Contactor Coil Voltage Calibration for On-Vehicle Repair

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Solution Overview

Problem

Current systems for dynamic braking in vehicles lack the ability to efficiently calibrate and repair individual components of contactor assemblies while they are installed on the vehicle, leading to significant downtime and higher replacement costs.

Innovation Solution

A voltage controlling apparatus that includes a housing, an ammeter, and a voltage adjustment mechanism, allowing for the calibration of contactor assemblies by adjusting voltage and measuring current, enabling incremental adjustments to the contact absorbing member, such as a spring, to achieve desired actuation thresholds without removing the assembly from the vehicle.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the entire contactor assembly is replaced when a component fails, then system reliability is restored, but vehicle downtime increases and repair costs increase

Engineering Contradiction:

Improvesystem reliabilityVSAvoidvehicle downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The contactor assembly is divided into replaceable modular components (contactor, contact absorbing member, coil assembly) that can be independently serviced. This allows replacement of only the failed component rather than the entire assembly, reducing downtime and cost while maintaining system reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent enables recovery and reuse of functional components within the contactor assembly. When one component fails, the others can be retained and reused, eliminating the need to discard the entire assembly and reducing waste.

Inventive Principle:

Principle #34Discarding and recovering

2Reliability

If the entire contactor assembly is replaced when a component fails, then system reliability is restored, but repair costs increase

Engineering Contradiction:

Improvesystem reliabilityVSAvoidrepair cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The contactor assembly is segmented into independently replaceable components with standardized interfaces. This modular design reduces repair costs by allowing replacement of only the failed component rather than the expensive entire assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Functional components are recovered and reused in the repaired assembly, eliminating the cost of replacing working components and reducing overall repair expenses.

Inventive Principle:

Principle #34Discarding and recovering

3Ease of repair

If contactor assemblies are removed from the vehicle for repair, then individual components can be replaced, but vehicle downtime increases

Engineering Contradiction:

Improvecomponent replaceabilityVSAvoidvehicle downtime

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The calibration device enables field calibration and adjustment of contactor components while installed on the vehicle, eliminating the need to remove the assembly for servicing. This self-service capability maintains component replaceability while minimizing vehicle downtime.

Inventive Principle:

Principle #25Self-service

4Ease of manufacture

If individual components are replaced within the contactor assembly, then repair costs decrease, but calibration capability is required

Engineering Contradiction:

Improverepair costVSAvoidcalibration requirement

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

A calibration device serves as an intermediary tool that simplifies the calibration process for replacement components. This intermediary device provides standardized calibration procedures, making the process manageable despite the added complexity of component-level repair capabilities.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This solution reduces downtime and costs by allowing for on-vehicle calibration and replacement of individual components, specifically the contact absorbing member, within the contactor assembly, thereby extending the life of the contactor assembly and reducing the need for full assembly replacement.

Implementation Method 1

The voltage adjustment mechanism may be configured to adjust a voltage being delivered to the device

Methodology Applied

Scientific EffectElectrical Resistance: Electrical Resistance

Implementation Method 2

the ammeter may be configured to display a corresponding current reading of the device in response to adjustment of the voltage

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Implementation Method 3

The contactor may be actuated by applying a voltage across the contactor coil

Methodology Applied

Scientific EffectElectromagnetic Induction: Electromagnetic Induction

Data Source

PatentUS20240372338A1Voltage controlling apparatus and methods of calibrating a device

Publication Date: 2024.11.07 TRANSPORTATION IP HOLDINGS LLC

AI summary

A voltage controlling apparatus includes a housing, an ammeter, and a voltage adjustment mechanism. The voltage adjustment mechanism is configured to be in electrical communication with a power source and a device, e.g., a vehicle contactor assembly. For calibration of the device, the voltage adjustment mechanism is configured to adjust a voltage being delivered to the device, and the ammeter is configured to display a corresponding current reading of the device in response to adjustment of the voltage to the device.