Controlling a speed of a moveable assembly of an electromechanical switching device

Abstract

Embodiments in accordance with the present disclosure are directed to apparatuses, devices, systems, and methods for controlling a speed of a moveable assembly of an electromechanical switching device. In a particular embodiment, an electromechanical switching device controller is disclosed that includes a memory and a processing device, operatively coupled to the memory. In this embodiment, the processing device is configured to utilize a stall current level to control a speed of a moveable assembly of an electromechanical switching device.

Description

CONTROLLING A SPEED OF A MOVEABLE ASSEMBLY OF AN ELECTROMECHANICAL SWITCHING DEVICEBACKGROUND

[0001] Electromechanical switching devices, such as contactors and relays, are engineered to handle specific levels of electrical current over defined time periods, making them essential components in electric vehicles. These devices often employ a movable contact that, when in the closed (or actuated) position, bridges and electrically connects two fixed contacts. The movable contact is held in this position by an actuator assembly, which in many cases is driven by a solenoid through an electromagnetic field generated in the coil. When the contact is in the open (or non-actuated) position, the holding force is either removed or significantly reduced, allowing the movable contact to disengage from the fixed contacts due to a biasing mechanism.

[0002] During normal operation, the closing phase of an electromechanical switching device is triggered by a close command sent from a controller that manages power delivery to the solenoid or coil. The controller initially supplies the coil with a pickup current, which may be limited by coil resistance. After a preset duration (e.g., 100 milliseconds), the controller reduces the coil current to conserve energy. This two-step process is necessary because the energy required to close the switching device is greater than the energy' needed to keep it closed. When the switching device closes, it produces a characteristic "thump" sound as the movable assembly impacts the high-voltage (HV) contacts and magnetic flux conductors (e.g., a plunger striking a flux tube within the switching device).

[0003] The opening operation is similarly initiated by an open command from the controller, which powers down the coil completely. Some magnetic field may remain however due to permanent magnetic components in the device. This reduction in current allows the internal spring to overcome the residual magnetic field, causing the movable contact to disengage and break the HV circuit. Like the closing action, opening the switching device also generates a "thump" sound, caused by the movable assembly striking a hard stop within the switching device. While this noise can be reduced by adjusting spring rates to slow the opening speed, such modifications can negatively impact the switching device's interrupt performance — a critical feature that must not be excessively compromised.SUMMARY

[0004] According to embodiments of the present disclosure, an electromechanical switching device controller may be configured to reduce the noise caused by opening and closing an electromechanical switching device by controlling a speed of the moveable assembly of theswitching device. In a particular embodiment, a method of controlling a speed of a moveable assembly of an electromechanical switching device includes during a closing operation, increasing to a stall current level, by a controller, a current applied to a coil of the electromechanical switching device to move a moveable assembly of the electromechanical switching device into a stall position in which a high voltage circuit between a moveable contact and high voltage contacts of the electromechanical switching device is closed and a magnetic circuit between a plunger and an upper flux tube of the electromechanical switching device is open. The method also includes subsequent to determining that the moveable assembly is in the stall position, increasing to a fully closed current level, by the controller, the current applied to the coil to move the moveable assembly into a fully closed position in which the magnetic circuit is closed.

[0005] In another embodiment, a method of controlling a speed of a moveable assembly of an electromechanical switching device includes applying a hold current level, by a controller, to a current to a coil of electromechanical switching device to generate an electromagnetic field that holds a moveable assembly of the electromechanical switching device in a seated position in which a high voltage (HV) circuit between a moveable contact and HV contacts of the electromechanical switching device is closed and a magnetic circuit between a plunger and an upper flux tube of the electromechanical switching device is closed. The method also includes during an opening operation, gradually decreasing from the hold current level, by the controller, the current applied to the coil to decrease an electromagnetic field directing the plunger towards the upper flux tube. In addition, the method also includes detecting, by the controller, a dropout in the magnetic circuit and in response to detecting the dropout in the magnetic circuit, temporarily increasing, by the controller, the current to the coil to temporarily activate a magnetic brake on movement of the plunger away from the upper flux tube. The method also includes after activating the magnetic brake, increasing to a stall current level, by the controller, the current to move the moveable assembly into a position in which the HV circuit is closed and the magnetic circuit is open.

[0006] In another embodiment, an electromechanical switching device controller is disclosed that includes a memory and a processing device, operatively coupled to the memory. In this embodiment, the processing device is configured to utilize a stall current level to control a speed of a moveable assembly of an electromechanical switching device.

[0007] This approach has the benefits of no additional cost in smart switching devices (switching devices that already feature electronics for economization and / or contactor state detection), no tradeoff in mechanical performance, reduced wear in the switching device (noharsh impacts internally), configurable for different customers, and automatic adaption over life for wear.

[0008] The foregoing and other objects, features and advantages of the invention will be apparent from the follow ing more particular descriptions of exemplary embodiments of the invention as illustrated in the accompanying drawings wherein like reference numbers generally represent like parts of exemplary’ embodiments of the invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a diagram of an example electromechanical switching device for coupling with a controller configured for controlling a speed of a moveable assembly of the switching device according to at least one embodiment of the present disclosure.

[0010] FIG. 2 is a diagram of an example system that includes a controller configured for controlling a speed of a moveable assembly of the electromechanical switching device of FIG. 1.

[0011] FIG. 3 A is a graph illustrating a normal closing operation of an electromechanical switching device.

[0012] FIG. 3B is a graph illustrating an initial life calibration phase of an electromechanical switching device controlled by a controller that is configured for controlling a speed of a moveable assembly of an electromechanical switching device according to at least one embodiment of the present disclosure.

[0013] FIG. 3C is a graph illustrating a multi-phase closing of an electromechanical switching device controlled by a controller configured for controlling a speed of a moveable assembly of an electromechanical switching device according to at least one embodiment of the present disclosure.

[0014] FIG. 4A is a graph illustrating a normal opening operation of an electromechanical switching device.

[0015] FIG. 4B is a graph illustrating a multi-phase opening of an electromechanical switching device controlled by a controller configured for controlling a speed of a moveable assembly of an electromechanical switching device according to at least one embodiment of the present disclosure.

[0016] FIG. 5 sets forth a flow chart of an example method for controlling a speed of a moveable assembly of an electromechanical sw itching device in accordance w ith at least one embodiment of the present disclosure.

[0017] FIG. 6 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical switching device in accordance with at least one embodiment of the present disclosure.

[0018] FIG. 7 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical switching device in accordance with at least one embodiment of the present disclosure.

[0019] FIG. 8 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical switching device in accordance with at least one embodiment of the present disclosure.

[0020] FIG. 9 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical switching device in accordance with at least one embodiment of the present disclosure.

[0021] FIG. 10 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical switching device in accordance with at least one embodiment of the present disclosure.

[0022] FIG. 11 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical switching device in accordance with at least one embodiment of the present disclosure.

[0023] FIG. 12 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical switching device in accordance with at least one embodiment of the present disclosure.

[0024] FIG. 13 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical switching device in accordance with at least one embodiment of the present disclosure.

