Electromechanical Contactor Coil Voltage Control
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Solution Overview
Problem
Existing electromechanical contactors in power circuits face high power consumption during the 'pick-up' stage and inefficient energy management during the 'holding' stage, leading to increased energy expenditure, especially in applications like electric vehicles, with existing solutions being costly or inefficient due to dual coils, resistor dividers, or generating electromagnetic interference.
Innovation Solution
A control system utilizing a regulated power supply with a controller that adjusts the relationship between output voltage and feedback voltage to switch between different power settings, reducing power consumption by providing a higher voltage during the 'pick-up' stage and a lower voltage during the 'holding' stage, leveraging existing power supplies and minimizing heat dissipation and space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a constant voltage is applied to the coil during the holding stage, then the contactor remains reliably closed, but power consumption remains high
Solution Approach 1:
The patent applies dynamics by transitioning from a static constant voltage application to a dynamic voltage control strategy. The controller switches between two voltage levels (first voltage during pick-up stage, second reduced voltage during holding stage) based on the operational phase of the contactor. This dynamic adjustment maintains reliability during holding while significantly reducing power consumption compared to continuous constant voltage application.
Solution Approach 2:
The patent implements parameter changes by modifying the voltage parameter applied to the coil based on operational stage. The controller changes the voltage from a first higher voltage level during the pick-up stage to a second lower voltage level during the holding stage. This parameter adjustment allows the system to maintain contactor closure reliability while reducing power consumption during the sustained holding period.
2Use of energy by moving object
If dual coils are used (one for pick-up, one for holding), then power consumption is reduced during holding stage, but device complexity and cost increase
Solution Approach 1:
The patent applies universality by making the single coil perform multiple functions through controlled voltage variation. Instead of requiring separate coils for pick-up and holding functions, the same coil is used for both purposes by dynamically adjusting the applied voltage. The controller enables the single coil to operate at different voltage levels to satisfy both the high-force pick-up requirement and the lower-power holding requirement, eliminating the need for dual coil architecture.
Solution Approach 2:
The patent effectively creates a functional copy of the dual-coil system's behavior using a single coil with variable voltage control. The controller simulates the dual-coil operation by applying appropriate voltage levels at appropriate times, achieving the same energy-saving effect without the physical duplication of coil components.
3Use of energy by moving object
If resistor voltage dividers are used to reduce holding current, then power consumption is reduced, but heat dissipation increases and space requirements increase
Solution Approach 1:
The patent replaces the passive resistor-based current reduction method with an active electronic control system. Instead of using resistors to dissipate excess power as heat, the controller dynamically adjusts the voltage supplied to the coil, reducing power consumption at the source rather than dissipating it through resistive heating. This substitution eliminates the harmful heat generation associated with resistor voltage dividers.
4Use of energy by moving object
If PWM techniques are used to reduce power consumption, then energy efficiency improves, but electromagnetic interference is generated
Solution Approach 1:
The patent applies periodic action by using the controller to periodically switch between two voltage levels based on the contactor's operational stage. The controller applies the first voltage during the pick-up stage and switches to the second reduced voltage during the holding stage. This periodic voltage adjustment achieves power consumption reduction without the high-frequency switching characteristic of PWM, thereby avoiding electromagnetic interference while maintaining energy efficiency.
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 system effectively reduces power consumption by adjusting voltage settings, achieving energy savings without the need for additional components, thus enhancing the efficiency and reliability of electromechanical contactors in power circuits.
Implementation Method 1
The coil is a kind of electromagnet that produces a mechanical force to move the contact
Implementation Method 2
a regulated power supply connected to the coil and configured to provide an output voltage to the coil
Data Source
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AI summary
Control system and method for an electromechanical contactor of a power circuit, the electromechanical contactor comprising: • a contact (1), movable between two positions: an open position and a closed position in which the contact (1) produces the connection, • a coil (2), in mechanical connection with the contact (1) and configured to drive the contact (1) between the open and the closed positions. The control system comprising a regulated power supply (3) connectable to the coil (2) and a controller (4) for varying the relationship k between the output voltage VOUT and the feedback voltage VFBK from at least a first relationship k1 to a second relationship k2, being k2>k1, such that, the regulated power supply (3) varies the provided output voltage VOUT from a first output voltage VOUT1 to a second lower output voltage VOUT2 for reducing power consumption of the coil (2).