High-voltage contactor or high-voltage relay
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- PIERBURG GMBH
- Filing Date
- 2023-08-10
- Publication Date
- 2026-06-17
Smart Images

Figure EP2023072249_13022025_PF_FP_ABST
Abstract
Description
[0001] DESCRIPTION
[0002] High-voltage contactor or high-voltage relay
[0003] The invention relates to a high-voltage contactor or high-voltage relay with an electromagnetic actuator, a housing with an inner contact chamber, a first contact element which projects into the contact chamber, a second contact element which projects into the contact chamber, a contact bridge which is connected to an actuating element which can be displaced by means of the actuator in the contact chamber at least into a first position in which the first contact element is electrically connected to the second contact element via the contact bridge, and into a second position in which an electrical contact between the first contact element and the second contact element is interrupted and an axial contact chamber wall which delimits the contact chamber axially in the direction of the actuator.
[0004] Such high-voltage switching devices are required to be able to establish and disconnect electrical connections in no-load conditions and in load conditions, where voltages of over 1000 V and currents of over 1000 A may be present, for example, in electrically powered vehicles between the battery and the drive motor or between a charging station and the battery.
[0005] Such a switching device is known, for example, from CN 207 302 980 U. For actuation, the actuating element of the disclosed switching device rests against the armature only under spring preload, necessitating separate guidance of the actuating element. For this purpose, the actuating element is guided in an opening of a core plate of the electromagnetic actuator, which is arranged between the actuator and the contact chamber and thus forms an axial boundary wall. However, the guide length of this guide section corresponds only to the wall thickness of the core plate, which is designed to be relatively thin due to the limited available installation space, so that sufficient security against tilting of the actuating element, for example, when forces acting transversely to the movement axis occur, is not guaranteed.
[0006] The present invention is therefore based on the object of creating a high-voltage contactor or high-voltage relay which, compared to the prior art, has improved guiding properties with regard to the guiding of the actuating element.
[0007] This object is achieved by a high-voltage contactor or high-voltage relay according to the invention having the features of claim 1.
[0008] The high-voltage contactor or high-voltage relay according to the invention has an electromagnetic actuator via which the contactor can be switched. An electromagnetic actuator is understood to mean all actuators that generate movement due to a force caused by electromagnetism. The electromagnetic actuator thus consists in particular of a coil consisting of a coil carrier and a winding wound thereon, as well as an iron circuit surrounding the coil and an armature that can be moved due to the electromagnetic force and is arranged within the coil and the iron circuit.
[0009] For simplicity, the term "high-voltage contactor" will be used below to ensure that the term "high-voltage relay" is also included. Furthermore, the terms "radial," "axial," and "diametrical" refer to the center axis of the high-voltage contactor along which the actuator's armature can move.
[0010] The high-voltage contactor comprises a housing with an inner contact chamber, which can be constructed in several parts and is preferably made of plastic.
[0011] The high-voltage contactor further comprises a first and second contact element fixedly arranged on the housing, which protrude into the contact chamber and are connected outside the high-voltage contactor to two busbars, one of which leads to the battery and the other, for example, to the drive motor or which can be connected to a charging station and the vehicle's battery. An electrical connection between these two contact elements can be established via a contact bridge, which is connected to an actuating element that is moved in the contact chamber by means of the actuator. In this case, the contact bridge, at the ends of which two electrical contacts can be formed, is usually displaced or rotated axially against the two contact elements fastened to the housing by energizing the winding in order to establish an electrical connection between the first contact element and the second contact element via the contact bridge in a first position.The actuating element is operatively connected to the actuator's armature and is pressed against the contact elements by the movement of the armature due to the electromagnetic force. To open this electrical connection, the contact bridge is loaded in the opposite direction, which is usually achieved by means of a spring force acting on the armature, the rotor, or the contact bridge in a manner opposite to the electromagnetic force, so that the contact bridge is displaced or rotated into a second position in which electrical contact between the first contact element and the second contact element is interrupted. The high-voltage contactor further comprises an axial contact chamber wall, which delimits the contact chamber in the axial direction and is arranged axially between the contact chamber and the actuator.The axial contact chamber wall, which is preferably made of plastic, acts as an electrical insulator and protects the actuator from arcs occurring in the contact chamber, thus preventing damage to the actuator and its sensitive components.
