Multi-switch contactor assembly, system, and method

Abstract

To provide a multi-switch contactor assembly that withstands mechanical shock and can coordinate a plurality of switches to prevent short circuit of battery packs.SOLUTION: A multi-switch contactor assembly includes: an array of two or more switches, each switch comprising a moveable contact and a fixed contact, where the moveable contact is configured to come into contact with a first end of the fixed contact in a closed switch state and the moveable contact and the fixed contact are oriented such that current passing between the moveable contact and the fixed contact induces an electromagnetic field that acts on the moveable contact in the direction of the first end of the fixed contact; and an actuator assembly configured to actuate each movable contact simultaneously, the actuator assembly including a shaft, where respective switch states of the two or more switches are changed in dependence upon rotation of the shaft.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a multi-switch contactor assembly and to a system and method using the multi-switch contactor assembly. [Background technology]

[0002] Electromechanical switching devices, such as contactors and relays, are designed to pass a specific amount of current for a specific period of time. Such devices are particularly important in electric vehicles. Typically, electric vehicles have multiple electromechanical switches that open and close high-current paths between the battery pack and the electrical system. These switches are controlled by various actuation mechanisms. To prevent shorting of the battery pack, the electromechanical switching elements of the battery component contactors must withstand mechanical shock and coordinate multiple switches to change the battery connection configuration. Summary of the Invention [Problem to be solved by the invention]

[0003] SUMMARY OF THE INVENTION It is an object of the present invention to provide a multi-switch contactor assembly that can withstand mechanical shock and coordinate multiple switches to prevent shorting of the battery pack. [Means for solving the problem]

[0004] To avoid undesirable switch combinations, a multi-switch contactor assembly is provided in which a single mechanical actuation mechanism actuates multiple switches such that dangerous switch combinations are mechanically impossible. In a specific example, the multiple switches can be actuated by multiple cams coupled to the same camshaft. Different switch state (open or closed) combinations are achieved by rotating the camshaft. This provides a limited set of configuration states that can be controlled by a single actuator. Different cam shapes or different orientations of the cams on the camshaft can be used to achieve different switch state combinations. This results in low contact resistance and high contact force without requiring power to maintain the switches in a specific state.

[0005] According to embodiments of the present disclosure, contact force is further increased by utilizing Lorentz forces acting on the movable contact due to the shape and orientation of the fixed and movable contacts. In some examples, the shape and orientation of the fixed and movable contacts are such that the fixed and movable contacts form conductors that fold back on themselves. In some embodiments, the fixed contacts form a C-shape or other partial loop shape, with the movable contact oriented to contact the inner surface of the fixed contact within the loop. In the presence of a large current through the fixed and movable contacts, the Lorentz forces acting on the movable contact repel the movable contact toward the fixed contact, thus increasing the contact force. In some embodiments, the multi-switch contactor assembly includes a pre-charge switch. These embodiments eliminate the need for a separate pre-charge circuit.

[0006] Certain embodiments are directed to a multi-switch contactor assembly including an array of two or more switches, each switch including a movable contact and a fixed contact. In a closed switch state, the movable contact is configured to contact a first end of the fixed contact. The movable and fixed contacts are oriented such that a current passing between the movable and fixed contacts induces an electromagnetic field on the movable contact that acts toward the first end of the fixed contact. The multi-switch contactor assembly further includes an actuator assembly configured to simultaneously actuate each of the movable contacts. The actuator assembly includes a shaft, and the switch state of each of the two or more switches is changed in response to rotation of the shaft. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a circuit diagram of a multi-switch contactor assembly in accordance with at least one embodiment of the present disclosure. [Figure 2A] FIG. 2 illustrates a first state of one exemplary switch assembly of a multi-switch contactor assembly in accordance with at least one embodiment of the present disclosure. [Figure 2B] 2B is a diagram of another state of the example switch assembly of FIG. 2A. [Figure 3] 1A-1C are diagrams of configurations of a multi-switch contactor assembly in accordance with at least one embodiment of the present disclosure. [Figure 4] FIG. 1 is an exploded view of a multi-switch contactor assembly according to at least one embodiment of the present disclosure. [Figure 5] 10A-10C are diagrams of various cam shapes according to embodiments of the present disclosure. [Figure 6] FIG. 10 is a diagram of the Lorentz force on a conductor in accordance with the principles of the present disclosure. [Figure 7] FIG. 1 illustrates an exemplary individual switch assembly of a multi-switch contactor assembly in accordance with at least one embodiment of the present disclosure. [Figure 8A] FIG. 1 illustrates one exemplary busbar configuration for a multi-switch contactor assembly in accordance with at least one embodiment of the present disclosure. [Figure 8B] FIG. 1 illustrates an exemplary individual switch assembly of a multi-switch contactor assembly in accordance with at least one embodiment of the present disclosure. [Figure 8C] FIG. 1 illustrates one exemplary busbar configuration for a multi-switch contactor assembly in accordance with at least one embodiment of the present disclosure. [Figure 9] FIG. 1 is a diagram of an exemplary electric vehicle power distribution system in accordance with at least one embodiment of the present disclosure. [Figure 10] FIG. 10 is a circuit diagram of another multi-switch contactor assembly in accordance with at least one embodiment of the present disclosure. [Figure 11] 10 is a table of switch states for another multi-switch contactor assembly in accordance with at least one embodiment of the present disclosure. [Figure 12] FIG. 1 illustrates an exemplary multi-switch contactor assembly incorporating a pre-charge relay in accordance with at least one embodiment of the present disclosure. [Figure 13] 1 is a flowchart of one exemplary method for multi-switch contactor assembly in accordance with at least one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0008] Connecting and disconnecting electrical circuits is as old as electrical circuits themselves and is often used as a way to switch power to connected electrical devices between an "on" and an "off" state. One example of a device commonly used to connect and disconnect a circuit is a contactor, which is electrically connected to one or more devices or power sources. Contactors are configured so that they can be changed between an "open" and a "closed" state to interrupt or conduct a circuit to control power to and from a device.

[0009] As society advances, various innovations have made electrical systems and electronic devices increasingly common. One example of such innovation is the recent advancement of electric vehicles, which have become the standard for energy efficiency and have the potential to replace most traditional petroleum-powered automobiles. In such expensive, everyday electronic devices, overcurrent protection is particularly applicable to prevent malfunctions and permanent damage to the device. Additionally, overcurrent protection can prevent safety hazards such as electric shock or electrical fire. These latest improvements to electrical systems and devices require improved solutions to enhance the safety, reliability, and efficiency of contactor actuating mechanisms.

[0010] Described herein are various embodiments of contactor assemblies having certain components, or portions thereof, integrally formed with one another to improve operational characteristics and increase operational reliability and safety. The present invention also provides novel features of the components of the contactor assembly, which provide desired operational characteristics, performance, and safety. Embodiments of the present invention are also directed to contactors (i.e., electrical switching devices) utilizing contactor assemblies according to the present invention, and to electrical circuits and systems utilizing electrical switching devices according to the present invention.

[0011] Terms used herein for the purpose of describing particular examples are not intended to be limiting to further examples. Wherever singular forms such as "a," "an," and "the" are used and are not explicitly or implicitly defined as requiring the use of only a single element, further examples may also implement the same function using multiple elements. Similarly, where a function is subsequently described as being implemented using multiple elements, further examples may implement the same function using a single element or processing entity. It will be further understood that the terms "comprises," "comprising," "includes," and / or "including," when used, specify the presence of stated features, integers, steps, operations, processes, acts, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, processes, acts, elements, components, and / or any groups thereof.

