Multiple switch contact devices with pre-charging relays

Abstract

In electromechanical switching devices, it provides low contact resistance and high contact force without requiring power to maintain the switch in a specific state. [Solution] In the contactor circuit 1000, the contact device 1020 of multiple switches equipped with a pre-charging system comprises a switch array and an actuator for operating each switch in the switch array. The switch array comprises a first switch 1010 (S1) for connecting a first battery pack 1004 to the circuit, a second switch 1012 (S2) for connecting a second battery pack 1004 to the circuit, a third switch 101 (S0) for connecting the second battery pack in series with the first battery pack to the circuit, and a fourth switch 1016 (S3) for connecting a pre-charging resistor to at least one of the second battery packs with the first battery pack.

Description

Background Art

[0001] Electromechanical switching devices such as contactors and relays are designed to conduct a certain amount of current over a certain period of time. Such devices are particularly important in electric vehicles. Usually, electric vehicles are equipped with a plurality of electromechanical switches that open and close the high-current path between the battery pack and the electrical system. These switches are controlled by different operating mechanisms. In order to prevent a short circuit of the battery pack, the electromechanical switching element of the contactor provided in the battery needs to withstand mechanical shock and be coordinated to change the configuration of connecting a plurality of switches to the battery.

Summary of the Invention

[0002] In order to avoid unnecessary combinations of switches, a multi-switch contact device is provided in which a single mechanical operating mechanism operates a plurality of switches so that dangerous combinations of switches are mechanically impossible. As a specific example, the plurality of switches can be actuated by a plurality of the cams coupled to the same camshaft. Different combinations of switch states (open or closed) between the plurality of switches are realized by the rotation of the camshaft. Thereby, a limited set of one of the configuration states that can be controlled by one actuator is provided. The use of different cam shapes or the cams on the shaft of the cam facing different directions can be done to achieve different combinations of switch states. Thereby, a low contact resistance and a high contact force are provided without the need for power to keep the switch in a specific state.

[0003] According to embodiments of this disclosure, the contact force is further increased by utilizing the Lorentz force acting on the movable contact due to the shape and orientation of the fixed and movable contacts. In some examples, the shape and orientation of the fixed and movable contacts are such that they form conductors that fold back in a loop relative to themselves. In some embodiments, the fixed contact forms a C-shape or other partial loop shape, and the movable contact is oriented to contact the inner surface of the fixed contact within the loop. When a high current flows through the fixed and movable contacts, the Lorentz force acting on the movable contact causes it to repel the fixed contact, increasing the contact force. In some embodiments, the contact equipment of the multiple switches includes a single pre-charge switch. These embodiments eliminate the need for a separate pre-charge circuit.

[0004] In one embodiment, a multi-switch contact device is disclosed that includes a pre-charging system comprising a switch array and an actuator configured to actuate each switch in the switch array. In this embodiment, the switch array includes a first switch configured to connect a first battery device to a circuit and a second switch configured to connect a second battery device to the circuit. The switch array also includes a third switch configured to connect the first and second battery devices in series to the circuit and a fourth switch configured to connect a pre-charging resistor to at least one of the first and second battery devices.

[0005] In another embodiment, a system having a plurality of components, including a first battery device and a second battery device, is disclosed. This system also includes a vehicle power distribution circuit and a plurality of switch contacts connecting the plurality of components to the vehicle power distribution circuit. In this embodiment, the plurality of switch contacts includes a switch array and an actuator configured to actuate each switch in the switch array. The switch array includes a first switch configured to connect the first battery device to the circuit and a second switch configured to connect the second battery device to the circuit. The switch array also includes a third switch configured to connect the first battery device and the second battery device in series to the circuit and a fourth switch configured to connect a pre-charging resistor to at least one of the first battery device and the second battery device.

[0006] In another embodiment, a method for operating a multi-switch contact device with a pre-charging system is disclosed. The multi-switch contact device further comprises a switch array and an actuator comprising a shaft and configured to actuate each switch in the switch array. The switch array includes a first switch configured to connect a first battery device to a circuit and a second switch configured to connect a second battery device to the circuit. The switch array also includes a third switch configured to connect the first and second battery devices in series to the circuit and a fourth switch configured to connect a pre-charging resistor to at least one of the first and second battery devices. The method includes rotating the shaft of the actuator from a fully open position with the first, second, third, and fourth switches open to a pre-charging position with the fourth switch closed and the first, second, and third switches open. This method also includes rotating the shaft from the pre-charging position to a series position where the fourth switch is closed and the third switch is closed. This method also includes rotating the shaft from the series position to the pre-charging position, and rotating the shaft from the pre-charging position to the fully open position. [Brief explanation of the drawing]

[0007] [Figure 1] This is a circuit diagram of a multi-switch contact device according to at least one embodiment of the present disclosure.

[0008] [Figure 2A] This is a diagram of a first state of an exemplary switch device for a multi-switch contact device, according to at least one embodiment of the present disclosure.

[0009] [Figure 2B] Figure 2A shows another state of the switch equipment, as described above.

[0010] [Figure 3] This figure shows the configuration of a multi-switch contact device according to at least one embodiment of the present disclosure.

[0011] [Figure 4] This is an exploded view of a multi-switch contact device according to at least one embodiment of the present disclosure.

[0012] [Figure 5] Various cam shapes according to embodiments of this disclosure are shown.

[0013] [Figure 6] The Lorentz force on a conductor, in accordance with the principles of this disclosure, is shown.

[0014] [Figure 7] This figure shows an example of individual switch contacts for a plurality of switch contacts according to at least one embodiment of the present disclosure.

[0015] [Figure 8A] An example of a busbar configuration for a multi-switch contact device according to at least one embodiment of the present disclosure is shown.

[0016] [Figure 8B] An example of individual switch equipment for contact devices of multiple switches, according to at least one embodiment of the present disclosure, is shown.

[0017] [Figure 8C] An example of a busbar configuration for a multi-switch contact device according to at least one embodiment of the present disclosure is shown.

[0018] [Figure 9] An outline of an example of a power distribution system for an electric vehicle, according to at least one embodiment of the present disclosure, is shown.

[0019] [Figure 10]Schematic circuit diagram of contact devices of multiple switches according to at least one embodiment of the present disclosure.

[0020] [Figure 11] Table of switch states of contact devices of multiple switches according to at least one embodiment of the present disclosure.

[0021] [Figure 12] An example of a contact device of multiple switches incorporating a pre-charging system according to at least one embodiment of the present disclosure is shown.

[0022] [Figure 13] Flowchart of an exemplary method for operating a contact device of multiple switches according to at least one embodiment of the present disclosure.

[0023] [Figure 14] Flowchart of an exemplary method for operating a contact device of multiple switches provided with a pre-charging system according to at least one embodiment of the present disclosure.

MODE FOR CARRYING OUT THE INVENTION

[0024] The conduction and interruption of an electric circuit have been carried out since ancient times as long as the electric circuit itself, and are often used as a method of switching the power to the connected electrical equipment between the "on" and "off" states. An example of a device often used for the conduction and interruption of a circuit is a contactor, which is electrically connected to one or more devices or power sources. The contactor is configured to be able to interrupt or conduct the circuit by switching between the "open" and "closed" states, and controls the power to and from the device.

[0025] As society develops, various innovations are accelerating the spread of electrical systems and equipment. Examples of these innovations include the recent advancements in electric vehicles, which are becoming the standard for high energy efficiency and will likely replace most conventional petroleum-fueled vehicles. In such expensive and commonly used electrical equipment, overcurrent protection is particularly useful to prevent malfunctions and permanent damage. Furthermore, overcurrent protection can prevent safety hazards such as electric shock and electrical fires. These modern improvements to electrical systems and equipment require improved means to enhance the safety, reliability, and efficiency of contactor starting mechanisms.

