Load pre-charging using main contactor coil

Abstract

Vehicle system (10), comprising: a contactor (50) including a coil (52) and a relay (54); a traction battery (14); a burden; and a controller configured to transfer current from the traction battery (14) through the coil (52) to precharge the load without causing the relay (54) to close, such that a voltage drop across the relay (54) falls below a threshold, and subsequently causing the relay (54) to close, characterized in that the vehicle system (10) further comprises a switching arrangement (40), wherein transferring current from the traction battery (14) through the coil (52) to precharge the load without causing the relay (54) to close includes actuating the switching arrangement (40) in a specified duty cycle.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to systems and methods for precharging an electrical load using a main contactor coil. BACKGROUND

[0002] A hybrid or electric vehicle may be provided with at least one traction battery connected to an electrical load and configured to provide power for propulsion. The traction battery may also provide power, e.g., via an electrical bus, to other vehicle electrical systems. For example, the traction battery may transfer power to high-voltage loads such as compressors and electric heating elements. In another example, the traction battery may supply power to low-voltage loads such as a 12V auxiliary battery.

[0003] The generic document DE 10 2014 219 211 A1 describes a vehicle system comprising a contactor with a coil and a relay, as well as a traction battery and a load. The coils can be preheated depending on the temperature inside the electrical energy storage device using temperature-dependent heating gradients. Further prior art relating to the background of the invention is provided by document DE 10 2010 030 693 A1. SUMMARY

[0004] A vehicle system includes a contactor including a coil and a relay, a traction battery, a load, and a controller configured to transfer current from the traction battery through the coil to precharge the load without causing the relay to close, such that a voltage drop across the relay falls below a threshold, and subsequently cause the relay to close.

[0005] A method for a vehicle includes transferring, by a controller, current from a traction battery through a coil of a contactor to precharge a load without causing a relay of the contactor to close, such that a voltage drop across the relay falls below a threshold, and then causing the relay to close.

[0006] A vehicle system includes a switching arrangement in communication with a coil and a relay of a contactor, a traction battery, a load, and a controller configured to actuate the arrangement to transfer current from the traction battery through the coil to precharge the load without causing the relay to close, such that a voltage drop across the relay falls below a threshold, and subsequently cause the relay to close. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a block diagram of a hybrid electric vehicle (HEV) illustrating a typical powertrain and energy storage components; Fig. 2A is a schematic diagram illustrating an arrangement for precharging an electrical load; Fig. Figure 2B is a schematic diagram illustrating a contactor; Fig. 3 is a schematic diagram illustrating a precharge circuit arrangement using a main contactor coil; Fig. 4 is a schematic diagram illustrating a precharge circuit arrangement using current direction; Fig. 5 is a flowchart illustrating an algorithm for precharging an electrical load using a main contactor coil; Fig. 6 is a flowchart illustrating an algorithm for performing precharging using the current magnitude; and Fig. Figure 7 is a flowchart illustrating an algorithm for performing pre-charging using current direction. DETAILED DESCRIPTION

[0007] Embodiments of the present disclosure are described herein. It should be understood, however, that the disclosed embodiments are merely examples, and other embodiments may take various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or reduced to show details of particular components. Accordingly, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching those skilled in the art to variously employ the present invention.Those of ordinary skill in the art will recognize that various features illustrated and described with respect to any of the figures may be combined with features illustrated in one or more other figures to produce embodiments not explicitly illustrated or described. The combinations of illustrated features provide representative embodiments for typical applications. However, various combinations and modifications of the features consistent with the teachings of this disclosure may be desirable for particular applications or implementations.

[0008] Fig. 1 depicts an exemplary hybrid electric vehicle (HEV) system 10. A hybrid electric vehicle 12, hereinafter referred to as vehicle 12, may include at least one traction battery 14. The traction battery 14 includes a battery controller 16 and, in one example, may be configured to receive an electrical charge via charging at a charging station connected to an electrical grid. In one example, the electrical grid may include a device that utilizes renewable energy, such as a photovoltaic (PV) solar panel or a wind turbine.

