Contactor device, high voltage power supply system and method for controlling contactor device

Abstract

The present disclosure relates to a contactor device, a high-voltage power supply system including the contactor device, and a corresponding method for controlling the contactor device. The contactor device (200) comprises a contact arrangement including at least one movable busbar (106, 108) and at least one fixed busbar (102, 104), where the at least one movable busbar (106, 108) has a first contact area and the at least one fixed busbar (102, 104) has a second contact area, and at least one actuating element (118) configured to change the state of the contactor device (200) at least from a closed state to an open state and from the open state to a closed state, where in the open state the first contact area is electrically isolated from the second contact area and in the closed state the first contact area is conductively coupled to the second contact area. The contactor device further comprises an assembly circuit (168) including a processing circuit configured to determine at least one operating parameter of the contactor device (200) and a control circuit configured to control operation of the at least one actuation element (118) in response to the operating parameter determined by the processing circuit.

Description

[Technical Field]

[0001] The present disclosure relates to a contactor device, a high voltage power supply system having a contactor device, and a corresponding method of controlling the contactor device. [Background technology]

[0002] The use of contactor devices to connect and disconnect electronic circuits within a power system is known in the art. With the advanced development of electric vehicles (EVs) and hybrid electric vehicles (HEVs), high-voltage (HV) power systems are becoming increasingly common in vehicles. Currently, such HV systems typically provide voltages ranging from 400V to 1kV, with even higher voltages expected in future applications. These HV power systems pose a higher risk of electric shock than traditional powertrains. Therefore, safety hazard prevention and overcurrent protection are of paramount importance for these systems. For example, ensuring the safety of vehicle occupants, roadside assistance personnel, or maintenance personnel in the event of a HV power system malfunction or a vehicle accident affecting the power system's electronic circuits is crucial.

[0003] Therefore, there are increasing safety requirements for contactor devices used to control the flow of current in a power supply system, especially when the power supply system is used to store energy for driving a vehicle. Figure 14 shows a typical configuration of a power supply system 10 used, for example, in an electric vehicle.

[0004] To supply a high voltage ranging from 400V or more to at least 1 kV to the motor of an EV or HEV vehicle during driving, multiple battery modules (or battery packs) are electrically connected to form a high-voltage battery 11. Each battery pack typically includes multiple battery cells electrically connected in series and / or parallel. Thus, for example, approximately 80 to 100 battery cells may be electrically connected to form one high-voltage battery pack.

[0005] If the power supply system's operating conditions become unsafe due to, for example, an overcurrent, a malfunction in the power supply system's electronic circuitry, or an accident involving a vehicle powered by the power stored in the power supply system, it is necessary to immediately and permanently interrupt the flow of current within the power supply system. To achieve this, it is known to connect an additional overcurrent protection device 12 in series with the high-voltage battery 11. One example of such an overcurrent protection device 12 is a fuse, which uses a metal wire or strip that melts when an overcurrent occurs. Recently, the use of pyroelectric devices (also known as pyrofuses), which are activated by a pyroelectric charge to disconnect busbars mounted on the power supply system's supply lines, has also become established as an overcurrent protection device 12. The overcurrent protection device 12 can be located at the positive terminal of the battery 11, the negative terminal of the battery 11, within the battery 11, or at multiple locations throughout the HV power supply system 10.

[0006] Positive and negative main contactors 13, 14 are electrically connected in series with the terminals of the battery 11 to connect and disconnect the positive and negative terminals to a DC bus that connects the battery 11 to an external load (or charger). The external load may include a motor inverter (DC-AC converter), a DC-DC converter, or a charger (AC-CDC converter), a heater, auxiliary loads, or other high-voltage components. Conventional contactor devices typically have at least one movable contact that can be moved to reversibly change states between a closed state, which allows current flow through the contactor device, and an open state, which prevents current flow through the contactor device.

[0007] To measure the battery current provided by the battery, the power system 10 further includes one or more current sensors, typically in the form of a dedicated shunt resistor 15 electrically connected in series with the HV battery 11. The power system 10 includes electronics for measuring the voltage drop across the shunt resistor 15. Typically, these electronics are part of a battery management system (BMS, not shown) that monitors the operation of the power system 10. The battery management system often also controls the operation of the positive side main contactor 13 and the negative side main contactor 14, and controls and diagnoses the function of the fuse or pyrofuse 12.

[0008] Therefore, in conventional power systems, various individual components within the HV power system must be interconnected, for example, when assembling the HV battery power system 10 or when assembling an HV battery subassembly, such as the HV battery junction box, HV battery disconnect unit, or HV battery power distribution unit. Copper or aluminum bus bars are typically used to connect the components of the power system 10. Interfaces between individual components are mostly bolted or connected by connectors. In rare cases, welding may be applied when individual components provide welded interfaces rather than bolted interfaces. Therefore, the interfaces between the battery 11 and the fuse 12, between the fuse 12 and the positive main contactor 13, between the battery 11 and the shunt current sensor 15, and between the shunt current sensor 15 and the negative main contactor 14 all introduce additional ohmic resistance into the main battery current path. Depending on the wiring technology, these interfaces can be a significant source of energy loss and unintended heat generation. Particularly in high-power applications, such as fast charging, this problem can become a system-level limitation, limiting the charging current available to the power supply system and lengthening charging times. Furthermore, the BMS for power supply system 10 may require dedicated control and monitoring functions for each component included in power supply system 10, which can complicate the BMS structure. Summary of the Invention [Problem to be solved by the invention]

[0009] In this regard, the inventors of the present invention have recognized that there remains a need for contactor devices that can provide higher levels of functional integration and / or reduce the amount of wiring required in a power supply system. Accordingly, it is an object of the present invention to provide an improved contactor device for high-voltage applications, a high-voltage energy storage system including a contactor device, and a corresponding method for controlling the contactor device, that can provide a higher level of functional integration and / or reduce the required interconnections and associated interconnection resistance in a power supply system. Furthermore, it is an object of the present invention to provide a space-saving, weight-saving, and economical solution.

[0010] At least one of these problems is solved by the subject matter of the independent claims. Advantageous aspects of the present disclosure are the subject matter of the dependent claims. [Means for solving the problem]

[0011] In particular, the present disclosure provides a contactor device comprising: a contact arrangement including at least one movable busbar and at least one fixed busbar, the at least one movable busbar having a first contact area and the at least one fixed busbar having a second contact area; and at least one actuating element configured to change a state of the contactor device at least from a closed state to an open state and from the open state to a closed state, the at least one actuating element being electrically isolated from the second contact area in the open state and conductively coupled to the second contact area in the closed state. The contactor device further comprises an assembled circuit including a processing circuit configured to determine at least one operating parameter of the contactor device; and a control circuit configured to control operation of the at least one actuating element in response to the operating parameter determined by the processing circuit.

[0012] In other words, the present disclosure is based on the idea of ​​integrating an assembly circuit into a contactor device as an internal controller. In this way, the control function for controlling the operation of the contactor device, which is usually performed by an external controller such as a battery management system or a vehicle electronic control unit (ECU), can be transferred to the internal controller of the contactor device. This provides a simplified structure for the battery management system or vehicle ECU, enabling faster and more cost-effective assembly of the HV power system or battery pack. Depending on the level of functional integration of the assembly circuit, the internal controller of the contactor device may even be able to replace the external battery management system.

[0013] According to a second example, the contactor device may include a contactor housing that at least partially houses the first bus bar and the second bus bar, and the assembled circuit is enclosed by the contactor housing. In an optional implementation of the second example, the contactor housing is a hermetically sealed housing, and the sealed housing may be filled with a vacuum and / or an electronegative gas, which further helps to suppress arcing.

[0014] According to a third example, the contactor device further comprises at least one second actuator configured to irreversibly block current flow through the contact arrangement when activated, and the control circuit is configured to control operation of the at least one second actuator in response to the operating parameters determined by the processing circuit. By integrating the second actuator, the functionality of the overcurrent protection device can be integrated into the contactor device. Furthermore, the control functionality for activating and monitoring the functionality of the overcurrent device can also be transferred from the external controller to the assembly circuit as an internal controller of the contactor device.

[0015] In an optional implementation of the third example, the second actuator is a pyrotechnic actuator, although the second actuator may also be a mechanical actuator. In other optional implementations of the third example, the second actuator is configured to irreversibly displace or irreversibly disconnect one or more of the at least one movable busbar and / or the second actuator is configured to irreversibly displace or irreversibly disconnect one or more of the at least one fixed busbar.

[0016] According to a fourth example, the at least one operating parameter includes at least one of a contactor current indicative of a current flowing through the contact arrangement in a closed state of the contactor device, a contactor voltage indicative of a voltage dropped between an input terminal of the contact arrangement and an output terminal of the contact arrangement, a leakage path resistance indicative of a resistance existing between a ground terminal of the assembly circuit and at least one of the bus bars of the contact arrangement, and a control command received from an external entity to change the state of the at least one actuation element. In an optional implementation of the fourth example, the at least one operating parameter may include a control command received from an external entity to actuate the second actuator.

