Contactor integrated with voltage detection function and electric equipment

Abstract

The invention provides a contactor integrated with a voltage detection function and electric equipment, and relates to the technical field of contactors, and the contactor comprises a moving iron core, a main contact assembly and an auxiliary contact assembly. The main contact assembly comprises a movable contact piece, a first static contact piece located at the first contact point and a second static contact piece located at the second contact point. The auxiliary contact assembly comprises an integrated metal structure integrated with a fixing part, a contact part and a leading-out part. The fixing part is used for fixing the integrated metal structure at a designated position between the first static contact piece and the second static contact piece, and the integrated metal structure does not relatively slide or rotate in the whole working process of the contactor. The contact part is located at an auxiliary contact between the first contact and the second contact, and when the movable contact piece moves to the first contact or the second contact, the contact part is in contact with the movable iron core to form a voltage signal. And the leading-out part is used for leading out the voltage signal so as to realize voltage detection of the auxiliary contact.

Description

Technical Field

[0001] This disclosure belongs to the field of contactor technology, specifically relating to a contactor and electrical equipment with integrated voltage detection function. Background Technology

[0002] Contactors, as electromagnetic switching devices widely used in industrial control, typically require auxiliary contacts to monitor the actual on / off state of their contacts. These auxiliary contacts are linked to the main contacts, transmitting status signals to the control system.

[0003] In related technologies, contactors typically employ an auxiliary contact design by adding a plastic auxiliary contact plate top and two auxiliary contacts above their moving iron core. When the contactor closes, the moving iron core rises, simultaneously lifting the auxiliary contact plate top, causing it to move upwards synchronously. This brings the two auxiliary contacts above the moving iron core into contact, forming a conductive circuit. By measuring the continuity of the pins connected to the two auxiliary contacts, it can be determined whether the contactor is closed.

[0004] The contactor with the above structure has the following drawbacks: First, the auxiliary contact piece is prone to fatigue or jamming after frequent operation, which can lead to abnormal contactor status problems such as false alarms. Second, the plastic auxiliary contact piece has poor temperature resistance and is prone to deformation and failure in high-temperature environments. Third, in order to ensure smooth operation, an assembly gap needs to be reserved. In a vibration environment, the top of the top is prone to tilting, which affects the reliability of the contactor.

[0005] In addition, related technologies typically use external voltage sensing modules to detect the voltage of contactors, which increases the complexity and cost of electrical equipment with contactors. Summary of the Invention

[0006] This disclosure provides a contactor and electrical equipment with integrated voltage detection function, aiming to at least partially solve the technical problems of signal acquisition failure, insufficient structural stability and excessive cost in the auxiliary contact design of related technologies.

[0007] At least one embodiment of this disclosure provides a contactor with integrated voltage detection function, including: A moving iron core, which reciprocates along a first direction; The main contact assembly includes a moving contact fixed to the moving iron core, a first stationary contact located at a fixed first contact point, and a second stationary contact located at a fixed second contact point. The main contact assembly is used to connect or disconnect the circuit containing the contactor. An auxiliary contact assembly, the auxiliary contact assembly comprising an integral metal structure; The integrated metal structure includes: The fixing part is used to fix the integrated metal structure at a designated position between the first stationary contact piece and the second stationary contact piece, and to ensure that the integrated metal structure has no relative sliding or rotational movement throughout the operation of the contactor. A contact portion, an auxiliary contact located between the first contact and the second contact, wherein when the moving contact piece moves to the first contact or the second contact, the contact portion contacts the moving iron core to form a voltage signal; and The lead-out section is used to lead out the voltage signal to realize the voltage detection of the auxiliary contact.

[0008] The above solution offers the following technical advantages: It provides a contactor with more stable auxiliary contact performance and lower cost. A one-piece metal structure replaces the auxiliary contact piece top and two auxiliary contact pieces of related technologies. No moving connection is required; the contact portion of the one-piece metal structure is directly connected to the moving iron core through the conductive properties between the metals. The voltage signal sampled by the moving iron core is then led out to the outside to achieve voltage acquisition. Subsequently, when the moving iron core is unexcited, the continuity between the auxiliary contact and the two main contacts can be measured to determine whether the contactor is properly disconnecting; and when the moving iron core is excited, the continuity between the auxiliary contact and the two main contacts can be measured to determine whether the contactor is properly closing. This one-piece metal structure has higher structural stability, temperature resistance, and fatigue resistance, making the electrical equipment using this contactor more stable. Furthermore, the one-piece metal structure has higher strength, effectively resisting the effects of vehicle vibration, preventing the auxiliary contact piece top from tilting, and ensuring smooth closing and opening of the auxiliary contacts. Even under high temperatures inside or outside the contactor, the structure remains stable and will not melt, significantly reducing signal instability and ensuring the normal operation of the auxiliary contacts. Furthermore, this structure simplifies contactor design, reduces the number of parts, lowers the complexity and cost of the contactor, and solves the technical problems of signal acquisition failure, insufficient structural stability, and excessive cost associated with auxiliary contact designs in related technologies.

[0009] In a contactor provided in at least one embodiment of this disclosure, the integrated metal structure has no moving parts, and the integrated metal structure includes: A first arm, disposed between the first stationary contact piece and the second stationary contact piece and located in the first direction, wherein the first arm integrates the fixing portion and the contact portion; and... The second arm is disposed in a second direction different from the first direction and is fixedly connected to the first arm. The second arm has no contact with the first stationary contact piece and the second stationary contact piece, and the lead-out portion is integrated on the second arm.

[0010] The above solution offers the following technical advantages: the first arm replaces the auxiliary contact plate top and two auxiliary contacts of related technologies, while the second arm replaces the external voltage sensing module of related technologies. This integrated metal structure is securely installed in the corresponding position inside the contactor, ensuring its stability under various operating conditions and preventing displacement due to vibration or external forces. This design not only simplifies the internal structure of the contactor, reduces the number of parts, and lowers assembly difficulty and cost, but also improves the reliability and stability of the contactor.