[0009] The traction battery 14 may include one or more battery cells (not shown), such as electromechanical cells, capacitors, or other implementations of energy storage devices. The battery cells may be arranged and configured in any suitable configuration to receive and store electrical energy for use in operating the vehicle 12. Each cell may provide a similar or different nominal voltage threshold. The battery cells may be further arranged into one or more series arrays, sections, or modules, further connected in series or in parallel.

[0010] The traction battery 14 may further include a bussed electrical center (BEC) 18 that is electrically connected to the battery cells, such as via positive and negative battery terminals. As described with reference to at least the Fig. 2A-5, the BEC 18 may be in communication with the battery controller 16 and may include a plurality of ports and switches that enable the supply and removal of electrical energy to and from the traction battery 14.

[0011] The battery controller 16 is electrically connected to the BEC 18 and controls the energy flow between the BEC 18 and the battery cells. For example, the battery controller 16 may be configured to monitor and manage the temperature and state of charge of each of the battery cells. The battery controller 16 may command the BEC 18 to open or close a plurality of switches in response to the temperature or state of charge in a respective battery cell reaching a predetermined threshold.

[0012] The battery controller 16 may be in communication with one or more vehicle controllers 38, such as an engine control module (ECM) and a transmission control module (TCM), and may command the BEC 18 to open or close a plurality of switches in response to a predetermined signal from the one or more vehicle controllers 38.

[0013] The vehicle 12 may further include one or more electric machines 22 mechanically connected to a hybrid transmission 24. The electric machines 22 may be capable of operating as an electric motor or generator. Furthermore, the hybrid transmission 24 may be mechanically connected to an engine 26. The hybrid transmission 24 is also mechanically connected to a drive shaft 28, which is mechanically connected to the wheels 30.

[0014] The electric machines 22 can provide propulsion and braking capability using energy stored in the traction battery 14 when the engine 26 is turned on or off, such as via the BEC 18. The electric machines 22 also function as generators and can provide fuel economy benefits by recovering energy that would normally be lost as heat in the friction braking system. The electric machines 22 can also provide reduced pollutant emissions because the vehicle 12 can operate in an electric mode under certain conditions.

[0015] The traction battery 14 typically provides a high-voltage DC output. The BEC 18 of the traction battery 14 may be electrically connected to an inverter system controller (ISC) 32. The ISC 32 is electrically connected to the electric machines 22 and provides the capability to transfer power bidirectionally between the traction battery 14 and the electric machines 22, such as via the BEC 18. In one example, the electric machines 22 and other components of the vehicle 12 that supply power to and / or receive power from the traction battery 14 may define a main load 34 of the traction battery 14.

[0016] In an electric motor mode, the ISC 32 may convert the DC output provided by the traction battery 14 into a three-phase alternating current (AC), as may be required for proper functionality of the electric machines 22. In a regeneration mode, the ISC 32 may convert the three-phase AC output from the electric machines 22, which act as generators, into the DC voltage required by the traction battery 14. During Fig. 1 depicts a typical hybrid electric vehicle, the description herein is equally applicable to a pure electric vehicle or a hybrid electric vehicle with a different configuration, such as, but not limited to, a series hybrid. For a pure electric vehicle, e.g., a battery electric vehicle (BEV), the hybrid transmission 24 may be a gear box connected to the electric machine 22, and the motor 26 may not be present. In one example, the main load 34 of the traction battery 14 in the BEV may include the electric machines 22 and the gear box.

[0017] In addition to providing power for propulsion, the traction battery 14 may provide power to other vehicle electrical systems (generally shown as auxiliary loads 36). For example, the traction battery 14 may transfer power to high-voltage loads such as compressors and electric heating elements. In another example, the traction battery 14 may power low-voltage loads such as a 12V auxiliary battery. In such an example, the vehicle 12 may include a DC / DC converter module (not shown) that converts the high-voltage DC output of the traction battery 14 into a low-voltage DC supply compatible with the low-voltage loads. The various components discussed may have one or more controllers associated therewith to control and monitor the operation of the components. The controllers may be connected via a serial bus (e.g.,a Controller Area Network (CAN)) or communicate via separate conductors.

