Controlling speed of movable component in electronic relay

Abstract

Embodiments in accordance with the present disclosure relate to devices, systems, and methods for controlling the speed of a movable component in an electronic relay. In a particular embodiment, an electronic relay assembly is disclosed that includes at least one fixed contact and a movable assembly that includes a movable contact coupled to a shaft that is coupled to a plunger. In an embodiment, a plunger is disposed in an actuation channel defined by a magnetic actuation assembly and is configured to move along an actuation path. The electronic relay also includes a magnetic bridge surrounding a portion of the actuation path of the plunger.

Description

Background Technology

[0001] Electromechanical switching devices such as contactors and relays are designed to carry a certain amount of current for a given period of time. These devices are particularly important in electric vehicles (EVs). Typically, an EV includes one or more high-voltage batteries connected to the vehicle's electrical distribution system via electronic relays or main contactors to power an electric motor. EV relays typically consist of electromechanical switches that open or close high-current paths between the battery pack and the vehicle's electrical distribution system. EV relays are used to interrupt high current in the event of a safety hazard. When the vehicle's electronics detect a high-current condition, the current supply to the EV relay actuator coil is interrupted. The EV relay breaks the circuit, cutting off the high current flowing through the high-voltage system. EV relays require a larger gap to interrupt high current. During closure, a larger gap can cause unacceptably high speeds for the moving parts in the EV relay. High impact speeds can damage and wear down EV relays. Summary of the Invention

[0002] Embodiments of this disclosure relate to apparatus, systems, and methods for controlling the speed of a movable component in an electronic relay. In some examples, a magnetic bridge is used to control the speed of the movable component in the electronic relay during closure, which allows for a larger electrical gap, thereby allowing for a greater current interruption capability. The magnetic bridge causes a decrease in magnetic force in the middle of the movable component's travel, which slows down and controls the speed of the movable component. The size and position of the magnetic bridge can be used to adjust the dynamic behavior of the movable component. Thus, a larger electrical gap and a higher interruption capability are achieved without causing the movable component to impact at high speed and cause damage.

[0003] In a particular embodiment, an electronic relay assembly is disclosed, comprising at least one fixed contact and a movable component including a movable contact coupled to a shaft coupled to a plunger. In this embodiment, the plunger is disposed in an actuation channel defined by a magnetic actuation component and configured to move along an actuation path. The electronic relay also includes a magnetic bridge surrounding a portion of the actuation path of the plunger.

[0004] In another embodiment, a method for controlling the speed of a movable component in an electronic relay is disclosed, comprising coupling the electronic relay to a circuit. The electronic relay includes at least one fixed contact and a movable component, the movable component including a movable contact coupled to a shaft coupled to a plunger. In this embodiment, the plunger is disposed in an actuation channel defined by a magnetic actuation component and configured to move along an actuation path. The electronic relay also includes a magnetic bridge surrounding a portion of the actuation path of the plunger. The method further includes applying power to the magnetic actuation component. In this embodiment, the magnetic actuation component applies a magnetic force to the movable component, and the speed of the movable component is controlled by the magnetic bridge.

[0005] These and other features, aspects and advantages of this disclosure can be better understood by reading the following detailed description with reference to the accompanying drawings, in which like characters denote like parts. Attached Figure Description

[0006] Figure 1 A side sectional view of an example electronic relay for controlling the speed of a movable component in an electronic relay according to at least one embodiment of the present disclosure is shown.

[0007] Figure 2A It shows the disconnected position. Figure 1 An isometric view of a portion of an example electronic relay.

[0008] Figure 2B It shows the closed position. Figure 1 An isometric view of a portion of an example electronic relay.

[0009] Figure 3 This is a diagram illustrating the relationship between force and movement position during closed operation of a conventional electronic relay design and a design incorporating a magnetic bridge, according to at least one embodiment of this disclosure.

[0010] Figure 4 This is a diagram illustrating the relationship between speed and movement position during closed operation of a conventional electronic relay design and a design incorporating a magnetic bridge, according to at least one embodiment of this disclosure.

[0011] Figure 5 A flowchart of an example method for controlling the speed of a movable component in an electronic relay according to at least one embodiment of the present disclosure is provided. Detailed Implementation

[0012] The terminology used to describe particular examples in this document is not intended to limit other examples. Whenever singular forms such as “a,” “an,” and “the” are used, and the use of only a single element is neither explicitly nor implicitly defined as mandatory, further examples may use multiple elements to achieve the same functionality. Similarly, when a function is subsequently described as being implemented using multiple elements, further 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 combination thereof.

