A dual contactor module with built-in mechanical interlock and status feedback

Abstract

The application discloses a kind of built-in mechanical interlock and state feedback double contactor module, the module includes basic shell, two contactor installation cabins and an interlock mechanism cavity are equipped in shell;First contactor unit and second contactor unit are respectively installed in contactor installation cabin, and its moving iron core extends to interlock mechanism cavity and is equipped with lock hole;Mechanical interlock mechanism is housed in interlock mechanism cavity, including rotating buckle arm, pivot, interlock slider and bidirectional torsion spring, and rotating buckle arm is rotated by driving interlock slider with moving iron core;State feedback system includes linear hall position sensor, state coding disc, photoelectric sensor, intelligent processing unit and communication interface, and data fusion and trend analysis are carried out by intelligent processing unit, realize fault early warning and maintenance.The application solves the problems of existing interlock mechanism, such as external bulky, complex installation, poor reliability and single state feedback, and has the advantages of compact structure, reliable interlock, intelligent diagnosis and the like.

Description

Technical Field

[0001] This invention belongs to the field of low-voltage electrical appliances and industrial automation control technology, specifically relating to a dual contactor module with built-in mechanical interlock and status feedback. Background Technology

[0002] In industrial control systems, for safety and equipment protection purposes, it is often necessary to ensure that two electrical circuits are not connected simultaneously to prevent power short circuits, equipment malfunctions, or even damage. Typical applications include, but are not limited to: forward and reverse control of three-phase asynchronous motors, dual power supply switching systems, and star-delta reduced-voltage starting of motors.

[0003] To achieve the interlocking functionality described above, existing technologies mainly employ the following solutions, but each has its own inherent drawbacks: 1. Pure electrical interlocking scheme: This is the most traditional and widely used solution. Its principle is to connect the normally closed auxiliary contact of contactor A in series with the coil circuit of contactor B, and simultaneously connect the normally closed auxiliary contact of contactor B in series with the coil circuit of contactor A. In this way, when A is energized, its normally closed contact opens, cutting off the circuit to the B coil and preventing B from energizing.

[0004] Inherent defects: Its interlocking function relies entirely on the reliability of the auxiliary contacts. In situations of frequent operation, heavy load, or short-circuit risk, the main or auxiliary contacts may weld together due to excessive arcing, meaning the moving and stationary contacts become stuck and cannot be separated. In this case, even if the coil is de-energized, the normally closed auxiliary contacts may reset, providing a path for the other contactor to engage, causing complete interlocking failure and catastrophic consequences. Lack of fault diagnosis capability: The control system cannot determine whether the main contacts have welded through the auxiliary contacts and can only passively wait for a short-circuit accident to occur.

[0005] 2. External additional mechanical interlock scheme: To compensate for the shortcomings of electrical interlocking, external mechanical interlocking devices have emerged. For example, prior art document CN109585196B (Permanent Magnet Type Combined Contactor Interlocking Mechanism) discloses a scheme that includes a separate interlocking mounting plate, an interlocking support fixed thereon, and a connecting rod rotatably connected to the support via a pin. The two ends of the connecting rod are positioned below the armatures of two contactors. When one contactor engages, its armature presses down one end of the connecting rod, causing the other end to lift and preventing the armature of the other contactor from moving.

[0006] However, the entire interlocking mechanism (mounting plate, support column, connecting rod) is an "external" structure attached to the two independent contactors. This results in a large overall size of the device, occupying valuable control cabinet installation space and hindering the miniaturization and compact design of the equipment.

[0007] Furthermore, the two contactors need to be precisely installed on the interlock mounting plate, and the gap between the connecting rod and the armature needs to be adjusted. The installation process is cumbersome and requires a high level of skill from the workers. During transportation and use, long-term vibration may cause the fixing screws to loosen and the connecting rod to shift, thereby affecting the reliability of the interlock.

[0008] Meanwhile, this type of lever-type interlock relies on the friction of one end being raised to block the other contactor, which limits its impact resistance and capability. Although this solution incorporates electrical interlocking, its status feedback still relies solely on traditional auxiliary contacts, and therefore cannot diagnose core faults such as contact welding.

[0009] 3. Limitations of condition monitoring: The status feedback of existing contactors, whether standalone or combined, provides very limited information. It typically only offers basic information such as "whether the coil is energized" (via auxiliary contacts) and "whether the main circuit is continuous" (via signal contacts after the main contacts). This information cannot reflect the health status of the contactor itself.