[0012] According to the invention, a guide section extends in the axial direction from the axial contact chamber wall. The guide section is designed, for example, as an annular, collar-like wall section protruding axially from the axial contact chamber wall on one or both sides, which extends in the axial direction along the movement axis of the actuating element and acts as a sliding bearing for the actuating element. The guide section is further formed integrally with the axial contact chamber wall, for example by a cylindrical bore in the axial contact chamber wall, against the inner wall of which the preferably cylindrical actuating element rests axially displaceably. As a result, the guide section has a significantly greater guide length than the prior art, which is not determined by the axial thickness of the axial contact chamber wall.Depending on the requirements, the guide length can be increased several times over compared to the state of the art by means of the guide section protruding from the axial contact chamber wall, and by increasing this length, a tilt-proof, sliding guide of the actuating element can be ensured, thereby ensuring smooth, low-wear and tilt-free displacement of the actuating element.
[0013] In a particularly preferred embodiment of the invention, the guide section extends axially from the axial contact chamber wall into the contact chamber. On the contact chamber side of the axial contact chamber wall, there is such a large installation space available axially between the contact chamber wall and the contact bridge that the axial length of the guide section extending from the axial contact chamber wall can be at least three times the axial contact chamber wall thickness, or alternatively at least twice the diameter of the actuating element, whereby the guide length is at least 25% of the axial length of the section of the actuating element guided in the guide section. Thus, tilting of the actuating element is virtually impossible, and precise and full-surface placement of the contact bridge on the housing-side contact elements is ensured.Furthermore, the end of this guide section projecting into the contact chamber can serve as a stop for the contact bridge or a stop surface of the actuating element in the position of the contact bridge interrupting the current flow.
[0014] In a further embodiment of the invention, the guide section in the contact chamber is supported by a plurality of ribs distributed over the circumference of the guide section, which extend between the outer circumferential surface of the guide section and the axial contact chamber wall. The ribs can, for example, have a triangular cross-sectional area with respect to a radial cross-sectional plane, with one leg of the triangle being formed by the connection of the rib to the circumferential surface of the guide section and one leg of the triangle being formed by the connection of the rib to the axial boundary wall. If the circumferential surface of the guide section and the axial contact chamber wall are arranged at right angles to one another, this results in a rib in the shape of a right-angled triangle, which is connected on the catheter side to the guide section and the axial contact chamber wall.This prevents deformation of the guide section, which is preferably made of plastic, in the guide section protruding axially from the axial contact chamber wall due to forces acting transversely to the movement axis, thus ensuring linear guidance of the actuating element. Furthermore, the ribs are preferably formed integrally with the guide section and the axial contact chamber wall, allowing them to be manufactured in a single injection molding process.
[0015] In another particularly preferred embodiment of the invention, the guide section extends axially from the axial contact chamber wall toward the actuator. Depending on the design, less installation space is available on this side of the axial contact chamber wall than on the contact chamber side. Nevertheless, the guide length of the guide section can be increased to at least twice the thickness of the axial contact chamber wall. Of course, the guide section can also extend from the contact chamber wall in both directions, thereby further increasing the guide length of the entire guide section compared to a guide section extending axially only on one side.In this case, the axial extent of the first guide section on the contact chamber side is preferably greater than the axial extent of the second guide section on the actuator side, whereby the high-voltage contactor can be designed to be relatively compact on the actuator side and thus overall.
[0016] The electromagnetic actuator advantageously comprises a coil, an iron circuit surrounding the coil, and an armature. This creates a purely translational actuator that eliminates the need for motion conversion. Such an actuator can be manufactured particularly compactly and cost-effectively.
[0017] Furthermore, it is advantageous if the iron circuit is formed from a return plate and a U-shaped yoke, the free legs of which rest on the return plate. The yoke can be manufactured by simple bending, while the straight return plate can serve as a support surface in the injection molding process to form the axial contact chamber wall. Accordingly, the return plate is arranged axially between the coil or coil carrier and the axial contact chamber wall and rests against the axial contact chamber wall, so that the axial contact chamber wall is additionally reinforced by the return plate.