[0013] It should be understood that when a component is referred to as "connected" or "coupled" to another component, that component may be directly connected or coupled via one or more intermediate components. If two components A and B are combined using "or," this should be understood to disclose all possible combinations, namely, only A, only B, and both A and B. An alternative wording for the same combination is "at least one of A and B." The same applies to combinations of more than two components.

[0014] Therefore, while other examples may have various modifications and alternatives, the figures show some specific examples, which will be described in detail below. However, this detailed description does not limit the other examples to the specific forms described. Other examples may cover all modifications, equivalents, and alternatives falling within the scope of this disclosure. Throughout the description of the figures, the same numbers refer to the same or similar elements that, when compared with each other, may be implemented identically or in modified form while providing the same or similar function.

[0015] Electric vehicle (EV) relays have movable components that close and open circuits. Typically, these movable components are actuated linearly by magnetic coils. The magnetic force is a non-linear function of the magnetic gap, approximately proportional to the -2 power of the gap length. Typically, the relay's open state is ensured by two springs: a return spring and a contact spring. Both springs produce the system's spring response. Typically, the two springs are linear and form a characteristic two-stage response.

[0016] During closure, the force difference between the magnetic force and the spring force causes the movable component to accelerate and close the contacts. The movable component contacts the fixed electrical contacts at high speed. The speed can be calculated by integrating the force difference between the magnetic force and the spring force over time. As the requirements for interruption capability increase, electric vehicle relays require larger electrical clearances, and therefore larger magnetic clearances. In one example, EV relays use magnetic clearances in the range of 1.5 to 4 mm. With such magnetic clearances, the electrical clearance is also small. The interruption capability in this implementation is limited to 2-3 kA, while modern interruption requirements reach 9 kA. To enable pick-up, the number of ampere turns can be increased. However, this change significantly increases the impact speed between the movable component and the fixed contacts, and increases wear and degradation. To interrupt high currents, a larger electrical clearance is needed, but a larger clearance results in the movable component moving too fast during closure. To limit damage to the relay during normal operation, the speed of the movable component should be controlled. One approach is to use a progressive spring and closely match the magnetic force within a sufficient safety margin. However, using this method results in excessively high spring holding force, and the required holding force is much higher than desired. Another approach is to use electronics within the relay to create the desired current supply profile. This method adds complex electronics to each contactor.

[0017] According to embodiments of this disclosure, a mechanism is provided for controlling and limiting the speed of a movable component during closure using a magnetic bridge. The magnetic bridge may be a fixed ring made of a magnetic material, located in the middle of the magnetic gap. In a particular embodiment, the magnetic bridge is made of steel with high magnetic permeability. The magnetic bridge provides a dynamic, adjustable, and cost-effective mechanism for controlling the speed of a movable component without adding complexity or electronics.

[0018] from Figure 1 Beginning with reference to the accompanying drawings, exemplary methods and apparatus for controlling the speed of a movable component in an electronic relay according to the present disclosure are described. For further explanation, Figure 1 A side sectional view of an example electronic relay 100 according to at least one embodiment of the present disclosure is provided. Figure 2A It shows the disconnected position. Figure 1 An isometric view of part 200 of an example electronic relay. Figure 2B It shows the closed position. Figure 1 An isometric view of part 200 of an example electronic relay. Figure 2A and Figure 2B In the example, part 200 includes magnetic coil 112, movable component 120, magnetic bridge 116, and other components.

[0019] Example electronic relay 100 includes fixed contacts 102, 104 and a movable contact 106 coupled to a shaft 108 coupled to a plunger 110. The movable contact 106, shaft 108 and plunger 110 form at least a portion of a movable assembly 120. Figure 1 The electronic relay 100 in the example indicates that it is in the off position. The example electronic relay 100 also includes a magnetic coil 112 (e.g., a magnetic coil of a magnetic actuator or armature) which is energized to actuate the movable component 120 by applying a magnetic force to a plunger 110, thereby causing the movable contact 106 to contact the fixed contacts 102, 104 to allow current to flow through the relay. The magnetic force applied to the plunger 110 forces the plunger 110 upward through the actuation path 192 in the actuation channel 118. When the movable component 120 is actuated, the electrical clearance E 194 and the magnetic clearance M 190 close. To assist actuation of the movable component 120, the plunger 110 is disposed in a flow tube 114 in the actuation channel 118. When the magnetic coil 112 is de-energized, the movable contact 106 is de-energized via a return spring (e.g., Figure 2A and Figure 2B The return spring 122 is pushed away from the fixed contacts 102 and 104 to cut off the current and return to the disconnected position. Figure 2A The reset spring 122 of the electronic relay in the off position is shown. Figure 2B The reset spring 122 of the electronic relay in the closed position is shown.

