Relay module and relay control system

Abstract

The present disclosure provides a relay module and a relay control system, the relay module comprising a case (1), two relay core mechanisms (2), one current transformer (3), two power terminals (5), and two load terminals (6), the two relay core mechanisms (2) are provided within the case (1), the two power terminals (5) and the two load terminals (6) are fixed to the case (1), the relay core mechanism (2) comprises a magnetic circuit portion (21) and a contact assembly (22), the two power terminals (5) are connected to the two load terminals (6) via the contact assemblies (22) of the two relay core mechanisms (2), respectively, to form two on-off control paths, the two on-off control paths are configured to form one circuit with the loads connected to the two load terminals (6), and the current transformer (3) is attached to one on-off control path.

Description

[Technical Field]

[0001] [Cross-Citation of Related Applications] This disclosure claims priority to a Chinese patent application bearing application number 202211422321.1 and entitled "Relay Module and Relay Control System," filed on November 14, 2022, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure relates to the field of relay technology, and more particularly to a relay module and a relay control system. [Background technology]

[0003] A relay is an electrical control element that has an interaction relationship between the control system (also called the input circuit) and the controlled system (also called the output circuit). In reality, it is an "automatic switch" that controls the operation of large currents with small currents, and in the circuit, it plays the role of automatic adjustment, safety protection, conversion circuit, etc.

[0004] When customers apply it to electric vehicle charging guns or charging stations, etc., a relay switch is only installed on the live line, and not on the zero line, resulting in problems such as the switch sticking and not being able to be turned off, low reliability, and low safety. It is also necessary to assemble it strictly according to the zero line and live line; if the zero line and live line are connected in reverse, the live line will be energized, posing a risk of electric shock. Furthermore, an electric quantity detection function is required, and a current transformer must also be installed. In the prior art, the relay and current transformer are separate, independent elements connected via a PCB board or wires, resulting in complex structures, low integration, disadvantages for miniaturization, inconvenience for customers in installation, and inconvenience for automation. Summary of the Invention

[0005] An object of the present disclosure is to provide a relay module to solve the above technical problems.

[0006] To achieve the above object, the technical solution adopted by the present disclosure provides a relay module comprising a case, two relay core mechanisms, one current transformer, two power terminals and two load terminals, wherein the two relay core mechanisms are arranged in the case, and the two power terminals and two load terminals are fixed to the case, the relay core mechanism comprises a magnetic circuit portion and a contact assembly, the two power terminals are respectively connected to the two load terminals via the contact assemblies of the two relay core mechanisms to form two on-off control paths, and the two on-off control paths are configured to form one circuit with the load connected to the two load terminals, and the current transformer is attached to one on-off control path.

[0007] In some embodiments, the relay module comprises: Leakage detection device Furthermore, Leakage detection device is attached to two on-off control passages.

[0008] In some embodiments, the current transformer and Leakage detection device are both provided outside the case, the case has a first side wall 112 and a second side wall 113 provided opposite to each other, the two power supply terminals and the two load terminals extend outside the first side wall 112 and outside the second side wall 113 of the case, respectively; Leakage detection device is fixed to the outside of the first side wall 112, and the two power terminals are Leakage detection device and / or the current transformer is fixed to the outside of the second side wall, and one of the load terminals extends after passing through the cavity of the current transformer.

[0009] In some embodiments, the contact assembly comprises a fixed spring reed, a fixed contact fixed to the fixed spring reed, a movable spring reed, a movable spring reed and a movable contact, one end of the movable spring reed is fixed to the movable spring reed and the movable contact is fixed to the other end of the movable spring, the movable contact and the fixed contact are brought into contact or separated by operation of a magnetic circuit portion, and the two power supply terminals and the two load terminals are respectively formed by portions of the movable spring reed and the fixed spring reed of the two contact assemblies extending from the case.

[0010] In some embodiments, the case and Leakage detection device a first insertion structure is provided between the Leakage detection device is inserted and fixed to the outside of the first side wall of the case via a first insertion structure, and / or a second insertion structure is provided between the second side wall of the case and the current transformer, and the current transformer is inserted and fixed to the outside of the second side wall of the case via the second insertion structure.

[0011] In some embodiments, the relay modules each have two power terminals. Leakage detection device The power supply terminal further includes two first connectors connected to outer ends extending from the cavity of the power supply terminal, the first connectors being configured to be connected to power lines, and the two power supply terminals are both made of rigid conductors. The two first connectors are connected perpendicularly to the two power supply terminals and extend toward two different outer sides, respectively. The first connectors are fixed to the power supply terminals by crimping, and the outer ends of the power supply terminals are provided with first locking blocks extending toward the first connectors, and the first connectors are provided with first locking openings. and the first locking block is locked in the first locking port, and / or the relay module further comprises one second connector connected to an outer end extending from the cavity of the current transformer of the load terminal, the second connector being configured to be connected to the load, the second connector being crimped to the load terminal, the outer end of the load terminal being provided with a second locking block extending towards the second connector, the second connector being provided with a second locking port, and the second locking block being locked in the second locking port.

[0012] In some embodiments, the Leakage detection device The inner end surface of the current transformer is spaced apart from the first side wall of the case, and / or the inner end surface of the current transformer is spaced apart from the second side wall of the case.

[0013] In some embodiments, the Leakage detection deviceThe inner end surface of the current transformer and the first side wall of the case are spaced apart via a first position limiting block, and / or the inner end surface of the current transformer and the second side wall of the case are spaced apart via a second position limiting block.