[0012] When an element is referred to as being "connected" or "coupled" to another element, it will be understood that the elements may be directly connected or coupled, or may be connected or coupled via one or more intervening elements. When two elements A and B are combined using "or," this should be understood to represent all possible combinations, i.e., A only, B only, and A and B. An alternative expression of the same combination is "at least one of A and B." The same applies to combinations of more than two elements.

[0013] Thus, while the further examples are susceptible to various modifications and alternative forms, some specific examples thereof are shown in the figures and will subsequently be described in detail. However, this detailed description does not limit the further examples to the specific forms described. The further examples may encompass all modifications, equivalents, and alternatives falling within the scope of this disclosure. The same numbers refer to the same or similar elements throughout the description of the figures, which may be implemented in the same or similar form when compared to one another while providing the same or similar functionality.

[0014] An exemplary method and apparatus for a multi-switch contactor assembly according to the present disclosure will be described with reference to the accompanying figures, beginning with FIG. 1 . FIG. 1 illustrates a battery component contactor circuit 100 using a multi-switch contactor assembly according to at least one embodiment of the present disclosure. The battery component contactor can be used in an electric vehicle to connect multiple battery packs to a vehicle power distribution system to power the electric vehicle and to charge the battery packs. In this example, a first switch 110 (referred to herein as “S1”) is operable to open and close a connection between a positive terminal of a first battery pack 104 and a positive terminal 106 of the vehicle power distribution system. A negative terminal of the first battery pack 104 is connected to a negative terminal 108 of the vehicle power distribution system. In this example, a second switch 112 (referred to herein as “S2”) is operable to open and close a connection between a negative terminal of a second battery pack 102 and a negative terminal 108 of the vehicle power distribution system. A positive terminal of the second battery pack 102 is connected to the positive terminal 106 of the vehicle power distribution system. In this example, the third switch 114 (referred to herein as "S0") is operable to open or close the series connection between the battery packs 102 and 104. When the first switch 110 is closed, the first battery pack 104 is directly connected to the vehicle power distribution system. When the second switch 112 is closed, the second battery pack 102 is directly connected to the vehicle power distribution system. When the first switch 110 and the second switch 112 are closed, both battery packs 102, 104 are connected in parallel to the vehicle power distribution system. When the third switch 114 is closed, both battery packs 102, 104 are connected in series to the vehicle power distribution system. However, closing either the first switch 110 or the second switch 112 while the third switch 114 is closed may directly short the battery packs 102, 104, which may weld the switch contactors and / or damage the battery packs 102, 104. To prevent this, the switch contactor has high requirements to withstand mechanical shock. The solenoid contactor coil requires a certain amount of power when operating.

[0015] Thus, according to some embodiments of the present disclosure, a battery component contactor utilizes a multi-switch contactor assembly 120 in which switches S0, S1, and S2 are mechanically linked to prevent switch S0 from being open while switch S1 or switch S2 is closed, and vice versa. A multi-switch contactor assembly according to at least one embodiment of the present disclosure comprises an array of switches (e.g., switches S0, S1, S2) including a first switch embodied by a first movable contact and at least one first fixed contact and configured to change its switch state between an open state and a closed state, a second switch embodied by a second movable contact and at least one second fixed contact and configured to change its switch state between an open state and a closed state, and a third switch embodied by a third movable contact and at least one third fixed contact and configured to change its switch state between an open state and a closed state. The multi-switch contactor assembly further includes an actuator assembly configured to actuate the first movable contact, the second movable contact, and the third movable contact. The actuator assembly includes a shaft, and the switch states of each of the three switches are changed in response to rotation of the shaft. While the multi-switch contactor assembly is described in the following examples as including three switches, the principles of the present disclosure are applicable to multi-switch contactor assemblies having fewer or more than three switches. That is, a single actuator is used to change multiple switches to different switch states such that some combinations of switch states are mechanically prevented. As shown in more detail below, mechanical interlocking of the contactor switches can be achieved with low contact resistance, no lift, no retention force, and high contact force.

[0016] 2A and 2B illustrate an example of a switch assembly 200 for use in a multi-switch contactor assembly in accordance with at least one embodiment of the present disclosure. The switch assembly 200 includes fixed contacts 202, 204 and a movable contact 206. The movable contact 206 is coupled to the fixed contact 202 at one end. The movable contact 206 may be rotatable, flexible, or deformable. The opposite end is coupled to a spring 208 carried by a support structure 220 (e.g., a contactor housing). In a first state, the movable contact 206 is held in a closed position by the spring 208. To transition to a second state, a force is applied to the movable contact 206 by a rotatable cam 212, thereby moving the movable contact 206 away from the fixed contacts and compressing the spring, thereby placing the switch assembly 200 in an open state. To transition the switch assembly 200 to a second state, the cam 212 is rotated out of contact with the movable contact 206, which causes the spring 208 to apply a force to the movable contact 206, moving it into contact with the fixed contact 204, thus closing the switch assembly. The cam 212 rotates via a shaft 214. In some examples, multiple cams 212 can be coupled to the same shaft 214, thus mechanically coordinating the actuation of multiple movable contacts corresponding to multiple switches of the multi-switch contactor assembly.

[0017] For further reference, FIG. 3 illustrates a configuration diagram 300 of a multi-switch contactor assembly in accordance with at least one embodiment of the present disclosure. Diagram 300 illustrates the states of three switches S0, S1, and S2 based on the rotation of a camshaft 302. To aid in illustration, the three switches S0, S1, and S2 may be included in a battery component contactor configured to connect battery pack A and battery pack B to a vehicle power distribution system. In such an example, battery pack A may correspond to battery pack 102 in FIG. 1 , and battery pack B may correspond to battery pack 104 in FIG. 1 , where switch S2 corresponds to switch 112, switch S1 corresponds to switch 110, and switch S0 corresponds to switch 114 in FIG. 1 . However, it should be appreciated that the configuration illustrated in FIG. 3 may be applied to other vehicle contactors, such as fast charge contactors, auxiliary contactors, or utility contactors, and contactors in non-vehicle applications. Switches S0, S1, and S2 may be aligned parallel to the axis of camshaft 302 (e.g., as shown in FIG. 4) so ​​that rotation of the camshaft changes the switch state of at least one of the switches. In this example, a 180 degree rotation changes the switch state of all of the switches. Three cams 301, 311, and 321 are coupled to camshaft 302 and together form the actuation assembly for all of the switch assemblies.

[0018] In the example of FIG. 3 , the first switch S2 includes a fixed bus bar 306 (i.e., a fixed contact) and a deformable bus bar 305 (i.e., a movable contact). The switch S2 further includes a rocker 308 coupled to the deformable bus bar 305. In this example, the switch S2 is a “normally closed” switch in that the deformable bus bar 305 is in contact with the fixed bus bar 306 unless the rocker 308 is actuated to deform the deformable bus bar 305 such that contact between the deformable bus bar 305 and the fixed bus bar 306 is broken, thereby opening the switch. In some examples, the rocker 308 is spring-loaded to hold the deformable bus bar 305 in contact with the fixed bus bar 306 unless the force applied to the rocker 308 by the cam 301 exceeds the spring bias force. The rocker 308 is actuated by the cam 301, which includes a substantially rounded portion 303 and one or more substantially flat portions 304. When the substantially round portion 303 of the cam 301 engages the rocker 308, one end of the rocker proximate the cam 301 is forced downward, thus pushing the other end of the rocker 308 and the deformable bus bar 305 upward, moving the deformable bus bar 305 out of contact with the fixed bus bar 306. When the substantially flat portion 304 of the cam 301 engages the rocker 308, the end of the rocker 308 proximate the cam 301 can return to a closed position in which the rocker 308 encourages contact between the deformable bus bar 305 and the fixed bus bar 306. In this example, the cam 301 includes two substantially flat portions 304, one corresponding to a closed switch state for direct connection of only battery pack A and one corresponding to a closed switch state for parallel connection of battery pack A and battery pack B. Thus, as cam 301 rotates, switch S2 is opened or closed depending on the rotation of camshaft 302 and whether rocker 308 engages the substantially rounded portion 303 or the substantially flat portion of the cam. In an alternative embodiment, switch S2 may be configured as a "normally open" switch, where cam 301 actuates rocker 308 to move deformable busbar 305 into contact with fixed busbar 306.

