noted here that the stationary contact 105, the positive copper busbar 103 and the negative copper busbar 104 are conventional technical components in this application, and their working principle and operation method are known technologies, so they will not be described in detail here.

[0045] Also includes:

[0046] The partition 2 is disposed inside the iron cup 101. The partition 2 is detachably connected to the iron cup 101 by means of threads. The interior of the iron cup 101 is divided by the partition 2 to form a driving cavity and an operating cavity. The driving cavity is located below the operating cavity.

[0047] The contact assembly is located inside the operating cavity for conducting the circuit. There are four sets of stationary contacts 105 evenly distributed on the upper cover 102. Two adjacent sets of stationary contacts 105 are electrically connected to the positive copper busbar 103 and the negative copper busbar 104, respectively. There are two sets of contact assemblies symmetrically arranged inside the operating cavity. The contact assembly is provided with a first moving contact 302 and a second moving contact 303 for contacting the two sets of stationary contacts 105 on the positive copper busbar 103 or the negative copper busbar 104. The operating cavity is provided with a spring force assembly for spring force pushing the first moving contact 302 and the second moving contact 303. The upper cover 102 is provided with an arc extinguishing assembly for extinguishing the arc during operation.

[0048] In addition, a pushing component for pushing the contact assembly is disposed between the driving cavity and the operating cavity, a driving component for driving the pushing component is disposed inside the driving cavity, and a support component for auxiliary support during the transmission of the pushing component is disposed on the partition 2.

[0049] It should be noted here that the contact assembly, spring assembly, support assembly, and push assembly work together to form a four-moving contact conductive operation. This allows for the distribution of a larger current, ensuring low heat generation when continuously carrying a large current. It also allows the first moving contact 302 and the second moving contact 303 on the two sets of contact assemblies to simultaneously disconnect from the two sets of stationary contacts 105. Before disconnection, the four moving contacts share the large current equally, such as 2000A, which is divided into 500A. At the moment of disconnection, the four points disconnect simultaneously, reducing the risk that the last contactor to disconnect will bear the entire voltage and disconnection current, avoiding disconnection failure and ensuring disconnection life.

[0050] Preferably, the contact assembly further includes a mounting rod 301. The first movable contact 302 and the second movable contact 303 are respectively provided with a first circular hole 304 and a second circular hole 305. The diameter of the first circular hole 304 is larger than the diameter of the second circular hole 305. The first movable contact 302 and the second movable contact 303 are respectively sleeved on the mounting rod 301 under the action of the first circular hole 304 and the second circular hole 305. The first movable contact 302 is U-shaped, and the second movable contact 303 is strip-shaped. The second movable contact 303 is attached to the top of the first movable contact 302. The mounting rod 301 is provided with a positioning component for positioning the first movable contact 302 and the second movable contact 303.

[0051] It should be noted here that: through transmission, the first moving contact 302 and the second moving contact 303 on the contact assembly move to the upper cover 102 and abut against the two sets of stationary contacts 105 on the positive copper busbar 103 and the negative copper busbar 104. Through the conductive effect of the first moving contact 302 and the second moving contact 303, the conductive path is connected. During the contact conductive process, the abutment of the first moving contact 302 and the second moving contact 303 on the two sets of contact assemblies against the two sets of stationary contacts 105 forms a four-moving contact conductive operation, which can share a large current and ensure that the heat generation of continuous large current is low. In addition, since the most serious heat generation point of the DC contactor is the contact position of the moving and stationary contacts.

[0052] Preferably, the positioning component includes a U-shaped positioning frame 401, which has a mounting hole 402. The U-shaped positioning frame 401 is sleeved on the outside of the mounting rod 301 under the action of the mounting hole 402. The first movable contact piece 302 and the second movable contact piece 303 are located on the inside of the U-shaped positioning frame 401 and abut against each other. A nut 403 for pushing the sleeved U-shaped positioning frame 401 is threadedly connected to the mounting rod 301.