[0014] In some embodiments, the case is provided with two sets of coil lead-out pins, and the two sets of coil lead-out pins are electrically connected to coils in the magnetic circuit portions of the two relay core mechanisms, respectively, the two relay core mechanisms are provided in parallel, and the contact assemblies of the two relay core mechanisms are provided opposite each other.

[0015] In some embodiments, two auxiliary contact assemblies are further provided within the case, and the two auxiliary contact assemblies are respectively coupled to the magnetic circuit portions of the two relay core mechanisms so that the magnetic circuit portions of the relay core mechanisms drive the on / off of the auxiliary contact assemblies.

[0016] In some embodiments, the auxiliary contact assembly includes an auxiliary movable spring member and an auxiliary fixed spring member, the auxiliary movable spring member having a protrusion that faces the armature, and when the armature is not adsorbed, the armature abuts the protrusion to bring the auxiliary movable spring member and the auxiliary fixed spring member into contact with each other and drive them to turn on, and when the armature is adsorbed, there is a gap between the armature and the protrusion that disconnects the auxiliary movable spring member and the auxiliary fixed spring member.

[0017] In some embodiments, the protrusions are made of an insulating material.

[0018] In some embodiments, the case is further provided with two first power output pins, which are electrically connected to two power terminals, respectively; and / or the case is further provided with two second power output pins, which are electrically connected to two load terminals, respectively.

[0019] The present disclosure further provides a relay control system, including the above relay module and a control unit, wherein a control output terminal of the control unit is connected to the coil of the magnetic circuit portion of the relay core mechanism, and a control input terminal of the control unit is connected to the output terminal of the auxiliary contact assembly.

[0020] The present disclosure further provides another relay control system, which includes the above-mentioned relay module, an AC / DC conversion circuit, and a control unit, wherein the two power supply terminals of the relay module are respectively connected to the live line and the zero line of the power supply, the two load terminals are connected to the load, the two first power supply output pins are connected to the input terminal of the AC / DC conversion circuit, the output terminal of the AC / DC conversion circuit is connected to the control unit, and the control output terminal of the control unit is connected to the magnetic circuit part of the relay core mechanism.

[0021] In some embodiments, the first power output pin is formed from either the movable spring reed or the fixed spring reed of the contact assembly and extends from the bottom of the housing.

[0022] The embodiments of the present disclosure have the following beneficial technical effects.

[0023] The relay module according to the embodiment of the present disclosure is provided with two relay core mechanisms, which can simultaneously disconnect the lines at both ends of the load circuit, have good disconnection capability, high reliability, and ensure safety performance. In addition, there is no need to distinguish between the two power terminals during use, making it easier and safer to use. At the same time, a current transformer is integrated, which increases the integration level of the entire relay module, which is advantageous for miniaturization, making it convenient for customers to implement and use, and achieving a high degree of automation. [Brief explanation of the drawings]

[0024] In order to more clearly explain the technical solutions in the embodiments of the present disclosure, the following will briefly describe the drawings that need to be used in the description of the embodiments. Obviously, the drawings in the following description are only some embodiments of the present disclosure, and those skilled in the art can also obtain other drawings based on these drawings without any creative work. [Figure 1] FIG. 1 is a configuration diagram of a relay module according to a specific embodiment of the present disclosure. [Figure 2] FIG. 10 is a structural diagram of a relay module according to a specific embodiment of the present disclosure from another perspective. [Figure 3] FIG. 10 is a structural diagram of a relay module according to a specific embodiment of the present disclosure from another perspective. [Figure 4] FIG. 10 is a structural diagram of a relay module according to a specific embodiment of the present disclosure from another perspective. [Figure 5] FIG. 2 is a partial exploded view of a relay module according to an exemplary embodiment of the present disclosure. [Figure 6] FIG. 10 is a partially exploded view of a relay module according to an exemplary embodiment of the present disclosure from another perspective. [Figure 7] 1 is a structural diagram of a relay module according to a specific embodiment of the present disclosure, with the upper case omitted; [Figure 8] FIG. 2 is a partial exploded view of a relay module according to a specific embodiment of the present disclosure, omitting the upper case. [Figure 9] 1 is a structural diagram of a relay module according to a specific embodiment of the present disclosure, omitting the upper case, current transformer, and leakage current detection device. [Figure 10] FIG. 10 is an exploded view of an auxiliary contact assembly of a relay module according to an exemplary embodiment of the present disclosure. [Figure 11] FIG. 10 is an exploded view of an auxiliary contact assembly of a relay module according to an exemplary embodiment of the present disclosure from another perspective. [Figure 12] FIG. 10 is an exploded view of an auxiliary contact assembly of a relay module according to an exemplary embodiment of the present disclosure from another perspective. [Figure 13] FIG. 10 is a cross-sectional view taken along the line AA in FIG. 9. [Figure 14] FIG. 2 is a circuit diagram of a relay control system according to a specific embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0025] To further explain each embodiment, the present disclosure provides drawings. These drawings are part of the disclosure content of the present disclosure and are mainly for explaining the embodiments, and can explain the operating principles of the embodiments in conjunction with the related description in the specification. By referring to these contents, those skilled in the art should be able to understand other possible embodiments and the advantages of the present disclosure. The components in the drawings are not drawn to scale, and similar component reference numerals are generally used to indicate similar components.

[0026] The present disclosure will now be further described with reference to the drawings and specific embodiments.

[0027] As shown in Figures 1 to 13, the relay module includes a case 1, two relay core mechanisms 2, a current transformer 3, and a Leakage detection device The two relay core mechanisms 2 are provided within the case 1, and the two power terminals 5 and the two load terminals 6 are both drawn out to the outside of the case 1, facilitating the connection of the power line and the load. Naturally, in some embodiments, the two power terminals 5 and the two load terminals 6 can be buried within the case 1 and connected by drilling connection holes.