[0010] In conclusion, it is essential to design a product that combines reliable mechanical interlocks and comprehensive intelligent condition diagnostics within a compact, standardized form factor, thereby fundamentally improving the system's safety, reliability, and maintainability. Summary of the Invention

[0011] This invention provides a dual contactor module with built-in mechanical interlock and status feedback to solve problems in existing technologies, such as bulky external interlock mechanisms, reliability affected by installation, and single status feedback that hinders intelligent diagnostics. This invention aims to provide a safe, compact, and intelligent ultimate solution through an integrated structural design and a multi-source information fusion intelligent diagnostic strategy.

[0012] To achieve the above objectives, the present invention provides the following technical solution: a dual contactor module with built-in mechanical interlock and status feedback, comprising: A basic housing having two mounting compartments arranged side-by-side inside for accommodating contactor units, and an interlocking mechanism cavity located between the two mounting compartments; A first contactor unit and a second contactor unit are respectively housed in the two mounting compartments. The driving ends of the moving iron cores of the first contactor unit and the second contactor unit extend into the interlocking mechanism cavity and are provided with lock holes at their ends. A mechanical interlock assembly disposed within the interlock mechanism cavity, the mechanical interlock assembly being linked to the two moving iron cores and configured such that: when one of the moving iron cores moves toward the engaging position, the mechanical interlock assembly is driven to actuate, thereby physically preventing the other moving iron core from moving toward its engaging position; And a status feedback system, which includes a sensing unit, an intelligent processing unit and a communication interface disposed on the base housing. The sensing unit is used to detect the position information of the moving iron core and the motion status information of the mechanical interlock assembly. The intelligent processing unit is electrically connected to the sensing unit and the communication interface, and is used to process the information of the sensing unit and realize status monitoring and fault early warning.

[0013] As a further improvement of the present invention, the mechanical interlock assembly includes: A rotating latch arm is rotatably disposed within the interlocking mechanism cavity, the axis of rotation of which is parallel to the mounting plane of the base housing; An interlocking slider is slidably disposed within the interlocking mechanism cavity, and its sliding direction is consistent with the arrangement direction of the two moving iron cores; The interlocking slider is connected to the middle of the rotating buckle arm via a transmission, and the two ends of the interlocking slider are selectively engaged with the driving ends of the two moving iron cores respectively. When any of the moving iron cores moves toward the engaging position, it pushes the interlocking slider to slide, and then drives the rotating latch arm to rotate around its rotation axis through the transmission connection, so that one end of the rotating latch arm is engaged in the locking hole of the other moving iron core.

[0014] As a further improvement of the present invention, the two ends of the rotating buckle arm are provided with irregular buckle parts, the ends of the irregular buckle parts are provided with guide slopes, and the roots are provided with vertical locking surfaces; correspondingly, the lock hole is an elongated hole, the length direction of which is consistent with the sliding direction of the interlocking slider, and the width direction of which is consistent with the movement direction of the moving iron core; when the irregular buckle part is engaged in the lock hole, the vertical locking surface and the hole wall of the lock hole in the movement direction of the moving iron core form a surface contact mechanical block.

[0015] As a further improvement of the present invention, the transmission connection between the interlocking slider and the rotating buckle arm is a linkage-sleeve structure, specifically including: A round rod fixed to the middle of the interlocking slider, the axis of the round rod being perpendicular to the sliding direction of the interlocking slider; A sleeve fixed to the middle of the bottom surface of the rotating buckle arm, the sleeve being slidably fitted onto the outside of the round rod; When the interlocking slider slides, the cooperation between the round rod and the sleeve converts the horizontal sliding into a rotational drive for the rotating buckle arm.

[0016] As a further improvement of the present invention, inclined driving heads are provided at the upper parts of both ends of the interlocking slider, and the front end face of the inclined driving head is a steep inclined surface facing the outer side of the end of the interlocking slider; when the moving iron core moves to the suction position, its driving end contacts and slides with the steep inclined surface of the corresponding inclined driving head, thereby pushing the interlocking slider to move.

