A permanent magnet anti-bounce electrical contactor

Abstract

The utility model discloses a kind of permanent magnet anti-swing power contactors, it is related to contactor technical field, including shell, electromagnetic drive component, permanent magnet retention component, main contact component, magnetic attraction mounting seat, anti-swing power control module and wiring terminal;The shell interior is equipped with drive cavity, contact cavity and control cavity, back is equipped with magnetic attraction mounting seat;The wiring terminal is set in shell side surface;The electromagnetic drive component includes coil framework, electromagnet coil and core, coil framework is fixed in drive cavity, electromagnet coil is wound in coil framework, core is slidably arranged in the center of coil framework;The permanent magnet retention component includes permanent magnet and attraction plate, permanent magnet is fixed in drive cavity bottom, attraction plate is fixed in the end of core close to permanent magnet.The utility model provides a kind of permanent magnet anti-swing power contactor, integrated supercapacitor energy storage and permanent magnet retention double protection, swing power identification response is fast, can resist voltage drop above 500ms, avoid motor misoperation, improve anti-swing power reliability.

Description

Technical Field

[0001] This utility model relates to the field of contactor technology, specifically a permanent magnet anti-sloshing contactor. Background Technology

[0002] Contactors are the core components of industrial motor control circuits. They achieve motor operation by using electromagnetic attraction generated when the coil is energized to close the main contacts. In industrial settings, power grids are prone to "voltage dips" caused by lightning strikes, momentary short circuits, and sudden load changes. These dips are characterized by a drop in effective voltage to 10%-90% of the rated voltage, lasting from 10ms to 600ms.

[0003] Existing conventional contactors rely on the self-holding circuit of the electromagnetic coil to operate. The voltage required to maintain engagement must be no less than 45% of the rated voltage and the duration must not exceed 60ms. When a voltage drop occurs, the coil voltage drops sharply, the electromagnetic attraction weakens rapidly, causing the contactor to release and the motor to stop. Even if the grid voltage recovers quickly, the motor needs to be manually restarted, which seriously affects the continuity of production.

[0004] Some anti-voltage drop solutions use supercapacitors to temporarily power the coil, but they can only cope with short-term voltage drops and lack compatibility with motor starting modes; other solutions use bypass parallel anti-voltage drop devices, which can achieve restart function, but require additional equipment installation, complex wiring and space occupation.

[0005] Therefore, there is an urgent need for an integrated contactor solution that is compatible with multiple starting modes and provides reliable protection against voltage fluctuations. Utility Model Content

[0006] The purpose of this utility model is to provide a permanent magnet anti-slip contactor, which solves the problems of weak anti-slip capability, need for additional supporting devices, and poor adaptability of existing contactors by integrating permanent magnet holding and supercapacitor energy replenishment design and combining a multi-mode adaptability structure.

[0007] To achieve the above objectives, this utility model provides the following technical solution:

[0008] A permanent magnet anti-sloshing contactor includes a housing, an electromagnetic drive assembly, a permanent magnet holding assembly, a main contact assembly, a magnetic mounting base, an anti-sloshing control module, and wiring terminals.

[0009] The housing has a drive cavity, a contact cavity, and a control cavity inside, and a magnetic mounting base is provided on the back; the wiring terminals are located on the side of the housing.

[0010] The electromagnetic drive assembly includes a coil frame, an electromagnetic coil, and an iron core. The coil frame is fixed in the drive cavity, the electromagnetic coil is wound around the coil frame, and the iron core is slidably inserted through the center of the coil frame.

[0011] The permanent magnet holding assembly includes a permanent magnet and a suction plate. The permanent magnet is fixed at the bottom of the drive cavity, and the suction plate is fixed at the end of the iron core near the permanent magnet.

[0012] The main contact assembly includes a stationary contact and a moving contact, with the stationary contact fixed in the contact cavity and the moving contact fixed at the top of the iron core.

[0013] The anti-power fluctuation control module is integrated into the control cavity and includes a voltage detection unit, an energy storage unit, a logic processing unit, a drive unit, and a communication unit.

[0014] As a further improvement to the above solution, the voltage detection unit of the anti-voltage fluctuation control module has a voltage fluctuation recognition response time of ≤1.667ms, an undervoltage action value error of ≤±2V or ±3% of the set value, and a voltage measurement accuracy of ±0.5%.

[0015] As a further improvement to the above solution, the energy storage unit is a supercapacitor module with a capacity of ≥5F, a charging time of ≤5s, and can maintain the anti-power-drop module for ≥500ms. It automatically discharges when the device is manually stopped.