[0011] In at least one embodiment of the contactor provided in this disclosure, a voltage sampling terminal is integrated at the end of the lead-out portion; and, The first direction and the second direction are perpendicular. The integrated metal structure is a right-angled piece formed by bending in one piece. The vertical section of the right-angled piece constitutes the first arm, the horizontal section of the right-angled piece constitutes the second arm, and the bent root of the right-angled piece constitutes the fixing part.

[0012] The above solution has the following technical effects: it better adapts to the internal spatial layout of the contactor, making the structure more compact, which is conducive to the miniaturization design of the contactor, and can ensure the reliability of electrical connection.

[0013] In at least one embodiment of the contactor provided in this disclosure, the first stationary contact piece and the second stationary contact piece are symmetrical about the first direction; and, The positions of the first contact and the second contact are matched with the movement trajectory of the moving contact piece, and the position of the auxiliary contact is matched with the movement trajectory of the moving iron core, so that when the moving contact piece moves to the first contact or the second contact, the moving contact piece contacts the first stationary contact piece and the second stationary contact piece, and the contact portion contacts the moving iron core; When the moving iron core is not energized or disconnected, the distances between the moving contact and the first stationary contact, the distances between the moving contact and the second stationary contact, and the distances between the contact portion and the moving iron core are all equal.

[0014] The above solution has the following technical effects: it ensures the structural stability of the contactor in both non-working and working states, and avoids problems such as malfunctions or poor contact that may be caused by component position deviations.

[0015] The contactor provided in at least one embodiment of this disclosure further includes: A coil assembly, sleeved on the outside of the moving iron core, for providing excitation to the moving iron core; and, An insulating fixing base is used to fix the integrated metal structure, the first stationary contact piece, and the second stationary contact piece to achieve rigid positioning of the integrated metal structure, the first stationary contact piece, and the second stationary contact piece.

[0016] The above solution has the following technical effects: the moving iron core is driven by the coil assembly, and the integrated metal structure, the first stationary contact piece and the second stationary contact piece are fixed by the insulating fixing seat, ensuring that the contactor will not be deformed or damaged during operation.

[0017] The contactor provided in at least one embodiment of this disclosure further includes: A housing having an opening, wherein the lead-out portion of the integral metal structure extends through the opening to the outside of the housing and forms a pin terminal for connection with an external device; The contact between the contact portion and the moving iron core in the attracted state is an elastic contact.

[0018] The above solution offers the following technical advantages: the housing protects the internal components of the contactor; the resilient contact design effectively buffers the impact forces generated during contact, reduces wear between components, and thus extends the service life of the contactor.

[0019] The contactor provided in at least one embodiment of this disclosure further includes: The controller is used to control the movement of the moving iron core and execute a pre-set voltage detection process; The voltage detection process is configured as follows: When the moving iron core is not excited, the first voltage signal of the integrated metal structure is acquired, and the first-level detection and diagnosis is performed based on the first voltage signal to determine whether the contactor is properly disconnected. After applying excitation to the moving iron core, the moving iron core drives the moving contact of the contactor to move to the first contact or the second contact, acquiring the second voltage signal of the integrated metal structure, and performing a second-level detection and diagnosis based on the second voltage signal to determine whether the contactor is properly closed; and, After the moving iron core stops being energized, the moving iron core drives the moving contact of the contactor to its initial position, acquires the third voltage signal of the integrated metal structure, and performs third-level detection and diagnosis based on the third voltage signal to determine whether the contactor is properly disconnected.

[0020] The above solution has the following technical effects: it introduces a multi-level detection and diagnosis mechanism, and performs a three-level assessment of the overall working status of the contactor during each operation, thereby obtaining a complete diagnostic result of the contactor's working status.

[0021] In the contactor provided in at least one embodiment of this disclosure, the voltage detection process is further configured as follows: When the contactor is normally disconnected after the first-level detection diagnosis, a first diagnostic result is generated to characterize that the contactor disconnection state is not abnormal. When the contactor fails to disconnect properly as diagnosed by the first-level detection, a second diagnostic result is generated to characterize the abnormal disconnection state of the contactor, and a first warning is issued; When the contactor is normally closed after the second-level diagnosis, a third diagnostic result is generated to characterize that the contactor's closing state is normal. When the contactor fails to close properly according to the second-level diagnosis, a fourth diagnostic result is generated to characterize the abnormal closing state of the contactor, and a second warning different from the first warning is issued. When the contactor is normally disconnected after the third-level detection diagnosis, a first diagnostic result is generated to characterize that the contactor switching state is normal; and... When the contactor fails to disconnect properly after the third-level detection diagnosis, a second diagnostic result is generated to characterize the abnormal switching state of the contactor, and a third warning is issued that is different from the first and second warnings.

[0022] The above solution has the following technical effects: when the contactor malfunctions during each level of detection, the system will promptly generate corresponding diagnostic results and trigger different levels of early warnings based on the type of malfunction, so that staff can quickly locate the problem and take appropriate measures, thereby ensuring the stable operation of the entire electrical system.

[0023] In the contactor provided in at least one embodiment of this disclosure, the voltage detection process is further configured as follows: The contactor's output voltage waveform is generated based on the first voltage signal, the second voltage signal, and the third voltage signal; and... The operational stability assessment result of the contactor is generated based on the output voltage waveform of the contactor.

[0024] The above solution offers the following technical advantages: the output voltage waveform can intuitively reflect the voltage changes of the contactor at different operating stages. By analyzing this waveform, the operational stability of the contactor can be determined more accurately.

[0025] At least one embodiment of this disclosure also provides an electrical device, the electrical device including a contactor as provided in any embodiment of this disclosure.

[0026] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of this disclosure, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of a contactor structure with auxiliary contacts in related technologies; Figure 2 A schematic diagram of the composition of a contactor provided for at least one embodiment of this disclosure; Figure 3 Example 1 structural diagram of an integral metal structure provided for at least one embodiment of the present disclosure; Figure 4 Example 2 structural diagram of an integral metal structure provided for at least one embodiment of the present disclosure; Figure 5 A schematic diagram of the composition of another contactor provided for at least one embodiment of this disclosure; Figure 6 A schematic diagram illustrating the composition of yet another contactor provided for at least one embodiment of this disclosure; Figure 7 A schematic diagram illustrating the composition of yet another contactor provided for at least one embodiment of this disclosure; Figure 8 A schematic diagram of the voltage detection process of a contactor provided in at least one embodiment of this disclosure; Figure 9 A structural block diagram of an electrical device provided for at least one embodiment of this disclosure.