[0019] In the example of FIG. 3 , similar to switch S2, the second switch S1 includes a fixed bus bar 326 (i.e., a fixed contact) and a deformable bus bar 325 (i.e., a movable contact). Switch S1 further includes a rocker 328 coupled to the deformable bus bar 325. In this example, switch S1 is a “normally closed” switch in that the deformable bus bar 325 is in contact with the fixed bus bar 326 unless the rocker 328 is actuated to deform the deformable bus bar 325 such that contact between the deformable bus bar 325 and the fixed bus bar 326 is broken, thereby opening the switch. In some examples, the rocker 328 is spring-loaded to hold the deformable bus bar 325 in contact with the fixed bus bar 326 unless the force applied to the rocker 328 by the cam 321 exceeds the spring bias force. The rocker 328 is actuated by a cam 321 that includes a substantially rounded portion 323 and one or more substantially flat portions 324. When the substantially round portion 323 of the cam 321 engages the rocker 328, one end of the rocker proximate the cam 321 is forced downward, thus pushing the other end of the rocker 328 and the deformable bus bar 325 upward, moving the deformable bus bar 325 out of contact with the fixed bus bar 326. When the substantially flat portion 324 of the cam 321 engages the rocker 328, the end of the rocker 328 proximate the cam 321 can return to a closed position in which the rocker 328 encourages contact between the deformable bus bar 325 and the fixed bus bar 326. In this example, the cam 321 includes two substantially flat portions 324, one corresponding to a closed switch state for direct connection of only battery pack B and one corresponding to a closed switch state for parallel connection of battery packs A and B. Thus, as cam 321 rotates, switch S1 is opened or closed depending on the rotation of camshaft 302 and whether rocker 328 engages the substantially rounded portion 323 or the substantially flat portion of the cam. In an alternative embodiment, switch S1 may be configured as a "normally open" switch, where cam 321 actuates rocker 328 to move deformable busbar 325 into contact with fixed busbar 326.

[0020] In the example of FIG. 3 , similar to switch S2, the third switch S0 includes a fixed bus bar 316 (i.e., a fixed contact) and a deformable bus bar 315 (i.e., a movable contact). Switch S0 further includes a rocker 318 coupled to the deformable bus bar 315. In this example, switch S0 is a “normally closed” switch in that the deformable bus bar 315 is in contact with the fixed bus bar 316 unless the rocker 318 is actuated to deform the deformable bus bar 315 such that contact between the deformable bus bar 315 and the fixed bus bar 316 is broken, thereby opening the switch. In some examples, the rocker 318 is spring-loaded to hold the deformable bus bar 315 in contact with the fixed bus bar 316 unless the force applied to the rocker 318 by the cam 311 exceeds the spring bias force. The rocker 318 is actuated by a cam 311 that includes a substantially rounded portion 313 and one or more substantially flat portions 314. When the substantially round portion 313 of the cam 311 engages the rocker 318, one end of the rocker proximate the cam 311 is forced downward, thus pushing the other end of the rocker 318 and the deformable bus bar 315 upward, moving the deformable bus bar 315 out of contact with the fixed bus bar 316. When the substantially flat portion 314 of the cam 311 engages the rocker 318, the end of the rocker 318 proximate the cam 311 can return to a closed position where the rocker 318 facilitates contact between the deformable bus bar 315 and the fixed bus bar 316. In this example, the cam 311 includes one substantially flat portion 314 that corresponds to a closed switch state for the series connection of battery pack A and battery pack B. Thus, as the cam 311 rotates, switch S0 is opened or closed depending on the rotation of the cam shaft 302 and whether the rocker 318 engages the substantially round portion 313 or the substantially flat portion of the cam. In an alternative embodiment, switch S0 may be configured as a “normally open” switch in which cam 311 actuates rocker 318 to move deformable busbar 315 into contact with fixed busbar 316.

[0021] Multi-switch contactor assembly configuration diagram 300 includes four different states. In a first state 352, the camshaft has zero degrees of rotation. At zero degrees of rotation, cams 301, 321 exert a force on rockers 308, 328 to ensure switches S2, S1 are open, while rocker 318 of switch S0 engages substantially flat portion 314 of cam 311, thereby allowing switch S0 to close. Thus, while switch S0 connects battery pack A and battery pack B in series, parallel connection of battery pack A and battery pack B, or direct connection of battery pack A or battery pack B, is mechanically prevented.

[0022] In second state 354, camshaft 302 has rotated 90 degrees (e.g., counterclockwise) relative to state 352. At the 90-degree rotation, cam 311 exerts a force on rocker 318 to open switch S0 before rocker 328 of switch S1 engages substantially flat portion 324 of cam 321 of switch S1. When rocker 328 engages substantially flat portion 324 of cam 321, switch S1 closes. Thus, series connection of battery packs A and B is mechanically prevented while switch S1 directly connects battery pack B to the power distribution system. Cam 301 continues to exert a force on rocker 308 to hold switch S2 open.

[0023] In third state 356, camshaft 302 has rotated 180 degrees (e.g., counterclockwise) relative to state 352. Cam 311 continues to exert a force on rocker 318, keeping switch S0 open. Rocker 328 of switch S1 engages second substantially flat portion 324 of cam 321 of switch S1 at 180 degrees of rotation, thereby maintaining switch S1 in a closed state. Simultaneously, rocker 308 of switch S2 engages first substantially flat portion 304 of cam 301 of switch S2, thereby allowing switch S2 to transition to a closed state. Thus, series connection of battery packs A and B is mechanically prevented while switches S1 and S2 connect battery packs A and B in parallel to the power distribution system.

[0024] In fourth state 358, the camshaft has rotated 270 degrees (e.g., counterclockwise) or −90 degrees (e.g., clockwise) relative to state 352. Cam 311 continues to exert a force on rocker 318 to keep switch S0 open. Cam 321 exerts a force on rocker 328 to keep switch S1 open. At 270 degrees of rotation, rocker 308 of switch S2 engages a second substantially flat portion of cam 301 of switch S2, thereby allowing switch S2 to transition to a closed state. Thus, series connection of battery packs A and B is mechanically prevented while switch S2 directly connects battery pack A to the power distribution system.

[0025] In some examples, as shown in FIG. 3, the state of switch S1 can be maintained in a closed state while switch S2 transitions between 90 and 180 degrees. In other examples, a break-before-make configuration is used so that all switches S0, S1, and S2 are open when the camshaft rotation is not 0, 90, 180, or 270 (-90) degrees. In some examples, a position sensor is used to measure the absolute rotation of the camshaft. Thus, the present multi-switch contactor assembly has only four different states in which at least one battery pack is connected to the power distribution system and series connection of the battery packs is mechanically prevented when the battery packs are connected in series or parallel.

[0026] It will be appreciated that other cam shapes can be utilized instead of cams having rounded and flat portions. For example, notches may be used instead of flat outer surfaces. In another example, a switch assembly may include a "normally open" switch, in which a lobe or other protruding actuation member applies a force to a deformable contact to make contact with a fixed contact to close the switch. In some variations, a combination of "normally open" and "normally closed" switches may be used in the same switch array.