[0016] As a further improvement to the above solution, the logic processing unit has built-in three adaptive logics: direct start, soft start, and frequency conversion start. It supports adjustment of the longest power drop time (0-9s) and restart delay time (0-9s), and can select immediate restart or delayed synchronous restart mode.

[0017] As a further improvement to the above solution, the auxiliary contact assembly includes 5 DO outputs, with a contact capacity of ≥250VAC / 30VDC, 5A (continuous), and an action time of ≤10ms, including operation signal, alarm signal, restart signal, and reset signal contacts.

[0018] As a further improvement to the above solution, the communication unit is equipped with an RS-485 interface, supports the Modbus-RTU protocol, and can upload up to 32 event records.

[0019] As a further improvement to the above solution, the permanent magnet is a neodymium iron boron magnet with a surface magnetic field strength ≥1000mT, the suction plate is a low carbon steel plate, and the magnetic force of the permanent magnet is greater than the elastic force of the return spring.

[0020] As a further improvement to the above solution, the housing protection level is ≥IP20, and the electromagnetic coil supports AC220V / 380V voltage input to adapt to different power supply levels.

[0021] Compared with the prior art, the beneficial effects of this utility model are:

[0022] 1. This utility model provides a permanent magnet anti-voltage drop contactor that integrates supercapacitor energy storage and permanent magnet holding for dual protection. It has a fast voltage drop detection response and can withstand voltage drops of more than 500ms, thus avoiding motor shutdown and improving the reliability of anti-voltage drop.

[0023] 2. It has three built-in starting mode logics, requiring no additional supporting devices, and can be directly applied to different motor control circuits, making it highly adaptable.

[0024] 3. It has a self-testing function to detect faults in key components such as supercapacitors and AD chips, and the fault does not affect the normal operation of the original control loop; it supports remote parameter setting and status monitoring to meet the needs of intelligent management in industrial sites. Attached Figure Description

[0025] Figure 1 This is a cross-sectional view of a permanent magnet anti-sloshing contactor.

[0026] Figure 2 This is a block diagram of the anti-sloshing control module for a permanent magnet anti-sloshing contactor.

[0027] Figure 3 This is a typical wiring diagram for the direct starting mode of a permanent magnet anti-sloshing contactor.

[0028] Figure 4 This is a typical wiring diagram for the soft-start mode of a permanent magnet anti-sloshing contactor.

[0029] Figure 5 This is a typical wiring diagram for the variable frequency starting mode of a permanent magnet anti-sloshing contactor.

[0030] In the diagram: 1. Housing; 2. Electromagnetic drive assembly; 3. Permanent magnet holding assembly; 4. Main contact assembly; 5. Magnetic mounting base; 6. Anti-power fluctuation control module; 7. Terminal block; 8. Return spring; 21. Coil frame; 22. Electromagnetic coil; 23. Iron core; 31. Permanent magnet; 32. Plug plate; 41. Stationary contact; 42. Moving contact; 61. Voltage detection unit; 62. Energy storage unit; 63. Logic processing unit; 64. Drive unit; 65. Communication unit. Detailed Implementation

[0031] The technical solution of this patent will be further described in detail below with reference to specific embodiments.

[0032] Example

[0033] Reference Figures 1-5 A permanent magnet anti-sloshing contactor includes a housing 1, an electromagnetic drive assembly 2, a permanent magnet holding assembly 3, a main contact assembly 4, a magnetic mounting base 5, an anti-sloshing control module 6, and wiring terminals 7.

[0034] The housing 1 has a drive cavity, a contact cavity, and a control cavity inside, and a magnetic mounting base 5 is provided on the back; the wiring terminals 7 are located on the side of the housing 1.

[0035] The electromagnetic drive assembly 2 includes a coil frame 21, an electromagnetic coil 22, and an iron core 23. The coil frame 21 is fixed in the drive cavity, the electromagnetic coil 22 is wound around the coil frame 21, and the iron core 23 is slidably inserted through the center of the coil frame 21.

[0036] The permanent magnet retaining assembly 3 includes a permanent magnet 31 and a suction plate 32. The permanent magnet 31 is fixed at the bottom of the drive cavity, and the suction plate 32 is fixed at the end of the iron core 23 near the permanent magnet 31.

[0037] The main contact assembly 4 includes a stationary contact 41 and a moving contact 42, with the stationary contact 41 fixed in the contact cavity and the moving contact 42 fixed at the top of the iron core 23.

[0038] The anti-power fluctuation control module 6 is integrated into the control cavity and includes a voltage detection unit 61, an energy storage unit 62, a logic processing unit 63, a drive unit 64, and a communication unit 65.