[0025] FIG. 14 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical switching device in accordance with at least one embodiment of the present disclosure.DETAILED DESCRIPTION

[0026] Connecting and disconnecting electrical circuits is as old as electrical circuits themselves and is often utilized as a method of switching power to a connected electrical device between “on” and “off’ states. An example of one device commonly utilized to connect and disconnect circuits is a switching device, which is electrically connected to one or more devices or power sources. A switching device is configured such that it can changebetween ‘‘open” and “closed” states to interrupt or complete a circuit to control electrical power to and from a device.

[0027] As society advances, various innovations have resulted in electrical systems and electronic devices becoming increasingly common. An example of such innovations includes recent advances in electrical automobiles, which are becoming the energy-efficient standard and will likely replace most traditional petroleum-powered vehicles. With a limited amount of stored energy available in the vehicle batteries, it is important that all devices in the vehicle are performing with the utmost energy efficiency so as to conserve the stored energy and extend the range of the vehicle.

[0028] Described herein are different embodiments of contact assemblies having certain components, or portions thereof, that are formed integral to one another to improve the operation characteristics and increase operational performance, reliability and safety. The present disclosure also provides for new features of components of the contact assemblies, with these features providing the desired operational characteristics, performance, and safety. Embodiments of the disclosure are also directed to switching devices (i.e., electrical switching devices) utilizing the switching device assemblies according to the present disclosure, and to electrical circuits and systems utilizing the electrical switching devices according to the present invention.

[0029] The terminology used herein for the purpose of describing particular examples is not intended to be limiting for further examples. Whenever a singular form such as “a”, “an” and “the” is used and using only a single element is neither explicitly or implicitly defined as being mandatory, further examples may also use plural elements to implement the same functionality. Likewise, when a functionality is subsequently described as being implemented using multiple elements, further examples may implement the same functionality using a single element or processing entity7. It will be further understood that the terms “comprises”, “comprising”, “includes” and / or “including”, when used, specify the presence of the stated features, integers, steps, operations, processes, acts, elements and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, processes, acts, elements, components and / or any group thereof.

[0030] It will be understood that when an element is referred to as being “connected” or “coupled” to another element, the elements may be directly connected or coupled or via one or more intervening elements. If two elements A and B are combined using an “or”, this is to be understood to disclose all possible combinations, i.e., only A, only B, as well as A and B.An alternative wording for the same combinations is “at least one of A and B”. The same applies for combinations of more than two elements.

[0031] Accordingly, while further examples are capable of various modifications and alternative forms, some particular examples thereof are shown in the figures and will subsequently be described in detail. However, this detailed description does not limit further examples to the particular forms described. Further examples may cover all modifications, equivalents, and alternatives falling within the scope of the disclosure. Like numbers refer to like or similar elements throughout the description of the figures, which may be implemented identically or in modified form when compared to one another while providing for the same or a similar functionality.

[0032] For further explanation, FIG. 1 sets forth a sectional view of an example electromechanical switching device 100 for coupling with a controller configured for controlling a speed of a moveable assembly of the switching device according to at least one embodiment of the present disclosure.

[0033] The switching device 100 includes an upper coil yoke (separator) 108 that separates an upper portion 104 and a lower portion 106 of a housing 102. The switching device also includes a lower coil yoke 196 that surround a coil assembly 193 that includes a plunger tube 194 and a coil enclosure 195. A lower static core 190 is positioned between the plunger tube 194 and the coil enclosure 195. The coil enclosure 195 surrounds a coil (e.g., solenoid) 118 and the plunger tube 194 surrounds a moveable assembly having a plunger 122 coupled to a plunger shaft 124. The upper coil yoke 108 is coupled to an upper flux tube 150 and a plunger spring 126 is coupled between the upper coil yoke 108 and the plunger 122. The switching device 100 also includes fixed contacts 112, 113 and a moveable contact 110. The moveable contact 110 is configured to create or break the connection between the fixed contacts 112, 113 in response to movement of the moveable assembly. The fixed contacts 112, 113 are coupled to external connections 114 for coupling with external components, such as a power supply and an electrical application.

[0034] In the open state, the moveable contact 110 is not in contact with the fixed contacts 112, 113. such that no current flows between the fixed contacts 112, 113. In this open state, the plunger spring 126 is configured to apply a pre-load force on the plunger 122 to prevent the moveable assembly from moving to a closed state. In the closed state, the moveable contact 110 is in contact with the fixed contacts 112, 113 such that current flows between the fixed contacts 112. 113 through the moveable contact 110.

[0035] The coil 118 consists of windings of conductive material such as copper or aluminum. When the coil 118 is connected to a power source and current flows through the windings, a strong magnetic field is generated that flows through the magnetic circuit pathways of the electromechanical switching device. This electromagnetic field is guided by the coil yoke and static core(s) which are made of ferromagnetic materials such as low-carbon steel. This path that the magnetic field travels on is known as the magnetic circuit 152, illustrated in FIG. 1 by arrows. The magnetic field is guided to the plunger 122. which resides within the enclosed plunger tube 194, and magnetizes it. The magnetized plunger 122 is then attracted by a magnetic force to the upper flux tube 150. The magnetic field forces the plunger 122 with upper direction. When enough magnetic force is generated, the plunger 122 will overcome any retaining spring forces (pre-load force from the plunger spring 126) and begin to move. The plunger 122 and the plunger shaft 124 drive the moveable contact 110 toward the fixed contacts 112, 113 until the moveable contact 110 is in a closed position in which contact is established between the moveable contact 110 and the fixed contacts 112, 113, thus transitioning the switching device assembly 100 from the open state to the closed state. When the moveable contact touches the stationary contacts, the high-voltage circuit is closed. At this time there is still an air gap between the plunger and the and the upper flux tube. If the magnetic force between the plunger and upper flux tube is above the pre-load force that was applied to the contact spring 187, the contact spring 187 is compressed and the plunger moves to a position where the air gap between the plunger and upper flux tube is essentially zero. When the plunger 122 contacts the upper flux tube 150, the magnetic circuit 152 is closed.

[0036] When the coil 118 is disconnected from the low-voltage power source, the ferromagnetic components lose their magnetization and the magnetic force on the plunger decreases. This decrease in magnetic field, separates the plunger 122 from the upper flux tube, opening the magnetic circuit 152. The plunger spring 126 returns the plunger to its original position. That is, when the coil 118 is de-energized, the plunger 122 is driven downward from the force of the energy stored in the compressed plunger spring 126 and the contact spring 187. and the moveable assembly pulls the moveable contact 110 downward until the moveable contact 110 is in an open position, thus breaking the high voltage circuit between the moveable contact 110 and the fixed contacts 112, 113.

[0037] A controller (not shown in FIG. 1) may be coupled to the switching device 100 and configured to control a current flowing to the coil 118 of the switching device. As previously discussed, in conventional controller designs, the controller applies and removes current tothe coil in a manner that results in a pronounced "thump" noise. This occurs during both the closing and opening phases of the switching device: when the movable assembly strikes the high-voltage (HV) contacts and magnetic flux conductors during closure, and when it drops and impacts the hard-stop within the device during opening. As will be explained in FIG. 2, an electromechanical switching device controller may be configured to reduce the noise caused by opening and closing the electromechanical switching device 100 by controlling a speed of the moveable assembly 116 of the switching device 100.