[0017] In other words, the operating parameters can be control commands that the internal controller (assembly circuit) of the contactor device receives from an external controller to change the state of the contactor device by actuating at least one actuation element or by actuating a pyrotechnic actuator, or alternatively, the operating parameters can be measurements that are determined directly by the internal controller (assembly circuit) or that are determined by an external controller and communicated to the internal controller (assembly circuit).

[0018] According to a fifth example, the at least one operating parameter includes at least a contactor current, the assembly circuit includes a first detection circuit configured to detect a first detected voltage indicative of the contactor current, the processing circuit is configured to determine the contactor current based on the detected first detected voltage, and the control circuit is configured to control operation of the at least one actuation element in response to the determined contactor current. In an optional implementation of the fifth example, the control circuit may be further configured to actuate a second actuator in response to determining that the contactor current is equal to or greater than a predetermined current threshold.

[0019] In other words, the internal controller of the contactor device may be capable of detecting and determining the contactor current and may control the operation of the at least one actuator element and / or the second actuator via communication with the external controller or by using an integrated internal control function. In this way, the contactor current detection function can be transferred from the external controller of the power supply system to the internal controller (assembly circuit) of the contactor device, further simplifying the structure of the battery management system and vehicle ECU.

[0020] According to a sixth example, the contact arrangement includes a first current sensing element having a first predetermined resistance, the first current sensing element being integrally formed with one of the bus bars included in the contact arrangement, the first detection circuit being configured to detect a first detected voltage by detecting a voltage at the first current sensing element, and the processing circuit being configured to determine the contactor current using the detected first detected voltage and the resistance value of the current sensing element. In this way, there is no need to provide an external shunt resistor in the HV power system, the amount of wiring required in the HV power system can be reduced, and energy loss and unintended heat generation in the HV power system can be reduced.

[0021] According to a seventh example, the contact arrangement includes a second current sensing element having a second predetermined resistance, the second current sensing element being integrally formed with one of the busbars included in the contact arrangement, and the first detection circuit being configured to detect the first detected voltage by detecting a voltage at the second current sensing element. In optional implementations of the seventh example, the first current sensing element and the second current sensing element are integrally formed with the same busbar included in the contact arrangement, or the first current sensing element and the second current sensing element are integrally formed with different busbars included in the contact arrangement.

[0022] Integrating a second current sensing element into the contactor device allows for redundant measurement of the contactor current and provides two independent voltage sense signals proportional to the contactor current. In this way, a single-point fault in one of the sense lines for detecting the voltage drop across either the first or second current sensing element only affects one of the two sense signals, allowing the contactor current to continue to be determined.

[0023] According to an eighth example, the first current sensing element is formed from a first resistive material having a first specific electrical conductivity and a first temperature coefficient, and the second current sensing element is formed from a second resistive material having a second specific electrical conductivity and a second temperature coefficient, whereby the first resistive region and the second resistive region may be formed from the same material or different materials.

[0024] According to a ninth example, at least a portion of the first current sensing element defines a weakened portion that assists the second actuator in breaking each busbar integrally formed with the first current sensing element. In an optional implementation of the ninth example, the weakened portion may be formed as a predetermined break region, where each busbar is configured to break at the predetermined break region in response to activation of the second actuator, or the weakened portion may be formed as a hinge bend portion, where each busbar is bendable about the hinge bend in response to activation of the second actuator. In this manner, the first current sensing element can integrate two functions and assist in breaking or bending the busbar after activation of the second actuator. This eliminates the need to specifically design a weakened portion in the busbar integrally formed with the first current sensing element.

[0025] According to a tenth example, the at least one operating parameter includes at least a contactor voltage, the assembly circuit includes a second detection circuit configured to detect a second detection voltage indicative of the contactor voltage, the processing circuit determines the contactor voltage based on the detected second detection voltage, and the control circuit is configured to control the operation of at least one actuating element in accordance with the determined contactor voltage.

[0026] In other words, in the tenth example, the internal controller of the contactor device may detect and determine the contactor voltage and control at least one actuator element according to the determined contactor voltage via communication with the external controller or by using an internal control function integrated therein. In this way, the contactor voltage detection function can be transferred from the external controller of the power supply system to the internal controller (assembly circuit), further simplifying the structure of the battery management system and the vehicle ECU.

[0027] According to an eleventh example, the assembly circuit optionally includes a pre-charge circuit configured to be conductively coupled in parallel to bypass the contact arrangement, the pre-charge circuit including at least one pre-charge resistor and at least one pre-charge switch conductively coupled in series to the pre-charge resistor, and the control circuit configured to control the opening and closing of the pre-charge switch. By integrating the pre-charge circuit into the assembly circuit, there is no need to connect an external pre-charge circuit to the contactor device, which can further simplify the structure of the HV power system.

[0028] According to a twelfth example, the control circuit controls the opening and closing of the pre-charge switch depending on the determined contactor voltage. In this way, in the closed state of the contactor device, the pre-charge of the contactor device can be internally controlled, so that dangerous current peaks can be avoided when the contactor device is closed.

[0029] In an optional implementation of the twelfth example, if the determined actual contactor voltage is greater than a predetermined pre-charge voltage threshold, the control circuit is configured to close the pre-charge switch and not change the state of the contactor device from an open state to a closed state, and / or if the determined actual contactor voltage is less than or equal to the predetermined pre-charge voltage threshold, the control circuit is configured to change the state of the contactor device from an open state to a closed state.

[0030] According to a thirteenth example, the at least one operating parameter includes at least a leakage path resistance, the assembly circuit includes a third detection circuit configured to detect a third detection voltage indicative of the leakage path resistance, the processing circuit is configured to determine the leakage path resistance based on the detected third detection voltage, and the control circuit is configured to control operation of the at least one actuation element according to the determined leakage path resistance. In an optional implementation of the thirteenth example, the control circuit is configured to control the at least one actuation element to change a state of the contactor device to an open state when it determines that the leakage path resistance is equal to or greater than a predetermined resistance threshold, and / or the control circuit is configured to actuate the second actuator when it determines that the leakage path resistance is equal to or greater than a predetermined resistance threshold.

[0031] In other words, in the thirteenth example, the internal controller of the contactor device may detect and determine the leakage path resistance and control at least one actuator element according to the determined leakage path resistance through communication with the external controller or by using an internal control function integrated therein. In this way, the leakage path resistance detection function can be transferred from the external controller of the power supply system to the internal controller (assembly circuit), further simplifying the structure of the battery management system and the vehicle ECU.

[0032] According to a fourteenth example, the assembled circuit further comprises a leakage path resistance detection circuit conductively coupled to the contact assembly by a first node and conductively coupled to a ground terminal of the assembled circuit by a second node. The first leakage path resistance detection circuit comprises: a voltage divider including a first series circuit in which a first leakage path resistance detection resistor and a second leakage path resistance detection resistor are conductively coupled in series; a leakage path resistance detection switch optionally conductively coupled in parallel to the first leakage path resistance detection resistor to bypass the first leakage path resistance detection resistor, the leakage path resistance detection switch shorting the first leakage path resistance detection resistor when the first leakage path resistance detection switch is closed and not shorting the first leakage path resistance detection resistor when the first leakage path resistance detection switch is open; and a third detection circuit configured to detect a first leakage path resistance detection voltage at the second leakage path resistance detection resistor when the first leakage path resistance detection switch is open and to detect a second leakage path resistance detection voltage at the second resistor when the first leakage path resistance detection switch is closed. The processing circuit is configured to determine the leakage path resistance based on a battery voltage of a battery to which the contactor device is connected and the first leakage path resistance detection voltage and the second leakage path resistance detection voltage.

[0033] The present disclosure also relates to a method for controlling a contactor device, the method being performed by a contact arrangement of the contactor device having at least one movable busbar with a first contact area and at least one fixed busbar with a second contact area, the method including determining at least one operating parameter of the contactor device and controlling operation of at least one actuating element in response to the determined operating parameter, whereby the at least one actuating element is configured to change a state of the contactor device at least from an open state to a closed state and from the closed state to an open state, wherein in the open state the first contact area is electrically isolated from the second contact area and in the closed state the first contact area is conductive to the second contact area.

[0034] As used herein, the term "terminal" is intended to describe a point at which a conductor from an electrical device, circuit, or component terminates, providing a point for electrically connecting an external electrical device, circuit, or component to the conductor. The term "node" may refer to a point at which the terminals of one or more circuit components meet, or may refer to an entire wire that conductively couples the terminals of one or more electrical circuit components. Furthermore, the terms "electrically connected" and "conductively coupled" describe the establishment of an electrical connection that allows current to flow between at least two electrical devices, components, or conductors. Thus, electrical connection should not be limited to the direct coupling of terminals of at least two electrical devices, components, or conductors; other electrical devices, components, or conductors may be coupled therebetween.

