High-voltage direct current contactor

Abstract

The invention relates to the technical field of high-voltage electric appliances, in particular to a high-voltage direct-current contactor. Comprising a shell assembly, a movable assembly, a static assembly, a coil assembly and a circuit board assembly. An inner shell in the shell assembly divides the inner space of the shell assembly into a high-pressure power cavity in the front portion and a low-pressure control cavity in the rear portion. The circuit board assembly is fixed on the back face of the inner shell and provided with a high-voltage terminal area and a low-voltage terminal area which are physically isolated. The high-voltage terminal area collects main loop current signals through a diverter, and the low-voltage terminal area is connected with the coil assembly to output driving signals. When abnormal current is detected, the circuit board assembly can control the coil assembly and the driving assembly to be separated, automatic breaking protection is achieved, and resetting can be achieved through power-off and power-on operation. By means of multiple insulation combining cavity isolation and board-level isolation, safety of a control circuit in a high-voltage environment is remarkably improved, intelligent protection and reusability of the contactor are achieved, and the high-voltage contactor has the advantages of being compact in structure, high in reliability and low in use cost.

Description

Technical Field

[0001] This invention relates to the technical field of high-voltage electrical appliances, and more particularly to a high-voltage DC contactor. Background Technology

[0002] In high-voltage direct current (HVDC) transmission and distribution systems, contactors are critical control components used to safely connect and disconnect the main circuit. Currently, the commonly used protection scheme in the industry involves connecting contactors and fuses in series. Under normal operating conditions, the contactor performs active on / off control, with the fuse acting only as part of the conductor. When an abnormally large current such as an overload or short circuit occurs in the main circuit, the circuit is passively disconnected by the fuse element heating up and blowing, thus protecting downstream circuits and the contactor itself. However, this scheme has significant shortcomings: First, fuses are one-time-use devices and must be replaced after blowing, leading to cumbersome maintenance procedures, high spare parts costs, and long system downtime. Second, contactors themselves lack the ability to actively identify and disconnect abnormal operating conditions. Under continuous overcurrent or abnormal contact heating, they are highly susceptible to damage due to arcing, contact adhesion, or even explosion, severely impacting system reliability and equipment lifespan. Summary of the Invention

[0003] The purpose of this invention is to provide a high-voltage DC contactor that addresses the shortcomings of existing technologies. This invention significantly improves the safety and reliability of the integrated control board of the high-voltage DC contactor in high-voltage environments, enabling the product to have intelligent functions such as self-identification of abnormalities and execution of disconnection protection. It replaces traditional fuses and achieves reusable protection functions. While ensuring high reliability and safety, it also achieves miniaturization of the overall contactor structure, reduction of energy consumption, and reduction of total life cycle operating costs, thus comprehensively improving the operating economy and maintenance convenience of high-voltage DC systems.

[0004] To achieve the above objectives, the technical solution adopted by the present invention includes a housing assembly, a moving assembly, a stationary assembly, a coil assembly, and a circuit board assembly disposed within the housing assembly. The circuit board assembly integrates a coil drive control unit, a current signal acquisition and processing unit, and a protection logic execution unit into an integrated control board. The housing assembly includes an inner housing, the front of which accommodates the moving and stationary components to form a high-pressure power chamber, and the rear of which carries the circuit board assembly to form a low-pressure control chamber. The circuit board assembly is fixedly mounted on the back of the inner housing, and has a high-voltage terminal area and a low-voltage terminal area that are physically isolated from each other. The high-voltage terminal area is electrically connected to the static component via a shunt as a current detection component to collect the current signal flowing through the main contacts; the signal output terminal of the shunt is connected to the shunt interface pin on the high-voltage terminal area. The low-voltage terminal area is electrically connected to the coil assembly and outputs a drive control signal; When the current signal collected by the current detection component exceeds a preset threshold, the circuit board component outputs a disconnection control signal to the coil component through the low-voltage terminal area, driving the moving component to separate from the stationary component; After the protection logic execution unit is disconnected due to abnormal current, if the power supply of the circuit board assembly undergoes a power-down and power-on reset operation, the protection latch state is cleared, and the contactor is reset; and at the same time as the drive disconnection, an abnormal status signal is output to the outside through the low-voltage terminal area.

[0005] Furthermore, it also includes a temperature detection component, which is disposed on the inner housing and thermally coupled to a stationary terminal in one of the stationary components; The temperature detection component is electrically connected to the high-voltage terminal area and transmits the temperature signal to the circuit board assembly.

[0006] Furthermore, the inner housing is provided with a through hole for mounting the temperature detection component; The through hole is provided with two opposing baffles extending inward from the hole wall; A lateral limiting space is formed between the two baffles, and the thermistor of the temperature detection component is housed within this limiting space and is adjacent to the side of the stationary terminal. The leads of the thermistor are fixed to the circuit board assembly by soldering. The two baffles are made of insulating material and provide restraint for the thermistor.

[0007] Furthermore, at least two first positioning protrusions are provided on the back side of the inner housing corresponding to the area of ​​the circuit board assembly; The coil assembly has at least two second positioning protrusions on the side of the coil frame. The circuit board assembly is positioned by engaging with the first positioning protrusion and the second positioning protrusion through its edges or openings.

[0008] Furthermore, the back of the inner housing is provided with several strip-shaped reinforcing ribs, and the circuit board assembly is supported and fixed on the reinforcing ribs.

[0009] Furthermore, the coil assembly includes an inner coil and an outer coil connected in parallel; The coil drive control unit of the circuit board assembly is configured to: simultaneously supply power to the inner coil and the outer coil during the contactor closing and starting phase; and after the contactor is stably closed, cut off the power supply to the outer coil while maintaining the power supply to the inner coil only.