[0038] For further explanation, FIG. 2 sets forth a system diagram 200 that includes a controller 250 configured for controlling a speed of a moveable assembly of the electromechanical switching device 100 of FIG. 1 according to at least one embodiment of the present disclosure. For ease of illustration, not all of the components of the switching device 100 of FIG. 1 are illustrated in FIG. 2. Readers of skill in the art will also realize that the controller 250 described below may be configured to control the current of a coil in other electromechanical switching device designs (besides the switching device 100 of FIG. 1) in which the moveable assembly is actuated by an energized coil.

[0039] The controller 250 can be implemented by a variety of devices. In various examples, the controller 250 is an Application Specific Integrated Circuit (ASIC), a Field Programmable Gate Array (FPGA), a processor coupled to a memory' device (e.g., a readonly memory (ROM)) that stores processor-executable instructions, or some other semiconductor device that carries out the operations detailed below. The controller 250 is configured to control the flow of current between the current source 220 and the coil 1 18. In standard operation, the controller 250 controls the current in accordance with an amount of current required by the solenoid 218 to generate a magnetic field sufficient to actuate an actuator assembly to provide a holding force that holds the moveable contact 110 in contact with the stationary contacts 1 1, 1 13.

[0040] In a particular embodiment, the controller 250 may be configured to during a close operation, increase to a stall current level, a current applied to the coil 118 of the electromechanical switching device 100 to move the moveable assembly 116 of the electromechanical switching device 100 into a stall position in which a high voltage circuit between the moveable contact 110 and the high voltage contacts 112, 113 of the electromechanical switching device 100 is closed and a magnetic circuit 152 between the plunger 122 and the upper flux tube 150 of the electromechanical switching device 100 is open. In this embodiment, the controller 250 may also be configured to subsequent to determining that the moveable assembly 116 is in the stall position, increase to a pre-seatcurrent level, the current applied to the coil 118 to move the moveable assembly 116 into a pre-seat position in which the plunger 122 is moved closer to the upper flux tube 150 without closing the magnetic circuit 152. In addition, the controller 250 may be configured to subsequent to determining that the moveable assembly 116 is in the pre-seat position, increase to a fully closed current level, the current applied to the coil 118 to move the moveable assembly 116 into a fully closed position in which the magnetic circuit 152 is closed. Alternatively, the controller may be configured to subsequent to determining that the moveable assembly 116 is in the stall position, increase to the fully closed current level, the current applied to the coil 118 to move the moveable assembly 116 into the fully closed position in which the magnetic circuit 152 is closed.

[0041] In another embodiment, the electromechanical switching device controller 250 is configured to apply a hold current level, to a current to the coil 118 of the electromechanical switching device 110 to generate an electromagnetic field that holds the moveable assembly 116 in a full closed position in which a high voltage (HV) circuit between the moveable contact 110 and HV contacts 112, 113 of the electromechanical switching device 100 is closed and the magnetic circuit 152 between the plunger 122 and the upper flux tube 150 of the electromechanical switching device 100 is closed. During an open operation, the controller 250 may be configured to gradually decrease from the hold current level, the current applied to the coil 118 to decrease an electromagnetic field directing the plunger 122 towards the upper flux tube 150. The controller 250 may also be configured to detect a dropout in the magnetic circuit 152. In response to detecting that the dropout in the magnetic circuit 152, the controller may be configured to temporarily increase, the current to the coil 118 to temporarily activate a magnetic brake on movement of the plunger 122 away from the upper flux tube 150. After activating the magnetic brake, the controller may be configured to increase to a stall current level, the current to move the moveable assembly 116 into a position in which the HV circuit is closed and the magnetic circuit 152 is open.

[0042] In another embodiment, the controller 250 may be configured to perform a multiphase calibration operation on the electromechanical switching device that includes in a first phase, determining parameters of the coil; and in a second phase, determining a stall current for the electromechanical switching device. The controller 250 may also be configured to perform a soft close operation on the electromechanical switching device by in a stall phase, applying, by the controller, a stall current to a coil of the electromechanical switching device such that a moveable contact within the switching device closes a high voltage (HV) circuit between the moveable contact and high voltage contacts within the electromechanicalswitching device without closing a magnetic circuit of the electromechanical switching device. In a pre-seat phase, the controller increases the stall current such that a magnetic circuit of the electromechanical contract is brought to a nearly fully closed position. In a final phase, the controller further increases the current applied to the electromechanical circuit such that the magnetic circuit is fully closed.

[0043] By utilizing a stall current level to stall the moveable assembly during opening and closing operations, the speed of the moveable assembly during such operations may be reduced, which also reduces the wear on the components of the switching device. This approach has the benefits of no additional cost in smart switching devices (switching devices that already feature electronics for economization and / or contactor state determination), no tradeoff in mechanical performance, reduced wear in the switching device (no harsh impacts internally), configurability for different customers, and automatic adaption over life for wear.

[0044] For further explanation, FIG. 3 A sets forth a graph 301 illustrating a normal closing phase of an electromechanical switching device. In the graphs of FIGs. 3A-C, line 1 is the microphone output 304, line 2 is the supply voltage (12.7V) 302, and line 4 is the coil current (306). In FIG. 3A. the normal closing phase is initiated by a close command. In response to the closing command, an electromechanical switching device controller powers up the coil to the desired pickup current (350), or limited by the coil resistance. After a predetermined amount of time (e.g.. 100 ms), the controller reduces (352) the coil current to prevent excessive power consumption. In the example of FIG. 3 A, the microphone output indicates a loud noise as the coil is powered to pickup current.

[0045] For further explanation, FIG. 3B is a graph 303 illustrating an initial life calibration phase of an electromechanical switching device controlled by a controller, such as controller 250 of FIG. 2, configured to control a speed of a moveable assembly of the switching device according to at least one embodiment of the present disclosure. In the initial life calibration phase, the switching device electronics (e.g., the controller 250 of FIG. 2) learn the specific switching device parameters before completing a soft-close operation of the switching device. The algorithm steps through multiple phases. First is learning basic coil parameters: resistance and inductance. Second is finding the stall current. Finding the stall current includes powering the coil for a predetermined amount of time (e.g., 100 ms) and examining the coil current for minute changes over time. If the desired current profile is not detected, the current is increased in a small step and the switching device tries again. Once the switching device controller has found the desired current profile, the controller saves the data (i.e., the stall current level).

[0046] For further explanation, FIG. 3C sets forth a graph 305 illustrating a multi-phase closing of an electromechanical switching device controlled by a controller, such as the controller 250 of FIG. 2, configured to control a speed of a moveable assembly of the switching device according to at least one embodiment of the present disclosure. The closing phase is initiated by a close command. In response to the close command, the controller powers up the coil to a previously determined stall current level to move a moveable assembly of the electromechanical switching device into a stall position in which a high voltage circuit between a moveable contact and high voltage contacts of the electromechanical switching device is closed and a magnetic circuit between a plunger and an upper flux tube of the electromechanical switching device is open. After confirming that the moveable assembly is in the stall position, the controller performs two phases with the coil power until it reaches complete closing of the magnetic circuit.