[0035] The accompanying drawings are incorporated into and form a part of the specification to illustrate several examples of the present disclosure. These drawings, together with the description, serve to explain the principles of the present disclosure. The drawings are intended to illustrate preferred and alternative examples of how the present disclosure can be made and used, and are not intended to limit the disclosure to only the examples shown and described. Furthermore, several aspects of the exemplary embodiments may form solutions according to the present disclosure, individually or in different combinations. The examples described below may thus be considered alone or in any combination. Further features and advantages will become apparent from the following more detailed description of various examples of the present disclosure, as illustrated in the accompanying drawings, in which like reference numerals refer to like elements. [Brief explanation of the drawings]

[0036] [Figure 1] 1 shows a schematic perspective view of a first exemplary contactor device. [Figure 2] 1 shows a schematic side view of a first exemplary contactor device in an open state. [Figure 3] 1 shows a schematic side view of a first exemplary contactor device in a closed state. [Figure 4] 1 shows a schematic plan view of a first exemplary contactor device. [Figure 5] 1 shows another schematic plan view of the first exemplary contactor device. [Figure 6] 1 shows another schematic plan view of the first exemplary contactor device. [Figure 7] 1 shows a schematic circuit diagram of a first exemplary contactor. [Figure 8] 1 shows a schematic perspective view of a first exemplary bus bar. [Figure 9] 1 shows another schematic perspective view of the first exemplary busbar. [Figure 10] 1 shows a schematic perspective view of a second exemplary bus bar. [Figure 11] 1 shows a circuit diagram of a second exemplary contactor device. [Figure 12] 1 shows a schematic circuit diagram of an exemplary precharge circuit. [Figure 13] 1 shows a schematic circuit diagram of an exemplary leakage resistance detection circuit. [Figure 14] 1 shows an exemplary circuit diagram of a conventional high voltage power supply system. DETAILED DESCRIPTION OF THE INVENTION

[0037] The present disclosure will now be further described with reference to the drawings, initially FIG. 1 , which shows a schematic perspective view of a first exemplary contactor device 100. In an example application, such as the one illustrated below, the contactor device 100 may be used in the power system of an electric vehicle to control the power supply of an electric load, such as an electric motor, supplied at a predetermined high voltage. However, the contactor device 100 may also be used in other applications requiring the storage and / or supply of high-voltage energy in one or more high-voltage batteries, such as energy storage systems used in power grids.

[0038] The contactor device 100 includes two fixed busbars 102 and 104 and two movable busbars 106 and 108 that form the contact arrangement of the contactor device 100. In this manner, the contactor device 100 can function as a two-pole compound contactor that functions as a two-pole single-break contactor.

[0039] Advantageously, the contact configuration design of contactor device 100 allows one of fixed busbars 102 and 104 and one of movable busbars 106 and 108 to function as a first main contactor, and the other of fixed busbars 102 and 104 and the other of movable busbars 106 and 108 to function as a second main contactor, thereby integrating the functions of two main contactors. However, the number of two movable busbars and two fixed busbars is not essential to the function of contactor device 100; contactor device 100 may have three or more movable busbars and three or more fixed busbars, or may have only one movable busbar and one fixed busbar. It is also contemplated that the number of movable busbars may differ from the number of fixed busbars. For example, the principles of the present disclosure may be applied to a contactor device that includes two fixed busbars and one movable busbar and is configured to reversibly connect the two fixed busbars.

[0040] Referring again to FIG. 1 , the movable busbars 106 and 108 are shown schematically to be in a closed position, where each of the movable busbars 106 and 108 is conductively coupled to one of the fixed busbars 102 and 104, thereby creating a closed contactor device. Thus, in the closed position, current can flow between a first terminal 110 integrally formed with the movable busbar 106 and a second terminal 112 integrally formed with the fixed busbar 102, and between a third terminal 114 integrally formed with the movable busbar 108 and a fourth terminal 116 integrally formed with the fixed busbar 104. Alternatively, each of the movable busbars 106, 108 may be in an open position, where the movable busbars 106, 108 are electrically isolated from the fixed busbars 102, 104, thereby creating an open contactor device. The open state therefore interrupts the flow of electrical current through the contact arrangement of the contactor device 100 .

[0041] The contactor device 100 includes an electromagnetic actuator 118 as an example of an actuating element for reversibly connecting and disconnecting a current path through the contactor device 100. The electromagnetic actuator 118 is configured to reversibly move the movable busbars 106, 108 between a closed position and an open position, changing the state of the contactor device 100 from a closed state to an open state, or from an open state to a closed state.

[0042] To facilitate the transition between the reversible open and closed positions, the movable bus bars 106, 108 are configured to resiliently flex between the open and closed positions at flexible bus bar regions 120 that constitute at least a portion of the movable bus bars 106, 108. To this end, the movable bus bars 106, 108 may be multi-layered structures, for example, 10-15 layers of copper, aluminum, or other suitable conductive material. Each of the movable bus bars 106, 108 may also include a bulge 122 to support the flexure capability of the movable bus bars 106, 108. The bulge 122 may also contribute to applying a preload to the movable bus bars 106, 108, urging them toward the open position.

[0043] The electromagnetic actuator 118 is configured to hold the movable busbars 106, 108 in a closed position when energized. To this end, the flexible busbar regions 120 of the movable busbars 106, 108 may be moved individually by the electromagnetic actuator 118 (e.g., by a shaft 124 disposed above the movable busbars 106, 108 at the flexible busbar regions 120). An additional spring element may be disposed around the shaft 124 to help absorb small misalignments or imbalances between the movable busbars 106, 108 during operation of the contactor device 100. This prevents such misalignments from affecting the electromagnetic actuator 118 or significantly affecting the force applied between the fixed busbars 102, 104 and the movable busbars 106, 108. In this way, tolerances between the fixed busbars 102, 104 and the movable busbars 106, 108 introduced during manufacturing of the contactor device 100 can be better compensated for. Additionally, the retaining spring 126 may be located below the movable bus bars 106, 108, i.e., on the bottom side of the movable bus bars 106, 108, to bias the movable bus bars 106, 108 to the open position when the electromagnetic actuator 118 is not energized, i.e., when no force is being applied by the shaft 124.

[0044] FIG. 2 illustrates the contactor device 100 in a de-energized state, with the electromagnetic actuator 118 de-energized, and the movable busbars 106, 108 simultaneously in an open position. Thus, the contact elements 128 of the movable busbars 106, 108 are electrically isolated from the contact elements 128 of the fixed busbars 102, 104 by a spatial gap, interrupting the flow of current through the contact arrangement of the contactor device 100. To reduce contact resistance, the contact elements 128 may be made of, for example, silver or a silver alloy and attached to the fixed busbars 102, 104 and the movable busbars 106, 108 by welding, soldering, or brazing. Each busbar may include two or more contact elements, with the contact elements of a busbar forming contact points that define the contact areas of the busbar for electrical contact with other busbars in the contact arrangement. Of course, other suitable conductive materials or wiring techniques may be used to form the contact elements 128 on the busbars of the contactor device 100.

[0045] FIG. 3 shows contactor device 100 in an energized state with movable busbars 106 and 108 in a closed position and contacts 128 of movable busbars 106 and 108 conductively coupled to contacts 128 of fixed busbars 102 and 104 .

[0046] To move the movable bus bars 106, 108 from the open position to the closed position, the movable core of the electromagnetic actuator 118 applies a closing force to the movable bus bars 106, 108, for example, via the shaft 124, thereby pushing the movable bus bars 106, 108 in the direction of the closing force, i.e., toward the fixed bus bars 102, 104.

[0047] As an alternative to the electromagnetic actuator 118, the contactor device 100 may include a linear motor actuator as an actuating element for moving the movable busbars 106, 108 between an open position (shown in FIG. 2 ) and a closed position (shown in FIG. 3 ). The linear motor actuator drives the shaft 124 to move the movable busbars 106, 108 between the open and closed positions. In such a configuration, when power is supplied to the linear motor actuator, only the shaft 124 moves; when power is not supplied to the linear motor actuator, the movable busbars 106, 108 remain in their previous positions. The linear motor actuator can thus function as a bistable actuator, introducing open and closed states of the contactor device 100 that change only when power is supplied to the linear motor actuator. Therefore, such a configuration allows the contactor device 100 to maintain a closed state (or open state) if the linear motor actuator experiences a loss of power, for example, due to a damage event or a communication loss.

