Multi-switch contactor assembly with pre-charge relay

Abstract

In one embodiment, a multi-switch contactor assembly with a pre-charge system is disclosed. The multi-switch contactor also includes a switch array and an actuator assembly configured to actuate each switch in the switch array. In this embodiment, the switch array includes a first switch configured to connect a first battery device to an electrical circuit and a second switch configured to connect a second battery device to the electrical circuit. The switch array also includes a third switch configured to connect the first battery device and the second battery device in series to the circuit and a fourth switch configured to connect the pre-charge resistor to at least one of the first battery device and the second battery device.

Description

Technical Field

[0001] This invention relates to a multi-switch contactor assembly, and more particularly to a multi-switch contactor assembly with a pre-charged relay. Background Technology

[0002] Electromechanical switching devices (such as contactors and relays) are designed to carry a certain amount of current for a given period of time. Such devices are particularly important in electric vehicles. Typically, electric vehicles have multiple electromechanical switches that open or close high-current paths between the battery pack and the electrical system. These switches are controlled by different actuating mechanisms. To prevent short circuits in the battery pack, the electromechanical switching elements of the battery-configured contactors must withstand mechanical shocks and coordinate multiple switches to change the battery connection configuration. Summary of the Invention

[0003] To avoid unnecessary switch combinations, a multi-switch contactor assembly is provided, wherein a single mechanical actuation mechanism operates multiple switches in a manner that makes it mechanically impossible to produce dangerous switch combinations. In a particular example, the multiple switches can be actuated by multiple cams coupled to the same camshaft. Different combinations of switch states (open or closed) between the multiple switches are achieved by rotation of the camshaft. This provides a limited set of configuration states that can be controlled by a single actuator. Different cam shapes or different orientations on the camshaft can be used to achieve different combinations of switch states. This provides low contact resistance and high contact force, while requiring no power supply to hold the switches in a specific state.

[0004] According to embodiments of this disclosure, the contact force is further increased by utilizing the Lorentz force acting on the movable contact due to the shape and orientation of the fixed and movable contacts. In some examples, the shape and orientation of the fixed and movable contacts cause them to form self-looping conductors. In some embodiments, the fixed contact is formed in a C-shape or other partially ring shape, and the movable contact is oriented to contact the inner surface of the fixed contact within the ring. In the presence of a high current flowing through the fixed and movable contacts, the Lorentz force acting on the movable contact pushes the movable contact toward the fixed contact, thereby increasing the contact force. In some embodiments, the multi-switch contactor assembly includes a pre-charge switch. These embodiments eliminate the need for a separate pre-charge circuit.

[0005] In one embodiment, a multi-switch contactor assembly with a pre-charging system is disclosed, comprising a switch array and an actuator assembly configured to actuate each switch in the switch array. In this embodiment, the switch array includes a first switch configured to connect a first battery device to a circuit and a second switch configured to connect a second battery device to a circuit. The switch array also includes a third switch configured to connect the first and second battery devices in series to a circuit and a fourth switch configured to connect a pre-charging resistor to at least one of the first and second battery devices.

[0006] In another embodiment, a system comprising a first battery device and a second battery device with multiple components is disclosed. The system also includes a vehicle power distribution circuit and a multi-switch contactor assembly connecting the multiple components and the vehicle power distribution circuit. In this embodiment, the multi-switch contactor assembly includes a switch array and an actuator assembly configured to actuate each switch in the switch array. The switch array includes a first switch configured to connect the first battery device to a circuit and a second switch configured to connect the second battery device to a circuit. The switch array also includes a third switch configured to connect the first battery device and the second battery device in series to a circuit and a fourth switch configured to connect a pre-charge resistor to at least one of the first battery device and the second battery device.

[0007] In another embodiment, a method for operating a multi-switch contactor assembly with a pre-charge system is disclosed. The multi-switch contactor assembly further includes a switch array and an actuator assembly, the actuator assembly including a shaft and configured to actuate each switch in the switch array. The switch array includes a first switch configured to connect a first battery device to a circuit and a second switch configured to connect a second battery device to a circuit. The switch array also includes a third switch configured to connect the first and second battery devices in series to a circuit and a fourth switch configured to connect a pre-charge resistor to at least one of the first and second battery devices. The method includes rotating the shaft of the actuator assembly from a fully open position to a pre-charge position, in which the first, second, third, and fourth switches are open, and in the pre-charge position, the fourth switch is closed and the first, second, and third switches are open. The method further includes rotating the shaft from the pre-charge position to a series position, in which the fourth switch is closed and the third switch is closed. The method further includes rotating the shaft from the series position to the pre-charge position and then rotating the shaft from the pre-charge position to a fully open position. Attached Figure Description

[0008] Figure 1 This is a circuit diagram of a multi-switch contactor assembly according to at least one embodiment of the present disclosure.

[0009] Figure 2AThis is a schematic diagram of a first state of an example switch assembly for a multi-switch contactor assembly according to at least one embodiment of the present disclosure.

[0010] Figure 2B yes Figure 2A Another state of the example switch component.

[0011] Figure 3 This is a schematic diagram of the configuration state of a multi-switch contactor assembly according to at least one embodiment of the present disclosure.

[0012] Figure 4 This is an exploded view of a multi-switch contactor assembly according to at least one embodiment of the present disclosure.

[0013] Figure 5 Various cam shapes according to embodiments of the present disclosure are shown.

[0014] Figure 6 The Lorentz force on a conductor according to the principles of this disclosure is shown.

[0015] Figure 7 A schematic diagram of an exemplary single switch assembly for a multi-switch contactor assembly according to at least one embodiment of the present disclosure is shown.

[0016] Figure 8A A schematic diagram of an example bus geometry for a multi-switch contactor assembly according to at least one embodiment of the present disclosure is shown.

[0017] Figure 8B A schematic diagram of an exemplary single switch assembly for a multi-switch contactor assembly according to at least one embodiment of the present disclosure is shown.

[0018] Figure 8C A schematic diagram of an example bus geometry for a multi-switch contactor assembly according to at least one embodiment of the present disclosure is shown.

[0019] Figure 9 A schematic diagram of an example electric vehicle power distribution system according to at least one embodiment of the present disclosure is shown.

[0020] Figure 10 This is a circuit diagram of another multi-switch contactor assembly according to at least one embodiment of the present disclosure.

[0021] Figure 11 This is a switch state table for another multi-switch contactor assembly according to at least one embodiment of the present disclosure.

[0022] Figure 12 An example multi-switch contactor assembly including a pre-charging system is shown according to at least one embodiment of the present disclosure.

[0023] Figure 13 This is a flowchart of an example method for operating a multi-switch contactor assembly according to at least one embodiment of the present disclosure.

[0024] Figure 14 This is a flowchart of an example method for operating a multi-switch contactor assembly having a pre-charging system according to at least one embodiment of the present disclosure. Detailed Implementation

[0025] Connecting and disconnecting circuits is as old as the circuit itself, and is commonly used as a method of switching the power supply of electrical devices between “open” and “closed” states. An example of a device commonly used for connecting and disconnecting circuits is a contactor, which is electrically connected to one or more devices or power sources. A contactor is configured to change between “open” and “closed” states to interrupt or complete the circuit, thereby controlling the power supply to the devices.

[0026] With societal progress, various innovations have made electrical systems and electronic devices increasingly prevalent. An example of this innovation is the recent advancements in electric vehicles, which are becoming the energy-efficient standard and may replace most traditional petroleum-powered vehicles. In these expensive and frequently used electrical installations, overcurrent protection is particularly useful for preventing device malfunctions and permanent damage. Furthermore, overcurrent protection can prevent safety hazards such as electric shock or electrical fires. These modern improvements to electrical systems and devices necessitate improved solutions to enhance the safety, reliability, and efficiency of contactor triggering mechanisms.