[0017] As a further improvement of the present invention, the mechanical interlock assembly further includes a bidirectional torsion spring, which is fitted on the rotating shaft of the rotating latch arm, with its two ends respectively fixed to the inner wall of the interlock mechanism cavity and the rotating latch arm; the bidirectional torsion spring is configured to: store potential energy and buffer impact when the moving iron core drives the rotating latch arm to rotate, and provide restoring force to reset the rotating latch arm to a neutral horizontal position after the moving iron core is released.

[0018] As a further improvement of the present invention, the sensing unit of the state feedback system includes an angle encoding component for detecting the motion state of the mechanical interlock assembly, the angle encoding component comprising: A status code disk is coaxially fixed to the rotating shaft, and its surface is provided with periodic optical markings; A photoelectric sensor fixed inside the interlocking mechanism cavity and positioned opposite the status encoding disk; The photoelectric sensor is used to identify changes in the optical markings of the status code disk when the rotating buckle arm rotates, and transmits the signal to the intelligent processing unit to calculate the rotation angle and angular velocity of the rotating buckle arm.

[0019] As a further improvement of the present invention, the sensing unit of the state feedback system includes a position sensing component for detecting the position information of the moving iron core, the position sensing component including: Multiple sets of linear Hall position sensors are respectively installed on the inner sidewalls of the two installation compartments; Permanent magnets are respectively disposed on the sides of the two moving iron cores and facing the linear Hall position sensor; The multiple sets of linear Hall position sensors are arranged at intervals along the motion axis of the moving iron core, and are used to output a voltage signal that is proportional to the absolute position of the moving iron core, and to obtain its motion speed by calculating the time difference between the moving iron core and the fixed sensor.

[0020] As a further improvement of the present invention, the intelligent processing unit is installed in a metal shielded compartment located at the bottom of the base housing. The communication interface is an industrial standard interface, with its female connector embedded and fixed to the side of the base housing and connected to the intelligent processing unit through internal wiring.

[0021] As a further improvement of the present invention, the base shell is integrally injection molded from engineering plastic, and its front is provided with observation windows corresponding to the two installation compartments. The interlocking mechanism cavity is a sealed dustproof chamber isolated from the upper and lower layers.

[0022] Compared with the prior art, the beneficial effects of the present invention are: 1. By integrating the mechanical interlock mechanism and the status feedback system into the same basic housing, the bulky structure and complex installation of external interlock mechanisms are avoided, significantly improving the overall integrity and installation efficiency of the module.

[0023] 2. A rigid blocking mechanism is adopted, which combines a rotating buckle arm with a lock hole, and a bidirectional torsion spring to buffer the impact, ensuring that the two contactors cannot be engaged at the same time under any circumstances, thus fundamentally eliminating the risk of power short circuit.

[0024] 3. By fusing multiple sensors such as Hall position sensors and photoelectric encoders, parameters such as the position of the moving iron core, interlock status, and movement speed can be monitored in real time, thus upgrading from condition monitoring to health prediction.

[0025] 4. The intelligent processing unit performs trend analysis based on sensor data, which can identify potential faults such as mechanical wear, spring fatigue, and electromagnetic performance degradation in advance, supporting predictive maintenance and reducing the risk of unplanned downtime.

[0026] 5. Sensor signals are isolated by a metal shielding chamber, and the communication interface adopts the industrial standard M12 / M8 interface to ensure stable operation even in environments with strong electromagnetic interference.

[0027] 6. Key moving parts such as the interlocking slider are made of self-lubricating POM material, and the rotating buckle arm is strengthened by heat treatment. The overall structure is wear-resistant and impact-resistant, suitable for high-frequency operation, and significantly extends service life. Attached Figure Description

[0028] Figure 1 This is a front-view external three-dimensional schematic diagram of an embodiment of the present invention.

[0029] Figure 2 This is a top view of the second contactor unit locking structure according to an embodiment of the present invention.

[0030] Figure 3 yes Figure 2 A magnified structural diagram at point A.

[0031] Figure 4 This is a top view schematic diagram of the interlocking slider and inclined plane drive head according to an embodiment of the present invention.

[0032] Figure 5 This is a schematic diagram of the bidirectional torsion spring structure according to an embodiment of the present invention.

[0033] Figure 6 This is a schematic diagram of the state pre-indication mechanism according to an embodiment of the present invention.

[0034] Figure 7 This is a schematic diagram of the state feedback system structure according to an embodiment of the present invention.