[0053] It should be noted here that: the U-shaped positioning bracket 401 is sleeved onto the mounting rod 301 from one end through the mounting hole 402. During the sleeved process, the U-shaped positioning bracket 401 positions the first movable contact piece 302 and the second movable contact piece 303 after connection, so as to prevent the first movable contact piece 302 and the second movable contact piece 303 from rotating radially.

[0054] Preferably, the elastic component includes a mounting sleeve 501 fixed to the outside of the mounting rod 301, a mounting ring 502 fixed to the outside of the mounting sleeve 501, a first spring 503 and a second spring 504 sleeved on the outside of the mounting rod 301, the first spring 503 being located inside the first circular hole 304, and the two ends of the first spring 503 abutting against the end of the second movable contact piece 303 and the mounting sleeve 501 respectively, and the second spring 504 being located outside the first spring 503, and the two ends of the second spring 504 abutting against the mounting ring 502 and the first movable contact piece 302 respectively;

[0055] It should be noted that after the U-shaped positioning bracket 401 is fitted and connected, the nut 403 is threaded onto the mounting rod 301 and abuts against the U-shaped positioning bracket 401. During the abutting process, the U-shaped positioning bracket 401 is pushed towards the connecting block 601. During the movement, the first spring 503 and the second spring 504 are compressed and deformed to generate elastic force. Through the elastic force of the first spring 503 and the second spring 504, the U-shaped positioning bracket 401, the first movable contact piece 302, and the second movable contact piece 303 are pushed into an abutting state. During the abutting process, the upper ends of the first movable contact piece 302 and the second movable contact piece 303 are in a flush state, completing the installation of the contact piece assembly. In addition, during the installation process, the U-shaped positioning bracket 401 is adjusted by the pushing action of the nut 403, so that the U-shaped positioning brackets 401 on the two sets of contact piece assemblies are flush, ensuring subsequent synchronous contact and synchronous separation.

[0056] Preferably, the pushing assembly includes a connecting block 601 disposed inside the operating cavity, two sets of contact assemblies are symmetrically arranged on the connecting block 601, the mounting rod 301 is detachably mounted on the connecting block 601 by means of threads, the partition 2 is provided with a connecting hole 602, a pushing shaft 603 is slidably connected to the connecting hole 602, one end of the pushing shaft 603 is fixed to the connecting block 601; the driving assembly includes a coil frame 701 fixed inside the driving cavity, a coil is wound on the outer side of the coil frame 701, a magnetic sleeve 702 is fixed on the inner side of the coil frame 701, a bushing 703 is fixed inside the magnetic sleeve 702, a moving iron core 704 is slidably connected to the inner side of the bushing 703, the pushing shaft 603 is detachably fixed to the moving iron core 704 by means of threads, a third spring 604 is sleeved on the outer side of the pushing shaft 603, and the two ends of the third spring 604 are respectively abutted against the partition 2 and the moving iron core 704;

[0057] It should be noted here that: when the coil on the coil frame 701 is energized, the energized coil generates electromagnetic attraction, which drives the moving iron core 704 to move upward along the axis of the bushing 703. During the movement, through the connecting action of the pushing shaft 603, the connecting block 601 and the two sets of contact plate assemblies on the connecting block 601 are driven to move towards the upper cover 102. During the movement of the moving iron core 704, the third spring 604 is deformed by force to generate elastic force. Through the elastic force of the third spring 604, it is easy to assist the subsequent reset of the moving iron core 704.

[0058] In addition, it should be noted that the coil frame 701, coil, magnetic sleeve 702, bushing 703 and moving iron core 704 are conventional technical components in this application, and their working principles and operation methods are well known technologies, so they will not be described in detail here.