[0010] Furthermore, the housing assembly also includes an upper outer shell and a lower outer shell; The upper outer shell covers the upper end of the inner shell, and the lower outer shell covers the back and lower end of the inner shell; The pins of the high-voltage terminal area and the low-voltage terminal area of ​​the circuit board assembly are exposed through the interface window reserved in the lower housing.

[0011] Furthermore, the high-voltage terminal area and the low-voltage terminal area are two physically separate sets of terminal blocks; The high-voltage terminal area includes at least one shunt interface pin and one temperature detection output pin; The low-voltage terminal area includes at least one power supply pin, one power supply control signal pin, and one abnormal current output pin.

[0012] Furthermore, the printed circuit board of the circuit board assembly is provided with a high-low voltage isolation structure for isolating high-voltage and low-voltage areas; The high-low voltage isolation structure includes a solid L-shaped isolation groove disposed between the high-voltage terminal area and the low-voltage terminal area, the width of which meets the predetermined electrical clearance and creepage distance requirements.

[0013] A control and protection method for a high-voltage DC contactor, characterized in that the method utilizes the physical isolation structure between the high-voltage power chamber and the low-voltage control chamber formed by the inner housing, and the physically isolated high-voltage terminal area and low-voltage terminal area on the circuit board assembly, to perform the following steps: S1. Safety signal acquisition: S11, High-voltage side sampling: The current signal flowing through the main contact is collected by a shunt connected between the stationary component in the high-voltage power cavity and the high-voltage terminal area; and the temperature signal is collected by a temperature detection component disposed on the inner housing and thermally coupled to the stationary terminal; the current signal is input through the high-voltage terminal area, and the temperature signal is input through the high-voltage terminal area to the circuit board assembly for processing; S12, Low-voltage side command reception: Receive external control commands through the low-voltage terminal area; S2. Integrated Processing and Judgment: In the circuit board assembly within the low-voltage control cavity, the sampled signals from the high-voltage terminal area and the control commands from the low-voltage terminal area are centrally processed; when the current signal exceeds a first preset threshold or the temperature signal exceeds a second preset threshold, a protection command is generated. S3, Protection Execution and Status Management: S31, Protection disconnection: The protection command is output to the coil assembly through the low-voltage terminal area to drive the moving assembly to separate from the stationary assembly; S32. Status Feedback and Reset: Abnormal status is fed back to the outside through the low-voltage terminal area; and after the circuit board assembly undergoes power-down and power-on, a reset is performed to clear the protection latch.

[0014] The system comprises a housing assembly, a moving component, a stationary component, a coil assembly, and a circuit board assembly disposed within the housing assembly. The circuit board assembly integrates a coil drive control unit, a current signal acquisition and processing unit, and a protection logic execution unit into an integrated control board. The housing assembly includes an inner housing. The front portion of the inner housing accommodates the moving and stationary components to form a high-voltage power chamber, while the rear portion carries the circuit board assembly to form a low-voltage control chamber. The circuit board assembly is fixedly disposed on the back of the inner housing and has physically isolated high-voltage and low-voltage terminal areas. The high-voltage terminal area is electrically connected to the stationary component via a shunt, which acts as a current detection component, and acquires the current signal flowing through the main contacts. The signal output terminal of the shunt is connected to the shunt interface pin on the high-voltage terminal area. The low-voltage terminal area is electrically connected to the coil assembly and outputs a drive control signal. When the current signal acquired by the current detection component exceeds... When the preset threshold is exceeded, the circuit board assembly outputs a disconnection control signal to the coil assembly through the low-voltage terminal area, driving the moving component to separate from the stationary component. After the protection logic execution unit disconnects due to abnormal current, if the power supply to the circuit board assembly undergoes a power-down and power-on reset operation, the protection latch state is cleared, and the contactor is reset. At the same time as driving the disconnection, an abnormal status signal is output to the outside through the low-voltage terminal area, which significantly improves the working safety and reliability of the integrated control board of the high-voltage DC contactor in the high-voltage environment. It enables the product to have the intelligent function of self-identifying abnormalities and performing disconnection protection, replacing the traditional fuse and realizing the reusability of the protection function. Under the premise of ensuring high reliability and safety, it realizes the miniaturization of the overall structure of the contactor, the reduction of energy consumption, and the reduction of the total life cycle cost, comprehensively improving the operating economy and maintenance convenience of the high-voltage DC system. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a three-dimensional schematic diagram of the housing assembly of the present invention; Figure 2 This is a schematic diagram of the inner shell of the present invention; Figure 3 This is a cross-sectional view of the inner shell of the present invention; Figure 4 This is a schematic diagram of the positioning convex hull of the present invention; Figure 5 This is a schematic diagram of the temperature detection component of the present invention; Figure 6 This is a schematic diagram of the high-voltage terminal area of ​​the present invention; Figure 7 This is a schematic diagram of the low-voltage terminal area of ​​the present invention.