[0035] In the diagram: 1-Basic housing, 11-Contactor mounting compartment, 12-Interlock mechanism cavity, 13-Slide rail; 2-First contactor unit, 21-First moving iron core, 22-First locking hole; 3-Second contactor unit, 31-Second moving iron core, 32-Second locking hole; 4-Mechanical interlock mechanism, 41-Rotating latch arm, 42-Rotating shaft, 44-Interlock slider, 441-Inclined drive head, 45-Bidirectional torsion spring; 5-Status code disk; 6-Photoelectric sensor; 51-First side position sensor; 61-Second side position sensor; 7-Intelligent processing unit; 8-Communication interface. Detailed Implementation

[0036] 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.

[0037] As attached Figures 1-3 As shown, the present invention provides a dual contactor module with built-in mechanical interlock and status feedback, comprising: Basic shell 1 The base housing 1 is an engineering plastic housing with a rectangular structure. Two observation windows made of transparent polycarbonate are located on the front of the housing for direct observation of the contactor unit's open / close indicators. The housing is made of V0 grade PBT (polybutylene terephthalate) material and is formed using a hot runner precision injection molding process. This material selection ensures that the housing possesses excellent mechanical strength, high-temperature resistance, and superior electrical insulation properties.

[0038] Contactor mounting compartment 11: It consists of two completely symmetrical rectangular cavities, used to install the first contactor unit 2 and the second contactor unit 3 respectively.

[0039] Interlocking mechanism cavity 12: It is a sealed, flat chamber isolated from the upper and lower layers, located slightly below the two contactor mounting compartments. The top of the chamber is the base plate of the contactor unit, and the bottom is the lower cover of the housing. They are pressed together by a sealing ring to form an independent space that is protected from dust and arc contamination.

[0040] The lower ends of the first moving iron core 21 and the second moving iron core 31 of the first contactor unit 2 and the second contactor unit 3 respectively extend into the interlocking mechanism cavity 12. The bottom plate of the contactor unit is provided with grooves for the first moving iron core 21 and the second moving iron core 31 to move back and forth. The two grooves are parallel to ensure the precise and interference-free operation of the subsequent interlocking mechanism.

[0041] Slide rail 13: Its cross-section is "T" shaped. It forms a precise sliding pair with the "T" shaped guide rail groove at the bottom of the interlocking slider 44, with a precise and smooth fit. Specifically, the interlocking slider 44 can only move left and right along the slide rail 13. This structure effectively prevents the slider from tilting or disengaging during movement, ensuring that the force transmission is always within the designed plane.

[0042] Rotary shaft support: The conventional mechanism is not shown in the figure. It is a bearing seat structure integrally set on the inner wall of the front and rear sides of the interlocking mechanism cavity 12. This structure rigidly connects the two side walls, which greatly improves the torsional stiffness of the area and ensures that the rotating shaft 42 between the rotating shaft support seats maintains low friction and noiseless rotation during long-term operation. It also ensures that the rotating buckle arm 41 fixedly connected to the rotating shaft 42 rotates smoothly without jamming.

[0043] Contactor unit (2, 3) The first contactor unit 2 and the second contactor unit 3 are standardized, modular electromagnetic contactors. They are flat and square in shape, and the shells are made of arc-resistant nylon 66 material.

[0044] As attached Figures 2-3 As shown, the bottom surfaces of the first moving iron core 21 and the second moving iron core 31, which are close to each other, are provided with lock holes, namely the first lock hole 22 and the second lock hole 32. The lock holes are the interfaces that directly interact with the interlocking mechanism.

[0045] Contactor units (2, 3) are equipped with stationary iron cores corresponding to the moving iron cores (21, 31). These stationary iron cores are "E"-shaped laminated structures with pole shoes, formed by stamping and riveting silicon steel sheets. The "E"-shaped structure and pole shoe design of the stationary iron cores optimize the magnetic circuit, reducing magnetic resistance and eddy current losses, resulting in smoother engagement characteristics and lower operating noise. The unit also includes a coil: it is a skeleton-wound coil, wound with heat-resistant enameled wire and wrapped with a composite insulating film. When energized, the moving iron core engages with the corresponding stationary iron core, simultaneously connecting the moving contact with the stationary contact, thus completing the corresponding electrical circuit. These structures are all conventional technologies and are not shown in the accompanying drawings.