[0027] It will be appreciated that two or more cams having different cam shapes may be used to achieve different switch states of the corresponding switches. Similarly, two or more cams having the same shape but different orientations on the cam shaft may be used to achieve different switch states of the corresponding switches. In some cases, two cams may have the same shape and the same orientation on the cam shaft to actuate the same switch states in the corresponding switches (e.g., to reduce current per contact). Thus, multiple cams corresponding to multiple switches may have different shapes, orientations, or alignments, but all cams are actuated by the same cam shaft.

[0028] It will be further appreciated that the deformable busbars may be replaced by fixed busbars coupled to rotatable or pivotable movable contacts. The flexible busbars may also be replaced by braided cables.

[0029] It will be further appreciated that the multi-switch contactor assemblies according to Figures 2A, 2B, and 3 have application in other devices than just battery component contactors. That is, other devices constructed similarly to those described above but with different cam geometries can enable high voltage, high current connections requiring low contactor resistance, such as fast charging contactors, or high voltage, high current connections requiring no device current consumption, such as auxiliary contactors used in grid systems in vehicles.

[0030] Thus, a multi-switch contactor assembly according to Figures 2A, 2B, and 3 is provided, in which: 1) a single mechanical actuation mechanism operates all switches to mechanically make dangerous combinations of switches impossible; 2) only four main possible states are possible: series, battery A only, battery B only, and parallel connection of A and B, with an intermediate state in which all contacts are open; 3) the actuator can move forward and backward to first allow either an A only or B only connection after the series or parallel configuration; 4) the actuator assembly uses no power once the desired connection state is achieved; 5) very high contact force (e.g., 100 N) allows very low device resistance (e.g., less than 50 μΩ) and high stray current (greater than 25 kA); 6) contact can be made using a single contact and a flexible busbar, or two movable contacts using rigid contacts.

[0031] 4 is an exploded view of an example multi-switch contactor assembly 400 in accordance with at least one embodiment of the present disclosure. The example contactor assembly 400 includes a cam assembly 401 including three cams 402, 403, 404 coupled to a camshaft 405, the rotation of which is driven by a motor 406. The contactor assembly includes three switch assemblies, each with a fixed contact 410 and a deformable contact 408. The cams 402, 403, 404 act on respective rockers 412 to deform the respective deformable contacts 408 and open the respective switches. When the rockers 412 are engaged by the flat profile of the cams, a biasing spring 414 urges the rockers into a closed position in which the deformable contacts 408 are held in contact with the fixed contacts 410. When the rocker 412 is engaged by the rounded portion of the cam, the cam exerts a force on the rocker 412 that overcomes the biasing force of the spring 414, thus pushing the rocker 412 to an open position, causing the rocker 412 to bend the deformable contact 408 out of contact with the fixed contact 410. In some examples, the multi-switch contactor assembly 400 includes a position sensor (not shown) to detect the rotation of the camshaft 405. The position sensor provides the absolute angle of the camshaft so that the camshaft can be rotated to a new setpoint to change the switch state. The position sensor may be, for example, a non-contact position sensor and a contact device (e.g., a potentiometer). The position sensor signal can be used both to control the position of the camshaft and to communicate the state of the contacts to a vehicle controller.

[0032] To further illustrate, FIG. 5 shows a variety of different cam shapes 502, 504, 506, 508, 510, 512, including examples of cam wing portions 511 and lobe portions 513, according to the present disclosure.

[0033] To further illustrate, Figure 6 shows the effect of the Lorentz force on a bent conductor in accordance with the principles of the present invention. When a current flows through a conductor, the Lorentz force creates a repulsive force within the conductor. When a conductor is bent into a half-loop, semicircle, or C-shape as shown in Figure 6, and a large current is applied to the conductor, the conductor will tend to expand outward from the magnetic field. In effect, the conductor repels itself.

[0034] To further illustrate, FIG. 7 illustrates another exemplary switch assembly 700 for a multi-switch contactor assembly in accordance with at least one embodiment of the present invention. The switch assembly 700 is similar to the switch assembly of FIG. 3 in that it includes a fixed bus bar 706, a deformable bus bar 705, a rotatable cam 701, and a rocker 708 fixed to one end of the deformable bus bar 705. The other end of the deformable bus bar 705 is coupled to a conductor 720. As shown in FIG. 7, the switch assembly 700 is normally closed. The rocker 708 is spring-loaded by a spring 707 to hold the rocker 708 in a closed position, such that the spring force acting on the rocker 708 causes the rocker 708 to bend the deformable bus bar 705 onto the fixed bus bar 706, thus creating contact between the contact points on the deformable bus bar 705 and the outer surface of the fixed bus bar 706. The other end of the fixed bus bar is coupled to a conductor 722. In the closed state, deformable busbar 705 and fixed busbar 706 close the circuit between conductor 720 and conductor 722. To open the circuit, cam 701 is rotated until wings or lobes 703 push rocker 708 to rotate, thus compressing spring 707 and bending deformable busbar 705 out of contact with fixed busbar 706.

[0035] The fixed busbar 706 is generally C-shaped or semicircular, and when the deformable busbar 705 and the fixed busbar 706 are in contact, they form a loop that doubles back on itself, similar to the conductor shown in FIG. 6. Current flowing through the fixed busbar 706 and the deformable busbar 705 creates a repulsive force, represented by force arrows 730, that spreads the deformable busbar 705 outward from the magnetic field. This effect reduces or eliminates the contact force between the fixed busbar 706 and the deformable busbar 705, as the deformable busbar 705 is repelled from the fixed busbar. As described below, the arrangement of the deformable busbar 705 relative to the fixed busbar 706 can be altered so that the Lorentz force actually increases the contact force.

[0036] To further illustrate, FIG. 8A shows a diagram of a fixed-contact-movable contact geometry for a multi-switch contactor assembly in accordance with at least one embodiment of the present disclosure. The example in FIG. 8A includes a deformable busbar 805 and a fixed busbar 806. The fixed busbar 806 forms a partial loop and may be generally C- or U-shaped in that the fixed busbar includes two protruding portions connected by a central portion. Thus, the fixed busbar 806 includes an inner surface 850. As used in this disclosure, a "C-shaped" busbar generally refers to a busbar having two connected protruding portions 854, 856 that are substantially parallel, with the connecting central portion 852 generally perpendicular to the protruding inner surface 850. In contrast to the previous example, the deformable busbar 805 is bent to contact the inner surface 850 of the fixed busbar 806, such that the Lorentz force 830 is utilized by that contact geometry to increase the contact force between the deformable busbar 805 and the fixed busbar 806. When current flows through the deformable busbar 805 and the fixed busbar 806, the resulting electromagnetic field generates a Lorentz force 830 acting on the deformable busbar 805 in the direction of the fixed busbar 806, holding the deformable busbar 805 relative to the fixed busbar 806 and thereby increasing the contact force. In other examples, the fixed busbar 806 may have a shape other than "C-shaped." FIG. 8C is a diagram of a fixed contact-movable contact geometry for a multi-switch contactor assembly in accordance with at least one embodiment of a contactor geometry of the present disclosure, in which the fixed busbar 890 is "S-shaped." Even though the lower protrusions 896 are bent outward in the opposite direction from the upper protrusions 895 (resulting in an "S-shaped" busbar), the Lorentz force still increases the contact pressure when current flows through the device.