[0017] Figure label: Housing assembly 1, inner housing 1-1, baffle 1-1-1, first positioning protrusion 1-1-2, reinforcing rib 1-1-3, upper outer shell 1-2, lower outer shell 1-3, moving assembly 2, stationary assembly 3, stationary terminal 3-1, coil assembly 4, coil frame 4-1, second positioning protrusion 4-1-1, inner coil 4-2, outer coil 4-3, circuit board assembly 5, high voltage terminal area 5-1, shunt interface pin 5-1-1, temperature detection output pin 5-1-2, low voltage terminal area 5-2, power supply pin 5-2-1, power supply control signal pin 5-2-2, abnormal current output pin 5-2-3, L-shaped isolation groove 5-3, current detection assembly 6, temperature detection assembly 7, thermistor 7-1. Detailed Implementation

[0018] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0019] In the description of this invention, it should be noted that the orientations or positional relationships indicated by terms such as "center", "up", "down", "left", "right", "vertical", "horizontal", "inner", and "outer" are based on the orientations or positional relationships shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0020] A high-voltage DC contactor, such as Figures 1-7 As shown, it includes a housing assembly 1, a moving assembly 2, a stationary assembly 3, a coil assembly 4, and a circuit board assembly 5 disposed within the housing assembly 1; The circuit board assembly 5 integrates a coil drive control unit, a current signal acquisition and processing unit, and a protection logic execution unit into an integrated control board. The housing assembly 1 includes an inner housing 1-1. The front part of the internal space of the inner housing 1-1 accommodates the moving assembly 2 and the stationary assembly 3 to form a high-pressure power chamber, and the rear part carries the circuit board assembly 5 to form a low-pressure control chamber. The circuit board assembly 5 is fixedly disposed on the back of the inner housing 1-1, and has a high voltage terminal area 5-1 and a low voltage terminal area 5-2 that are physically isolated from each other. The high-voltage terminal area 5-1 is electrically connected to the static component 3 via a shunt as a current detection component 6 to collect the current signal flowing through the main contact; the signal output terminal of the shunt is connected to the shunt interface pin on the high-voltage terminal area 5-1. The low-voltage terminal area 5-2 is electrically connected to the coil assembly 4 and outputs a drive control signal; When the current signal collected by the current detection component exceeds a preset threshold, the circuit board component 5 outputs a disconnection control signal to the coil component 4 through the low-voltage terminal area 5-2, driving the moving component 2 to separate from the stationary component 3; After the protection logic execution unit is disconnected due to abnormal current, if the power supply of the circuit board assembly 5 undergoes a power-down and power-on reset operation, the protection latch state is cleared, and the contactor is reset; and at the same time as the drive disconnection, an abnormal status signal is output to the outside through the low-voltage terminal area 5-2.

[0021] Specifically, the device comprises a housing assembly 1, a moving assembly 2, a stationary assembly 3, a coil assembly 4, and a circuit board assembly 5. The housing assembly 1 serves as the overall support and protective structure, housing the moving assembly 2, stationary assembly 3, coil assembly 4, and circuit board assembly 5. The moving assembly 2 and stationary assembly 3 together form the main contacts of the contactor, used to connect or disconnect the main circuit. The coil assembly 4 receives electrical signals to drive the moving assembly 2. The circuit board assembly 5, as the control core, is integrated and installed on the back of the inner housing 1-1. This circuit board assembly 5 is an integrated control board that combines a coil drive control unit, a current signal acquisition and processing unit, and a protection logic execution unit. It operates via software... Intelligent control is achieved through integration with hardware. A key component of housing assembly 1 is the inner housing 1-1, which is made of insulating material and divided into a front high-voltage power chamber and a rear low-voltage control chamber. The high-voltage power chamber tightly houses the moving component 2 and the stationary component 3, directly bearing the system's high voltage and high current. The low-voltage control chamber supports and fixes the circuit board assembly 5; this area is for low-voltage signal processing and control, thus achieving initial physical isolation between high and low voltage. The circuit board assembly 5 is fixed to the back of the inner housing 1-1, and its board body has physically isolated high-voltage terminal area 5-1 and low-voltage terminal area 5-2. 5-1 is electrically connected to the stationary component 3 via a shunt, which functions as the current detection component 6. The shunt is connected in series in the main circuit to collect the current signal flowing through the main contacts. Its weak voltage signal output is directly connected to the dedicated shunt interface pin on the high-voltage terminal area 5-1. The low-voltage terminal area 5-2 is electrically connected to the coil assembly 4 via a coil insert, responsible for outputting the control signal to drive the coil to open or close. When the system is working normally, the circuit board assembly 5 can receive external commands and control the coil assembly 4 to move through the output signal of the low-voltage terminal area 5-2, thereby driving the moving component 2 and the stationary component 3 to close or open. When the current signal collected by the current detection component 6 exceeds a preset threshold, the circuit board... The current signal acquisition and processing unit of component 5 will identify the abnormality. The protection logic execution unit will then output a disconnection control signal to the coil component 4 through the low-voltage terminal area 5-2, so that the moving component 2 and the stationary component 3 can be quickly separated to cut off the main circuit. In addition, after the protection logic execution unit disconnects due to abnormal current, if the power supply of the circuit board component 5 undergoes a power-down and power-on reset operation, it will clear the internal protection latch state, so that the contactor can be restored to the standby state that can accept the closing command again. At the same time as executing the protection disconnection drive, the protection logic execution unit will output a status signal indicating the occurrence of the abnormality through the low-voltage terminal area 5-2 for the upper system to monitor.This solution firstly provides a safe installation space for the integrated circuit board assembly 5, free from interference from the high-voltage section, through the physical isolation layout of the high-voltage power chamber and low-voltage control chamber formed by the inner shell 1-1. This provides the basic structural guarantee for the intelligent protection function. Secondly, the physically isolated high-voltage terminal area 5-1 and low-voltage terminal area 5-2 on the circuit board assembly 5 effectively prevent the risk of damage to the control circuit caused by high-voltage crosstalk. Thirdly, the integrated control board integrates current sampling, logic processing, and drive control functions, and has software reset protection logic. This allows the contactor to be reused after interrupting an abnormally large current without replacing any parts, replacing the traditional approach of having to connect a disposable fuse in series. This improves the product's service life and economy, while reducing the overall installation size. Fourthly, the combination of the above structural improvements and intelligent control logic enables the high-voltage DC contactor to achieve complete protection functions such as self-identification of abnormal current, rapid interruption, status feedback, and convenient reset while maintaining a compact structure, thus improving the reliability and safety of the system operation.