[0029] Figure label: 1- Moving iron core; 2- Main contact assembly; 3- Auxiliary contact assembly; 4- Coil assembly; 5- Insulating mounting base; 6- Housing; 7- Auxiliary contact piece top; 8- First auxiliary contact piece; 9- Second auxiliary contact piece; 21- Moving contact piece; 22- First stationary contact piece; 23- Second stationary contact piece; 31- Integrated metal structure; 311- Fixing part; 312- Contact part; 313- Lead-out part; 314- First arm; 315- Second arm; 100- Electrical equipment; 101- Contactor. Detailed Implementation

[0030] The present disclosure will now be described in further detail with reference to the accompanying drawings and embodiments. It should be particularly noted that the following embodiments are for illustrative purposes only and do not limit the scope of the disclosure. Similarly, the following embodiments are only some, not all, embodiments of the present disclosure, and all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this disclosure.

[0031] The terms "first," "second," and "third" used in the embodiments of this disclosure are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first," "second," and "third" may explicitly or implicitly include at least one of that feature.

[0032] In the description of this disclosure, "multiple" means at least two, such as two or three, unless otherwise expressly and specifically limited.

[0033] In this disclosure, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of this disclosure. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0034] The terms “comprising” and “having”, and any variations thereof, used in the embodiments of this disclosure, are intended to cover non-exclusive inclusion. For example, a process, method, system, apparatus, or device that includes a series of steps or units is not limited to the steps or units listed, but may optionally include steps or units not listed, or may optionally include other steps or components inherent to such process, method, apparatus, or device.

[0035] In this disclosure, the term "contactor" refers to an electrical appliance in the industrial electrical field that uses current passing through a coil to generate a magnetic field, causing contacts to close, thereby controlling the load. It is an automatic switching device that uses electromagnetic principles to control the on / off state of a circuit.

[0036] In this disclosure, the term "main contact" refers to the critical contact component in a contactor that performs the main current switching task. It is typically made of a highly conductive and wear-resistant metallic material, such as a silver alloy, to ensure stable electrical performance and a long service life during frequent switching operations.

[0037] In this disclosure, the term "auxiliary contact" refers to a small-capacity contact within a contactor used for control circuits, generally classified into normally open (NO) and normally closed (NC) types. These contacts work in conjunction with the main contacts but operate independently, primarily used in signal transmission, interlocking protection, and other similar applications.

[0038] The following is based on Figure 1 Taking this as an example, we will explain in detail the contactor with auxiliary contacts in the relevant technology.

[0039] Figure 1 This is a schematic diagram of a contactor structure with auxiliary contacts in related technologies. For example... Figure 1 As shown, this type of contactor achieves its auxiliary contact design by adding an auxiliary contact plate top 7, a first auxiliary contact plate 8, and a second auxiliary contact plate 9 above the moving iron core 1. Typically, the auxiliary contact plate top 7, the first auxiliary contact plate 8, and the second auxiliary contact plate 9 are required to move up and down multiple times. After repeated movements, the first auxiliary contact plate 8 and the second auxiliary contact plate 9 become fatigued, causing them to fail to disconnect properly. This results in the auxiliary contacts remaining in a closed state, ultimately leading to an abnormal operating state of the contactor.

[0040] In the above-described scheme, the auxiliary contacts have an unfixed position and a large range of motion, resulting in insufficient structural stability. Furthermore, this type of contactor has poor temperature resistance, frequently causing contactor malfunctions due to auxiliary contact jamming, leading to signal acquisition failure. Since the auxiliary contact tip 7 is made of plastic, it will melt when high temperatures occur inside or outside the contactor, causing insufficient upward movement of the first auxiliary contact piece 8 and the second auxiliary contact piece 9, also resulting in abnormal auxiliary contact conditions.

[0041] When this type of contactor is used in a vehicle environment, vehicle vibration may exacerbate the tilt of the auxiliary contact plate top 7, causing the auxiliary contact plate top 7 to be unable to move up and down smoothly, resulting in abnormal contactor status and signal acquisition failure.

[0042] Furthermore, the above solutions typically employ an external voltage sensing module to detect the contactor's voltage, which increases the complexity and cost of the electrical equipment.

[0043] It is evident that the design of auxiliary contacts in related technologies is prone to technical problems such as signal acquisition failure, insufficient structural stability, and excessive cost.

[0044] To address the aforementioned technical problems, this disclosure proposes a contactor with more stable auxiliary contact performance and lower cost. It replaces the auxiliary contact piece top and two auxiliary contact pieces of related technologies with a one-piece metal structure. This eliminates the need for moving connections; the contact portion of the one-piece metal structure is directly connected to the moving iron core through the conductive properties between the metals. The voltage signal sampled by the moving iron core is then led out to the outside to achieve voltage acquisition. Subsequently, when the moving iron core is unexcited, the continuity between the auxiliary contact and the two main contacts can be measured to determine if the contactor is properly open; conversely, when the moving iron core is excited, the continuity between the auxiliary contact and the two main contacts can be measured to determine if the contactor is properly closed. This one-piece metal structure offers higher structural stability, temperature resistance, and fatigue resistance, resulting in more stable operation of electrical equipment using this contactor. Furthermore, the one-piece metal structure has higher strength, effectively resisting the effects of vehicle vibration, preventing the auxiliary contact piece top from tilting, and ensuring smooth closing and opening of the auxiliary contacts. Even under high temperatures inside or outside the contactor, the structure remains stable and will not melt, significantly reducing signal instability and ensuring the normal operation of the auxiliary contacts. Furthermore, this structure simplifies contactor design, reduces the number of parts, lowers the complexity and cost of the contactor, and solves the technical problems of signal acquisition failure, insufficient structural stability, and excessive cost associated with auxiliary contact designs in related technologies.

[0045] Figure 2 This is a schematic diagram illustrating the composition of a contactor provided for at least one embodiment of this disclosure. Figure 2 As shown, the contactor may include a moving iron core 1, a main contact assembly 2, and an auxiliary contact assembly 3.