[0028] The two power supply terminals 5 are configured to connect the live line and the zero line of the AC power supply, and the two load terminals 6 are configured to connect the live line end and the zero line end of the power supply end of the load. Of course, in some embodiments, the two power supply terminals 5 may be connected to the positive output end and the negative output end of the DC power supply. Leakage detection device 4 doesn't work.

[0029] In this embodiment, the case 1 includes an upper case 11 and a base 12. The upper housing 11 is covered by the base 12. The two relay core mechanisms 2 are both attached to the base 12 and covered by the upper case 11. This structure of the case 1 facilitates product assembly and maintenance. The upper case 11 and the base 12 may be fixedly connected by means of engagement, welding, adhesive bonding, screw fastening, or other fixing methods.

[0030] The upper case 11 and the base 12 are made of plastic and can be formed by injection molding, which makes them easy to process, low cost, has good insulating properties, and is lightweight, but is not limited to this. In some embodiments, the upper case 11 and the base 12 may be made of other insulating materials, such as ceramic.

[0031] In some embodiments, the case 1 has an approximately rectangular parallelepiped structure, and the thickness direction of the case 1 is aligned with the vertical direction, making the overall structure more compact and advantageous for miniaturization. Of course, in some embodiments, the case 1 may have other shaped structures such as a cube or a cylinder.

[0032] 1 , mounting holes 111 are further provided on the outer surface of the upper case 11, which facilitates mounting and fixing the relay module. Specifically, there are two mounting holes 111, which are provided on two opposing outer surfaces of the upper case 11 that are parallel to the length direction of the upper case 11 and are diagonally arranged, thereby improving stability after mounting the relay module. Of course, in some embodiments, the number of mounting holes 111 may be one, three, or more than three, and the mounting holes 111 may be provided on the outer wall of the base 12.

[0033] As shown in FIG. 7 , the relay core mechanism 2 includes a magnetic circuit portion 21 and a contact assembly 22. The two power terminals 5 are connected to the two load terminals 6 via the contact assemblies 22 of the two relay core mechanisms 2, respectively, to form two on / off control paths. The two on / off control paths are configured to form a single circuit with the loads connected to the two load terminals 6, thereby simultaneously disconnecting the lines on both ends of the load circuit (for example, the live line and the zero line in an AC power supply). This provides good disconnection capability and ensures circuit disconnection even if one contact is stuck, resulting in high reliability and guaranteed safety performance. Furthermore, there is no need to distinguish between the two power terminals during use. Regardless of whether the two power terminals are connected in forward or reverse direction, the contact assembly 22 simultaneously controls the on / off state of both the live line and the zero line, making it easier to use. Furthermore, by providing two relay core mechanisms 2 and driving two contact assemblies 22 with two magnetic circuit parts 21, respectively, the impact resistance is better than that of a double-pole double-throw (DPDT) structure in which two contact assemblies are driven simultaneously by one magnetic circuit part, but the DPDT structure in which two contact assemblies are driven simultaneously by one magnetic circuit part requires a push latch, and the push latch is attached to a movable spring, which results in poor impact resistance when used in a mobile environment, such as a charging gun for an electric vehicle.

[0034] Further referring to FIG. 7, the current transformer 3 may be installed in an on-off control path to realize functions such as current detection, electrical quantity detection, etc. In this specific embodiment, the current transformer 3 is a measuring current transformer for electrical quantity detection. Of course, in some embodiments, the current transformer 3 may also be a protective current transformer, configured to perform overload protection, short circuit protection, etc.

[0035] Specifically, in this embodiment, the current transformer 3 is a through-type current transformer, sleeved with one on-off control passage, which has a simple structure and is easy to assemble, but is not limited thereto. In some embodiments, the current transformer 3 may be realized using current transformers of other structures in the related art, such as a switch-type current transformer, a wire-type current transformer, etc.

[0036] Further referring to Figure 7, Leakage detection device 4 is installed in two on-off control passages to realize the earth leakage detection function. Leakage detection device 4 is through-type Leakage detection device and sleeved into two on / off control passages, the structure is simple and easy to assemble, but not limited thereto, in some embodiments: Leakage detection device 4 is a wired type Leakage detection device may be realized using

[0037] The current transformer 3, the leakage detector 4 and the two relay core mechanisms 2 are integrated into one relay module, which is highly integrated, convenient for customers to install and use, and has a high degree of automation.

[0038] In this embodiment, the current transformer 3 and Leakage detection device 4 are provided outside the case 1, which not only reduces the volume of the case 1 but also contributes to miniaturization of the relay module and heat dissipation, and also allows the current transformer 3 and Leakage detection device Of course, in some embodiments, the current transformer 3 and Leakage detection device 4 may be provided inside the case 1.

[0039] As shown in FIG. 7, in this embodiment, both of the two power connection terminals 5 are Leakage detection device 4 and then extends through the cavity, i.e. Leakage detection device 4 is sleeved outside the two power terminals 5, so that the leakage detection is more comprehensive, not only can detect the leakage situation of the load circuit, but also can detect the leakage situation of other power supply circuits drawn by the relay module. Of course, in some embodiments, Leakage detection device4 may be sleeved outside the two load terminals 6 to detect only the earth leakage condition in the load circuit.