[0048] Referring back to FIG. 1 , the contactor device 100 may advantageously further include a pyrotechnic actuator 130 configured to permanently displace the fixed busbars 102 and 104 in the firing position after being triggered. In the firing position, the fixed busbars 102 and 104 are permanently electrically isolated from the movable busbars 106 and 108. This may result in displacement of the fixed busbars 102, 104 as a whole, or only displacement regions 132 of the fixed busbars 102, 104 including the contact elements 128. In this manner, the movable busbars 106, 108 can be prevented from being conductively coupled to the fixed busbars 102, 104, even after activation of the pyrotechnic actuator 130. Thus, the flow of current through the contact arrangement of the contactor device 100 is permanently interrupted after activation of the pyrotechnic actuator 130.

[0049] The pyrotechnic actuator 130 may include two or more pyrotechnic pins 134 that, in response to receiving an electrical control signal, cause ignition of a pyrotechnic charge. The pyrotechnic charge may be an explosive that is directly ignited by the electrical control signal, or may be a gas generator charge that rapidly expands after receiving the electrical control signal. Alternatively, the pyrotechnic charge may have a multi-charge configuration, including, for example, an initiator charge and a secondary gas generator charge.

[0050] Alternatively, as described below, the pyrotechnic pin 134 may be connected to an internal controller of the contactor device 100, or may be connected to an external controller, such as a battery management system for a high voltage battery, an ECU, or a vehicle crash sensor. An electrical control signal to activate the pyrotechnic actuator 130 may be issued by the internal or external controller in response to, for example, a detected anomaly or malfunction in any of the other circuit components of the electrical circuit to which the contactor device 100 is conductively coupled, or the detection of a vehicle accident.

[0051] Upon activation, the pyrotechnic actuator 130 is driven by ignition of a pyrotechnic charge, which in turn drives a displacement element 136 via a piston structure 138 to force the fixed bus bars 102 and 104 into a firing position where the fixed bus bars 102 and 104 are electrically isolated from the movable bus bars 106 and 108. For example, the displacement element 136 may be a stud or bolt that displaces or shears the fixed bus bars 102, 104 via the energy of the piston structure 138.

[0052] To facilitate displacement of the fixed busbars 102, 104, weakened portions (or areas of weakness) may be formed in each of the fixed busbars 102, 104. The weakened portions may be formed, for example, in the form of hinge flexures 140. In the illustrated example, the hinge flexures 140 are formed by cutouts in the busbars. The positions of the cutouts forming the hinge flexures 140 can be adjusted to change the swing radius of the displacement regions 132 of the fixed busbars 102, 104. In this way, the path of movement of the fixed busbars 102, 104, or at least the path of movement of the displacement regions 132 of the fixed busbars 102, 104, can be well defined as the fixed busbars 102, 104 are moved to the post-fire position.

[0053] Alternatively, the weakened portions may be formed by notches or notches in each bus bar that define the predetermined breakage area. In this manner, the weakened portions serve to cut or break each bus bar at the predetermined breakage area in response to actuation of the pyrotechnic actuator 130.

[0054] Figures 4 and 5 illustrate the operation of an example pyrotechnic actuator 130. Both Figures 4 and 5 show a schematic plan view of the contactor device 100. Figure 4 shows the contactor device 100 in a closed state before the pyrotechnic actuator 130 is actuated. In this example, a holding force 142 directed into the paper holds the movable bus bars 106, 108 in electrical contact with the fixed bus bars 102, 104.

[0055] 5 shows a plan view of the contactor device 100 with the pyrotechnic actuator 130 activated. Note that while the fixed busbar 104 is shown in the post-fire position, the fixed busbar 102 may also be simultaneously moved to the post-fire position after the pyrotechnic actuator 130 is activated. The pyrotechnic-generated force drives the displacement elements 136 to irreversibly move the fixed busbars 102 and 104 to the fired position to electrically isolate the fixed busbars 102 and 104 from the movable busbars 106 and 108. As indicated by arrow 144, the fixed busbars 102, 104, or the displacement regions 132 of the fixed busbars 102, 104, undergo rotational movement about hinge flexures 140, which define weakened portions of the fixed busbars 102, 104. This rotational movement preferably occurs in a plane perpendicular to the direction of the retention force 142 applied by the electromagnetic actuator 118 to the movable busbars 106, 108. However, the plane in which the fixed busbars 102, 104, or the displacement regions 132 of the fixed busbars 102, 104, move to the post-fire position need not necessarily be perpendicular to the direction of the retention force 142. Instead, this plane may be at an angle to the direction of the retention force 142, such that the direction of movement of the fixed busbars 102, 104, or the direction of movement of the displacement regions 132 of the fixed busbars 102, 104, is at least angled relative to the direction of movement of the movable busbars 106, 108 between the open and closed positions.

[0056] In this way, it is ensured that the fixed busbars 102, 104 can be moved to the post-fire position without affecting the actuation mechanism that moves and holds the movable busbars 106, 108 in the closed position. Similarly, the movement of the fixed busbars 102, 104 to the post-fire position is prevented from being affected by the actuation mechanism that moves and holds the movable busbars 106, 108 in the closed position, because the force generated by the pyrotechnic actuator 130 is transmitted to the fixed busbars 102, 104 so as not to act against the force generated by the electromagnetic actuator 118. The movement of the fixed busbars 102, 104 or displacement region 132 to the post-fire position is also not limited to rotational movement, but may follow a linear movement path.

[0057] It should be noted that, by applying the same principles to the movable busbars 106, 108, the pyrotechnic actuator 130 may displace or sever the movable busbars 106, 108 rather than permanently displacing or severing the fixed busbars 102, 104. Alternatively, the contactor device 100 may be provided with a second pyrotechnic actuator, one dedicated to permanently displacing or severing the fixed busbars 102, 104, respectively, and one dedicated to permanently displacing or severing the movable busbars 106, 108, respectively. Furthermore, instead of using the energy of one or more pyrotechnic actuators to sever and / or displace one or more busbars of the contactor device 100, the energy of one or more mechanical actuators may be used. The mechanical actuator may be, for example, a biased spring, and may be configured to permanently disconnect and / or displace one or more bus bars of the contactor device 100 after the mechanical actuator is triggered (activated), for example, by releasing the biased spring.

[0058] In another alternative, instead of mechanically moving one or more busbars of contactor device 100 to a post-firing position (or breaking one or more busbars), at least one insulating cap may be actuated to completely encase the end regions of fixed busbars 102, 104, irreversibly separating fixed busbars 102, 104 and movable busbars 106, 108 after activation of pyrotechnic actuator 124. In this manner, the insulating cap interrupts the flow of current through the contact arrangement of contactor device 100 while simultaneously suppressing the generation of an electric arc. Details of this mode of operation are further described with respect to Figures 23 and 24 of European Patent Application EP 22177000.1, which are incorporated herein by reference.

[0059] FIG. 6 illustrates the contactor device 100 with an optional contactor housing 146 that houses most of the internal components of the contactor device 100. In this example, the terminals 112, 116 of the stationary busbars 102, 104 and the terminals 110, 114 of the movable busbars 106, 108 are not enclosed within the contactor housing 146. However, the terminals 110, 112, 114, 116 could be formed by connectors, which could be integrated into the contactor housing 146. The contactor housing 146 could be a sealed housing filled with a vacuum or an electronegative gas to suppress arcing when the movable contacts 106, 108 are opened. However, the specific design of the movable busbars 106, 108 may already provide sufficient electrical insulation between the movable busbars 106, 108 and the stationary busbars 102, 104 under normal atmosphere. Therefore, sealing the contactor housing 146 or using a vacuum or electronegative gas is not required. Additionally, although terminals 110, 112, 114, 116 are shown as bolt interfaces in FIGS. 1-6, welded interfaces or connectors may also be used, for example, provided as part of connector housing 146.

[0060] 7 shows a schematic circuit diagram of the contactor device 100 conductively coupled to a high-voltage battery 500. In the illustrated example, a first terminal 110 of the contactor device 100 is electrically connected to the positive terminal of the HV battery 500. A second terminal 112 may be electrically connected to the positive voltage side of a high-voltage DC bus supplied by power from the HV battery 500. Similarly, a third terminal 114 is electrically connected to the negative terminal of the HV battery 500. The second terminal 112 may be electrically connected to the negative voltage side of the HV DC bus. Thus, in the illustrated example, the fixed bus bar 102 and the movable bus bar 106 function as a positive main contactor (schematically indicated by the numeral 148) that can be opened or closed to control the electrical connection between the battery 500 and the positive side of the HV DC bus. Similarly, the fixed busbar 104 and the movable busbar 108 function as negative side main contactors (schematically indicated by reference numeral 150 in the figures) that can be opened or closed to control the electrical connection between the battery 500 and the positive side of the HV DC bus.

[0061] Thus, as shown schematically in FIG. 7 , the two movable busbars 106, 108 are moved by the same actuation element 118 to change the state of the contactor device 100 between an open state in which the HV DC bus is disconnected from the HV battery 500, and a closed state in which the HV DC bus is connected to the HV battery 500.