[0018] In a further embodiment of the invention, the actuator-side guide section extends into an opening in the return plate arranged adjacent to the axial contact chamber wall. This opening is advantageously designed as a bore and extends axially through the return plate. The inner diameter of the opening corresponds to the outer diameter of the guide section, so that it fits precisely in the opening. This can be produced relatively easily, for example, by overmolding the return plate using an injection molding process. Thus, the guide length of the guide section can be increased axially in the direction of the actuator within the return plate without restricting the installation space on the actuator side, allowing the high-voltage contactor to be designed relatively compactly overall.
[0019] In a further advantageous embodiment of the invention, the axial contact chamber wall and the guide section are manufactured in a joint injection molding process during the overmolding of the actuator. This creates an actuator housing part that is integrally formed with the axial contact chamber wall and the guide section and completely surrounds the actuator, allowing the housing of the high-voltage contactor to be manufactured relatively easily and cost-effectively.
[0020] In a further embodiment of the invention, the actuator housing part produced by overmolding has a circumferential radial contact chamber wall extending axially from the actuator, which radially delimits the contact chamber.
[0021] The radial contact chamber wall is preferably formed integrally with the actuator housing part and can, for example, be manufactured together with the actuator housing part in a single injection molding process, making the housing of the high-voltage contactor relatively simple and cost-effective to manufacture. Furthermore, in the area of the housing wall bordering the contact chamber, connections and abutting edges that could lead to leaks are completely eliminated. Furthermore, no additional components are required, increasing the strength of the contactor.
[0022] In a further embodiment of the invention, the axial contact chamber wall and the radial contact chamber wall are formed as a single piece. The two contact chamber walls are manufactured using the same injection molding process. This completely eliminates the need for joints and abutting edges that could lead to leaks in the area of the contact chamber wall bordering the contact chamber. As a result, the entire housing, apart from the axial end faces, which are preferably provided with covers, forms a completely enclosed unit that seals the interior of the high-voltage contactor from the environment.
[0023] In a further advantageous embodiment of the invention, the iron circuit of the electromagnetic actuator is completely surrounded radially on the inside and outside by the actuator housing part produced by overmolding and axially by the contact chamber wall in the direction of the contact chamber. The actuator, or the current-carrying part of the actuator, is thus completely galvanically separated from the contact chamber, whereby the actuator circuit is also completely separated from the circuit to be switched. In a further particularly preferred embodiment of the invention, the actuating element rests axially against the armature of the actuator. The actuating element is therefore not firmly connected to the armature. If the armature is thus moved towards the contact chamber as a result of the current being applied to the coil, the armature pushes the actuating element in front of it and presses the contact bridge against the contact elements on the housing.When the coil is deactivated, the armature and the actuating element would not return to their rest position, which is why an additional reset device is used to separate the contact bridge from the contact elements. However, the manufacturing process, especially the assembly process of the high-voltage contactor, is significantly simplified compared to a high-voltage contactor with an actuating element permanently connected to the armature.
[0024] In a further embodiment of the invention, a return spring presses the actuating element axially against the armature. The return spring is preferably designed as a helical compression spring, but can also have any other shape suitable for a compression spring. Alternatively, the return spring can also be designed as a tension spring. This creates a relatively simple and cost-effective return device that ensures the return movement of the actuating element and the armature by permanently pressing the actuating element against the armature by means of the spring force, and transmitting the spring force to the armature. However, due to the lack of a transverse connection between the actuating element and the armature, the actuating element is no longer additionally guided and supported by the armature.However, this is compensated for by the guide section of the high-voltage contactor according to the invention being extended compared to the prior art, so that the extended guide section also leads to a particularly simple and cost-effective design of the high-voltage contactor from this point of view.
[0025] In a further embodiment of the invention, the return spring is arranged in the contact chamber on the side of the actuating element axially opposite the actuator. The return spring preferably rests against the second contact chamber wall, which defines the contact chamber axially opposite the actuator, and contacts the actuating element on the side of the contact bridge axially facing away from the actuator. In combination with the axial contact of the actuating element on the armature, this results in a relatively simple design of the high-voltage contactor.