[0046] The moving iron core 1 moves back and forth along the first direction.

[0047] The main contact assembly 2 includes a moving contact 21 fixed to the moving iron core 1, a first stationary contact 22 located at a fixed first contact point, and a second stationary contact 23 located at a fixed second contact point. The main contact assembly 2 is used to connect or disconnect the circuit in which the contactor is located.

[0048] The auxiliary contact assembly 3 includes a one-piece metal structure 31. The structure of the one-piece metal structure 31 is as follows: Figure 3As shown, it integrates a fixing part 311, a contact part 312, and a lead-out part 313. The fixing part 311 is used to fix the integrated metal structure 31 at a designated position between the first stationary contact piece 22 and the second stationary contact piece 23, and to ensure that the integrated metal structure 31 has no relative sliding or rotational movement during the operation of the contactor. The contact part 312 is an auxiliary contact located between the first contact and the second contact. When the moving iron core 1 moves to the first contact or the second contact, the contact part 312 contacts the moving iron core 1 to form a voltage signal. The lead-out part 313 is used to lead out the voltage signal to realize voltage detection of the auxiliary contact.

[0049] It should be noted that the first and second contacts serve as the main contacts of the contactor. The specified position is not limited to the middle position. This disclosure does not limit the first direction. The first direction can be vertical, horizontal, or any other arbitrarily set direction, as long as it meets the usage requirements of the contactor in the actual working scenario and the reasonable layout and cooperation between the components.

[0050] In the above scheme, the moving iron core 1, as the core component of the contactor's operation, directly affects the contactor's working performance due to the accuracy of its motion trajectory. During contactor operation, the moving iron core 1 moves linearly along a preset first direction under the action of electromagnetic force, thereby achieving reliable contact and separation between the moving contact 21 and the first stationary contact 22 and the second stationary contact 23, as well as reliable contact and separation between the moving iron core 1 and the contact portion 312. The moving iron core 1 needs to possess good conductivity, magnetic permeability, and strength to ensure stable performance during frequent contact and separation processes, and to prevent wear or deformation.

[0051] In the above scheme, the main contact assembly 2, as the core part of the contactor, undertakes the critical task of controlling the current flow. It consists of key components such as the moving contact 21, the first stationary contact 22, and the second stationary contact 23. Driven by the moving iron core 1, the moving contact 21 can flexibly contact or separate from either the first stationary contact 22 or the second stationary contact 23, thereby connecting or disconnecting the circuit. This design not only ensures the stability of current transmission but also significantly improves the reliability and service life of the contactor. One of the first stationary contact 22 and the second stationary contact 23 is responsible for connecting the circuit, while the other is specifically responsible for disconnecting it; neither is energized simultaneously, thus minimizing the risks of arcing, ablation, and short circuits. The rational layout and optimized design of the main contact assembly 2 provide a strong guarantee for the safe operation of the contactor.

[0052] In the above scheme, the auxiliary contact component 3, as an important part of the contactor, serves the function of voltage detection for the auxiliary contacts. Simultaneously with the main circuit where the main contact component 2 is located is turned on or off, the auxiliary contact component 3 can synchronously close or open the auxiliary circuit where it is located based on the state changes of the main contacts (i.e., the first and second contacts), thereby obtaining the voltage signal of the auxiliary contacts. This design allows the contactor not only to control the on / off state of the main circuit but also to provide feedback on the contactor's operating status to external devices or control systems through the auxiliary contact component 3, such as whether the circuit has been successfully connected or disconnected. The presence of the auxiliary contact component 3 significantly enhances the functionality and practicality of the contactor, enabling it to better adapt to complex circuit control requirements.

[0053] In the above scheme, the design of the fixing part 311, the contact part 312, and the lead-out part 313 allows the external connection of the auxiliary contact to be matched with the moving iron core, leading the voltage signal on the moving iron core 1 out of the contactor, thereby realizing the voltage acquisition function of the contactor. At the same time, the fixing part 311 is used to fix the contactor, which can prevent abnormal conditions of the contactor caused by frequent movement, fatigue, or overheating.

[0054] Some embodiments of this disclosure also provide electrical equipment having the contactor described above.

[0055] The contactor provided in at least one embodiment of this disclosure is applicable to any existing contactor application scenario that requires improved signal acquisition success rate, structural stability, and reduced cost. For example, in the field of new energy vehicles, this contactor can be applied to the relay module in a battery management system. New energy vehicles have extremely high requirements for the accuracy and reliability of battery management. This contactor, with its high signal acquisition success rate, can accurately reflect the voltage state of various parts of the battery pack, providing accurate data to the battery management system and helping to achieve precise charging and discharging control of the battery. Its stable structural design ensures reliable operation even under various complex road conditions and vibration environments during vehicle operation, reducing system anomalies caused by faults such as poor contact. Moreover, compared with traditional contactors, it reduces costs while maintaining performance, which is beneficial to improving the overall cost-effectiveness of new energy vehicles. In the field of industrial automation control, many large electrical devices require a large number of contactors to control circuit switching and signal transmission. The contactor disclosed in this disclosure can be used in the relay control part of these devices. The high signal acquisition success rate can obtain equipment operating status information in a timely and accurate manner, such as motor speed, temperature, and other parameters, providing a reliable basis for intelligent control of the equipment. A stable structure ensures reduced equipment downtime and improved production efficiency during long-term continuous operation and in complex industrial environments. Simultaneously, lower costs enable wider application during equipment upgrades and modifications, enhancing the company's automation level.

