Vacuum contactor

Abstract

This invention discloses a vacuum contactor, comprising a housing forming a sealed space with no internal or external penetrations, and an overall static seal / constant volume, encapsulating a vacuum environment. A moving contact divides the sealed space into a first and a second chamber, wherein at least one chamber is provided with a stationary contact and at least one stationary contact unit. The moving contact is provided with at least one hollow moving contact unit, enabling communication between the first and second chambers and forming at least one arc gap with each of the at least one stationary contact unit. The moving contact and the stationary contact undergo relative reciprocating motion, causing the hollow moving contact unit to engage and disengage from the stationary contact unit. The first and second chambers alternately compress and expand, and the vacuum environment remains connected between the first and second chambers through the hollow moving contact unit. The stroke of the moving contactor of this invention can be precisely adjusted via a guide rail, screw, and motor drive, without being limited by the stroke of a single bellows or spring energy storage device. It can cover a wide range of rated voltage and current, and is suitable for applications such as industrial automation, power distribution, and distributed power switching.

Description

Technical Field

[0001] This invention relates to a vacuum contactor, which is a contactor device that utilizes a vacuum environment to synchronously extinguish arc gaps. Background Technology

[0002] A contactor is a switching device that connects an external power supply end and a load end through the contact of their respective internal electrical contacts. Smart grids, power generation grid connection, and distributed contactor equipment at various nodes such as urban, industrial, and community power supply entrances and distribution systems require systematic automatic management, involving large capacity, stability, and predictable maintenance. Meanwhile, electric locomotives, large electromagnetic power units, electric vehicle power batteries, green energy power generation operations, and extreme application environments (such as aerospace and underwater power systems) are distributed and frequently switching power switching devices, requiring high power density, safety, arc resistance, durability, lifespan, and controllability.

[0003] However, prior art contactors have a small number of contacts and high contact resistance; touch-type contacts are prone to bouncing, contact deformation, displacement, and wear; electric arcs combined with high contact resistance lead to irreversible aging of contacts, and atmospheric conditions cause contact contamination and oxidation; single-bellows contact chambers are prone to leakage due to large pressure fluctuations, while sealing increases the resistance of the moving contact, limiting its stroke and increasing its dynamic and static losses; the problem of electric arcs during contact contact and disengagement needs to be effectively solved; the combination and accumulation of multiple factors further lead to the gradual aging or rapid damage of contacts, eventually resulting in unannounced accidents such as welding and burning, causing collateral damage to the load and the power recipient, with huge costs; electric arcs can ignite accidentally leaked flammable gases; the pneumatic and electromagnetic operating devices and their arc-extinguishing mechanisms of contactors make them large and complex, and problems such as manual reset, high noise, high power consumption, electromagnetic interference from electromagnetic operating devices, and potential misoperation due to electromagnetic shocks all need to be solved. Summary of the Invention

[0004] The vacuum contactor of this invention maintains communication between the first and second chambers in a vacuum environment, ensuring the contactor's arc gap is within a vacuum, effectively protecting the contactor contacts from arc damage. The contactor's contact ends engage via a socketing and lateral sliding mechanism, avoiding the mechanical impact, noise, and contact bounce caused by the contact-by-contact method in prior art. The contactor maintains contact through the lateral elasticity of the contact ends, requiring no power consumption. Furthermore, a single contact end is divided into multiple contact ends, each forming several contacts, creating a multi-contact, low-resistance contact interface. In this invention, if the contactor has an array of contact terminals, the number of contacts is considerable, which significantly reduces the contactor's power consumption, increases its power density, and slows down contact aging caused by long-term electrothermal effects. This is especially true in oxygen-free, clean, vacuum-sealed spaces, significantly extending the contactor's service life. Furthermore, the array of contact terminals provides an array of arc gap interfaces, allowing the arc to either occur in all gaps or a few arcs to move between gaps. The former disperses the arc, while the latter has a short duration of impact on individual contacts, avoiding the high-temperature, concentrated arcs generated at a few contacts in prior art contactors. The contactor of this invention is also equipped with a microprocessor module, a motion control system, and a contactor sensing and early warning system. The microprocessor module implements automatic and intelligent control of the contactor. The motion control system, in addition to performing continuous automatic switching operations, further improves arc extinguishing and contact protection. The contactor sensing and early warning system issues different warnings before a contactor failure occurs, ensuring the contactor has sufficient service life while preventing failures without warning.

[0005] The contactor is located in a sealed space containing a liquid or gaseous arc-extinguishing medium or a vacuum. A moving contact divides the sealed space into two chambers, at least one of which has a stationary contact and its contact unit. The stationary contact unit is aligned with the moving contact unit. The moving contact has a hollow contact unit, allowing the two chambers to communicate. The moving contact reciprocates, and the moving contact unit engages with and disengages from the stationary contact unit. Simultaneously, the two chambers alternately compress and expand, and the arc-extinguishing medium impacts the arc gap between the moving and stationary contact ends through the hollow contact unit, circulating between the two chambers. This provides a contactor and its self-circulating reciprocating synchronous arc-extinguishing pump to perform the contactor's opening, closing, and synchronous arc extinguishing.

[0006] A moving contact motion frame includes: a moving contact sleeve with at least two bearing seats, linear bearings, and bearing guides extending from its outer wall; the bearing guides are fixed at both ends to the corners of parallel first and second fixed plates; and other fixing and supporting components to form a two-layer rigid frame; the stationary contact is fixed to the first fixed plate; a metal elastic bellows has the stationary contact fitted at its first opening and the moving contact fitted at its second opening; the moving contact sleeve fits the second opening of the first bellows, the moving contact, and the first opening of the second bellows; and the... The second opening of the two corrugated pipes is fixed to the second fixed plate, or a second stationary contact is sleeved on and then fixed to the second fixed plate; the moving contact sleeve reciprocates along the bearing guide rail between the two fixed plates under the action of external force; the moving contact contact unit is sleeved on and disengaged from the contact end of the stationary contact; the two corrugated pipes alternately extend and retract; the arc extinguishing medium circulates between the two corrugated pipes; and flows back and forth through the hollow part of the moving contact contact unit in the arc gap between the contact ends of the moving and stationary contacts, carrying away the electric arc and its heat, thus providing a double corrugated pipe arc extinguishing pump contactor. The moving contact sleeve is subjected to a force at one point, directly or through other structures, driven by human force, or by spring force, pneumatic, hydraulic, electromagnetic operating devices, and other power devices, to drive the moving contact to move unidirectionally or reciprocally, thereby performing the opening or closing of the contactor, or both opening and closing; optionally, the moving contact sleeve is fixed, and the force is applied to the part outside the moving contact sleeve, so that the stationary contact performs unidirectional or reciprocating motion relative to the moving contact, thereby performing the opening or closing of the contactor, or both opening and closing.