[0046] Integrated built-in rotary snap-lock mechanical interlock mechanism 4 As attached Figure 1 , Figure 4 As shown, this mechanism is the core of the invention for achieving a highly reliable mechanical interlock. All its components are housed within the interlock mechanism cavity 12, including: Rotary latch arm 41: Its design resembles a seesaw-like lever, with a pivot hole in the middle and perfectly symmetrical "J"-shaped latching parts 411 at both ends. The body is made of chromium-molybdenum alloy steel to ensure extremely high dimensional consistency and uniform internal structure. Subsequent vacuum quenching and low-temperature tempering treatments are performed to eliminate internal stress and ensure the optimal balance between toughness and hardness.

[0047] The “J”-shaped locking part 411 is hook-shaped with a guide cone structure at the head end, which allows it to enter the lock hole quickly and without obstruction. It also includes a 90° vertical locking surface with a shot-peened surface, which forms a surface contact with the lock hole of the moving iron core, providing a rigid and insurmountable mechanical barrier. The first lock hole 22 and the second lock hole 32 are both elongated holes. In the length direction (i.e., the left-right direction), there is an outer clearance space reserved for the part of the locking part 411 that enters, so that the locking part 411 can swing in and out. In the width direction (i.e., the front-back direction), it is in contact with the outer wall of the locking part 411 after it enters, allowing for a gap of about 0.5 mm, thereby restricting the front-back movement of the moving iron core (21, 31).

[0048] Rotating shaft 42: This is a smooth shaft that engages with the rotating latch arm 41 and status code disk mounted on it to ensure synchronous rotation. The rotating shaft 42 has a D-shaped section approximately 3mm long in the middle, made of 420 stainless steel. The smooth shaft portion engages with a bushing to provide smooth rotation. The D-shaped section engages with the D-shaped hole of the rotating latch arm 41 mounted on it to restrict relative rotation. This fixing structure is conventional and is not shown in the accompanying drawings.

[0049] Interlocking slider 44: It is a long, narrow slider with inclined drive heads 441 at both ends. It is made of wear-resistant POM (polyoxymethylene) and precision-machined by CNC. Its low coefficient of friction and self-lubricating properties are key to achieving long-term maintenance-free operation.

[0050] Inclined drive head 441: The front end face is a steep slope, and the thickness gradually decreases towards the end of the interlock slider 44. When the interlock slider 44 is in its initial position, the moving iron core (21, 31) is located on the front side of the inclined drive head 441 near the direction of greater thickness (i.e., near the inclined drive head 441 near the middle of the interlock slider 44). This is used to quickly respond and cooperate with the sliding during the backward movement of the moving iron core, drive the rotating buckle arm 41 to rotate, and start the interlock action.

[0051] A round rod 442 is hinged to the middle of the interlocking slider 44. The round rod 442 can only swing left and right. A sleeve 443 that cooperates with the round rod 442 is provided in the middle of the bottom surface of the rotating buckle arm 41. The sleeve 443 is fitted on the outside of the round rod 442 and slides and extends and contracts. Its function is to drive the rotating buckle arm 41 to rotate synchronously through the cooperation of the round rod 442 and the sleeve 443 when the interlocking slider 44 slides left and right.

[0052] As attached Figure 5 As shown, the bidirectional torsion spring 45 is fitted on the rotating shaft 42, with its two ends fixedly connected to the inner wall of the interlocking mechanism cavity 12 and the side wall of the rotating latch arm 41 (e.g., fixedly connected to the rear inner wall of the interlocking mechanism cavity 12 and the rear side wall of the rotating latch arm 41). The connection method can be a conventional fixing method. For example, the inner wall of the interlocking mechanism cavity 12 and the side wall of the rotating latch arm 41 are provided with corresponding insertion holes at the ends of the bidirectional torsion spring. The two ends of the bidirectional torsion spring 45 are respectively inserted into the corresponding insertion holes for fixing. The specification is high-strength stainless steel. Its function is to absorb most of the impact kinetic energy when the moving iron core is attracted, convert it into the potential energy of the spring and release it slowly, which greatly reduces the instantaneous impact load on the interlocking mechanism and improves the mechanical life. At the same time, after the moving iron core (21, 31) and the stationary iron core are separated and reset, the bidirectional torsion spring 45 drives the rotating latch arm 41 to reset horizontally.