[0020] To increase the current rating of the electronic relay, the electrical clearance E 194 must also be increased because the electronic relay 100 is capable of interrupting current. This also means that the magnetic clearance M190 between the plunger 110 and the top core 151 of the electronic relay increases. However, as the magnetic clearance M 190 increases, the speed of the movable component 120 during actuation also increases. To control or limit the speed of the movable component 120, thereby preventing damage to the electronic relay 100, the electronic relay 100 also includes a magnetic bridge 116 surrounding the magnetic clearance M 190 in the actuation channel 118. In some examples, the magnetic bridge 116 is a retaining ring made of magnetic material, located in the middle of the stroke of the magnetic clearance M 190. As the plunger passes through the magnetic bridge 116, the magnetic bridge has the function of limiting the speed of the movable component.

[0021] Compared to a design without a magnetic bridge, the magnetic bridge 116 offers several advantages: a) increased initial force, b) decreased force during the intermediate stroke, and c) a slightly increased final force. The decrease in magnetic force during the intermediate stroke is used to slow down and control the speed of the movable component 120. The size and position of the magnetic bridge can be used to adjust the dynamic behavior of the movable component 120. The effect of the magnetic bridge 116 can be adjusted by variations in size, including adding two or more magnetic bridges, creating magnetic bridges with different thicknesses and lengths, and / or adjusting their position within the magnetic gap.

[0022] To further illustrate, Figure 3 Figure 300 is provided, which illustrates the relationship between relative force and relative movement position during closed operation in a conventional electronic relay design and a design incorporating a magnetic bridge. The figure includes three curves to illustrate this relationship: load force, the original design, and the design with the magnetic bridge. The horizontal axis represents the relative movement position of the movable component (indicated by a range of 0 to 1), while the vertical axis represents the relative force from 0 to 1.

[0023] A dashed line is used to depict the load force curve, illustrating how the spring system affects the forces acting on the moving component. The original design used a solid line to represent the force distribution in a relay without a magnetic bridge.

[0024] The design with the magnetic bridge is shown as a dotted line. Initially, the force is greater than the original design, indicating an increase in initial force. As the moving position advances into the middle stroke region, the force in the design with the magnetic bridge decreases, highlighting the reduction in force during the middle stroke. Near the final stage of the movement, the force increases slightly compared to the original design, reflecting an increase in closing force.

[0025] This figure distinguishes the effects of incorporating a magnetic bridge into a relay design, demonstrating how it modifies the magnetic force distribution to control and reduce the speed of a movable component in contact with a fixed electrical contact.

[0026] To further illustrate, Figure 4 Figure 400 is provided, illustrating the relationship between velocity and movement position during closed operation in a conventional electronic relay design and a design incorporating a magnetic bridge. The horizontal axis of the graph represents the relative movement position of the movable component during closure, ranging from 0 to 1, where 0 indicates the initial position and 1 indicates the fully closed position. Similarly, the vertical axis represents the relative velocity of the movable component relative to its relative movement position during closure.

[0027] The graph includes two distinct curves: one representing the original design and the other representing the design with a magnetic bridge. The discontinuous line represents the performance of the original design. The original design shows the speed of the movable component steadily increasing throughout its travel until it approaches the fully closed position. The design with the magnetic bridge is represented by a dashed line. This design shows a varying speed curve characterized by a rapid initial speed increase, followed by deceleration in the middle of the travel, and a moderate increase in speed near the fully closed position.

[0028] The two curves show that the magnetic bridge reduces the intermediate stroke speed, effectively reducing the collision speed (~0.82 relative position) when the movable component and the fixed electrical contact come into contact. This results in controlled and reduced final speed, thereby minimizing wear and degradation of relay components and extending the relay's service life.

[0029] To further illustrate, Figure 5 A flowchart of an example method for controlling the speed of a movable component in an electronic relay is provided. The method includes: coupling an electronic relay 502 to a circuit, the electronic relay including at least one fixed contact and a movable component including a movable contact coupled to a shaft coupled to a plunger. The plunger is disposed in an actuation channel defined by a magnetic actuation component and configured to move along an actuation path. The electronic relay also includes a magnetic bridge surrounding a portion of the actuation path of the plunger.

[0030] In some examples, electronic relays are referenced above. Figure 1 , Figure 2A and Figure 2B The electronic relay 100 is discussed. For example, the electronic relay can be coupled to the high-voltage battery and power distribution system in an electric vehicle, wherein the electronic relay controls when power from the battery is supplied to the power distribution system.

