Integrated contactor and pre-charge relay assembly

Abstract

The present disclosure relates to an integrated contactor and pre-charge relay assembly comprising: a housing comprising a first contactor lead and a second contactor lead; a main contactor configured to selectively conduct current between the first contactor lead and the second contactor lead; and a pre-charge contactor configured to selectively conduct current between the first contactor lead and the second contactor lead through a resistor. The housing contains the main contactor, the pre-charge contactor, and the resistor. The present disclosure also relates to an electric vehicle and a method.

Description

Technical Field

[0001] This disclosure relates to integrated contactor and precharge relay assemblies. 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 operable to conduct high-voltage power from the high-voltage battery to the capacitive load. However, to avoid damaging the capacitor components, the circuit is first pre-charged by applying a high-voltage source to the load via a pre-charge resistor. Summary of the Invention

[0003] Specific embodiments relate to an integrated contactor and pre-charge relay assembly, comprising a housing including first and second contactor leads. The integrated contactor and pre-charge relay assembly also includes a main contactor configured to selectively conduct current between the first and second contactor leads. The integrated contactor and pre-charge relay assembly further includes a pre-charge contactor configured to selectively conduct current between the first and second contactor leads via a resistor. The housing contains the main contactor, the pre-charge contactor, and the resistor. Attached Figure Description

[0004] Figure 1 This is a circuit diagram of a multi-switch contactor assembly according to at least one embodiment of the present disclosure.

[0005] Figure 2 yes Figure 1 Another view of the integrated contactor and precharge relay assembly.

[0006] Figure 3 yes Figure 1 Another view of the integrated contactor and precharge relay assembly.

[0007] Figure 4 yes Figure 1 Another view of the integrated contactor and precharge relay assembly.

[0008] Figure 5 yes Figure 1 Another view of the integrated contactor and precharge relay assembly.

[0009] Figure 6 yes Figure 1 Another view of the integrated contactor and precharge relay assembly.

[0010] Figure 7 yes Figure 1 Another view of the integrated contactor and precharge relay assembly.

[0011] Figure 8 This is a flowchart of an exemplary method for an integrated contactor and precharge relay assembly according to at least one embodiment of the present disclosure. Detailed Implementation

[0012] Connecting and disconnecting circuits is as old as the circuit itself and is often used as a method to switch the power supply to connected electrical devices between an "on" and "off" state. 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 a power source. A contactor is configured such that it can change between an "off" and "closed" state to interrupt or complete the circuit, thereby controlling the power supplied to and from the devices.

[0013] With societal progress, various innovations have led to the increasing prevalence of electrical systems and electronic devices. Examples of such innovations include recent advancements in electric vehicles, which are becoming the energy-efficient standard and are likely to replace most traditional petroleum-powered vehicles. In such expensive and routinely used electrical installations, overcurrent protection is particularly useful for preventing device failure and permanent damage. Furthermore, overcurrent protection can prevent safety hazards such as electric shock or electrical fires. These modernization improvements to electrical systems and devices necessitate improved solutions to enhance the safety, reliability, and efficiency of the mechanisms used to trigger contactors.

[0014] This document describes different embodiments of contact assemblies in which certain components or portions thereof are integrally formed 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) employing contactor assemblies according to the invention, and circuits and systems employing electrical switching devices according to the invention.

[0015] The terminology used in this document to describe particular examples is not intended to limit other examples. The use of singular forms such as “a,” “an,” and “the,” and the use of a single element in any instance, is neither explicitly nor implicitly defined as mandatory; other examples may use multiple elements to achieve the same function. 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 function. It should also be understood that the terms “comprising,” “consisting of,” “including,” and / or “includes”, when used, indicate the presence of the stated feature, whole, step, operation, process, action, element, and / or component, but do not preclude the presence or addition of one or more other features, wholes, steps, operations, processes, actions, elements, components, and / or any combination thereof.

[0016] It should be understood that when one element is referred to as "connected" or "linked" to another element, these elements can be directly connected or linked via one or more intermediate elements. If "or" is used to combine two elements A and B, this should be understood to disclose all possible combinations, namely, only A, only B, and 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 elements.

