Contactor Coil Shutdown Circuit With Integrated Diode Protection
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Solution Overview
Problem
Existing contactors for switching large electrical loads require complex circuits and multiple components, leading to high costs and space requirements, particularly in circuit boards, and lack efficient quick shutdown mechanisms.
Innovation Solution
A contactor design utilizing a coil, a control unit, and a voltage converter that converts input voltage into coil voltage, allowing for direct switching on and off of the coil voltage, with a voltage-limiting component and diode for rapid shutdown, reducing component count and space needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex circuits and multiple components are used for contactor control, then reliability and functionality are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the freewheeling diode and voltage suppression diode into a single integrated component. This merging of functions reduces the number of discrete components from two separate diodes to one integrated device, thereby simplifying the circuit while maintaining the reliability benefits of both protective functions.
Solution Approach 2:
The integrated diode component performs multiple functions simultaneously: it serves as both a freewheeling diode for inductive load protection and a voltage suppression diode for overvoltage protection. This multi-functionality eliminates the need for separate components, reducing device complexity while preserving reliability.
2Reliability
If multiple protective components are added to the contactor circuit, then reliability is improved, but manufacturing cost and space requirements increase
Solution Approach 1:
By integrating the freewheeling and voltage suppression functions into a single diode component, the patent reduces the total component count. This consolidation directly lowers manufacturing costs by reducing assembly steps, component procurement costs, and inventory requirements while maintaining comprehensive circuit protection.
Solution Approach 2:
The integrated diode provides dual protective functions (freewheeling and voltage suppression) that would otherwise require two separate components. This multi-functionality reduces manufacturing complexity and cost while ensuring reliable protection against both inductive kickback and overvoltage conditions.
3Reliability
If multiple protective components are added to the contactor circuit, then reliability is improved, but space requirements particularly on circuit boards increase
Solution Approach 1:
The patent merges two separate diode components into one integrated device, thereby halving the space required for diode mounting on the circuit board. This consolidation maintains all necessary protective functions while significantly reducing the footprint occupied by protective components.
Solution Approach 2:
The integrated diode performs both freewheeling and voltage suppression functions in a single component package. This multi-functionality eliminates the need for two separate component footprints on the circuit board, thereby reducing overall space requirements while maintaining comprehensive protection reliability.
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
Enables quick and efficient shutdown of the contactor within less than 50 ms, using only the control unit and voltage converter, thereby minimizing component costs and space requirements, while ensuring rapid deactivation of the contactor contact.
Implementation Method 1
a coil through which current flows when the contactor is in an active state
Implementation Method 2
a voltage converter, in particular a power supply unit... provided for converting an input voltage into a coil voltage which drops across the coil in the active state
Implementation Method 3
a coil voltage dropping across the coil in the active state, and can be electrically switched from an inactive state to the active state and back with the control unit
Data Source
Figure 1(a)
Figure 1(b)
Figure 1(c)
AI summary
The present invention relates to a contactor (10), in particular a contactor or relay comprising a) a coil (5) through which a current flows in an active state (I) of the contactor (10), b) a control unit (2) provided for controlling the contactor (10), and c) a voltage transformer (1), wherein d) the voltage transformer (1) is provided, in the active state, to convert an input voltage (UE) into a coil voltage (U5) that decreases across the coil (5), and e) an inactive state (II) can be switched electrically to an active state (I) and vice versa using the control unit (2). The present invention also relates to a method for the high-speed disconnection of a contactor.