[0040] As shown in Figure 7, one load terminal 6 extends after penetrating the cavity of the current transformer 3, that is, the current transformer 3 is sleeved outside one load terminal 6, and the other load terminal 6 is located on the outer surface of the current transformer 3, and the current transformer 3 is configured to detect the amount of electricity in the load circuit, for example, if the load is a battery, it can detect the amount of electricity charged and perform corresponding billing. Of course, in some embodiments, the current transformer 3 may be sleeved outside one power terminal 5 to detect the total amount of power that has passed through the relay module. The current transformer 3 and Leakage detection device 4 are attached to the power supply terminal 5 and the load terminal 6, respectively, the structure is simpler, assembly is easier, and the current transformer 3 and Leakage detection device 4 can be separated to improve heat dissipation performance and reliability.

[0041] As shown in FIG. 5, the current transformer 3 and Leakage detection device The pins 4 are all installed downwards and perpendicular to the load terminal 6 and the power terminal 5, ensuring an air gap, and the structure is more compact, making it easier to connect and use.

[0042] In this embodiment, the two power supply terminals 5 and the two load terminals 6 are both made of hard conductors (rigid conductors), Leakage detection device There is no need to use a soft wire to penetrate the cavity of the current transformer 3 and the cavity of the current transformer 4, which is convenient for customer installation and automation.

[0043] Specifically, in this embodiment, the two power terminals 5 and the two load terminals 6 are both made of copper bus bars, which have good conductivity, are easy to manufacture, and are low cost; of course, in some embodiments, the two power terminals 5 and the two load terminals 6 may also be made of other hard conductors, such as nickel bus bars.

[0044] As shown in FIGS. 6 and 7, the relay module has two power terminals 5. Leakage detection device The power supply terminal 5 further includes two first connectors 51 connected to the outer ends extending from the cavities of the power supply terminals 4, and the first connectors 51 are configured to be connected to power lines. Specifically, as shown in FIG. 6, the first connectors 51 are provided with connection holes 511 for connecting the power lines. Leakage detection device Since the cross-sectional dimensions of the two power terminals 5 are generally small, it is inconvenient to connect the power lines in this way. Therefore, by providing the first connector 51, Leakage detection device 4 is sleeved onto the two power terminals 5, and then the first connector 51 is fixed to the outer end of the power terminal 5, so that the size of the first connector 51 can be made larger, which is convenient for connecting the power line, and the two power terminals 5 Leakage detection device No impact on penetrating cavity 4.

[0045] In some embodiments, as shown in FIGS. 3 and 7, the two first connectors 51 are connected to the two power terminals 5 approximately perpendicularly, respectively, and extend outward in two different directions. In this way, the distance between the two connection holes 511 can be increased, and sufficient space can be secured for the connection of the two power lines, making the connection easier. Leakage detection device This solves the problem that the wire needs to be located close to penetrate the cavity 4, which makes wiring inconvenient.

[0046] The first connector 51 is fixed to the outer end of the power terminal 5 by crimping, which simplifies assembly and facilitates automation. Of course, in some embodiments, the first connector 51 may be fixed to the outer end of the power terminal 5 by other fixing methods, such as welding or screwing. Specifically, in this embodiment, as shown in FIG. 6 , the first connector 51 has an L-shaped structure and includes a first connecting portion 512 and a first mounting portion 513, the connecting hole 511 is provided in the first connecting portion 512, the first connecting portion 512 is approximately perpendicular to the power terminal 5 and extends outward, and the first mounting portion 513 is fixed to the outer end of the power terminal 5 by crimping, but is not limited thereto.

[0047] Furthermore, as shown in FIG. 6, a first locking block 52 extending toward a first mounting portion 513 is provided at the outer end of the power terminal 5, and a first locking opening 5131 is provided in the first mounting portion 513. The first locking block 52 is locked into the first locking opening 5131, thereby making the connection between the first connector 51 and the power terminal 5 more stable, and avoiding the problem of the first connector 51 easily becoming loose or coming off due to the large force it receives for wiring purposes, and also functions to position it in advance when crimping, making crimping more convenient.

[0048] In this embodiment, the number of first locking blocks 52 is two, and the two first locking blocks 52 are respectively arranged on adjacent two sides of the power terminal 5. Accordingly, the number of first locking openings 5131 is also two, and the two first locking openings 5131 are arranged on adjacent two sides of the first mounting portion 513, thereby making the relationship between the first connector 51 and the power terminal 5 more stable. However, this is not limited to this, and in some embodiments, the number of first locking blocks 52 and first locking openings 5131 may be one or more than two, and the positions of the first locking blocks 52 and first locking openings 5131 may also be selected according to actual conditions.

[0049] 6 , a second connector 61 for connecting to a load is further connected to the outer end of the load terminal 6 extending from the cavity of the current transformer 3. Specifically, the second connector 61 is provided with a connection hole 611 for easily connecting a load. The load terminal 6 needs to pass through the cavity of the current transformer 3, and the cross-sectional size of the load terminal 6 is generally small, making connection inconvenient. Therefore, by installing the second connector 61, during assembly, the current transformer 3 is sleeved onto the load terminal 6 and then the second connector 61 is fixed to the outer end of the load terminal 6. This allows the second connector 61 to be manufactured with a larger size, making it easier to connect a load and not affecting the passage of the load terminal 6 through the cavity of the current transformer 3.

[0050] The second connector 61 is fixed to the outer end of the load terminal 6 by crimping, which simplifies assembly and facilitates automation. Of course, in some embodiments, the second connector 61 may be fixed to the outer end of the load terminal 6 by other fixing methods, such as welding or screwing. Specifically, in this embodiment, the second connector 61 has an L-shaped structure and includes a second connecting portion 612 and a second mounting portion 613, the connecting hole 611 is provided in the second connecting portion 612, the second connecting portion 612 is approximately perpendicular to the load terminal 6 and extends outward, and the second mounting portion 613 is fixed to the outer end of the load terminal 6 by crimping, but is not limited thereto.