[0062] 7 further illustrates a first aspect of the present disclosure, namely, the integration of a (first) current sensing element 152 (also referred to as a shunt resistor or shunt current sensor) into the contactor device 100. The current sensing element 152 is integrally formed with one of the busbars of the contactor device 100, here, for example, the movable busbar 108. In this manner, the need for a separate shunt current sensor connected in series with the contactor device 100 and the HV battery 500 is eliminated. Thus, by integrating the first current sensing element 152 within the contactor device 100, the (bolted) interconnection between one of the main contactors 148 and 150 and the current sensing element 152 formed by the contact arrangement of the contactor 100 can be eliminated.

[0063] Thus, the movable busbar 108 includes a current sensing element 152 that has a predetermined resistance and can be used to measure the battery current provided by the HV battery 500. The battery current corresponds to the current flowing through the contactor device, and is therefore also referred to as the "contactor current" throughout this specification. To measure the voltage drop occurring at the first current sensing element 152, the contactor device 100 includes detection nodes 154 and 156. A battery management system of the battery 500 in which the contactor 100 is used, or other external controller of the HV power system, can be electrically connected to the detection nodes 154 and 156, for example, by a wire harness or flex circuit. The BMS or external controller can then measure the battery current I bat of,

number

[0064] 8 to 10 schematically illustrate the integration of the first current sensing element 152 into one of the busbars of the contact configuration of the contactor 100. In the example of FIG. 7 , the movable busbar 108 arranged on the negative output side of the HV battery 500 is shown below as an example of one busbar of the contactor device 100 integrally formed with the first current sensing element 152. However, the first current sensing element may be integrally formed with the fixed busbar 104 arranged on the negative output side of the HV battery 500 in the example of FIG. 7 , or may be integrally formed with either the movable busbar 106 or the fixed busbar 102 arranged on the positive output side of the HV battery 500 in the example of FIG. 7 . It should be noted that in Figures 8-10, the dimensions and shapes of the exemplary busbars are shown only schematically, and the inventive concepts described with respect to this figure may be applied, inter alia, to one or more of the movable busbars 106 and 108 and fixed busbars 102 and 104 of the contactor device 100 shown and described with reference to Figures 1-5.

[0065] 8 illustrates three interconnected, strip-shaped movable busbars 108, each including a first busbar portion 108(1), a second busbar portion 108(2), and a current sensing element 152 disposed between the first busbar portion 108(1) and the second busbar portion 108(2). As described above, the first busbar portion 108(1) and the second busbar portion 108(2) may be formed of copper, aluminum, or other suitable conductive materials known in the art. In the illustrated example, the current sensing element 152 is preferably formed as a manganin strip and fixedly connected to the first busbar portion 108(1) and the second busbar portion 108(2) at wiring interfaces 158 and 160 by welding the manganin strip to the first busbar portion 108(1) and the second busbar portion 108(2).

[0066] In addition to manganin, current sensing element 152 may also be formed from isotane, isabelline, constantane, or other copper alloys containing copper, manganese, and / or nickel. However, other suitable materials known in the art that enable current sensing element 152 to be manufactured with a well-defined resistance are also contemplated. Instead of welding, current sensing element 152 may be interconnected to first busbar portion 108(1) and second busbar portion 108(2) by soldering, brazing, or other suitable interconnection method, thereby introducing only a small resistance at wiring interfaces 158 and 160.

[0067] Alternatively, the current sensing element 152 may be formed directly from the movable busbar 108 and therefore from the same material as the current sensing element. In this exemplary embodiment, the predetermined resistance of the current sensing element 152 may be defined as a region of the first busbar 108 that is shaped to have a predefined resistance and that forms the current sensing element 152. For example, an aperture may be formed in the movable busbar 108 to have a predetermined width and / or thickness transverse to the primary direction of current flow and function as the current sensing element 152. Techniques for forming the current sensing element 152 from the movable busbar 108 include, for example, stamping or punching. Alternatively, a portion of a pre-shaped busbar may be cut out to integrate the current sensing element 152 into the busbar.

[0068] By forming the current sensing element 152 directly from the bus bars of the contactor device 100, each bus bar can be directly manufactured integrally with the current sensing element, thus further reducing the resistance of the wiring interfaces 158, 160 since no additional interface resistance needs to be introduced.

[0069] 9 illustrates an exemplary arrangement of a first current sensing element 152 between a contact element 128 of the movable busbar 108 and a third terminal 114 (not shown in FIG. 8 ) integrally formed with the movable busbar 108. Here, the second busbar portion 108(2) includes, for example, the flexible busbar region 120, and the current sensing element 152 is disposed within a static region of the movable busbar 108 that is not affected by actuation of the electromagnetic actuator 118. Thus, changes in the state of the contactor device, for example, due to changes in the resistance of the current sensing element 152, are prevented from affecting detection of the battery current.

[0070] In another advantageous configuration, the current sensing element 152 may be disposed on one of the bus bars of the contactor device 100 and configured as a weakened portion to facilitate displacement or severing of the bus bar. For example, the current sensing element 152 may be disposed on one of the bus bars of the contactor device 100 as a hinged flexure 140 to displace the bus bar, as described with respect to Figures 1-5. Alternatively, the current sensing element 152 may define a predetermined break zone to facilitate severing or severing the bus bar at the predetermined break zone in response to actuation of the pyrotechnic actuator 130, as described above with particular reference to Figures 4 and 5.

[0071] 10 illustrates another advantageous configuration of the movable busbar 108. In addition to the (first) current sensing element 152, the movable busbar 108 may include a (second) current sensing element 162. Like the first current sensing element 152, the second current sensing element 162 is formed as a manganin strip and fixedly connected to the second busbar portion 108(2) and the third busbar portion 108(3) at wiring interfaces 164 and 166 by welding the manganin strip to the first busbar portion 108(1) and the second busbar portion 108(2). However, other manufacturing and wiring techniques described above for integrating the first current sensing element 152 may also be used to integrate the second current sensing element 162 into either the movable busbar 108 or the busbar of the contactor device 100. Thus, each of the first and second current sensing elements 152 and 162 may be formed from the same conductive material, or the first and second current sensing elements 152 and 162 may be formed from different conductive materials.

[0072] The integration of the second current sensing element allows the voltage drop across each of the first current sensing element 152 and the second current sensing element 162 to be measured once, thereby providing two independent voltage sense signals proportional to the battery current and enabling redundant measurements of the battery current. In this way, a single point fault in one of the sense lines used to sense the voltage drop across each of the first and second current sensing elements 152, 162 only affects one of the two sense signals, allowing the battery current to continue to be determined.

[0073] Note that the first current sensing element 152 and the second current sensing element 162 do not necessarily have to be arranged on the same busbar of the contactor device 100, and may be provided on different busbars of the contactor device. For example, in the example of FIG. 7, the first current sensing element 152 may be part of one of the fixed busbar 104 and the movable busbar 108 electrically connected to the negative output side of the HV battery 500, and the second current sensing element 162 may be part of one of the fixed busbar 102 and the movable busbar 106 electrically connected to the positive output side of the HV battery 500. Furthermore, three or more current sensing elements may be integrally formed with the busbars of the contactor device 100.

[0074] FIG. 11 illustrates a schematic circuit diagram of a second exemplary contactor device 200 conductively coupled to a high-voltage battery 500. Elements of the second exemplary contactor device 200 that correspond to elements of the first exemplary contactor device 100 are referred to by corresponding reference numerals. The second exemplary contactor device 200 benefits from a second aspect of the present disclosure, namely, integrated assembly circuitry. The integrated assembly circuitry allows the contactor device 200 to transfer at least some of the functionality of the battery management system of the battery 500 to the contactor device 200, or allows the contactor device 200 to integrate the battery management system of the battery 500, thereby enabling the contactor device to function more independently. As will become apparent below, the integrated assembly circuitry may be performed without or in conjunction with the integration of at least one current sensing element 152 described for the first exemplary contactor device 100 described with reference to FIGS. 7-11.

[0075] 11 by lines 270, 272, and 274, the assembly circuit 268 includes a control circuit that controls the operation of the electromagnetic actuator 118 to open and close the positive side main contactor 148 formed by the movable busbar 106 and the fixed busbar 102, and the negative side main contactor 150 formed by the movable busbar 108 and the fixed busbar 104. In this way, the control circuit of the assembly circuit 268 can directly take over control of the actuator 118, eliminating the need to implement a control function for the actuator 118 in the battery management system of the HV battery 500 or in other external control devices of the HV power system including the HV battery 500.

[0076] The control circuitry can control the operation of the electromagnetic actuator 118 in response to an operating parameter determined by the processing circuitry of the assembly circuit. The operating parameter can be a control command received by the processing circuitry from an external controller, such as a BMS of the battery 500 or a vehicle ECU, located external to the contactor device 200 to change the state of the contactor device 100 by actuating the electromagnetic actuator 118, or a control command received by the processing circuitry from an external entity to actuate a pyrotechnic actuator. Alternatively, the operating parameter can be a measurement determined directly by the processing circuitry or determined by an external controller and communicated to the processing circuitry. The measurement can be one of a battery current, a contactor voltage indicating the voltage drop between the first terminal 110 and the second terminal 112 or between the third terminal 114 and the fourth terminal 116, or a leakage path resistance existing between a ground terminal (or voltage reference terminal) of the assembly circuit and at least one busbar of the contactor device 200.

