Electrical Switch with Electromagnetic Actuator for Arc Suppression
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Solution Overview
Problem
High-voltage contactors in motor vehicles face challenges with electrical arcs during switching, leading to insufficient current carrying and separating capacity, high costs, and potential damage due to arc formation and levitation issues, necessitating improved arc suppression and rapid interruption mechanisms.
Innovation Solution
An electrical switch design featuring a movable contact point with a separating element that lifts and insulates the contacts, utilizing an electromagnetic actuator with kinetic energy storage and a conductive top to prevent arc formation, eliminating the need for inert gases and blowout magnets, and allowing for efficient current interruption without contact actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-voltage contactors are used with large actuators to ensure shock resistance, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the traditional mechanical actuator system with an electromagnetic actuator that uses magnetic fields to actuate the contact. This substitution eliminates the need for large mechanical components while maintaining the required shock resistance and reliability, directly resolving the contradiction between reliability and device complexity.
2Reliability
If contactors are designed for high current ranges, then current carrying capacity is improved, but holding current and power losses increase
Solution Approach 1:
By replacing the mechanical actuator with an electromagnetic actuator, the system achieves high current carrying capacity through optimized magnetic field design rather than relying on large mechanical components that require high holding currents. This reduces power losses while maintaining reliability.
Solution Approach 2:
The patent optimizes the electromagnetic actuator parameters (magnetic field strength, coil design, magnetic circuit) to achieve the required current carrying capacity with minimized holding current, directly addressing the energy consumption issue while maintaining high reliability.
3Reliability
If switching speed is increased to rapidly interrupt arcs, then arc suppression is improved, but voltage increase occurs requiring additional components
Solution Approach 1:
The electromagnetic actuator enables rapid contact separation through controlled magnetic field collapse, achieving fast arc interruption without requiring additional mechanical components for overvoltage protection. The magnetic field dynamics inherently manage the switching process efficiently.
Solution Approach 2:
The patent utilizes the dynamic characteristics of the electromagnetic actuator, where the magnetic field builds up and collapses rapidly to control contact separation timing. This dynamic approach enables precise control of switching speed to suppress arcs while minimizing voltage spikes, avoiding the need for additional protection components.
4Reliability
If inert gas and blowout magnets are used for arc extinction, then arc suppression is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the complex combination of inert gas systems and blowout magnets with a simplified electromagnetic actuator design. The magnetic field control inherent in the actuator system provides arc suppression functionality without requiring separate arc extinction components, reducing device complexity while maintaining 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
The design enhances the disconnection capability for both soft and hard short circuits, reduces wear, and eliminates the need for a HV fuse, resulting in lower costs and improved performance by preventing arc formation and maintaining high current carrying capacity.
Implementation Method 1
an electromagnetic actuator (124)
Implementation Method 2
The separating element (116) is made of an electrically insulating material, preferably ceramic or glass
Implementation Method 3
a device (126) for generating and/or storing a kinetic energy
Data Source
AI summary
An electrical switch for interrupting a current path. The switch includes a contact point formed from a first and a second contact piece mounted such that it can move about a rotation axis. The contact point is closed when the two contact pieces are in contact and is electrically opened when the two contact pieces are not in contact. The electrical switch includes an actuator unit and an electrically non-conductive separating element which can be moved in a translatory manner by means of the actuator unit and is designed to isolate the two contact pieces and then to keep the two contact pieces apart. The actuator unit includes a movement element mechanically coupled to the separating element, a drive device designed to move the movement element in order to close the contact point, a device for generating and/or storing kinetic energy and an electromagnetic actuator.