[0051] Furthermore, a second locking block 62 extending toward the second mounting portion 613 is provided at the outer end of the load terminal 6, and a second locking opening 6131 is provided in the second mounting portion 613. The second locking block 62 is locked into the second locking opening 6131, thereby making the connection between the second connector 61 and the load terminal 6 more stable and avoiding the problem of the second connector 61 easily loosening or coming off due to being subjected to a large amount of force for wiring, and also functions to position the second connector 61 in advance when crimping, making crimping more convenient.

[0052] In this embodiment, the number of second locking blocks 62 is two, and the two second locking blocks 62 are respectively arranged on adjacent two sides of the load terminal 6. Accordingly, the number of second locking holes 6131 is also two, and the two second locking holes 6131 are arranged on adjacent two sides of the second mounting portion 613, thereby making the relationship between the second connector 61 and the load terminal 6 more stable. However, this is not limited to this, and in some embodiments, the number of second locking blocks 62 and second locking holes 6131 may be one or more than two, and the positions of the second locking blocks 62 and second locking holes 6131 may also be selected according to actual conditions.

[0053] Since the other load terminal 6 does not need to penetrate the cavity of the current transformer 3, there is no problem that the second connector 61 is too large to penetrate the cavity of the current transformer 3, and therefore the second connector 61 is integrally formed at the outer end of the other load terminal 6, which reduces the number of parts and makes assembly easier.

[0054] In some embodiments, both the wire connection holes 511 and the wire connection holes 611 are bolt holes, thereby facilitating a bolted connection, but this is not limiting.

[0055] In some embodiments, the two power terminals 5 and the two load terminals 6 are respectively led out to the outside of the first side wall 112 and the outside of the second side wall 113 opposite to each other of the case 1; Leakage detection device The current transformer 4 and the current transformer 3 are respectively provided outside the first side wall 112 and the second side wall 113 of the case 1, which not only makes the overall structure more compact and rational, but also favors miniaturization, makes assembly more convenient, and makes use more convenient. Leakage detection device This improves the heat dissipation performance and reliability of the current transformer 3 and the power supply terminals 5. However, without being limited thereto, in some embodiments, the two power supply terminals 5 and the two load terminals 6 may be disposed at other positions on the case 1, for example, on the outsides of adjacent side walls of the case 1, and the specific positions may be selected according to the actual usage situation.

[0056] The first side wall 112 of the case 1 and Leakage detection device a first insertion structure is provided between the first and second electrodes; Leakage detection device 4 is inserted and fixed to the outside of the first side wall 112 of the case 1 via the first insertion structure, so that Leakage detection device 6, two elongated first mounting members 1-1 extending outward are provided on the outside of the first side wall 112 of the base 12, the two first mounting members 1-1 are installed side by side with a gap between them, and elongated bosses 1-11 extending along the length of each of the two first mounting members 1-1 are provided on the opposing inner surfaces of the two first mounting members 1-1, Leakage detection deviceThe first engagement grooves 41 are provided on the opposing outer surfaces of the bosses 1-4, and the two elongated bosses 1-11 are inserted into and engaged with the two first engagement grooves 41, respectively. Leakage detection device 4 is fixed between the two first mounting members 1-1 and fixedly attached to the outside of the first side wall 112 of the case 1, adopting this first insertion structure, which is convenient for installation and removal. Of course, in some embodiments, the first insertion structure may be realized by other insertion structures, for example, an insertion post is provided on the first side wall 112 of the case 1, Leakage detection device 4 has an insertion hole, and the insertion post is inserted into the insertion hole with a tight fit to form an insertion structure. Leakage detection device 4 may be fixedly attached to the exterior of the first side wall 112 of the case 1 using other conventional fastening structures, such as snap-fit, adhesive, screw fastening, and the like.

[0057] Furthermore, as shown in FIG. 9, first position limiting blocks 1-12 are provided at the ends of the inner surfaces of the two first mounting members 1-1 that are connected to the first side wall 112 of the case 1, Leakage detection device The inner end surface 401 of the fourth block 4 abuts against the first position limiting block 1-12 and is spaced apart from the first side wall 112 of the case 1, so that Leakage detection device 4 and the case 1 to improve the heat dissipation effect.

[0058] A second insertion structure is provided between the second side wall 113 of the case 1 and the current transformer 3, and the current transformer 3 is inserted and fixed to the outside of the second side wall 113 of the case 1 via the second insertion structure, thereby making it easy to attach and detach the current transformer 3. Specifically, as shown in FIG. 9, two elongated second mounting members 1-2 extending outward are provided on the outside of the second side wall 113 of the base 12, and the two second mounting members 1-2 are installed side by side with a gap between them. The opposing inner surfaces of the two second mounting members 1-2 are each provided with an elongated boss 1-21 extending along its length. As shown in FIG. 5, second engaging grooves 31 are provided on the opposing outer surfaces of the current transformer 3, and the two elongated bosses 1-21 are inserted and engaged into the two second engaging grooves 31, respectively, so that the current transformer 3 is fixed between the two second mounting members 1-2 and fixed and attached to the outside of the second side wall 113 of the case 1. This second insertion structure makes it easy to attach and detach. Of course, in some embodiments, the second insertion structure may be realized by other insertion structures, for example, an insertion post is provided on the second side wall 113 of the case 1, an insertion hole is provided in the current transformer 3, and the insertion post is inserted into the insertion hole with an interference fit to form an insertion structure. Alternatively, the current transformer 3 may be fixed and attached to the outside of the second side wall 113 of the case 1 using other conventional fixing structures, such as snap fitting, adhesive, screw fastening, etc.