[0027] This document describes different embodiments of contact assemblies having certain components or portions thereof integrally formed with each other to improve operating characteristics and enhance operational reliability and safety. The invention also provides novel features of the components of the contact assembly that provide the desired operating characteristics, performance, and safety. Embodiments of the invention also relate to contactors (i.e., electrical switching devices) utilizing contactor assemblies according to the invention, and circuits and systems utilizing electrical switching devices according to the invention.

[0028] The terminology used to describe particular examples in this document is not intended to limit other examples. Whenever a singular form such as “a,” “an,” and “the” is used, and the use of a single element is neither explicitly nor implicitly defined as mandatory, other examples may use multiple elements to achieve the same functionality. Similarly, when a function is subsequently described as being implemented using multiple elements, other examples may use a single element or processing entity to achieve the same functionality. It should also be understood that the terms “comprises,” “comprising,” “includes,” and / or “including” specify, when used, the presence of the stated feature, integer, step, operation, process, action, element, and / or component, but do not preclude the presence or addition of one or more other features, integers, steps, operations, processes, actions, elements, components, and / or any group thereof.

[0029] It is understandable that when one element is referred to as "connected" or "coupled" to another element, these elements can be directly connected or coupled through one or more intermediate elements. If "or" is used to combine two elements A and B, it should be understood that all possible combinations are disclosed: A only, B only, and A and B. Another way to phrase the same combination is "at least one of A and B." The same applies to combinations of more than two elements.

[0030] Therefore, while other examples are capable of various modifications and alternative forms, only a few specific examples are shown in the figures, which will be described in detail below. However, this detailed description does not limit further examples to the specific forms described. Further examples may cover all modifications, equivalents, and alternatives falling within the scope of this disclosure. Throughout the description of the figures, the same numerals refer to the same or similar elements that, when compared with each other, can be implemented identically or in modified form while providing the same or similar functionality.

[0031] from Figure 1 Exemplary methods and apparatus for multi-switch contactor assemblies according to this disclosure are described initially with reference to the accompanying drawings. Figure 1A battery configuration contactor circuit 100 employing a multi-switch contactor assembly is illustrated according to at least one embodiment of the present disclosure. The battery configuration contactor can be used in electric vehicles for connecting multiple battery packs to a vehicle power distribution system to drive the electric vehicle and charge the battery packs. In this example, a first switch 110 (referred to herein as "S1") is operable to disconnect and close the connection between the positive terminal of a first battery pack 104 and the positive terminal 106 of the vehicle power distribution system. The negative terminal of the first battery pack 104 is connected to the negative terminal 108 of the vehicle power distribution system. In this example, a second switch 112 (referred to herein as "S2") is operable to disconnect and close the connection between the negative terminal of a second battery pack 102 and the negative terminal 108 of the vehicle power distribution system. The positive terminal of the second battery pack 102 is connected to the positive terminal 106 of the vehicle power distribution system. In this example, a third switch 114 (referred to herein as "S0") is operable to disconnect and close the series connection of battery packs 102, 104. When the first switch 110 is closed, the first battery pack 104 is directly connected to the vehicle's power distribution system. When the second switch 112 is closed, the second battery pack 102 is directly connected to the vehicle's power distribution system. When both the first and second switches 110 and 112 are closed, the two battery packs 102 and 104 are connected in parallel to the vehicle's power distribution system. When the third switch 114 is closed, the two battery packs 102 and 104 are connected in series to the vehicle's power distribution system. However, closing the first switch 110 or the second switch 112 when the third switch 114 is closed may cause a direct short circuit between battery packs 102 and 104, which could potentially weld the switch contactors and / or damage battery packs 102 and 104. To prevent this, the switch contactors must withstand high levels of mechanical shock. When activated, the electromagnetic contactor coil requires constant power.

[0032] Therefore, according to some embodiments of this disclosure, the battery configuration contactor utilizes a multi-switch contactor assembly 120, wherein switches S0, S1, and S2 are mechanically connected to prevent switch S0 from opening when switch S1 or switch S2 is closed, and vice versa. A multi-switch contactor assembly according to at least one embodiment of this disclosure includes a switch array (e.g., switches S0, S1, S2) comprising a first switch implemented by a first movable contact and at least one first fixed contact, the first switch being configured to change a switch state between an open state and a closed state; a second switch implemented by a second movable contact and at least one fixed second contact, the second switch being configured to change a switch state between an open state and a closed state; and a third switch implemented by a third movable contact and at least one third fixed contact, the third switch being configured to change a switch state between an open state and a closed state. The multi-switch contactor assembly also includes an actuator assembly configured to actuate the first movable contact, the second movable contact, and the third movable contact. The actuator assembly includes a shaft in which the corresponding switching states of three switches change with rotation of the shaft. Although the multi-switch contactor assembly is described in the following example as including three switches, the principles of this disclosure apply to multi-switch contactor assemblies including fewer or more than three switches. That is, a single actuator is used to change multiple switches to different switching states, thereby mechanically prohibiting certain combinations of switching states. As will be shown in more detail below, the mechanical linkage of the contactor switches can be achieved through low contact resistance, no levitation, no holding power, and high contact force.

[0033] To further explain, Figure 2A and 2BAn example of a switch assembly 200 for a multi-switch contactor assembly according to at least one embodiment of the present disclosure is shown. The switch assembly 200 includes fixed contacts 202, 204 and a movable contact 206. One end of the movable contact 206 is coupled to the fixed contact 202. The movable contact 206 may be rotatable, flexible, or deformable. The other end is coupled to a spring 208 held by a support structure 220 (e.g., a contactor housing). In a first state, the movable contact 206 is held in a closed position by the spring 208. To transition to a second state, a force is applied to the movable contact 206 by a rotatable cam 212 to move the movable contact 206, causing the movable contact 206 to separate from the fixed contact and compress the spring, thereby placing the contactor assembly 200 in an open state. To transition the switch assembly 200 to the second state, cam 212 rotates out of contact with movable contact 206, allowing spring 208 to apply force to movable contact 206 to move it into contact with fixed contact 204, thereby placing the switch assembly in the closed state. Cam 212 rotates via shaft 214. In some examples, multiple cams 212 may be coupled to the same shaft 214, thereby providing mechanical connection for actuation of multiple movable contacts corresponding to multiple switches of a multi-switch contactor assembly.

[0034] For further reference, Figure 3 A schematic diagram 300 illustrates the configuration state of a multi-switch contactor assembly according to at least one embodiment of the present disclosure. Schematic diagram 300 shows the state of three switch assemblies S0, S1, and S2 based on the rotation of the camshaft 302. For ease of illustration, the three switch assemblies S0, S1, and S2 may be included in a battery configuration contactor configured to connect battery pack A and battery pack B to a vehicle power distribution system. In such an example, battery pack A may correspond to… Figure 1 Battery pack 102, battery pack B can correspond to Figure 1 The battery pack 104, wherein switch assembly S2 corresponds to switch 112, switch assembly S1 corresponds to switch 110, and switch assembly S0 corresponds to... Figure 1 Switch 114 in the middle. However, it should be understood that, Figure 3 The configuration shown can be applied to other vehicle contactors, such as fast-charging contactors, auxiliary or public service contactors, and contactors for applications outside of vehicles. The switch assemblies S0, S1, and S2 can be arranged in a direction parallel to the axis of the camshaft 302 (e.g., as shown). Figure 4 As shown, rotation of the camshaft alters the switching state of at least one switch. In this example, a 180-degree rotation changes the switching state of all switches. Three cams 301, 311, and 321 are coupled to the camshaft 302, together forming an actuation assembly for all switching components.