[0056] Figure 4Example two structural diagrams of an integral metal structure provided for at least one embodiment of this disclosure. Figure 2 On the basis of, such as Figure 4 As shown, the integrated metal structure 31 has no moving parts and includes a first arm 314 and a second arm 315. The first arm 314 is disposed between the first stationary contact piece 22 and the second stationary contact piece 23 and is located in a first direction. The first arm 314 integrates a fixing part 311 and a contact part 312. The second arm 315 is disposed in a second direction different from the first direction and is fixedly connected to the first arm 314. The second arm 315 does not contact the first stationary contact piece 22 and the second stationary contact piece 23, and the second arm 315 integrates a lead-out part 313. The function of the fixing part 311 is to firmly install the integrated metal structure 31 in the corresponding position inside the contactor, ensuring that it can maintain a stable state under various working conditions and will not be displaced due to vibration or external force. The contact part 312 is responsible for achieving reliable electrical contact with the stationary contact piece. When the circuit needs to be turned on, it can quickly and accurately establish an electrical connection to ensure smooth current transmission. The lead-out section 313 connects the integrated metal structure 31 to other circuit components to bring out voltage detection signals, providing input for subsequent signal processing and analysis. This integrated metal structure design not only simplifies the internal structure of the contactor, reduces the number of parts, and lowers assembly difficulty and cost, but also improves the reliability and stability of the contactor.

[0057] In the above scheme, the first arm 314 replaces the auxiliary contact piece top and two auxiliary contacts of the related technology, and the second arm 315 replaces the external connection point (external voltage sensing module) of the related technology. Only one connection point needs to be left for external connection.

[0058] Figure 5 This is a schematic diagram illustrating the composition of another contactor provided for at least one embodiment of this disclosure. Figure 4 On the basis of, such as Figure 5 As shown, to optimize the internal space layout of the contactor, the integrated metal structure 31 adopts a right-angled metal structure. The angle between the first arm 314 and the second arm 315 is 90°, meaning the first and second directions are perpendicular. This design uses an L-shaped lead-out. The right-angle design better adapts to the internal space layout of the contactor, making the structure more compact. This right-angled metal structure ensures reliable electrical connections while effectively reducing space occupation, which is beneficial for the miniaturization design of the contactor. Moreover, the right-angled structure is relatively simple to manufacture, reducing processing difficulty and manufacturing costs, and improving production efficiency.

[0059] In some embodiments, Figure 4Based on this, to adapt to the internal spatial layout of the contactor, the angle between the first arm 314 and the second arm 315 is not 90°. This non-right-angle metal structure design allows for adjustment of the angle between the first arm 314 and the second arm 315 according to the actual space and layout requirements within the contactor. This design not only maintains the reliability of the electrical connection but also better adapts to various complex installation environments. While the manufacturing process of the non-right-angle metal structure may be slightly more complex than that of the right-angle structure, its optimized spatial layout and adaptability give it significant advantages in specific application scenarios. Furthermore, by precisely controlling the angle of the first arm 314 and the second arm 315, the performance of the contactor can be further optimized, improving working efficiency and stability.

[0060] In some embodiments, Figure 2 Based on this, and to accommodate the internal spatial layout of the contactor, the integrated metal structure 31 adopts a non-right-angled metal structure, which can have only a first arm 314 and no second arm 315. For example, Figure 6 This is a schematic diagram of another contactor provided in at least one embodiment of the present disclosure, which adopts a vertical lead-out method. For example, Figure 7 This is a schematic diagram of another contactor provided in at least one embodiment of the present disclosure, which employs a wire harness lead-out method. The vertical lead-out method, by designing the integrated metal structure 31 as a vertical form containing only the first arm 314, can further reduce the lateral space occupied inside the contactor, making it particularly suitable for installation scenarios where the left and right directions are restricted. The wire harness lead-out method replaces the rigid metal arm with a flexible wire harness, not only eliminating the need for a fixed structure for the second arm 315, but also enabling flexible wiring in three-dimensional space through the bending characteristics of the wire harness. This design has significant advantages in complex circuit layouts requiring multi-directional connections. Both non-right-angle structures simplify the shape of metal components, providing more freedom for the arrangement of internal components of the contactor while maintaining electrical performance.

[0061] exist Figures 2-7 In the scheme shown, the dimensions and height of the integrated metal structure 31 need to match the moving iron core 1. The shape of the other parts can be modified according to the usage requirements. The external lead-out parts can even be made into pins so that they can be plugged into the plug for easy connection.

[0062] exist Figures 2-7In the illustrated scheme, the integrated metal structure 31 is a one-piece molded fixed metal conductor. The fixed metal conductor 316 is positioned between the first stationary contact piece 22 and the second stationary contact piece 23, and integrates a fixing part 311, a contact part 312, and a lead-out part 313. The fixing part 311 securely mounts the fixed metal conductor 316 at a designated position inside the contactor, ensuring it does not loosen or shift during operation, thus guaranteeing the stability of the electrical connection. The contact part 312 closely cooperates with the first stationary contact piece 22 and the second stationary contact piece 23, accurately and reliably connecting and disconnecting the corresponding circuit when the contactor operates, ensuring normal current transmission. The lead-out part 313 is responsible for leading out the voltage signal from the auxiliary contacts for connection to external circuits. Its reasonable design ensures the accuracy and stability of signal transmission, reducing signal interference and loss. This one-piece molded fixed metal conductor 316 design not only simplifies the internal structure of the contactor and improves assembly efficiency but also enhances the overall performance and reliability of the contactor.

[0063] In some embodiments, Figure 4 Based on this, to achieve a stable connection of the integrated metal structure 31, the integrated metal structure 31 is a right-angled piece formed by one-time bending. The vertical section of the right-angled piece forms the first arm 314, the horizontal section forms the second arm 315, and the bent root of the right-angled piece forms the fixing part 311. The right-angle structure formed by the vertical and horizontal sections of the right-angled piece gives the integrated metal structure a clear spatial positioning and orientation. This structure not only facilitates installation and fixing but also effectively disperses stress, improving the stability and reliability of the structure. The fixing part 311, as the bent root of the right-angled piece, is tightly connected to the other parts of the contactor, ensuring the stable position of the integrated metal structure 31 within the contactor. Simultaneously, the first arm 314 and the second arm 315 extend along the first and second directions respectively, facilitating the arrangement of voltage sampling terminals and the extraction of voltage signals.

