Dual voltage contactor

Abstract

The invention presents a motorized contactor comprising at least three pairs of contacts composed of a fixed contact and a movable contact, these pairs of contacts each having a closed state where the movable contact is in the position of maximum approach to said associated fixed contact and an open state where the movable contact is as far apart as possible from the associated fixed contact, all of the movable contacts being mobilized by at least one carriage,as well as an electric actuator controlling the movement of the entire carriage(s) reversibly between a position P1 where a first pair of contacts is in the closed state and at least two pairs of contacts are in the open state and a position P2 where said first pair of contacts is in the open state and said at least two pairs of contacts are in the closed state, characterized in that the open and closed states of each of said at least 3 pairs of contacts is mechanically imposed by the control of the electric actuator. The electric actuator mechanically controls, via said carriage(s), the forced passage between a closed state and an open state of each of said at least three pairs of contacts. Abstract figure: Figure 3,

Description

Title of the invention: Dual voltage contactor Technical field of the invention

[0001] The present invention relates to a contactor capable of connecting, to a charging station, two accumulators of a battery in series or in parallel depending on the voltage offered by this battery. This invention also aims at applications integrating high-power accumulators, such as for example charging stations for electric vehicles and, in particular, electric cars.

[0002] Electrically powered motor vehicles require batteries with a relatively high voltage, typically 400V or 800V. While equipment operating at 400V was initially predominantly developed, there has been a migration of architectures from 400V to 800V. However, this migration is gradual and a significant portion of the infrastructure for recharging vehicle batteries will remain capable of delivering only a voltage of 400V. In order to make vehicle batteries compatible with these two charging voltages, it is possible to separate the battery into two sub-assemblies of 400V accumulators capable of being connected in parallel or in series to be compatible with one or other of the two voltages.The present invention aims to operate the transition from one voltage to the other automatically and securely, that is to say, without manual intervention by the user, capable of detecting a switching fault and intrinsically robust to the short-circuiting of one of the accumulators by an internal fault. state of the prior art

[0003] Patent application US11801770 is known from the state of the art, describing a battery system addressing the problem of connecting batteries in series or in parallel. It comprises a first and a second set of batteries connected to positive and negative DC voltage bus rails, a contactor connected between the sets of batteries.

[0004] Also known from the state of the art is patent application US2725488A relating to an electromagnetic relay comprising a mobile assembly provided with multiple pairs of contacts and switching between two positions by the power supply of a solenoid.

[0005] Also known in the art is international patent application WO2023168388A1 which relates to a multi-switch contactor assembly which comprises an array of at least three switches, the array comprising a first switch comprising a first movable contact and at least one first fixed contact, the first switch being adapted to change a switching state between an open state and a closed state; a second switch comprising a second movable contact and at least one second fixed contact, the second switch being configured to change a switching state between an open state and a closed state; and a third switch comprising a third movable contact and at least one third fixed contact, the third switch being configured to change a switching state between an open state and a closed state. The multi-switch contactor assembly further comprises an actuator assembly configured to actuate the first movable contact, the second movable contact and the third movable contact, the actuator assembly comprising a shaft, the respective switching states of the three switches changing in accordance with rotation of the shaft. Disadvantages of the prior art

[0006] The solutions of the prior art are not entirely satisfactory because they present risks of arcing when the opening or closing of the different contacts have a slight time lag, or when a single electromechanical contact is requested to open a line of a high voltage or even causes a transient short circuit. Furthermore, the electrical conductance of a contact is never perfect and the multiplication of the number of contacts results in an increase in resistance. In particular, patent US11801770 is silent on how to make the switch to switch from one voltage to another. Known technical solutions such as patent application US2725488A use a greater number of contacts than necessary to switch from one voltage to another, this causes an unnecessarily high contact resistance which impacts the performance of the system.Also the use of a solenoid, or bistable technology, does not ensure that the return to position is correctly carried out. This pitfall is shared by the international patent application WO2023168388A1 which has a cam drive whose return to position is ensured by a spring, the actuation of the actuator alone therefore does not ensure that the return to position is correctly carried out for each of the contacts. Finally, this last solution involves multiple moving parts which makes the production complex and not very robust to defects. Statement of the invention

[0007] The present invention aims to overcome the drawbacks of the state of the art by proposing a compact, reliable and secure way of adapting the voltage at the terminals of a battery by reconfiguring the routing of its internal accumulators.