[0007] The stationary contact includes: a conductor substrate encapsulated within a stationary contact insulating disk, or extending outward to form an external terminal; one or an array of stationary contact units, one end of which is connected to the conductor substrate, and the other end of which is a contact end protruding from the surface of the insulating disk; the moving contact includes: a conductor substrate encapsulated within a moving contact insulating disk, or extending outward to form an external terminal; one or an array of hollow moving contact units passing through and connected to the conductor substrate, one end of which is open on one side of the insulating disk, serving as a contact end protruding from the surface of the insulating disk, and paired one-to-one with the contact end of the stationary contact to form an arc gap; the moving contact may have double contact ends protruding from both sides of the insulating disk. The materials of the stationary contact, moving contact units, and conductor substrate, because they are placed in an oxygen-free, clean, or sealed environment, can be, in addition to commonly used metals, readily available and processable metals such as iron and aluminum. The contact units and conductor substrate can be made from one or more of these available metals through mixing or layering. The contact end of the stationary contact unit is a hollow or solid conductor, and its end is divided into multiple contact ends by a longitudinal slot. The hollow contact unit of the moving contact is divided into multiple contact ends by a longitudinal slit. The inner opening of the contact end of the hollow contact unit may have two narrow sections, deep and shallow. The contact ends of the moving and stationary contacts are connected in an alternating manner with the slits and slots, so that one contact end obtains multiple contacts. The number of contacts formed by one contact end is several times the number of its contact ends, providing a multi-contact, low-resistance contact interface. The hollow contact unit can be an electrical cannula, and the stationary contact unit can be an electrical pin. The electrical cannula is divided into several tile-shaped contact ends by a narrow slit, and the electrical pin is divided into several finger-shaped ends by a wider slot. The number of contact ends of both is the same. The inner opening of the electrical cannula may have two layers of annular narrow sections, and the slits and slots are orthogonally interlocked to implement the contact between the moving contact and the stationary contact. The number of contact points obtained is two or four times the number of finger-shaped or tile-shaped ends. Furthermore, the contact unit can also be a non-circular structure and can implement longitudinal insertion and lateral sliding contact, as well as maintain contact by the lateral elasticity of the contact ends.

[0008] This invention also provides a piston-type moving contactor, comprising: a sealed cylinder-type housing, the interior of which is filled with an arc-extinguishing medium or set to a vacuum, and the inner wall is provided with a longitudinally protruding slide rail; the stationary contact, comprising a stationary contact conductor substrate and its external terminals and an array of contact units, and a stationary contact insulator encapsulating the conductor substrate therein and disposed at one end of the cylinder-type housing; a piston-type moving contact, which is movable and fits against the inner cavity wall of the housing, dividing the inner cavity into two chambers, the conductor substrate being encapsulated therein, the array of contact units connected to the conductor substrate and open at both ends being equidistant from the stationary contact units, and a piston center thread; and a motion actuator fixed to the second end of the housing, driving the moving contact units to engage with and disengage from the stationary contact units, thus providing a contactor and a cylinder-piston type arc-extinguishing pump thereof.

[0009] The contactor also includes a controller, comprising a microprocessor, a communication module, sensors, an actuator, and a power module. The microprocessor, sensors, and actuator provide a motion control system for controlling the motion of the moving contact, implementing segmented speed control, precise positioning, and mechanical locking during the engagement and disengagement of the moving contact unit with the stationary contact unit. The microprocessor, communication module, and sensors provide a contactor monitoring and early warning system for monitoring the contactor, sending data and alarms to external and remote terminals, performing contactor maintenance and fault warnings, and receiving commands and data from external and remote terminals, including contactor opening and closing commands. The power module provides power conversion to power the controller and includes a rechargeable battery that is activated when the controller's input power is interrupted. Optionally, the controller can be replaced by a simplified circuit composed of analog circuits, logic circuits, and a motor drive power chip, or by a single-chip IC integrating this simplified circuit, providing only the opening / closing operation control of the contactor.

[0010] The motion control includes: contactor opening: the moving contact is released from mechanical locking, the moving contact moves from the contactor off position to the stationary contact at a rated second speed, when an arc or an arc critical position signal appears, the moving contact moves to the stationary contact at a first speed at high speed or an increasing speed, the contact end of the moving contact touches the contact end of the stationary contact, the moving contact immediately moves at a slowest third speed until the precise position of the moving contact when the contactor is turned on is completed, and the moving contact is locked; wherein, the arc critical position is usually derived theoretically and determined experimentally, and an arc will be generated within this position relative to the stationary contact; and contactor closing: the moving contact is released from locking in the contactor on position, the moving contact moves away from the stationary contact at a reverse first speed at high speed or a decreasing speed, when the arc disappears or the arc critical position signal appears, it moves at a reverse second speed, stops when the moving contact position signal when the contactor is turned off occurs, and the moving contact is locked. The controller also provides an automatic control method for contactor opening and closing, including: a time control method, setting a timed triggering method for the microprocessor chip to execute the contactor opening and closing in an interrupt mode at regular intervals; and a parameter triggering method, whereby sensor data exceeding a set value or range triggers the contactor to open or close, such as a circuit breaker.

