A miniaturized high voltage contactor with auxiliary contact

Abstract

The utility model provides a kind of miniaturization's high voltage contactor with auxiliary contact, it is related to high voltage contactor technical field, including shell, contact structure, coil, fixed frame and temperature sensor;The contact structure is installed above the coil, the fixed frame is installed above the contact structure, the temperature sensor is installed inside the fixed frame. Fixed frame is set up above ceramic cover, fixed frame central part is hollow, for placing temperature sensor;Due to being close to two side contacts, temperature conduction to thermistor speed is fast, and the accurate and reliable temperature monitoring function is realized. Thermistor is connected with circuit board by wire, then is led out with coil insert piece, realizes function integration, customer only needs to connect plug-in socket, relay driving power supply, temperature sensor signal acquisition and auxiliary contact state feedback can be realized simultaneously;High voltage DC contactor is compact inside, and it is integrated auxiliary contact and temperature monitoring unit in one.

Description

Technical Field

[0001] This utility model relates to the field of high voltage contactor technology, and more specifically, to a miniaturized high voltage contactor with auxiliary contacts. Background Technology

[0002] The core function of a high-voltage DC contactor is to reliably connect and disconnect the high-voltage DC main circuit, ensuring safe and stable load current carrying under high-voltage and high-current conditions, and rapid disconnection under system commands or fault conditions, effectively isolating faults and ensuring system safety. The contactor boasts a long electrical and mechanical lifespan, meeting the long-term, reliable operation requirements of vehicle electrical systems. It is particularly suitable for high-voltage electrical systems in commercial vehicles such as heavy-duty trucks and engineering vehicles, and is mainly used for: Main circuit on / off control of the power battery: As a key actuator, it is responsible for the vehicle's high-voltage power-on / off process and high-voltage isolation in emergencies. Power supply control for high-power equipment (such as electric drive systems, high-power DC / DC converters, PTC heaters, etc.): Reliably managing the connection and disconnection of high-power loads. Charging circuit control: Safely connecting and disconnecting the high-voltage charging circuit during fast charging.

[0003] However, in existing technologies, although high-voltage DC contactors used in commercial vehicles such as heavy-duty trucks are generally equipped with auxiliary contacts, there are inherent defects when adding copper busbar temperature monitoring functions:

[0004] (1) Space conflict: External temperature sensors or functional stacking designs increase the overall size of the contactor, which conflicts with the limited installation space in the vehicle.

[0005] (2) Structural degradation: The addition of new components forces the housing to expand or open for wiring, reducing the protection level and mechanical strength;

[0006] (3) Increased overall costs: The independent procurement, installation and wiring harness connection of temperature sensors increase the material and labor costs for customers.

[0007] In conclusion, there is an urgent need for a miniaturized high-voltage contactor with auxiliary contacts to solve the above problems. Utility Model Content

[0008] To overcome the above shortcomings, this utility model provides a miniaturized high-voltage contactor with auxiliary contacts.

[0009] This utility model is implemented as follows:

[0010] A miniaturized high-voltage contactor with auxiliary contacts includes a housing, a contact structure, a coil, a mounting bracket, and a temperature sensor; the contact structure is mounted above the coil, the mounting bracket is mounted above the contact structure, and the temperature sensor is mounted inside the mounting bracket to monitor the temperature of the contact structure.

[0011] The contact structure is installed inside the housing. The housing includes an upper cover, a lower cover, a fixing hole, and a connector. The upper cover is located on top of the housing, the lower cover is located on the bottom of the housing, the fixing hole is installed at the bottom of the lower cover, and the connector is fixedly installed at the bottom of the upper cover.

[0012] The contact structure includes a push rod, an auxiliary spring, a moving contact, a main contact spring, a main contact, and an auxiliary contact. The push rod is installed inside the coil. The auxiliary spring is installed above the push rod, and auxiliary contacts are fixedly connected to the upper ends of the auxiliary spring away from the push rod. The main contact spring is fixedly connected to the upper end of the push rod, and a moving contact is fixedly installed above the main contact spring. The main contacts are fixedly connected to the upper ends of the moving contact away from the main contact spring.