[0008] To do this, the present invention proposes a motorized contactor solution having the characteristics of claim 1.

[0009] A contactor according to the invention comprises at least three pairs of contacts composed of a fixed contact and a movable contact, these pairs of contacts each having a closed state where the movable contact is in the position of maximum approach with said associated fixed contact and an open state where the movable contact is separated as far as possible from the associated fixed contact, all of the movable contacts being mobilized by at least one carriage, as well as an electric actuator controlling the movement of the whole of said carriage(s) reversibly between a position PI where a first pair of contacts is in the closed state and at least two pairs of contacts are in the open state and a position P2 where said first pair of contacts is in the open state and said at least two pairs of contacts are in the closed state characterized in that the open and closed states of each of said at least 3 pairs of contacts are mechanically imposed by the control of the electric actuator.

[0010] The electric actuator mechanically controls, via said carriage(s) (200), the forced passage between a closed state and an open state of each of said at least three pairs of contacts.

[0011] By "forced passage" is meant a passage between the closed state and the open state with a force applied by the electric actuator to the movable contact exceeding the static bonding force of two contacts or the bonding resulting from heating undergone by the contacts after formation of an electric arc. An electric arc can occur in particular during a rebound of the closure or a transient stage of the closure.

[0012] Said carriage has interaction zones or cams configured to interact, during the movement stroke between a starting position and an arrival position, first with the contacts to be opened and only then with the contacts to be closed.

[0013] The invention also relates to a motorized contactor furthermore having some of the following characteristics taken alone or in compatible combinations: • the carriage is movable in rotation, • the motorized contactor has exactly 3 pairs of contacts, • the moving contacts are connected by a connection without degrees of freedom of the embedding type, • in a position P3, intermediate in the travel of the carriage between positions PI and P2 of the carriage, the at least three pairs of contacts are in the open state, • optionally in a position P4, intermediate in the travel of the carriage between the positions PI and P2 of the carriage, the first pair of contacts and at least one of the two other pairs of contacts are in the open state and the other of the two other pairs of contacts is in the closed state closing, • the positions PI and P2 are extreme positions of the travel of the carriage.

[0014] The invention also relates to an electrical system comprising a battery provided with two accumulators each provided with a positive termination B^ B2+ and a negative termination B B2_, as well as a positive termination D+, a negative termination D- and a motorized contactor as described previously, the positive termination Bl+ of one of said accumulators is connected to the positive termination D+ of the electrical system, and the positive termination B2_ of the other of said accumulators is connected to the negative termination of the electrical system, characterized in that said motorized contactor controls the electrical connection of the positive termination B2+ and the negative termination of said accumulators between them or to the terminations and D+ of the electrical system, and optionally: • the 4 terminations are connected to the fixed contacts so that in the PI position, the two accumulators are connected in series to the terminations of the electrical system, and in the P2 position the two accumulators are connected in parallel to the terminations of the electrical system, • in position P4, only one of the two accumulators is connected to the electrical system terminals.