[0011] This invention also provides a universal automatic and intelligent switching technology, offering universal automatic switching devices of various specifications, rated voltages, and rated operating currents, including contactors, circuit breakers, relays, and logic-type power switches. The technology is characterized by comprising: a contact interface composed of a single or arrayed contact unit; a contact device with a self-circulating reciprocating synchronous arc-extinguishing pump; motion control for the opening / closing operation; selection of different sizes and specifications of structures to change the stroke span of the moving contact, the conductor substrate spacing, and the contact interface opening distance to conform to the voltage type (AC or DC) and rated voltage of the device, thus solving the problem of an upper limit for a rated voltage; selection of different numbers of moving / stationary contact units and their corresponding support systems to conform to the rated operating current and power level required by the device, thus solving the problem of an upper limit for a rated operating current; and a controller with a microprocessor as its core, providing communication, motion control for executing the opening / closing operation, and contactor monitoring and fault warning, or the single-chip IC providing the opening / closing operation control. Attached Figure Description

[0012] Figure 1 This is an overall top view of the contactor in some embodiments of the present invention.

[0013] Figure 2 yes Figure 1 An example of a contactor with an open internal structure.

[0014] Figure 3 yes Figure 1 A sectional view of the centerline of the contactor stationary contact 200 and moving contact 400.

[0015] Figure 4 This is a diagram of the core electrical structure of the stationary contact 200 and the moving contact 400 encapsulated within a ceramic disc.

[0016] Figure 5 yes Figure 1 Exploded view of the contactor in the embodiment.

[0017] Figure 6 shows the structure of the contactor with electrical connectors and electrical pins in some embodiments.

[0018] Figure 7 is a schematic diagram of an orthogonal connection of an electrical connector to an electrical connector pin.

[0019] Figure 8 is a cross-sectional view of the orthogonal connection of the electrical connector pins to the electrical connector tube.

[0020] Figure 9 is a cross-sectional view of the center line of the electrical connector connected to the electrical connector pin.

[0021] Figure 10 This document presents a block diagram of the controller and schematic diagrams of the contactors in some embodiments, along with their interrelationships.

[0022] Figure 11 The diagram illustrates the motion control of the electrical connector sleeve, the electrical pin, and the movement of the arc-extinguishing medium, as well as its arc-extinguishing effect.

[0023] Figure 12 The diagram illustrates the disengagement of the electrical connector from the electrical connector pin under motion control, as well as the movement of the arc-extinguishing medium and its arc-extinguishing effect.

[0024] Figure 13 These are examples of three-way synchronous parallel contactors consisting of a combination of three identical contactors.

[0025] Figure 14 These are the core electrical structures of the moving and stationary contacts in some embodiments of double-stationary contactors.

[0026] Figure 15 This is an internal open structure diagram of an embodiment of a piston-type moving contactor.

[0027] Figure 16 It is a composite device of moving contact movement, stroke and positioning. Implementation Methods

[0028] This invention relates to a contactor. Figure 1-5 The diagram shows an overall top view, an internal open view, a cross-sectional view along the centerline of the moving and stationary contacts, the electrical core structure of the moving and stationary contacts, and an exploded view of the structure for some embodiments of the contactor.

[0029] Figure 1This shows an overall top view of some contactor embodiments, the contactor including: a moving contact motion frame 100, a stationary contact 200, a first bellows 300, and a moving contact 400 (not shown, see reference). Figure 5 The moving contact moving frame 100 includes: a moving contact sleeve 101 and its crossbeam 102, and a thread 103 (not shown, see reference). Figure 5 ), first bearing housing 104 and its first linear bearing 105 and first bearing guide rail 106, second bearing housing 107 and its second linear bearing 108 and second bearing guide rail 109, first fixed plate support rod 110, second fixed plate support rod 111 (not shown, see reference) Figure 5 The contactor 200 includes first and second fixing plates 112 and 113. The stationary contact 200 has a first terminal 201 and a second terminal 202. A transformer-type current sensor 701 is installed at the first terminal 201 to measure the current flowing through it. The first and second bearing guide rails 106 and 109, and the first and second fixing plate support rods 110 and 111 are fixed at their two ends at the four corners of the first and second fixing plates 112 and 113, forming a rigid two-layer frame. The fixing plate support rods can be replaced by other structural components. The bearing guide rails can also be installed inside the contactor.

[0030] Figure 2 yes Figure 1 An internal open view of the contactor in the embodiment shows the stationary contact 200 and its contact unit, which is an array of electrical pins 203, and the moving contact 400 and its contact unit, which is an array of electrical tubes 401. The stationary contact 200 is fixed to the first fixing plate 112 and is sealed with the first opening of the first bellows 300 (not shown, see reference). Figure 5 The moving contact sleeve 101 is fitted with the second port of the first bellows 300 (not shown, see reference). Figure 5 ), moving contact 400 and second bellows 500 with its first port (not shown, see reference) Figure 5 ), Second corrugated pipe 500 second port (not shown, see reference) Figure 5The first bellows 300 is fixed to the second fixed plate 113, forming a coaxial structure internally isolated from the atmosphere, capable of withstanding the internal arc-extinguishing medium and pressure changes caused by temperature variations and the movement of the moving contact 400. Inside the first bellows 300, the contact ends of the array electrical connectors 401 and the contact ends of the array electrical pins 203 are coaxially and equidistantly opposite each other. The port 402 of the array electrical connectors 401 is opened through the surface of the moving contact insulating disk 403, allowing the first bellows 300 to communicate with the second bellows 500. The interior can also be set as a vacuum or filled with an arc-extinguishing medium. The array electrical connectors / pins, their conductor substrates, and external terminals are always in a stable, clean environment and in a sealed state, so common materials such as copper and other metals can be used, or low-cost metals such as aluminum and iron can be selected, and they can be made by layering or mixing one or more of the aforementioned metals.

[0031] The geared motor 601 engages with the moving contact sleeve 101 via the screw 602, wherein the thread 103 (not shown, see reference) on the crossbeam 102 is located. Figure 5 The moving contact sleeve 101 and moving contact 400 move toward stationary contact 200, the first bellows 300 is compressed, and the second bellows 500 is extended. The arc-extinguishing medium (not shown) in the first bellows 300 flows to the second bellows through the array electrical connector 401 and the port 402, and directly cools and transfers the high-temperature arc particles in the arc gap between the array electrical connector 401 and the array electrical connector 203, performing synchronous arc extinguishing until the array electrical connector 401 is connected to the array electrical connector 203 to the set depth, wherein the first terminal 201 and the second terminal 202 are electrically connected, and the contactor is turned on; the geared motor rotates in the reverse direction, the moving contact 400 moves away from the stationary contact 200, the first bellows 300 is extended and the second bellows 500 is compressed, and the arc-extinguishing medium flows in the reverse direction to perform synchronous arc extinguishing on the arc gap. The liquid arc-extinguishing medium immerses the electrical connector / pin contact unit, but retains a partial negative pressure space to prevent leakage caused by large internal pressure changes due to the movement of the moving contact and changes in ambient temperature. The moving contact sleeve 101 can obtain its movement power not only internally, but also externally: directly or through levers or other structures by human power, spring force, pneumatic, hydraulic, or electromagnetic devices.