[0018] At this point, Fig. 2A, which shows an exemplary arrangement 40 of the BEC 18 for transferring energy between the traction battery 14 and the main load (generally indicated using a capacitor symbol) 34. The arrangement 40 may include a pair of contactors 42a, 42b, such as a positive main contactor and a negative main contactor, electrically connected to corresponding terminals of the traction battery 14. In one example, closing the contactors 42a, 42b completes a circuit between the load 34 and the traction battery 14, allowing the flow of electrical energy between the traction battery 14 and the main load 34. In another example, opening one or more of the contactors 42a, 42b opens the circuit between the main load 34 and the traction battery 14, interrupting the flow of energy between them.In one example, the battery controller 16 may command the BEC 18 to open or close one or more of the contactors 42a, 42b in response to receiving a signal from the one or more vehicle controllers 38, e.g., ECM, TCM, and so on, indicating a request to initiate or terminate the transfer of electrical energy between the main load 34 and the traction battery 14.

[0019] The assembly 40 may further include a precharge circuit 44 configured to control a current flow process to one of the terminals of the traction battery 14. The precharge circuit 44 may include a precharge contactor 46 connected in series with a precharge resistor 48. The precharge circuit 44 may be electrically connected in parallel with the contactor 42a such that when the contactor 42a is open, the precharge contactor 46, and the contactor 42b are closed, electrical current can flow through the precharge circuit 44, providing a controlled current flow to the terminal of the main load 34 connected to the contactor 42a.

[0020] In one example, the battery controller 16 may be configured to initiate a precharge operation using the precharge circuit 44 in response to receiving a signal indicating a request to close the contactors 42a, 42b. For example, the battery controller 16 may issue one or more commands to the BEC 18 to close the contactor 42b and the precharge contactor 46 and control the flow of current to the terminal of the traction battery 14 that is in communication with the contactor 42a.

[0021] Battery controller 16 may also be configured to terminate the precharge operation in response to the voltage across the open contactor, e.g., contactor 42a, being less than a specified threshold. Battery controller 16 may further be configured to command BEC 18 to close contactor 42a in response to the voltage across open contactor 42a being less than a specified threshold.

[0022] As in Fig. 2B, each of the contactors 42a, 42b and the pre-charging contactor 46 may define an electromechanical device 50 that includes an inductive coil 52 and a relay 54. In one example, energizing the inductive coil 52 using a predetermined amount of current, e.g., pull-in current I Anzug that the relay 54 closes and the inductive coil 52 is switched off; e.g., providing a current amount that is less than the drop current IAbfall is that the relay 54 opens. In another example, the electromechanical device 50 may be configured to supply a predetermined amount of current, e.g., holding current I Halt , provided by the inductive coil 52 to hold the relay 54 in a closed position.

[0023] In one example, the starting current I Anzug stronger than the holding current I Halt and stronger than waste stream I Abfall In such an example, the holding current I Halt stronger than waste stream I Abfall A value for the starting current I Anzug can be, for example, 1.7 amperes (A), with a corresponding value for the holding current I Halt 1 A and a corresponding value for the waste current I Abfall 0.5 A. The values ​​for the starting current I Anzug , the holding current I Halt and waste stream I Abfallfor a particular contactor may be a function of one or more device characteristics, such as, but not limited to, design and manufacturer specifications, manufacturing processes and materials, testing, age and / or cycle count of the contactor, and so on.

[0024] In relation to Fig. 3, an exemplary arrangement 56 for precharging the main load 34 is shown. The contactor 42a may include a coil 58 and a relay 60, as described, for example, with reference to Fig. 2B. In one example, contactor 42a may be selectively driven using high-voltage (HV) power, such as DC output of traction battery 14. A pair of switches 62a, 62b may be electrically connected to and selectively enabled and disabled by battery controller 16. Battery controller 16 may be configured to enable one or more of switches 62a, 62b to operate in a same or different predefined duty cycle to selectively drive coil 58 of contactor 42a. In one example, a diode 64 may prevent reverse current flow into traction battery 14 when battery controller 16 actuates one or more of switches 62a, 62b.