[0035] exist Figure 3 In one example, the first switching assembly S2 includes a fixed busbar 306 (i.e., a fixed contact) and a deformable busbar 305 (i.e., a movable contact). The switching assembly S2 also includes a rocker arm 308 coupled to the deformable busbar 305. In this example, the switching assembly S2 is a "normally closed" switch because the deformable busbar 305 is in contact with the fixed busbar 306 unless the rocker arm 308 is actuated to deform the deformable busbar 305, thereby breaking the contact between the deformable busbar 305 and the fixed busbar 306, thus opening the switch. In some examples, the rocker arm 308 is spring-loaded to maintain the deformable busbar 305 in contact with the fixed busbar 306 unless the force applied to the rocker arm 308 by the cam 301 exceeds the spring bias force. The rocker arm 308 is actuated by a cam 301 comprising a generally circular portion 303 and one or more generally flat portions 304. When the fundamentally circular portion 303 of the cam 301 engages with the rocker arm 308, the end of the rocker arm near the cam 301 is pushed downwards, thereby forcing the other end of the rocker arm 308 and the deformable generatrix 305 upwards, disengaging the deformable generatrix 305 from the fixed generatrix 306. When the fundamentally flat portion 304 of the cam 301 engages with the rocker arm 308, the end of the rocker arm 308 near the cam 301 is allowed to return to the closed position, in which contact between the deformable generatrix 305 and the fixed generatrix 306 is facilitated. In this example, the cam 301 includes two fundamentally flat portions 304, one corresponding to a closed switch state for direct connection only for battery pack A, and one corresponding to a closed switch state for parallel connection of battery pack B and battery pack A. Therefore, the rotation of the cam 301 opens and closes switch S2 depending on the rotation of the camshaft 302 and whether the rocker arm 308 is engaged by the fundamentally circular portion 303 or the fundamentally flat portion of the cam. In an alternative embodiment, switch S2 may be arranged as a "normally open" switch, wherein cam 301 actuates rocker arm 308 to move deformable busbar 305 into contact with fixed busbar 306.

[0036] exist Figure 3In this example, similar to switch assembly S2, the second switch assembly S1 includes a fixed busbar 326 (i.e., a fixed contact) and a deformable busbar 325 (i.e., a movable contact). Switch assembly S1 also includes a rocker arm 328 coupled to the deformable busbar 325. In this example, switch assembly S1 is a "normally closed" switch, wherein the deformable busbar 325 is in contact with the fixed busbar 326 unless the rocker arm 328 is actuated to deform the deformable busbar 325, thereby breaking the contact between the deformable busbar 325 and the fixed busbar 326, thus opening the switch. In some examples, the rocker arm 328 is spring-loaded to maintain the deformable busbar 325 in contact with the fixed busbar 326 unless the force applied to the rocker arm 328 by the cam 321 exceeds the spring bias force. The rocker arm 328 is actuated by a cam 321 including a generally circular portion 323 and one or more generally flat portions 324. When the fundamentally circular portion 323 of cam 321 engages with rocker arm 328, the end of rocker arm near cam 321 is pushed downwards, thereby forcing the other end of rocker arm 328 and deformable generatrix 325 upwards, disengaging deformable generatrix 325 from fixed generatrix 326. When the fundamentally flat portion 324 of cam 321 engages with rocker arm 328, the end of rocker arm 328 near cam 321 is allowed to return to a closed position, in which contact between deformable generatrix 325 and fixed generatrix 326 is facilitated. In this example, cam 321 includes two fundamentally flat portions 324, one corresponding to a closed switch state for direct connection of battery pack B only, and one corresponding to a closed switch state for parallel connection of battery pack A and battery pack B. Therefore, rotation of cam 321 opens and closes switch S1 depending on rotation of camshaft 302 and whether rocker arm 328 is engaged by the fundamentally circular portion 323 or the fundamentally flat portion of cam. In an alternative embodiment, switch S1 may be arranged as a "normally open" switch, wherein cam 321 actuates rocker arm 328 to move deformable busbar 325 into contact with fixed busbar 326.

[0037] exist Figure 3In this example, similar to switch assembly S2, third switch assembly S0 includes a fixed busbar 316 (i.e., a fixed contact) and a deformable busbar 315 (i.e., a movable contact). Switch assembly S0 also includes a rocker arm 318 coupled to the deformable busbar 315. In this example, switch assembly S0 is a "normally closed" switch, wherein the deformable busbar 315 is in contact with the fixed busbar 316 unless the rocker arm 318 is actuated to deform the deformable busbar 315, thereby breaking the contact between the deformable busbar 315 and the fixed busbar 316, thus opening the switch. In some examples, the rocker arm 318 is spring-loaded to maintain the deformable busbar 315 in contact with the fixed busbar 316 unless the force applied to the rocker arm 318 by the cam 311 exceeds the spring bias force. The rocker arm 318 is actuated by a cam 311 comprising a generally circular portion 313 and one or more generally flat portions 314. When the fundamentally circular portion 313 of the cam 311 engages with the rocker arm 318, the end of the rocker arm near the cam 311 is pushed downwards, thereby forcing the other end of the rocker arm 318 and the deformable generatrix 315 upwards, disengaging the deformable generatrix 315 from the fixed generatrix 316. When the fundamentally flat portion 314 of the cam 311 engages with the rocker arm 318, the end of the rocker arm 318 near the cam 311 is allowed to return to the closed position, in which contact between the deformable generatrix 315 and the fixed generatrix 316 is facilitated. In this example, the cam 311 includes a fundamentally flat portion 314 corresponding to the closed switch state connected in series with battery pack A and battery pack B. Therefore, the rotation of the cam 311 opens and closes the switch S0 according to the rotation of the camshaft 302 and whether the rocker arm 318 engages with the fundamentally circular portion 313 or the fundamentally flat portion of the cam. In an alternative embodiment, switch S0 may be configured as a "normally open" switch, wherein cam 311 actuates rocker arm 318 to move deformable busbar 315 to contact fixed busbar 316.

[0038] The schematic diagram 300 of the multi-switch contactor assembly configuration includes four different states. In the first state 352, the camshaft is at 0 degrees of rotation. Cams 301 and 321 apply force to rockers 308 and 328 to ensure that when rocker 318 of switch assembly S0 engages the substantially flat portion 314 of cam 311 and allows switch assembly S0 to close at 0 degrees of rotation, switch assemblies S2 and S1 are in the open state. Therefore, when switch assembly S0 is connected in series with battery pack A and battery pack B, parallel or direct connection of battery pack A and battery pack B is mechanically prevented.

[0039] In the second state 354, the camshaft 302 rotates 90 degrees relative to state 352 (e.g., counterclockwise). Before the rocker arm 328 of the switching assembly S1 engages the substantially flat portion 324 of the cam 321 in the switching assembly S1 by rotating 90 degrees, the cam 311 applies force to the rocker arm 318 to disconnect the switching assembly S0. When the rocker arm 328 engages the substantially flat portion 324 of the cam 321, the switching assembly S1 is closed. Therefore, when the switching assembly S1 directly connects the battery pack B to the power distribution system, it mechanically prevents the series connection of the battery pack A and the battery pack B. The cam 301 continues to apply force to the rocker arm 308 to hold the switching assembly S2 in the open state.