[0047] The algorithm steps through multiple phases. First is the stall phase 380. In this phase, the moveable contact moves up to close the HV circuit but the magnetic circuit is not closed yet. Second is the pre-seat phase 382 in which the magnetic circuit is brought to a nearly fully closed position. In this phase, the controller increases to a pre-seat current level, the current applied to the coil to move the moveable assembly into a pre-seat position in which the plunger is moved closer to the upper flux tube without closing the magnetic circuit. Third is the fully closed position 386 in which the magnetic circuit is closed by the plunger. In contrast to the microphone output of FIG. 3 A during the closing phase, the microphone output of FIG. 3C is smaller and indicates the closing of the switching device in the operation of FIG. 3C was quieter. The final phase is the hold phase in which the controller reduces to a holding current level, the current applied to the coil.

[0048] The example phases described in FIG. 3C are the result of operations performed on a switching device by a controller configured to control a speed of a moveable assembly of the switching device in accordance with a particular embodiment. Readers of skill in the art will realize that in other embodiments, a controller may be configured to control the speed the moveable assembly in ways that will result in different phases during opening and closing operations.

[0049] For further explanation, FIG. 4A sets forth a graph 401 illustrating a normal opening phase of an electromechanical switching device. In the graphs of FIGs. 4A-B, line 1 is the microphone output 404, line 2 is the supply voltage (12.7V) 402, and line 4 is the coil current 406. In FIG. 4A, the normal opening phase is initiated by an open command. In response to the opening command, an electromechanical switching device controller powers down 430the coil and the switching device drops out. In the example of FIG. 4A, the microphone output indicates a loud noise as the coil is powered down.

[0050] For further explanation, FIG. 4B is a graph 403 illustrating an opening phase of an electromechanical switching device controlled by a controller, such as the controller 250 of FIG. 2, configured to control a speed of a moveable assembly of the switching device according to at least one embodiment of the present disclosure. Prior to initial opening, the controller applies a hold current level, to a current to a coil of electromechanical switching device to generate an electromagnetic field that holds a moveable assembly of the electromechanical switching device in a seated position in which a high voltage (HV) circuit between a moveable contact and HV contacts of the electromechanical switching device is closed and a magnetic circuit between a plunger and an upper flux tube of the electromechanical switching device is closed.

[0051] The opening phase is initiated by an open command. In response to the open command, the switching device electronics (e.g., the controller 250 of FIG. 2) gradually decreases the current applied to the coil to decrease an electromagnetic field directing the plunger towards the upper flux tube until dropout is detected in the magnetic circuit. Upon this detection, the current is temporarily boosted (increased) (e.g., to a predetermined stall current level which was determined during a calibration phase) to temporarily activate a magnetic brake on movement of the plunger away from the upper flux tube. After activating the magnetic brake, the controller increases to a stall current level, the current to move the moveable assembly into an open position in which the HV circuit is closed and the magnetic circuit is open. After a “stall” position, the current is completely removed. In the example of FIG. 4B, the phases of the algorithm are illustrated. First is the slow open detection 450. Upon detecting dropout, the magnetic circuit is now “open.” Second is the boost step 452. in which the coil current is increased to activate a magnetic brake. Third is the stall phase 454 in which the switching device is levitated in a middle position. The fourth phase 456 is the complete removal of the current. The example phases described in FIG. 4B are the result of operations performed on a switching device by a controller configured to control a speed of a moveable assembly of the switching device in accordance with a particular embodiment. Readers of skill in the art will realize that in other embodiments, a controller may be configured to control the speed the moveable assembly in ways that will result in different phases during opening and closing operations.

[0052] For further explanation, FIG. 5 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical sw itching device inaccordance with at least one embodiment of the present disclosure. The method of FIG. 5 includes a controller 500, such as the controller 250 of FIG. 2, during a closing operation, increasing 502 to a stall current level a current applied to a coil of the electromechanical switching device to move a moveable assembly of the electromechanical switching device into a stall position in which a high voltage circuit between a moveable contact and high voltage contacts of the electromechanical switching device is closed and a magnetic circuit between a plunger and an upper flux tube of the electromechanical switching device is open. Increasing 502 to a stall current level, a current applied to a coil of the electromechanical switching device during a closing operation may be carried out by the controller increasing the current applied to the coil at a first predetermined rate.

[0053] In addition, the method of FIG. 5 includes the controller 500, subsequent to determining that the moveable assembly is in the stall position, increasing 506 to a fully closed current level the current applied to the coil to move the moveable assembly into a fully closed position in which the magnetic circuit is closed. Increasing 506 to a fully closed current level the cunent applied to the coil to move the moveable assembly into a fully closed position in which the magnetic circuit is closed may be carried out by increasing the current to the current level applied to coil during normal close operations.

[0054] For further explanation, FIG. 6 sets forth a flow chart of an example method for controlling a speed of a moveable assembly of an electromechanical switching device in accordance with at least one embodiment of the present disclosure. FIG. 6 is similar to the method of FIG. 5 in that the method of FIG. 6 includes all of the elements of FIG. 5. In addition, the method of FIG. 6 also includes subsequent to determining that the moveable assembly in the fully closed position, decreasing 602 to ahold current level, by the controller, the current applied to the coil. Decreasing 602 to a hold current level, by the controller, the current applied to the coil may be carried out by gradually decreasing at a fourth predetermined rate, the current level to a level that generates an electromagnetic field that holds the moveable assembly in a full closed position in which a high voltage (HV) circuit between the moveable contact and HV contacts of the electromechanical switching device is closed and the magnetic circuit betw een the plunger and the upper flux tube of the electromechanical switching device is closed.

[0055] For further explanation, FIG. 7 sets forth a flow chart of an example method for controlling a speed of a moveable assembly of an electromechanical switching device in accordance with at least one embodiment of the present disclosure. FIG. 7 is similar to the method of FIG. 6 in that the method of FIG. 7 includes all of the elements of FIG. 6. Inaddition, the method of FIG. 7 also includes the controller 500 performing 702 a multi-phase calibration sequence for the electromechanical switching device. Performing 702 a multiphase calibration sequence for the electromechanical switching device may be carried out by “dry’’ switching (without any significant load or current flowing through the contacts) until several parameters (e.g., resistance and inductance values) are characterized and stored within a memory associated with the controller. Readers of skill in the art will realize that the multi-phased calibration sequence may be performed at any time necessary as long as the system is pre-conditioned.

[0056] In the example of FIG. 7, performing 702 a multi-phase calibration sequence for the electromechanical switching device includes in a first phase, determining 704, by the controller, parameters of the coil. Determining 704, by the controller, parameters of the coil in a first phase may be carried out by applying a known signal to the coil and measuring the resulting current and voltage; using those determines values to determine a resistance value and an inductance value associated with the coil; and storing the resistance value and inductance value in a memory of the controller.