[0017] Therefore, although other examples can have various variations and alternative forms, some specific examples are shown in the accompanying drawings and will be described in detail thereafter. However, this detailed description is not intended to limit the other examples to the specific forms described. Other examples can cover all variations, equivalents, and alternatives falling within the scope of this disclosure. In the description of the drawings, the same reference numerals always refer to the same or similar elements that, when compared with each other, can be implemented equivalently or in modified form while providing the same or similar function.

[0018] Pre-charge relays are used in conjunction with high-voltage contactors to safely manage the connection of high-voltage components (such as batteries and inverters) in electrical systems. Pre-charge relays are provided to gradually charge the input capacitors of high-voltage loads (e.g., motor controllers or inverters) before the main contactor closes, thus preventing inrush currents that could damage the system or cause arcing at the contactor. For example, when a high-voltage contactor connects a power source (e.g., a battery) to a load, there are typically large, initially uncharged input capacitors on the load side. Without a pre-charge mechanism, these capacitors would draw a sudden, large inrush current when the contactor closes, which could damage the capacitors or other components and / or cause excessive wear or welding of the contactor contacts due to arcing.

[0019] A pre-charge relay allows current to flow through a resistor (called a pre-charge resistor) before the main contactor closes. This resistor limits the current and ensures the capacitor is gradually charged to a safe voltage level. Once the capacitor is charged to nearly the same voltage as the battery, the pre-charge relay disengages (unlocks), and the main contactor closes. At this point, the voltage difference across the contactor is minimal, preventing arcing and wear on the contactor contacts. By preventing high inrush currents, the pre-charge relay protects sensitive electrical components, reduces mechanical stress on the contactor, and extends system life.

[0020] In typical operation, the pre-charge relay is activated, guiding current through the pre-charge resistor to the load. The system monitors the voltage across the load to determine when it is fully charged. The pre-charge relay is then deactivated, and the main contactor closes to establish a direct connection between the battery and the load. The high-voltage system then operates normally with the main contactor fully engaged.

[0021] However, connecting the pre-charge relay and the connection between the pre-charge relay and the load requires a separate wiring harness in addition to the main contactor's wiring harness. According to embodiments of this disclosure, the pre-charge relay and pre-charge resistor are integrated into the same housing as the main contactor. This saves space and reduces the number of electrical connection harnesses required to implement the pre-charge circuitry for the contactor.

[0022] from Figure 1 We begin by describing an exemplary method and apparatus for an integrated contactor and precharge relay assembly according to the present disclosure, with reference to the accompanying drawings. Figure 1-7 An exemplary integrated contactor / precharge assembly 100 for an integrated contactor and precharge relay assembly according to at least one embodiment of the present disclosure is shown. Figure 1 A first isometric view is shown of an assembled integrated contactor / precharge assembly 100 comprising both a high-voltage (HV) contactor and a precharge relay within the same housing 102. The integrated contactor / precharge assembly 100 includes a housing 102, with a first contactor lead 104 and a second contactor lead 105 exposed through a top 106 of the housing 102. The contactor leads 104 and 105 are used to connect the integrated contactor / precharge assembly 100 between a power source (e.g., a high-voltage battery) and a load. The bottom 108 of the housing 102 includes a first cavity 110 and a second cavity 112. The first cavity 110 houses a contactor solenoid for actuating a contactor actuator assembly to open and close the contactor, and the second cavity 112 houses a precharge relay solenoid for actuating a precharge actuator assembly to open and close the precharge relay. The bottom 108 of the housing 102 also includes a connector 114 for providing an activation signal to operate the contactor solenoid and the precharge relay solenoid.

[0023] Figure 2 It shows Figure 1 A view of the integrated contactor / precharge assembly 100, wherein the bottom 108 of the housing 102 is removed to show the shield 116 for the contactor solenoid and the shield 118 for the precharge relay solenoid. Also visible are leads 120 and 122 for activating the contactor solenoid and the precharge relay solenoid, respectively. Figure 3 It shows Figure 2 A view of the integrated contactor / precharge assembly 100, with shields 116, 118 removed to show the contactor solenoid 124 and the precharge relay solenoid 126. Figure 4 It shows Figure 3 A view of the integrated contactor / precharge assembly 100, wherein the contactor solenoid 124 and the precharge relay solenoid 126 are removed to show the contactor plunger tube 128 for housing the plunger of the actuator assembly of the contactor and the precharge relay plunger tube 130 for housing the plunger of the actuator assembly of the precharge relay.