[0013] A bracket is installed on one side of the moving contact piece, and a ceramic cover is fixedly installed on the outside of the bracket.

[0014] The miniaturized high-voltage contactor with auxiliary contacts also includes a circuit board, which is installed at one end of the contact structure along its length and includes a base plate. The base plate is shaped like a "7" and has several solder pads fixedly installed on it. Copper foil is disposed between the solder pads. The base plate has mounting holes and a wire is connected to one end of the base plate.

[0015] The mounting bracket includes a frame, lead-out holes, a hub, a top block, a cutout, and a connecting post. The frame is fixedly installed on the outside of the ceramic cover. The lead-out holes are located on the top of the frame, and the auxiliary contact extends from the lead-out hole at the end furthest from the auxiliary spring. The hub is located at one end of the top of the mounting bracket. The top block is located between the two lead-out holes, and a cutout is provided between the two top blocks. A temperature sensor is installed in the cutout, and the temperature sensor is connected to the wire through the hub. A connecting post is provided at the end of the mounting bracket near the circuit board, and the connecting post corresponds to the mounting hole.

[0016] The coil frame includes a coil socket, one end of which is fixedly connected to a hollow column, a coil is installed inside the hollow column, and a fixing base is fixedly connected to the end of the hollow column away from the coil socket; a plug assembly is installed inside the coil socket.

[0017] The insert assembly includes a first insert, a second insert, a third insert, a fourth insert, a fifth insert, and a sixth insert, with one end of the insert assembly away from the coil socket disposed within the plug socket.

[0018] The miniaturized high-voltage contactor with auxiliary contacts also includes an arc-extinguishing structure, which is fixedly installed on the side wall of the mounting frame. The arc-extinguishing structure includes a magnet frame and a magnet. The magnet is installed on the side wall of the mounting frame in the width direction, and the magnet frame is installed on the side wall of the mounting frame in the length direction.

[0019] The coil includes a return spring, a stationary iron core, and a moving iron core. The return spring is located outside the push rod, and the stationary and moving iron cores are located outside the return spring. The stationary iron core is located above the moving iron core.

[0020] A U-shaped yoke is fixedly installed below the coil; a yoke plate is fixedly installed on top of the U-shaped yoke.

[0021] Preferably, a conductive plate is fixedly connected to the top of the auxiliary contact.

[0022] Preferably, the temperature sensor is an NTC thermistor.

[0023] The beneficial effects of this utility model compared to the prior art are:

[0024] 1. The miniaturized high-voltage contactor with auxiliary contacts described in this utility model features a mounting bracket above a ceramic cover. The bracket has a hollowed-out center for housing a temperature sensor. Due to its proximity to the side contacts, temperature is rapidly conducted to the thermistor, ensuring accurate and reliable temperature monitoring. The thermistor is connected to the circuit board via wires and then led out through the coil inserts, achieving functional integration. Customers only need to connect a connector to simultaneously achieve relay drive power supply, temperature sensor signal acquisition, and auxiliary contact status feedback. The high-voltage DC contactor is compact, multifunctional, and integrates auxiliary contacts and a temperature monitoring unit into one unit.

[0025] 2. The miniaturized high-voltage contactor with auxiliary contacts described in this utility model, by placing the auxiliary spring inside the contactor above the push rod, ensures reliable installation and reduces the product's size and space, thus achieving miniaturization. This integrated design optimizes space utilization, enabling a miniaturized and compact layout, effectively solving the problem of limited installation space; at the same time, it reduces the number of system components, lowering the overall cost of the terminal application system. Attached Figure Description

[0026] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0027] Figure 1 This is a three-dimensional structural diagram of a miniaturized high-voltage contactor with auxiliary contacts according to the present invention;

[0028] Figure 2 This is a three-dimensional structural diagram (without top cover) of a miniaturized high-voltage contactor with auxiliary contacts according to the present invention.

[0029] Figure 3 This is a three-dimensional structural diagram (without housing and circuit board) of a miniaturized high-voltage contactor with auxiliary contacts according to the present invention.