[0026] This specification describes various embodiments of contact devices having specific components or parts thereof that are integrally formed as a whole to improve the above operating characteristics and enhance the reliability and safety of operation. The present invention also provides novel features to the components of the above contact devices, which provide desired operating characteristics, performance and safety. Embodiments of the present invention also relate to contactors (i.e., electrical switching devices) using the above contact devices according to the present invention, as well as electrical circuits and systems using the electrical switching devices according to the present invention.

[0027] The syntax used herein to illustrate specific examples is not intended to restrict other examples. Wherever singular forms such as “a,” “an,” and “the” are used, unless it is explicitly or implicitly defined that the use of only a single element is required, other examples may use multiple elements to implement the same function. Similarly, where it is stated that a function is implemented using multiple elements, other examples may implement the same function using a single element or processing mechanism. Furthermore, where the terms “comprises,” “comprising,” “includes,” and / or “include” are used, they identify the presence of the described features, components, steps, operations, processes, actions, elements, and / or components, but it will be understood that they do not exclude the presence or addition of one or more other features, components, steps, operations, processes, actions, elements, components, and / or any set thereof.

[0028] When an element is described as being "connected" or "joined" to another element, it should be understood that those elements may be connected or joined directly or by one or more intervening elements. When two elements A and B are combined using "or," this should be understood to disclose all possible combinations, namely A only, B only, and a combination of A and B. Another way to express all the above possible combinations is "at least one of A and B." The same applies to combinations of three or more elements.

[0029] Therefore, while various modifications and alternative forms are possible in the additional examples, some specific examples are shown in the figures and described in detail below. However, this detailed description is not limited to the specific forms described for further examples. Further examples may encompass all modifications, equivalents, and alternative forms included within the scope of this disclosure. Throughout the description of the figures, similar numbers refer to similar or similar elements that may be implemented in the same or modified forms, providing the same or similar functionality when compared to one another.

[0030] An exemplary method and apparatus for a multi-switch contact device relating to this disclosure will be described starting with Figure 1, with reference to the accompanying drawings. Figure 1 shows a circuit 100 of a battery-configured contactor using a multi-switch contact device according to at least one embodiment of this disclosure. This battery-configured contactor may be used in an electric vehicle to drive the electric vehicle by connecting multiple battery packs to a vehicle power distribution system and to charge the battery packs. In this example, a first switch 110 (hereinafter referred to as "S1") is operable to open and close the connection between the positive terminal of a first battery pack 104 and the positive terminal 106 of the vehicle power distribution system. The negative terminal of the first battery pack 104 is connected to the negative terminal 108 of the vehicle power distribution system. In this example, a second switch 112 (hereinafter referred to as "S2") is operable to open and close the connection between the negative terminal of a second battery pack 102 and the negative terminal 108 of the vehicle power distribution system. The positive terminal of the second battery pack 102 is connected to the positive terminal 106 of the vehicle power distribution system. In this example, the third switch 114 (hereinafter referred to as "S0") can be operated to open and close the series connection of battery packs 102 and 104. When the first switch 110 is closed, the first battery pack 104 is directly connected to the vehicle power distribution system. When the second switch 112 is closed, the second battery pack 102 is directly connected to the vehicle power distribution system. When both the first switch 110 and the second switch 112 are closed, both battery packs 102 and 104 are connected in parallel to the vehicle power distribution system. When the third switch 114 is closed, both battery packs 102 and 104 are connected in series to the vehicle power distribution system. However, if either the first switch 110 or the second switch 112 is closed while the third switch 114 is closed, the battery packs 102 and 104 may be directly short-circuited, potentially causing the switch contacts to weld together and / or damaging the battery packs 102 and 104. To prevent this, the switch contacts are required to have high resistance to mechanical shock. The solenoid contactor coil requires a certain amount of power during startup.

[0031] Accordingly, according to some embodiments of the present disclosure, a battery-configured contactor utilizes a multi-switch contactor 120 in which switches S0, S1, and S2 are mechanically coupled to prevent switch S0 from being opened while switch S1 or switch S2 is closed, and vice versa. A multi-switch contactor according to at least one embodiment of the present disclosure comprises a switch array (e.g., switches S0, S1, S2) including: a first switch implemented by one first movable contact and at least one first fixed contact and configured to switch a switch state between an open state and a closed state; a second switch implemented by one second movable contact and at least one second fixed contact and configured to switch a switch state between an open state and a closed state; and a third switch implemented by one third movable contact and at least one third fixed contact and configured to switch a switch state between an open state and a closed state. The multi-switch contact device described above further comprises an actuator configured to actuate the first movable contact, the second movable contact, and the third movable contact. The actuator comprises a shaft, and the switch state of each of the three switches changes in accordance with the rotation of the shaft. In the following examples, the multi-switch contact device is described as including three switches, but the principles of this disclosure are also applicable to multi-switch contact devices including fewer than three switches or more than three switches. That is, a single actuator is used to change multiple switches to different switch states so that some combinations of switch states are mechanically prohibited. As will be shown in more detail below, the mechanical coupling of contactor switches can be achieved with low contact resistance, no buoyancy, no holding force, and a large contact action.

[0032] For further explanation, Figures 2A and 2B show an example of a single switch contact device 200 for a multi-switch contact device, according to at least one embodiment of the present disclosure. The switch contact device 200 includes fixed contacts 202, 204 and a movable contact 206. One end of the movable contact 206 is coupled to the fixed contact 202. The movable contact 206 may be rotatable, flexible, or deformable. The other end is coupled to a spring 208 held by a support structure 220 (e.g., a contactor housing). In a first state, the movable contact 206 is held in a closed position by the spring 208. To transition to a second state, a force is applied to the movable contact 206 by a rotating cam 212, causing the movable contact 206 to move, separating the movable contact 206 from the fixed contact and compressing the spring, thus opening the contact device 200. To move the switch device 200 to a second state, the cam 212 is rotated to release contact with the movable contact 206, thereby causing the spring 208 to apply force to the movable contact 206 and make contact with the fixed contact 204, thus closing the switch device. The cam 212 rotates via the shaft 214. In some examples, multiple cams 212 may be coupled to the same shaft 214, thereby providing a mechanical link for acting on multiple movable contacts corresponding to multiple switches in the multi-switch contact device.

[0033] For further reference, Figure 3 shows a diagram 300 of the configuration of a multi-switch contact device according to at least one embodiment of the present disclosure. The diagram 300 shows the state of three switch devices S0, S1, and S2 based on the rotation of the camshaft 302. For ease of explanation, the three switch devices S0, S1, and S2 may be included in a contacter of a battery configuration configured to connect battery packs A and B to a vehicle power distribution system. In such an example, battery pack A would correspond to battery pack 102 in Figure 1, and battery pack B would correspond to battery pack 104 in Figure 1, in which case switch device S2 would correspond to switch 112 in Figure 1, switch device S1 would correspond to switch 110, and switch device S0 would correspond to switch 114 in Figure 1. However, it should be understood that the above configuration shown in Figure 3 is also applicable to other vehicle contactors, such as fast-charging contactors, auxiliary contactors, or general-purpose contactors, as well as contactors for non-vehicle applications. The switch contacts S0, S1, and S2 may be arranged parallel to the axis of the camshaft 302 such that the rotation of the camshaft changes the switched state of at least one switch (for example, as shown in Figure 4). In this example, a 180-degree rotation changes the switched state of all of the switches. Three cams 301, 311, and 321 are coupled to the camshaft 302, and together they form an actuator for all of the switch contacts.