[0057] In the example of FIG. 7. performing 702 a multi-phase calibration sequence for the electromechanical switching device includes in a second phase, determining 706 based on the determined parameters, by the controller, the stall current for the electromechanical switching device. Determining 706 based on the determined parameters, the stall current for the electromechanical switching device may be carried out by powering the coil for a predetermined amount of time (e.g., 100 ms) and examining the coil current for minute changes over time. Alternatively, determining 706 based on the determined parameters, the stall current for the electromechanical switching device may be carried out by receiving from an external system, by the controller, information indicating the parameters. For example, a testing device may identify the parameters and transmit the identified parameters to the controller.

[0058] For further explanation, FIG. 8 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical switching device in accordance with at least one embodiment of the present disclosure. FIG. 8 is similar to the method of FIG. 7 in that the method of FIG. 8 includes all of the elements of FIG. 7. In the example of FIG. 8, determining 706 based on the determined parameters, the stall current for the electromechanical switching device includes identifying 802, by the controller, minute changes in the current over time to detect a desired current profile. A current profile refers to how the current evolves over time in response to changes in voltage or (external) loadcondition. The plunger moving through the circuit induces a voltage which changes the current, representing an external load condition. Identifying 802. by the controller, minute changes in the current over time to detect a desired current profile may be carried out by analyzing the current behavior to detect whether the armature is moving as expected. If the current remains high or shows irregular minute changes, the controller may determine that the switching device is in a stall condition and the plunger has moved such that the HV contact are closed, but the magnetic force is not yet high enough to compress the contact spring and close the magnetic circuit.

[0059] In the example of FIG. 8, determining 706 based on the determined parameters, the stall current for the electromechanical switching device also includes if the desired current profile is not detected, increasing 804. by the controller, the stall current level in a small step. Increasing 804, by the controller, the stall cunent level in a small step may be carried out by incrementing the current level; and after having first reduced the coil current / power to zero and given the magnetic circuit time to "reset,’' analyzing the current behavior again at the incremented power level to determine whether a stall condition exists at that current level. Alternatively, increasing 804, by the controller, the stall current level in a small step may be carried out by incrementing the current level without resetting the magnetic circuit first.

[0060] In the example of FIG. 8, determining 706 based on the determined parameters, the stall current for the electromechanical switching device also includes if the desired current profile is detected, saving 806. by the controller, the stall cunent level. Saving 806, by the controller, the stall current level may be carried out by storing the current level in the memory of the controller.

[0061] For further explanation, FIG. 9 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical sw itching device in accordance with at least one embodiment of the present disclosure. FIG. 9 is similar to the method of FIG. 5 in that the method of FIG. 9 includes all of the elements of FIG. 5. In addition, the method of FIG. 9 also includes the controller 500 detecting 902 that the moveable assembly is in the stall position. Detecting 902 that the moveable assembly is in the stall position may be earned out by detecting a change in the coil cunent and use that as an indication that the plunger has moved into a position in which the magnetic circuit is open and the high voltage circuit is closed.

[0062] The method of FIG. 9 also includes the controller 500 determining 904 the level of the current applied to the coil when the controller detected that the moveable assembly is in the stall position. Determining 904 the level of the cunent applied to the coil when the controllerdetected that the moveable assembly is in the stall position may be carried out by utilizing a current sensor to detect the amount of cunent flowing through the coil.

[0063] In addition, the method of FIG. 9 also includes using 906, by the controller 500, the determined level to detect wear or abnormalities of the electromechanical switching device. Using 906, by the controller 500, the determined level to detect wear or abnormalities of the electromechanical switching device may be carried out by comparing the determined level to one or more levels predetermined to indicate wear in the switching device or an abnormality in the switching device; in response to the level matching the one or more levels, determining that the switching device is experiencing the wear or the abnormality associated with the one or more levels; and transmitting to an external device, an alert or indication that the switching device is experiencing wear or an abnormality.

[0064] For further explanation, FIG. 10 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical sw itching device in accordance with at least one embodiment of the present disclosure. The method of FIG. 10 includes the controller 1000. such as the controller 250 of FIG. 2, applying 1002 a hold current level to a current to a coil of electromechanical switching device to generate an electromagnetic field that holds a moveable assembly of the electromechanical switching device in a seated position in which a high voltage (HV) circuit between a moveable contact and HV contacts of the electromechanical switching device is closed and a magnetic circuit between a plunger and an upper flux tube of the electromechanical switching device is closed. Applying 1002 a hold current level to a current to a coil of electromechanical switching device to generate an electromagnetic field may be carried out by applying a constant current level to the coil of the switching device.

[0065] The method of FIG. 10 also includes during an opening operation, gradually decreasing 1004 from the hold current level, by the controller, the current applied to the coil to decrease an electromagnetic field directing the plunger towards the upper flux tube. Gradually decreasing 1004 from the hold current level, by the controller 1000, the current applied to the coil to decrease an electromagnetic field directing the plunger towards the upper flux tube may be carried out by in response to receiving a command (such as from a switch, automation system or relay) to active the switching device; and reducing the current applied to the coil at a predetermined rate.

[0066] In addition, the method of FIG. 10 includes the controller 1000 detecting 1006 a dropout in the magnetic circuit. A dropout in the magnetic circuit refers to the moment when the electromagnetic force generated by the coil is no longer sufficient to hold the plunger inplace with the upper flux tube. Detecting 1006 a dropout in the magnetic circuit may be carried out by monitoring the coil current as the plunger movement / separation will induce a chance in coil current which is detectable with a current sensor.

[0067] The method of FIG. 10 also includes in response to detecting the dropout in the magnetic circuit, temporarily increasing 1008, by the controller 1000, the current to the coil to temporarily activate a magnetic brake on movement of the plunger away from the upper flux tube. Temporarily increasing 1008. by the controller 1000, the current to the coil to temporarily activate a magnetic brake on movement of the plunger away from the upper flux tube may be carried out by increasing the current to the coil for a predetermined period of time and after the predetermined period of time, decreasing the coil applied to the current to a level that the current was at before the temporary increase.

[0068] The method of FIG. 10 includes after activating the magnetic brake, increasing 1010 to a stall current level, by the controller 1000, the current to move the moveable assembly into a position in which the HV circuit is closed and the magnetic circuit is open. Increasing 1010 to a stall current level, by the controller 1000, the current to move the moveable assembly into a position in which the HV circuit is closed and the magnetic circuit is open may be carried out by retrieving a value indicating the stall current level from a memory associated with the controller; and increasing the current applied to the coil to match the stall current level indicated by the retrieved value.

[0069] For further explanation, FIG. 1 1 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical switching device in accordance with at least one embodiment of the present disclosure. FIG. 11 is similar to the method of FIG. 10 in that the method of FIG. 11 includes all of the elements of FIG. 10. In addition, the method of FIG. 11 also includes gradually decreasing 1102, by the controller 1000, the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open. Gradually decreasing 1102, by the controller 1000, the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open may be carried out by decreasing the current at another predetermined rate.

[0070] The method of FIG. 11 also includes after the current is reduced to a predetermined level, removing 1104, by the controller, the current to the coil. Removing 1104, by the controller, the current to the coil after the current is reduced to a predetermined level may be carried out by disconnecting the cunent source from the coil.