[0064] In some embodiments, Figure 3 or Figure 4 Building upon this foundation, to provide reliable data support for subsequent voltage detection and analysis, a voltage sampling terminal is integrated at the end of the lead-out section 313. This voltage sampling terminal is used to acquire the voltage signal of the circuit containing the contactor, enabling real-time monitoring of the circuit's voltage status. This voltage sampling terminal features high precision and low error, accurately acquiring voltage values ​​and providing reliable data support for subsequent voltage detection and analysis. Furthermore, the design of the voltage sampling terminal considers compatibility with external voltage detection equipment, facilitating connection to various voltage detection instruments for rapid and accurate voltage detection.

[0065] In some embodiments, to avoid problems such as motion fatigue, overheating, and jamming in the integrated metal structure 31, the integrated metal structure 31 can be directly welded to the moving iron core 1, and the voltage signal of the moving iron core 1 can be sampled and led out from the contactor to the outside of the contactor. This can also realize the connection between the moving iron core 1 and the outside, and lead out the voltage sampling, thus avoiding problems such as motion fatigue, overheating, and jamming in the metal.

[0066] In some embodiments, to ensure the balance and stability of current transmission, the first stationary contact 22 and the second stationary contact 23 are symmetrical about a first direction. Specifically, the first stationary contact 22 and the second stationary contact 23 adopt a completely symmetrical layout design about the first direction. This symmetrical structure ensures that the current load borne by the two contact pieces remains highly consistent during current transmission. This symmetrical arrangement not only effectively avoids local overheating caused by uneven current distribution but also significantly improves the stability of the entire conductive system. Simultaneously, the symmetrical design makes the electromagnetic field distribution more balanced, further enhancing the reliability of current transmission, thereby ensuring the balance and stability of long-term operation of electrical equipment, extending the service life of the equipment, and reducing electromagnetic interference to a certain extent, improving the reliability of contactor operation. This symmetrical design also makes the contactor structurally more regular, which is conducive to the overall miniaturization and integration development.

[0067] In some embodiments, to reduce contact resistance and energy loss, the positions of the first and second contacts are matched with the movement trajectory of the moving contact 21, and the position of the auxiliary contact is matched with the movement trajectory of the moving iron core 1. This ensures that when the moving contact 21 moves to the first or second contact, it contacts the first stationary contact 22 and the second stationary contact 23, and the contact portion 312 contacts the moving iron core 1. Furthermore, when the moving iron core 1 is unexcited or disconnected, the distances between the moving contact 21 and the first stationary contact 22, the distances between the moving contact 21 and the second stationary contact 23, and the distances between the contact portion 312 and the moving iron core 1 are all equal. This positional matching design allows the moving contact 21 to reliably contact the first stationary contact 22 and the second stationary contact 23 precisely during movement, and the moving iron core 1, after being raised, contacts the contact portion 312, ensuring the stability of current conduction. When the moving contact 21 moves to the corresponding contact, a stable electrical connection can be quickly established, reducing contact resistance and energy loss. The fact that all components are equidistant when the moving iron core 1 is unexcited or disconnected further ensures the structural stability of the contactor in its non-operating state, avoiding problems such as malfunctions or poor contact caused by component position deviations. At the same time, this precise positional matching relationship provides a foundation for contactor performance optimization, helping to improve the overall reliability and service life of the contactor.

[0068] In some embodiments, to effectively drive the moving iron core 1, the contactor further includes a coil assembly 4, such as... Figure 5 , Figure 6 or Figure 7 As shown, the coil assembly 4 is sleeved on the outside of the moving iron core 1 to provide excitation for the moving iron core 1. Specifically, the coil assembly 4 includes a coil frame and an excitation coil wound on the coil frame. When the excitation coil is energized, it generates a magnetic field. This magnetic field acts on the moving iron core 1, driving it to move linearly. This, in turn, causes the moving contact 21 to make contact with and separate from the first stationary contact 22 and the second stationary contact 23, thus completing the on / off control of the contactor. It also achieves contact between the moving iron core 1 and the contact portion 312, completing the voltage signal acquisition of the contactor. The number of turns and wire diameter of the coil assembly 4 can be optimized according to the actual required driving force and response speed to meet the working requirements of the contactor in different application scenarios.

[0069] In some embodiments, to prevent damage to the contactor during operation, the contactor further includes an insulating mounting base 5, such as... Figure 3 As shown, the insulating fixing base 5 is used for the integrated metal structure 31, the first stationary contact 22, and the second stationary contact 23 to achieve rigid positioning of the integrated metal structure 31, the first stationary contact 22, and the second stationary contact 23. The insulating fixing base 5 is made of high-strength insulating material, which ensures that the contactor not only has excellent insulation performance but can also withstand a certain degree of stress, ensuring that it will not deform or be damaged during operation.

[0070] In some embodiments, to improve the overall structural strength of the contactor, the contactor further includes a housing 6, such as... Figure 5 , Figure 6 or Figure 7 As shown, the insulating mounting base 5 is made of ceramic and is fixed inside the housing 6. The housing 6 is typically made of high-strength, corrosion-resistant metal or engineering plastic, providing a robust protective shell for the entire contactor. The ceramic insulating mounting base 5 and the housing 6 are fixed together using a precision assembly process, ensuring a stable and reliable connection. This design not only improves the overall structural strength of the contactor but also effectively prevents interference and damage to internal components from the external environment.

[0071] In some embodiments, to ensure stable operation of the contactor, the integrated metal structure 31, the first stationary contact 22, and the second stationary contact 23 are all fixed to the insulating mounting base 5 by welding, and then led out through the housing 6. The welding process employs advanced technology to ensure a strong connection and good conductivity. The housing 6 not only provides insulation but also protects the internal components from damage caused by external factors such as dust and moisture. Simultaneously, the design of the housing 6 also considers heat dissipation, effectively dissipating the heat generated during contactor operation and ensuring stable operation.

[0072] In some embodiments, to reduce wear between components, the contact portion 312 and the moving iron core 1 make elastic contact in the engaged state. This elastic contact design effectively buffers the impact force generated during contact, reducing wear between components and extending the contactor's service life. This contact method can also absorb vibration within a certain range, improving the stability of the contactor's operation. Simultaneously, the force of the elastic contact can be precisely controlled by adjusting the parameters of the elastic element to meet the contact pressure requirements under different operating conditions. Figure 8 This diagram illustrates the voltage detection process of a contactor provided in at least one embodiment of the present disclosure. The contactor also includes a controller. The controller is used to control the movement of the moving iron core 1 and execute a pre-set voltage detection process. Figure 8 As shown, the voltage detection process is configured to include the following steps S10-S30.