[0032] Figure 3 for Figure 1The cross-sectional view along the central axis of the stationary contact 200 and the moving contact 400 in the embodiment shows that the array electrical pins 203 are divided into two parts, array electrical pins 203a and 203b, which are not connected to each other; the first conductor substrate 201a of the stationary contact 200 is connected to the array electrical pins 203a and extends to form the first terminal 201; the second conductor substrate 202a is connected to the array electrical pins 203b and extends to form the second terminal 202; the first and second conductor substrates 201a and 202a are encapsulated in the stationary contact insulating disk 204; the center hole 205 of the stationary contact is the temperature-pressure-photoelectric sensor kit inside the contactor (see reference). Figure 5 The mounting space is provided; the screw hole 206 is used for the screw fixing position between the stationary contact insulating disk 204 and the first bellows 300. The moving contact 400 array electrical plug tube 401 includes two parts, 401a and 401b, both of which are connected to the moving contact conductor substrate 404 and encapsulated in the moving contact insulating disk 403, wherein the moving contact screw hole 405 is used for the screw fixing position between the first bellows 300 and the moving contact insulating disk 403.

[0033] Figure 4 Showing Figure 1 The core electrical structure diagram of the stationary contact 200 and the moving contact 400 in the embodiment is shown. The array of electrical connectors 401 and array of electrical pins 203 are paired equidistantly and coaxially to form arc gaps. Unlike contacts in prior art contactors, arcs may be generated during contact and disengagement. This results in either all arc gaps generating low-intensity arcs, or the arcs migrating between different arc gaps. Therefore, the arc duration at the contact end of a single electrical connector / pin is short, reducing damage and forming a structural arc-reducing interface. Furthermore, each arc is further weakened, eliminated, or even prevented from forming in the first place by the synchronous arc-extinguishing medium. The electrical connectors are coaxially sleeved with the electrical pins, sliding tangentially into place and maintaining contact with radial elasticity. This avoids the increased power consumption caused by the contact being maintained by electromagnetic force in prior art contacts, and the potential for bounces during collision contact or electromagnetic interference.

[0034] When an array of electrical cannulas is fitted with an array of electrical pins, the contact end cuts of all the cannulas are orthogonally fitted with the contact end slots of the pins (refer to Figures 6, 7, 8, and 9). That is, the cuts are in the exact middle of two adjacent slots, so that the tile-shaped end of one cannulas contacts the finger-shaped ends of two adjacent pins. When the number of equally divided cuts on the cannulas and the number of equally divided slots on the pins are both N, at least approximately 2*N contacts are formed. If the finger-shaped ends of the pins touch the deep and shallow narrow sections of the cannulas, approximately 4N contacts are formed. (Array of electrical cannulas / electrical pins) When the number of pairs is P, 4*N*P contacts are formed, resulting in two series-connected contact interfaces between the first terminal 201 and the second terminal 202. Each interface has 2*N*P parallel contacts. With a contact resistance of Rc, the internal resistance of the contactor between the first and second terminals 201 and 202 is Rc / N*P (ignoring the resistance of the electrical connector, pins, and substrate). This reduces contact power consumption, increases power density, and slows down contact aging. Aging further leads to an irreversible increase in contact resistance, which is accelerated by moisture, dust, oxygen, etc., ultimately causing failure.

[0035] Figure 5 yes Figure 1 An exploded view of the contactor in the embodiment shows that the contactor includes: a moving contact motion frame 100 (reference). Figure 2 The components include a stationary contact 200, a first bellows 300, a moving contact 400, and a second bellows 500. A geared motor 601 drives a crossbeam 102 and its moving contact sleeve 101 via a screw 602 engaging a thread 103. The crossbeam 102 reciprocates linearly between the first and second fixed plates 112 and 113 via first and second linear bearings 105 and 108 along first and second bearing guides 106 and 109. The same motion can also be achieved through the external thread of the moving contact sleeve 101 or by other force application methods.

[0036] The stationary contact 200 is fixed to the first fixed plate 112. The first bellows first port 300a is sealed with the stationary contact 200 and fixed by the first ring clamp 301. The second bellows second port 300b is sealed with the moving contact 400 and is further fixed by a moving contact sleeve 101. The second bellows first port 500a is sealed with the moving contact sleeve 101 and fixed by the second ring clamp 501. The second bellows second port 500b is sealed with a bellows seat (not shown) on the second fixed plate 113 and fixed by the third ring clamp 502. In this embodiment, the geared motor 601 and its screw 602 are housed inside the second bellows and fixed to the second fixed plate 113.

[0037] The first terminal 201 of the stationary contact is equipped with a main power current sensor 701, which uses two C-shaped silicon steel sheets 701a and 701b to form a closed magnetic circuit structure. A cavity 701c between the sheets houses a linear Hall sensor chip, which performs open-loop current detection of the power supplied by the main power supply to the load. The cross arms of the silicon steel sheets 701a and 701b can also be wound with coils and connected in series to form a closed-loop current detection device with the Hall sensor and its circuit. A Rogowski coil can also be used for current detection.

[0038] The center hole 112a of the first fixing plate 112 and the center hole 205 of the stationary contact 200 Figure 3 A temperature-pressure-photoelectric sensor kit 702 is placed, with the sensor kit detection tube 702a extending into the first bellows. The static temperature of the contact interface of the array of electrical plugs / pins is measured by thermocouples, and the dynamic and static arc light and pressure changes of the contact interface are detected by the detection tube 702a and the pressure and photoelectric sensors located in the sensor base 702b.