[0059] The supporting components include a mounting ring 801, which is detachably mounted on the upper end of the partition 2 by means of threads. The mounting ring 801 is concentrically arranged with the push shaft 603. The inner side of the mounting ring 801 is connected to multiple sets of arc-shaped support plates 802 through a pressure component. The multiple sets of arc-shaped support plates 802 are arranged in a circular array. Arc-shaped grooves 803 are opened on the arc-shaped support plates 802. Balls are rotatably connected to the inner side of the arc-shaped grooves 803 through spherical grooves. Under the action of the pressure component, the balls in the arc-shaped grooves 803 of each set of arc-shaped support plates 802 abut against the outer side of the push shaft 603. The lower end of the arc-shaped support plate 802 is provided with an inclined surface 804 for abutting against the end of the push shaft 603 for transmission.

[0060] It should be noted that during the installation of partition 2, the push shaft 603 on the moving iron core 704 passes through the connecting hole 602 and is located inside the operating cavity. In addition, during the installation of partition 2, the front end of the push shaft 603 abuts against the inclined surface 804 of each set of arc-shaped support plates 802 on the inner side of the mounting ring 801 on partition 2. During the abutment process, the push shaft 603 pushes each set of arc-shaped support plates 802 to move away from each other and contract. After the push shaft 603 passes through each set of arc-shaped support plates 802, the pressure component pushes the balls of the arc grooves 803 on each set of arc-shaped support plates 802 to abut against the outer side of the push shaft 603, thus supporting the push shaft 603.

[0061] The pressure assembly includes multiple sets of sleeves 901 fixed inside the mounting ring 801. A slide rod 902 is slidably connected to the sleeve 901. One end of the slide rod 902 is fixed to the arc-shaped support plate 802. A pressure spring 903 is sleeved on the outside of the sleeve 901. The two ends of the pressure spring 903 are respectively abutted against the inside of the mounting ring 801 and the arc-shaped support plate 802.

[0062] It should be noted that: the multiple sets of sleeves 901 and slide rods 902 facilitate the movement guidance of the arc-shaped support plate 802 after being subjected to force, and the pressure spring 903 facilitates the elastic force action on the arc-shaped support plate 802 after movement.

[0063] Preferably, the cover 102 includes a cover body 1021 and an isolation cover 1022 fixed inside the cover body 1021. One end of the stationary contact 105 is located inside the isolation cover 1022. A sealing ring 1023 for sealing against the inner wall of the iron cup 101 is sleeved and fixed on the outer side of the cover body 1021.

[0064] It should be noted here that after the internal components of the iron cup 101 are installed, the top cover 102, which is pre-installed with the stationary contact 105, the positive copper busbar 103 and the negative copper busbar 104, is installed inside the iron cup 101. During the installation process, the top cover 102 is pushed toward the inside of the iron cup 101. During the pushing process, the isolation cover 1022 abuts against the partition 2. In addition, during the pushing process of the top cover 102 toward the inside of the iron cup 101, the sealing ring 1023 on the outside of the cover 1021 abuts against the inside of the iron cup 101. At this time, an annular cavity is formed between the inner wall of the iron cup 101, the sealing ring 1023 and the outside of the cover 1021. The external epoxy resin is injected into this position to seal the iron cup 101 and the top cover 102 after installation.

[0065] Additionally, it is worth noting that the sealing ring 1023 is supported by a flexible material. The working principle and operation of the sealing ring 1023, a conventional sealing component, will not be elaborated on here.

[0066] The arc extinguishing assembly is located inside the isolation cover 1022. The arc extinguishing assembly includes a first frame 1001 and a second frame 1002 located on both sides of the stationary contact 105. A magnet is placed inside the first frame 1001 and the second frame 1002. The first frame 1001 and the second frame 1002 are fixed inside the isolation cover 1022. A ceramic arc extinguishing plate 1003 is arranged between the first frame 1001 and the second frame 1002. The ceramic arc extinguishing plate 1003 is installed inside the isolation cover 1022. An isolation frame 1004 is fixed between two adjacent sets of stationary contacts 105. The interior of the isolation frame 1004 is filled with epoxy resin.