[0024] Figure 5 It shows Figure 4 A view of the integrated contactor / precharge assembly 100, rotated 90 degrees to show the top of the integrated contactor / precharge assembly 100. Figure 6 It shows Figure 5 An integrated contactor / precharge assembly 100, wherein the top 106 of the housing 102 is removed to show the first relay lead 132 and the substrate 136 electrically connected to the first contactor lead 104 and the arc chamber housing 134.

[0025] Figure 7 Another isometric view of an integrated contactor / precharge assembly 100 according to at least one embodiment of the present disclosure is shown. Figure 7 In this diagram, housing 102 and arc chamber housing 134 are removed to reveal contactor assembly 140 and pre-charge relay assembly 160. Contactor assembly 140 includes fixed contacts 141, 142 and a movable contact 143 configured to move to engage and disengage with the fixed contacts 141, 142 to transfer energy from one fixed contact 141 to the other. The movable contact 143 is actuated by a shaft (not visible) coupled to a plunger (not visible) disposed in contactor plunger tube 128. The shaft and plunger are part of an actuator assembly in which the plunger is actuated by a magnetic field generated by activation of the contactor solenoid 124. Contactor assembly 140 also includes a yoke 144, which may be a magnetic yoke.

[0026] The precharge relay assembly 160 includes fixed contacts 161, 162 and a movable contact 163 configured to move to engage and disengage with the fixed contacts 161, 162 to conduct energy from one fixed contact 161 to the other. The movable contact 163 is actuated by a shaft 164 coupled to a plunger (not visible) disposed in a precharge relay plunger tube 130. The shaft 164 and the plunger are part of an actuator assembly in which the plunger is actuated by a magnetic field generated by the activation of the precharge relay solenoid 126. The precharge relay assembly 160 also includes a first relay lead 132 for electrical connection to a first contactor lead 104 of the integrated contactor / precharge assembly 100.

[0027] The precharge relay assembly 160 also includes a second relay lead 133 connected to the first resistor lead 150. The contactor assembly 140 includes a second resistor lead 152 for electrical connection via pin 153 to the second contactor lead 105. A resistor 154 connects the first resistor lead 150 to the second resistor lead 152. In this manner, when the precharge relay assembly 160 is in the closed state with the movable contact 163 in contact with the fixed contacts 161, 162, current is conducted through the resistor 154 from the first contactor lead 104 to the second contactor lead 105. This limits the current and allows the capacitor components to be precharged at a slower rate before the contactor assembly 140 is closed and full voltage is applied to those components.

[0028] To further illustrate, Figure 8 A flowchart of a method for an integrated contactor and precharged relay assembly according to at least one embodiment of the present disclosure is shown. Figure 8 The method includes step 802 of connecting an integrated contactor and pre-charge relay assembly between a power source and a load, the integrated contactor and pre-charge relay assembly being configured to selectively connect the power source to the load. In some examples, the integrated contactor and pre-charge relay assembly is coupled with... Figure 1-7 The integrated contactor and precharge relay assembly shown are similar or identical.

[0029] Figure 8 The method also includes step 804 of activating the pre-charge contactor before activating the main contactor. In some examples, step 804 of activating the pre-charge contactor is performed by supplying an activation signal to a pre-charge contactor solenoid, which actuates a movable contact in the pre-charge contactor to move into contact with a first fixed contact and a second fixed contact, thereby electrically connecting the first and second contacts in the pre-charge contactor. Current is conducted from the first contact to the second contact through a pre-charge resistor.

[0030] Figure 8The method also includes step 806 of activating the main contactor. In some examples, step 806 of activating the main contactor is performed by supplying an activation signal to a main contactor solenoid, which actuates a movable contact in the main contactor to move into contact with a third fixed contact and a fourth fixed contact in the main contactor, thereby electrically connecting the third and fourth contacts.

[0031] In view of the foregoing, it should be understood that, as provided in this disclosure, integrating the contactor and pre-charge relay in the same component and housing saves space because the pre-charge relay, pre-charge resistor, and contactor components are housed together. It should also be understood that the integrated contactor and pre-charge relay assembly according to this disclosure reduces the number of electrical wiring harnesses / wiring required to implement the pre-charge circuitry of the contactor.