[0053] Work process: Rotation direction and engagement of the rotating latch arm 41: The rotating latch arm 41 can rotate around the pivot 42 in a vertical plane, and its rotation direction depends on which side of the moving iron core is driven. When the first moving iron core 21 is engaged, its rear part pushes the interlock slider 44 to move horizontally towards the second contactor unit. The interlock slider 44 drives the rotating latch arm 41 to rotate counterclockwise around the pivot 42 (viewed from the front of the module). At this time, the irregularly shaped latching part 411 at the left end of the rotating latch arm 41 rotates downward, while the irregularly shaped latching part 411 at the right end rotates upward, engaging in the second locking hole 32 of the second moving iron core 31, thereby physically locking the second moving iron core 31 and preventing it from moving backward to engage. Conversely, when the second moving iron core 31 is engaged, the interlock slider 44 moves towards the first contactor unit, driving the rotating latch arm 41 to rotate clockwise, and the left-end latching part engages in the first locking hole 22 of the first moving iron core 21.

[0054] As attached Figure 6 As shown, it also includes a status pre-indication mechanism: Status Encoding Disc 5: This small, black PBT plastic disc is laser-engraved with evenly spaced black and white stripes. These stripes form a precise angle encoder. In conjunction with a fixed photoelectric sensor, it can provide real-time feedback on the precise angular position of the rotating latch arm, thereby predicting the interlocking status (about to lock, already locked, about to release, already released). This provides the intelligent processing unit 7 with earlier and richer interlocking process information than traditional moving iron core position signals.

[0055] Photoelectric sensor 6: A surface-mount reflective photoelectric sensor (such as TCST2103) is selected, which is small in size and has an SMD package. It outputs a square wave signal by detecting the black and white changes on the surface of the encoder disk. By counting the number and frequency of the square wave pulses, the MCU can accurately calculate the rotation angle and angular velocity of the rotating latch arm 41, providing key data for mechanical performance trend analysis.

[0056] The coordination between the status code disk 5 and the photoelectric sensor 6: The status code disk 5 is coaxially fixed on the rotating shaft 42 and rotates synchronously with the shaft 42. The photoelectric sensor 6 is fixed on the side wall of the interlocking mechanism cavity 12, facing the status code disk 5. When the rotating latch arm 41 rotates, the black and white stripes on the status code disk 5 alternately pass through the photoelectric sensor 6, generating pulse signals. The intelligent processing unit 7 calculates the rotation angle and angular velocity of the rotating latch arm 41 in real time through pulse counting and frequency analysis, thereby predicting the interlocking state. The entire interlocking action precedes the closing of the main contacts, ensuring "interlock first, then conduction," providing high foresight in state perception and offering earlier decision-making basis and richer diagnostic information for the control system.

[0057] As attached Figure 7 As shown, it also includes a state feedback system. Including position sensors (51, 61) It employs a programmable linear Hall sensor (such as the TLV4906K), encapsulated in a dedicated PPS plastic housing with locating pins.

[0058] Two blind holes, precision-formed on the left and right walls of the contactor mounting compartment 11, form sensor mounting positions. Two position sensors on each side are pressed into the mounting blind holes on the side walls, namely the first side position sensor 51 and the second side position sensor 61, and are tightly fitted with the positioning holes at the bottom of the blind holes by positioning pins on their housings to prevent displacement. Conventional technology is not shown in the accompanying drawings.

[0059] The two position sensors on each side are precisely spaced along the axis of motion (i.e., the front-to-back direction) of the first moving iron core 21. The first position sensor is closer to the engaged position of the moving iron core, and the second position sensor is closer to the released position.

[0060] The sensor's sensing surface faces and is in close contact with the side of the moving iron core. A rectangular neodymium iron boron permanent magnet is embedded in this side, with its magnetization direction perpendicular to the sensor's sensing surface.

[0061] When the moving iron core moves, the magnet on its side and the sensor undergo relative displacement, causing a linear change in the magnetic field. The sensor outputs a voltage signal proportional to the absolute position of the moving iron core. The core purpose of the dual-sensor layout is to calculate the average speed of the moving iron core during this travel segment by measuring the time difference of the moving iron core traveling a fixed distance.

[0062] Each sensor's pins are soldered to a flexible printed circuit, which runs along an arc-shaped cable channel embedded in the housing, eventually converging and connecting to the PCB of the intelligent processing unit 7.