[0039] Figures 6-9 show the contact end structure and contact method of the electrical connector and electrical pin in some contactor embodiments. Figure 6 shows that the electrical connector 401 is connected to the contact end 408 through the pipe port 402. The contact end has six equally divided narrow slits 406 and its tile-shaped ends 407. The narrow slits are almost closed, so that the arc-extinguishing medium basically enters and exits from the pipe port 408 and is concentrated in the arc gap to improve the arc-extinguishing effect. The electrical pin 203 is a solid conductor. Its contact end has six equally divided wide slots 207 and its finger-shaped ends 208. There is a shallow hole in the center to improve the flow of the arc-extinguishing medium and its arc-extinguishing effect. Figure 7 shows the electrical connector 401 orthogonally connected to the electrical pin 203 to a certain depth. Figure 8 is a cross-sectional view of the electrical connector connected to the electrical pin, showing that one finger-shaped end 208 is in contact with two tile-shaped ends 407a and 407b, and similarly, one tile-shaped end is in contact with two finger-shaped ends. Figure 9 is a cross-sectional view of the center line of the electric insertion cannula and the electric insertion pin, showing that the finger-like end 208 of one electric insertion pin touches the deep and shallow narrow sections 409a and 409b inside the contact end of the electric insertion cannula 408.

[0040] Figure 10This document presents a block diagram and schematic diagram of a controller for some contactor embodiments. The controller includes a microprocessor, a communication module, sensors, an actuator, and a power module, constituting a microprocessor module 800, a motion control system, and a contactor monitoring and early warning system, respectively. The microprocessor module 800 includes a microprocessor 801, a communication module 802, and a control panel 803. The communication module 802 includes a wired module and a wireless module. The wired module communicates via serial, wired network, and fiber optic communication, while the wireless module communicates via mobile wireless platforms (low-Earth orbit satellite networks, drones, infrared, lasers, etc.) and distributed platforms (WiFi, mobile networks, 5G+, etc.). The control panel 803 is an external terminal embedded in the contactor's housing (not shown). It allows manual input of contactor on / off commands, function and parameter settings, and display of data and status from the contactor, providing an instrument-type contactor. The microprocessor 801 communicates with a remote terminal via the communication module 802 and with the control panel 803 via the microprocessor chip's communication port; both communication methods cover communication over all distances. The power module 804 performs voltage conversion on the input power supply 804a and provides power to various parts of the contactor through the output power supply 804b; the power module also includes a rechargeable battery (not shown) to provide backup power when the input power supply 804a is powered off.

[0041] The microprocessor 801 receives commands and data from external and remote terminals, executes commands and parameter settings, monitors contactor sensors to obtain data and sends data and alarms to external and remote terminals, and receives contactor open / close commands to execute contactor opening and closing through the motion control system. The microprocessor 801 can also execute contactor opening and closing through automatic control methods, including: time control methods, using timers and counters in the microprocessor 801 chip to generate timed execution for contactor opening and closing; and parameter triggering methods, where contactor sensor data exceeds a set value or range, triggering contactor opening or closing, such as when the main (supply) power current or voltage exceeds or falls below parameters set internally by the microprocessor, automatic shutdown is executed, such as a circuit breaker function.

[0042] The motion control system includes a microprocessor 801 and a sensor and actuator kit 600, forming a digital closed-loop servo control system to perform motion control on the moving contact sleeve 101 and its moving contact 400, as well as the process of the electric connector engaging and disengaging from the electric connector pin. The sensors include: a contact signal sensor 603, a position sensor 604, a motor current and speed sensor 605, and a photoelectric sensor 606. The contact signal sensor 603 provides a signal when the electric connector contacts the electric connector pin. The position sensor 604 includes a first position switch and a second position switch, providing the electric connector position when the contactor is off (i.e., the first position signal ①) and the electric connector position when the contactor is on (i.e., the fourth position signal ④) (see reference). Figure 11 , 12 The motor current and speed sensor 605 detects the motor armature current and determines the moving contact distance and motor speed by measuring the number and interval of pulses generated by the motor rotation. The number of pulses can be converted into the distance between the electric insertion tube and the first and second position switches, thereby determining the critical position of the arc, i.e., the second position ② of the electric insertion tube (reference). Figure 11 , 12 The arc critical position is a conclusion based on theory and experiments. It refers to a position where, compared to the stationary contact, the moving contact is considered unlikely to generate an arc outside this position. Within this position, the moving contact's movement speed will significantly increase, thereby increasing the flow rate of the arc-extinguishing medium and enhancing arc-extinguishing efficiency. Alternatively, the speed may be adjusted incrementally to effectively extinguish the arc without placing excessive burden on the motor. It should be noted that an arc may not necessarily occur within the arc critical position, and an arc may occur outside this position. Therefore, the arc signal will be preferentially used as the signal to trigger changes in the moving contact's movement speed relative to the arc critical position. When no arc is generated, the arc critical position signal can be used. The photoelectric sensor 606 detects the arc at the contact interface and uses it as a control signal for the moving contact's movement. An enhanced arc signal indicates a change at the contact interface, such as internal leakage or contamination. The actuator 607 includes: a moving contact lock 608, which locks the moving contact sleeve 101 when the contactor is turned on and off to prevent the moving contact from disengaging, shifting, or misoperating; and a power unit, including: a motor driver 609, a geared motor 601, and a screw 602. The geared motor and its screw are not limited to being inside the contactor; they can also be located externally, as long as they can drive the moving contact sleeve. In this embodiment, the built-in geared motor and its screw utilize the internal space of the second bellows and reduce electromagnetic interference (EMI). A disadvantage is that it may generate metal, lubricating oil particles, or harmful chemicals, compromising the cleanliness of the internal space.