[0025] The battery controller 16 may be configured to enable the switches 62a, 62b to operate in a predefined duty cycle such that a predefined amount of current is generated in the coil 58. For example, the battery controller 16 may enable the switches 62a, 62b to operate in a duty cycle such that the amount of current flowing through the coil 58 is at least the pull-in current I pull_in of the relay 60, e.g., amount of current corresponding to the use of the coil 58 to close the relay 60. In another example, the battery controller 16 may allow one or more switches 62a, 62b to operate in a duty cycle such that the amount of current flowing through the coil 58 is less than the waste current Z drop_ourof the relay 60. In yet another example, the battery controller 16 may enable one or more switches 62a, 62b to operate in a duty cycle such that the amount of current flowing through the coil 58 is not less than holding current I hold of relay 60, e.g., the amount of current required to maintain relay 60 in a closed position. These are merely examples, and operating one or more of switches 62a, 62b in one or more different duty cycles and / or to generate different current values ​​in coil 58 is also contemplated.

[0026] As mentioned with reference to Fig. 2A, the battery controller 16 may initiate a pre-charge operation in response to receiving a signal indicative of a request to close the contactors 42a, 42b. The battery controller 16 may command the contactor 42b to close in response to receiving a request to transfer energy between the traction battery 14 and the main load 34. The battery controller 16 may enable the switch 62b to operate in a predefined duty cycle. In one example, the battery controller 16 may enable the switch 62b to operate in a predefined duty cycle such that current flowing through the coil 58 of the contactor 42a is less than a predefined current, e.g., less than pull-in current I pull_in of relay 60 so that relay 60 remains open.

[0027] The battery controller 16 may be configured to measure voltage through the contactor 42a while the switch 62b is actuated so that the relay 60 remains open. In response to the voltage through the contactor 42a being less than a threshold voltage, the battery controller 16 may command, e.g., by transmitting a signal to the BEC 18, the contactor 42a to close. In one case, the battery controller 16 may close the contactor 42a by allowing the switch 62a and the switch 62b to operate in a duty cycle such that the current value through the coil 58 is at least the pull-in current I pull_in of relay 60.

[0028] The battery controller 16 may be configured to actuate the switches 62a, 62b so that current flowing through the coil 58 is at least over a predefined period of time the pull-in current I pull_inof the relay 60. In one example, after a predefined period of time, the battery controller 16 may enable the switches 62a, 62b, e.g., by transmitting a signal to the BEC 18, to operate in a duty cycle, e.g., such that current through the coil 58 is not less than holding current I hold of relay 60 and relay 60 remains closed.

[0029] In relation to Fig. 4, an exemplary arrangement 66 for precharging the main load 34 is shown. The arrangement 66 may include main contactors 68a, 68b for activating and deactivating the transfer of energy between the traction battery 14 and the main load 34. The contactor 68a may comprise a coil 70 around a core, such as, but not limited to, a permanent magnet core, wherein bidirectional current flow through the coil 70 (e.g., generally indicated using respective arrows 74a, 74b) may enable one or more operating characteristics of a relay 72. In one case, current flowing in a first direction 74a through the coil 70 may cause the relay 72 to open, and current flowing in a second direction 74b through the coil 70 may cause the relay 72 to close.The battery controller 16 may be configured to selectively activate and deactivate a plurality of switches 76a, 76b, 76c, and 76d electrically connected to the contactor 68a and capable of generating current therethrough in one of the first direction 74a and the second direction 74b. In one example, the switches 76a, 76b, 76c, and 76d may be connected in an H-bridge configuration. The battery controller 16 may be configured to enable one or more of the switches 76a, 76b, 76c, and 76d to operate in a same or different predefined duty cycle to selectively generate current through the coil 70 of the contactor 68a.

[0030] In one example, the battery controller 16 may initiate a pre-charge operation in response to receiving a signal indicative of a request to close the contactors 68a, 68b. The battery controller 16 may, for example, by transmitting a signal to the BEC 18, command the contactor 68b to close in response to receiving a request to transfer power between the traction battery 14 and the main load 34. The battery controller 16 may enable the switches 76b, 76d to operate in a predefined duty cycle, for example, such that current flowing through the coil 70 of the contactor 68a flows in the first direction 74a.