[0015] The invention also relates to an electrical system comprising a battery provided with N accumulators, N being greater than or equal to 2, a load and a motorized contactor as described previously, characterized in that said motorized contactor controls the power supply of the load by said N batteries, said contactor being capable of connecting the accumulators in series or in parallel. brief description of the figures

[0016] Other characteristics and advantages of the invention will emerge from the following reading of detailed embodiment examples, with reference to the appended figures which represent respectively: 1. [Fig.l] represents a schematic view of a contactor according to the invention in a switching state allowing respectively the parallel connection and the series connection of two accumulators, 2. [Fig. 2] represents another schematic view of a contactor according to the invention in a switching state allowing respectively the paralleling and the series connection of two accumulators, 3. [Fig.3] represents a perspective view of an exemplary embodiment of the contactor allowing two accumulators to be connected, 4. [Fig.4] represents a schematic view of the contactor shown in [Fig.3] in the PI position, 5. [Fig.5] represents a schematic view of the contactor shown in [Fig.3] in position P2, 6. [Fig.6] represents a schematic view of the contactor shown in [Fig.3] in position P3, 7. [Fig.7] represents a schematic view of the contactor shown in [Fig.3] in position P4. General principle of the invention

[0017] The general principle of the invention consists in reconfiguring the electrical connection between the multiple terminals of an electrical contactor for the purpose of connecting accumulators of a battery in series or in parallel to adapt the voltage at the terminals of said battery. The invention relates more particularly to the contactor itself and its internal arrangement.

[0018] To connect two accumulators (31, 32) of the same voltage in series or in parallel, the contactor (10) according to the invention proposes to limit the number of pairs of contacts (410, 420, 430) used to open and close the electrical circuits. This makes it possible to minimize the contact resistance and therefore to improve the performance of the device. Each pair of contacts (410, 420, 430) is provided with a fixed contact (610, 620, 630) and a movable contact (510, 520, 530), each of these movable contacts is driven by a carriage (200) to come to bear against the associated fixed contact. The carriage (200) is mobilized by an electric actuator (100), preferably a geared motor associated with a cam, but could also be a motor or a linear actuator associated or not with a transmission of movement with or without reduction.

[0019] The carriage (200) can be made up of a single part, for example a molded plastic part, or by an assembly of several parts, but which are moved under the action of a single electric actuator (100).

[0020] The interaction between the carriage (200) common to all pairs of contacts (410, 420, 430), and each of the movable contacts (510, 520, 530), is configured so that the closing and opening of the contacts (410, 420, 430) is forced by the control of the movement of the carriage (200) by an electric actuator (100), independently of the possible action of a short-stroke compression spring to stabilize the closing quality of a contact. In particular, the opening of the contacts (410, 420, 430) is not done by the release of such a compression spring, but is controlled by the movement of the carriage, as well as the closing.

[0021] The fact that the opening of each of the contacts (410, 420, 430) is imposed mechanically by the electrical actuator (100), and not only by an elastic release of the closure of the contact is essential to avoid that an unexpected sticking of the contact which can occur for example after the formation of an electric arc during a previous closure, does not maintain the contact in the closed position, causing then a risk of a highly damaging short circuit.

[0022] Optionally, it is desirable that during the movement of the carriage (200), there is a moment of the stroke where all the contacts (410, 420, 430) are open

[0023] Each movable contact (510, 520, 530) is activated by interaction with a carriage (200) moved by direct drive by an electric actuator (100), whether to open or close the contact. Direct drive means that the motor control imposes a force on the movable contact which causes it to move over part of the opening stroke, in contrast to indirect drive where the motor control only releases a stress on the movable contact, which can then be mobilized by a previously compressed elastic return means.

[0024] By change of state is meant the passage of the electrical state, between opening resulting in the absence of current flow, and closing which results in the flow of current. It is desirable that the passage from an open state to a closed state takes place sufficiently quickly to avoid the risk of an electric arc forming between the contacts.

[0025] It is also possible to provide an accessory means for preventing the formation of arcs when the contacts change from the open state to the closed state.