[0043] The contactor monitoring and early warning system includes a microprocessor module 800 and a sensor assembly 700. The sensor assembly 700 includes a motor current and speed sensor 605 (shared with the motion control system), a temperature-pressure-photoelectric sensor kit 702, a main power supply voltage and current sensor 705 (including a current sensor 701, not shown), and a power module monitoring sensor 706. The motor current and speed sensor 605 provides the current and speed, and can calculate the ratio of speed to motor current. A decrease in this ratio indicates an increase in the moving contact's resistance and a change or damage to the shape of the electrical connector / pin contact end. The temperature-pressure-photoelectric sensor kit 702 detects the temperature through the sensor kit detection tube 702a located within the first bellows 300. Figure 5This system detects the temperature, pressure, and arcing at the contact interface of the electrical connector / pin, including: a photoelectric sensor 606 (shared with the motion control system), a pressure sensor 703, and a contact interface temperature sensor 704. An increase in contact interface temperature (excluding the influence of ambient temperature) indicates contact damage leading to increased contact resistance; the degree of damage is temperature-dependent. Changes in arcing indicate adverse changes in the contacts; arcing under steady-state conditions indicates a serious problem. Changes in pressure indicate internal or external leakage in the contact device; leakage can lead to irreversible changes such as contact contamination and oxidation, but these changes are slow. Changes in the internal temperature, pressure, and arcing of the contact device, as well as the rate of change, are collected by a remote terminal, and different levels of warnings are issued based on the fault data model, indicating the need for contactor maintenance or replacement and their schedule. Significant changes in temperature, pressure, and arcing within a short period can be identified and judged by the microprocessor's internal program, which sends an emergency alarm to the control panel and remote terminal, requesting emergency handling. Temperature, pressure, and photoelectric sensors are inexpensive, provide high-value information, are small in size, and have low accuracy requirements, making them ideal sensor components for the contactor of this invention. The main power supply voltage and current sensor 705 measures the voltage and current data of the power supply flowing through the contactor to the load, for use in system control, management, and commercial settlement. Changes in voltage and current data are also used as monitoring signals to trigger the automatic opening and closing of the contactor, such as a circuit breaker: if the current change exceeds the contactor's internal set value, the contactor will close; if the main power supply voltage exceeds the internal set range, the contactor will automatically close. It can also be programmed to automatically open or remain closed when the voltage returns to the normal range; the specific implementation depends on the microprocessor program and its internal settings. Voltage and current data can also serve as the raw signal for the contact signal sensor 603. Once a main power failure is detected, the main power failure emergency handling procedure will be activated, maintaining the contactor open or closed according to internal settings, and issuing alarms to external and remote terminals. The power module monitoring sensor 706 monitors the voltage and changes of the input power supply 804a, output power supply 804b, and backup battery of the power module 804. If the controller input power supply 804a is interrupted, the backup battery will be activated, and the controller power failure emergency procedure will be initiated, especially by issuing a battery voltage warning to prevent the battery from being depleted. If the controller input power supply is connected to the main power supply, the main power failure emergency procedure will also be initiated. With the addition of more sensors and actuators, as well as the optimization and upgrading of the microprocessor program, this contactor will provide more data information, safer operation, a simpler structure, and a longer service life.

[0044] Figure 10The diagram also shows the working principle of contactor 000. Contactor 000 includes: moving contact motion frame 100, stationary contact 200, first bellows 300, moving contact 400, and second bellows 500; in the moving contact motion frame 100, the moving contact sleeve 101 is fitted with the first bellows 300, moving contact 400, and second bellows 500. Under the push of screw 602, the moving contact 400 and its electrical connector 401 move in a linear reciprocating motion 114. The electrical connector 401 engages with and disengages from the electrical connector 203. Simultaneously, the two bellows 300 and 500 alternately extend and retract. The arc extinguishing medium 412 extinguishes the arc 421 synchronously through the electrical connector 401. When the position sensor 604 signal is generated, the contactor completes the opening and closing, and the moving contact sleeve 101 is locked by the passive contact locker 608.

[0045] Figures 11-12 The methods, processes, and differences between them for synchronous arc extinguishing under motion control, including the connection and disconnection of the electrical plug pin and its arc-extinguishing medium (see reference). Figure 10 ). Figure 11 In the process, the electric connector 401 starts from the first position ① of the contactor being turned off, i.e., the first position switch signal changes. The electric connector begins the first forward stroke 411 at the rated second speed 410. The arc-extinguishing medium 412 enters the contact end port 408 of the electric connector and directly impacts the arc gap. When the electric connector reaches the second position ②, an arc or an arc critical position signal occurs. The electric connector moves towards the electric pin at a high speed 413, which is higher than the second speed, or at an increasing speed (the average value of which is equivalent to the first speed). It enters the second forward stroke 414 and the arc-extinguishing medium 412 directly impacts the arc at high speed (not shown). The closer the electric connector is to the electric pin, the smaller the arc gap and the higher the impact speed of the arc-extinguishing medium. When the first speed is increasing, the flow rate, impact force, and arc-extinguishing effect of the arc-extinguishing medium are stronger, thereby effectively and synchronously suppressing the arc that is enhanced due to the electric connector approaching the electric pin. When the electric connector reaches the third position ③ and touches the electric pin, a contact signal appears (from the contact signal sensor 603, reference). Figure 10 The electric connector enters the third forward stroke 416 at a third speed 415, which is lower than the second speed. The inner wall of the tile-shaped end of the electric connector slides tangentially against the outer wall of the finger-shaped end of the electric connector. The arc-extinguishing medium with a slower flow rate continues to cool the contact end of the electric connector / electric connector until the fourth position ④ is reached. At this time, the second position switch signal is generated, and the finger-shaped end of the electric connector touches the two narrow sections of the electric connector, and the contactor is turned on. Figure 12In the process, the electric connector starts from the contactor's open position, i.e., the fourth position ④, and enters the first reverse stroke 418 at a reverse first speed 417. It then disengages from the electric connector at a high speed or a decreasing speed (the average of which is equivalent to the first speed). The arc-extinguishing medium enters the inlet 402 and is discharged at high speed through the contact end inlet 408, impacting the arc gap to effectively and synchronously suppress the arc throughout the process. When the arc disappears or the arc critical position signal is generated at the second position ②, the electric connector enters the second reverse stroke 420 at the rated reverse second speed 419. When the first position ① is reached, the first position switch signal is generated, and the contactor is turned off.