[0037] To further illustrate, Figure 8B shows another exemplary multi-switch contactor assembly 800 for a multi-switch contactor assembly according to at least one embodiment of the present invention, utilizing the contact geometry of Figure 8A. In previous examples (e.g., the exemplary switch assemblies of Figures 3 and 7), the rocker is actuated by cam 701 to bend the deformable busbar into contact with the outer surface of a C-shaped fixed busbar. In contrast to those examples, multi-switch contactor assembly 800 includes a deformable busbar 805 that is bent into contact with the inner surface of a C-shaped fixed busbar 806, such that Lorentz forces are utilized by the contact geometry to increase the contact force between the deformable busbar 805 and the fixed busbar 806. The fixed busbars are sometimes referred to as partial loop busbars in that, although the fixed busbars 806 include inner surfaces that face each other, the fixed busbars do not form a complete physical loop.

[0038] In the example of FIG. 8B , the multi-switch contactor assembly 800 is a “normally closed” switch in that the deformable bus bar 805 is in contact with the fixed bus bar 806 unless the rocker 808 is actuated to deform the deformable bus bar 805 such that contact between the deformable bus bar 805 and the fixed bus bar 806 is broken, thereby opening the switch. In some examples, the rocker 808 is spring loaded by a spring 807 to hold the deformable bus bar 805 in contact with the fixed bus bar 806 unless the force applied to the rocker 808 by the cam 801 exceeds the spring force. In the example of FIG. 8B , the contact end 815 of the deformable bus bar 805 is attached to the rocker 808, which is biased by the spring 807. The other end of the deformable bus bar 805 is coupled to a conductor 820. The force exerted by spring 807 on rocker 808 holds contact end 815 of deformable busbar 805 in contact with inner surface 816 of fixed busbar 806. The other end of fixed busbar 806 is coupled to conductor 822.

[0039] Rocker 808 is actuated by rotation of an irregularly shaped cam 801 (e.g., having one of the cam shapes of FIG. 5) attached to camshaft 870. When actuation point 809 of rocker 808 is engaged by actuator portion 803 (e.g., lobe or wing portion) of cam 801 during rotation of the cam by camshaft 870, the rotation of rocker 808 compresses spring 807, moving deformable busbar 805 out of contact with fixed busbar 806.

[0040] Further or reverse rotation of the cam causes the actuator portion 803 (e.g., lobe or wing portion) of the cam 801 to disengage from the actuation point 809 of the rocker 808, thereby allowing the spring 807 to rotate so that it is decompressed and pushes the rocker 808 back to the closed position, bending the deformable busbar 805 to a closed position where the deformable busbar 805 contacts the inner surface 816 of the fixed busbar 806. As the cam 801 rotates, the switch is opened or closed depending on the rotation of the cam shaft and whether the rocker 808 engages the actuator portion (e.g., lobe or wing portion of the cam; there can be multiple wings or lobes) of the cam 801. In an alternative embodiment, the multi-switch contactor assembly 800 may be configured as a "normally open" switch in which the cam 801 actuates the rocker 808 to move the deformable busbar 805 into contact with the fixed busbar 806, closing the switch. In such a configuration, the lobes or wings of the cam 801 engage the rocker 808, moving the deformable busbar 805 into contact with the inner surface 816 of the fixed busbar. In some examples, the multi-switch contactor assembly 800 includes a position sensor (not shown) to detect the rotation of the camshaft 870. The position sensor provides the absolute angle of the camshaft so that the camshaft can be rotated to a new setpoint to change the switch state. The position sensor may be, for example, a non-contact position sensor and a contact device (e.g., a potentiometer). The position sensor signal is provided to a camshaft motor controller to control the position of the camshaft and communicated to a vehicle controller to indicate the status of the contacts.

[0041] In the example of Figure 8B, the shape and orientation of each busbar or conductor in the component contactor contributes to an increased contact force 830 at high currents. Current flow (indicated by the arrows within the busbars) through the deformable busbar 805 and fixed busbar 806 creates an electromagnetic field that induces a Lorentz force 830 (indicated by the arrows protruding from the busbars 805, 806). The Lorentz force is used to partially compensate for lift forces that could open the contacts or cause sparking and welding. Increasing the contact force by utilizing the Lorentz force through the shape and orientation of the busbars 805, 806 allows the spring force of the spring 807 to be reduced without compromising short-circuit performance.

[0042] Some of the above-described embodiments have been described in the context of the movable contact being in the form of a deformable busbar. In other variations, the movable contact of the switch may be a floating contact that is actuated to contact either a first fixed contact or a second fixed contact. In one example, one end of the floating movable contact is disposed between the first fixed contact and the second fixed contact, while the other end of the floating movable contact is actuable by a cam having one or more actuation points (e.g., wings or lobes) as discussed above. For example, the movable contact may be configured to rotate about a fixed point. When the cam rotates in one direction, the movable contact is actuated to rotate toward the first fixed contact. When the cam rotates further or in the opposite direction, the movable contact is actuated to rotate toward the second fixed contact. Thus, the switch can have three states: a closed state with the first fixed contact, a closed state with the second fixed contact, or an open state. As discussed above, a number of such switches can be arranged and actuated by respective cams attached to a camshaft, so that the switches change state as the camshaft rotates.

[0043] Some of the above embodiments have been described in the context of a three-switch, three-electrode configuration where the switch state configurations include: 1) a direct connection to a first battery pack to power the electric vehicle motor, 2) a direct connection to a second battery pack to power the electric vehicle motor, 3) a series connection of two battery packs to power the electric vehicle motor, and 4) a parallel connection of two battery packs for a charging configuration. However, other applications may require a different number of switches to be simultaneously driven by the camshaft.

[0044] To further illustrate, FIG. 9 shows an example power distribution system circuit diagram for an electric vehicle in accordance with at least one embodiment of the present invention. In the example of FIG. 9, auxiliary contactors 902 for connecting the vehicle to a grid subsystem 904 may require two electrodes. As previously described in the context of the component contactors of FIG. 3, electrodes 903 of auxiliary contactors 902 are simultaneously opened and closed by rotation of a single camshaft to rotate multiple cams that actuate switches between open and closed states. Main contactors 906 for connecting and disconnecting inverter 908 to the high-power bus may require two electrodes. As previously described in the context of the component contactors of FIG. 3, electrodes 907 of main contactors 906 are simultaneously opened and closed by rotation of a single camshaft to rotate multiple cams that actuate switches between open and closed states. The fast charge contactor 910 for connecting the DCDC fast charge subsystem 912 may require two or more electrodes (e.g., two electrodes for currents up to 1000 A, four electrodes for currents up to 2000 A, six electrodes for currents up to 3000 A, etc.) As previously discussed in the context of the component contactor of FIG. 3, the electrodes 911 of the fast charge contactor 910 are opened and closed simultaneously by rotation of a single camshaft to rotate multiple cams that actuate the switch between open and closed states.

[0045] To further illustrate, FIG. 10 shows a component contactor circuit 1000 using a multi-switch contactor assembly according to at least one embodiment of the present disclosure. A component contactor using the component contactor circuit 1000 can be used in an electric vehicle to connect multiple battery packs to a vehicle power distribution system to power the electric vehicle and to charge the battery packs. In this example, a first switch 1010 (also referred to herein as switch “S1”) is operable to open and close a connection between a positive terminal of a first battery pack 1004 and a positive terminal 1006 of the vehicle power distribution system. A negative terminal of the first battery pack 1004 is connected to a negative terminal 1008 of the vehicle power distribution system. In this example, a second switch 1012 (also referred to herein as switch “S2”) is operable to open and close a connection between a negative terminal of a second battery pack 1002 and a negative terminal 1008 of the vehicle power distribution system. The positive terminal of the second battery pack 1002 is connected to the positive terminal 1006 of the vehicle power distribution system. In this example, a third switch 1014 (also referred to herein as switch "S0") is operable to open or close the series connection of the battery packs 1002, 1004. When the first switch 1010 is closed, the first battery pack 1004 is directly connected to the vehicle power distribution system. When the second switch 1012 is closed, the second battery pack 1002 is directly connected to the vehicle power distribution system. When the first switch 1010 and the second switch 1012 are closed, both battery packs 1002, 1004 are connected in parallel to the vehicle power distribution system. When the third switch 1014 is closed, both battery packs 1002, 1004 are connected in series to the vehicle power distribution system.

