Insulated Push-Rod Contact Structure for High-Voltage Switch Isolation
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Solution Overview
Problem
Conventional electromagnetic switches in electric vehicles face safety risks due to insufficient insulation between high-voltage and low-voltage components, leading to potential breakdowns and accidents, especially with increasing battery voltages exceeding 450 VDC.
Innovation Solution
A contact apparatus with an insulated sleeve on the push rod and a moving contact component, along with a frame structure, ensures electrical isolation between high-voltage and low-voltage loops, preventing damage to low-voltage coils during high-voltage operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional epoxy package and ceramic packages are used without isolation, then device complexity is reduced, but safety reliability deteriorates due to insufficient insulation between high voltage and low voltage
Solution Approach 1:
The contact apparatus is divided into distinct high-voltage and low-voltage sections with clear isolation. The moving contact component handles high voltage while the coil system operates at low voltage, with physical barriers preventing electrical breakdown between them.
Solution Approach 2:
Insulating components serve as intermediaries between high-voltage and low-voltage systems. The insulating sleeve on the push rod and insulating support structures act as mediators that prevent direct electrical contact while allowing mechanical transmission of motion.
2Reliability
If insulation structures are added to isolate high voltage and low voltage, then safety reliability is improved, but device complexity increases
Solution Approach 1:
Multiple insulation functions are merged into integrated structures. The insulating sleeve simultaneously provides electrical insulation, mechanical support for the moving contact, and guidance for push rod motion, reducing the need for separate components.
Solution Approach 2:
The insulating components perform multiple functions: electrical insulation between high and low voltage systems, mechanical support for moving parts, structural guidance for motion, and protection against electrical breakdown. This multi-functionality reduces overall device complexity despite adding safety features.
3Productivity
If moving contact connects to fixed contact in high-voltage system, then switching function is achieved, but harmful factors increase due to potential breakdown affecting low-voltage coil
Solution Approach 1:
Insulation structures are pre-installed before high-voltage operation to prevent potential breakdown. The insulating sleeve and support structures are positioned in advance to block any possible electrical discharge paths from the high-voltage contact area to the low-voltage coil system.
Solution Approach 2:
The high-voltage switching operation, which poses a risk of breakdown, is converted into a safe operation by using the insulating structures to contain and direct the high-voltage field. The insulation materials are selected to withstand high voltage stress, transforming the potential harmful effect into a controlled and safe switching operation.
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
Enhances safety reliability by maintaining electrical insulation, preventing breakdowns between high and low voltages, and protecting low-voltage coils from high-voltage and large-current loads.
Implementation Method 1
the insulated sleeve can insulate the push rod from the moving contact
Implementation Method 2
The contact spring elastically abuts between the moving contact and the contact bracket
Implementation Method 3
a current flows through coils to generate a magnetic field to switch on/off a contact
Data Source
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AI summary
This application provides a contact apparatus and an electromagnetic switch. The contact apparatus includes a fixed contact and a moving contact component. The moving contact component includes a push rod, a contact bracket, an insulated sleeve, a moving contact, and a contact spring. The insulated sleeve is fixedly sleeved on a first end of the push rod, a second end of the push rod is configured to connect a drive apparatus, the contact bracket is fixedly sleeved on the insulated sleeve, the moving contact and the contact spring are both flexibly sleeved on the insulated sleeve, the contact spring elastically abuts between the moving contact and the contact bracket, the moving contact and the fixed contact are disposed relative to each other in an extension direction of the push rod, and the moving contact can be driven by the push rod to be connected to the fixed contact. Because the insulated sleeve is fixedly sleeved on the first end of the push rod, and the moving contact is sleeved on the insulated sleeve, the insulated sleeve can insulate the push rod from the moving contact, thereby reducing a security risk of the contact apparatus and the electromagnetic switch.