[0031] The battery controller 16 may be configured to measure voltage through contactor 68a while the switches 76b, 76d are operated in a predefined duty cycle, e.g., such that current flowing through the coil 70 is in the first direction 74a. In response to voltage through contactor 68a being less than a threshold voltage, the battery controller 16 may command, e.g., by transmitting a signal to the BEC 18, the contactor 68a to close. In one case, the battery controller 16 may close the contactor 68a by deactivating the switches 76b, 76d and allowing the switches 76a, 76c to operate in a duty cycle such that current flowing through the coil 70 is in the second direction 74b.

[0032] With reference to Fig. 5, an exemplary process 78 for precharging the main load 34 is shown. The process 78 may begin at block 80, where the battery controller 16 receives a signal indicative of a request to close the contactors 42a, 42b, e.g., a request to close respective relays of the contactors 42a, 42b. In response to the request, the battery controller 16 may cause the contactor 42b to close at block 82, such as by issuing a command to the BEC 18 and so forth. In one example, the battery controller 16 may cause the contactor 42b to close by causing a relay of the contactor 42b to close. At block 84, the battery controller 16 may transfer current from the traction battery 14 through the coil 58 of the contactor 42a to precharge the main load 34 without causing the relay 60 of the contactor 42a to close.

[0033] The battery controller 16 may determine at block 86 whether pre-charging of the main load 34 is complete. In one example, the battery controller 16 may determine whether pre-charging of the main load 34 is complete based on determining whether a voltage drop across the contactor 42a has fallen below a specified threshold. In another example, the battery controller 16 may wait a predetermined period of time before determining whether a voltage drop across the contactor 42a has fallen below a specified threshold. At block 88, in response to the determination at block 86 that pre-charging of the main load 34 is not complete, e.g., a voltage drop across the contactor 42a is above a specified threshold after a predefined period of time, the battery controller 16 may output a diagnostic message indicating a pre-charge fault. The battery controller 16 may then terminate the process 78.

[0034] At block 90, the battery controller 16 may cause, e.g., by transmitting a command to the BEC 18, the relay 60 of the contactor 42a to close in response to the determination at block 86 that pre-charging of the main load 34 is complete, e.g., a voltage drop across the contactor 42a is less than a specified threshold. Thereafter, the process 78 may end. In some examples, the process 78 may be repeated in response to receiving a signal indicative of a request to close the contactors 42a, 42b, e.g., a request to close respective relays of the contactors 42a, 42b, or in response to another signal or request.

[0035] With reference to Fig. 6, an exemplary process 92 for precharging the main load 34 is shown. The process 92 may begin at block 94, where the battery controller 16 receives a signal indicative of a request to close the contactors 42a, 42b, e.g., a request to close respective relays of the contactors 42a, 42b. In response to the request, the battery controller 16 may, at block 96, cause the contactor 42b to close, such as by issuing a command to the BEC 18. At block 98, the battery controller 16 may transfer current through the coil 58 of the contactor 42a without closing the relay 60 of the contactor 42a. In one case, the battery controller 16 may enable the switch 62b to operate in a specified duty cycle such that current flowing through the coil of the contactor 42a is less than a predefined current, e.g., less than pull-in current I pull_in of relay 60 of contactor 42a.

[0036] The battery controller 16 may determine at block 100 whether pre-charging of the main load 34 is complete. In one example, the battery controller 16 may determine whether pre-charging of the main load 34 is complete based on determining whether voltage through the contactor 42a is less than a specified threshold. In another example, the battery controller 16 may wait a predetermined period of time before determining whether voltage through the contactor 42a is less than a specified threshold. At block 102, in response to the determination at block 100 that pre-charging of the main load 34 has not been completed, e.g., voltage through the contactor 42a is greater than a specified threshold after a predefined period of time, the battery controller 16 may output a diagnostic signal indicative of a pre-charge fault. The battery controller 16 may then terminate the process 92.