[0022] As a preferred embodiment of the above, such as Figures 1-7 As shown, it also includes a temperature detection component 7, which is disposed on the inner housing 1-1 and thermally coupled to a stationary terminal 3-1 in a stationary component 3; The temperature detection component 7 is electrically connected to the high-voltage terminal area 5-1 and transmits the temperature signal to the circuit board assembly 5.

[0023] Specifically, the temperature detection component 7 is located at a specific position in the inner housing 1-1 and thermally coupled to a stationary terminal 3-1 in the stationary component 3. The temperature sensing element of the temperature detection component 7 ensures accurate sensing of its operating temperature. The lead of the thermistor 7-1 is connected to the temperature detection output pin 5-1-2 on the high-voltage terminal area 5-1, thereby transmitting the electrical signal characterizing the temperature of the stationary terminal 3-1 to the current signal acquisition and processing unit of the circuit board assembly 5 for processing. This allows the contactor to have both current protection and temperature monitoring capabilities, organically integrating the temperature monitoring function into the existing cavity isolation and electrical isolation structure. The signal, as another source of status information from the high-voltage power chamber, is introduced through a dedicated high-voltage terminal area 5-1. This follows the safety design principle of separating high and low voltage signal paths, avoiding additional electrical risks introduced by the monitoring circuit. It enables real-time online monitoring of the main contact operating temperature, providing direct data for preventing overheating faults caused by increased contact resistance, loose connections, or long-term overload. Through collaboration with the current protection logic, it forms a dual fault judgment and protection mechanism for abnormal current and abnormal temperature rise, further enhancing the contactor's status perception capability and the overall safety and reliability of the system, without increasing the overall size and complexity of the contactor.

[0024] As a preferred embodiment of the above, such as Figures 1-7 As shown, the inner housing 1-1 has a through hole for installing the temperature detection component 7; The through hole is provided with two opposing baffles 1-1-1 extending inward from the hole wall; A lateral limiting space is formed between the two baffles 1-1-1, and the thermistor 7-1 of the temperature detection component 7 is housed in the limiting space and is adjacent to the side of the stationary terminal 3-1. The leads of the thermistor 7-1 are fixed to the circuit board assembly 5 by soldering. The two baffles 1-1-1 are made of insulating material and provide a limit for the thermistor 7-1.

[0025] Specifically, a through hole for mounting the temperature sensing component 7 is precisely formed on the inner housing 1-1. The position of this through hole corresponds to the side of a stationary terminal 3-1 in the stationary component 3. Two opposing baffles 1-1-1 are integrally formed or assembled on the inner wall of the through hole. These two baffles 1-1-1 extend from the hole wall towards the inner center, thereby defining a lateral limiting space between the two baffles 1-1-1, the size of which matches the thermistor 7-1 of the temperature sensing component 7. The thermistor 7-1 is accommodated and constrained within this limiting space, and its temperature sensing surface is thermally coupled to the side of the stationary terminal 3-1 through thermally conductive adhesive. The two baffles 1-1-1 provide radial limiting for the thermistor 7-1, thereby achieving accurate thermal coupling. The metal leads of the thermistor 7-1 are led out from the limiting space and reliably fixed to the corresponding pads on the circuit board assembly 5 by welding, completing the electrical connection and mechanical anchoring. The limiting space formed by the baffle 1-1-1 enables precise radial and axial positioning of the thermistor 7-1, ensuring consistency in its contact position with the high-voltage conductor. The elastic holding force effectively compensates for differences in manufacturing tolerances, coefficients of thermal expansion, and stress relaxation that may occur during long-term use, ensuring long-term stability of thermal contact and temperature conduction efficiency. This structure firmly integrates the sensor into the high-voltage chamber while maintaining the critical contact pressure through a simple mechanical structure. Furthermore, the entire installation method is integrated with the inner housing 1-1, without compromising the original insulation and isolation integrity, thus supporting the long-term accuracy and durability of the temperature monitoring function under harsh high-voltage DC environments.

[0026] As a preferred embodiment of the above, such as Figures 1-7 As shown, at least two first positioning protrusions 1-1-2 are provided on the back side of the inner housing 1-1 corresponding to the area of ​​the circuit board assembly 5; At least two second positioning protrusions 4-1-1 are provided on the side of the coil frame 4-1 of the coil assembly 4; The circuit board assembly 5 is positioned by engaging with the first positioning protrusion 1-1-2 and the second positioning protrusion 4-1-1 through its edge or opening.

[0027] Specifically, at least two integrally formed or separately assembled first positioning protrusions 1-1-2 are provided on the back of the inner shell 1-1 at a specific position corresponding to the mounting area of ​​the circuit board assembly 5. At the same time, at least two second positioning protrusions 4-1-1 are also provided on the side of the coil frame 4-1 of the coil assembly 4, corresponding to the mounting height of the circuit board assembly 5. The printed circuit board of the circuit board assembly 5 has pre-designed openings or grooves on its edges or inside that match the position and shape of the first positioning protrusions 1-1-2 and the second positioning protrusions 4-1-1. During assembly, the circuit board assembly 5 aligns and fits with the aforementioned protrusions through these openings or grooves, thereby achieving precise positioning and circumferential limiting in three-dimensional space and preventing displacement during subsequent use. After limiting and fitting, the circuit board assembly 5 is finally fixed by hot riveting, welding or applying adhesive to the joint between the protrusions and the circuit board. The first positioning protrusion 1-1-2 and the second positioning protrusion 4-1-1 together constitute a composite support and constraint for the circuit board assembly 5. This fully utilizes the spatial position and rigidity of the existing core structural components inside the contactor, and provides a stable and reliable installation solution for the relatively large integrated control board without significantly increasing the number and complexity of parts. This collaborative fixing method effectively distributes the mechanical stress and vibration load borne by the circuit board, ensuring the stability of its connection under various operating conditions of the vehicle or equipment. Furthermore, through precise positioning, it ensures the accuracy of the preset connection relationship between the high voltage terminal area 5-1, the low voltage terminal area 5-2, and other interfaces on the circuit board assembly 5 and the inner shell 1-1 and the coil assembly 4, thus structurally ensuring the reliability of the electrical connection and maintaining the stability of the key insulation gap.