[0026] In a further advantageous embodiment of the invention, the axial length of the guide section extending beyond the axial contact chamber wall corresponds at least to the axial thickness of the axial contact chamber wall. This at least doubles the guide length compared to a prior art high-voltage contactor, resulting in particularly tilt-proof guidance of the actuating element.
[0027] Three embodiments of a high-voltage contactor or high-voltage relay according to the invention are shown in the figures and are described below.
[0028] Figure 1 shows a side view of a high-voltage contactor according to the invention according to a first embodiment in a sectional view.
[0029] Figure 2 shows a side view of a high-voltage contactor according to the invention in accordance with a second exemplary embodiment, in a sectional view. Figure 3 shows a side view of a high-voltage contactor according to the invention in accordance with a third exemplary embodiment, in a sectional view.
[0030] The high-voltage contactor 10 shown in Figure 1 comprises an electromagnetic actuator 112 having a coil 114 consisting of a coil carrier 116 and a winding 118 wound thereon, a ferromagnetic iron circuit 120, and an armature 122. The ferromagnetic iron circuit 120 has a U-shaped yoke 124, the legs 126 of which rest on a return plate 128 or are attached to the return plate 128, thereby forming the closed iron circuit 120.
[0031] The yoke 124 has a central opening 132 at its base portion 130, the diameter of which essentially corresponds to the inner diameter of the coil carrier 116. A bushing 134 is secured in this opening 132, or rather, inside the coil carrier 116, in which the armature 122 is slidably arranged and guided. When current is applied to the coil 114, the armature 122 is drawn toward the return plate 128 in a known manner against the force of a return spring 136.
[0032] The actuating element 12 rests axially against the armature 122 and projects through a central opening 40 in the return plate 128 into a contact chamber 42. The actuating element 12 is pressed against the armature 122 of the actuator 112 by the return spring 136, which is designed as a helical compression spring and is arranged in the contact chamber 42. The return spring 136 rests axially against a collar-like flange 13 of the actuating element 12 and is supported on the axially opposite side against a contact chamber cover 88 that axially closes the contact chamber 42.
[0033] The first contact element 24 of the contact bridge 20 is arranged axially opposite a first housing-side contact element 54, which can be connected to a high-voltage battery, in particular via a busbar (not shown). The second contact element 26 of the contact bridge 20 is arranged opposite a second housing-side contact element 56, which can be connected, for example, via a busbar to a drive motor of a motor vehicle.
[0034] The contact bridge 20 rests against the flange 13 in the axial direction with a first axial end face facing the flange 13. A contact spring 30 is arranged on the end face of the contact bridge 20 facing the actuator 112, which contact spring rests against the end face of the contact bridge 20 facing the actuator 112.
[0035] On the axial side of the contact spring 30 opposite the contact bridge 20, the contact spring 30 rests against a disk-like retaining element 16, which is firmly connected to the actuating element 12. The contact spring 30 is thus arranged axially between the retaining element 16 and the contact bridge 20 and biases the contact bridge 20 axially in the direction of the contact elements 54, 56 against the axial end face of the flange 13. The contact spring 30 further has a central cylindrical opening 39, by means of which the contact spring 30 is plugged onto the actuating element 12. The actuating element 12 thus extends axially through the contact bridge 20, the contact spring 30, and through the retaining element 16.
[0036] The entire high-voltage contactor 10 is arranged in a housing 58, which is composed of a total of three parts. The actuator 112 is overmolded with a plastic to form an actuator housing part 60. This plastic completely surrounds the coil 114 radially to form a radial boundary wall 66 and also fills a gap 68 radially between the coil 114 and the yoke 124. In addition, the yoke 124 itself is completely surrounded radially by this plastic and is thus shielded from the environment. Furthermore, the return plate 128, which bears against the coil carrier 116 on its side facing the coil carrier 116, is covered axially by this plastic in the direction of the contact chamber 42 and forms an axial contact chamber wall 69.