[0034] In the example shown in Figure 3, the first switch device S2 includes a fixed busbar 306 (i.e., a fixed contact) and a deformable busbar 305 (i.e., a movable contact). The switch device S2 further includes a rocking shaft 308 coupled to the deformable busbar 305. In this example, the switch device S2 is a "normally closed" switch in that the deformable busbar 305 is in contact with the fixed busbar 306 in such a way that the contact between the deformable busbar 305 and the fixed busbar 306 is insulated, unless the rocking shaft 308 is actuated and deforms the deformable busbar 305. In some examples, the rocking shaft 308 is equipped with a spring, and the deformable busbar 305 maintains contact with the fixed busbar 306 as long as the force applied to the rocking shaft 308 by the cam 301 does not exceed the biasing force of the spring. The rocking shaft 308 is actuated by the cam 301, which includes a substantially circular portion 303 and one or more substantially flat portions 304. When the substantially circular portion 303 of the cam 301 engages with the rocking shaft 308, one end of the rocking shaft closer to the cam 301 is pushed downward, pushing the other end of the rocking shaft 308 and the deformable busbar 305 upward, disengaging the deformable busbar 305 from contact with the fixed busbar 306. When the substantially flat portion 304 of the cam 301 engages with the rocking shaft 308, the end of the rocking shaft 308 closer to the cam 301 is able to return to a closed position that facilitates contact between the deformable busbar 305 and the fixed busbar 306. In this example, the cam 301 includes two substantially flat portions, one corresponding to a closed switch state for direct connection of battery pack A only, and the other corresponding to a closed switch state for parallel connection of battery pack A and battery pack B. Thus, the rotation of the cam 301 opens and closes the switch S2 depending on the rotation of the camshaft 302 and whether the rocking shaft 308 is engaged with the substantially circular portion 303 of the cam or with the substantially flat portion. In an alternative embodiment, the switch S2 may be configured as a "normally open" switch that acts on the cam 301 to move the deformable busbar 305 and bring it into contact with the fixed busbar 306.

[0035] In the example of Figure 3, the second switch device S1, like the switch device S2, includes a fixed busbar 326 (i.e., a fixed contact) and a deformable busbar 325 (i.e., a movable contact). The switch device S1 further includes a rocking shaft 328 coupled to the deformable busbar 325. In this example, the switch device S1 is a "normally closed" switch in that, unless the rocking shaft 328 is actuated to deform the deformable busbar 325, the deformable busbar 325 contacts the fixed busbar 326 in such a way that the contact between the deformable busbar 325 and the fixed busbar 326 is broken, and the switch is opened, and as a result the switch is open. In some examples, the rocking shaft 328 is equipped with a spring that keeps the deformable busbar 325 in contact with the fixed busbar 326 as long as the force applied to the rocking shaft 328 by the cam 321 does not exceed the biasing force of the spring. The rocking shaft 328 is actuated by the cam 321, which includes a substantially circular portion 323 and one or more substantially flat portions 324. When the substantially circular portion 323 of the cam 321 engages with the rocking shaft 328, one end of the rocking shaft closer to the cam 321 is pushed downward, thereby pushing the other end of the rocking shaft 328 and the deformable busbar 325 upward, disengaging the deformable busbar 325 from contact with the fixed busbar 326. When the substantially flat portion 324 of the cam 321 engages with the rocking shaft 328, the end of the rocking shaft 328 closer to the cam 321 is able to return to a closed position that facilitates contact between the deformable busbar 325 and the fixed busbar 326. In this example, the cam 321 includes two substantially flat portions 324, one corresponding to a closed switch state for directly connecting only battery pack B, and the other corresponding to a closed switch state for connecting battery pack A and battery pack B in parallel. Thus, the rotation of the cam 321 causes the switch S1 to open and close, depending on the rotation of the camshaft 302 and whether the oscillating shaft 328 is engaged with the substantially circular portion 323 of the cam or with the substantially flat portion.In an alternative embodiment, switch S1 may be configured as a "normally open" switch, in which the cam 321 actsuates the rocking shaft 328 to move the deformable busbar 325 and bring it into contact with the fixed busbar 326.

[0036] In the example above in Figure 3, the third switch device S0, like the switch device S2, includes a fixed busbar 316 (i.e., a fixed contact) and a deformable busbar 315 (i.e., a movable contact). The switch contact device S0 further includes a rocking shaft 318 coupled to the deformable busbar 315. In this example, the switch contact device S0 is a "normally closed" switch in that the deformable busbar 315 is in contact with the fixed busbar 316 unless the rocking shaft 318 is actuated in such a way that the contact between the deformable busbar 315 and the fixed busbar 316 is broken and the switch opens, thereby deforming the deformable busbar 315. In some examples, the rocking shaft 318 is equipped with a spring, which maintains the contact of the deformable busbar 315 with the fixed busbar 316 as long as the force applied to the rocking shaft 318 by the cam 311 does not exceed the biasing force of the spring. The rocking shaft 318 is actuated by the cam 311, which includes a substantially circular portion 313 and one or more substantially flat portions 314. When the substantially circular portion 313 of the cam 311 engages with the rocking shaft 318, one end of the rocking shaft closer to the cam 311 is pushed downward, thereby pushing the other end of the rocking shaft 318 and the deformable busbar 315 upward, disengaging the deformable busbar 315 from contact with the fixed busbar 316. When the substantially flat portion 314 of the cam 311 engages with the rocking shaft 318, the end of the rocking shaft 318 closer to the cam 311 is allowed to return to a closed position, and the rocking shaft 318 facilitates contact between the deformable busbar 315 and the fixed busbar 316. In this example, the cam 311 includes one substantially flat portion 314 corresponding to a closed switch state for connecting battery pack A and battery pack B in series. Accordingly, the rotation of the cam 311 opens and closes the switch S0 depending on the rotation of the camshaft 302 and whether the rocking shaft 318 is engaged with the substantially circular portion 313 of the cam or with the substantially flat portion of the cam. In an alternative embodiment, the switch S0 may be configured as a "normally open" switch in which the cam 311 actsuates the rocking shaft 318 to move the deformable busbar 315 into contact with the fixed busbar 316.

[0037] Figure 300 above, which shows the configuration state of the contact device of the multiple switch, includes four different states. In the first state 352, the camshaft is rotated 0 degrees. Cams 301 and 321 apply force to the oscillating shafts 308 and 328, causing the switch devices S2 and S1 to be in the open state when the oscillating shaft 318 of the switch device S0 is engaged with the substantially flat portion 314 of the cam 311, and causing the switch device S0 to be closed when rotated 0 degrees. Thus, while the switch device S0 connects battery pack A and battery pack B in series, parallel or direct connection of battery pack A and battery pack B is mechanically prevented.

[0038] In the second state 354, the camshaft 302 is rotated 90 degrees (e.g., counterclockwise) relative to state 352. Before the oscillating shaft 328 of the switch device S1 engages with the substantially flat portion 324 of the cam 321 of the switch device S1, which has been rotated 90 degrees, the cam 311 applies force to the oscillating shaft 318 to open the switch contact device S0. Once the oscillating shaft 328 engages with the substantially flat portion 324 of the cam 321, the switch device S1 closes. Thus, while the switch device S1 connects battery pack B directly to the power distribution system, a series connection between battery pack A and battery pack B is mechanically prevented. The cam 301 continues to apply force to the oscillating shaft 308, holding the switch contact device S2 in the open state.