[0026] The analysis of the electrical signals of the actuator makes it possible to monitor the proper progress of the movement operation and makes it possible to know the position of the movable contact relative to the fixed contact. It is also envisaged to diagnose the state of health of the system and to identify a fault on the contacts, such as an inability to open one of the contacts due to welding or even a mechanical breakage within the system. Of course, the direct drive mentioned does not exclude the use of a spring with a short compression stroke, making it possible to press the fixed contact on the movable contact with a tolerance range of the movement of the movable contact, avoiding a breakage of the system while ensuring a contact force minimizing the surface resistance. Schematic description of an embodiment

[0027] Figures 1 and 2 represent schematic views of a first embodiment according to the invention allowing the connection in series or in parallel of two accumulators (31, 32) of the same voltage of a battery (30) so as to present a variable voltage between the positive D+ and negative terminations of the system connected to a device (20), typically a charging station. In this first embodiment, the contactor (10) is provided with 3 pairs of contacts (410, 420, 430) the movable contact (510, 520, 530) of each of the pairs of contacts (410, 420, 430) is set in motion by an actuator (100) via the same carriage (200), or several mechanically linked carriages.

[0028] The electrical connection between the different components of the system is described as follows. The positive termination B1+ of one accumulator (31) is electrically connected to the positive termination D+ of the system and the negative termination B2. of the other accumulator (32) is connected to the negative termination of the system. The other two terminations (B^ B2+) are electrically connected to the two input terminals (110, 120) of the contactor (10). The two output terminals (130, 140) of the contactor (10) are respectively electrically connected to the negative and positive terminations D+) of the system.

[0029] Within the contactor (10), the first input terminal (110) is electrically connected on the one hand to the movable contact (520) of the second pair of contacts (420) and on the other hand to the fixed contact (610) of the first pair of contacts. The second input terminal (120) is electrically connected to the movable contacts (510, 530) of the first and third pairs of contacts (410, 430). The first output terminal (130) is electrically connected to the fixed contact (620) of the second pair of contacts (420) and the second output terminal is electrically connected to the fixed contact (630) of the third pair of contacts (430).

[0030] Figure 1 shows a first switching state P2, for which the second and third pairs of contacts (420, 430) are in the closed state, i.e. the fixed (620, 630) and movable (520, 530) contacts within the same contact pair are electrically connected, and the first pair of contacts (410) is in the open state, i.e. the fixed (610) and movable (510) contacts are not electrically connected. In this position P2, the two accumulators (31, 32) are connected in parallel and the voltage across the system terminations (&, B*) is equal to that of each of the accumulators (31, 32).

[0031] Figure 2 shows a second PI switching state, for which the second and third pairs of contacts (420, 430) are in the open state and the first pair of contacts (410) is in the closed state, so as to connect the two accumulators in series. The voltage across the terminals (£\ D+) of the system is then twice that of each of the accumulators (31, 32). detailed description of an embodiment

[0032] [Fig. 3] represents a perspective view of an exemplary embodiment of a first embodiment corresponding to the schematic view of Figures 1 and 2. In this embodiment, the carriage (200) is moved by the electric actuator (100) in rotation about an axis (250). The movable contacts (510, 520, 530) are held in housings (210, 220, 230) of the carriage (200) by means of claws, allowing their movement relative to the associated fixed contact (610, 620, 630) when the carriage pivots.

[0033] The input (110, 120) and output (130, 140) terminals are fixed in a housing (not shown). The output terminals (130, 140) are in the form of cylindrical protuberances, provided on their upper part with a thread for fixing the conductive sheet connecting the contactor (10) to the system terminations and to the battery. The fixed contacts (620, 630) are directly made by the lower part of the output terminals (130, 140), it is optionally provided to deposit a metallic pellet made of silver or other good conductor there to improve the resistivity of the contact.