[0046] Figure 13 Examples of three-way contactors consisting of three identical contactors 001, 002, and 003 are shown, but only contactor 001 is described here. Contactor 001 includes: external terminals 221 and 222, first and second bellows 320 and 520, main power current sensor 721, temperature-pressure-photoelectric sensor kit 722, and moving contact motion frame 120. Moving contact motion frame 120 includes: first fixed plate 121, second fixed plate 122, four bearing rails 124a, 124b, 124c and a fourth bearing rail (not shown) with its linear bearing and bearing housing, and moving contact motion platform 123. Moving contact motion platform 123 is attached to the bearing housing and performs up and down lifting movements under the drive of proportional linkage screws 602a and 602b, realizing synchronous movement of the moving contacts of the three contactors and parallel opening and closing of the three contactors. Contactors of different structures and numbers can also be set in a moving contact motion frame, performing synchronous motion and switching operations under the drive of a moving contact motion platform, or they can be independently composed of a similar moving contact sleeve 101, its motor, and a screw. Figure 2 , 5 It drives and executes synchronous logic switching operations or time-sequential process control switching operations.

[0047] Figure 14This is the core electrical structure of the moving and stationary contacts in an embodiment of a double-stationary contactor. The double-stationary contactor includes: a first stationary contact 230, a dual-contact moving contact 430, and a second stationary contact 240. The first stationary contact 230 includes: four conductor substrates and their arrayed electrical pins, and four external terminals 231, 232, 233, and 234. The dual-contact moving contact 430 includes three conductor substrates and their dual-contact electrical pin array, including: a semi-circular conductor substrate 431 without external terminals, and two conductor substrates respectively with external terminals 432 and 433. The second stationary contact 240 includes two conductor substrates and their arrayed electrical pins and external terminals 241 and 242, and a semi-circular conductor substrate 243 without external terminals and its arrayed electrical pins. In this double-stationary contactor, the moving contact has three functional positions: contacting the first stationary contact, contacting the second stationary contact, and no contact. The dual-contact moving contact 430 contacts the first stationary contact 230. Through the semi-circular conductor substrate 431 of the moving contact and its array of electrical connectors, the stationary contact terminals 231 and 232 are electrically connected. Furthermore, terminals 233 and 234 of the first stationary contact 230 are electrically connected to the moving contact terminals 432 and 433, respectively. The dual-contact moving contact 430 contacts the second stationary contact 240. Terminal 241 of the second stationary contact 240 is electrically connected to the moving contact terminal 432 through the moving contact array of electrical connectors and its semi-circular conductor substrate 431, then through the second stationary contact semi-circular conductor substrate 243 and its array of electrical connectors, forming a three-break electrical connection. Finally, the moving contact terminal 433 is electrically connected to the second stationary contact terminal 242. The stationary and moving contacts can have one or more conductor substrates and can also have terminals. Especially in double-stationary contact contactors, various combinations can be provided to form composite logic contactors or multiplexed power switches, and multiple such contactors can be combined together (see reference). Figure 13 ), to construct complex power switching systems.

[0048] Figure 15This is an internal open structural diagram of an embodiment of a piston-type moving contactor. The piston-type moving contactor 900 includes: a cylinder-type housing 901 and its longitudinal slide rail 902, a moving contact slide groove 903, a first array of electrical pins 904 and a first external electrode 905 connected thereto, a power supply and single-input control terminal 906, a second external electrode 907 and a second array of electrical pins 908 connected thereto, a piston-type moving contact 909, a moving contact array socket 910, and a screw 911 and its motor 912. It also includes a controller (not shown) connected to the power supply and control input terminal 906 and the motor 912. Motor 912 drives piston-type moving contact 909 via screw 911. Moving contact array socket 910 engages or disengages from array electrical pins 904 and 908. First and second external electrodes 905 and 907 are turned on or off. When the contactor is turned on or off, the position of its moving contact is determined by a position switch signal. Alternatively, a rigid travel limit structure can be set for the movement of the moving contact. The two endpoints of the travel are the on and off positions of the moving contact. The on or off position is determined based on the logical relationship between zero motor speed, non-zero armature current, and motor rotation direction. Depending on its size, specifications, and application environment, the controller of the piston-type moving contactor can be equipped with a microprocessor, or a simplified circuit including only analog, logic, and motor drive chips, or a single-chip IC integrating all three.

[0049] Figure 16 This is a moving contact movement-stroke-positioning composite device 610, including a fixed frame 611 and a movable arm 612. The fixed frame 611 includes: a base plate 613, two parallel and perpendicular folded plates 614 and 615 formed by stamping, slots 616 and 617 passing through the two folded plates, and a vertically open channel 618 between the two folded plates. The channel is blocked at the front and rear by the base plate 613. The moving contact locking bars 619 and 620 are hinged to the pivot 621 and can rotate. Under the elastic force of the spring 622, they respectively engage with the slots 616 and 617, and when the electromagnetic coil 623 is energized, the electromagnetic force overcomes the spring force and lifts the device out of the slot. Mouths 616 and 617; the movable arm 612 is inserted into the channel 618 and can move back and forth within the channel 618, but is blocked by the front and rear of the base plate 613. The part of the movable arm 612 inserted into the channel 618 has a slot 624. When the movable arm 612 is in the front or rear position blocked by the base plate 613, its slot 624 is aligned with slot 616 or slot 617. When the electromagnetic coil 623 is de-energized, the moving contact locking bar 619 or 620 is engaged with slot 624 and slot 616 or 617, and the movable arm 612 is locked. In the contactor, the movable arm 612 and the moving contact sleeve 101 (reference) Figure 5 ) are fixed together; the base plate 613 is fixed to the moving contact motion frame 100 ( Figure 1 , 5The immovable part limits the travel of the moving contact sleeve 101. The end position of its travel is the position of the moving contact when the contactor is turned on or off, and it is also the locked position. At the end position of the travel of the moving contact sleeve 101, the speed of the geared motor is zero, and its armature current increases significantly. These signals can be converted into level inversion and processed by a microprocessor or logic and steady-state switch to turn off the electromagnetic coil 623 and the motor drive current. The moving contact sleeve is locked, thereby completing the contactor's on or off operation. Figure 16 The first and second position switches 604a and 604b are also shown, providing position signals for the moving contact sleeve to turn the contactor on and off.

[0050] The claims, embodiments, drawings, technical solutions, and descriptions of this invention aim to explain the contactor technical features involved in this invention using the most basic structure and method, so as to facilitate rapid understanding by relevant organizations and personnel. Based on all the above content, those skilled in the art can easily conceive, design, expand, and implement other structures, methods, and effects to solve the problems raised or not raised in this description, and those structures and methods fall within the protection scope of this invention.