[0039] In the third state 356, the camshaft 302 is rotated 180 degrees (for example, counterclockwise) relative to state 352. The cam 311 continues to apply force to the oscillating shaft 318, maintaining the switch device S0 in the open state. The oscillating shaft 328 of the switch device S1 engages with the second substantially flat portion 324 of the cam 321 of the 180-degree rotated switch contact device S1, maintaining the switch contact device S1 in the closed state. Simultaneously, the oscillating shaft 308 of the switch device S2 engages with the first substantially flat portion 304 of the cam 301 of the switch device S2, thereby allowing the switch device S2 to transition to the closed state. Thus, while the switch devices S1 and S2 connect battery pack A and battery pack B in parallel to the power distribution system, the series connection of battery pack A and battery pack B is mechanically prevented.

[0040] In the fourth state 358, the camshaft is rotated 270 degrees (e.g. counterclockwise) or -90 degrees (e.g. clockwise) relative to state 352. Cam 311 continues to apply force to the oscillating shaft 318, keeping the switch device S0 in the open state. Cam 321 applies force to the oscillating shaft 328, keeping the switch device S1 in the open state. Upon rotation of 270 degrees, the oscillating shaft 308 of the switch device S2 engages with the second substantially flat portion of the cam 301 of the switch device S2, thereby causing the switch device S2 to move to the closed state. Therefore, while the switch device S2 is directly connecting battery pack A to the power distribution system, the series connection of battery pack A and battery pack B is mechanically prevented.

[0041] As shown in Figure 3, in some examples, the state of switch contact S1 can be maintained in the closed state while switch contact S2 transitions to the closed state between 90 and 180 degrees. In other examples, a configuration is employed in which the original contact is insulated before the new contact makes contact, so that all switch devices S0, S1, and S2 are in the open state when the rotation of the camshaft is not 0, 90, 180, or 270 degrees (-90 degrees). In some examples, a position sensor is used to determine the absolute rotation of the camshaft. Thus, the contact devices of the multiple switches have only four different states: a state in which at least one battery pack is connected to the power distribution system, and a state in which the series connection of the battery packs is mechanically prevented when the battery packs are connected directly or in parallel.

[0042] It will be understood that other cam shapes may be used instead of a cam having a circular portion and a flat portion. For example, a groove may be used instead of a flat surface. In another example, the switch device includes a "normally open" switch in which a leaf-shaped or other protruding actuating member applies force to the deformable contact, bringing it into contact with the fixed contact and closing the switch. In some variations, "normally open" and "normally closed" switches can be used in combination within the same array of switches.

[0043] It will be understood that two or more cams with different cam shapes may be used to achieve different switch states between the corresponding switches described above. Similarly, two or more cams having the same shape but different orientations on the camshaft may be used to achieve different switch states between the corresponding switches described above. In some cases, two cams may have the same shape and the same orientation on the camshaft so that they operate the same switch state (for example, to reduce the current per contact) between the corresponding switches. Therefore, the multiple cams corresponding to the multiple switches described above may differ in shape, orientation, or arrangement, in which case all cams are actuated by the same camshaft.

[0044] Furthermore, it will be understood that the deformable busbar may be replaced with a fixed busbar coupled to a movable contact that can rotate or swivel. This flexible busbar may be replaced with a braided cable.

[0045] The multi-switch contact devices described above, according to Figures 2A, 2B, and 3, can be applied to battery-configured contactors, as well as to other devices configured as described above with different cam shapes, and it will be further understood that they enable high-voltage, high-current connections requiring low contactor resistance, such as fast-charging contactors, or high-voltage, high-current connections with no equipment current consumption, such as general-purpose contactors used for power supply from vehicles to grid systems.

[0046] Based on the above, a contact device with multiple switches, as shown in Figures 2A, 2B, and 3, is provided, and in this contact device, (1) A single mechanical actuation mechanism operates all the switches, making it mechanically impossible to create dangerous combinations of switches. (2) The only four main possible states are series, battery A connected only, battery B connected only, and A+B connected in parallel. An intermediate state in which all contacts are open may also be defined. (3) Since the above operating mechanism can move in the forward and backward directions, after a series or parallel configuration, it is possible to connect only A or only B first. (4) The above-mentioned operating device does not consume power once the desired connection state described above is achieved. (5) Very high contact force (e.g., 100N) enables very low equipment resistance (e.g., < 50 μHm) and high stray current (> 25 kA). (6) Contact can be made using a single contact and a flexible busbar, or a dual movable contact using a rigid contact.

[0047] Figure 4 shows an exploded view of an exemplary multiple-switch contact device 400 according to at least one embodiment of the present disclosure. The exemplary contact device 400 comprises a cam contact device 401 including three cams 402, 403, and 404 coupled to a camshaft 405, the rotation of which is driven by a motor 406. The contact device comprises three switch devices, each including a fixed contact 410 and a deformable contact 408. The cams 402, 403, and 404 act on their respective oscillating shafts 412 to deform their respective deformable contacts 408 and open each of the switches. When the oscillating shaft 412 engages with the planar portion of the cam, a biasing spring 414 attempts to move the oscillating shaft to a closed position, maintaining contact between the deformable contact 408 and the fixed contact 410. When the rocking shaft 412 engages with the circular portion of the cam, the cam applies a force to the rocking shaft 412 that overcomes the biasing force of the spring 414, thereby moving the rocking shaft 412 to the open position, and as a result the rocking shaft 412 bends the deformable contact 408, releasing contact with the fixed contact 410. In some examples, the contact device 400 of the multiple switches includes a position sensor (not shown) for detecting the rotation of the camshaft 405. The position sensor provides the absolute angle of the camshaft, allowing the camshaft to rotate to a new set point to change the switch state. The position sensor may consist of, for example, a non-contact type position sensor and a contact device (e.g., a potentiometer). The signal from the position sensor can be used to control the position of the camshaft and to transmit the state of the contact to the vehicle controller.

[0048] To further illustrate, Figure 5 shows various different cam shapes 502, 504, 506, 508, 510, and 512, including examples of cam blades 511 and leaf-like portions 513 according to this disclosure.

[0049] To further explain, Figure 6 shows the effect of the Lorentz force on a bent conductor based on the principle of the present invention. When an electric current flows through a conductor, the Lorentz force generates a repulsive force on the conductor. As shown in Figure 6, when a conductor is bent into a half-loop, semicircle, or C-shape, a high current flows through the conductor, causing it to expand outward from the magnetic field. As a result, the conductor develops a self-repulsive force.

[0050] To further illustrate, Figure 7 shows a switch device 700, which is another example for a multi-switch contact device according to at least one embodiment of the present invention. The switch contact device 700 is similar to the switch contact device in Figure 3 in that it includes a fixed busbar 706, a deformable busbar 705, a rotating cam 701, and a rocking shaft 708 fixed to one end of the deformable busbar 705. The other end of the deformable busbar 705 is coupled to a lead 720. As shown in Figure 7, the switch contact device 700 is normally closed. The rocking shaft 708 is spring-biased by a spring 707 to hold the rocking shaft 708 in a closed position, and the biasing force acting on the rocking shaft 708 bends the deformable busbar 705 toward the fixed busbar 706, resulting in contact between the contacts on the deformable busbar 705 and the contacts on the outer surface of the fixed busbar 706. The other end of the fixed busbar is coupled to a lead 722. In the closed state described above, the deformable busbar 705 and the fixed busbar 706 close the circuit between the leads 720 and 722. To open the circuit, the cam 701 is rotated, causing the blade or leaf-shaped portion 703 to rotate the oscillating shaft 708, which in turn compresses the spring 707, bending the deformable busbar 705 and eliminating contact with the fixed busbar 706.