[0040] In the third state 356, the camshaft 302 rotates 180 degrees (e.g., counterclockwise) relative to state 352. The cam 311 continues to apply force to the rocker arm 318 to hold the switch assembly S0 in the open state. The rocker arm 328 of the switch assembly S1, upon 180-degree rotation, engages the second substantially flat portion 324 of the cam 321 of the switch assembly S1, thus holding the switch assembly S1 in the closed state. Simultaneously, the rocker arm 308 of the switch assembly S2 engages the first substantially flat portion 304 of the cam 301 of the switch assembly S2, thereby allowing the switch assembly S2 to transition to the closed state. Therefore, when the switch assemblies S1 and S2 connect battery pack A and battery pack B in parallel to the power distribution system, a series connection between battery pack A and battery pack B is mechanically prevented.

[0041] In the fourth state 358, the camshaft rotates 270 degrees (e.g., counterclockwise) or -90 degrees (e.g., clockwise) relative to state 352. Cam 311 continues to apply force to rocker 318 to hold switch assembly S0 in the open state. Cam 321 applies force to rocker 328 to hold switch assembly S1 in the open state. During the 270-degree rotation, rocker 308 of switch assembly S2 engages the second substantially flat portion of cam 301 of switch assembly S2, thereby allowing switch assembly S2 to transition to the closed state. Therefore, when switch assembly S2 directly connects battery pack A to the power distribution system, series connection of battery pack A and battery pack B is mechanically prevented.

[0042] In some examples, such as Figure 3As shown, switch assembly S1 can remain in the closed state, while switch assembly S2 transitions to the closed state between 90 degrees and 180 degrees. In other examples, a break-before-make arrangement is used, such that all switch assemblies S0, S1, and S2 are in the open state when the camshaft rotation is not 0, 90, 180, or 270 (-90) degrees. In some examples, a position sensor is used to determine the absolute rotation of the camshaft. Therefore, the multi-switch contactor assembly has only four different states, with at least one battery pack connected to the power distribution system, and series connection of the battery packs is mechanically prevented when they are connected directly or in parallel.

[0043] It should be understood that other cam shapes can be used instead of a cam with both circular and flat portions. For example, a notch can be used instead of a flat face. In other examples, the switch assembly may include a "normally open" switch, wherein a convex angle or other protruding actuating member applies force to a deformable contact to engage with a fixed contact and close the switch. In some variations, a combination of "normally open" and "normally closed" switches may be used in the same switch array.

[0044] It should be understood that different switching states in a corresponding switch can be achieved using two or more cams with different cam shapes. Similarly, different switching states in a corresponding switch can be achieved using two or more cams with the same shape but different orientations on a camshaft. In some cases, two cams may have the same shape and the same orientation on the camshaft, such that the cams actuate the same switching state on the corresponding switch (e.g., to reduce the current at each contact). Therefore, multiple cams corresponding to multiple switches can vary in shape, orientation, or alignment, wherein all cams are actuated by the same camshaft.

[0045] It should be further understood that deformable busbars can be replaced by fixed busbars coupled to rotatable or pivotable movable contacts. Flexible busbars can also be replaced by braided cables.

[0046] It will also be understood that, according to Figure 2A , Figure 2B and Figure 3 The multi-switch contactor assembly can be applied to battery configuration contactors and other devices constructed as described above with different cam shapes to enable high-voltage, high-current connections that require low contactor resistance (e.g., fast-charging contactors), or high-voltage, high-current connections that do not require device current consumption (e.g., auxiliary contactors used in vehicle-to-grid systems).

[0047] In view of the above, a method based on Figure 2A , Figure 2B and Figure 3The multi-switch contactor assembly has the following characteristics: 1) a single mechanical actuation mechanism operates all switches, making dangerous switch combinations mechanically impossible; 2) only four possible primary states: series, battery A connected only, battery B connected only, A+B in parallel, and an intermediate state where all contacts are open can be defined; 3) the actuator can move forward and backward to allow only A or only B to be connected after a series or parallel configuration; 4) the actuator assembly does not consume any power once the desired connection state is reached; 5) it provides very high contact force (e.g., 100 N) enabling very low device resistance (e.g., <50 μOhm) and high floating current (>25 kA); 6) contacts can be a single contact with a flexible busbar, or dual movable contacts with rigid contacts.

[0048] Figure 4 An exploded view of an example multi-switch contactor assembly 400 according to at least one embodiment of the present disclosure is shown. The example contactor assembly 400 includes a cam assembly 401 comprising three cams 402, 403, and 404 coupled to a camshaft 405, the rotation of which is driven by a motor 406. The contactor assembly includes three switch assemblies, each including a fixed contact 410 and a deformable contact 408. Cams 402, 403, and 404 act on a corresponding rocker arm 412 to deform the corresponding deformable contact 408 and open the corresponding switch. When the rocker arm 412 engages with the flat surface of the cam, a bias spring 414 forces the rocker arm to a closed position, in which the deformable contact 408 remains in contact with the fixed contact 410. When rocker arm 412 engages with the circular portion of the cam, the cam applies a force to rocker arm 412 that overcomes the biasing force of spring 414, thereby forcing rocker arm 412 into the disengaged position and bending deformable contact 408 away from fixed contact 410. In some examples, the multi-switch contactor assembly 400 includes a position sensor (not shown) for detecting rotation of camshaft 405. The position sensor provides the absolute angle of the camshaft, allowing it to rotate to a new set point to change the switching state. The position sensor can be, for example, a non-contact position sensor and a contact device (e.g., a potentiometer). The signal from the position sensor can be used to control the camshaft position and communicate the state of the contacts to the vehicle controller.

[0049] To further explain, Figure 5 Examples of various cam shapes 502, 504, 506, 508, 510, 512, including a cam wing 511 and a cam angle 513, are shown according to this disclosure.

[0050] To further explain, Figure 6The effect of the Lorentz force, according to the principle of the present invention, on a bent conductor is illustrated. When current flows through the conductor, the Lorentz force generates a repulsive force within the conductor. When the conductor is bent into a semi-circle, semi-loop, or C-shape, such as... Figure 6 As shown, when a high current passes through a conductor, the conductor will attempt to expand out of the magnetic field. In reality, the conductor itself is repulsive.

[0051] To further explain, Figure 7 Another example switch assembly 700 for a multi-switch contactor assembly according to at least one embodiment of the present invention is shown. The switch assembly 700 is similar to... Figure 3 A switching assembly, wherein the switching assembly 700 includes a fixed busbar 706, a deformable busbar 705, a rotatable cam 701, and a rocker arm 708 fixed to one end of the deformable busbar 705. The other end of the deformable busbar 705 is connected to a lead wire 720. Figure 7 As shown, the switch assembly 700 is normally closed. A rocker arm 708 is spring-loaded by a spring 707 to hold the rocker arm 708 in the closed position, such that the spring force acting on the rocker arm 708 bends the deformable busbar 705 onto the fixed busbar 706, thereby forming contact between the contact points on the deformable busbar 704 and the contact points on the outer surface of the fixed busbar 706. The other end of the fixed busbar is connected to a lead 722. In the closed state, the deformable busbar 705 and the fixed busbar 706 close the circuit between the leads 720 and 722. To disconnect the circuit, a cam 701 rotates until a wing or convex angle 703 forces the rocker arm 708 to rotate, thereby compressing the spring 707 and bending the deformable busbar 705, disengaging it from the fixed busbar 706.