[0071] For further explanation, FIG. 12 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical sw itching device in accordance with at least one embodiment of the present disclosure. FIG. 12 is similar to the method of FIG. 10 in that the method of FIG. 12 includes all of the elements of FIG. 10. In addition, the method of FIG. 12 also includes detecting 1202 whether a fast open condition is active. A fast open condition refers to a situation in which the switching device must break the current quickly, such as in overcurrent or short circuit conditions. Detecting 1202 whether a fast open condition is active may be carried out by receiving a fast open condition command. Alternatively, the controller may utilize a current sensor to detect current flowing through the high voltage circuit after the stall phase, which indicates a fast open condition.

[0072] The method of FIG. 12 also includes in response to detecting that the fast open condition is active, removing 1204, by the controller, the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open. Removing 1204, by the controller, the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open may be carried out by immediately reducing the cunent level applied to the coil instead of gradually reducing the current level applied to the coil.

[0073] The method of FIG. 12 also includes in response to detecting that the fast open condition is not active, gradually decreasing 1206, by the controller 1000, the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open. Gradually decreasing 1206, by the controller 1000, the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open may be carried out by reducing the current at another predetermined rate.

[0074] In addition, the method of FIG. 12 also includes in response to detecting that the fast open condition is not active, after the current is reduced to a predetermined level, removing 1208, by the controller, the current to the coil. Removing 1208, by the controller, the current to the coil may be carried out by disconnecting the current source from the coil.

[0075] For further explanation, FIG. 13 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical sw itching device in accordance with at least one embodiment of the present disclosure. FIG. 13 is similar to the method of FIG. 10 in that the method of FIG. 13 includes all of the elements of FIG. 10. In addition, the method of FIG. 13 also includes performing 1302. by the controller, a multiphase calibration sequence for the electromechanical switching device. Performing 1302, bythe controller, a multi-phase calibration sequence for the electromechanical switching device may be carried out by "dry" switching (without any significant load or cunent flowing through the contacts) until several parameters (e.g., resistance, inductance and threshold current levels at which certain actions in the contactor are triggered, such as movement) are characterized and stored within a memory associated with the controller.

[0076] In the example of FIG. 13, performing 1302, by the controller, a multi-phase calibration sequence for the electromechanical switching device includes in a first phase, determining 1304, by the controller, parameters of the coil. Determining 1304, by the controller, parameters of the coil may be carried out by applying a known signal to the coil and measuring the resulting current and voltage; using those determines values to determine a resistance value and an inductance value associated with the coil; and storing the resistance value and inductance value in a memory of the controller.

[0077] In this embodiment, performing 1302, by the controller, a multi-phase calibration sequence for the electromechanical switching device includes in a second phase, determining 1306 based on the determined parameters, by the controller, the stall current for the electromechanical switching device. Determining 1306 based on the determined parameters, by the controller, the stall current for the electromechanical switching device may be carried out by powering the coil for a predetermined amount of time (e.g., 100 ms) and examining the coil current for minute changes over time.

[0078] For further explanation, FIG. 14 sets forth a flowchart of an example method for controlling a speed of a moveable assembly of an electromechanical switching device in accordance with at least one embodiment of the present disclosure. FIG. 14 is similar to the method of FIG. 14 in that the method of FIG. 14 includes all of the elements of FIG. 13. In the example of FIG. 14, determining 1306 based on the determined parameters, by the controller, the stall current for the electromechanical switching device includes identifying 1402 minute changes in the coil current over time to detect a desired current profile. A current profile refers to how the current evolves over time in response to changes in voltage or load condition. By measuring small variations in current, the controller can determine whether the moveable assembly has stalled. Identifying 1402 minute changes in the coil current over time to detect a desired current profile may be carried out by analyzing the current behavior to detect whether the armature is moving as expected.

[0079] Determining 1306 based on the determined parameters, by the controller, the stall current for the electromechanical switching device also includes if the desired current profile is not detected, increasing 1404, by the controller, the stall current level in a small step.Increasing 1404, by the controller, the stall current level in a small step may be carried out by incrementing the current level and analyzing the current behavior again to determine whether a stall condition exists.

[0080] In the example of Fig. 14, determining 1306 based on the determined parameters, by the controller, the stall current for the electromechanical switching device includes if the desired current profile is detected, saving 1406 the stall current level. Saving 1406 the stall current level may be carried out by storing the current level in the memory of the controller.

[0081] Some embodiments of the present invention are described largely in the context of a fully functional controller. Readers of skill in the art will recognize, however, that the present invention also may be embodied in a computer program product disposed upon computer readable storage media for use with any suitable data processing system. Such computer readable storage media may be any storage medium for machine-readable information, including magnetic media, optical media, or other suitable media. Examples of such media include magnetic disks in hard drives or diskettes, compact disks for optical drives, magnetic tape, and others as will occur to those of skill in the art. Persons skilled in the art will immediately recognize that any computer system having suitable programming means will be capable of executing the steps of the method of the invention as embodied in a computer program product. Persons skilled in the art will recognize also that, although some of the exemplary embodiments described in this specification are oriented to software installed and executing on computer hardware, nevertheless, alternative embodiments implemented as firmware or as hardware are well within the scope of the present invention.

[0082] The present invention may be a system, an apparatus, a method, and / or a computer program product. The computer program product may include a computer readable storage medium (or media) having computer readable program instructions thereon for causing a processor to carry out aspects of the present invention.

[0083] The computer readable storage medium can be a tangible device that can retain and store instructions for use by an instruction execution device. The computer readable storage medium may be, for example, but is not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of the computer readable storage medium includes the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanically encoded device such as punch-cards or raised structures in a groove having instructions recorded thereon, and any suitable combination of the foregoing. A computer readable storage medium, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiberoptic cable), or electrical signals transmitted through a wire.

[0084] Computer readable program instructions for carrying out operations of the present invention may be assembler instructions, instruction-set-architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code or object code written in any combination of one or more programming languages, including an object oriented programming language such as Smalltalk, C++ or the like, and conventional procedural programming languages, such as the "C" programming language or similar programming languages. In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field- programmable gate arrays (FPGA), or programmable logic arrays (PLA) may execute the computer readable program instructions by utilizing state information of the computer readable program instructions to personalize the electronic circuitry7, in order to perform aspects of the present invention.

[0085] Aspects of the present invention are described herein with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer readable program instructions.

[0086] These computer readable program instructions may be provided to a processor of a general-purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions / acts specified in the flowchart and / or block diagram block or blocks. These computer readable program instructions may also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and / or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises an article ofmanufacture including instructions which implement aspects of the function / act specified in the flowchart and / or block diagram block or blocks.

[0087] The computer readable program instructions may also be loaded onto a computer, other programmable data processing apparatuses, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatuses or other devices to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions / acts specified in the flowchart and / or block diagram block or blocks.

[0088] The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, apparatuses, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and / or flowchart illustration, and combinations of blocks in the block diagrams and / or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.