[0067] It should be noted here that when the contactor interrupts a large current, the magnetic field generated by the magnets inside the first frame 1001 and the second frame 1002 will exert an electromagnetic force on the DC arc ignited at the contact, quickly "blowing" the arc towards the ceramic arc extinguishing plate 1003 area, lengthening and cooling the arc, accelerating the arc extinguishing, and preventing the arc from burning the contact plate or causing a phase-to-phase short circuit. The isolation frame 1004 and the epoxy resin inside the isolation frame 1004 play an insulating role, preventing creepage and leakage under high voltage.

[0068] In addition, the working principle and installation method of the magnet, ceramic arc extinguishing plate 1003 and epoxy resin are conventional components for arc extinguishing, and will not be described in detail here.

[0069] In this solution, the working principle of a single high-current DC contactor with four moving contacts includes the following steps:

[0070] When circuit connection is required, the coil on the coil holder 701 is energized. The energized coil generates electromagnetic attraction, driving the moving iron core 704 to move upward along the axial direction of the bushing 703. During this movement, through the connecting action of the pushing shaft 603, the connecting block 601 and the two sets of contact assemblies on the connecting block 601 move towards the upper cover 102. During this movement, the first moving contact 302 and the second moving contact 303 on the contact assembly move towards the upper cover 102 and abut against the two sets of stationary contacts 105 on the positive copper busbar 103 and the negative copper busbar 104 (see...). Figure 12 In the state of contact, the conductive path is connected through the conductive action of the first moving contact 302 and the second moving contact 303. During the contact conduction process, the first moving contact 302 and the second moving contact 303 on the two sets of contact assemblies abut against the two sets of stationary contacts 105, forming a four-moving-contact conductive operation. This can share a large current and ensure low heat generation when continuously carrying a large current. In addition, since the most serious heat generation point of the DC contactor is the contact position of the moving and stationary contacts, the present invention forms four sets of point contacts through four moving contacts. The four sets of contact points are equivalent to parallel connection, resulting in extremely low total internal resistance and a significant reduction in heat generation, which is convenient for large-scale contact. For stable use of the DC contactor, after the DC contactor is used, the energization of the coil is disconnected. Through the elastic force of the third spring 604, the moving iron core 704, the connecting block 601, and the two sets of contact assemblies are reset. During the reset process, the first moving contact 302 and the second moving contact 303 on the two sets of contact assemblies are synchronously disconnected from the two sets of stationary contacts 105. Before disconnection, the four moving contacts share a large current, such as 2000A, which is divided into 500A. At the moment of disconnection, the four points are disconnected synchronously, reducing the risk that the last contactor to disconnect will bear the entire voltage and disconnection current, avoiding disconnection failure and ensuring disconnection life.

[0071] During the process of driving the push shaft 603 to move the two sets of contact assemblies, the elastic force of the pressure spring 903 on the pressure assembly causes the balls on the inner side of the arc groove 803 on the arc support plate 802 to abut against the push shaft 603. During the abutting process, the rotation of the balls and the abutting action can assist the normal driving movement of the push shaft 603 and provide radial compression support, preventing the push shaft 603 from tilting or wobbling due to the existence of gaps during electromagnetic transmission. This ensures that the two sets of contact assemblies on the front connecting block 601 of the push shaft 603 remain flush, further ensuring the simultaneous contact and separation of the subsequent four sets of contact points.

[0072] Example 2: In this solution: a method for manufacturing a single high-current DC contactor with four moving contacts, including the following steps:

[0073] S1: The magnetic sleeve 702, the coil frame 701 with the coil wound on it, the bushing 703 and the moving iron core 704 are sequentially installed inside the iron cup 101. During the installation process, the magnetic sleeve 702 is sleeved on the inner side of the coil frame 701, the bushing 703 is fixed on the inner side of the magnetic sleeve 702, and the moving iron core 704 is slidably connected to the inner side of the bushing 703. During the installation of the moving iron core 704, a push shaft 603 is pre-installed on the moving iron core 704 and a third spring 604 is sleeved on the push shaft 603.