[0052] The fixed busbar 706 is typically C-shaped or semi-circular. When the deformable busbar 705 and the fixed busbar 706 come into contact, they form a shape similar to... Figure 6 The conductor shown is a self-bending loop. The current flowing through the fixed busbar 706 and the deformable busbar 705 generates a repulsive force, as indicated by force arrow 730, and causes the deformable busbar 705 to extend out of the magnetic field. This effect reduces or suppresses the contact force between the fixed busbar 706 and the deformable busbar 705 because the deformable busbar 705 is repelled away from the fixed busbar. As will be explained below, the placement of the deformable busbar 705 relative to the fixed busbar 706 can be modified so that the Lorentz force actually increases the contact force.

[0053] To further explain, Figure 8A This is a schematic diagram of the fixed contact-movable contact geometry of a multi-switch contactor assembly according to at least one embodiment of the present disclosure. Figure 8AExamples include a deformable busbar 805 and a fixed busbar 806. The fixed busbar 806 forms a partial loop and is typically C-shaped or U-shaped, wherein the fixed busbar includes two forked portions connected by a central portion. Thus, the fixed busbar 806 includes an inner surface 850. As used in this disclosure, a "C-shaped" busbar generally refers to a busbar having two substantially parallel connecting forks 854, 856, wherein the connecting central portion 852 is typically orthogonal to the inner surface 850 of the forks. In contrast to the preceding example, the deformable busbar 805 is bent to contact the inner surface 850 of the fixed busbar 806 such that a Lorentz force 830 is utilized by the contact geometry to increase the contact force between the deformable busbar 805 and the fixed busbar 806. When current flows through the deformable busbar 805 and the fixed busbar 806, the resulting electromagnetic field generates a Lorentz force 830. This Lorentz force 830 acts on the deformable busbar 805 in the direction of the fixed busbar 806, keeping the deformable busbar 805 against the fixed busbar 806, thereby increasing the contact force. In other examples, the fixed busbar 806 may have a geometry other than a "C-shape". Figure 8C This is a schematic diagram of the fixed contact-movable contact geometry of a multi-switch contactor assembly according to at least one embodiment of the contactor geometry of this disclosure, wherein the fixed busbar 890 is “S-shaped”. Even though the bottom fork 896 bends outward in the opposite direction to the top fork 895 (resulting in an “S-shaped” busbar), the Lorentz force still increases the contact force when current flows through the device.

[0054] To further explain, Figure 8B Another example switch assembly 800 for a multi-switch contactor assembly according to at least one embodiment of the present invention is shown, which utilizes Figure 8A The contact geometry. In the previous example (for example, Figure 3 and Figure 7 In the example switch assembly (e.g., a rocker arm actuated by a cam 801), a deformable busbar is bent to contact the outer surface of a C-shaped fixed busbar. In contrast to these examples, the switch assembly 800 includes a deformable busbar 805 bent to contact the inner surface of a C-shaped fixed busbar 806, such that Lorentz forces are utilized by the contact geometry to increase the contact force between the deformable busbar 805 and the fixed busbar 806. The fixed busbar may be referred to as a partially looped busbar because the fixed busbar 806 includes inner surfaces facing each other, but the fixed busbar does not form a complete physical loop.

[0055] exist Figure 8BIn the example, the switch assembly 800 is a "normally closed" switch because the deformable busbar 805 is in contact with the fixed busbar 806 unless the rocker arm 808 is actuated to deform the deformable busbar 805, thereby breaking the contact between the deformable busbar 805 and the fixed busbar 806, thus opening the switch. In some examples, the rocker arm 808 is spring-loaded by a spring 807 to maintain the deformable busbar 805 in contact with the fixed busbar 806 unless the force applied to the rocker arm 808 by the cam 801 exceeds the spring force. Figure 8B In the example, the contact end 815 of the deformable busbar 805 is attached to a rocker arm 808, which is biased by a spring 807. The other end of the deformable busbar 805 is coupled to a lead wire 820. The force applied to the rocker arm 808 by the spring 807 keeps the contact end 815 of the deformable busbar 805 in contact with the inner surface 816 of the fixed busbar 806. The other end of the fixed busbar 806 is coupled to a lead wire 822.

[0056] The rocker arm 808 is driven by an irregularly shaped cam 801 (e.g., having) mounted on the camshaft 870. Figure 5 The rocker arm 308 is actuated by the rotation of one of the cam shapes. When the actuation point 809 of the rocker arm 808 is engaged by the actuator portion 803 (e.g., a convex angle or wing) of the cam 801 during the rotation of the cam via the camshaft 870, the rocker arm 308 rotates, causing the spring 807 to compress and move the deformable busbar 805, disengaging it from the fixed busbar 806.

[0057] As the cam rotates further or in the reverse direction, the actuator portion 803 of the cam 801 (e.g., a cam horn or wing) disengages from the actuation point 809 of the rocker arm 808, allowing the spring 807 to depressurize and forcing the rocker arm 808 to rotate rearward to a closed position. This bends the deformable busbar 805 into a closed position, where it contacts the inner surface 816 of the fixed busbar 306. The rotation of the cam 801 opens and closes the switch based on the rotation of the camshaft and whether the rocker arm 808 engages with the actuator portion of the cam 801 (e.g., a cam horn or wing—there may be multiple wings or cam horns). In an alternative embodiment, the switch assembly 800 may be arranged as a "normally open" switch, wherein the cam 801 actuates the rocker arm 808 to move the deformable busbar 805 into contact with the fixed busbar 806, thereby closing the switch. In this arrangement, the cam 801's convex angle or wing engages with the rocker arm 808 to move the deformable busbar 805 into contact with the inner surface 816 of the fixed busbar. In some examples, the multi-switch contactor assembly 800 includes a position sensor (not shown) to detect rotation of the camshaft 870. The position sensor provides the absolute angle of the camshaft, allowing it to rotate to a new set point to change the switching state. The position sensor can be, for example, a non-contact position sensor and a contact device (e.g., a potentiometer). The signal from the position sensor is provided to the camshaft motor controller for controlling the camshaft position and is transmitted to the vehicle controller to indicate the state of the contacts.

[0058] exist Figure 8B In the example, configuring the appropriate shape and orientation of the busbars or conductors in the contactor helps to increase the contact force 830 during high-current events. The current flowing through the deformable busbar 805 and the fixed busbar 806 (indicated by the arrows in the busbars) generates an electromagnetic field that induces a Lorentz force 830 (represented by the arrows extending from the busbars 805, 806). The Lorentz force is used to partially compensate for the levitation force that could break the contacts and cause sparks and welds. With the increased contact force utilizing the Lorentz force through the geometry and orientation of the busbars 805, 806, the spring force of the spring 807 can be reduced without compromising short-circuit performance.

[0059] Some of the embodiments described above have already been described in the context of movable contacts in the form of deformable busbars. In other variations, the movable contact of the switch can be a floating contact, which is actuated to contact a first fixed contact or a second fixed contact. In one example, one end of the floating movable contact is positioned between the first and second fixed contacts, while the other end of the floating movable contact can be actuated by a cam having one or more actuation points (e.g., wings or convex angles) as described above. For example, the movable contact can be configured to rotate about a fixed point. When the cam rotates in one direction, the movable contact is actuated to rotate toward the first fixed contact. When the cam rotates further or in the opposite direction, the movable contact is actuated to rotate toward the second fixed contact. Thus, the switch can have three states: closed at the first fixed contact, closed at the second fixed contact, or open. As described above, multiple such switches can be arranged and actuated by corresponding cams mounted on a camshaft, such that rotation of the camshaft changes the state of the switch.

[0060] Some of the embodiments described above have been described in the context of a three-switch (i.e., three-electrode) contactor configuration, wherein the switch state configurations include 1) direct connection to a first battery pack for powering an electric vehicle motor, 2) direct connection to a second battery pack for powering an electric vehicle motor, 3) series connection of the two battery packs for powering an electric vehicle motor, and 4) parallel connection of the two battery packs for a charging configuration. However, other applications may require a different number of switches simultaneously driven by a camshaft.

