High-Voltage Switching Device with Segmented Contact Bolt
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Solution Overview
Problem
High-voltage electrical switching devices in electric vehicles face challenges in safely and reliably disconnecting the load circuit from the energy storage device, particularly under extreme conditions, leading to frequent contact burning and short service life.
Innovation Solution
A high-voltage switching device utilizing a contact bolt connected to a linear drive, allowing precise control over the switching states and preventing unintentional opening, combined with a gas generator for rapid disconnection during accidents, ensuring safe and reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a contactor is used to switch the load circuit, then the switching operation can be performed, but the contacts may open unintentionally under strong acceleration leading to arcing and contact burning
Solution Approach 1:
The switching device is segmented into a contact bolt that can be positioned in multiple discrete positions (first position for connection, second position for disconnection). This segmentation allows the switching function to be separated from the holding function, enabling reliable disconnection without arcing by ensuring complete separation between contacts in the second position.
Solution Approach 2:
A bridge element is introduced as an intermediary component between the contact bolt and the contact rings. The bridge element facilitates controlled electrical connection in the first position while allowing complete disconnection in the second position, preventing direct arcing between main contacts during switching operations.
2Adaptability or versatility
If the switching device must withstand extreme conditions during travel, then it can operate in various positions, but conventional switches cannot prevent unintentional opening under these conditions
Solution Approach 1:
The switching device employs a linear drive mechanism that can actively position the contact bolt between two stable positions (first and second positions). This dynamic positioning system ensures the contact bolt remains firmly in either the connected or disconnected state regardless of installation position or external vibrations, preventing unintentional opening under extreme conditions.
3Ease of operation
If switching operations occur with load present, then the switching device can be operated, but arcing occurs leading to shortened service life
Solution Approach 1:
The system is designed to perform preliminary disconnection of the load circuit before any switching operations. The control unit ensures the linear drive positions the contact bolt in the second position (disconnected) before allowing switching, eliminating arcing and extending contact life by preventing premature wear from load-present switching.
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 solution provides a safe, reliable, and long-lasting switching mechanism that prevents arcing and contact burning, significantly extending the service life of the switching device and ensuring safe disconnection during accidents.
Implementation Method 1
a linear drive (2), in particular a linear motor, for moving the contact bolt (6) back and forth
Implementation Method 2
the contact bolt (6) establishes electrical conduction between the at least two contact rings (5)
Implementation Method 3
a gas generator (10) for rapid disconnection of the contact bolt (6) from the contact rings (5) in the event of an accident
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a device for connecting and disconnecting an electrical load circuit, operated at high voltage by a voltage source, in a transportation means that is electrically driven by a drive operated at low voltage. According to the invention, a contact stud (6) is connected to the push rod (11) of a linear drive (2) and the contact stud (6) can be moved into at least two positions in a switch housing (4), wherein the switch housing (4) has, on its internal wall, at least two contact rings (5), one of which is connected to the voltage source (7) and the other is connected to the consumer circuit (8).