[0031] Figure 5 The method also includes applying 504 electrical current to a magnetic actuator, wherein the magnetic actuator applies a magnetic force to a movable component, and wherein the speed of the movable component is controlled by a magnetic bridge. In some examples, as described above, a magnetic coil is energized to apply a magnetic force to the movable component, thereby forcing the movable component upward and closing the electrical gap between the movable contact and the fixed contact. A magnetic bridge is disposed in the magnetic gap and controls the speed of the movable component by changing the magnetic force acting on the plunger when the magnetic gap is closed.

[0032] In view of the foregoing, it should be understood that the electronic relay utilizing a magnetic bridge according to this disclosure has many advantages, including but not limited to: ● Increase initial (starting) force; ● Control the speed of movable components to limit damage to electronic relays; ● Larger electrical and magnetic clearances are achieved, allowing the relay to have greater interruption capacity; ● It eliminates the need for electronic devices to adjust the actuation current or complex spring arrangements.

[0033] The advantages and features of this disclosure can be further described by the following statements:

[0034] 1. An electronic relay assembly comprising: at least one fixed contact; a movable assembly including a movable contact coupled to a shaft coupled to a plunger, wherein the plunger is disposed in an actuation channel defined by a magnetic actuation assembly, the plunger being configured to move along an actuation path; and a magnetic bridge surrounding a portion of the actuation path of the plunger.

[0035] 2. The electronic relay assembly according to statement 1, wherein the magnetic bridge is disposed in the magnetic gap between the plunger and the top core of the electronic relay assembly.

[0036] 3. The electronic relay assembly according to statement 1 or 2, wherein the magnetic bridge is a ring made of magnetic material.

[0037] 4. The electronic relay assembly according to any one of statements 1-3, wherein, during actuation of the movable component, the plunger passes through the magnetic bridge.

[0038] 5. The electronic relay assembly according to any one of statements 1-4, wherein the magnetic actuation assembly includes a magnetic coil surrounding the actuation channel.

[0039] 6. The electronic relay assembly according to any one of statements 1-5, wherein the magnetic actuator is energized to apply a magnetic force to the movable component.

[0040] 7. The electronic relay assembly according to any one of statements 1-6, wherein a magnetic force applied to the movable assembly moves the movable assembly to close the electrical gap between the movable contact and at least one fixed contact.

[0041] 8. The electronic relay assembly according to any one of statements 1-7, wherein the magnetic bridge controls the speed at which the movable component is moved by inducing magnetic force on the movable contact during passage through the actuation path.

[0042] 9. The electronic relay assembly according to any one of statements 1-8, further comprising: one or more additional magnetic bridges surrounding one or more portions of the actuation path of the plunger.

[0043] 10. A method for controlling the speed of a movable component in an electronic relay, the method comprising: coupling the electronic relay to a circuit, the electronic relay including: at least one fixed contact, a movable component, and a magnetic bridge, the movable component including a movable contact coupled to a shaft coupled to a plunger, wherein the plunger is disposed in an actuation channel defined by a magnetic actuation component, the plunger being configured to move along an actuation path, the magnetic bridge surrounding a portion of the actuation path of the plunger; and applying power to the magnetic actuation component, wherein the magnetic actuation component applies a magnetic force to the movable component, and wherein the speed of the movable component is controlled by the magnetic bridge.

[0044] 11. The method according to statement 10, wherein the magnetic bridge is disposed in the magnetic gap between the plunger and the core of the electronic relay assembly.

[0045] 12. The method according to statement 10 or 11, wherein the magnetic bridge is a ring having a magnetic material.

[0046] 13. The method according to any one of statements 10-12, wherein the plunger passes through the magnetic bridge during actuation of the movable component.

[0047] 14. The method according to any one of statements 10-13, wherein the magnetic actuation assembly includes a magnetic coil surrounding the actuation channel.

[0048] 15. The method according to any one of statements 10-14, wherein the magnetic actuator is energized to apply a magnetic force to the movable component.

[0049] 16. The method according to any one of statements 10-15, wherein a force applied to the movable component moves the movable component to close the electrical gap between the movable contact and at least one fixed contact.

[0050] 17. The method according to any one of statements 10-16, wherein the magnetic bridge controls the speed at which the movable component is moved by inducing magnetic force on the movable contact during passage through the actuation path.

[0051] 18. The method according to any one of statements 10-17, wherein the electronic relay includes one or more additional magnetic bridges surrounding one or more portions of the actuation path of the plunger.