[0077] The assembly circuit 268 may further include several peripheral circuits, such as a communication circuit that enables communication between the processing circuit and one or more external controllers, such that the processing circuit can receive and / or send control commands from the one or more external controllers, and thus the one or more external controllers can monitor the operation of the contactor device 200. Communication between the communication circuit and the external controllers may be performed, for example, using a Controller Area Network (CAN) bus and CAN protocol, an isolated Serial Port Interface (isoSPI) interface and isoSPI protocol, or Ethernet. However, other known automotive network and industrial communication protocols may also be used.

[0078] The peripheral circuits may, for example, comprise a power supply unit that supplies power to the circuits of the assembly circuit 268. This allows the assembly circuit 268 to be supplied directly from the HV battery 500. However, other (external) power sources for the power supply of the assembly circuit 268 are also conceivable.

[0079] The various circuits of the assembly circuit 268 may be mounted on a single component carrier to form the assembly circuit as an integrated component. Thus, the term integrated component specifically refers to the fact that all of the components of the assembly circuit are packaged together as a single compact component. For example, a printed circuit board (PCB) may be used as the component carrier, and by mounting the assembly circuit 268 on the PCB, the PCB becomes a printed circuit board assembly (PCBA).

[0080] To further increase the degree of integration, the assembly circuit 268, which is mounted on a PCB to form a PCBA, can be located inside the contactor housing 146 (shown in FIG. 6 ). For example, a connector housing can provide specific housing sections for the assembly circuit 268 and / or specific cooling channels for effectively cooling the assembly circuit 268. The connection interface required to enable a wired connection between the assembly circuit 268 and an external controller can be provided in the form of a connector integrated into the contactor housing 146. However, it is also conceivable that a communication circuit in the assembly circuit 268 enables wireless communication with an external circuit.

[0081] It is also possible that the contactor device 200 is not housed in the contactor housing 146. In this case, the PCBA on which the assembly circuit 268 is mounted may be secured to the contactor device 200 by, for example, screwing, welding, etc. In such an embodiment, protection of the PCBA may be provided by, for example, a protective coating or by overmolding the PCBA.

[0082] In addition to receiving measurements from an external controller, additional sensing functionality may be implemented in the assembled circuitry to further increase the integration of contactor device 200 by enabling the assembled circuitry to directly sense and / or determine at least one of battery current, contactor voltage, or leakage path resistance.

[0083] In a first example, the assembly circuit 268 includes a first detection circuit configured to detect a first detection voltage indicative of the battery current (or contactor current). To this end, the contactor device 200 may include an integrated current sensing element 152 integrally formed with one of the busbars of the contactor 200. Here, the current sensing element 152 may be designed in any manner, as described with reference to FIGS. 8-10 in the description of the first exemplary contactor device 100. To measure the voltage drop across the current sensing element 152, the first detection circuit may be electrically connected to detection nodes 254 and 256 of the busbar on which the current sensing element 152 is formed (in this example, the movable busbar 108) via detection wires 276 and 278. As described above, there may be two or more current sensing elements integrally formed with the busbars of the contactor device 200. In this case, the first detection circuit may be electrically connected to each of the current sensing elements individually via the detection wires and measure the voltage drop across each of the current sensing elements individually.

[0084] It is not essential that the integrated current sensing element be integrally formed with the contactor device 200, and the first detection circuit and at least one external shunt resistor (for example, the shunt resistor 15 shown in FIG. 14) may be electrically connected by external wiring. In this case, the first detection circuit detects the voltage across the at least one external shunt resistor as the first detection voltage.

[0085] The processing circuit calculates the detected first detected voltage as the detected drop voltage V using the above equation (1) based on the detected voltage drop. resand determining the contactor current by setting the resistance of each current sensing element (or external shunt) to a predetermined resistance R. Alternatively, to determine the contactor current, the processing circuit can communicate the detected first detection voltage to an external controller, which can calculate the contactor current and communicate the calculation result to the processing circuit.

[0086] The control circuitry controls operation of the electromagnetic actuation element 118 and, optionally, actuation of a pyrotechnic actuator or an external fuse (e.g., fuse 12 shown in FIG. 14 ) based on the contactor current determination. For example, electromagnetic forces may be unable to separate the moving contacts 106, 108 from the stationary contacts 102, 104 when the contactor current (or battery current) exceeds a predetermined current threshold. Thus, if the control circuitry determines that the determined contactor current is equal to or exceeds the predetermined current threshold, it does not actuate the electromagnetic actuator 118 but instead issues an actuation signal to actuate the pyrotechnic actuator or the external fuse. However, in some exemplary configurations, if the external controller determines that the control circuitry cannot interrupt the contactor current by actuating the electromagnetic actuator 118, this actuation signal may instead be issued by the external controller.

[0087] In a second example, assembly circuit 268 includes a second detection circuit configured to detect a second detection voltage indicative of the contactor voltage. To this end, the second detection circuit may determine the voltage drop across negative main contactor 150, i.e., the voltage drop between movable busbar 108 and fixed busbar 104. To detect the voltage drop between movable busbar 108 and fixed busbar 104, the second detection circuit may be electrically connected to detection node 254 of movable busbar 108 via detection line 276 and to detection node 286 of fixed busbar 104 via detection line 280.

[0088] Alternatively or additionally, the second detection circuit may determine the voltage drop across the positive main contactor 148, i.e., the voltage drop between the movable busbar 106 and the fixed busbar 102. To detect the voltage drop between the movable busbar 106 and the fixed busbar 102, the second detection circuit may be electrically connected to a detection node 288 on the fixed busbar 102 via a detection wire 282 and to a detection node 290 on the movable busbar 106 via a detection wire 284.

[0089] The processing circuitry is configured to determine the contactor voltage based on the detected voltage drop as the voltage drop across one of the main contactors 148 and 150, or as an average of these voltages. Note that determining the contactor voltage may include the processing circuitry communicating the detected second detected voltage to an external controller, which then calculates the contactor voltage and communicates the calculation to the processing circuitry. By implementing contactor voltage detection as a function of the assembly circuitry 268, the condition of the contactor device 200 can be ascertained by the assembly circuitry 268 and / or an external controller monitoring operation of the contactor device 200, and contactor health and wear can be determined.

[0090] The control circuit controls the operation of the electromagnetic actuator 118 based on the contactor voltage determination. For example, because current peaks that may damage components electrically connected to the HV DC bus, such as DC link capacitors, may occur, the control circuit activates the electromagnetic actuator 118 to bring the movable busbars 106, 108 into a closed position only if the determined contactor voltage is less than or equal to a predetermined voltage threshold, but refrains from activating the electromagnetic actuator 118 if the determined contactor voltage is greater than the predetermined voltage threshold.

[0091] The assembly circuit may further include a pre-charge circuit 301 that may be electrically connected in parallel to one of the main contactors 148, 150 to reduce the contactor voltage before changing the state of the contactor device 100. Figure 12 shows a schematic circuit diagram of an exemplary pre-charge circuit 301 electrically connected in parallel to the positive main contactor 148, with the pre-charge circuit electrically connected to each busbar by being electrically connected to a node 303 on the movable busbar 108 and a node 305 on the fixed busbar 102. The pre-charge circuit includes at least one pre-charge resistor 307 and at least one pre-charge switch 309, with the pre-charge resistor 307 and the pre-charge switch 309 conductively coupled in series between the node 303 and the node 305. In this manner, the precharge circuit 301 can optionally bypass the main contactor 148 formed by the contact points between the movable busbar 108 and the fixed busbar 102 to short the terminals 110, 112 of the contactor device when the precharge switch 309 is closed.

[0092] The resistance of the precharge resistor 307 can be selected depending on the application to limit the maximum current flowing through the precharge circuit 301 when the precharge switch 309 is closed, thereby avoiding dangerous current peaks. The precharge switch 309 is a semiconductor switch, for example a metal-oxide-semiconductor field-effect transistor (MOSFET) or an insulated-gate bipolar transistor (IGBT), which can be easily integrated into the assembly circuit 268. However, other types of precharge relays may also be used.