[0074] S2: The partition 2 is installed inside the iron cup 101 by means of threads. The partition 2 divides the iron cup 101 into a driving cavity and an operating cavity. During the installation of the partition 2, the push shaft 603 on the moving iron core 704 passes through the connecting hole 602 and is located inside the operating cavity. In addition, during the installation of the partition 2, the front end of the push shaft 603 abuts against the inclined surface 804 of each set of arc-shaped support plates 802 on the inner side of the mounting ring 801 on the partition 2. During the abutting process, the push shaft 603 pushes each set of arc-shaped support plates 802 to move away from each other and contract. After the push shaft 603 passes through each set of arc-shaped support plates 802, the pressure component pushes the balls of the arc grooves 803 on each set of arc-shaped support plates 802 to abut against the outer side of the push shaft 603 to support the push shaft 603.

[0075] S3: After the partition plate 2 is installed, the connecting block 601 is installed on the push shaft 603. After the connecting block 601 is installed, the two sets of contact plate assemblies are symmetrically installed on the connecting block 601 in sequence. During the installation process, one end of the mounting rod 301 is installed on the connecting block 601 by means of a thread. During the installation process, the bottom of the mounting ring 502 is made to abut against the upper end of the connecting block 601 to assist in the positioning of the mounting rod 301 during the installation process (see...). Figure 9 );

[0076] S4: After the mounting rod 301 is installed, the first spring 503 and the second spring 504 are sleeved on the outside of the mounting rod 301. After the sleeves are sleeved, the second movable contact 303 and the first movable contact 302 are sleeved on the mounting rod 301 from the other end through the second round hole 305 and the first round hole 304. After the sleeves are sleeved, the U-shaped positioning frame 401 is sleeved on the mounting rod 301 through the mounting hole 402. During the sleeve process, the second movable contact 303 and the first movable contact 302 are located inside the U-shaped positioning frame 401. The U-shaped positioning frame 401 is used to position the sleeved and connected second movable contact 303 and first movable contact 302.

[0077] S5: After the U-shaped positioning bracket 401 is fitted and connected, the nut 403 is threaded onto the mounting rod 301 and abuts against the U-shaped positioning bracket 401. During the abutting process, the U-shaped positioning bracket 401 is pushed toward the connecting block 601. During the movement, the first spring 503 and the second spring 504 are compressed and deformed to generate elastic force. Through the elastic force of the first spring 503 and the second spring 504, the U-shaped positioning bracket 401, the first movable contact piece 302 and the second movable contact piece 303 are pushed into an abutting state. During the abutting process, the upper ends of the first movable contact piece 302 and the second movable contact piece 303 are in a flush state, completing the installation of the contact piece assembly. In addition, during the installation process, the position of the U-shaped positioning bracket 401 is adjusted by the pushing action of the nut 403 on the U-shaped positioning bracket 401, so that the U-shaped positioning brackets 401 on the two sets of contact piece assemblies are flush, ensuring subsequent synchronous contact and synchronous separation.

[0078] S6: After the internal components of the iron cup 101 are installed, the top cover 102, which is pre-installed with the static contact 105, the positive copper busbar 103 and the negative copper busbar 104, is installed. During the installation process, the ceramic arc extinguishing plate 1003 and the magnet are installed in the designated positions inside the isolation cover 1022 in sequence, and epoxy resin is filled inside the isolation frame 1004 to complete the installation of the top cover 102.

[0079] S7: After the upper cover 102 is installed, install the upper cover 102 inside the iron cup 101. During the installation process, push the upper cover 102 toward the inside of the iron cup 101. During the pushing process, make the isolation cover 1022 abut against the partition 2 (see...). Figure 10 In addition, during the process of pushing the upper cover 102 toward the inside of the iron cup 101, the sealing ring 1023 on the outside of the cover 1021 abuts against the inside of the iron cup 101. At this time, an annular cavity is formed between the inner wall of the iron cup 101, the sealing ring 1023 and the outside of the cover 1021. The external epoxy glue is injected into this position to seal the iron cup 101 and the upper cover 102 after installation, thus completing the preparation and installation of the single high-current DC contactor with four moving contacts.