[0037] At block 104, in response to the determination at block 100 that pre-charging of the main load 34 is complete, the battery controller 16 may increase the current transmitted through the coil 58 of the contactor 42a, thereby causing the relay 60 of the contactor 42a to close. In one case, the battery controller 16 may increase the current transmitted through the coil 58 of the contactor 42a by transmitting a signal to the BEC 18 indicating a request to enable one or more switches to operate at a specified duty cycle. In such an example, the battery controller 16 may enable the switches 62a, 62b to operate at a specified duty cycle such that current through the coil 58 of the contactor 42a is not less than pull-in current I pull_in is, e.g., greater than or equal to the starting current I pull_in , of relay 60 of contactor 42a.

[0038] In one example, at block 106, after a predefined period of time after causing relay 60 to close, battery controller 16 may reduce current transmitted through coil 58 such that relay 60 of contactor 42a remains closed. In such an example, battery controller 16 may reduce current transmitted through coil 58 by transmitting a signal to BEC 18 indicating a request to allow switches 62a, 62b to operate in a specified duty cycle such that current through coil 58 is not less than, e.g., greater than or equal to, holding current I hold of the relay 60, where holding current I hold of relay 60 less than starting current I pull_in of relay 60 and is greater than dropout current I drop_outof relay 60. At this point, process 92 may end. In one example, process 92 may be repeated in response to receiving a signal indicative of a request to close contactors 42a, 42b, e.g., a request to close respective relays of contactors 42a, 42b, or in response to another signal or request.

[0039] With reference to Fig.7, an exemplary process 108 for precharging the main load 34 is shown. The process 108 may begin at block 110, where the battery controller 16 receives a signal indicative of a request to close the contactors 68a, 68b, e.g., a request to close respective relays of the contactors 68a, 68b. In response to the request, at block 112, the battery controller 16 may cause the contactor 68b to close, such as by issuing a command to the BEC 18. At block 114, the battery controller 16 may transfer current through the coil 70 of the contactor 68a without closing the relay 72 of the contactor 68a. In one example, the battery controller 16 may transfer current through the coil 70 of the contactor 68a without closing the relay 72 of the contactor 68a by allowing current through the coil 70 to be in the first direction 74a.In such an example, the battery controller 16 may enable the switches 76b, 76d to operate in a specified duty cycle such that current through the coil 70 is in the first direction 74a.

[0040] The battery controller 16 may determine at block 116 whether pre-charging of the main load 34 is complete. In one example, the battery controller 16 may determine whether pre-charging of the main load 34 is complete based on determining whether voltage through the contactor 68a is less than a specified threshold. In another example, the battery controller 16 may wait a predetermined period of time before determining whether voltage through the contactor 68a is less than a specified threshold. At block 118, in response to the determination at block 116 that pre-charging of the main load 34 has not been completed, e.g., voltage through the contactor 68a is greater than a specified threshold after a predefined period of time, the battery controller 16 may output a diagnostic signal indicative of a pre-charge fault. The battery controller 16 may then terminate the process 108.

[0041] At block 120, in response to the determination at block 116 that pre-charging of the main load 34 is complete, the battery controller 16 may transfer current through the coil 70 of the contactor 68a, causing the relay 72 of the contactor 68a to close. In one example, the battery controller 16 may transfer current through the coil 70 of the contactor 68a, causing the relay 72 to close by allowing current through the coil 70 to be in the second direction 74b. In such an example, the battery controller 16 may disable operation of the switches 76b, 76d and allow the switches 76a, 76c to operate in a specified duty cycle such that current through the coil 70 is in the second direction 74b. At this point, the process 108 may end. In one example, the process 108 may, in response to receiving a signal indicative of a request to close the contactors 68a, 68b, e.g.request to close respective relays of contactors 68a, 68b, or in response to another signal or request.

[0042] The methods, techniques, or algorithms disclosed herein may be executable by or implemented by a processing device, controller, or computer, which may include an existing programmable electronic control unit or a dedicated electronic control unit. Likewise, the methods, techniques, or algorithms may be stored as data and instructions executable by a controller or computer in many forms, including, but not limited to, information permanently stored on non-writable storage media such as ROM devices and information modifiably stored on writable storage media such as floppy disks, magnetic tapes, CDs, RAM devices, and other magnetic and optical media. The methods, techniques, and algorithms may also be implemented in a software-executable object.Alternatively, the methods, techniques, or algorithms may be implemented in whole or in part using suitable hardware components, such as application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), state machines, controllers, or other hardware components or devices, or a combination of hardware, software, and firmware components.