[0061] To further illustrate, Figure 9 A circuit diagram of an example power distribution system for an electric vehicle according to at least one embodiment of the present invention is shown. Figure 9 In the example, the auxiliary contactor 902 used to connect the vehicle to the power grid subsystem 904 may require two electrodes. As mentioned above... Figure 3 As described in the context of configuring contactors, the electrode 903 of the auxiliary contactor 902 simultaneously opens and closes via rotation of a single camshaft to rotate multiple cams that actuate the switch between open and closed states. The main contactor 906, used to connect or disconnect the inverter 908 from the high-power bus, may require two electrodes. As described above... Figure 3 As described in the context of configuring contactors, the electrode 907 of the main contactor 906 simultaneously opens and closes via the rotation of a single camshaft to rotate multiple cams that actuate the switch between open and closed states. A fast-charging contactor 910 used to connect a DC-DC fast-charging subsystem 912 may require two or more electrodes (e.g., 2 electrodes for currents up to 1000A, 4 electrodes for 2000A, 6 electrodes for 3000A, etc.). As described above... Figure 3As described in the context of a configuration contactor, the electrode 911 of the fast charging contactor 910 simultaneously opens and closes by rotating a single camshaft to rotate multiple cams that actuate the switch between open and closed states.

[0062] To further explain, Figure 10 A configuration contactor circuit 1000 employing a multi-switch contactor assembly is illustrated according to at least one embodiment of the present disclosure. The configuration contactor using the configuration contactor circuit 1000 can be used in electric vehicles for connecting multiple battery packs to a vehicle power distribution system to drive the electric vehicle and charge the battery packs. In this example, a first switch 1010 (also referred to herein as switch "S1") is operable to disconnect and close the connection between the positive terminal of a first battery pack 1004 and the positive terminal 1006 of the vehicle power distribution system. The negative terminal of the first battery pack 1004 is connected to the negative terminal 1008 of the vehicle power distribution system. In this example, a second switch 1012 (also referred to herein as switch "S2") is operable to disconnect and close the connection between the negative terminal of a second battery pack 1002 and the negative terminal 1008 of the vehicle power distribution system. The positive terminal of the second battery pack 1002 is connected to the positive terminal 1006 of the vehicle power distribution system. In this example, the third switch 1014 (also referred to herein as switch 'S0') is operable to open and close the series connection of battery packs 1002 and 1004. When the first switch 1010 is closed, the first battery pack 1004 is directly connected to the vehicle's power distribution system. When the second switch 112 is closed, the second battery pack 1002 is directly connected to the vehicle's power distribution system. When the first switch 1010 and the second switch 1012 are closed, the two battery packs 1002 and 1004 are connected in parallel to the vehicle's power distribution system. When the third switch 1014 is closed, the two battery packs 1002 and 1004 are connected in series to the vehicle's power distribution system.

[0063] exist Figure 10 In the example, the contactor circuit 1000 also includes a fourth switch 1016 (also referred to herein as switch 'S3') operable to open and close the series connection between the pre-charge resistor 1018 and the battery packs 1002, 1004. The pre-charge resistor 1018 gradually energizes the high-voltage circuit before the main contactor or switch closes. In high-voltage systems, sudden closing of a switch or contactor can cause inrush current, potentially damaging the system. The pre-charge resistor helps mitigate these problems by reducing inrush current in the circuit, allowing capacitors and other components to charge more slowly. Initially, the fourth switch ("pre-charge switch") 1016 is open, preventing full voltage from being applied to the circuit. When the system is ready to be energized, the pre-charge switch closes, allowing a limited current to flow through the circuit. This limited current pre-charges the capacitors and other components. Once the pre-charging process is complete, the main contactor or switch closes.

[0064] When the third switch 1014 is closed, closing the first switch 1010 or the second switch 1012 may cause a direct short circuit in battery packs 1002 and 1004, which could potentially solder the switch contactors and / or damage battery packs 1002 and 1004. Closing the first switch 1010, the second switch 1012, or the third switch 1014 simultaneously with the fourth switch 1016 will eliminate the pre-charge resistor 1018, thereby allowing a sudden influx of current that could potentially damage electrical components. Furthermore, the pre-charge fourth switch 1016 should be closed before closing the third switch 1014 to connect battery packs 1002 and 1004 in series to apply the full voltage to the battery packs.

[0065] Therefore, according to at least one embodiment of the present disclosure, the contactor is configured using a multi-switch contactor assembly 1020, wherein switches S0, S1, S2, and S3 are mechanically connected to prevent switch S0 from opening when switch S1 or switch S2 is closed, and vice versa, and to prevent switches S0, S1, and S2 from closing when switch S3 is closed. The multi-switch contactor assembly 1020 according to at least one embodiment of the present disclosure includes a switch array (e.g., switches S0, S1, S2, S3) comprising a first switch implemented by a first movable contact and at least one first fixed contact, the first switch being configured to change its switching state between an open state and a closed state to directly connect to a first battery pack. The multi-switch contactor assembly 1020 also includes a second switch implemented by a second movable contact and at least one fixed second contact, the second switch being configured to change its switching state between an open state and a closed state to directly connect to a second battery pack. The multi-switch contactor assembly 1020 further includes a third switch implemented by a third movable contact and at least one third fixed contact, the third switch being configured to change its switching state between an open state and a closed state for series connection of a first battery pack and a second battery pack. The multi-switch contactor assembly 1020 also includes a fourth switch implemented by a fourth movable contact and at least one fourth fixed contact, the fourth switch being configured to change its switching state between an open state and a closed state for connecting a pre-charge resistor. The multi-switch contactor assembly 1020 also includes an actuator assembly configured to actuate the first movable contact, the second movable contact, the third movable contact, and the fourth movable contact. The actuator assembly includes a shaft, wherein the corresponding switching states of the switches are mechanically connected and change with rotation of the shaft. Although the multi-switch contactor assembly is described in the following example as including four switches, the principles of this disclosure apply to multi-switch contactor assemblies including fewer than four switches or more than four switches. That is, a single actuator is used to change multiple switches to different switching states, thereby mechanically prohibiting certain combinations of switching states. As mentioned above, the mechanical linkage of contactor switches can achieve low contact resistance, no floating, no holding power, and high contact force.

[0066] In some embodiments, each switch of the multi-switch contactor assembly 1020 includes a fixed busbar and a deformable busbar (i.e., a movable contact) coupled to a rocker mechanism. (Refer to the above text.) Figure 3 and Figure 8B The switch is actuated by a rocker arm that moves a deformable busbar to disengage from a fixed busbar. The rocker arm is actuated by the rotation of a cam coupled to a camshaft. Each switch is independently driven by its own cam, and all cams are mechanically connected via the camshaft. Each cam may have a cam shape, for example... Figure 5 The cam shape includes actuator portions (e.g., wing or convex corners). These actuator portions are not aligned along the length of the camshaft. Therefore, the switching states of the four switches vary depending on the rotation angle of the camshaft. In some examples, the stationary busbar is implemented as a partial loop, such as a C-shape, bracket shape, or U-shape, and the deformable busbar contacts the inner surface of the stationary busbar, as referenced above. Figure 8A The high current flowing through the fixed busbar and the deformable busbar generates a Lorentz force, causing the deformable busbar to come into contact with the fixed busbar.