Claims

1. A vacuum contactor, comprising a housing, characterized in that: The shell forms a closed space with no internal or external penetration, and is statically sealed / constantly voluminous, encapsulating a vacuum environment; A moving contact divides the enclosed space into a first and a second chamber, wherein at least one of the chambers is provided with a stationary contact; The stationary contact is provided with at least one conductor substrate, and the moving contact is provided with at least one conductor substrate, forming at least one break; The stationary contact conductor substrate and the moving contact conductor substrate each have at least one contact unit, namely a stationary contact unit and a hollow moving contact unit, and at least one equidistant arc gap, wherein the hollow moving contact unit enables communication between the first and second chambers; and The moving contact and the stationary contact reciprocate relative to each other, causing the hollow moving contact unit to engage with and disengage from the stationary contact unit. The first and second chambers alternately compress and expand, and the vacuum environment remains connected between the first and second chambers through the hollow moving contact unit.

2. The contactor according to claim 1, characterized in that: The first and second chambers are respectively defined by a first bellows and a second bellows; The relative reciprocating motion between the moving contact and the stationary contact is driven by a force. The at least one hollow moving contact unit is sleeved onto and disengaged from the at least one stationary contact unit. The first bellows and the second bellows alternately extend and retract. The vacuum environment is maintained in communication between the first and second bellows through the hollow moving contact unit, providing a double bellows vacuum contactor.

3. The contactor according to claim 2, characterized in that: The relative reciprocating motion is achieved through one of the following methods: The force is applied to the moving contact, causing the moving contact to perform the relative reciprocating motion relative to the stationary contact, so as to realize the contactor opening and / or closing; Alternatively, the moving contact or the component connected to the moving contact is fixed, and the force is applied to other parts of the contactor other than the moving contact, causing the stationary contact to perform the relative reciprocating motion relative to the moving contact to perform the contactor opening and / or closing.

4. The contactor according to claim 1, characterized in that: The static contact units and the hollow dynamic contact units are arranged in an array, paired one-to-one at equal intervals, to form the array-distributed arc gaps.

5. The contactor according to claim 1, characterized in that: The contact end of the static contact unit is divided into multiple contact ends by a longitudinal slot, and / or the contact end of the hollow dynamic contact unit is divided into multiple contact ends by a longitudinal slit.

6. The contactor according to claim 1, characterized in that: The hollow moving contact unit is an electrical connector, and the static contact unit is an electrical pin.

7. The contactor according to claim 1, characterized in that: The contactor is a piston-type moving contactor; The housing is a sealed cylinder-type housing, which is encapsulated in a vacuum environment, and its inner wall is provided with at least one raised slide rail. The stationary contact includes at least one conductor substrate and one or an array of stationary contact units. The moving contact is a piston-type moving contact that fits against the inner wall of the housing and is movable through a sliding groove and a sliding rail to separate the interior of the housing into the first and second chambers; The piston-type moving contact includes at least one conductor substrate and one or an array of hollow moving contact units that are open at both ends. The hollow moving contact units are equidistant from the static contact units. The contactor also includes a motion actuator that drives the piston-type moving contact to move, causing the hollow moving contact unit to engage with and disengage from the stationary contact unit, thus providing a piston-type vacuum contactor.

8. The contactor according to claim 1, characterized in that: The contactor also includes a controller, which includes a microprocessor, a set of sensors and an actuator. The controller performs motion control on the relative reciprocating motion between the moving contact and the stationary contact, and performs speed control and positioning on the process of the at least one hollow moving contact unit engaging and disengaging from the at least one stationary contact unit.

9. The contactor according to claim 8, characterized in that: The actuator includes a power drive assembly, a transmission assembly, and a motion guide assembly; The power drive assembly is used to generate driving force, the transmission assembly is used to transmit the driving force to the moving contact or the stationary contact, and the motion guide assembly is used to define the relative reciprocating motion direction between the moving contact and the stationary contact. The power drive component includes a guide rail, and the transmission component includes a screw.

10. The contactor according to claim 8, characterized in that: The controller also includes a contactor monitoring and early warning system, which monitors the contactor, sends data and alarms to an external and / or remote terminal, provides contactor maintenance prompts and / or fault warnings, and receives instructions and data from the external and / or remote terminal, including contactor turn-on and turn-off instructions.

11. The contactor according to claim 8, characterized in that: The controller is also used to periodically turn the contactor on and / or off; and / or trigger the contactor to turn on or off when the sensor data of the contactor exceeds a set value or range.

12. The contactor according to claim 1, characterized in that: The hollow moving contact unit is provided with two contact ends, which respectively contact and detach from the static contact units of the first and second chambers.

13. The contactor according to claim 1, characterized in that: The inner opening of the contact end of the hollow moving contact unit is provided with two narrow sections, one deep and one shallow, forming two contact points when in contact with the static contact unit.

14. The contactor according to claim 1, characterized in that: The hollow moving contact unit and the static contact unit are non-circular structures.

15. The contactor according to claim 1, characterized in that: The hollow moving contact unit and the static contact unit make contact by longitudinal insertion and lateral sliding.

16. The contactor according to claim 1, characterized in that: The stationary contact includes a first stationary contact and a second stationary contact, and the moving contact is a double-contact moving contact; The moving contact has at least three functional positions relative to the first stationary contact and the second stationary contact: a first position that contacts the first stationary contact to form an electrical connection; a second position that contacts the second stationary contact to form an electrical connection; and an isolated position that does not contact either the first stationary contact or the second stationary contact. Therefore, the contactor provides circuit switching functionality.

17. The contactor according to claim 1, characterized in that: The conductor substrate of the stationary contact and / or the moving contact is configured with a variable number of the stationary contact units and / or the hollow moving contact units to adapt to the rated operating current of the contactor; and / or The hollow moving contact unit and the static contact unit are arranged in an array, so that the electric arc is dispersed or moves between the multiple arc gaps in the array, thereby increasing the breaking current of the contactor.

18. The contactor according to claim 1 or 7, characterized in that: The contactor further includes at least one guide rail, a screw that cooperates with the guide rail, and a motor that drives the screw, for guiding and driving the moving contact to perform the relative reciprocating motion relative to the stationary contact; The travel span of the moving contact is adjusted to match the rated voltage of the contactor.

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