[0028] As a preferred embodiment of the above, such as Figures 1-7 As shown, the back of the inner shell 1-1 is also provided with several strip-shaped reinforcing ribs 1-1-3, and the circuit board assembly 5 is supported and fixed on the reinforcing ribs 1-1-3.

[0029] Specifically, several strip-shaped reinforcing ribs 1-1-3 are integrally formed on the back of the inner shell 1-1. These reinforcing ribs 1-1-3 are distributed at a certain height and interval in the mounting area of ​​the circuit board assembly 5, providing the main support reference surface for the circuit board assembly 5. At the top of at least two reinforcing ribs 1-1-3, an upwardly protruding columnar structure is integrally formed, constituting the first positioning protrusion 1-1-2. At the same time, at least two second positioning protrusions 4-1-1 are provided at the corresponding positions on the side of the coil frame 4-1 of the coil assembly 4. The printed circuit board of the circuit board assembly 5 has pre-drilled positioning holes or notches that match the shape of these protrusions at corresponding positions. During assembly, the circuit board assembly 5 first aligns and fits with the first positioning protrusion 1-1-2 and the second positioning protrusion 4-1-1 through its positioning holes to achieve precise pre-positioning and circumferential limiting in three-dimensional space. Then, its back is placed as a whole and supported and fixed on the top plane of the reinforcing rib 1-1-3. Finally, the protrusions are fastened to the circuit board by means of hot riveting, welding or bonding, thereby efficiently combining the support function and the precise positioning function through the integrated design of the reinforcing rib 1-1-3 and the first positioning protrusion 1-1-2. The reinforcing rib 1-1-3 provides large-area structural support, ensuring the overall flatness and deformation resistance of the circuit board during installation. The first positioning protrusion 1-1-2, which protrudes from the rib, provides a precise positioning reference point. First, it ensures that the circuit board assembly 5 has extremely high positional accuracy and repeatability after installation, guaranteeing the accuracy of the preset connection relationship between the high-voltage terminal area 5-1, the low-voltage terminal area 5-2, the inner shell 1-1, and the coil assembly 4 on the board. Second, the one-piece molded structure avoids the use of additional independent positioning parts, simplifies the assembly process, and improves structural reliability. Third, it strengthens the rigidity of the local area on the back of the inner shell, enabling the entire installation structure to better resist vibration and impact stress.

[0030] As a preferred embodiment of the above, such as Figures 1-7 As shown, the coil assembly 4 includes an inner coil 4-2 and an outer coil 4-3 connected in parallel; The coil drive control unit of the circuit board assembly 5 is configured to: simultaneously supply power to the inner coil 4-2 and the outer coil 4-3 during the contactor closing and starting phase; and cut off the power supply to the outer coil 4-3 and maintain only the power supply to the inner coil 4-2 after the contactor is stably closed.

[0031] Specifically, the coil assembly 4 consists of an inner coil 4-2 and an outer coil 4-3 connected in parallel, both coaxially wound on a coil frame 4-1. The coil drive control unit within the circuit board assembly 5 is connected to these two coils through its output circuit and is programmed to execute specific energy-saving drive logic. That is, during the contactor closing and starting phase after receiving a closing command, the coil drive control unit simultaneously provides operating current to both the inner coil 4-2 and the outer coil 4-3 to generate a sufficiently large total electromagnetic attraction force to ensure that the moving assembly 2 can reliably overcome the reaction force spring and close quickly. When the moving assembly 2 and the stationary assembly 3 are fully closed and held stable by the mechanical structure... Once set, the coil drive control unit cuts off the power supply circuit to the outer coil 4-3, and only maintains a small holding current to the inner coil 4-2. The electromagnetic force generated by this holding current is sufficient to keep the contactor in a stable closed and locked state. The energy-saving logic is deeply integrated into the intelligent control board, realizing the on-demand distribution of driving force. Through this dual-coil sequential power supply strategy, the coil power consumption and heat generation during steady-state operation are greatly reduced while ensuring the reliable operation and holding of the contactor. This solves the problem of high energy consumption and temperature rise caused by the need for a large current to be maintained in the traditional single-coil scheme, and also optimizes the overall energy efficiency of the contactor.

[0032] As a preferred embodiment of the above, such as Figures 1-7 As shown, the housing assembly 1 also includes an upper outer shell 1-2 and a lower outer shell 1-3; The upper outer shell 1-2 covers the upper end of the inner shell 1-1, and the lower outer shell 1-3 covers the back and lower end of the inner shell 1-1; The pins of the high-voltage terminal area 5-1 and the low-voltage terminal area 5-2 of the circuit board assembly 5 are exposed through the interface window reserved in the lower housing 1-3.