[0030] Figure 4 for Figure 3 A schematic diagram of the cross-sectional structure;

[0031] Figure 5 This is a three-dimensional structural diagram of the fixing frame in this utility model.

[0032] Figure 6 This is a three-dimensional structural diagram of the contact structure in this utility model;

[0033] Figure 7 This is a three-dimensional structural diagram of the coil frame in this utility model;

[0034] Figure 8 This is a front view of the coil frame structure of this utility model;

[0035] Figure 9 This is a three-dimensional structural diagram of the insert assembly in this utility model;

[0036] Figure 10 This is a three-dimensional structural diagram of the circuit board in this utility model.

[0037] In the diagram: 1. Outer shell; 11. Top cover; 12. Bottom cover; 13. Mounting hole; 14. Socket; 2. Circuit board; 21. Base plate; 22. Solder pad; 23. Copper foil; 24. Mounting hole; 25. Wire; 3. Coil frame; 31. Mounting base; 32. Hollow column; 33. Coil socket; 34. First insert; 35. Second insert; 36. Third insert; 37. Fourth insert; 38. Fifth insert; 39. Sixth insert; 4. Contact structure; 41. Auxiliary spring; 42. Push 43. Rod; 44. Moving contact piece; 45. Conductive plate; 46. Bracket; 47. Main contact spring; 48. Main contact; 49. Auxiliary contact; 50. Fixing frame; 51. Frame body; 52. Lead-out hole; 53. Cable bundle; 54. Top block; 55. Hollowed-out; 56. Connecting column; 67. Arc extinguishing structure; 68. Magnet frame; 69. Magnet; 70. Coil; 71. Return spring; 72. Static iron core; 73. Moving iron core; 84. U-shaped yoke; 85. Yoke plate; 9. Ceramic cover; 10. Temperature sensor. Detailed Implementation

[0038] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0039] Example 1:

[0040] Please see Figure 1-10 This utility model provides a technical solution:

[0041] A miniaturized high-voltage contactor with auxiliary contacts includes a housing 1, a contact structure 4, a coil 7, a mounting bracket 5, and a temperature sensor 10; Figure 1 As shown, the contact structure 4 is installed inside the housing 1. The housing 1 includes an upper cover 11, a lower cover 12, a fixing hole 13, and a plug socket 14. The upper cover 11 is located above the housing 1, the lower cover 12 is located below the housing 1, the fixing hole 13 is installed at the bottom of the lower cover 12, and the plug socket 14 is fixedly installed at the bottom of the upper cover 11. The positioning accuracy is good, which is convenient for customers to install and plug in.

[0042] like Figure 4 , Figure 6 As shown, the contact structure 4 is installed above the coil 7. The contact structure 4 includes a push rod 42, an auxiliary spring 41, a moving contact 43, a main contact spring 46, a main contact 47, and an auxiliary contact 48. The push rod 42 is installed inside the coil 7, and the auxiliary spring 41 is installed above the push rod 42, ensuring reliable installation and reducing the product's size and space requirements, thus achieving product miniaturization. This integrated design optimizes space utilization, achieving a miniaturized and compact layout, effectively solving the problem of limited installation space; at the same time, it reduces the number of system components, lowering the overall cost of the end-application system. The auxiliary spring 41 is less susceptible to deformation from impacts during assembly and handling, improving the stability of the product's auxiliary circuit. Auxiliary contacts 48 are fixedly connected above the two ends of the auxiliary spring 41 away from the push rod 42; a main contact spring 46 is fixedly connected above the push rod 42, a movable contact piece 43 is fixedly installed above the main contact spring 46, and main contacts 47 are fixedly connected above the two ends of the movable contact piece 43 away from the main contact spring 46.

[0043] like Figure 4 As shown, a bracket 45 is installed on one side of the moving contact piece 43, and a ceramic cover 9 is fixedly installed on the outside of the bracket 45.

[0044] like Figure 2 As shown, the circuit board 2 is mounted at one end of the contact structure 4 along its length.