[0037] A first hollow-cylindrical, sleeve-like guide section 34 extends axially from the axial contact chamber wall 69 into the contact chamber 42. The guide section 34 is formed integrally with the axial contact chamber wall 69 and is manufactured therewith in a common injection-molding process during the overmolding of the actuator 112. The first guide section 34 is supported by four ribs 38, which are evenly distributed along the circumference of the first guide section 34, with each rib 38 extending triangularly between the lateral surface 341 of the guide section 34 and the axial contact chamber wall 69. Furthermore, a second guide section 36 extends axially from the axial contact chamber wall 69 in the direction of the actuator 112.The second guide section 36 extends axially into the opening 40 of the return plate 128 and, with its radial outer wall, fits snugly against the inner wall of the opening 40. This guide section 36 is also formed integrally with the axial contact chamber wall 69 and manufactured with it in a common injection-molding process. Together, the two guide sections 34, 36 form a central guide 70, through which the actuating element 12 is radially mounted and guided slidingly in the axial direction during displacement.
[0038] In addition, a circumferential radial contact chamber wall 86 extends from the return plate 128 as an extension of the plastic surrounding the actuator 112, radially delimiting the contact chamber 42. The radial contact chamber wall 86 is also formed integrally with the axial contact chamber wall 69 and is manufactured during the overmolding of the actuator 112, thus forming four side walls of the contact chamber 42 in the present embodiment.
[0039] On the axial outer side 72 of the actuator housing part 60 opposite the contact chamber 42, the plastic extends further radially inward along a radially outer region 74 of the base part 130 of the yoke 124 or of the actuator 112 and leaves an opening 78 free only in the central, radially inner region 76, which opening is concentric to the opening 132 but has a slightly larger diameter so that there is sufficient space for pressing in the bushing 134.
[0040] This opening 78 is closed by a plastic cover 80, which is firmly attached to the actuator housing part 60 in the opening 78, in particular by laser welding, ultrasonic welding or rotational vibration welding.
[0041] Furthermore, the actuator housing part 60 produced by overmolding the actuator 112 forms a molding 82 in the form of a plug housing 82, through which the connecting lines to the winding 118 of the coil 114 are led outwards, so that the electrical connection of the coil 114 to a voltage source can be established via a plug counterpart.
[0042] The contact chamber 42 is axially closed on the axial side opposite the axial boundary wall 69 by the contact chamber cover 88. Two axial openings 90 are formed on the contact chamber cover 88, in which the two contact elements 54, 56 are received and secured, for example, by ultrasonic welding or overmolding. An outer wall 92 extends circumferentially in the axial direction from this contact chamber cover 88 and encloses the radial contact chamber wall 86 of the actuator housing part 60, so that these two walls 86, 92 can be connected to one another circumferentially in a materially bonded manner, for example, by laser welding, ultrasonic welding, or rotational vibration welding, thereby creating a high-strength housing 58.
[0043] If the current flow between the electric motor or the charging station and the battery is to be enabled, the coil 114 is energized, pulling the armature 122 toward the return plate 128 due to the acting electromagnetic forces. This causes the high-voltage contactor 10 to switch to the switched state, in which the actuating element 12 with the contact bridge 20 and the contact elements 24, 26 on the contact bridge side is pushed against the housing-side contact elements 54, 56, so that a current can flow via the contact bridge 20 from the first contact element 54 to the second contact element 56 and thus from the battery to the electric motor or from the charging station to the battery.The stroke of the armature 122 is dimensioned such that, in the switched state, the contact bridge lifts off the end stop 13 on the actuating element 12, so that the spring force of the contact spring 30 presses the contact bridge-side contact elements 24, 26 against the housing-side contact elements 54, 56. If the coil 114 is not energized, the actuating element 12 and the armature 122 are loaded in the opposite direction by the spring 136, so that the contact bridge 20 is lifted off the contact elements 54, 56 and the circuit is interrupted.
[0044] Figure 2 differs from Figure 1 in that the guidance is provided solely by the single guide section 34, which extends axially from the axial contact chamber wall 69 into the contact chamber 42, so that the actuating element 12 is not guided in the region of the return plate 128. Figure 3 differs from Figure 1 in that the guidance is provided solely by the single guide section 36, which extends axially from the axial contact chamber wall 69 in the direction of the actuator 112. Just as in Figure 1, the guide section 36 extends into the opening 40 of the return plate 128, so that the actuating element 12 is guided over a guide length that approximately corresponds to the thickness of the axial contact chamber wall 69 and the thickness of the return plate 128.