[0067] To further explain, Figure 11 Table 1100 lists the camshaft angles and circuit states corresponding to the connections of the two battery packs and the precharge switch. Figure 11 In the example, for illustrative purposes, two 400V battery packs, "Bank A" and "Bank B," of the electric vehicle are shown. Additional battery packs or alternative voltages may be used without departing from the embodiments of this disclosure. Column 1101 in Table 1100 indicates the rotation angle of the camshaft. The angles shown in the table are for illustrative purposes only; various embodiments may use different angles based on camshaft motor speed and isolation requirements. Column 1102 in Table 1100 indicates the high-voltage circuit state. Column 1103 in Table 1100 indicates the switching state of the direct connection of Bank A. Column 1104 in Table 1100 indicates the switching state of the series connection of Bank A and Bank B. Column 1105 in Table 1100 indicates the switching state of the direct connection of Bank B. Column 1106 in Table 1100 indicates the switching state of the pre-charge resistor connection. Figure 11In the example, when the camshaft is at 0 degrees, the circuit is in 800V drive / charge mode, the switch connecting Bank A and Bank B in series is closed, and all other switches are open. When the camshaft is at 45 degrees or 315 degrees (45 degrees forward or backward from the 800V drive / charge state), the switch connecting the pre-charge resistor is closed, and all other switches are open. When the camshaft is at 90 degrees or 270 degrees (90 degrees forward or backward from the 800V drive / charge state), all switches are open. This ensures that all switches are open before entering the pre-charge state. When the camshaft is at 135 degrees, the direct connection switch for Bank A for 400V charging is closed, and all other switches are open. When the camshaft is at 180 degrees, the direct connection switch for Bank A for 400V charging is closed, the direct connection (i.e., parallel charging) switch for Bank B for 400V charging is closed, and all other switches are open. When the camshaft is at 225 degrees, the switch for the direct connection of Bank B, used for 400V charging, is closed, and all other switches are open. Therefore, regardless of whether the camshaft rotates in the forward or reverse direction, the switches are open before transitioning to a single battery pack charging state and then to a parallel battery pack charging state, and before transitioning to a pre-charge state. This mechanically prevents combinations of switch states that could damage the system.

[0068] To further explain, Figure 12 A perspective view of an example multi-switch contactor assembly 1200 with a pre-charging system is given. For example, the multi-switch contactor assembly 1200 can implement... Figure 10 Multi-switch contactor assembly 1020. Multi-switch contactor assembly 1200 includes four contactors 1201, 1202, 1204, and 1205. Reference is also made, by way of example and not limitation. Figure 10 Contactor 1201 enables switch S1, contactor 1202 enables switch S2, contactor 1204 enables switch S3, and contactor 1205 enables switch S0. A drive motor 1203 is disposed between two contactors (e.g., between contactor 1202 and contactor 1204). A cam actuator shaft 1206 extends through contactors 1201, 1202, 1204, and 1205 and through motor 1203. The cam actuator shaft mechanically connects a cam to each contactor 1201, 1202, 1204, and 1205 to prevent dangerous combinations of switching states. Rotation of the cam shaft rotates each cam of each contactor 1201, 1202, 1204, and 1205.

[0069] To further explain, Figure 13 A flowchart illustrating an example method of operating a multi-switch contactor assembly according to at least one embodiment of the present disclosure is shown. Figure 13The method includes connecting a multi-switch contactor assembly 1302 to a power distribution system and at least one component. For example, the at least one component may be one or more battery packs or inverter motors. In some examples, the contactor assembly may be any of the multi-switch contactor assemblies described above, as the contactor assembly includes an array of two or more switches, each switch including a movable contact and a fixed contact. The movable contact is configured to contact a first end of the fixed contact in a closed switch state. The movable and fixed contacts are oriented such that a current passing between the movable and fixed contacts induces an electromagnetic force acting on the movable contact in the direction of the first end of the fixed contact. The multi-switch contactor assembly also includes an actuator assembly configured to simultaneously actuate each movable contact. The actuator assembly includes a shaft, wherein the respective switching states of two or more switches change with rotation of the shaft. For example, two or more switches may be implemented using a switch assembly (e.g., switch assembly 800) disposed on the same actuator shaft. The contactor assembly may be, for example... Figure 1 Multi-switch contactor assembly 120 (e.g., configured contactor), Figure 9 Main contactor 906 Figure 9 The fast charging contactor 910, auxiliary contactor 902 or Figure 10 The multi-switch contactor assembly 1020 (e.g., configuration contactor) in the middle.

[0070] In some examples, at least one fixed contact includes a second end substantially parallel to the first end and an intermediate portion substantially perpendicular to both the first and second ends. A contact portion of a movable contact is located between the first and second ends of the at least one fixed contact. The contact portion of the movable contact is configured to contact the inner side of the first end, which is opposite to the inner side of the second end of the at least one fixed contact. In the presence of a high current through the fixed contact in contact with the movable contact, a Lorentz force acting on the movable contact pushes the movable contact toward the fixed contact, thereby increasing the contact force.

[0071] Figure 13 The method also includes rotating the 1304 shaft to change the respective switching states of two or more switches in a multi-switch contactor assembly, wherein specific combinations of switching states are mechanically prevented. The rotation of the camshaft to change the switching states is described above. Rotation of the camshaft causes two or more cams to rotate. In each switch, a cam engages with a rocker arm attached to a movable contact according to its direction of rotation, causing the rocker arm to rotate, thereby making or disengaging the movable contact with a fixed contact. The camshaft rotates multiple cams simultaneously, thereby changing the switching states of the switches.

[0072] To further explain, Figure 14A flowchart illustrating an example method for operating a multi-switch contactor assembly having a pre-charging system according to at least one embodiment of the present disclosure is shown. Figure 14 In the method, the multi-switch contactor assembly further includes a switch array. The assembly also includes an actuator assembly comprising a shaft configured to actuate each switch in the switch array. As described above, rotation of the shaft of the multi-switch contactor assembly is used to change the state of the switches in the switch array. In each switch of the switch array, a cam (depending on its direction of rotation) engages with a rocker arm attached to a movable contact and rotates the rocker arm, thereby causing the movable contact to engage or disengage with a fixed contact. The rotation of the shaft simultaneously rotates multiple cams, thereby changing the switching state of the switches.

[0073] The switch array includes a first switch configured to connect a first battery device to a circuit, a second switch configured to connect a second battery device to a circuit, a third switch configured to connect the first and second battery devices in series to a circuit, and a fourth switch configured to connect a pre-charge resistor to at least one of the first and second battery devices. For example, the switches can be implemented using a switch assembly (e.g., switch assembly 800) disposed on the same actuator shaft. The contactor assembly can be, for example... Figure 10 The multi-switch contactor assembly 1020 (e.g., a configuration contactor).

[0074] In this embodiment of the method, a high-current-carrying main contact (e.g., the contacts of the first and second batteries) is combined with a low-current-carrying pre-charge contact in the same device, such that the contactor actuator is mechanically forced to change from an open state to a closed state of the main contacts via a pre-charge state, in which the pre-charge contacts are initially closed. As described above, the pre-charge system is configured to gradually energize the high-voltage circuit before the main contactor or switch closes. When dealing with high-voltage systems, sudden closing of a switch or contactor can cause inrush current, which can damage the system. Pre-charge switches and resistors help mitigate these problems by reducing inrush current in the circuit, allowing capacitors and other components to charge more slowly.