[0089] Advantages and features of the present disclosure can be further described by the following statements:

[0090] 1. A method of controlling a speed of a moveable assembly of an electromechanical switching device, the method comprising: during a closing operation, increasing to a stall current level, by a controller, a current applied to a coil of the electromechanical switching device to move a moveable assembly of the electromechanical switching device into a stall position in which a high voltage circuit between a moveable contact and high voltage contacts of the electromechanical switching device is closed and a magnetic circuit between a plunger and an upper flux tube of the electromechanical switching device is open; and subsequent to determining that the moveable assembly is in the stall position, increasing to a fully closed current level, by the controller, the current applied to the coil to move the moveable assembly into a fully closed position in which the magnetic circuit is closed.

[0091] 2. The method of statement 1 further comprising subsequent to determining that the moveable assembly in the fully closed position, decreasing to a hold current level, by the controller, the current applied to the coil.

[0092] 3. The method of statements 1 or 2 further comprising performing, by the controller, a multi-phase calibration sequence for the electromechanical switching device.

[0093] 4. The method of any of statements 1-3, wherein the multi-phase calibration sequence is performed at an end of production of the electromechanical switching device.

[0094] 5. The method of any of statements 1-4, wherein performing a multi-phase calibration sequence for the electromechanical switching device includes: in a first phase, determining, by the controller, parameters of the coil; and in a second phase, determining based on the determined parameters, by the controller, the stall current level for the electromechanical switching device.

[0095] 6. The method of any of statements 1-5, wherein determining the stall current level for the electromechanical switching device includes: identifying, by the controller, minute changes in the current over time to detect a desired current profile; if the desired cunent profile is not detected, increasing, by the controller, the stall current level in a small step; and if the desired current profile is detected, saving, by the controller, the stall current level.

[0096] 7. The method of any of statements 1-6 further comprising: detecting, by the controller, that the moveable assembly is in the stall position; determining, by the controller, the level of the current applied to the coil when the controller detected that the moveable assembly is in the stall position; and using, by the controller, the determined level to detect wear or abnormalities of the electromechanical switching device.

[0097] 8. A method of controlling a speed of a moveable assembly of an electromechanical switching device, the method comprising: applying a hold current level, by a controller, to a current to a coil of electromechanical switching device to generate an electromagnetic field that holds a moveable assembly of the electromechanical switching device in a seated position in which a high voltage (HV) circuit between a moveable contact and HV contacts of the electromechanical switching device is closed and a magnetic circuit between a plunger and an upper flux tube of the electromechanical switching device is closed; during an opening operation, gradually decreasing from the hold current level, by the controller, the current applied to the coil to decrease an electromagnetic field directing the plunger towards the upper flux tube; detecting, by the controller, a dropout in the magnetic circuit; in response to detecting the dropout in the magnetic circuit, temporarily increasing, by the controller, the current to the coil to temporarily activate a magnetic brake on movement of the plunger awayfrom the upper flux tube; and after activating the magnetic brake, increasing to a stall current level, by the controller, the current to move the moveable assembly into a position in which the HV circuit is closed and the magnetic circuit is open.

[0098] 9. The method of statement 8 further comprising: gradually decreasing, by the controller, the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open; and after the current is reduced to a predetermined level, removing, by the controller, the current to the coil.

[0099] 10. The method of statements 8 or 9 further comprising: detecting, by the controller, whether a fast open condition is active; in response to detecting that the fast open condition is active, removing, by the controller, the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open; and in response to detecting that the fast open condition is not active: gradually decreasing, by the controller, the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open; and after the current is reduced to a predetermined level, removing, by the controller, the current to the coil.

[0100] 11. The method of any of statements 8- 10 further comprising: performing, by the controller, a multi-phase calibration sequence for the electromechanical switching device.

[0101] 12. The method of any of statements 8-11, wherein the multi-phase calibration sequence is performed at an end of production of the electromechanical switching device.

[0102] 13. The method of any of statements 8-12, wherein performing a multi-phase calibration sequence for the electromechanical switching device includes: in a first phase, determining, by the controller, parameters of the coil; and in a second phase, determining based on the determined parameters, by the controller, the stall current level for the electromechanical switching device.

[0103] 14. The method of any of statements 8-13, wherein determining the stall current level for the electromechanical switching device includes: identifying, by the controller, minute changes in the coil current over time to detect a desired current profile; if the desired current profile is not detected, increasing, by the controller, the stall current level in a small step; and if the desired current profile is detected, saving the stall current level.

[0104] 15. An electromechanical switching device controller including: a memory; and a processing device, operatively coupled to the memory', the processing device configured to utilize a stall current level to control a speed of a moveable assembly of an electromechanical switching device.

[0105] 16. The electromechanical switching device of statement 15, wherein utilizing a stall current level to control a speed of a moveable assembly of an electromechanical switching device includes: during a close operation, increasing to the stall current level, a current applied to a coil of the electromechanical switching device to move the moveable assembly of the electromechanical switching device into a stall position in which a high voltage circuit between a moveable contact and high voltage contacts of the electromechanical switching device is closed and a magnetic circuit between a plunger and an upper flux tube of the electromechanical switching device is open; and subsequent to determining that the moveable assembly is in the stall position, increasing to a fully closed current level, the current applied to the coil to move the moveable assembly into a fully closed position in which the magnetic circuit is closed.

[0106] 17. The electromechanical switching device of statement 15 or 16, wherein utilizing a stall current level to control a speed of a moveable assembly of an electromechanical switching device includes: applying a hold current level, to a current to a coil of the electromechanical switching device to generate an electromagnetic field that holds the moveable assembly in a full closed position in which a high voltage (HV) circuit between a moveable contact and HV contacts of the electromechanical switching device is closed and a magnetic circuit between a plunger and an upper flux tube of the electromechanical switching device is closed; during an open operation, gradually decreasing from the hold current level, the current applied to the coil to decrease an electromagnetic field directing the plunger towards the upper flux tube; detecting a dropout in the magnetic circuit; in response to detecting that the dropout in the magnetic circuit, temporarily increasing, the current to the coil to temporarily activate a magnetic brake on movement of the plunger away from the upper flux tube; and after activating the magnetic brake, increasing to the stall current level, the current to move the moveable assembly into a position in which the HV circuit is closed and the magnetic circuit is open.

[0107] 18. The electromechanical switching device of any of statements 15-18, wherein utilizing a stall current level to control a speed of a moveable assembly of an electromechanical switching device includes: gradually decreasing the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open; and after the current is reduced to a predetermined level, removing the current to the coil.

[0108] 19. The electromechanical switching device of any of statements 15-19, wherein utilizing a stall current level to control a speed of a moveable assembly of anelectromechanical switching device includes: detecting whether a fast open condition is active; in response to detecting that the fast open condition is active, removing the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open; and in response to detecting that the fast open condition is active: gradually decreasing the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open; and after the current is reduced to a predetermined level, removing the cunent to the coil.

[0109] 20. The electromechanical switching device of any of statements 15-20, wherein utilizing a stall current level to control a speed of a moveable assembly of an electromechanical switching device includes: performing a multi-phase calibration sequence for the electromechanical switching device.