[0033] Specifically, the housing assembly 1 includes an upper outer shell 1-2 and a lower outer shell 1-3 in addition to the inner shell 1-1. The upper outer shell 1-2 is usually made of insulating material and its inner cavity covers and encapsulates the upper end of the inner shell 1-1, completely covering the high-voltage power chamber and the internal moving component 2 and stationary component 3 to provide external insulation and mechanical protection. The lower outer shell 1-3 is also made of insulating material and designed as a cover structure that matches the contour of the back and lower end of the inner shell 1-1. After its cover is installed, it and the inner shell 1-1 together form a closed space for accommodating the circuit board assembly 5 and the lower part of the coil assembly 4, thereby completing the encapsulation of the entire low-voltage control chamber. At the position of the pin array of the high-voltage terminal area 5-1 and the low-voltage terminal area 5-2 on the circuit board assembly 5, a regular-shaped interface window is reserved in the lower outer shell 1-3, so that all electrical pins of the two sets of terminals can pass through the interface window and be neatly exposed to the outside of the lower outer shell 1-3 after the whole machine is assembled, so as to facilitate docking with external wiring harnesses or connectors. The product achieves integrated, separate packaging of the internal high-voltage power chamber and low-voltage control chamber. Its significant progress is reflected in the fact that the packaging structure physically continues and consolidates the internal isolation design. The upper shell 1-2 and the lower shell 1-3 serve as the final barrier, enhancing the overall insulation performance and environmental protection capabilities of the product. At the same time, by centrally opening interface windows on the lower shell 1-3, all external electrical connection interfaces are integrated into the same area, which greatly facilitates the wiring, installation and maintenance of the contactor in the system cabinet, reduces the risk of assembly errors or interference caused by multi-directional dispersed wiring, and improves the integration convenience and reliability of the product as a standardized module.

[0034] As a preferred embodiment of the above, such as Figures 1-7 As shown, the high-voltage terminal area 5-1 and the low-voltage terminal area 5-2 are two physically separate sets of terminal blocks; The high-voltage terminal area 5-1 includes at least one shunt interface pin 5-1-1 and one temperature detection output pin 5-1-2; The low-voltage terminal area 5-2 includes at least one power supply pin 5-2-1, one power supply control signal pin 5-2-2, and one abnormal current output pin 5-2-3.

[0035] Specifically, the high-voltage terminal area 5-1 and the low-voltage terminal area 5-2, which are physically isolated from each other on the circuit board assembly 5, are physically separate as two independent sets of terminal blocks. Each of them has an independent insulating base and conductive pin array. The terminal block of the high-voltage terminal area 5-1 integrates at least one shunt interface pin 5-1-1 for connecting the current detection component 6, i.e., the shunt signal output line, and one temperature detection output pin 5-1-2 for connecting the output signal line of the temperature detection component 7. The terminal block of the low-voltage terminal area 5-2 integrates at least one power supply pin 5-2-1 for connecting to the external control power supply, one power supply control signal pin 5-2-2 for receiving external on / off commands, and one abnormal current output pin 5-2-3 for outputting a fault indication signal when the protection is activated. All pins are reliably connected to the corresponding functional unit circuits through the internal wiring of the circuit board assembly 5. Extending electrical isolation requirements from the internal circuit board routing level to the external physical interface level, two completely separate terminal blocks achieve complete physical separation of high and low voltage signals and power supply at the connection port. This fundamentally eliminates the risk of high voltage signals being mistakenly connected to low voltage circuits due to incorrect connector insertion, short circuits caused by wire harness wear, or condensation creepage, greatly improving the inherent safety of external wiring links. At the same time, this clear functional and potential zoning makes on-site installation and line inspection more intuitive and reliable, reducing the possibility of misconnection.

[0036] As a preferred embodiment of the above, such as Figures 1-7 As shown, the printed circuit board of the circuit board assembly 5 is provided with a high-low voltage isolation structure for isolating high-voltage and low-voltage areas. The high-low voltage isolation structure includes a solid L-shaped isolation groove 5-3 disposed between the high voltage terminal area 5-1 and the low voltage terminal area 5-2. The width of the L-shaped isolation groove 5-3 meets the predetermined electrical clearance and creepage distance requirements.

[0037] Specifically, the printed circuit board of the circuit board assembly 5 is designed with a high-low voltage isolation structure to achieve electrical isolation between high-voltage and low-voltage areas. This high-low voltage isolation structure includes a solid L-shaped isolation groove 5-3 formed by machining in the circuit board area between the high-voltage terminal area 5-1 and the low-voltage terminal area 5-2. The L-shaped isolation groove 5-3 completely penetrates the substrate of the circuit board. Its direction and shape are designed to effectively separate the high-voltage side wiring area and the low-voltage side wiring area within the limited board surface. The width of this isolation groove 5-3 is precisely calculated and set to ensure that it can meet the electrical clearance and creepage distance values ​​required by the predetermined safety standards. For example, the width is not less than the minimum isolation distance determined according to the system's highest operating voltage and pollution level. The concept of spatial isolation is realized on a single printed circuit board through precise machining. The L-shaped slot structure provides a longer surface creepage path compared to a straight slot, thus achieving higher insulation reliability within the same projected distance. This structure effectively blocks the possibility of abnormal potentials from the high-voltage side to the low-voltage control area at the circuit board level through a simple and reliable physical barrier. Together with the aforementioned cavity physical isolation and terminal block physical separation, it constitutes a multi-layered, three-dimensional insulation protection system, significantly improving the inherent safety of the integrated control board in high-voltage DC environments. Furthermore, this design ensures the reliability and consistency of isolation performance through quantifiable and verifiable slot width parameters, facilitating production quality control and safety certification.