[0051] The fixed busbar 706 is generally C-shaped or semicircular, and when the deformable busbar 705 and the fixed busbar 706 come into contact, a loop is formed, similar to the conductor shown in Figure 6, and this loop folds back relative to itself. The current flowing through the fixed busbar 706 and the deformable busbar 705 generates a repulsive force, indicated by the force arrow 730, which pushes the deformable busbar 705 out of the magnetic field and expands it. The deformable busbar 705 is repelled from the fixed busbar 706, and this effect reduces or suppresses the contact force between the fixed busbar 706 and the deformable busbar 705. As will be described later, the arrangement of the deformable busbar 705 relative to the fixed busbar 706 can be changed so that the contact force actually increases due to the Lorentz force.

[0052] For further explanation, Figure 8 illustrates the shapes of fixed and movable contacts of a multi-switch contact device according to at least one embodiment of the present disclosure. An example in Figure 8A includes a deformable busbar 805 and a fixed busbar 806. The fixed busbar 806 may generally be C-shaped or U-shaped by forming a partial loop and including two projections connected by a central portion. Thus, the fixed busbar 806 includes an inner surface 850. As used in the present disclosure, a “C-shaped” busbar generally refers to a busbar having two projections 854, 856 that are substantially parallel to each other and connected, with the connecting central portion 852 generally perpendicular to the inner surface 850 of the projections. In contrast to the above example, the deformable busbar 805 is bent to contact the inner surface 850 of the fixed busbar 806, and the contact shape causes the Lorentz force 830 to act, increasing the contact force between the deformable busbar 805 and the fixed busbar 806. When current flows through the deformable busbar 805 and the fixed busbar 806, the resulting electromagnetic field generates a Lorentz force 830, which acts on the deformable busbar 805 in the direction of the fixed busbar 806, increasing the contact force by pressing the deformable busbar 805 against the fixed busbar 806. In other examples, the fixed busbar 806 may have a shape other than "C-shaped". Figure 8C shows the shapes of the fixed contact and the movable contact of a multi-switch contact device according to at least one embodiment of the present disclosure, in which the contactor shape of the fixed busbar 890 is "S-shaped". Although the lower projection 896 is bent outward in the opposite direction to the upper projection 895 (resulting in an "S-shaped" busbar), when current flows through the device, the Lorentz force still increases the contact force.

[0053] To further elaborate, Figure 8B shows an example of another switch contact device 800 for a multi-switch contact device, utilizing the contact shape shown in Figure 8A, according to at least one embodiment of the present invention. In previous examples (e.g., the switch devices in Figures 3 and 7), a pivot shaft was actuated by a cam 801 to bend a deformable busbar into contact with the outer surface of a C-shaped fixed busbar. In contrast to these examples, the switch contact device 800 includes a deformable busbar 805 bent to contact the inner surface of a C-shaped fixed busbar 806, and the Lorentz force is utilized by the contact shape to increase the contact force between the deformable busbar 805 and the fixed busbar 806. The fixed busbar 806 is sometimes called a partially looping busbar, in that it includes opposing inner surfaces but does not form a complete physical loop.

[0054] In the example shown in Figure 8B, the switch contact device 800 is a "normally closed" switch, and as long as the rocking shaft 808 is actuated to deform the deformable busbar 805 and the contact between the deformable busbar 805 and the fixed busbar 806 is not broken, the deformable busbar 805 will contact the fixed busbar 806 and the switch will open. In some examples, the rocking shaft 808 is biased by a spring 807, and as long as the force applied to the rocking shaft 808 by the cam 801 does not exceed the restoring force, the deformable busbar 805 will remain in contact with the fixed busbar 806. In the example shown in Figure 8B, the contact end 815 of the deformable busbar 805 is attached to the rocking shaft 808, which is biased by a spring 807. The other end of the deformable busbar 805 is coupled to a lead 820. The force applied to the rocking shaft 808 by the spring 807 holds the contact end 815 of the deformable busbar 805 in contact with the inner surface 816 of the fixed busbar 806. The other end of the fixed busbar 806 is connected to the lead 822.

[0055] The rocking shaft 808 is actuated by the rotation of an irregularly shaped cam 801 (for example, having one of the cam shapes shown in Figure 5) attached to the camshaft 870. When the cam rotates via the camshaft 870, the operating point 809 of the rocking shaft 808 engages with the operating portion 803 of the cam 801 (for example, a leaf-shaped or wing-shaped portion), causing the rocking shaft 808 to rotate, compressing the spring 807 and disengaging the deformable busbar 805 from contact with the fixed busbar 806.

[0056] As the cam rotates further or in the reverse direction, the operating portion 803 of the cam 801 (e.g., a leaf-shaped or wing-shaped portion) moves away from the operating point 809 of the rocking shaft 808, thereby reducing the force exerted by the spring 807 on the rocking shaft 808, causing it to rotate to the closed position, and the deformable busbar 805 is bent to the closed position where it contacts the inner surface 816 of the fixed busbar 806. The rotation of the cam 801 causes the switch to open or close depending on the rotation of the cam shaft and whether the rocking shaft 808 is engaged with the operating portion of the cam 801 (e.g., a leaf-shaped or wing-shaped portion of the cam, of which there may be multiple). In another embodiment, the switch device 800 may be configured as a "normally open" switch in which the cam 801 acts on the rocking shaft 808 to move the deformable busbar 805 to contact the fixed busbar 806 and close the switch. In this configuration, the leaf-shaped or wing-shaped portion of the cam 801 engages with the rocking shaft 808, causing the deformable busbar 805 to contact the inner surface 816 of the fixed busbar. In some examples, the contact device 800 of the multiple switches includes a position sensor (not shown) for detecting the rotation of the camshaft 870. The position sensor provides the absolute angle of the camshaft, thereby allowing the camshaft to be rotated to a new setpoint to change the switch state. The position sensor may be, for example, a non-contact type position sensor and a contact type device (e.g., a potentiometer). The signal from the position sensor is provided to a motor controller of the camshaft to control the position of the camshaft and transmitted to a vehicle controller to indicate the state of the contacts.

[0057] In the example shown in Figure 8B, the shape and orientation of the busbars or conductors in the contactor configuration contribute to the increase in the contact force 830 during high-current events. The current flowing through the deformable busbar 805 and the fixed busbar 806 (indicated by arrows within each busbar) generates an electromagnetic field that induces a Lorentz force 830 (indicated by arrows protruding from the busbars 805 and 806). This Lorentz force is used to partially compensate for the upward force that can open the contacts and cause sparks or welding. Because the Lorentz force is utilized by the shape and orientation of the busbars 805 and 806 to increase the contact force, the restoring force of the spring 807 can be reduced without impairing short-circuit performance.

[0058] Some of the embodiments described above have been described in relation to a movable contact in the form of a deformable busbar. In other variations, the movable contact of the switch may be a floating contact that is actuated to contact either a first fixed contact or a second fixed contact. In one example, one end of the movable and floating contact is positioned between the first fixed contact and the second fixed contact, and the other end of the floating contact is actuated by a cam having one or more actuation points (e.g., wings or leaves) as described above. For example, the movable contact may be configured to rotate about a fixed point. When the cam rotates in one direction, the movable contact is actuated to rotate toward the first fixed contact. When the cam rotates further or in the opposite direction, the movable contact is actuated to rotate toward the second fixed contact. Thus, the switch can be in three states: closed on the first fixed contact, closed on the second contact, or open. As described above, multiple such switches can be arranged and operated by each cam attached to a single camshaft, and the state of the switches changes as the camshaft rotates.

[0059] Some of the embodiments described above use a 3-switch, i.e., a 3-pole contactor, as an example, and the configuration of the switch state includes: (1) Direct connection to a first battery pack for supplying power to the above-mentioned electric vehicle motor, (2) Direct connection to a second battery pack for supplying power to the electric vehicle motor mentioned above, (3) Two battery packs connected in series to supply power to the electric vehicle motor, (4) The charging configuration includes the parallel connection of the two battery packs described above. However, other applications may require a different number of switches driven simultaneously by the camshaft described above.