[0045] Specifically, such as Figure 10 As shown, it includes a base plate 21, which is shaped like the number "7". Several pads 22 are fixedly installed on the base plate 21. Copper foil 23 is arranged between the pads 22. Mounting holes 24 are provided on the base plate 21. A wire 25 is connected to one end of the base plate 21.

[0046] like Figure 3 As shown, the mounting bracket 5 is installed above the contact structure 4, and the temperature sensor 10 is installed inside the mounting bracket 5. An NTC thermistor is selected to monitor the temperature of the contact structure 4. An NTC thermistor is a device whose resistance decreases exponentially with increasing temperature and has a negative temperature coefficient. Installed inside the mounting bracket 5, close to the two contacts, the thermistor undergoes thermal conduction as the contact temperature rises with the flow of current, causing a change in resistance. Due to its proximity to the contacts, the temperature is quickly conducted to the thermistor, ensuring accurate and reliable temperature monitoring. The thermistor is connected to the circuit board 2 via wire 25 and then led out through the plug-in assembly, achieving functional integration. Customers only need to connect the plug-in socket 14 to simultaneously achieve relay drive power supply, temperature sensor signal acquisition, and auxiliary contact status feedback. The high-voltage DC contactor is compact, multifunctional, and integrates auxiliary contacts and a temperature monitoring unit into one unit.

[0047] like Figure 5 As shown, the fixing frame 5 includes a frame body 51, a lead-out hole 52, a cable hub 53, a top block 54, a cutout 55, and a connecting post 56. The frame body 51 is fixedly installed on the outside of the ceramic cover 9. The lead-out hole 52 is located on the top of the frame body 51. The auxiliary contact 48 extends from the lead-out hole 52 at one end away from the auxiliary spring 41. The cable hub 53 is located at one end of the top of the fixing frame 5. The top block 54 is located between the two lead-out holes 52. A cutout 55 is provided between the two top blocks 54. A temperature sensor 10 is installed in the cutout 55. The temperature sensor 10 is connected to the wire 25 through the cable hub 53. The cutout 55 holds the temperature sensor and has four cable hub 53 features to facilitate fixing the wire 25 and prevent scratching during assembly. A connecting post 56 is provided at one end of the fixing frame 5 near the circuit board 2. The connecting post 56 corresponds to the mounting hole 24.

[0048] like Figures 7-8 As shown, a coil frame 3 is installed above the coil 7; the coil frame 3 includes a coil socket 33, one end of which is fixedly connected to a hollow column 32, the coil 7 is installed inside the hollow column 32, and a fixing seat 31 is fixedly connected to the end of the hollow column 32 away from the coil socket 33; a plug assembly is installed inside the coil socket 33.

[0049] like Figure 9 As shown, the insert assembly includes a first insert 34, a second insert 35, a third insert 36, a fourth insert 37, a fifth insert 38, and a sixth insert 39. One end of the insert assembly, away from the coil socket 33, is disposed within the plug-in socket 14. The first insert 34 and the second insert 35, along with the enameled wire of the winding terminal, are used to power the contactor drive end. The third insert 36, the fourth insert 37, the fifth insert 38, and the sixth insert 39 are respectively connected to a thermistor and an auxiliary circuit via the circuit board 2, facilitating the customer's acquisition of low-voltage signals.

[0050] like Figure 3 As shown, the miniaturized high-voltage contactor with auxiliary contacts also includes an arc-extinguishing structure 6, which is fixedly installed on the side wall of the fixed frame 5. The arc-extinguishing structure 6 includes a magnet frame 61 and a magnet 62. The magnet 62 is installed on the side wall of the fixed frame 5 in the width direction, and the magnet frame 61 is installed on the side wall of the fixed frame 5 in the length direction.

[0051] like Figure 4 As shown, the coil 7 includes a return spring 71, a stationary iron core 72, and a moving iron core 73. The return spring 71 is disposed outside the push rod 42, and the stationary iron core 72 and the moving iron core 73 are disposed outside the return spring 71. The stationary iron core 72 is disposed above the moving iron core 73.

[0052] like Figure 4 As shown, a U-shaped yoke 81 is fixedly installed below the coil 7; a yoke plate 82 is fixedly installed on the top of the U-shaped yoke 81.