[0038] A control and protection method for a high-voltage DC contactor, characterized in that the method utilizes the physical isolation structure between the high-voltage power chamber and the low-voltage control chamber formed by the inner housing 1-1, and the physically isolated high-voltage terminal area 5-1 and low-voltage terminal area 5-2 on the circuit board assembly 5, to perform the following steps: S1. Safety signal acquisition: S11, High-voltage side sampling: The current signal flowing through the main contact is collected through a shunt connected between the stationary component 3 in the high-voltage power chamber and the high-voltage terminal area 5-1; and the temperature signal is collected through a temperature detection component 7 disposed on the inner housing 1-1 and thermally coupled to the stationary terminal 3-1; the current signal is input through the high-voltage terminal area 5-1, and the temperature signal is input through the high-voltage terminal area 5-1 to the circuit board assembly 5 for processing; S12, Low-voltage side command reception: Receive external control commands through the low-voltage terminal area 5-2; S2. Integrated processing and judgment: In the circuit board assembly 5 within the low-voltage control cavity, the sampled signal from the high-voltage terminal area 5-1 and the control command from the low-voltage terminal area 5-2 are centrally processed; when the current signal exceeds a first preset threshold or the temperature signal exceeds a second preset threshold, a protection command is generated; S3, Protection Execution and Status Management: S31, Protection disconnection: The protection command is output to the coil assembly 4 through the low-voltage terminal area 5-2 to drive the moving assembly 2 to separate from the stationary assembly 3; S32, Status Feedback and Reset: Abnormal status is fed back to the outside through the low-voltage terminal area 5-2; and after the circuit board assembly 5 undergoes power-down and power-on, a reset is performed to clear the protection latch.

[0039] Specifically, the implementation of this method relies heavily on the unique physical structure of the aforementioned high-voltage DC contactor. Specifically, it utilizes the physical isolation structure between the high-voltage power chamber and the low-voltage control chamber formed by the inner housing 1-1, and the physically isolated high-voltage terminal area 5-1 and low-voltage terminal area 5-2 on the circuit board assembly 5, to execute a complete control and safety protection process. The method begins with a safety signal acquisition step, which includes two parallel sub-processes. The first is high-voltage side sampling, where the current signal flowing through the main contacts is acquired in real time through a shunt permanently connected between the stationary component 3 and the high-voltage terminal area 5-1 within the high-voltage power chamber. Simultaneously, the temperature signal of this critical current-conducting component is acquired through a temperature detection component 7 located on the inner housing 1-1 and directly thermally coupled to the stationary terminal 3-1. All these sampling signals from the high-voltage region are input to the subsequent circuits through the specially designed safe path of the high-voltage terminal area 5-1. The second is low-voltage side command reception, where low-voltage control signals such as on / off commands from the external control system are received through the completely independent low-voltage terminal area 5-2. Next comes the integrated processing and judgment step. All safety sampling signals input through the high-voltage terminal area 5-1 and control commands received through the low-voltage terminal area 5-2 are centrally processed and analyzed by the integrated microprocessor and related circuits in the circuit board assembly 5 within the low-voltage control cavity. When the processing logic determines that either the current signal or the temperature signal exceeds its corresponding preset safety threshold, the protection logic execution unit of the circuit board assembly 5 will generate a clear protection command. Finally, there is the protection execution and status management step. This step first performs protection disconnection, outputting the generated protection command through the low-voltage terminal area 5-2 to the coil assembly 4, driving the moving assembly 2 and the stationary assembly 3 to reliably separate and cut off the main circuit. At the same time, an abnormal status signal is fed back to the external system through a specific pin on the low-voltage terminal area 5-2 to indicate that a fault has occurred. Subsequently, if the power supply to the circuit board assembly 5 undergoes a complete power-off and power-on cycle, its internal logic will perform a reset operation to clear the previous fault latching state, allowing the contactor to return to the standby mode where it can receive closing commands again. The control logic flow of this method is deeply integrated and adapted to the innovative hardware structure of the product. The acquisition and introduction of high-voltage side signals strictly follow the isolation path through the high-voltage terminal area 5-1. All processing activities are confined within the low-voltage control cavity, while all control outputs and feedback are conducted through the low-voltage terminal area 5-2. This forms a clear, unidirectional, and controlled signal and energy flow. This method fully utilizes the hardware advantages of cavity isolation and board-level isolation to construct a complete closed loop from signal perception, centralized intelligent processing to action execution and state management. Under the premise of electrical isolation, this closed loop achieves comprehensive monitoring and autonomous protection of the contactor's operating status. Thus, at the software logic level, it consolidates and realizes the integration, safety, and reliability goals pursued by the hardware structure design, enabling the contactor as a whole to have reusable intelligent protection functions.

[0040] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A high-voltage DC contactor, characterized in that, It includes a housing assembly (1), a moving assembly (2), a stationary assembly (3), a coil assembly (4), and a circuit board assembly (5) disposed within the housing assembly (1); The circuit board assembly (5) integrates a coil drive control unit, a current signal acquisition and processing unit, and a protection logic execution unit into an integrated control board. The housing assembly (1) includes an inner housing (1-1). The front part of the internal space of the inner housing (1-1) accommodates the moving assembly (2) and the stationary assembly (3) to form a high-pressure power chamber, and the rear part carries the circuit board assembly (5) to form a low-pressure control chamber. The circuit board assembly (5) is fixedly disposed on the back of the inner housing (1-1), and a high voltage terminal area (5-1) and a low voltage terminal area (5-2) are physically isolated from each other. The high-voltage terminal area (5-1) is electrically connected to the static component (3) via a shunt as a current detection component (6) to collect the current signal flowing through the main contact; the signal output terminal of the shunt is connected to the shunt interface pin on the high-voltage terminal area (5-1); The low-voltage terminal area (5-2) is electrically connected to the coil assembly (4) and outputs a drive control signal; When the current signal collected by the current detection component exceeds the preset threshold, the circuit board component (5) outputs a disconnection control signal to the coil component (4) through the low-voltage terminal area (5-2) to drive the moving component (2) to separate from the stationary component (3); After the protection logic execution unit is disconnected due to abnormal current, if the power supply of the circuit board assembly (5) undergoes a power-down and power-on reset operation, the protection latch state is cleared and the contactor is reset; and at the same time as the drive is disconnected, an abnormal status signal is output to the outside through the low-voltage terminal area (5-2).