[0060] For further explanation, Figure 9 shows a circuit diagram of an example of a power distribution system for an electric vehicle according to at least one embodiment of the present invention. In the above example in Figure 9, the auxiliary contactor 902 for connecting the vehicle to the subsystem 904 of the grid may require two poles. The pole 903 of the auxiliary contactor 902 is opened and closed simultaneously by rotating a single camshaft to rotate multiple cams, thereby operating the switch between the open and closed states, as described above with respect to the contactor configuration in Figure 3. The main contactor 906 for connecting or disconnecting the inverter 908 to the high-power bus may also require two poles. The pole 907 of the main contactor 906 is opened and closed simultaneously by rotating a single camshaft to rotate multiple cams, as described above with respect to the contactor configuration in Figure 3. The fast-charging contactor 910 for connecting the DC-DC fast-charging subsystem 912 may require two or more poles (for example, two poles for a maximum current of 1000A, four poles for a maximum current of 2000A, six poles for a maximum current of 3000A, etc.). The poles 911 of the fast-charging contactor 910 are opened and closed simultaneously by rotating a single camshaft, which rotates multiple cams and activates the opening and closing of the switches, as described above for the contactor configuration in Figure 3.

[0061] For further explanation, Figure 10 shows a contactor circuit 1000 configured with a multi-switch contactor according to at least one embodiment of the present disclosure. A contactor configured with the above-described contactor circuit 1000 may be used in an electric vehicle to connect multiple battery packs to a vehicle power distribution system to drive the electric vehicle and charge the battery packs. In this example, a first switch 1010 (also referred to herein as switch "S1") is operable to open and close the connection between the positive terminal of a first battery pack 1004 and the positive terminal 1006 of the vehicle power distribution system. The negative terminal of the first battery pack 1004 is connected to the negative terminal 1008 of the vehicle power distribution system. In this example, a second switch 1012 (also referred to herein as switch "S2") is operable to open and close the connection between the negative terminal of a second battery pack 1002 and the negative terminal 1008 of the vehicle power distribution system. The positive terminal of the second battery pack 1002 is connected to the positive terminal 1006 of the vehicle power distribution system. In this example, the third switch 1014 (also referred to herein as switch "S0") is operable to open and close the series connection of the battery packs 1002 and 1004. When the first switch 1010 is closed, the first battery pack 1004 is directly connected to the vehicle power distribution system. When the second switch 1012 is closed, the second battery pack 1002 is directly connected to the vehicle power distribution system. When both the first switch 1010 and the second switch 1012 are closed, both battery packs 1002 and 1004 are connected in parallel to the vehicle power distribution system. When the third switch 1014 is closed, both battery packs 1002 and 1004 are connected in series to the vehicle power distribution system.

[0062] In the example shown in Figure 10, the contactor circuit 1000 with the above configuration also includes a fourth switch 1016 (also referred to herein as switch "S3") which can be operated to open or close a series connection between a pre-charging resistor 1018 and the battery packs 1002 and 1004. The pre-charging resistor 1018 gradually energizes the high-voltage circuit before the main contactor or switch closes. When dealing with high-voltage systems, suddenly closing a switch or contactor can cause an inrush current, which can damage the system. The pre-charging resistor helps mitigate these problems by reducing the inrush current in the circuit, thereby allowing capacitors and other components to be charged more gradually. In the initial state, the fourth switch ("pre-charging switch") 1016 is open, preventing the maximum voltage from being applied to the circuit. When the system becomes energized, the pre-charging switch closes, allowing a limited current to flow through the circuit. This limited current charges the capacitors and other components. Once the above charging process is complete, the main contactor or switch closes.

[0063] If either the first switch 1010 or the second switch 1012 is closed while the third switch 1014 is closed, the battery packs 1002 and 1004 may become a short-circuited circuit, potentially causing the contacts of the switches to weld together and / or damaging the battery packs 1002 and 1004. If either the first switch 1010, the second switch 1012, or the third switch 1014 is closed while the fourth switch 1016 is closed, the pre-charging resistor 1018 will cease to function, potentially causing a sudden inrush current that could damage electrical components. Furthermore, in order to connect the battery packs 1002 and 1004 in series and apply the maximum voltage to the battery packs, the pre-charging fourth switch 1016 should be closed before closing the third switch 1014.

[0064] Accordingly, according to at least one embodiment of the present disclosure, the configuration contactor utilizes a multi-switch contactor 1020 in which switches S0, S1, S2, and S3 are mechanically coupled. In this contactor, switch S0 is prevented from opening while switch S1 or switch S2 is closed, and vice versa. And switches S1, S2, and S0 are prevented from closing while switch S3 is closed. The multi-switch contactor 1020 according to at least one embodiment of the present disclosure comprises an array of switches (e.g., switches S0, S1, S2, S3) including a first switch, which is implemented by a first movable contact and at least one first fixed contact, the first switch being configured to change its switch state between an open state and a closed state in order to directly connect a first battery pack. The above-described multi-switch contact device 1020 also includes a second switch, which is implemented by a second movable contact and at least one second fixed contact, and the second switch is configured to switch between an open state and a closed state in order to directly connect the second battery pack. The above-described multi-switch contact device 1020 also includes a third switch, which is implemented by a third movable contact and at least one third fixed contact, and the third switch is configured to switch between an open state and a closed state in order to connect the first battery pack and the second battery pack in series. The above-described multi-switch contact device 1020 also includes a fourth switch, which is implemented by a fourth movable contact and at least one fourth fixed contact, and the fourth switch is configured to switch between an open state and a closed state in order to connect a pre-charging resistor. The above-described multi-switch contact device 1020 further includes an actuator configured to actuate the first movable contact, the second movable contact, the third movable contact, and the fourth movable contact. The above-described actuator comprises a shaft, and the switch state of each switch is mechanically coupled and changes in accordance with the rotation of the shaft. In the following examples, the multi-switch contact device is described as including four switches, but the principles of this disclosure are also applicable to multi-switch contact devices including fewer than four switches or more than four switches.In other words, a single actuator is used to change multiple switches to different switch states, and some combinations of switch states are mechanically prohibited. As described above, the mechanical coupling of the switches of the above contactor can be achieved with low contact resistance, no buoyancy, no holding force, and high contact force.

[0065] In some embodiments, each switch in the multi-switch contact device 1020 includes a fixed busbar and a deformable busbar (i.e., a movable contact) coupled to a rocking shaft mechanism. As described above with reference to Figures 3 and 8B, the switch is actuated by a rocking shaft that releases contact between the deformable busbar and the fixed busbar. The rocking shaft is actuated by the rotation of a cam coupled to a camshaft. Each switch is actuated independently by each cam, and all of the cams are mechanically coupled by the camshaft. Each cam may have a cam shape that includes an actuating part (e.g., a blade or leaf-shaped part), such as the cam shape shown in Figure 5. These actuating parts are not arranged in a longitudinal direction along the camshaft. Thus, the switch state of the four switches changes depending on the angle of rotation of the camshaft. In some examples, the fixed busbar is implemented in a partial loop shape such as a C-shape, bracket shape, or U-shape, and the deformable busbar is in contact with the inner surface of the fixed busbar as described above with reference to Figure 8A. Based on this, a Lorentz force is generated by the high current passing through the fixed busbar and the deformable busbar, which keeps the deformable busbar in contact with the fixed busbar.