[0039] The voltage detection unit 61 of the anti-voltage fluctuation control module 6 has a voltage fluctuation recognition response time of ≤1.667ms, an undervoltage action value error of ≤±2V or ±3% of the set value, and a voltage measurement accuracy of ±0.5%.

[0040] The energy storage unit 62 is a supercapacitor module with a capacity of ≥5F, a charging time of ≤5s, and can maintain the anti-power drop module for ≥500ms. It automatically discharges when the vehicle is manually stopped.

[0041] The logic processing unit 63 has built-in three adaptive logics: direct start, soft start, and frequency conversion start. It supports adjustment of the maximum power dip time (0-9s) and restart delay time (0-9s), and can select immediate restart or delayed synchronous restart mode.

[0042] Drive unit 64 controls the on / off state of electromagnetic coil and current regulation, and triggers energy storage unit to replenish coil energy when power is interrupted;

[0043] The communication unit 65 is equipped with an RS-485 interface, supports the Modbus-RTU protocol, and can upload up to 32 event records.

[0044] When the contactor receives a start signal (manual or remote), the electromagnetic coil 22 is energized to generate electromagnetic attraction, pushing the iron core 23 towards the permanent magnet 31 until the suction plate 32 at the end of the iron core 23 contacts the permanent magnet 31. At this time, the electromagnetic attraction not only closes the main contacts but also makes the suction plate 32 and the permanent magnet 31 tightly attracted, establishing a stable mechanical holding structure. After the supercapacitor of the anti-power-drop control module 6 completes charging (about 5 seconds) and the device enters the anti-power-drop standby mode, the electromagnetic coil 22 can switch to a low-power maintenance state, or even be briefly de-energized. The attraction force between the permanent magnet 31 and the suction plate 32 alone maintains the closure of the main contacts, reducing energy consumption while ensuring operational stability.

[0045] When a power grid voltage dip occurs, and the voltage detection unit 61 detects that the coil voltage and grid voltage are lower than the no-voltage setting, the electromagnetic attraction of the electromagnetic coil 22 will weaken as the voltage drops. At this time, the magnetic force of the permanent magnet 31 is greater than the elastic force of the return spring 8, which can firmly attract the suction plate 32, preventing the iron core 23 from rebounding, thereby ensuring that the moving contact 42 and the stationary contact 41 remain closed and preventing the contactor from releasing. During this process, the energy storage unit 62 of the anti-power dip control module 6 will simultaneously replenish the electromagnetic coil 22 with electrical energy to help enhance the electromagnetic attraction, but the core mechanical holding force is still provided by the permanent magnet 31 and the suction plate 32, ensuring that even if the energy storage unit 62 is temporarily short of power, the contactor will not trip erroneously.

[0046] When a manual stop signal is received, or when the anti-voltage fluctuation control module 6 detects that the mains voltage is normal but the coil voltage is lower than the no-voltage setting, it is determined to be a normal stop. The electromagnetic coil 22 will be energized in reverse, generating a repulsive force opposite to the magnetic force of the permanent magnet 31, thus counteracting the attraction force of the permanent magnet 31 on the suction plate 32. At the same time, the return spring 8 pushes the iron core 23 to spring back, the suction plate 32 separates from the permanent magnet 31, the moving contact 42 disconnects from the stationary contact 41, and the contactor completes the reset. If the device has a self-test abnormality (such as a supercapacitor failure), the electromagnetic coil 22 will also be de-energized in reverse to release the attraction, ensuring that the contactor can be safely disconnected and avoiding malfunctions in fault conditions.

[0047] The auxiliary contact assembly includes 5 DO outputs with a contact capacity of ≥250VAC / 30VDC, 5A (continuous), and an action time of ≤10ms, including operation signal, alarm signal, restart signal, and reset signal contacts.

[0048] The permanent magnet 31 is a neodymium iron boron magnet with a surface magnetic field strength ≥1000mT. The suction plate 32 is a low carbon steel plate. The magnetic force of the permanent magnet 31 is greater than the elastic force of the return spring.

[0049] The housing 1 has a protection rating of ≥IP20, and the electromagnetic coil 22 supports AC220V / 380V voltage input, adapting to different power supply levels.

[0050] Working principle of this utility model:

[0051] Normal start-up: According to the motor start-up mode (direct / soft / frequency conversion), the corresponding logic is selected by the DIP switch. The external control signal triggers the electromagnetic coil 22 to be energized, generating electromagnetic attraction to push the iron core 23 to move. The moving contact 42 and the stationary contact 41 close, and the main circuit is turned on. After the anti-voltage fluctuation control module 6 detects that the voltage is higher than the set voltage, the supercapacitor starts to charge and enters the anti-voltage fluctuation standby mode after 5 seconds.