[0080] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0081] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A single-unit high-current DC contactor with four moving contacts, comprising: Iron cup (101) and top cover (102), with a positive copper busbar (103) and a negative copper busbar (104) provided on the top cover (102), and a static contact (105) provided on the top cover (102) for electrical connection with the positive copper busbar (103) and the negative copper busbar (104). Its characteristic is that it further includes: A partition (2) is provided inside the iron cup (101). The partition (2) is detachably connected to the iron cup (101) by means of threads. The interior of the iron cup (101) is divided by the partition (2) to form a driving cavity and an operating cavity. The driving cavity is located below the operating cavity. The contact assembly is located inside the operating cavity for conducting the circuit. The stationary contacts (105) are evenly distributed in four sets on the upper cover (102). The two adjacent sets of stationary contacts (105) are electrically connected to the positive copper busbar (103) and the negative copper busbar (104) respectively. The contact assembly is symmetrically arranged in two sets inside the operating cavity. The contact assembly is provided with a first moving contact (302) and a second moving contact (303) for contacting the two sets of stationary contacts (105) on the positive copper busbar (103) or the negative copper busbar (104). The operating cavity is provided with a spring force assembly for spring force pushing the first moving contact (302) and the second moving contact (303). The upper cover (102) is provided with an arc extinguishing assembly for extinguishing the arc during operation. In addition, a pushing component for pushing the contact assembly is disposed between the driving cavity and the operating cavity, the driving cavity is provided with a driving component for driving the pushing component, and the partition (2) is provided with a support component for auxiliary support during the transmission of the pushing component; The contact assembly further includes a mounting rod (301), the first movable contact (302) is U-shaped, the second movable contact (303) is strip-shaped, and the second movable contact (303) is attached to the top of the first movable contact (302). The mounting rod (301) is provided with a positioning component for positioning the first movable contact (302) and the second movable contact (303). The positioning component includes a U-shaped positioning frame (401), which has a mounting hole (402). The U-shaped positioning frame (401) is sleeved on the outside of the mounting rod (301) under the action of the mounting hole (402). The first movable contact piece (302) and the second movable contact piece (303) are located on the inside of the U-shaped positioning frame (401) and abut against each other. A nut (403) for pushing the sleeved U-shaped positioning frame (401) is threaded on the mounting rod (301).

2. A single high-current DC contactor with four moving contacts according to claim 1, characterized in that: The first movable contact (302) and the second movable contact (303) are respectively provided with a first circular hole (304) and a second circular hole (305). The diameter of the first circular hole (304) is larger than the diameter of the second circular hole (305). The first movable contact (302) and the second movable contact (303) are respectively sleeved on the mounting rod (301) under the action of the first circular hole (304) and the second circular hole (305).

3. A single high-current DC contactor with four moving contacts according to claim 2, characterized in that: The elastic component includes a mounting sleeve (501) fixed to the outside of the mounting rod (301). A mounting ring (502) is fixed to the outside of the mounting sleeve (501). A first spring (503) and a second spring (504) are sleeved on the outside of the mounting rod (301). The first spring (503) is located inside the first circular hole (304), and the two ends of the first spring (503) abut against the ends of the second movable contact piece (303) and the mounting sleeve (501), respectively. The second spring (504) is located outside the first spring (503), and the two ends of the second spring (504) abut against the mounting ring (502) and the first movable contact piece (302), respectively.

4. A single high-current DC contactor with four moving contacts according to claim 3, characterized in that: The pushing component includes a connecting block (601) disposed inside the operating cavity. Two sets of the contact assemblies are symmetrically arranged on the connecting block (601). The mounting rod (301) is detachably installed on the connecting block (601) by means of threads. The partition plate (2) is provided with a connecting hole (602). A pushing shaft (603) is slidably connected to the connecting hole (602). One end of the pushing shaft (603) is fixed to the connecting block (601).