[0066] For further explanation, Figure 11 shows Table 1100 of the camshaft angles and circuit states relating to the connection of the two battery packs and the charged switch described above. In the example above in Figure 11, two 400V battery packs of an electric vehicle, "Bank A" and "Bank B," are shown for illustrative purposes. Additional battery packs or alternative voltages may be used without departing from the embodiments of the present disclosure. Column 1101 of Table 1100 shows the rotation angles of the camshafts. The angles shown in the table are provided for illustrative purposes, and there may be various implementations in which different angles are used based on the motor speed and insulation requirements relating to the camshafts. Column 1102 of Table 1100 shows the states of the high-voltage circuit. Column 1103 of Table 1100 shows the state of the switch for directly connecting Bank A. Column 1104 of Table 1100 shows the state of the switch for connecting Bank A and Bank B in series. Column 1105 of Table 1100 shows the state of the switch for directly connecting Bank B. Column 1106 of Table 1100 above shows the switch states for connecting the pre-charging resistor. In the example above in Figure 11, when the camshaft is at 0 degrees, the circuit is driven / charged at 800V, the switch for connecting bank A and bank B in series is closed, and all other switches are open. When the camshaft is at 45 degrees or 315 degrees (45 degrees forward or reverse from the 800V driven / charged state), the switch for connecting the pre-charging resistor is closed, and all other switches are open. When the camshaft is at 90 degrees or 270 degrees (90 degrees forward or reverse from the 800V driven / charged state), all switches are open. This ensures that all switches are open before entering the pre-charging state. When the camshaft is at 135 degrees, the switch for direct coupling for 400V charging of bank A is closed, and all other switches are open. When the camshaft is at 180 degrees, the switch for direct coupling to charge bank A at 400V closes, the switch for direct coupling to charge bank B at 400V closes (i.e., parallel charging), and all other switches open.When the camshaft is at 225 degrees, the switch for direct coupling for charging bank B at 400V closes, and all other switches open. Therefore, regardless of whether the camshaft is rotating forward or backward, all the switches are open before transitioning to the charging state of a single battery pack, then to the charging state of the parallel battery packs, and then to the pre-charging state. In this way, combinations of switch states that could lead to system damage are mechanically prevented.

[0067] For further explanation, Figure 12 shows a perspective view of an example of a multi-switch contact device 1200 equipped with a pre-charging system. For example, the above multi-switch contact device 1200 may implement the above multi-switch contact device 1020 in Figure 10. The above multi-switch contact device 1200 includes four contactors 1201, 1202, 1204, and 1205. Referring also to Figure 10 as an example, contactor 1201 may implement switch S1, contactor 1202 may implement switch S2, contactor 1204 may implement switch S3, and contactor 1205 may implement switch S0, but are not limited to these. A drive motor 1203 is positioned between two of the above contactors (for example, between contactor 1202 and contactor 1204). The shaft 1206 of the cam actuator passes through contactors 1201, 1202, 1204, and 1205 and the motor 1203. The cam-actuating shaft mechanically connects the cams of each contactor 1201, 1202, 1204, and 1205, preventing dangerous combinations of switch states. The rotation of the camshaft causes each cam of each contactor 1201, 1202, 1204, and 1205 to rotate.

[0068] For further explanation, Figure 13 shows a flowchart illustrating an exemplary method for operating a multi-switch contact device according to at least one embodiment of the present disclosure. The method in Figure 13 includes step 1302 of connecting the multi-switch contact device to a power distribution system and at least one component. For example, the at least one component may be one or more battery packs or a reversing motor. In some examples, the contact device may be any of the multi-switch contact devices described above, in that it includes an array of two or more switches, each of which includes a movable contact and a fixed contact. The movable contact is configured to contact the first end of the fixed contact when the switch is closed. The movable contact and the fixed contact are oriented such that a current flowing between the movable contact and the fixed contact induces an electromagnetic force on the movable contact acting toward the first end of the fixed contact. The multi-switch contact device further includes an actuator configured to actuate each of the movable contacts simultaneously. The actuator includes a shaft, and the switching state of each of the two or more switches changes as the shaft rotates. For example, two or more of the above switches may be implemented by a switch device such as a switch device 800 arranged on the same operating shaft. The contact device may be, for example, the contact device 120 of the multiple switches in Figure 1 (e.g., a configuration contactor), the main contactor 906 in Figure 9, the rapid charging contactor 910 in Figure 9, the auxiliary contactor 902, or the contact device 1020 of the multiple switches in Figure 10 (e.g., a configuration contactor).

[0069] In some examples, at least one fixed contact comprises a second end substantially parallel to the first end and an intermediate portion substantially perpendicular to the first and second ends. The contact portion of the movable contact is oriented between the first and second ends of at least one of the fixed contacts. The contact portion of the movable contact is configured to contact the inside of the first end of at least one of the fixed contacts, which is located opposite the inside of the second end. When a high current flows through the fixed contact in contact with the movable contact, the Lorentz force acting on the movable contact causes the movable contact to repel the fixed contact, increasing the contact force.

[0070] The method shown in Figure 13 also includes changing the switch state of two or more switches in the multi-switch contact device by rotating the shaft (1304), where a specific combination of switch states is mechanically prevented. The method of changing the switch state by rotating the camshaft is as described above. The rotation of the camshaft causes two or more cams to rotate. In each switch, the cam engages with a pivot shaft attached to the movable contact depending on its direction of rotation, rotating the pivot shaft, thereby causing the movable contact to contact or disengage from the fixed contact. The camshaft rotates multiple cams simultaneously, changing the switch state of the switches.

[0071] For further explanation, Figure 14 shows a flowchart of an exemplary method of operating a multi-switch contact device with a pre-charge system according to at least one embodiment of the present disclosure. In the method of Figure 14, the multi-switch contact device further includes a switch array. The device also includes an actuator which includes a shaft and is configured to actuate each switch in the switch array. As described above, rotation of the shaft of the multi-switch contact device is used to change the state of the switches in the switch array. In each switch of the switch array, a cam (depending on its direction of rotation) engages with a swivel shaft attached to a movable contact, and by rotating the swivel shaft, the movable contact comes into contact with or disengages from a fixed contact. The rotation of the shaft causes the multi-cam to rotate simultaneously, changing the switch state of the switches.

[0072] The above switch array includes a first switch configured to connect a first battery device to the circuit, a second switch configured to connect a second battery device to the circuit, a third switch configured to connect the first and second battery devices in series to the circuit, and a fourth switch configured to connect a pre-charging resistor to at least one of the first and second battery devices. For example, the switches can be implemented by switch contact devices such as the switch contact device 800 located on the same operating shaft. The contact device may be, for example, the contact device 1020 of the above-mentioned multiple switches in Figure 10 (e.g., a configuration contact).

[0073] In embodiments of this method, a main contact carrying a high current (for example, the contact between the first battery and the second battery) and a pre-charging contact carrying a low current are combined within the same device, so that the contactor actuator mechanically forces the main contact from the open state to the closed state, after passing through a pre-charging state in which the pre-charging contact is closed first. As described above, the pre-charging system is configured to gradually energize the high-voltage circuit before the main contactor or switch is closed. When dealing with high-voltage systems, a sudden closing of a switch or contactor can lead to the generation of an inrush current, which can damage the system. The pre-charging switch and resistor reduce these problems by reducing the inrush current in the circuit, allowing the capacitor and other components to be charged more slowly.