[0052] Power Surge Response: When the voltage detection unit 61 detects that the grid voltage, coil voltage, and control circuit voltage are lower than the no-voltage setpoint, it determines that there is a power surge. The energy storage unit 62 immediately activates to replenish the power surge protection module and coil energy. If the power surge time is ≤500ms, the permanent magnet holding component 3 maintains the iron core 23 in contact and the main contacts remain closed. If the power surge time is >500ms and the contactor releases, it will automatically restart according to the set mode after the voltage is restored.

[0053] Meanwhile, the device records power fluctuations and protection actions in real time and uploads them to the host computer via the communication unit 65; when a self-test is abnormal or the supercapacitor fails, the alarm signal contact is activated and the indicator light turns red to indicate the problem.

[0054] This invention provides a permanent magnet anti-voltage fluctuation contactor that integrates supercapacitor energy storage and permanent magnet holding for dual protection. It features fast voltage fluctuation detection response, can withstand voltage drops exceeding 500ms, prevents motor malfunctions, and improves anti-voltage fluctuation reliability. It incorporates three built-in starting mode logics, requiring no additional supporting devices and can be directly applied to different motor control circuits, offering strong adaptability. Parameters can be quickly set via DIP switches, and the magnetic installation method is flexible, supporting hot-plugging of terminals. Event records are traceable. It has a self-test function, detecting faults in key components such as the supercapacitor and AD chip, ensuring that faults do not affect the normal operation of the original control circuit. It supports remote parameter setting and status monitoring, meeting the needs of intelligent management in industrial settings.

Claims

1. A permanent magnet anti-sloshing contactor, characterized in that, It includes a housing (1), an electromagnetic drive assembly (2), a permanent magnet holding assembly (3), a main contact assembly (4), a magnetic mounting base (5), an anti-sloshing control module (6), and wiring terminals (7); The housing (1) has a drive cavity, a contact cavity and a control cavity inside, and a magnetic mounting base (5) is provided on the back; the wiring terminal (7) is provided on the side of the housing (1); The electromagnetic drive assembly (2) includes a coil frame (21), an electromagnetic coil (22) and an iron core (23). The coil frame (21) is fixed in the drive cavity, the electromagnetic coil (22) is wound around the coil frame (21), and the iron core (23) is slidably inserted through the center of the coil frame (21). The permanent magnet holding assembly (3) includes a permanent magnet (31) and a suction plate (32). The permanent magnet (31) is fixed at the bottom of the drive cavity, and the suction plate (32) is fixed at one end of the iron core (23) near the permanent magnet (31). The main contact assembly (4) includes a stationary contact (41) and a moving contact (42) respectively. The stationary contact (41) is fixed in the contact cavity, and the moving contact (42) is fixed at the top of the iron core (23). The anti-power fluctuation control module (6) is integrated into the control cavity and includes a voltage detection unit (61), an energy storage unit (62), a logic processing unit (63), a drive unit (64), and a communication unit (65).

2. The permanent magnet anti-sloshing contactor according to claim 1, characterized in that, The voltage detection unit (61) of the anti-voltage fluctuation control module (6) has a voltage fluctuation recognition response time of ≤1.667ms, an undervoltage action value error of ≤±2V or ±3% of the set value, and a voltage measurement accuracy of ±0.5%.

3. A permanent magnet anti-sloshing contactor according to claim 1, characterized in that, The energy storage unit (62) is a supercapacitor module with a capacity of ≥5F, a charging time of ≤5s, and can maintain the anti-power-drop module for ≥500ms. It automatically discharges when the device is manually stopped.

4. A permanent magnet anti-sloshing contactor according to claim 1, characterized in that, The logic processing unit (63) has built-in three adaptive logics: direct start, soft start, and frequency conversion start. It supports the adjustment of the longest power drop time (0-9s) and the restart delay time (0-9s). It can select the immediate restart or delayed synchronous restart mode.

5. A permanent magnet anti-sloshing contactor according to claim 1, characterized in that, The communication unit (65) is equipped with an RS-485 interface, supports the Modbus-RTU protocol, and can upload up to 32 event records.

6. A permanent magnet anti-sloshing contactor according to claim 1, characterized in that, The permanent magnet (31) is a neodymium iron boron magnet with a surface magnetic field strength ≥1000mT. The suction plate (32) is a low carbon steel plate. The magnetic force of the permanent magnet (31) is greater than the elastic force of the return spring (8).

7. A permanent magnet anti-sloshing contactor according to claim 1, characterized in that, The housing (1) has a protection level of ≥IP20, and the electromagnetic coil (22) supports AC220V / 380V voltage input to adapt to different power supply levels.

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