[0093] The opening and closing of the pre-charge switch 309 may be controlled by a control circuit in the assembly circuit 268 or by an external controller depending on the contactor voltage. For example, if the contactor voltage is determined to be greater than a predetermined voltage threshold, the electromagnetic actuator 118 is deactivated, and the pre-charge switch 309 is closed. The electromagnetic actuator 118 may activate the movable contacts 106, 108 to a closed position, allowing current to flow through the main contactors 148, 150, as soon as the contactor voltage reaches or falls below the predetermined voltage threshold. In this way, the contactor device 200 is closed only when the contactor voltage is equal to or less than the predetermined voltage threshold, significantly reducing the risk of dangerous current peaks occurring after closing the movable contacts 106, 108. Because the pre-charge circuit 301 is an integral part of the assembly circuit 268, it is directly integrated into the contactor device 200, eliminating the need to connect an external pre-charge circuit to the contactor device 200.

[0094] In a third example, the assembly circuit 268 includes a third detection circuit configured to detect a third detection voltage indicative of leakage path resistance between one of the busbars of the contactor device 200 and ground potential (or a reference potential). The third detection voltage corresponds, for example, to the potential of the vehicle chassis. For the detection of leakage path resistance, the third detection circuit may be part of a leakage path resistance detection circuit. FIG. 13 shows a circuit diagram of an exemplary leakage path resistance detection circuit 311. The leakage path resistance detection circuit 311 is, for example, conductively coupled to the movable busbar 108 by node 313 and to a ground terminal 317 of the contactor device by node 315. The ground terminal 317 of the contactor device may be electrically connected to the vehicle chassis or other reference potential.

[0095] The leakage path resistance detection circuit 311 includes at least a first leakage path resistance detection resistor 319 and a second leakage path resistance detection resistor 321, and is conductively coupled in series to a node 323 between the movable bus bar 108 and the ground terminal 317. The leakage path resistance detection switch 323 is conductively coupled in parallel to the first leakage path resistance detection resistor 319 and optionally bypasses (shorts) the first leakage path resistance detection resistor 319 when the leakage path resistance detection switch 323 is closed. The leakage path resistance detection switch 323 is a semiconductor switch, such as a metal-oxide semiconductor field-effect transistor (MOSFET) or an insulated-gate bipolar transistor (IGBT), and can be easily integrated into the assembly circuit 268. However, other types of relays may also be used.

[0096] A third detection circuit (see reference numeral 325 in FIG. 13 ) is conductively coupled to a node 323 between the first leakage path resistance detection resistor 319 and the second leakage path resistance detection resistor 321. The third detection circuit detects the first leakage path resistance detection voltage V V across the second leakage path resistance detection resistor 321 when the leakage path resistance detection switch 323 is open. leak,1 and a second leakage path resistance detection voltage at the second leakage path resistance detection resistor 321 when the leakage path resistance detection switch 323 is closed. Vleak,2 is configured to detect

[0097] The processing circuit measures the detected leakage path resistance and detects the voltage V leak,1 and V leak,2 based on which the leakage path resistance of the contactor contact configuration is determined using the following equation (2):

number

[0098] where V bat is the voltage of the battery 500, and R ST1is the resistance of the leakage path resistance detection circuit 311 when the leakage path resistance detection switch 323 is closed. A more detailed description of determining the leakage path resistance can be found in the description of FIG. 1 of European Patent Application EP 18209536.4, which is incorporated herein by reference. Details of a possible leakage path resistance detection circuit 311 are described in the description of FIGS. 2 and 3 of European Patent Application EP 18209536.4. Of course, the circuits and methods disclosed in European Patent Application EP 18209536.4 can also be implemented to detect the leakage path resistance of the assembly circuit 268. However, other known leakage path resistance circuits and detection methods may also be implemented to detect the leakage path resistance of the assembly circuit 268.

[0099] Instead of being electrically connected to the movable busbar 108, the leakage path resistance detection circuit 311 may be electrically connected to other busbars of the contactor 200. Furthermore, leakage path resistance detection may be performed for more than one busbar of the contactor 200. In particular, it is particularly advantageous if leakage path resistance detection is performed for one busbar that is part of the positive main contactor 148 and one busbar that is part of the negative main contactor 150.

[0100] In addition, determining the leakage path resistance may include the processing circuit communicating the detected third detection voltage to an external controller, and the external controller calculating the leakage path resistance of the contact assembly and communicating the calculated result to the processing circuit.

[0101] Based on the leakage path resistance determination, the control circuitry may control the operation of the electromagnetic actuator 118 or activate the pyrotechnic actuator 130. In particular, the control circuitry may be configured to control the electromagnetic actuator 118 to change the state of the contactor device 200 to an open state if the control circuitry determines that the leakage path resistance of the assembly circuit (i.e., the leakage path resistance of any bus bar of the assembly circuit) is equal to or less than a predetermined resistance threshold. For example, if the movable contact cannot be moved any further because the contactor current exceeds a predetermined current threshold, the control circuitry may be configured to activate the pyrotechnic actuator 130 to permanently interrupt the current through the contactor device. Alternatively, in some exemplary configurations, if the external controller determines that the leakage path resistance of the assembly circuit is equal to or less than a predetermined resistance threshold, the external controller may issue a command to open the movable contacts 106, 108 or an activation signal to activate the pyrotechnic actuator, which may be processed by the processing circuitry and control circuitry of the assembly circuit.

[0102] The detection lines 276, 278, 280, 282, 284 electrically connecting the individual detection circuits to the respective detection nodes, as well as other wiring electrically connecting components of the assembled circuit (e.g., the pre-charge circuit 301 and the leakage path resistance detection circuit 311) to one or more of the bus bars of the contactor device 200, may be provided in the form of a wire harness or in the form of conductors of a flexible PCB. For example, the latter option allows the assembled circuit to be integrated directly onto a flexible PCB to further increase the integration density of the contactor device 200.

[0103] It should be noted that the functionality of each circuit in assembled circuit 268 may be realized by software, hardware, or software in conjunction with hardware. Furthermore, each circuit in assembled circuit 268 may be realized as a dedicated integrated circuit, and the dedicated integrated circuits are assembled to form the assembled circuit. Alternatively, the functionality of each circuit may be integrated into a common integrated circuit that forms the assembled circuit. Furthermore, one or more circuits in the assembled circuit may be realized using a general-purpose processor, a dedicated processor, or a programmable field programmable gate array (FPGA).

[0104] Furthermore, the voltage detection circuit of the assembly circuit may be formed by a dedicated analog-to-digital converter (ADC converter) or may be formed by a single ADC converter that sequentially performs the individual voltage detections as described above.

[0105] The present disclosure relates to a high-voltage power supply system including a first exemplary contactor device 100 or a second exemplary contactor device 200 and a battery 500. The HV power supply system may further include an external controller, such as a BMS of the battery 500 or a vehicle ECU, that controls the operation of the battery 500. As described above, the external controller may control the operation of the contactor device alone (in the case of the contactor device 100) or in cooperation with an internal controller (circuit assembly 268) of the contactor (contactor device 200). This allows the internal controller to take over at least some of the functions of the external controller and thus control the contactor device at least partially without relying on the external controller. In particular, the internal controller in the form of the circuit assembly 268 may also replace the BMS of the battery 500. Furthermore, the contactor devices 100 and 200 may allow for direct electrical connection of the contactor device 100 or 200 to the HV battery 500 without an external busbar. This can be achieved, for example, by increasing the length of the bus bars of the battery-side contact assembly, such as the movable bus bars 106 and 108 in the example above. This reduces the likelihood of short circuits during assembly of the HV power system or during a vehicle collision. Furthermore, the contactor devices 100 and 200 can be installed within the battery pack formed by the HV battery 500 by simply connecting two conductive elements.

[0106] As is clear from the above description, the idea of ​​the first aspect of the present disclosure, either individually or in combination with the idea of ​​the second aspect of the present disclosure, can increase the integration level of a contactor device and contribute to providing a contactor device that is inexpensive, space-saving, and lightweight. However, it should be noted that in implementing the second aspect of the present disclosure, it is not essential to integrate a current sensing element into the contactor device, and similarly, in implementing the first aspect of the present disclosure, it is not essential to integrate an assembly circuit into the contactor device. [Explanation of symbols]

[0107] 10 Power System 11 (High voltage) battery 12 Overcurrent protection device 13, 14 Main contactor 15 Shunt resistor 100, 200 Contactor Device 102, 104 Fixed busbar 106, 108 Movable busbar 110, 112, 114, 116, 317 Contactor terminals 118 Electromagnetic Actuator 120 Flexible contact area 122 Bulge 124 shaft 126 Retaining spring 128 contact elements 130 Pyrotechnic Actuator 132 Displacement Area 134 Pyrotechnic Pin 136 Displacement Elements 138 Piston structure 140 Hinge bending part 142 Holding power 146 Contactor housing 148, 150 Main contactor 152 (first) current sensing element 154, 156, 254, 256, 286, 288, 290 Detected nodes 158, 160, 164, 166 Wiring Interface 268 Assembled Circuit 276, 278, 280, 282, 284 Detection lines 301 Precharge circuit 303, 305, 313, 315, 323 nodes 307 Precharge Resistor 309 Precharge Switch 311 Leakage path resistance detection circuit 319, 321 Leakage path resistance detection resistor 325 Third detection circuit 10 Power System 11 (High voltage) battery 12 Overcurrent protection device 13, 14 Main contactor 15 Shunt resistor

Claims

1. a contact arrangement including at least one movable busbar (106, 108) and at least one fixed busbar (102, 104), the at least one movable busbar (106, 108) having a first contact area and the at least one fixed busbar (102, 104) having a second contact area; at least one actuating element (118) configured to change the state of the contactor device (200) at least from a closed state to an open state and from an open state to a closed state, wherein in the open state, the first contact area is electrically isolated from the second contact area, and in the closed state, the first contact area is conductively coupled to the second contact area; an assembly circuit (168) including a processing circuit configured to determine at least one operating parameter of the contactor device (200) and a control circuit configured to control operation of the at least one actuation element (118) in response to the operating parameter determined by the processing circuit; A contactor device (200) comprising:

2. a contactor housing (168) that at least partially houses the first busbars (106, 108) and the second busbars (102, 104); The assembly circuit is enclosed by the contactor housing (168); Optionally, the contactor housing (168) is a hermetically sealed housing. The contactor device (200) of claim 1.