[0046] In the example of FIG. 10 , the component contactor circuit 1000 also includes a fourth switch 1016 (also referred to herein as switch “S3”) operable to open or close the series connection of a pre-charge relay 1018 with the battery packs 1002, 1004. The pre-charge relay 1018 gradually energizes the high-voltage circuit before the main contactor or switch is closed. When dealing with high-voltage systems, a sudden closure of a switch or contactor can result in an inrush current that can cause damage to the system. The pre-charge relay helps to alleviate these problems by reducing the inrush current in the circuit, thereby allowing the capacitors and other components to charge more gradually. Initially, the pre-charge relay is open, preventing full voltage from being applied to the circuit. When the system is ready to be energized, the pre-charge relay closes, thereby allowing a limited current to flow through the circuit. This limited current pre-charges the capacitors and other components. When the pre-charge process is complete, the main contactor or switch closes.

[0047] Closing either the first switch 1010 or the second switch 1012 while the third switch 1014 is closed may cause a direct short circuit of the battery packs 1002, 1004, which may weld the switch contactors and / or cause damage to the battery packs 1002, 1004. Closing either the first switch 1010, the second switch 1012, or the third switch 1014 while the fourth switch 1016 is closed may disable the pre-charge relay 1018, thereby allowing a sudden inrush of current to damage electrical components. Furthermore, the pre-charge fourth switch 1016 must be closed before the third switch 1014 is closed to connect the battery packs 1002, 1004 in series and apply the full battery pack voltage.

[0048] Thus, in accordance with at least one embodiment of the present disclosure, the component contactor utilizes a multi-switch contactor assembly 1020 in which switches S0, S1, S2, and S3 are mechanically linked to prevent switch S0 from opening while switch S1 or switch S2 are closed, and vice versa, and to prevent switches S0, S1, and S2 from closing while switch S3 is closed. The multi-switch contactor assembly 1020, in accordance with at least one embodiment of the present disclosure, comprises an array of switches (e.g., switches S0, S1, S2, S3) including a first switch embodied by a first movable contact and at least one first fixed contact, the first switch configured to change switch states between an open state and a closed state for direct connection of a first battery pack. The multi-switch contactor assembly 1020 also includes a second switch embodied by a second movable contact and at least one second fixed contact, where the second switch is configured to change its switch state between an open state and a closed state for direct connection of the second battery pack. The multi-switch contactor assembly 1020 also includes a third switch embodied by a third movable contact and at least one third fixed contact, where the third switch is configured to change its switch state between an open state and a closed state for series connection of the first battery pack and the second battery pack. The multi-switch contactor assembly 1020 also includes a fourth switch embodied by a fourth movable contact and at least one fourth fixed contact, where the fourth switch is configured to change its switch state between an open state and a closed state for connection of the pre-charge relay. The multi-switch contactor assembly 1020 further includes an actuator assembly configured to actuate the first movable contact, the second movable contact, the third movable contact, and the fourth movable contact. The actuator assembly includes a shaft, and the switch states of each of the switches are mechanically linked and change in response to rotation of the shaft. In the examples below, the multi-switch contactor assembly is described as including four switches, however, the principles of the present disclosure are applicable to multi-switch contactor assemblies with fewer or more than four switches.That is, a single actuator is used to change multiple switches to different switch states such that some combinations of switch states are mechanically prohibited. As discussed above, mechanical interlocking of contactor switches can be achieved with low contact resistance, no lift, no retention force, and high contact force.

[0049] In some embodiments, each switch of the multi-switch contactor assembly 1020 includes a fixed bus bar and a deformable bus bar (i.e., a movable contact) coupled to a rocker mechanism. As discussed above with reference to FIGS. 3 and 8B, the switches are actuated by the rocker moving the deformable bus bar out of contact with the fixed bus bar. The rocker is actuated by the rotation of a cam coupled to a cam shaft. Each switch is independently actuated by its respective cam, and all cams are mechanically linked by the cam shaft. Each cam may have a cam shape, such as the cam shape of FIG. 5, including actuator portions (e.g., wing portions or lobe portions). These actuator portions are not aligned along the length of the cam shaft. Therefore, the switch states of the four switches change depending on the rotation angle of the cam shaft. In some examples, the fixed busbar is embodied as a partial loop, such as a C-shape, bracket-shape, or U-shape, as discussed above with reference to FIG. 8A, and the deformable busbar contacts the inner surface of the fixed busbar, such that when a large current passes through the fixed busbar and the deformable busbar, a Lorentz force is generated that keeps the deformable busbar in contact with the fixed busbar.

[0050] To further illustrate, FIG. 11 shows a table 1100 of camshaft angles and circuit states for two battery packs and a pre-charge relay connection. In the example of FIG. 11, for illustrative purposes, two 400V battery packs, “Bank A” and “Bank B,” of an electric vehicle are shown. Additional battery packs or alternative voltages may be used without departing from the embodiments of the present disclosure. Column 1101 of table 1100 shows the camshaft rotation angle. The angles shown in the table are provided for illustrative purposes; different angles may be used in various embodiments based on camshaft motor speed and insulation requirements. Column 1102 of table 1100 shows the high-voltage circuit state. Column 1103 of table 1100 shows the switch states for a direct connection of Bank A. Column 1104 of table 1100 shows the switch states for a series connection of Bank A and Bank B. Column 1105 of table 1100 shows the switch states for a direct connection of Bank B. Column 1106 of table 1100 shows the switch states for a pre-charge relay connection. In the example shown in Figure 11, when the camshaft is at 0 degrees, the circuit state is 800V drive / charge, with the switch connecting Bank A and Bank B in series closed and all other switches open. When the camshaft is at 45 degrees or 315 degrees (45 degrees forward or reverse from the 800V drive / charge state), the switch connecting the precharge relay is closed and all other switches are open. When the camshaft is at 90 degrees or 270 degrees (90 degrees forward or reverse from the 800V drive / charge state), all switches are open. This ensures that all switches are open before entering the precharge state. When the camshaft is at 135 degrees, the switch for the direct connection of Bank A for 400V charging is closed and all other switches are open. When the camshaft is at 180 degrees, the switch for the direct connection of Bank A for 400V charging is closed, the switch for the direct connection of Bank B for 400V charging is closed (i.e., parallel charging), and all other switches are open. When the camshaft is at 225 degrees, the switch for the direct connection of 400V charging bank B is closed and all other switches are open.Therefore, regardless of the camshaft rotation direction, the switch states are all open before the transition to the single battery pack charging state followed by the parallel battery pack charging state and before the transition to the pre-charging state, regardless of whether the camshaft is rotating in the forward or reverse direction. In this way, switch state combinations that could lead to system damage are mechanically prevented.

[0051] To further illustrate, FIG. 12 shows a perspective view of an exemplary multi-switch contactor assembly 1200. For example, multi-switch contactor assembly 1200 may embody multi-switch contactor assembly 1020 of FIG. 10. Multi-switch contactor assembly 1200 includes four contactors 1201, 1202, 1204, and 1205. By way of example only, and not limitation, and also referring to FIG. 10, contactor 1201 may embody switch S1, contactor 1202 may embody switch S2, contactor 1204 may embody switch S3, and contactor 1205 may embody switch S0. A pre-charge relay 1203 is disposed between two contactors (e.g., between contactor 1202 and contactor 1204). A cam actuator shaft 1206 extends through contactors 1201, 1202, 1204, and 1205 and precharge relay 1203. The cam actuator shaft mechanically links the cams of each contactor 1201, 1202, 1204, and 1205 to prevent dangerous switch-state combinations. As the cam shaft rotates, the cams of each contactor 1201, 1202, 1204, and 1205 rotate.