[0034] The input terminals (110, 120) are in the form of monolithic parts from which extend, on either side, flexible conductive strips (525, 615; 535, 515) to ensure the electrical connection to the movable contacts (510, 520, 530) and to the fixed contact (630) of the third pair of contacts. The movable contacts (510, 520, 530) are directly made by the end of the conductive strips (515, 525, 535).Thus, the pivoting of the carriage (200) around its axis (250) causes the deformation of the conductive strips (515, 525, 535), one end of which is fixed and the other set in motion. Note that the flexible conductive strip (615), connecting the input terminal (110) to the fixed contact (610), is not mobilized by the movement of the carriage (200), its flexibility is therefore solely the result of the economic desire to produce the input terminal and the associated contacts in a single piece.

[0035] The housing (210) receiving the first movable contact (510) is located at the end of an extension of the carriage (200) extending from the axis (250) in a direction substantially orthogonal to the extensions of the housings (220, 230) of the other two movable contacts (250, 530). The extensions are rigid parts of the carriage (200) and this configuration ensures that pivoting the carriage in one direction causes the first pair of contacts (410) to close and the second and third pairs of contacts (420, 430) to open, while pivoting in the other direction causes the first pair of contacts (410) to open and the second and third pairs of contacts (420, 430) to close. It is thus not permitted to leave a switch in a closed state when another switch is closed.Note that the orthogonal arrangement of the two extensions aims to improve the compactness of the actuator, protection against short circuits is ensured as soon as the actuator is configured so that one contact closes when the others open, and vice versa, and that there is a range of travel for which all the contacts are simultaneously open.

[0036] The conductive strips (515, 525, 535) are retained in their respective housing (210, 220, 230) by hooks, so as to prevent their movement in the direction of the associated fixed contact (610, 620, 630). A clearance can therefore be provided between the bottom of each housing and the conductive strip located therein so as to arrange a spring (not shown) pushing the strip against the hooks. This configuration advantageously allows a slight movement of the conductive strip in its housing, by compression of the spring, when the moving contact comes into contact with the fixed contact, and therefore to avoid damaging a component if the carriage is moved in rotation slightly beyond the contact pairs. This movement in abutment also makes it possible to minimize the resistance of the contacts and compensate for alignment errors of the contact faces.

[0037] It may be noted that the extensions supporting the housings (220, 230) of the second and third movable contacts (250, 530) are shown in parallel to ensure synchronism of the closing of the contacts, however it may be desired that this is not the case to ensure a slight delay between the contacting of one of the movable contacts (520, 530) with their associated fixed contact (620, 630), relative to the other.

[0038] Figures 4, 5, 6, 7 schematically represent different possible switching positions of the contactor (10) shown in [Fig.3].

[0039] [Fig.4] represents a state called PI for which the second and third pairs of contacts (420, 430) are in the open state and the first pair of contacts (410) is in the closed state, so as to connect the two accumulators in series. This position PI corresponds to an end position of the travel of the carriage (200).

[0040] [Fig.5] represents a state called P2 for which the second and third pairs of contacts (420, 430) are in the closed state and the first pair of contacts (410) is in the open state, so as to connect the two accumulators in parallel. This position P2 corresponds to the other end position of the travel of the carriage (200) opposite PL

[0041] [Fig.6] represents a state called P3 for which all the pairs of contacts (410, 420, 430) are in the open state so that none of the accumulators are connected to the terminations. This position P3 is an intermediate position of the carriage travel between positions PI and P2. In order to avoid short-circuiting one of the accumulators, this position P3 is always necessary between positions PI and P2. Position P3 is an intermediate and transient safety state of the travel between PI and P2, but it is also envisaged that the carriage can voluntarily move there and remain there.

[0042] [Fig.7] represents a state called P4 for which the first and third pairs of contacts (410, 430) are in the open state and the second pair of contacts (420) is in the closed state, so that only the first accumulator (31) is connected to the system terminations. Note that a similar state could exist so that only the second accumulator is connected to the system terminations. Note that this state could be enabled by associating a spring with the moving contacts and desynchronizing the contacting, as for example described in the embodiment of [Fig.3].