5. A single high-current DC contactor with four moving contacts according to claim 4, characterized in that: The drive assembly includes a coil frame (701) fixed inside the drive cavity. A coil is wound on the outer side of the coil frame (701). A magnetic sleeve (702) is fixed on the inner side of the coil frame (701). A bushing (703) is fixed inside the magnetic sleeve (702). A moving iron core (704) is slidably connected to the inner side of the bushing (703). The push shaft (603) is detached and fixed to the moving iron core (704) by means of threads. A third spring (604) is sleeved on the outer side of the push shaft (603). The two ends of the third spring (604) are respectively abutted against the partition plate (2) and the moving iron core (704).

6. A single high-current DC contactor with four moving contacts according to claim 5, characterized in that: The support assembly includes a mounting ring (801), which is detachably mounted on the upper end of the partition (2) by means of threads. The mounting ring (801) is concentrically arranged with the push shaft (603). The inner side of the mounting ring (801) is connected to multiple sets of arc-shaped support plates (802) through a pressure assembly. The multiple sets of arc-shaped support plates (802) are arranged in a ring array. The arc-shaped support plates (802) are provided with arc-shaped grooves (803). The inner side of the arc-shaped grooves (803) is rotatably connected with balls through spherical grooves. The balls in the arc-shaped grooves (803) of each set of arc-shaped support plates (802) abut against the outer side of the push shaft (603) under the action of the pressure assembly. The lower end of the arc-shaped support plate (802) is provided with an inclined surface (804) for abutting against the end of the push shaft (603) for transmission.

7. A single high-current DC contactor with four moving contacts according to claim 6, characterized in that: The pressure assembly includes multiple sets of sleeves (901) fixed inside the mounting ring (801). A slide rod (902) is slidably connected to the sleeve (901). One end of the slide rod (902) is fixed to the arc-shaped support plate (802). A pressure spring (903) is sleeved on the outside of the sleeve (901). The two ends of the pressure spring (903) are respectively abutted against the inside of the mounting ring (801) and the arc-shaped support plate (802).

8. A single high-current DC contactor with four moving contacts according to claim 7, characterized in that: The upper cover (102) includes a cover body (1021) and an isolation cover (1022) fixed inside the cover body (1021). One end of the static contact (105) is inside the isolation cover (1022). A sealing ring (1023) for sealing against the inner wall of the iron cup (101) is sleeved and fixed on the outside of the cover body (1021). The arc extinguishing assembly is disposed inside the isolation cover (1022). The arc extinguishing assembly includes a first frame (1001) and a second frame (1002) disposed on both sides of the stationary contact (105). A magnet is placed inside the first frame (1001) and the second frame (1002). The first frame (1001) and the second frame (1002) are fixed inside the isolation cover (1022). A ceramic arc extinguishing plate (1003) is disposed between the first frame (1001) and the second frame (1002). The ceramic arc extinguishing plate (1003) is installed inside the isolation cover (1022). An isolation frame (1004) is fixed between two adjacent sets of stationary contacts (105). The isolation frame (1004) is filled with epoxy resin.