[0074] The method in Figure 14 begins by rotating the shaft of the actuator from the fully open position, where the first, second, third, and fourth switches are open, to the pre-charging position, where the fourth switch is closed and the first, second, and third switches are open (1402). In this initial fully open position, the fourth switch is open, preventing the maximum voltage from being applied to the circuit. When the system is ready to be energized, the fourth switch is closed, and a limited current flows through the circuit. This limited current charges the capacitor and other components. Once the pre-charging process is complete, the series switch is closed by rotating the shaft from the pre-charging position to the series position, where the fourth switch is closed and the third switch is closed (1404). Next, the method in Figure 14 includes rotating the shaft from the series position back to the pre-charging position. The method shown in Figure 14 also includes rotating the shaft from the pre-charging position to the fully open position.

[0075] Those skilled in the art will recognize that, according to embodiments of the present invention, the rotational speed of the actuator may be selected such that the mechanical design ensures that the system is always fully charged before the main contacts (e.g., in series connection) engage.

[0076] Based on the above, the contact devices and battery-powered contactors of the above-mentioned multiple switches are, The ability to configure two battery packs in series and parallel configurations (for example, one for driving an electric vehicle and the other for charging an electric vehicle). Low contact resistance (e.g., less than 50 μΩ per switch), High buoyancy resistance due to considerably large contact force, Mitigation of the risk of battery short circuits due to loss of switching coordination or mechanical shock. A function to manage the potential mismatch of the battery pack. A function that actively destroys tack welds. Reduced power consumption required to maintain operation. Reduction of switching noise, and Increased contact force through the use of Lorentz force depending on the shape and direction of the conductor. It is understood that this offers many advantages, including those mentioned above. Furthermore, a pre-charging switch is incorporated within the contact device of the multiple switches described above.

[0077] From the above description, it will be understood that various embodiments of this disclosure can be modified and altered without departing from the true spirit of this disclosure. The descriptions herein are for illustrative purposes only and should not be construed as restrictive. The scope of this disclosure is limited only by the language of the following claims.

Claims

1. A contact device for multiple switches equipped with a pre-charging system, The contact devices of the aforementioned multiple switches are, Switch arrangement and The device comprises an actuator configured to operate each switch in the aforementioned switch array, The aforementioned switch array is A first switch configured to connect a first battery device to a circuit, A second switch configured to connect a second battery device to the circuit, A third switch configured to connect the first battery device and the second battery device in series to the circuit, A fourth switch configured to connect a pre-charging resistor to at least one of the first battery device and the second battery device, Contact devices for multiple switches, including [specific components / devices].

2. A contact device for multiple switches according to claim 1, wherein the pre-charging resistor can be connected in series between the first battery device and the second battery device via the fourth switch.

3. A contact device for multiple switches according to claim 1, Each switch in the aforementioned switch array includes a movable contact and a fixed contact. The movable contact is configured to contact the first end of the fixed contact when the switch is closed. A contact device for multiple switches, wherein the movable contact and the fixed contact are oriented such that the current flowing between the movable contact and the fixed contact induces an electromagnetic force acting in the movable contact toward the first end of the fixed contact.

4. A contact device for multiple switches according to claim 3, The aforementioned actuator is configured to operate each movable contact simultaneously. The aforementioned operating device includes a shaft, A contact device with multiple switches, wherein the state of each switch in the switch array changes in accordance with the rotation of the shaft.

5. A contact device for multiple switches according to claim 3, The fixed contactor has a substantial C-shape with an inner surface and an outer surface. A contact device for multiple switches, wherein the movable contact is oriented to contact the inner surface of the fixed contact.

6. A contact device for multiple switches according to claim 5, The fixed contactor includes a second end substantially parallel to the first end and an intermediate portion substantially perpendicular to the first and second ends. The contact portion of the movable contact is directed between the first end and the second end of the fixed contact, A contact device for multiple switches, wherein the contact portion of the movable contact is configured to contact the inner surface of the first end of the fixed contact opposite to the inner surface of the second end.

7. A contact device for multiple switches according to claim 3, The contact portion of the movable contact is coupled to the rocking shaft of the actuator. A contact device for multiple switches, wherein the rocking shaft is rotated in accordance with the cam of the actuator so as to move the contact portion relative to the first end of the fixed contact.

8. A contact device for multiple switches according to claim 7, The movable contact is deformable, The contact portion of the movable contact is moved by bending the movable contact, A contact device for multiple switches, wherein when the pivot shaft rotates, the pivot shaft bends the movable contact.

9. A contact device for multiple switches according to claim 3, The aforementioned fixed contactor is substantially S-shaped, A contact device for multiple switches, wherein the movable contact is oriented to contact the inner surface of the first projection of the fixed contact.

10. A contact device for multiple switches according to claim 3, A contact device for multiple switches, wherein when current is passed through the movable contact and the fixed contact, a Lorentz force is generated that increases the contact force between the movable contact and the fixed contact.

11. A contact device for multiple switches according to claim 4, The actuator includes two or more cams that are rotatable by the rotation of the shaft, and the two or more cams are configured to actuate the array of switches based on the rotation of the shaft, wherein the actuator is a multi-switch contact device.

12. A contact device for multiple switches according to claim 11, Each of the two or more cams includes an operating member, A contact device for multiple switches in which at least two of the operating members of the cam are not aligned along the shaft.

13. A contact device for multiple switches according to claim 3, Each switch further comprises a second fixed contact, A contact device for multiple switches, wherein the movable contact is configured to contact the second fixed contact in different closed-switch states.

14. A plurality of components including a first battery device and a second battery device, Vehicle power distribution circuit, Multiple switch contact devices that connect multiple components and the vehicle power distribution circuit, A system equipped with, The contact devices of the aforementioned multiple switches are, Switch arrangement and The device comprises an actuator configured to operate each switch in the aforementioned switch array, The aforementioned switch array is A first switch configured to connect the first battery device to the circuit, A second switch configured to connect the second battery device to the circuit, A third switch configured to connect the first battery device and the second battery device in series to the circuit, A system comprising: a fourth switch configured to connect a pre-charging resistor to at least one of the first battery device and the second battery device.

15. The system according to claim 14, The system further includes an inverter, a fast-charging connector, and an auxiliary connector as its multiple components.

16. The system according to claim 14, The pre-charging resistor can be connected in series between the first battery device and the second battery device via the fourth switch in the system.

17. The system according to claim 14, Each switch in the aforementioned switch array includes a movable contact and a fixed contact. The movable contact is configured to contact the first end of the fixed contact when the switch is closed. A system in which the movable contact and the fixed contact are oriented such that the current flowing between the movable contact and the fixed contact induces an electromagnetic force in the movable contact that acts toward the first end of the fixed contact.

18. The system according to claim 17, The actuator is configured to actuate each movable contact simultaneously, and the actuator includes a shaft. A system in which each of the switch states of the switch array changes in accordance with the rotation of the shaft.

19. The system according to claim 17, The fixed contactor has a substantial C-shape with an inner surface and an outer surface. A system in which the movable contact is oriented to contact the inner surface of the fixed contact.

20. A method for operating a contact device of multiple switches, the method comprising: a pre-charging system; the contact device of multiple switches further including a switch array; and an actuator including a shaft and configured to operate each switch of the switch array, The aforementioned switch array is A first switch configured to connect a first battery device to a circuit, A second switch configured to connect a second battery device to the circuit, A third switch configured to connect the first battery device and the second battery device in series to the circuit, A fourth switch configured to connect a pre-charging resistor to at least one of the first battery device and the second battery device, The aforementioned method, The shaft of the actuator is rotated from the fully open position, where the first switch, the second switch, the third switch, and the fourth switch are open, to the pre-charging position, where the fourth switch is closed and the first switch, the second switch, and the third switch are open. The shaft is rotated from the pre-charging position to a series position where the fourth switch is closed and the third switch is closed. The shaft is rotated from the series position to the pre-charging position. A method for rotating the shaft from the pre-charging position to the fully open position.

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