[0052] To further illustrate, FIG. 13 depicts a flowchart illustrating one exemplary method of operating a multi-switch contactor assembly in accordance with at least one embodiment of the present disclosure. The method of FIG. 13 includes step 1302 of connecting the multi-switch contactor assembly to an electrical distribution system and at least one component. For example, the at least one component may be one or more battery packs or inverter motors. In some examples, the contactor assembly may be any of the multi-switch contactor assemblies described above in that the contactor assembly includes an array of two or more switches, each switch including a movable contact and a fixed contact. In a closed switch state, the movable contact is configured to contact a first end of the fixed contact. The movable contact and the fixed contact are oriented such that a current flowing between the movable contact and the fixed contact induces an electromagnetic field on the movable contact, acting in the direction of the first end of the fixed contact. The multi-switch contactor assembly further includes an actuator assembly configured to simultaneously actuate each of the movable contacts. The actuator assembly includes a shaft, and the switch state of each of the two or more switches is changed in response to rotation of the shaft. For example, two or more switches may be embodied by a switch assembly, such as multi-switch contactor assembly 800, located on the same actuator shaft. The contactor assembly may be, for example, multi-switch contactor assembly 120 (e.g., component contactor) of Figure 1, main contactor 906 of Figure 9, fast charge contactor 910 of Figure 9, auxiliary contactor 902, or multi-switch contactor assembly 1020 (e.g., component contactor) of Figure 10.

[0053] In some examples, the at least one fixed contact includes a second end substantially parallel to the first end and an intermediate portion substantially perpendicular to the first and second ends. The contact portion of the movable contact is oriented between the first and second ends of the at least one fixed contact. The contact portion of the movable contact is configured to contact an inner side of the first end opposite an inner side of the second end of the at least one fixed contact. When a large current flows through the fixed contact in contact with the movable contact, a Lorentz force acting on the movable contact repels the movable contact toward the fixed contact, thus increasing the contact force.

[0054] The method of FIG. 13 also includes step 1304 of rotating a shaft to change the switch state of each of two or more switches of the multi-switch contactor assembly, where certain combinations of switch states are mechanically prevented. Rotation of the camshaft to change switch states is described above. As the camshaft rotates, two or more cams rotate. In each switch, the cam engages a rocker attached to a movable contact and rotates the rocker, which moves the movable contact into or out of contact with a fixed contact, depending on the direction of rotation. The camshaft simultaneously rotates multiple cams, thereby changing the switch state of the switch.

[0055] From the foregoing, it will be appreciated that the above-described multi-switch contactor assembly and battery component contactor offer several advantages, including the ability to configure two battery packs in series and parallel (e.g., one for powering the electric vehicle and one for charging the electric vehicle), low contact resistance (e.g., less than 50 μΩ per switch), significant contact force providing high resistance to lift, reduced risk of battery shorting due to switching misalignment or mechanical shock, management of potential mismatch in the battery packs, active prevention of tack welding, low hold power required for active state, low switching noise, and increased contact force through utilization of Lorentz forces due to conductor shape and orientation. Additionally, a precharge relay is integrated into the multi-switch contactor assembly.

[0056] From the foregoing, it will be appreciated that the present disclosure describes one embodiment directed to a multi-switch contactor assembly including an array of two or more switches, each switch having a movable contact and a fixed contact, the movable contact configured to contact a first end of the fixed contact in a closed switch state, the movable contact and the fixed contact oriented such that current passing between the movable contact and the fixed contact induces an electromagnetic field on the movable contact acting toward the first end of the fixed contact. The multi-switch contactor assembly also includes an actuator assembly configured to simultaneously actuate each of the movable contacts, the actuator assembly including a shaft, and wherein the switch state of each of the two or more switches is changed in response to rotation of the shaft.

[0057] In some examples, the fixed contact is substantially C-shaped having an inner surface and an outer surface, and the movable contact is oriented to contact the inner surface of the fixed contact. In some examples, the fixed contact includes a second end substantially parallel to the first end and an intermediate portion substantially perpendicular to the first and second ends, and the contact portion of the movable contact is oriented between the first and second ends of the fixed contact, and the contact portion of the movable contact is configured to contact the inner surface of the first end opposite the inner surface of the second end of the fixed contact. In some examples, the fixed contact is substantially S-shaped, and the movable contact is oriented to contact the inner surface of a first protrusion of the fixed contact.

[0058] In some examples, the contact portion of the movable contact is coupled to a rocker of the actuator assembly, and the rocker rotates in response to a cam of the actuator assembly to move the contact portion relative to the first end of the fixed contact. In some examples, the movable contact is deformable, and the contact portion of the movable contact is moved by bending the movable contact, and the rocker bends the movable contact as it rotates.

[0059] In some examples, passing a current through the movable contact and the fixed contact generates a Lorentz force that increases the contact force between the movable contact and the fixed contact. In some examples, the actuator assembly includes two or more cams rotatable by rotation of the shaft, and the two or more cams are configured to respectively activate two or more switches based on the rotation of the shaft. In some embodiments, each of the two or more cams includes an actuating member, and the actuating members of at least two of the cams are not geometrically aligned along the direction of the shaft.

[0060] In some variations, the multi-switch contactor assembly includes a first switch configured to connect a first battery device to the circuit, a second switch configured to connect a second battery device to the circuit, and a third switch configured to connect the first battery device and the second battery device in series in the circuit. In some embodiments, the two or more switches include a fourth switch configured to connect a pre-charge relay to at least one of the first battery device and the second battery device, and the first switch, second switch, third switch, and fourth switch are actuated by respective cams attached to the shaft. In some examples, the pre-charge relay is connectable in series between the first battery device and the second battery device via the fourth switch.

[0061] In some variations, each switch further comprises a second fixed contact, and the movable contact is configured to contact the second fixed contact in different closed switch states.

[0062] Another embodiment is directed to a system for a multi-switch contactor assembly. The system includes one or more components, a vehicle power distribution circuit, and a multi-switch contactor assembly connecting the one or more components to the vehicle power distribution circuit. The multi-switch contactor assembly includes an array of two or more switches, each switch having a movable contact and a fixed contact, the movable contact configured to contact a first end of the fixed contact in a closed switch state, the movable contact and the fixed contact oriented such that a current passing between the movable contact and the fixed contact induces an electromagnetic field on the movable contact acting in a direction toward the first end of the fixed contact. The multi-switch contactor assembly also includes an actuator assembly configured to simultaneously actuate each of the movable contacts, the actuator assembly including a shaft, and the switch state of each of the two or more switches is changed in response to rotation of the shaft.

[0063] In some examples, the one or more components include a first battery device and a second battery device. In some examples, the one or more components are an inverter. In some examples, the one or more components are a fast charge connector. In some examples, the one or more components are an auxiliary connector.

[0064] In some examples, the one or more components include a first battery device and a second battery device, and the two or more switches include a first switch configured to connect the first battery device to the vehicle power distribution circuit, a second switch configured to connect the second battery device to the vehicle power distribution circuit, and a third switch configured to connect the first battery device and the second battery device in series to the vehicle power distribution circuit.

[0065] In some examples, the two or more switches include a fourth switch configured to connect a pre-charge relay to at least one of the first battery device and the second battery device, the first switch, the second switch, the third switch, and the fourth switch being actuated by respective cams attached to the shaft. In some examples, the pre-charge relay is connectable in series between the first battery device and the second battery device via the fourth switch, and the pre-charge relay pre-charges the vehicle power distribution circuit.