[0073] Step S10: When the moving iron core 1 is not energized, acquire the first voltage signal of the integrated metal structure 31, and perform the first-level detection and diagnosis based on the first voltage signal to determine whether the contactor is properly disconnected.

[0074] Step S20: After applying excitation to the moving iron core 1, the moving iron core 1 drives the moving contact piece 21 of the contactor to move to the first contact or the second contact, and obtains the second voltage signal of the integrated metal structure 31. Based on the second voltage signal, a second-level detection and diagnosis is performed to determine whether the contactor is closed normally.

[0075] Step S30: After the moving iron core 1 stops being energized, the moving iron core drives the moving contact piece 21 of the contactor to move to its initial position, acquires the third voltage signal of the integrated metal structure 31, and performs third-level detection and diagnosis based on the third voltage signal to determine whether the contactor is properly disconnected.

[0076] During the execution of steps S10 to S30, the controller is responsible for storing and analyzing the acquired first, second, and third voltage signals. The controller has an internal data analysis module that comprehensively evaluates the results of the three diagnostic tests based on preset algorithms and judgment criteria. If all three diagnostic results indicate that the contactor is in normal condition, the controller determines that the contactor's overall operating condition is good. If any one of the diagnostic results is abnormal, the controller will activate an alarm mechanism and send a fault signal via a preset communication interface, thereby promptly notifying maintenance personnel to carry out repairs. Simultaneously, the controller has a self-learning function, continuously optimizing the diagnostic algorithm based on the contactor's historical operating data to improve the accuracy and reliability of the tests. In some embodiments, in order to further determine the voltage detection, the voltage detection process executed by the controller is configured to further include the following steps S40 and S50.

[0077] Step S40: Generate the output voltage waveform of the contactor based on the first voltage signal, the second voltage signal and the third voltage signal.

[0078] Step S50: Generate the contactor's operational stability assessment results based on the contactor's output voltage waveform.

[0079] The output voltage waveform directly reflects the voltage changes of the contactor during different operating stages. Analyzing this waveform allows for a more accurate assessment of the contactor's operational stability. For example, abnormal fluctuations or distortions in the output voltage waveform may indicate problems such as poor contact or coil malfunction within the contactor. Furthermore, comparing the generated output voltage waveform with a preset standard waveform allows for rapid fault location and assessment of the contactor's operating status, providing a strong basis for subsequent maintenance and repair, and further improving the stability and reliability of the contactor's operation.

[0080] In some embodiments, in order to ensure the stable operation of the electrical system using the contactor, the voltage detection process executed by the controller is configured to further include the following steps S11, S12, S21, S22, S31 and S32.

[0081] Step S11: When the contactor is normally disconnected after the first-level detection diagnosis, a first diagnostic result is generated to characterize that there is no abnormality in the contactor disconnection state.

[0082] Step S12: When the contactor fails to disconnect properly after the first-level detection diagnosis, a second diagnostic result is generated to characterize the abnormal disconnection state of the contactor, and a first warning is issued.

[0083] Step S21: When the contactor is closed normally after the second-level diagnosis, a third diagnostic result is generated to characterize that there is no abnormality in the contactor's closing state.

[0084] Step S22: When the contactor fails to close properly after the second-level diagnosis, a fourth diagnostic result is generated to characterize the abnormal contactor closure state, and a second warning is issued that is different from the first warning.

[0085] Step S31: When the contactor is normally disconnected after the third-level detection diagnosis, a first diagnostic result is generated to characterize that there is no abnormality in the contactor switching state.

[0086] Step S32: When the contactor fails to disconnect properly after the third-level detection diagnosis, a second diagnostic result is generated to characterize the abnormal switching state of the contactor, and a third warning is issued that is different from the first and second warnings.

[0087] It should be noted that steps S11 and S12 are set after step S10, steps S21 and S22 are set after step S20, and steps S31 and S32 are set after step S30.

[0088] The contactor, which integrates voltage detection, can accurately determine its operating status under different conditions through a multi-level detection and diagnostic mechanism. When an abnormality is detected in any level of the contactor, the system will promptly generate corresponding diagnostic results and trigger different levels of warnings based on the type of abnormality. This allows staff to quickly locate the problem and take appropriate measures, thereby ensuring the stable operation of the entire electrical system.

[0089] In some embodiments, to further optimize the configuration, the voltage detection process includes steps S41 and S42.

[0090] Step S41: Identify that the contactor frequently experiences abnormal open and closed states within a preset time, generate a comprehensive abnormality diagnosis result to characterize the abnormality of the contactor's operational stability, and trigger a comprehensive early warning mechanism. This comprehensive early warning mechanism is configured to integrate the first early warning, the second early warning, and the third early warning and provide a fault analysis report.

[0091] Step S42: After the comprehensive abnormal diagnosis results are generated, the detection frequency of the contact part 312 is switched from the conventional detection mode to the high-frequency detection mode, that is, the detection frequency of the contact part 312 is increased to obtain new operational stability assessment results of the contactor, providing strong support for subsequent maintenance and repair work.

[0092] The voltage detection process, through the coordinated action of steps S41 and S42, achieves comprehensive monitoring and intelligent response to the contactor's operating status. When the contactor experiences frequent abnormal conditions, the system can not only issue timely comprehensive warnings but also provide detailed fault information to staff through fault analysis reports, helping to quickly pinpoint the root cause of the problem. Simultaneously, the controller automatically adjusts the detection frequency to a high-frequency mode, further improving the accuracy and timeliness of status monitoring and providing a more reliable guarantee for the stable operation of the electrical system.

[0093] This disclosure also provides an electrical device. Figure 9 This is a structural block diagram of an electrical device provided for at least one embodiment of this disclosure. (See diagram below.) Figure 9 As shown, the electrical equipment 100 includes a contactor 101 as described in the above embodiment.

[0094] Although embodiments of the present disclosure have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the present disclosure, and such modifications and variations all fall within the scope defined by the appended claims.