9. A method for manufacturing a single high-current DC contactor with four moving contacts as described in claim 8, characterized in that, Includes the following steps: S1: The magnetic sleeve (702), the coil frame (701) with the coil wound on it, the bushing (703) and the moving iron core (704) are installed in sequence inside the iron cup (101). During the installation process, the magnetic sleeve (702) is sleeved on the inner side of the coil frame (701), the bushing (703) is fixed on the inner side of the magnetic sleeve (702), and the moving iron core (704) is slidably connected to the inner side of the bushing (703). During the installation of the moving iron core (704), a push shaft (603) is pre-installed on the moving iron core (704) and a third spring (604) is sleeved on the push shaft (603). S2: Install the partition (2) inside the iron cup (101) by means of thread. The partition (2) divides the iron cup (101) into a driving cavity and an operating cavity. During the installation of the partition (2), the push shaft (603) on the moving iron core (704) passes through the connecting hole (602) and is located inside the operating cavity. In addition, during the installation of the partition (2), the front end of the push shaft (603) abuts against the inclined surface (804) of each set of arc support plates (802) on the inner side of the mounting ring (801) on the partition (2). During the abutting process, the arc support plates (802) are pushed to move away from each other and contract. After the push shaft (603) passes through each set of arc support plates (802), the pressure component pushes the balls of the arc groove (803) on each set of arc support plates (802) to abut against the outer side of the push shaft (603) to support the push shaft (603). S3: After the partition (2) is installed, the connecting block (601) is installed on the push shaft (603). After the connecting block (601) is installed, the two sets of contact plate assemblies are symmetrically installed on the connecting block (601) in sequence. During the installation process, one end of the mounting rod (301) is installed on the connecting block (601) by means of thread. During the installation process, the bottom of the mounting ring (502) is made to abut against the upper end of the connecting block (601) to assist in the positioning of the mounting rod (301) during the installation process. S4: After the mounting rod (301) is installed, the first spring (503) and the second spring (504) are sleeved on the outside of the mounting rod (301). After the sleeve is completed, the second movable contact piece (303) and the first movable contact piece (302) are sleeved on the mounting rod (301) from the other end through the second round hole (305) and the first round hole (304). After the sleeve is completed, the U-shaped positioning frame (401) is sleeved on the mounting rod (301) through the mounting hole (402). During the sleeve process, the second movable contact piece (303) and the first movable contact piece (302) are located inside the U-shaped positioning frame (401). The U-shaped positioning frame (401) is used to position the sleeved and connected second movable contact piece (303) and first movable contact piece (302). S5: After the U-shaped positioning bracket (401) is fitted and connected, the nut (403) is threaded onto the mounting rod (301) and abuts against the U-shaped positioning bracket (401). During the abutment process, the U-shaped positioning bracket (401) is pushed towards the connecting block (601). During the movement, the first spring (503) and the second spring (504) are compressed and deformed to generate elastic force. Through the elastic force of the first spring (503) and the second spring (504), the U-shaped positioning bracket (401) and the first moving contact are pushed. The first movable contact piece (302) and the second movable contact piece (303) are in abutting state. During the abutting process, the upper ends of the first movable contact piece (302) and the second movable contact piece (303) are in a flush state, thus completing the installation of the contact piece assembly. In addition, during the installation process, the U-shaped positioning frame (401) is adjusted by the pushing action of the nut (403) on the U-shaped positioning frame (401), so that the U-shaped positioning frames (401) on the two sets of contact piece assemblies are flush, ensuring subsequent synchronous contact and synchronous separation. S6: After the internal components of the iron cup (101) are installed, the top cover (102) pre-installed with the static contact (105), positive copper busbar (103) and negative copper busbar (104) is installed. During the installation process, the ceramic arc extinguishing plate (1003) and the magnet are installed in the designated positions inside the isolation cover (1022) in sequence, and epoxy resin is filled inside the isolation frame (1004) to complete the installation of the top cover (102). S7: After the top cover (102) is installed, the top cover (102) is installed inside the iron cup (101). During the installation process, the top cover (102) is pushed towards the inside of the iron cup (101). During the pushing process, the isolation cover (1022) abuts against the partition (2). In addition, during the pushing process of the top cover (102) towards the inside of the iron cup (101), the sealing ring (1023) on the outside of the cover body (1021) abuts against the inside of the iron cup (101). At this time, an annular cavity is formed between the inner wall of the iron cup (101), the sealing ring (1023) and the outside of the cover body (1021). The external epoxy glue is injected into this position to seal the iron cup (101) and the top cover (102) after installation, thus completing the preparation and installation of the single high-current DC contactor with four moving contact pieces.

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