[0059] Furthermore, a second position limiting block 1-22 is provided at the end of the inner surface of the two second mounting members 1-2 that connects to the second side wall 113 of the case 1, and the inner end surface 301 of the current transformer 3 abuts against the second position limiting block 1-22 and is spaced apart from the second side wall 113 of the case 1, thereby improving the heat dissipation effect between the current transformer 3 and the case 1.

[0060] In a specific embodiment, as shown in FIG. 7, the magnetic circuit portion 21 includes a coil 211, a coil frame 212, a yoke 213, an armature 214, and a push latch 215, and the contact assembly 22 is a normally open contact assembly, including a fixed spring reed 221, a fixed contact 222 fixed to the fixed spring reed 221, a movable spring reed 223, a movable spring 224, and a movable contact 225, with one end of the movable spring 224 fixed to the movable spring reed 223 and the movable contact 225 fixed to the other end of the movable spring 224. The coil 211 is mounted on the coil frame 212, the yoke 213 is positioned outside the circumference of the coil 211, and the push latch 215 is fixed to the armature 214. After the coil 211 is excited, the coil 211 attracts the armature 214 and rotates it, thereby moving the push latch 215 and moving the movable contact 225 of the movable spring piece 224 toward the fixed contact 222, bringing the movable contact 225 and the fixed contact 222 into contact and electrically connecting with each other to turn on the contact assembly 22. The coil 211 is wound with enameled copper wire, which has good conductivity and low cost, and the coil frame 212 is made of plastic material, which has light weight and low cost, but is not limited to this. Of course, in other embodiments, the contact assembly 22 may be a normally closed contact assembly.

[0061] As shown in FIG. 3, two sets of coil lead-out pins 7 are provided on the base 12, and each set of coil lead-out pins 7 is electrically connected to two coils 211, respectively. The lower ends of the coil lead-out pins 7 pass through the bottom of the base 12 for easy wiring. The coil lead-out pins 7 are made of copper material, which has good conductivity and low cost.

[0062] In this embodiment, the two relay core mechanisms 2 are installed side by side, the contact assemblies 22 of the two relay core mechanisms 2 are installed side by side opposite each other, and the two magnetic circuit parts 21 are respectively installed on the outside of both sides of the two contact assemblies 22, so that the two power terminals 5 and the two load terminals 6 are drawn out to connect the current transformer 3 and Leakage detection device It is convenient for penetrating the cavity of 4.

[0063] The axial direction of the coil 211 of the magnetic circuit portion 21 is perpendicular to the first side wall 112 and the second side wall 113 of the case 1, making the overall structure more compact.

[0064] Furthermore, the two relay core mechanisms 2 are installed with rotational symmetry, specifically, the two relay core mechanisms 2 are rotationally symmetrical by 180 degrees, so that the movable spring pieces 224 of the two contact assemblies 22 are offset from each other, allowing the two relay core mechanisms 2 to be arranged more closely, which is advantageous for miniaturization, and the two relay core mechanisms 2 may have the same structure, which is convenient for production and assembly.

[0065] In this embodiment, the two power terminals 5 are respectively formed by the fixed spring reed 221 of one contact assembly 22 and the movable spring reed 223 of the other contact assembly 22 extending from the first side wall 112 of the case 1, and the two load terminals 6 are respectively formed by the fixed spring reed 221 of one contact assembly 22 and the movable spring reed 223 of the other contact assembly 22 extending from the second side wall 113 of the case 1, i.e., the power terminals 5 and the load terminals 6 are integral structural members with the fixed spring reed 221 or the movable spring reed 223 of the contact assembly 22, thereby reducing the number of parts, making assembly easier, and improving conductivity.

[0066] Furthermore, in this embodiment, as shown in FIG. 10 , two auxiliary contact assemblies 8 are further provided on the base 12, and the two auxiliary contact assemblies 8 are provided to work in conjunction with the magnetic circuit portions 21 of the two relay core mechanisms 2, respectively, and the auxiliary contact assemblies 8 are driven to turn on / off via the magnetic circuit portions 21 of the relay core mechanism 2, thereby detecting the states of the two contact assemblies 22.

[0067] 10 to 13, the auxiliary contact assembly 8 includes an auxiliary movable spring member 81 and an auxiliary fixed spring member 82. The auxiliary movable spring member 81 includes an auxiliary movable spring reed piece 811, an auxiliary movable spring piece 812 fixed to the auxiliary movable spring reed piece 811, and an auxiliary movable contact 813 and a protrusion 814 fixed to the auxiliary movable spring piece 812. More specifically, the upper end of the auxiliary movable spring piece 812 is fixed to the auxiliary movable spring reed piece 811, and the auxiliary movable contact 813 and the protrusion 814 are fixed to the auxiliary movable spring piece 812. The auxiliary movable contact 813 is provided at the lower end of the auxiliary movable spring piece 812, and the attachment portions of the auxiliary movable contact 813 and the auxiliary movable spring reed piece 811 are provided offset from each other. The protrusion 814 is provided on the side of the auxiliary movable spring piece 812 facing the armature 214 of the relay core mechanism 2. The auxiliary fixed spring component 82 includes an auxiliary fixed spring reed piece 821 and an auxiliary fixed contact 822. The base 12 is provided with a first attachment hole 121 and a second attachment hole 122. The lead piece 811 and the auxiliary fixed spring lead piece 821 are fixedly inserted into the first mounting hole 121 and the second mounting hole 122, respectively, and their bottoms extend from the bottom surface of the base 12 to form the auxiliary contact pull-out pin 83. When the armature 214 is in its initial position (i.e., when the coil 211 is not excited), the armature 214 abuts against the protrusion 814, driving the auxiliary movable spring piece 812 to deform toward the auxiliary fixed contact 822 until the auxiliary movable contact 813 comes into contact with and is electrically connected to the auxiliary fixed contact 822. After the coil 211 is excited, the armature 214 moves away from the protrusion 814, assisting the auxiliary movable spring piece 812 to return to its original position and disconnecting the auxiliary movable contact 813 from the auxiliary fixed contact 822. Therefore, by monitoring the on / off status of the auxiliary contact assembly 8, the movement status of the armature 214 of the relay core mechanism 2 can be known, and the status of the contact assembly 22 can be determined. By providing the protrusion 814, the armature 214 presses the auxiliary movable spring piece 812 more stably and reliably.