3. and further comprising at least one second actuator (130) configured, upon actuation, to irreversibly prevent the passage of electrical current through said contact arrangement; the control circuitry is configured to control operation of the at least one second actuator (130) in response to the operating parameters determined by the processing circuitry; Optionally, the second actuator (130) is a pyrotechnic actuator; Optionally, the second actuator (130) is a mechanical actuator; Optionally, the second actuator (130) is configured to irreversibly displace or sever one or more of the at least one movable busbar (106, 108); and / or Optionally, the second actuator (130) is configured to irreversibly displace or sever one or more of the at least one fixed busbar (102, 104). A contactor device (200) according to claim 1 or 2.

4. The at least one operating parameter is: a contactor current indicative of the current flowing through the contact arrangement in a closed state of the contactor device (200); a contactor voltage indicative of the voltage drop between the input terminals (110, 114) of the contact arrangement and the output terminals (112, 116) of the contact arrangement; a leakage path resistance indicative of the resistance existing between a ground terminal of the assembly circuit and at least one of the bus bars (102, 104, 106, 108) of the contact arrangement; a control command received from an external entity to change the state of the at least one actuation element; optionally, a control command received from an external entity to actuate said second actuator (130); at least one of A contactor device (200) according to any one of claims 1 to 3.

5. the at least one operating parameter includes at least the contactor current; the assembly circuit (168) comprises a first detection circuit configured to detect a first detection voltage indicative of the contactor current; the processing circuitry is configured to determine the contactor current based on the detected first sensed voltage; the control circuit is configured to control operation of the at least one actuation element (118) in response to the determined contactor current; Optionally, the control circuit is configured to activate the second actuator (130) when the contactor current is determined to be equal to or greater than a predetermined current threshold. The contactor device (200) of claim 4.

6. the contact arrangement comprises a first current sensing element (152) having a first predetermined resistance; the first current sensing element (152) is integrally formed with one of the bus bars (102, 104, 106, 108) included in the contact arrangement; the first detection circuit is configured to detect the first detection voltage by detecting a voltage drop across the first current sensing element (152); the processing circuit is configured to determine the contactor current using the detected first sensed voltage and a resistance value of the current sensing element (152). The contactor device (200) of claim 5.

7. the contact arrangement comprises a second current sensing element (162) having a second predetermined resistance; the second current sensing element (162) is integrally formed with one of the bus bars included in the contact arrangement; the first detection circuit is configured to detect a first detection voltage by detecting a voltage drop across the second current sensing element (162); Optionally, the first current sensing element (152) and the second current sensing element (162) are integrally formed with the same busbar (102, 104, 106, 108) included in the contact arrangement, or Optionally, the first current sensing element (152) and the second current sensing element (162) are integrally formed with different bus bars (102, 104, 106, 108) included in the contact arrangement. The contactor device (200) of claim 6.

8. the first current sensing element (152) is formed from a first resistive material having a first specific electrical conductivity and a first temperature coefficient, and the second current sensing element (162) is formed from a second resistive material having a second specific electrical conductivity and a second temperature coefficient; Optionally, the first resistive region and the second resistive region are formed from the same material, or Optionally, the first resistive region and the second resistive region are formed from different materials. The contactor device (200) of claim 7.

9. at least a portion of the first current sensing element (152) defines a weakened portion (140) that assists the second actuator (130) in severing the busbar (102, 104, 106, 108) integrally formed with the current sensing element (152); Optionally, the weakened portion (140) is formed as a predetermined break zone, the busbar (102, 104, 106, 108) being configured to break at the predetermined break zone in response to actuation of the second actuator (130); and / or Optionally, the weakened portion (140) is formed as a hinge flexure, and the busbars (102, 104, 106, 108) are bendable about the hinge flexure in response to actuation of the second actuator (130). A contactor device (200) according to any one of claims 6 to 8.

10. the at least one operating parameter includes at least the contactor voltage; the assembly circuit (168) includes a second detection circuit configured to detect a second detection voltage indicative of the contactor voltage; the processing circuitry is configured to determine the contactor voltage based on the detected second detected voltage; the control circuit is configured to control operation of the at least one actuation element (118) in response to the determined contactor voltage. A contactor device (200) according to any one of claims 4 to 9.

11. the assembly circuit optionally having a precharge circuit (301) configured to be conductively coupled in parallel with the contact arrangement so as to bypass the contact arrangement; The precharge circuit (301) includes at least one precharge resistor (307) and at least one precharge switch (309) conductively coupled in series with the precharge resistor (307); The control circuit is configured to control the opening and closing of the precharge switch (309). The contactor device (200) of claim 10.

12. the control circuit is configured to control opening and closing of the precharge switch (309) in response to the determined contactor voltage; Optionally, if the actual determined contactor voltage is greater than a predetermined pre-charge voltage threshold, the control circuit is configured to close the pre-charge switch (309) and not change the state of the contactor device (200) from an open state to a closed state; and / or Optionally, the control circuit is configured to change the state of the contactor device (200) from an open state to a closed state if the actual determined contactor voltage is less than or equal to the predetermined pre-charge voltage threshold. The contactor device (200) of claim 11.

13. the at least one operating parameter includes at least the leakage path resistance; the assembly circuit (168) includes a third detection circuit configured to detect a third detection voltage indicative of the leakage path resistance; the processing circuitry is configured to determine the leakage path resistance based on the detected third detected voltage; the control circuit is configured to control operation of the at least one actuating element (118) in response to the determined leakage path resistance; Optionally, the control circuit is configured to control the at least one actuation element (118) to change the state of the contactor device (200) to an open state when the control circuit determines that the leakage path resistance is equal to or greater than a predetermined resistance threshold; and / or Optionally, the control circuit is configured to activate the second actuator (130) when the control circuit determines that the leakage path resistance is greater than or equal to the predetermined resistance threshold. A contactor device (200) according to any one of claims 4 to 12.

14. the assembly circuit (168) further comprises a leakage path resistance detection circuit (311) conductively coupled to the contact assembly by a first node (313) and to the ground terminal (315) of the assembly circuit by a second node (315); The leakage path resistance detection circuit (311) a voltage divider including a first series circuit in which a first leakage path resistance detection resistor (319) and a second leakage path resistance detection resistor (321) are conductively coupled in series with each other; a first leakage path resistance detection switch (323) optionally conductively coupled in parallel to the first leakage path resistance detection resistor (319) to bypass the first leakage path resistance detection resistor (319), wherein the first leakage path resistance detection switch (323) shorts out the first leakage path resistance detection resistor (319) when closed, and does not short out the first leakage path resistance detection resistor (319) when open; a third detection circuit (325) configured to detect a first leakage path resistance detection voltage across the second leakage path resistance detection resistor (321) when the first leakage path resistance detection switch (323) is open, and to detect a second leakage path resistance detection voltage across the second leakage path resistance detection resistor (321) when the first leakage path resistance detection switch (323) is closed; the processing circuit is configured to determine the leakage path resistance based on the first leakage path resistance detection voltage and the second leakage path resistance detection voltage and a battery voltage of a battery (500) to which the contactor device (200) is connected. The contactor device (200) of claim 13.

15. 1. A method for controlling a contactor device (200) performed by an assembly circuit (168) of said contactor device (200) having a contact arrangement including at least one movable busbar (106, 108) having a first contact area and at least one fixed busbar (102, 104) having a second contact area, comprising: determining at least one operating parameter of the contactor device (200); and controlling operation of at least one actuation element (118) in response to the determined operating parameter; the at least one actuation element (118) is configured to change the state of the contactor device (200) at least from a closed state to an open state and from an open state to a closed state, wherein in the open state the first contact area is electrically isolated from the second contact area and in the closed state the first contact area is conductively coupled to the second contact area; method.

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