[0052] 19. An electric vehicle system comprising: a high-voltage battery, a power distribution system, and an electronic relay coupling the high-voltage battery to the power distribution system, the electronic relay including: at least one fixed contact, a movable component, and a magnetic bridge, the movable component including a movable contact coupled to a shaft coupled to a plunger, wherein the plunger is disposed in an actuation channel defined by a magnetic actuation component, the plunger being configured to move along an actuation path; the magnetic bridge surrounding a portion of the actuation path of the plunger.

[0053] 20. The electric vehicle system according to statement 19, wherein the magnetic bridge is disposed in the magnetic gap between the plunger and the core of the electronic relay assembly.

[0054] As can be understood from the foregoing description, various modifications and alterations can be made to the embodiments of this disclosure 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 defined only by the language of the claims.

Claims

1. An electronic relay assembly, comprising: At least one fixed contact; A movable component includes a movable contact coupled to a shaft coupled to a plunger, wherein the plunger is disposed in an actuation channel defined by a magnetic actuation component and the plunger is configured to move along an actuation path; as well as A magnetic bridge, which surrounds a portion of the actuation path of the plunger.

2. The electronic relay assembly according to claim 1, wherein, The magnetic bridge is disposed in the magnetic gap between the plunger and the core of the electronic relay assembly.

3. The electronic relay assembly according to claim 1, wherein, The magnetic bridge is a ring made of magnetic material.

4. The electronic relay assembly according to claim 3, wherein, During actuation of the movable component, the plunger passes through the magnetic bridge.

5. The electronic relay assembly according to claim 1, wherein, The magnetic actuation assembly includes a magnetic coil surrounding the actuation channel.

6. The electronic relay assembly according to claim 1, wherein, The magneto-actuated component is energized to apply a magnetic force to the movable component.

7. The electronic relay assembly according to claim 6, wherein, A magnetic force applied to the movable component moves the movable component to close the electrical gap between the movable contact and the at least one fixed contact.

8. The electronic relay assembly according to claim 7, wherein, The magnetic bridge controls the speed at which the movable component is moved by changing the magnetic force acting on the plunger as it traverses the actuation path.

9. The electronic relay assembly according to claim 1, further comprising: One or more additional magnetic bridges, the one or more additional magnetic bridges surrounding one or more portions of the actuation path of the plunger.

10. A method for controlling the speed of a movable component in an electronic relay, the method comprising: An electronic relay is coupled to a circuit, the electronic relay comprising: at least one fixed contact, a movable component, and a magnetic bridge; the movable component includes a movable contact coupled to a shaft coupled to a plunger, wherein the plunger is disposed in an actuation channel defined by a magnetic actuation component, the plunger being configured to move along an actuation path; the magnetic bridge surrounds a portion of the actuation path of the plunger; and Electricity is applied to the magnetic actuator, wherein the magnetic actuator applies a magnetic force to the movable component, and wherein the speed of the movable component is controlled by the magnetic bridge.

11. The method according to claim 10, wherein, The magnetic bridge is disposed in the magnetic gap between the plunger and the core of the electronic relay assembly.

12. The method according to claim 10, wherein, The magnetic bridge is a ring made of magnetic material.

13. The method according to claim 12, wherein, During actuation of the movable component, the plunger passes through the magnetic bridge.

14. The method of claim 10, wherein, The magnetic actuation assembly includes a magnetic coil surrounding the actuation channel.

15. The method according to claim 10, wherein, The magneto-actuated component is energized to apply a magnetic force to the movable component.

16. The method according to claim 15, wherein, A force applied to the movable component moves the movable component to close the electrical gap between the movable contact and the at least one fixed contact.

17. The method according to claim 16, wherein, The magnetic bridge controls the speed at which the movable component is moved by changing the magnetic force acting on the plunger as it traverses the actuation path.

18. The method according to claim 10, wherein, The electronic relay includes one or more additional magnetic bridges that surround one or more portions of the actuation path of the plunger.

19. An electric vehicle system, comprising: High-voltage batteries; Power distribution system; as well as An electronic relay, which couples the high-voltage battery to the power distribution system, the electronic relay comprising: At least one fixed contact; A movable component includes a movable contact coupled to a shaft coupled to a plunger, wherein the plunger is disposed in an actuation channel defined by a magnetic actuation component, and the plunger is configured to move along an actuation path; and A magnetic bridge, which surrounds a portion of the actuation path of the plunger.

20. The electric vehicle system according to claim 19, wherein, The magnetic bridge is disposed in the magnetic gap between the plunger and the core of the electronic relay assembly.

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