[0043] The embodiment shown in [Fig. 3] is in no way limiting of the invention and the person skilled in the art could easily imagine other solutions for connecting the accumulators securely while avoiding short circuits. For example, the movement of the carriage could be linear, there could also be multiple carriages each carrying a movable contact, all motorized by the same electric actuator.

[0044] The person skilled in the art could also envisage, based on these teachings, changing the series / parallel configuration of a greater number of accumulators by juxtaposing carriages all mobilized by the same electric actuator.

Claims

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5. Claims Motorized contactor comprising at least three pairs of contacts (410, 420, 430) composed of a fixed contact (610, 620, 630) and a movable contact (510, 520, 530), • these pairs of contacts each having a closed state where the movable contact (510, 520, 530) is in the position of maximum approach to said associated fixed contact (610, 620, 630) and an open state where the movable contact (510, 520, 530) is as far apart as possible from the associated fixed contact (610, 620, 630), • all of the movable contacts being mobilized by at least one carriage (200), as well as an electric actuator (100) controlling the movement of all of said carriage(s) (200) reversibly between a position PI where a first pair of contacts (410) is in the closed state and at least two pairs of contacts (420, 430) are in the open state and a position P2 where said first pair of contacts (410) is in the open state and said at least two pairs of contacts (420, 430) are in the closed state characterized in that the electric actuator (100) mechanically controls, via said carriage(s) (200), the forced passage between a closed state and an open state of each of said at least three pairs of contacts (410, 420, 430). Motorized contactor according to claim 1 characterized in that said carriage (200) has interaction zones or cams configured to interact mechanically, during the movement stroke between a starting position and an arrival position, first with the contacts (410, 420, 430) to be opened and only after with the contacts (410, 420, 430) to be closed. Motorized contactor according to claim 1 characterized in that the carriage (200) is movable in rotation. Motorized contactor according to claim 1 characterized in that it comprises exactly three pairs of contacts (410, 420, 430). Motorized contactor according to claim 1 characterized in that the movable contacts are connected by a connection without degrees of freedom of recessed type.

6. Motorized contactor according to claim 1 characterized in that in a position P3, intermediate in the travel of the carriage between the positions PI and P2 of the carriage (200), the at least three pairs of contacts (410, 420, 430) are in the open state.

7. Motorized contactor according to claim 1 characterized in that the positions PI and P2 are extreme positions of the travel of the carriage (200).

8. Motorized contactor according to claim 5 characterized in that in a position P4, intermediate in the travel of the carriage between the positions PI and P2 of the carriage (200), the first pair of contacts (410) and at least one of the two other pairs of contacts (420, 430) are in the open state and the other of the two other pairs of contacts (420, 430) is in the closed state.

9. Electrical system comprising a battery (30) provided with two accumulators (31, 32) each provided with a positive termination (^u, B^) and a negative termination (B^ as well as a positive termination D+, a negative termination and a motorized contactor (10) according to claim 1, the positive termination B1+ of one of said accumulators (31, 32) is connected to the positive termination D+ of the electrical system, and the positive termination B2_ of the other of said accumulators (31, 32) is connected to the negative termination of the electrical system, characterized in that said motorized contactor (10) controls the electrical connection of the positive termination 52+ and the negative termination Bx_ of said accumulators (31, 32) between them or to the terminations & and D+ of the electrical system.

10. Electrical system according to the preceding claim characterized in that the 4 terminations are connected to the fixed contacts (610, 620, 630) so that in the PI position, the two accumulators are connected in series to the terminations of the electrical system, and in the P2 position the two accumulators are connected in parallel to the terminations of the electrical system.

11. Electrical system according to claim 8 characterized in that in position P4, only one of the two accumulators is connected to the terminations of the electrical system.

12. Electrical system comprising a battery provided with N accumulators, N being greater than or equal to 2, a load and a motorized contactor according to claim 1, characterized in that said motorized contactor controls the power supply of the load by said N batteries, said contactor being capable of connecting the accumulators in series or in parallel.

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