[0095] Although embodiments of the present disclosure have been shown and described above, it is to be understood that the above embodiments are exemplary and should not be construed as limiting the present disclosure. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present disclosure.

Claims

1. A contactor integrating voltage detection function, characterized in that, include: The moving iron core (1) reciprocates along a first direction; The main contact assembly (2) includes a moving contact piece (21) fixed on the moving iron core (1), a first stationary contact piece (22) located at a fixed first contact point, and a second stationary contact piece (23) located at a fixed second contact point. The main contact assembly (2) is used to connect or disconnect the circuit where the contactor is located. as well as, The auxiliary contact assembly (3) includes an integral metal structure (31). The integrated metal structure (31) integrates: The fixing part (311) is used to fix the integrated metal structure (31) at a designated position between the first stationary contact piece (22) and the second stationary contact piece (23), and to ensure that the integrated metal structure (31) has no relative sliding or rotational movement during the operation of the contactor. A contact portion (312) is located as an auxiliary contact between the first contact and the second contact. When the moving contact piece (21) moves to the first contact or the second contact, the contact portion (312) contacts the moving iron core (1) to form a voltage signal; and Lead-out section (313) is used to lead out the voltage signal to realize voltage detection of the auxiliary contact.

2. The contactor according to claim 1, characterized in that, The integrated metal structure (31) has no moving parts, and the integrated metal structure (31) includes: A first arm (314) is disposed between the first stationary contact piece (22) and the second stationary contact piece (23) and located in the first direction. The first arm (314) integrates the fixing part (311) and the contact part (312); and, The second arm (315) is located in a second direction different from the first direction and is fixedly connected to the first arm (314). The second arm (315) has no contact with the first stationary contact piece (22) and the second stationary contact piece (23), and the lead-out portion (313) is integrated on the second arm (315).

3. The contactor according to claim 2, characterized in that, The end of the lead-out portion (313) is integrated with a voltage sampling terminal; and, The first direction and the second direction are perpendicular. The integrated metal structure (31) is a right-angled piece formed by bending in one go. The vertical section of the right-angled piece constitutes the first arm (314), the horizontal section of the right-angled piece constitutes the second arm (315), and the bent root of the right-angled piece constitutes the fixing part (311).

4. The contactor according to claim 1 or 2, characterized in that, The first stationary contact piece (22) and the second stationary contact piece (23) are symmetrical about the first direction; and, The positions of the first contact and the second contact are matched with the movement trajectory of the moving contact piece (21), and the position of the auxiliary contact is matched with the movement trajectory of the moving iron core (1), so that when the moving contact piece (21) moves to the first contact or the second contact, the moving contact piece (21) contacts the first stationary contact piece (22) and the second stationary contact piece (23), and the contact portion (312) contacts the moving iron core (1); When the moving iron core (1) is not energized or disconnected, the distance between the moving contact piece (21) and the first stationary contact piece (22), the distance between the moving contact piece (21) and the second stationary contact piece (23), and the distance between the contact portion (312) and the moving iron core (1) are all equal.

5. The contactor according to claim 1 or 2, characterized in that, Also includes: Coil assembly (4), which is sleeved on the outside of the moving iron core (1) and is used to provide excitation for the moving iron core (1); as well as, An insulating fixing seat (5) is used to fix the integrated metal structure (31), the first static contact piece (22) and the second static contact piece (23) to achieve rigid positioning of the integrated metal structure (31), the first static contact piece (22) and the second static contact piece (23).

6. The contactor according to claim 1 or 2, characterized in that, Also includes: The housing (6) has an opening, and the lead-out portion (313) of the integral metal structure (31) extends through the opening to the outside of the housing (6) and forms a pin terminal for connection with external devices. The contact part (312) and the moving iron core (1) in the attracted state are in elastic contact.

7. The contactor according to claim 1 or 2, characterized in that, Also includes: The controller is used to control the movement of the moving iron core (1) and execute a pre-set voltage detection process; The voltage detection process is configured as follows: When the moving iron core (1) is not excited, the first voltage signal of the integrated metal structure (31) is acquired, and the first-level detection and diagnosis is performed based on the first voltage signal to determine whether the contactor is properly disconnected. After applying excitation to the moving iron core (1), the moving iron core (1) drives the moving contact piece (21) of the contactor to move to the first contact or the second contact, acquires the second voltage signal of the integrated metal structure (31), and performs a second-level detection and diagnosis based on the second voltage signal to determine whether the contactor is properly closed; and, After the moving iron core (1) stops being excited, the moving iron core drives the moving contact (21) of the contactor to move to its initial position, obtains the third voltage signal of the integrated metal structure (31), and performs third-level detection and diagnosis based on the third voltage signal to determine whether the contactor is properly disconnected.

8. The contactor according to claim 7, characterized in that, The voltage detection process is also configured as follows: When the contactor is normally disconnected after the first-level detection diagnosis, a first diagnostic result is generated to characterize that the contactor disconnection state is not abnormal. When the contactor fails to disconnect properly as diagnosed by the first-level detection, a second diagnostic result is generated to characterize the abnormal disconnection state of the contactor, and a first warning is issued; When the contactor is normally closed after the second-level diagnosis, a third diagnostic result is generated to characterize that the contactor's closing state is normal. When the contactor fails to close properly after the second-level diagnosis, a fourth diagnostic result is generated to characterize the abnormal closing state of the contactor, and a second warning different from the first warning is issued. When the contactor is normally disconnected after the third-level detection diagnosis, a first diagnostic result is generated to characterize that the contactor switching state is not abnormal. as well as, When the contactor fails to disconnect properly after the third-level detection diagnosis, a second diagnostic result is generated to characterize the abnormal switching state of the contactor, and a third warning is issued that is different from the first and second warnings.

9. The contactor according to claim 7, characterized in that, The voltage detection process is also configured as follows: The contactor's output voltage waveform is generated based on the first voltage signal, the second voltage signal, and the third voltage signal; as well as, The operational stability assessment result of the contactor is generated based on the output voltage waveform of the contactor.

10. An electrical appliance, characterized in that, The electrical equipment includes a contactor as described in any one of claims 1 to 9.

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