[0066] In some examples, the system further comprises a position sensor configured to detect rotation of the shaft, and a signal output by the position sensor is provided to one or more controllers for controlling rotation of the shaft and indicating a state of the switch.

[0067] Another embodiment is directed to a method for a multi-switch contactor assembly. The method includes connecting the multi-switch contactor assembly to an electrical power distribution system and at least one component. The multi-switch contactor assembly includes an array of two or more switches, each switch having a movable contact and a fixed contact, the movable contact configured to contact a first end of the fixed contact in a closed switch state, the movable contact and the fixed contact oriented such that a current passing between the movable contact and the fixed contact induces an electromagnetic field on the movable contact acting in the direction of the first end of the fixed contact. The multi-switch contactor assembly also includes an actuator assembly configured to simultaneously actuate each of the movable contacts, the actuator assembly including a shaft, wherein the switch state of each of the two or more switches is changed in response to rotation of the shaft. The method also includes rotating the shaft to change the switch state of each of the two or more switches of the multi-switch contactor assembly.

[0068] It will be understood from the foregoing description that modifications and changes can be made in various embodiments of the present disclosure without departing from the true spirit thereof. The description herein is for purposes of illustration only and is not to be construed in a limiting sense. The scope of the present disclosure is limited only by the language of the appended claims. [Explanation of symbols]

[0069] 110, 112, 114, 1010, 1012, 1014, 1016 switches 120, 400, 700, 800 Multi-Switch Contactor Assembly 202, 204, 410 fixed contacts 206, 408 Movable contact 212, 301, 311, 321, 402, 403, 404, 701, 801 Cam 214, 302, 405, 870, 1206 axes 308, 318, 328, 412, 708, 808 Lockers 1018, 1203 Pre-charging relay

Claims

1. an array of two or more switches and an actuator assembly; the array of two or more switches, each switch having a movable contact and a fixed contact, configured such that in a closed switch state, the movable contact contacts a first end of the fixed contact, and the movable contact and the fixed contact are oriented such that a current passing between the movable contact and the fixed contact induces an electromagnetic field on the movable contact acting in a direction toward the first end of the fixed contact; 1. A multi-switch contactor assembly, wherein the actuator assembly is configured to simultaneously actuate each of the movable contacts, the actuator assembly including a shaft, and wherein the switch state of each of the two or more switches is changed in response to rotation of the shaft.

2. 2. The multi-switch contactor assembly of claim 1, wherein the fixed contact is substantially C-shaped having an inner surface and an outer surface, and the movable contact is oriented to contact the inner surface of the fixed contact.

3. 3. The multi-switch contactor assembly of claim 2, wherein the fixed contact includes a second end substantially parallel to the first end and an intermediate portion substantially perpendicular to the first end and the second end, a contact portion of the movable contact oriented between the first end and the second end of the fixed contact, and the contact portion of the movable contact configured to contact an inner surface of the first end opposite an inner surface of the second end of the fixed contact.

4. 2. The multi-switch contactor assembly of claim 1, wherein a contact portion of the movable contact is coupled to a rocker of the actuator assembly, the rocker rotating in response to a cam of the actuator assembly to move the contact portion relative to the first end of the fixed contact.

5. 5. The multi-switch contactor assembly of claim 4, wherein the movable contact is deformable, the contact portion of the movable contact is moved by bending the movable contact, and the rocker bends the movable contact as the rocker rotates.

6. 2. The multi-switch contactor assembly of claim 1, wherein the fixed contact is substantially S-shaped and the movable contact is oriented to contact an inner surface of a first protrusion of the fixed contact.

7. 10. The multi-switch contactor assembly of claim 1, wherein passing a current through the movable contact and the fixed contact creates a Lorentz force that increases the contact force between the movable contact and the fixed contact.

8. 2. The multi-switch contactor assembly of claim 1, wherein the actuator assembly includes two or more cams rotatable by rotation of the shaft, the two or more cams configured to respectively actuate the two or more switches based on rotation of the shaft.

9. The multi-switch contactor assembly of claim 8 , wherein each of the two or more cams includes an actuating member, and the actuating members of at least two cams are misaligned along the axis.

10. The two or more switches a first switch configured to connect the first battery device to the circuit; a second switch configured to connect a second battery device to the circuit; 10. The multi-switch contactor assembly of claim 1, further comprising: a third switch configured to connect the first battery device and the second battery device in series in the circuit.

11. the two or more switches further include a fourth switch configured to connect a pre-charge relay to at least one of the first battery device and the second battery device; The multi-switch contactor assembly of claim 10 , wherein the first switch, the second switch, the third switch, and the fourth switch are actuated by respective cams mounted on the shaft.

12. The multi-switch contactor assembly of claim 11 , wherein the pre-charge relay is connectable in series between the first battery device and the second battery device via the fourth switch.

13. 10. The multi-switch contactor assembly of claim 1, wherein each switch further comprises a second fixed contact, the movable contact configured to contact the second fixed contact in different closed switch states.

14. 1. A system for a multi-switch contactor assembly, comprising: one or more components; a vehicle power distribution circuit; a multi-switch contactor assembly connecting the one or more components with the vehicle electrical distribution circuit; The multi-switch contactor assembly comprises: an array of two or more switches, each switch having a movable contact and a fixed contact, wherein in a closed switch state, the movable contact is configured to contact a first end of the fixed contact, and the movable contact and the fixed contact are oriented such that a current passing between the movable contact and the fixed contact induces an electromagnetic field on the movable contact acting in a direction toward the first end of the fixed contact; an actuator assembly configured to simultaneously actuate each of the movable contacts, the actuator assembly including a shaft, wherein a switch state of each of the two or more switches is changed in response to rotation of the shaft.

15. The system of claim 14 , wherein the one or more components include at least one of a battery unit, an inverter, a fast charge connector, and an auxiliary connector.

16. the one or more components include a first battery device and a second battery device; The two or more switches a first switch configured to connect the first battery device to the vehicle power distribution circuit; a second switch configured to connect the second battery device to the vehicle power distribution circuit; a third switch configured to connect the first battery device and the second battery device in series to the vehicle power distribution circuit; The system of claim 14 , comprising:

17. the two or more switches further include a fourth switch configured to connect a pre-charge relay to at least one of the first battery device and the second battery device; 17. The system of claim 16, wherein the first switch, the second switch, the third switch, and the fourth switch are actuated by respective cams mounted on the shaft.

18. 18. The system of claim 17, wherein the pre-charge relay is connectable in series between the first battery device and the second battery device via the fourth switch, and the pre-charge relay pre-charges the vehicle power distribution circuit.

19. 15. The system of claim 14, further comprising a position sensor configured to detect rotation of the shaft, wherein a signal output by the position sensor is provided to one or more controllers for controlling rotation of the shaft and indicating a state of the switch.

20. 1. A method for a multi-switch contactor assembly, comprising: connecting the multi-switch contactor assembly to an electrical power distribution system and at least one component; and changing a switch state of each of two or more switches of the multi-switch contactor assembly; the multi-switch contactor assembly an array of two or more switches, each switch having a movable contact and a fixed contact, wherein in a closed switch state, the movable contact is configured to contact a first end of the fixed contact, and the movable contact and the fixed contact are oriented such that a current passing between the movable contact and the fixed contact induces an electromagnetic field on the movable contact acting in a direction toward the first end of the fixed contact; an actuator assembly configured to simultaneously actuate each of the movable contacts, the actuator assembly including a shaft; The method of claim 1, wherein the step of changing the switch state of each of two or more switches of the multi-switch contactor assembly comprises rotating the shaft.

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