[0032] As will be understood from the foregoing description, various modifications and variations 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 limiting. The scope of this disclosure is defined only by the statements in the appended claims.

Claims

1. An integrated contactor and pre-charged relay assembly, comprising: A housing, the housing including a first contactor lead and a second contactor lead; A main contactor configured to selectively conduct current between a first contactor lead and a second contactor lead; as well as A pre-charge contactor configured to selectively conduct current between a first contactor lead and a second contactor lead via a resistor; The housing includes the main contactor, the pre-charge contactor, and the resistor.

2. The integrated contactor and pre-charge relay assembly according to claim 1, wherein, The main contactor is actuated by a first solenoid and the pre-charge contactor is actuated by a second solenoid, and the housing defines corresponding cavities for the first solenoid and the second solenoid.

3. The integrated contactor and pre-charge relay assembly according to claim 2, wherein, The housing includes a connector configured to transmit signals for activating the first solenoid and the second solenoid.

4. The integrated contactor and pre-charge relay assembly according to claim 1, wherein, The main contactor includes a first fixed contact electrically connected to the first contactor lead; a second fixed contact electrically connected to the second contactor lead; and a movable contact operable to engage and disengage the first fixed contact and the second fixed contact. and The precharge contactor includes a third fixed contact electrically connected to the first contactor lead; a fourth fixed contact electrically connected to the resistor, wherein the resistor is also electrically connected to the second contactor lead; and a movable contact operable to engage and disengage the third and fourth fixed contacts.

5. An electric vehicle, comprising: One or more battery packs; Inverter; as well as An integrated contactor and pre-charge relay assembly, operable to close a circuit connecting the one or more battery packs to the inverter, the integrated contactor and pre-charge relay assembly comprising: A housing, the housing including a first contactor lead and a second contactor lead; A main contactor configured to selectively conduct current between the first contactor lead and the second contactor lead; and A pre-charge contactor configured to selectively conduct current between a first contactor lead and a second contactor lead via a resistor; The housing contains the main contactor, the pre-charge contactor, and the resistor.

6. The electric vehicle according to claim 5, wherein, The main contactor is actuated by a first solenoid and the pre-charge contactor is actuated by a second solenoid, and the housing defines corresponding cavities for the first solenoid and the second solenoid.

7. The electric vehicle according to claim 6, wherein, The housing includes a connector configured to transmit signals for activating the first solenoid and the second solenoid.

8. The electric vehicle according to claim 5, wherein, The main contactor includes a first fixed contact electrically connected to the first contactor lead; a second fixed contact electrically connected to the second contactor lead; and a movable contact operable to engage and disengage the first fixed contact and the second fixed contact. and The precharge contactor includes a third fixed contact electrically connected to the first contactor lead; a fourth fixed contact electrically connected to the resistor, wherein the resistor is also electrically connected to the second contactor lead; and a movable contact operable to engage and disengage the third and fourth fixed contacts.

9. A method comprising: An integrated contactor and pre-charge relay assembly is connected between a power source and a load, the integrated contactor and pre-charge relay assembly being configured to selectively connect the power source to the load, the integrated contactor and pre-charge relay assembly comprising: A housing, the housing including a first contactor lead and a second contactor lead; A main contactor configured to selectively conduct current between the first contactor lead and the second contactor lead; and A pre-charge contactor configured to selectively conduct current between a first contactor lead and a second contactor lead via a resistor; The housing includes the main contactor, the pre-charge contactor, and the resistor; Activate the pre-charge contactor before activating the main contactor; and Activate the main contactor.

10. The method according to claim 9, wherein, The main contactor is actuated by a first solenoid and the pre-charge contactor is actuated by a second solenoid, and the housing defines corresponding cavities for the first solenoid and the second solenoid.

11. The method according to claim 10, wherein, The housing includes a connector configured to transmit signals for activating the first solenoid and the second solenoid.

12. The method according to claim 9, wherein, The main contactor includes a first fixed contact electrically connected to the first contactor lead; a second fixed contact electrically connected to the second contactor lead; and a movable contact operable to engage and disengage the first fixed contact and the second fixed contact. and The precharge contactor includes a third fixed contact electrically connected to the first contactor lead; a fourth fixed contact electrically connected to the resistor, wherein the resistor is also electrically connected to the second contactor lead; and a movable contact operable to engage and disengage the third and fourth fixed contacts.

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