Adjustable Holding Voltage Drive Circuit for Contactor Coils
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Solution Overview
Problem
Existing drive circuits for contactors require larger component parts due to temperature-dependent conductivity, leading to increased installation space and costs, as they need to be dimensioned to handle extreme temperatures and fluctuating currents, especially in high-voltage battery systems for vehicles.
Innovation Solution
A drive circuit with an adjustable holding voltage source that connects drive coils in series, allowing for precise adjustment of holding current through a single current control loop, reducing the complexity of component parts and enabling operation in both attraction and holding modes with optimized energy and cost savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If component parts are dimensioned larger to handle temperature-dependent conductivity and fluctuating currents, then reliability is improved, but device complexity and installation space increase
Solution Approach 1:
The patent applies dynamics by making the holding voltage adjustable rather than fixed. The control unit dynamically adapts the holding voltage to compensate for temperature-dependent conductivity changes and manufacturing scatter, allowing the system to maintain reliable operation without requiring oversized components. This dynamic adjustment resolves the contradiction by enabling reliable performance with properly dimensioned components through active control.
Solution Approach 2:
The patent changes the parameter of holding voltage from a fixed value to an adjustable value that can be adapted to actual operating conditions. By measuring or estimating actual drive coil resistance and calculating an appropriate holding voltage, the system maintains reliable contactor holding across temperature variations without needing to dimension components for worst-case scenarios, thus reducing complexity while maintaining reliability.
2Reliability
If component parts are dimensioned larger to handle extreme temperatures, then reliability is improved, but installation space and costs increase
Solution Approach 1:
The patent changes the holding voltage parameter dynamically based on actual drive coil resistance, which varies with temperature. This allows the system to maintain reliable operation at extreme temperatures using properly dimensioned components rather than oversized components, thereby reducing installation space while maintaining reliability.
3Device complexity
If fixed holding voltage is used for production, then device complexity is reduced, but manufacturing precision deteriorates due to temperature and resistance variations
Solution Approach 1:
The patent implements feedback by measuring or estimating the actual drive coil resistance and using this information to adjust the holding voltage. The control unit calculates an appropriate holding voltage based on the actual resistance value, compensating for manufacturing scatter and temperature effects. This feedback mechanism improves holding current precision without significantly increasing device complexity.
Solution Approach 2:
The patent changes the holding voltage from a fixed production parameter to an adjustable operational parameter. By adapting the holding voltage based on actual drive coil resistance measurements, the system achieves precise holding current control despite variations in component manufacturing and temperature, resolving the contradiction between simplicity and precision.
4Reliability
If larger components are used to account for conductivity fluctuations, then reliability is improved, but use of energy increases due to oversized component dimensions
Solution Approach 1:
The patent changes the holding voltage dynamically to match actual drive coil resistance, preventing the use of oversized components that would consume excessive energy. By properly dimensioning components based on actual operating conditions rather than worst-case assumptions, the system reduces energy consumption while maintaining reliable operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables efficient operation of multiple contactors with reduced component complexity, precise current control, and energy savings by using a single adjustable holding voltage source, optimizing the holding current and reducing the need for oversized components.
Implementation Method 1
The drive circuit comprises n first and n second connections, wherein in each case one first and one second connection is connectable to in each case one of the two connections of in each case one drive coil of one of the n contactors
Data Source
AI summary
The disclosure provides a drive circuit for n contactors, which circuit comprises a first input and a second input as well as n first connections and n second connections, wherein a first connection and a second connection in each case can be respectively connected to one of the two connections of a drive coil of one of the n contactors in each case. According to the disclosure, the drive circuit also comprises an adjustable holding voltage source, the first pole of which is connected to the second input and the second pole of which is connected to the first of the first connections. A method for driving n contactors is also disclosed.