[0063] Intelligent processing unit 7 A four-layer PCB board (such as STM32F407) is preferred. This PCB board is installed in a separate metal shielded chamber. This shielded chamber is a recessed cavity at the bottom of the base housing 1, located directly below the interlocking mechanism cavity 12.

[0064] The metal shielding chamber is fixed to the housing with screws and covers the PCB board inside, forming a Faraday cage that effectively shields against external electromagnetic interference and prevents digital circuit noise from affecting sensitive analog sensor signals.

[0065] All of the aforementioned sensors are connected to specific interface sockets on the edge of the main PCB board via FPC or wires. Power and communication interfaces are connected to the motherboard via board-to-board connectors or soldering.

[0066] Communication Interface 8 It adopts an industry-standard M12-4 pin or M8-4 pin connector. The female head of the connector is directly embedded and fixed to the right side of the base housing 1, and its metal shell is connected to the grounding copper busbar inside the housing.

[0067] External interface relationship: It is the only physical port for the module to exchange data and power with external control systems (such as PLC), and it is located on the side of the casing for easy plugging and unplugging.

[0068] Internal connection: Inside the module, the connector pins are connected to the communication controller chip (such as IO-Link transceiver) on the main PCB board of the intelligent processing unit 7 via an internal ribbon cable or direct soldering.

[0069] The communication interface 8 and the intelligent processing unit 7 are electrically connected via hardwire or board-to-board connectors to transmit modulation signals, device parameters and diagnostic data of protocols such as IO-Link.

[0070] By recording and analyzing the closing time and average speed of the moving iron core for each operation, and calculating its exponential moving average, the system can keenly detect minute degradations in mechanical performance. For example, a sustained, slow increase in closing time may indicate fatigue of the reaction spring or increased friction in the moving mechanism; a decrease in the average speed of the moving iron core may point to reduced efficiency of the electromagnetic system (such as coils or magnetic circuits). This data-driven predictive maintenance capability allows users to schedule maintenance before a failure occurs, changing the traditional "reactive maintenance" model.

[0071] 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 dual contactor module with built-in mechanical interlock and status feedback, characterized in that, include: A basic housing (1) has two mounting compartments arranged side by side inside for accommodating contactor units, and an interlocking mechanism cavity (12) located between the two mounting compartments. A first contactor unit (2) and a second contactor unit (3) are respectively housed in the two installation chambers. The driving ends of the moving iron cores (21, 31) of the first contactor unit (2) and the second contactor unit (3) extend into the interlocking mechanism cavity (12) and are provided with lock holes (22, 32) at their ends. A mechanical interlock assembly is disposed in the interlock mechanism cavity (12), the mechanical interlock assembly is linked with the two moving iron cores (21, 31), and is configured to: when one of the moving iron cores moves toward the suction position, drive the mechanical interlock assembly to move, thereby physically blocking the other moving iron core from moving toward its suction position; And a status feedback system, which includes a sensing unit, an intelligent processing unit (7) and a communication interface (8) disposed on the base housing (1). The sensing unit is used to detect the position information of the moving iron core (21, 31) and the motion status information of the mechanical interlock assembly. The intelligent processing unit (7) is electrically connected to the sensing unit and the communication interface (8) to process the information of the sensing unit and realize status monitoring and fault warning. The mechanical interlock assembly includes: A rotating latch arm (41) is rotatably disposed in the interlock mechanism cavity (12), and its rotation axis is parallel to the mounting plane of the base housing (1); An interlocking slider (44) is slidably disposed in the interlocking mechanism cavity (12), and its sliding direction is consistent with the arrangement direction of the two moving iron cores (21, 31); The interlocking slider (44) is connected to the middle of the rotating buckle arm (41) via a transmission, and the two ends of the interlocking slider (44) are selectively engaged with the driving ends of the two moving iron cores (21, 31), respectively. When any of the moving iron cores moves toward the engaging position, it pushes the interlocking slider (44) to slide, and then drives the rotating latch arm (41) to rotate around its rotation axis through the transmission connection, so that one end of the rotating latch arm (41) is engaged in the locking hole (32, 22) of the other moving iron core.

