Integrated HV Contactor With Pyrotechnic Overcurrent Isolation
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Solution Overview
Problem
Conventional high voltage power supply systems in electric vehicles face issues with increased interconnection resistances and complexity due to numerous components, leading to energy loss and heat generation, necessitating a more integrated and simplified contactor device for safer and more efficient operation.
Innovation Solution
The contactor device integrates control functions, such as overcurrent protection and current sensing, within the device itself, reducing the need for external controllers and minimizing interconnections, and includes a pyrotechnic actuator for irreversible disconnection, thereby simplifying the battery management system and reducing energy loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components (contactor, overcurrent protection device, current sensor) are used in the high voltage power supply system, then the system provides comprehensive safety and control functions, but the interconnection resistance increases and the system complexity increases
Solution Approach 1:
The patent combines the contactor device, overcurrent protection device, and current sensor into a single integrated contactor device. The contactor device includes a contact arrangement with movable and fixed contacts, a control circuit integrated into the device, and a pyrotechnic actuator for overcurrent protection, eliminating the need for separate components and reducing interconnection resistance while maintaining comprehensive safety and control functions
2Adaptability or versatility
If multiple separate components are used with numerous interconnections, then the system provides comprehensive functionality, but the interconnection resistance increases leading to energy loss
Solution Approach 1:
The integration of multiple functions into a single contactor device eliminates numerous interconnections between separate components. The control circuit is directly integrated with the contact arrangement, and the pyrotechnic actuator is built into the device, thereby reducing interconnection resistance and minimizing energy loss while maintaining comprehensive control and safety functionality
3Reliability
If separate overcurrent protection devices are used, then overcurrent protection is provided, but the system requires additional interconnections and assembly steps
Solution Approach 1:
The pyrotechnic actuator for overcurrent protection is integrated directly into the contactor device structure, eliminating the need for separate overcurrent protection devices and their associated interconnections. This integration simplifies assembly by reducing the number of components and connection steps while maintaining reliable overcurrent protection functionality
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 integration results in a more efficient, safer, and cost-effective power supply system with reduced energy loss and simplified assembly, enhancing safety by integrating functionalities like overcurrent protection and current sensing directly within the contactor device.
Implementation Method 1
a pyrotechnic actuator (130), which, upon activation, is configured to permanently displace the movable contact (106, 108)
Data Source
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AI summary
The present disclosure relates to a contactor device, a high voltage power supply system comprising the contactor device and a corresponding method for controlling the contactor device. The contactor device (200) comprises a contact arrangement, which includes at least one moveable bus bar (106, 108) and at least one fixed bus bar (102, 104), wherein the at least one moveable bus bar (106, 108) has a first contact region and the at least one fixed bus bar (102, 104) has a second contact region, and at least one actuation element (118), which is configured to change a state of the contactor device (200) at least to and from an open state, and to and from a closed state, wherein in the open state the first contact region is electrically isolated from the second contact region, and in the closed state the first contact region is conductively coupled to the second contact region. The contactor device further comprises an assembled circuit (168), which includes a processing circuit, which is configured to determine at least one operational parameter of the contactor device (200), and a control circuit, which is configured to control the operation of the at least one actuation element (118) in accordance with the operational parameter determined by the processing circuit.