[0075] Figure 14The method begins by rotating the shaft of the actuator assembly from the fully open position (in the fully open position, the first, second, third, and fourth switches are open) 1402 to the pre-charge position (in the pre-charge position, the fourth switch is closed, and the first, second, and third switches are open). In this initial fully open position, the fourth switch is open, preventing full voltage from being applied to the circuit. When the system is ready to be energized, the fourth switch closes, allowing a limited current to flow through the circuit. This limited current pre-charges the capacitors and other components. Once the pre-charge process is complete, the series switch is closed by rotating the shaft from the pre-charge position 1404 to the series position, in which the fourth switch is closed and the third switch is closed. Then, Figure 14 The method involves rotating the shaft from the tandem position to the pre-charge position. Figure 14 The method also includes rotating the shaft from the precharged position to the fully disconnected position.

[0076] Those skilled in the art will recognize that, according to embodiments of the invention, the rotational speed of the actuator can be selected such that the system can be pre-charged by mechanical design before the main contacts (e.g., in series connection) engage.

[0077] In light of the foregoing, it is understood that the aforementioned multi-switch contactor assembly and battery configuration contactor offer numerous advantages, including the ability to configure two battery packs in series and parallel configurations (e.g., one for driving an electric vehicle and the other for charging the electric vehicle), low contact resistance (e.g., less than 50 μΩ per switch), high suspension tolerance achieved through considerable contact force, mitigation of the risk of battery short circuits due to loss of switch coordination or mechanical shock, the ability to manage voltage potential mismatch in the battery pack, the ability to actively disconnect spot welds, low holding power required for actuation, reduced switching noise, and increased contact force through the use of Lorentz force via conductor geometry and orientation. Furthermore, a pre-charge switch is integrated within the multi-switch contactor assembly.

[0078] As can be understood from the foregoing description, various embodiments of this disclosure can be modified and altered without departing from the true spirit of this disclosure. The descriptions in this specification are for illustrative purposes only and should not be construed as restrictive. The scope of this disclosure is limited only by the language of the appended claims.

Claims

1. A multi-switch contactor assembly with a pre-charging system, the multi-switch contactor assembly comprising: Switch array; as well as Actuator assembly configured to actuate each switch in the switch array, the switch array comprising: A first switch, configured to connect a first battery device to a circuit; A second switch, configured to connect a second battery device to the circuit; A third switch, configured to connect the first battery device and the second battery device in series to the circuit; and A fourth switch is configured to connect a pre-charge resistor to at least one of the first battery device and the second battery device.

2. The multi-switch contactor assembly according to claim 1, wherein, The pre-charge resistor can be connected in series between the first battery device and the second battery device via the fourth switch.

3. The multi-switch contactor assembly according to claim 1, wherein, Each switch in the switch array includes a movable contact and a fixed contact; wherein the movable contact is configured to contact a first end of the fixed contact in a closed switch state; wherein the movable contact and the fixed contact are oriented such that a current passing between the movable contact and the fixed contact induces an electromagnetic force, the electromagnetic force acting on the movable contact in the direction of the first end of the fixed contact.

4. The multi-switch contactor assembly according to claim 3, wherein, The actuator assembly is configured to simultaneously actuate each movable contact, and the actuator assembly includes a shaft, wherein the corresponding switching state of the switch array changes according to the rotation of the shaft.

5. The multi-switch contactor assembly according to claim 3, wherein, The fixed contact is basically C-shaped and has an inner surface and an outer surface; wherein the movable contact is oriented to contact the inner surface of the fixed contact.

6. The multi-switch contactor assembly according to claim 5, wherein, The fixed contact includes a second end substantially parallel to the first end and an intermediate portion substantially perpendicular to the first and second ends, wherein a contact portion of the movable contact is oriented between the first and second ends of the fixed contact; wherein the contact portion of the movable contact is configured to contact the inner surface of the first end, the inner surface being opposite to the inner surface of the second end of the fixed contact.

7. The multi-switch contactor assembly according to claim 3, wherein, The contact portion of the movable contact is coupled to a rocker arm of the actuator assembly; wherein the rocker arm rotates in response to a cam of the actuator assembly to move the contact portion relative to a first end of the fixed contact.

8. The multi-switch contactor assembly according to claim 7, wherein, The movable contact is deformable; wherein the contact portion of the movable contact is moved by bending the movable contact; wherein the rocker arm bends the movable contact when the rocker arm is rotated.

9. The multi-switch contactor assembly according to claim 3, wherein, The fixed contact is generally S-shaped; wherein the movable contact is oriented to contact the inner surface of the first branch of the fixed contact.

10. The multi-switch contactor assembly according to claim 3, wherein, The current flowing through the movable contact and the fixed contact generates a Lorentz force, which increases the contact force between the movable contact and the fixed contact.

11. The multi-switch contactor assembly according to claim 4, wherein, The actuator assembly includes two or more cams that rotate via rotation of the shaft, the two or more cams being configured to actuate the switch array based on rotation of the shaft.

12. The multi-switch contactor assembly according to claim 11, wherein, Each of the two or more cams includes an actuating member, wherein the actuating members of at least two cams are not aligned along the axis.

13. The multi-switch contactor assembly according to claim 3, wherein, Each switch also includes a second fixed contact; wherein the movable contact is configured to contact the second fixed contact in different closed switch states.

14. A system comprising: Multiple components, including a first battery device and a second battery device; Vehicle power distribution circuit; as well as A multi-switch contactor assembly, the multi-switch contactor assembly connecting the plurality of components and the vehicle power distribution circuit, the multi-switch contactor assembly comprising: Switch array; and Actuator assembly configured to actuate each switch in the switch array, the switch array comprising: A first switch, configured to connect the first battery device to a circuit; A second switch, configured to connect the second battery device to a circuit; A third switch, configured to connect the first battery device and the second battery device in series to the circuit; and A fourth switch is configured to connect a pre-charge resistor to at least one of the first battery device and the second battery device.

15. The system according to claim 14, wherein, Several components also include an inverter, a fast charging connector, and an auxiliary connector.

16. The system according to claim 14, wherein, The pre-charge resistor can be connected in series between the first battery device and the second battery device via the fourth switch.

17. The system according to claim 14, wherein, Each switch in the switch array includes a movable contact and a fixed contact; wherein the movable contact is configured to contact a first end of the fixed contact in a closed switch state; wherein the movable contact and the fixed contact are oriented such that a current passing between the movable contact and the fixed contact induces an electromagnetic force, the electromagnetic force acting on the movable contact in the direction of the first end of the fixed contact.

18. The system according to claim 17, wherein, The actuator assembly is configured to simultaneously actuate each movable contact, and the actuator assembly includes a shaft, wherein the corresponding switching state of the switch array changes according to the rotation of the shaft.

19. The system according to claim 17, wherein, The fixed contact is basically C-shaped and has an inner surface and an outer surface; wherein the movable contact is oriented to contact the inner surface of the fixed contact.

20. A method for operating a multi-switch contactor assembly having a pre-charging system, the multi-switch contactor assembly further comprising a switch array; and an actuator assembly including a shaft and configured to actuate each switch in the switch array, the switch array comprising: A first switch, configured to connect a first battery device to a circuit; A second switch, configured to connect a second battery device to the circuit; A third switch is configured to connect the first battery device and the second battery device in series to the circuit. as well as A fourth switch is configured to connect a pre-charge resistor to at least one of the first battery device and the second battery device; The method includes: Rotate the shaft of the actuator assembly from a fully open position where the first switch, second switch, third switch, and fourth switch are off to a pre-charge position where the fourth switch is closed and the first switch, second switch, and third switch are off; The shaft is rotated from the pre-charge position to the series position, in which the fourth switch is closed and the third switch is closed; Rotate the shaft from the tandem position to the pre-charge position; and Rotate the shaft from the precharge position to the fully disconnected position.

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