[0043] The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments may be combined to form other embodiments of the invention that may not be expressly described or illustrated.While various embodiments may be described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, one of ordinary skill in the art will recognize that one or more features or characteristics may be compromised to achieve the desired overall system attributes, depending on the particular application and implementation. These attributes may include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, operability, weight, manufacturability, ease of assembly, etc.As such, embodiments that are described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for certain applications.

Claims

[1] Vehicle system (10), comprising: a contactor (50) including a coil (52) and a relay (54); a traction battery (14); a burden; and a controller configured to transfer current from the traction battery (14) through the coil (52) to precharge the load without causing the relay (54) to close, such that a voltage drop across the relay (54) falls below a threshold, and subsequently causing the relay (54) to close, characterized by , that the vehicle system (10) further comprises a switching arrangement (40), wherein transferring current from the traction battery (14) through the coil (52) to precharge the load without causing the relay (54) to close includes actuating the switching arrangement (40) in a specified duty cycle. [2] The system (10) of claim 1, wherein causing the relay (54) to close includes causing a magnitude of the current to increase. [3] The system (10) of claim 1, wherein causing the relay (54) to close includes causing a direction of the current to change. [4] The system (10) of claim 1, wherein operating the switching assembly (40) in the specified duty cycle includes operating a plurality of switches of the switching assembly (40) such that current flows through the coil (52) in a first direction defining an open position of the relay (54), and wherein causing the relay (54) to close includes operating the plurality of switches of the switching assembly (40) such that current flows through the coil (52) in a second direction defining a closed position of the relay (54). [5] The system (10) of claim 1, further comprising a switching assembly (40), wherein transferring current from the traction battery (14) through the coil (52) to precharge the load without causing the relay (54) to close includes actuating the switching assembly (40) in a first duty cycle, and wherein causing the relay (54) to close includes actuating the switching assembly (40) in a second duty cycle greater than the first duty cycle. [6] The system (10) of claim 5, wherein the first duty cycle defines a magnitude of current through the coil (52) as below a pull-in current magnitude associated with the relay (54) and the second duty cycle defines a magnitude of current through the coil (52) as above the pull-in current magnitude associated with the relay (54). [7] A method for a vehicle (12), comprising: Transferring, by a controller, current from a traction battery (14) through a coil (52) of a contactor (50) to precharge a load without causing a relay (54) of the contactor (50) to close, such that a voltage drop across the relay (54) falls below a threshold value, and then causing the relay (54) to close, characterized by , that transferring current from the traction battery (14) through the coil (52) to precharge the load without causing the relay (54) to close includes actuating a switching arrangement (40) in a specified duty cycle. [8] The method of claim 7, wherein causing the relay (54) to close includes causing a magnitude of the current to increase. [9] The method of claim 7, wherein causing the relay (54) to close includes causing a direction of the current to change. [10] The method of claim 7, wherein operating the switching assembly (40) in the specified duty cycle includes operating a plurality of switches of the switching assembly (40) such that current flows through the coil (52) in a first direction defining an open position of the relay (54), and wherein causing the relay (54) to close includes operating the plurality of switches of the switching assembly (40) such that current flows through the coil (52) in a second direction defining a closed position of the relay (54). [11] Method according to claim 7, wherein the switching arrangement (40) forms an H-bridge. [12] The method of claim 7, wherein transferring current from the traction battery (14) through the coil (52) to precharge the load without causing the relay (54) to close includes actuating a switching arrangement (40) in a first duty cycle, and wherein causing the relay (54) to close includes actuating the switching arrangement (40) in a second duty cycle greater than the first duty cycle. [13] The method of claim 12, wherein the first duty cycle defines a magnitude of current through the coil (52) as below a pull-in current magnitude associated with the relay (54) and the second duty cycle defines a magnitude of current through the coil (52) as above the pull-in current magnitude associated with the relay (54).

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