[0068] In some embodiments, the protrusion 814 is made of an insulating material, such as ceramic or plastic, to further improve the insulating performance between the auxiliary contact assembly 8 and the relay core mechanism 2 and to improve safety. Of course, in some embodiments, the protrusion 814 may be integrally molded with the auxiliary movable spring piece 812, which has a simple structure and is easy to assemble.

[0069] In some embodiments, providing the auxiliary fixed contact 822 close to the base 12 not only makes the structure more compact, but also makes the auxiliary fixed contact 822 more stable.

[0070] In a specific embodiment, as shown in FIG. 3 , the base 12 is further provided with two first power output pins 91, which are electrically connected to two power terminals 5, respectively. More specifically, the two first power output pins 91 are electrically connected to the fixed spring reed 221 of one contact assembly 22 and the movable spring reed 223 of the other contact assembly 22, respectively. The two first power output pins 91 penetrate the outside of the bottom surface of the base 12. By providing the two first power output pins 91, power can be supplied to the control circuit portion of the relay module or other elements, such as a display, an alarm, etc.

[0071] In this embodiment, the first power output pin 91 and the fixed spring reed 221 or the movable spring reed 223 of the contact assembly 22 are integrally molded members, so there are fewer parts and assembly is easy.

[0072] Furthermore, as shown in FIG. 3 , the base 12 is further provided with two second power output pins 92, which are electrically connected to the two load terminals 6, respectively. More specifically, the two second power output pins 92 are electrically connected to the movable spring reed 223 of one contact assembly 22 and the fixed spring reed 221 of the other contact assembly 22, respectively. The two second power output pins 92 penetrate the outside of the bottom surface of the base 12. By providing the two second power output pins 92, power can be supplied to other elements, such as a display, an alarm, etc., and the power supply can be synchronously controlled by a relay module, which is easy to use and energy-saving.

[0073] In this embodiment, the second power output pin 92 and the fixed spring reed 221 or the movable spring reed 223 of the contact assembly 22 are integrally molded members, so there are fewer parts and assembly is easy.

[0074] FIG. 14 discloses a relay control system, which includes the above-mentioned relay module, AC / DC conversion circuit 100, and control unit 200. In use, the two power supply terminals 5 of the relay module are respectively connected to the live line and the dead line of the AC power supply, the two load terminals 6 are connected to a load 300, which may be a battery or other electronic element such as a motor, the two first power supply output pins 91 are connected to the input terminals of the AC / DC conversion circuit 100, the output terminal of the AC / DC conversion circuit 100 is connected to the control unit 200, and the control output terminal of the control unit 200 is connected to the magnetic circuit part of the relay core mechanism 2, specifically to the coil lead-out pin 7. The AC power supply outputs to the AC / DC conversion circuit 100 via the first power output pin 91, rectifies and reduces the voltage, and then converts it into low-voltage DC to supply power to the control unit 200. After the control unit 200 receives an ON signal, it outputs current to the coil 211, and after the coil 211 is excited, it attracts and moves the armature 214, thereby interlocking the push latch 215 and moving the movable contact 225 of the movable spring piece 224 toward the fixed contact 222, bringing the movable contact 225 and the fixed contact 222 into contact and electrically connecting them to turn on the contact assembly 22. The AC power supply supplies power to the load 300 via the two contact assemblies 22, forming a power supply circuit. The current transformer 3 detects the current in the load circuit and outputs it to the control unit 200 for electrical quantity detection, or to another electrical quantity detection unit for electrical quantity detection. Leakage detection device 4 detects the leakage state of the circuit and outputs a detection signal to the control unit 200. If a leakage is detected, the control unit 200 cuts off the power supply to the coil 211 and turns off the two contact assemblies 22, thereby simultaneously disconnecting the live and zero wires of the circuit, providing good disconnection capability, high reliability, and ensuring safety performance. The auxiliary contact pull-out pin 83 is connected to the control unit 200, which can determine the status of the contact assembly 22 by detecting the on / off status of the auxiliary contact assembly 83 and determine whether a fault exists in the contact assembly 22. Of course, the auxiliary contact pull-out pin 83 can also be connected to other detection units, such as a background system for monitoring the status of the contact assembly 22.

[0075] The control unit 200 is implemented as a one-chip microcomputer, which has a simple structure, a small volume, is easy to implement, and is low cost; of course, in some embodiments, the control unit 200 may also be implemented as other conventional controllers.

[0076] Of course, in some embodiments, if there is no need for ground fault detection, the relay module Leakage detection device You don't have to assemble it.

[0077] Although the present disclosure has been specifically shown and described in combination with preferred embodiments, it should be understood by those skilled in the art that various changes can be made to the present disclosure in form and details without departing from the spirit and scope of the present disclosure as defined in the appended claims, all of which are within the protection scope of the present disclosure.