Claims
P A T E N T A N S P R Ü C H E 1. High-voltage contactor (10) or high-voltage relay with an electromagnetic actuator (112), a housing (58) with an inner contact chamber (42), a first contact element (54) which projects into the contact chamber (42), a second contact element (56) which projects into the contact chamber (42), a contact bridge (44) which is connected to an actuating element (12) which is displaceable by means of the actuator (112) in the contact chamber (42) along a movement axis (B) at least into a first position in which the first contact element (54) is electrically connected to the second contact element (56) via the contact bridge (44), and is displaceable into a second position in which an electrical contact between the first contact element (54) and the second contact element (56) is interrupted, an axial contact chamber wall (69) which delimits the contact chamber (42) axially in the direction of the actuator (112), characterized in that a guide section (34, 36) from the axial Contact chamber wall (69) extends in the axial direction, which is formed integrally with the axial contact chamber wall (69) and in which the actuating element (12) is mounted so as to be axially displaceable.
2. High-voltage contactor (10) or high-voltage relay according to claim 1, characterized in that the guide section (34) extends axially from the axial contact chamber wall (69) into the contact chamber (42).
3. High-voltage contactor (10) or high-voltage relay according to claim 2, characterized in that the guide section (34) is supported in the contact chamber (42) by a plurality of ribs (38) distributed over the circumference of the guide section (34) which extend between the outer circumferential surface (341) of the guide section (34) and the axial contact chamber wall (69).
4. High-voltage contactor (10) or high-voltage relay according to one of the preceding claims, characterized in that the guide section (36) extends from the axial contact chamber wall (69) axially in the direction of the actuator (112).
5. High-voltage contactor (10) or high-voltage relay according to one of the preceding claims, characterized in that the electromagnetic actuator (112) has a coil (114), an iron circuit (120) surrounding the coil (114) and an armature (122).
6. High-voltage contactor (10) or high-voltage relay according to claim 5, characterized in that the iron circuit (120) is formed from a return plate (128) and a U-shaped yoke (124), the free legs (126) of which rest on the return plate (128).
7. High-voltage contactor (10) or high-voltage relay according to claim 6, characterized in that the actuator-side guide section (36) extends through an opening (40) of the return plate (128) arranged axially adjacent to the axial contact chamber wall (69).
8. High-voltage contactor (10) or high-voltage relay according to one of the preceding claims, characterized in that the axial contact chamber wall (69) and the guide section (34, 36) are manufactured in a common injection molding process when encapsulating the actuator (112).
9. High-voltage contactor (10) or high-voltage relay according to claim 8, characterized in that an actuator housing part (60) produced by overmolding has a circumferential radial contact chamber wall (86) extending axially from the actuator (112) and radially delimiting the contact chamber (42).
10. High-voltage contactor (10) or high-voltage relay according to claim 9, characterized in that the radial contact chamber wall (86) is formed integrally with the actuator housing part (60).
11. High-voltage contactor (10) or high-voltage relay according to claim 9 or 10, characterized in that the axial contact chamber wall (45) and the radial contact chamber wall (86) are formed in one piece.
12. High-voltage contactor (10) or high-voltage relay according to one of claims 5-12, characterized in that the iron circuit (120) of the electromagnetic actuator (112) is completely surrounded radially inside and outside by the actuator housing part (60) produced by overmolding and is axially in the direction of Contact chamber (42) is surrounded by the axial contact chamber wall (45).
13. High-voltage contactor (10) or high-voltage relay according to one of claims 5-13, characterized in that the actuating element (13) bears axially against the armature (122) of the actuator (112).
14. High-voltage contactor (10) or high-voltage relay according to claim 14, characterized in that a return spring (136) presses the actuating element (13) axially against the armature (122).
15. High-voltage contactor (10) or high-voltage relay according to claim 15, characterized in that the return spring (136) is arranged in the contact chamber (136) on the side of the actuating element (13) which is axially opposite to the actuator (112).
16. High-voltage contactor (10) or high-voltage relay according to one of the preceding claims, characterized in that the axial length of the guide section (34, 36) extending beyond the axial contact chamber wall (69) corresponds at least to the axial thickness of the axial contact chamber wall (69).