2. The high-voltage DC contactor according to claim 1, characterized in that, It also includes a temperature detection component (7), which is disposed on the inner housing (1-1) and thermally coupled to a stationary terminal (3-1) in a stationary component (3); The temperature detection component (7) is electrically connected to the high-voltage terminal area (5-1) and transmits the temperature signal to the circuit board assembly (5).

3. The high-voltage DC contactor according to claim 2, characterized in that, The inner housing (1-1) has a through hole for installing the temperature detection component (7); Two opposing baffles (1-1-1) extending inward from the hole wall are provided at the through hole. A lateral limiting space is formed between the two baffles (1-1-1), and the thermistor (7-1) of the temperature detection component (7) is housed in the limiting space and is adjacent to the side of the stationary terminal (3-1); The leads of the thermistor (7-1) are fixed to the circuit board assembly (5) by soldering. The two baffles (1-1-1) are made of insulating material and provide a limit for the thermistor (7-1).

4. The high-voltage DC contactor according to claim 1, characterized in that, The back of the inner housing (1-1) is provided with at least two first positioning protrusions (1-1-2) in the area corresponding to the circuit board assembly (5). At least two second positioning protrusions (4-1-1) are provided on the side of the coil frame (4-1) of the coil assembly (4). The circuit board assembly (5) is positioned by cooperating with the first positioning protrusion (1-1-2) and the second positioning protrusion (4-1-1) through its edge or opening.

5. The high-voltage DC contactor according to claim 1, characterized in that, The back of the inner shell (1-1) is also provided with several strip-shaped reinforcing ribs (1-1-3), and the circuit board assembly (5) is supported and fixed on the reinforcing ribs (1-1-3).

6. The high-voltage DC contactor according to claim 1, characterized in that, The coil assembly (4) includes an inner coil (4-2) and an outer coil (4-3) connected in parallel. The coil drive control unit of the circuit board assembly (5) is configured to: simultaneously supply power to the inner coil (4-2) and the outer coil (4-3) during the contactor closing and starting phase; and cut off the power supply to the outer coil (4-3) and maintain only the power supply to the inner coil (4-2) after the contactor is stably closed.

7. The high-voltage DC contactor according to claim 1, characterized in that, The housing assembly (1) further includes an upper outer shell (1-2) and a lower outer shell (1-3). The upper outer shell (1-2) covers the upper end of the inner shell (1-1), and the lower outer shell (1-3) covers the back and lower end of the inner shell (1-1); The pins of the high voltage terminal area (5-1) and the low voltage terminal area (5-2) of the circuit board assembly (5) are exposed through the interface window reserved in the lower housing (1-3).

8. The high-voltage DC contactor according to claim 1, characterized in that, The high-voltage terminal area (5-1) and the low-voltage terminal area (5-2) are two physically separate sets of terminal blocks; The high-voltage terminal area (5-1) includes at least one shunt interface pin (5-1-1) and one temperature detection output pin (5-1-2). The low-voltage terminal area (5-2) includes at least one power supply pin (5-2-1), one power supply control signal pin (5-2-2), and one abnormal current output pin (5-2-3).

9. The high-voltage DC contactor according to claim 1, characterized in that, The printed circuit board of the circuit board assembly (5) is provided with a high-low voltage isolation structure for isolating high-voltage and low-voltage areas. The high-low voltage isolation structure includes a solid L-shaped isolation groove (5-3) disposed between the high voltage terminal area (5-1) and the low voltage terminal area (5-2), the width of the L-shaped isolation groove (5-3) meeting the predetermined electrical clearance and creepage distance requirements.

10. A control and protection method for a high-voltage DC contactor as described in claim 1, characterized in that, The method utilizes the physical isolation structure between the high-voltage power chamber and the low-voltage control chamber formed by the inner housing (1-1), and the physically isolated high-voltage terminal area (5-1) and low-voltage terminal area (5-2) on the circuit board assembly (5) to perform the following steps: S1. Safety signal acquisition: S11, High-voltage side sampling: The current signal flowing through the main contact is collected by a shunt connected between the stationary component (3) in the high-voltage power cavity and the high-voltage terminal area (5-1); and the temperature signal is collected by a temperature detection component (7) provided on the inner housing (1-1) and thermally coupled to the stationary terminal (3-1); the current signal is input through the high-voltage terminal area (5-1), and the temperature signal is input through the high-voltage terminal area (5-1) to the circuit board assembly (5) for processing; S12, Low-voltage side command reception: Receive external control commands through the low-voltage terminal area (5-2); S2. Integrated processing and judgment: In the circuit board assembly (5) in the low-voltage control cavity, the sampling signal from the high-voltage terminal area (5-1) and the control command from the low-voltage terminal area (5-2) are centrally processed; when the current signal exceeds the first preset threshold or the temperature signal exceeds the second preset threshold, a protection command is generated; S3, Protection Execution and Status Management: S31, Protection disconnection: The protection command is output to the coil assembly (4) through the low-voltage terminal area (5-2) to drive the moving assembly (2) to separate from the stationary assembly (3); S32, Status Feedback and Reset: Abnormal status is fed back to the outside through the low-voltage terminal area (5-2); and after the circuit board assembly (5) undergoes power-down and power-on, a reset is performed to clear the protection latch.

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