[0110] It will be understood from the foregoing description that modifications and changes may be made in various embodiments of the present disclosure without departing from its true spirit. The descriptions in this specification are for purposes of illustration only and are not to be construed in a limiting sense. The scope of the present disclosure is limited only by the language of the following claims.

Claims

CLAIMSWhat is claimed is:

1. A method of controlling a speed of a moveable assembly of an electromechanical switching device, the method comprising: during a closing operation, increasing to a stall current level, by a controller, a current applied to a coil of the electromechanical switching device to move a moveable assembly of the electromechanical switching device into a stall position in which a high voltage circuit between a moveable contact and high voltage contacts of the electromechanical switching device is closed and a magnetic circuit between a plunger and an upper flux tube of the electromechanical switching device is open; and subsequent to determining that the moveable assembly is in the stall position. increasing to a fully closed current level, by the controller, the current applied to the coil to move the moveable assembly into a fully closed position in which the magnetic circuit is closed.

2. The method of claim 1 further comprising: subsequent to determining that the moveable assembly in the fully closed position, decreasing to a hold current level, by the controller, the current applied to the coil.

3. The method of claim 1 further comprising: performing, by the controller, a multi-phase calibration sequence for the electromechanical switching device.

4. The method of claim 3 wherein the multi-phase calibration sequence is performed at an end of production of the electromechanical switching device.

5. The method of claim 3 wherein performing a multi-phase calibration sequence for the electromechanical switching device includes: in a first phase, determining, by the controller, parameters of the coil; and in a second phase, determining based on the determined parameters, by the controller, the stall current level for the electromechanical switching device.

6. The method of claim 1 wherein determining the stall current level for the electromechanical switching device includes: identifying, by the controller, minute changes in the current over time to detect a desired current profile; if the desired current profile is not detected, increasing, by the controller, the stall current level; andif the desired current profile is detected, saving, by the controller, the increased stall current level as the stall current level.

7. The method of claim 1 further comprising: detecting, by the controller, that the moveable assembly is in the stall position; determining, by the controller, the level of the current applied to the coil when the controller detected that the moveable assembly is in the stall position; and using, by the controller, the determined level to detect wear or abnormalities of the electromechanical switching device.

8. A method of controlling a speed of a moveable assembly of an electromechanical switching device, the method comprising: applying a hold current level, by a controller, to a current to a coil of electromechanical switching device to generate an electromagnetic field that holds a moveable assembly of the electromechanical switching device in a seated position in which a high voltage (HV) circuit between a moveable contact and HV contacts of the electromechanical switching device is closed and a magnetic circuit between a plunger and an upper flux tube of the electromechanical switching device is closed; during an opening operation, gradually decreasing from the hold current level, by the controller, the current applied to the coil to decrease an electromagnetic field directing the plunger towards the upper flux tube; detecting, by the controller, a dropout in the magnetic circuit; in response to detecting the dropout in the magnetic circuit, temporarily increasing, by the controller, the current to the coil to temporarily activate a magnetic brake on movement of the plunger away from the upper flux tube; and after activating the magnetic brake, increasing to a stall current level, by the controller, the current to move the moveable assembly into a position in which the HV circuit is closed and the magnetic circuit is open.

9. The method of claim 8 further comprising: gradually decreasing, by the controller, the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open; and after the current is reduced to a predetermined level, removing, by the controller, the current to the coil.

10. The method of claim 8 further comprising: detecting, by the controller, whether a fast open condition is active;in response to detecting that the fast open condition is active, removing, by the controller, the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open; and in response to detecting that the fast open condition is not active: gradually decreasing, by the controller, the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open; and after the current is reduced to a predetermined level, removing, by the controller, the current to the coil.

11. The method of claim 8 further comprising: performing, by the controller, a multi-phase calibration sequence for the electromechanical switching device.

12. The method of claim 11 wherein the multi-phase calibration sequence is performed at an end of production of the electromechanical switching device.

13. The method of claim 11 wherein performing a multi-phase calibration sequence for the electromechanical switching device includes: in a first phase, determining, by the controller, parameters of the coil; and in a second phase, determining based on the determined parameters, by the controller, the stall current level for the electromechanical switching device.

14. The method of claim 13 wherein determining the stall current level for the electromechanical switching device includes: identifying, by the controller, minute changes in the coil current over time to detect a desired current profile; if the desired current profile is not detected, increasing, by the controller, the stall current level; and if the desired current profile is detected, saving, by the controller, the increased stall current level as the stall current level.

15. An electromechanical switching device controller including: a memory; and a processing device, operatively coupled to the memory, the processing device configured to utilize a stall current level to control a speed of a moveable assembly of an electromechanical switching device.

16. The electromechanical switching device controller of claim 15, wherein utilizing a stall current level to control a speed of a moveable assembly of an electromechanical switching device includes: during a close operation, increasing to the stall current level, a current applied to a coil of the electromechanical switching device to move the moveable assembly of the electromechanical switching device into a stall position in which a high voltage circuit between a moveable contact and high voltage contacts of the electromechanical switching device is closed and a magnetic circuit between a plunger and an upper flux tube of the electromechanical switching device is open; and subsequent to determining that the moveable assembly is in the stall position, increasing to a fully closed current level, the current applied to the coil to move the moveable assembly into a fully closed position in which the magnetic circuit is closed.

17. The electromechanical switching device controller of claim 15, wherein utilizing a stall current level to control a speed of a moveable assembly of an electromechanical switching device includes: applying a hold current level, to a current to a coil of the electromechanical switching device to generate an electromagnetic field that holds the moveable assembly in a full closed position in which a high voltage (HV) circuit between a moveable contact and HV contacts of the electromechanical switching device is closed and a magnetic circuit betw een a plunger and an upper flux tube of the electromechanical switching device is closed; during an open operation, gradually decreasing from the hold current level, the current applied to the coil to decrease an electromagnetic field directing the plunger towards the upper flux tube; detecting a dropout in the magnetic circuit; in response to detecting that the dropout in the magnetic circuit, temporarily increasing, the current to the coil to temporarily activate a magnetic brake on movement of the plunger away from the upper flux tube; and after activating the magnetic brake, increasing to the stall current level, the current to move the moveable assembly into a position in which the HV circuit is closed and the magnetic circuit is open.

18. The electromechanical switching device controller of claim 17, wherein utilizing a stall current level to control a speed of a moveable assembly of an electromechanical switching device includes: gradually decreasing the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open; and after the current is reduced to a predetermined level, removing the current to the coil.

19. The electromechanical switching device controller of claim 17, wherein utilizing a stall current level to control a speed of a moveable assembly of an electromechanical switching device includes: detecting whether a fast open condition is active; in response to detecting that the fast open condition is active, removing the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open; and in response to detecting that the fast open condition is active: gradually decreasing the current to the coil to move the moveable assembly into an open position in which the HV circuit is open and the magnetic circuit is open; and after the current is reduced to a predetermined level, removing the current to the coil.

20. The electromechanical switching device controller of claim 15, wherein utilizing a stall current level to control a speed of a moveable assembly of an electromechanical switching device includes: performing a multi -phase calibration sequence for the electromechanical switching device.

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