2. The dual contactor module with built-in mechanical interlock and status feedback according to claim 1, characterized in that, The rotating buckle arm (41) is provided with irregular buckle parts (411) at both ends. The ends of the irregular buckle parts (411) are provided with guide slopes and the roots are provided with vertical locking surfaces. Correspondingly, the lock holes (22, 32) are elongated holes. Their length direction is consistent with the sliding direction of the interlocking slider (44), and their width direction is consistent with the movement direction of the moving iron core (21, 31). When the irregular buckle parts (411) are engaged in the lock holes (22, 32), the vertical locking surfaces and the hole walls of the lock holes (22, 32) in the movement direction of the moving iron core form a surface contact mechanical block.

3. The dual contactor module with built-in mechanical interlock and status feedback according to claim 1, characterized in that, The transmission connection between the interlocking slider (44) and the rotating latch arm (41) is a linkage-sleeve structure, specifically including: A round rod (442) fixed in the middle of the interlocking slider (44), the axis of the round rod (442) being perpendicular to the sliding direction of the interlocking slider (44); A sleeve (443) is fixed to the middle of the bottom surface of the rotating buckle arm (41), and the sleeve (443) is slidably sleeved on the outside of the round rod (442); When the interlocking slider (44) slides, the horizontal sliding is converted into a rotational drive of the rotating buckle arm (41) through the cooperation of the round rod (442) and the sleeve (443).

4. A dual contactor module with built-in mechanical interlock and status feedback according to claim 1, characterized in that, The upper part of both ends of the interlock slider (44) is provided with inclined driving head (441), and the front end face of the inclined driving head (441) is a steep inclined surface facing the outer side of the end of the interlock slider (44). When the moving iron core (21, 31) moves to the suction position, its driving end contacts and slides with the steep inclined surface of the corresponding inclined driving head (441), thereby pushing the interlock slider (44) to move.

5. A dual contactor module with built-in mechanical interlock and status feedback according to claim 1, characterized in that, The mechanical interlock assembly also includes a bidirectional torsion spring (45), which is fitted onto the pivot (42) of the rotating latch arm (41), with its two ends fixed to the inner wall of the interlock mechanism cavity (12) and the rotating latch arm (41), respectively. The bidirectional torsion spring (45) is configured to store potential energy and buffer impact when the moving iron core (21, 31) drives the rotating latch arm (41) to rotate, and to provide restoring force to reset the rotating latch arm (41) to a neutral horizontal position after the moving iron core (21, 31) is released.

6. A dual contactor module with built-in mechanical interlock and status feedback according to claim 5, characterized in that, The sensing unit of the state feedback system includes an angle encoding component for detecting the motion state of the mechanical interlock assembly, the angle encoding component comprising: A status code disk (5) is coaxially fixed to the rotating shaft (42), and its surface is provided with periodic optical markings; A photoelectric sensor (6) is fixed inside the interlock mechanism cavity (12) and is disposed opposite to the status code disk (5); The photoelectric sensor (6) is used to identify changes in the optical markings of the status code disk (5) when the rotating buckle arm (41) rotates, and transmits the signal to the intelligent processing unit (7) to calculate the rotation angle and angular velocity of the rotating buckle arm (41).

7. A dual contactor module with built-in mechanical interlock and status feedback according to claim 1, characterized in that, The sensing unit of the state feedback system includes a position sensing component for detecting the position information of the moving iron core (21, 31), the position sensing component including: Multiple sets of linear Hall position sensors (51, 61) are respectively installed on the inner sidewalls of the two installation compartments. Permanent magnets are respectively disposed on the sides of the two moving iron cores (21, 31) and facing the linear Hall position sensors (51, 61); The multiple sets of linear Hall position sensors (51, 61) are arranged at intervals along the motion axis of the moving iron core (21, 31) to output voltage signals proportional to the absolute position of the moving iron core (21, 31) and to obtain its motion speed by calculating the time difference between the moving iron core and the fixed sensor.

8. A dual contactor module with built-in mechanical interlock and status feedback according to claim 1, characterized in that, The intelligent processing unit (7) is installed in a metal shielded compartment located at the bottom of the base housing (1). The communication interface (8) is an industrial standard interface, with its female connector embedded and fixed to the side of the base housing (1) and connected to the intelligent processing unit (7) through internal wiring.

9. A dual contactor module with built-in mechanical interlock and status feedback according to claim 1, characterized in that, The base shell (1) is integrally injection molded from engineering plastic, and its front is provided with observation windows corresponding to the two installation compartments. The interlocking mechanism cavity (12) is a sealed dustproof chamber isolated from the upper and lower layers.

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