[0053] like Figure 1 As shown, a conductive plate 44 is fixedly connected to the top of the auxiliary contact 48.

[0054] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A miniaturized high-voltage contactor with auxiliary contacts, characterized in that, It includes a housing (1), a contact structure (4), a coil (7), a mounting bracket (5), and a temperature sensor (10); the contact structure (4) is installed above the coil (7), the mounting bracket (5) is installed above the contact structure (4), and the temperature sensor (10) is installed inside the mounting bracket (5) to monitor the temperature of the contact structure (4).

2. A miniaturized high-voltage contactor with auxiliary contacts according to claim 1, characterized in that, The contact structure (4) is installed inside the housing (1). The housing (1) includes an upper cover (11), a lower cover (12), a fixing hole (13), and a plug-in socket (14). The upper cover (11) is located above the housing (1), the lower cover (12) is located below the housing (1), the fixing hole (13) is installed at the bottom of the lower cover (12), and the plug-in socket (14) is fixedly installed at the bottom of the upper cover (11).

3. A miniaturized high-voltage contactor with auxiliary contacts according to claim 1, characterized in that, The contact structure (4) includes a push rod (42), an auxiliary spring (41), a moving contact (43), a main contact spring (46), a main contact (47), and an auxiliary contact (48). The push rod (42) is installed inside the coil (7). The auxiliary spring (41) is installed above the push rod (42). The auxiliary contact (48) is fixedly connected above the two ends of the auxiliary spring (41) away from the push rod (42). The main contact spring (46) is fixedly connected above the push rod (42). The moving contact (43) is fixedly installed above the main contact spring (46). The main contact (47) is fixedly connected above the two ends of the moving contact (43) away from the main contact spring (46).

4. A miniaturized high-voltage contactor with auxiliary contacts according to claim 3, characterized in that, A bracket (45) is installed on one side of the moving contact piece (43), and a ceramic cover (9) is fixedly installed on the outside of the bracket (45).

5. A miniaturized high-voltage contactor with auxiliary contacts according to claim 4, characterized in that, The miniaturized high-voltage contactor with auxiliary contacts also includes a circuit board (2), which is installed at one end of the contact structure (4) along its length and includes a base plate (21). The base plate (21) is shaped like a "7". Several pads (22) are fixedly installed on the base plate (21). Copper foil (23) is provided between the pads (22). Mounting holes (24) are provided on the base plate (21). A wire (25) is connected to one end of the base plate (21).

6. A miniaturized high-voltage contactor with auxiliary contacts according to claim 5, characterized in that, The mounting bracket (5) includes a frame (51), a lead-out hole (52), a cable tray (53), a top block (54), a cutout (55), and a connecting post (56). The frame (51) is fixedly installed on the outside of the ceramic cover (9). The lead-out hole (52) is located on the top of the frame (51). The auxiliary contact (48) extends from the lead-out hole (52) at one end away from the auxiliary spring (41). The cable tray (53) is located on the top of the mounting bracket (5). At one end, the top block (54) is disposed between the two lead-out holes (52), and a cutout (55) is disposed between the two top blocks (54). A temperature sensor (10) is installed in the cutout (55), and the temperature sensor (10) is connected to the wire (25) through the hub (53). A connecting post (56) is disposed at one end of the fixing bracket (5) near the circuit board (2), and the connecting post (56) corresponds to the mounting hole (24).

7. A miniaturized high-voltage contactor with auxiliary contacts according to claim 1, characterized in that, A coil frame (3) is installed above the coil (7); the coil frame (3) includes a coil socket (33), one end of the coil socket (33) is fixedly connected to a hollow column (32), and the end of the hollow column (32) away from the coil socket (33) is fixedly connected to a fixing seat (31); a plug assembly is installed inside the coil socket (33).

8. A miniaturized high-voltage contactor with auxiliary contacts according to claim 3, characterized in that, A conductive plate (44) is fixedly connected to the top of the auxiliary contact (48).

9. A miniaturized high-voltage contactor with auxiliary contacts according to claim 1, characterized in that, The temperature sensor (10) is an NTC thermistor.

Images