Claims

1. A relay module comprising a case, two relay core mechanisms, a current transformer, two power terminals, and two load terminals, two relay core mechanisms are provided in a case, two power supply terminals and two load terminals are fixed to the case, the relay core mechanisms include a magnetic circuit portion and a contact assembly, the two power supply terminals are connected to the two load terminals via the contact assemblies of the two relay core mechanisms, respectively, to form two on-off control paths, the two on-off control paths are configured to form one circuit with a load connected to the two load terminals, and a current transformer is attached to one on-off control path; A relay module characterized by:

2. Further comprising a ground fault current transformer, the ground fault current transformer being attached to the two on / off control paths; 2. The relay module according to claim 1.

3. The current transformer and the earth leakage current transformer are both arranged outside the case, the case has a first side wall and a second side wall arranged opposite to each other, the two power supply terminals and the two load terminals extend outward from the first side wall and the second side wall of the case, respectively, the earth leakage current transformer is fixedly arranged outside the first side wall, and the two power supply terminals extend outward after penetrating a cavity in the earth leakage current transformer, and / or the current transformer is fixedly arranged outside the second side wall, and one load terminal extends outward after penetrating a cavity in the current transformer.

3. The relay module according to claim 2.

4. The contact assembly comprises a fixed spring reed, a fixed contact fixed to the fixed spring reed, a movable spring reed, a movable spring, and a movable contact, one end of the movable spring is fixed to the movable spring reed, and the movable contact is fixed to the other end of the movable spring, and the movable contact and the fixed contact are brought into contact or separated by operation of a magnetic circuit portion, and the two power supply terminals and the two load terminals are respectively constituted by portions of the movable spring reed and the fixed spring reed of the two contact assemblies extending from the cases.

4. The relay module according to claim 3.

5. a first insertion structure is provided between the first side wall of the case and the earth leakage current transformer, and the earth leakage current transformer is inserted and fixed to the outside of the first side wall of the case via the first insertion structure; and / or a second insertion structure is provided between the second side wall of the case and the current transformer, and the current transformer is inserted and fixed to the outside of the second side wall of the case via the second insertion structure; 4. The relay module according to claim 3.

6. The relay module further includes two first connectors each connected to an outer end of one of the two power supply terminals extending from the cavity of the earth leakage current transformer, the first connectors being configured to be connected to a power supply line, the two power supply terminals both being made of rigid conductors, the two first connectors being connected perpendicularly to the two power supply terminals and extending outward in two different directions, the first connectors being crimped to the power supply terminals, the outer ends of the power supply terminals being provided with first locking blocks extending toward the first connectors, the first connectors being provided with first locking openings, the first locking blocks being locked in the first locking openings, and / or The relay module further includes a second connector connected to an outer end of the load terminal extending from the cavity of the current transformer, the second connector being configured to be connected to a load, the second connector being fixed to the load terminal by crimping, the outer end of the load terminal being provided with a second locking block extending toward the second connector, the second connector being provided with a second locking opening, and the second locking block being locked into the second locking opening.

4. The relay module according to claim 3.

7. an inner end surface of the earth leakage current transformer is spaced apart from a first side wall of the case, and / or an inner end surface of the current transformer is spaced apart from a second side wall of the case; 4. The relay module according to claim 3.

8. an inner end surface of the current transformer and a first side wall of the case are spaced apart via a first position limiting block, and / or an inner end surface of the current transformer and a second side wall of the case are spaced apart via a second position limiting block; 8. The relay module according to claim 7.

9. two sets of coil lead-out pins are provided on the case, and the two sets of coil lead-out pins are electrically connected to coils of magnetic circuit portions of the two relay core mechanisms, respectively; the two relay core mechanisms are provided in parallel; and the contact assemblies of the two relay core mechanisms are provided opposite to each other.

2. The relay module according to claim 1.

10. Two auxiliary contact assemblies are further provided within the case, and the two auxiliary contact assemblies are respectively interlocked with magnetic circuit portions of the two relay core mechanisms so that the magnetic circuit portions of the relay core mechanisms drive the on / off of the auxiliary contact assemblies.

3. A relay module according to claim 1 or 2.

11. the auxiliary contact assembly comprises an auxiliary movable spring member and an auxiliary fixed spring member, the auxiliary movable spring member is provided with a protrusion, the protrusion is provided toward the armature, when the armature is not adsorbed, the armature abuts on the protrusion to bring the auxiliary movable spring member and the auxiliary fixed spring member into contact with each other and drive them to turn on, and when the armature is adsorbed, there is a gap between the armature and the protrusion to cut off the connection between the auxiliary movable spring member and the auxiliary fixed spring member; 11. The relay module according to claim 10.

12. The protrusion is made of an insulating material.

12. The relay module according to claim 11.

13. the case is further provided with two first power output pins, which are electrically connected to two power terminals, respectively; and / or the case is further provided with two second power output pins, which are electrically connected to two load terminals, respectively; 3. A relay module according to claim 1 or 2.

14. a control unit including the relay module of claim 10, wherein a control output terminal of the control unit is connected to a coil of the magnetic circuit portion of the relay core mechanism, and a control input terminal of the control unit is connected to an output terminal of the auxiliary contact assembly; A relay control system comprising:

15. A relay module according to claim 13, comprising an AC / DC conversion circuit and a control unit, wherein the two power supply terminals of the relay module are respectively connected to a live line and a zero line of a power supply, the two load terminals are connected to a load, the two first power supply output pins are connected to input ends of the AC / DC conversion circuit, the output end of the AC / DC conversion circuit is connected to the control unit, and the control output end of the control unit is connected to a magnetic circuit portion of the relay core mechanism. A relay control system comprising:

16. the first power output pin is formed by being drawn from the movable spring reed or the fixed spring reed of the contact assembly and extends from the bottom of the housing; 16. The relay control system of claim 15.

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