Integrated Contactor Service Disconnect Assembly
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Solution Overview
Problem
Electrified vehicles require a solution to safely isolate high voltage energy storage devices from the high voltage bus for both normal operation and service procedures, while existing solutions often involve separate and heavier components that increase costs and complexity.
Innovation Solution
An integrated contactor/service disconnect assembly that combines a standard contactor and a manually operated service disconnect within a single unit, featuring a stationary contact, a movable contact, a service disconnect unit, and a control unit to manage high voltage current, allowing for safe isolation and reconnection of the energy storage device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate contactor and service disconnect components are used, then safety isolation function is achieved, but device complexity and weight increase
Solution Approach 1:
The patent combines the contactor and service disconnect into a single integrated assembly where the service disconnect unit is physically integrated with the contactor structure. The service disconnect unit includes a service button and prong that interact with the contactor's movable and stationary contacts, eliminating the need for separate components while maintaining both safety isolation functions.
Solution Approach 2:
The integrated assembly performs multiple functions: the contactor portion provides automatic high voltage relay switching for normal vehicle operation, while the service disconnect portion provides manual isolation capability for servicing. This multi-functional design allows a single component to replace what were previously separate safety devices.
2Reliability
If separate contactor and service disconnect components are used, then safety isolation function is achieved, but weight increases
Solution Approach 1:
The service disconnect unit is physically merged with the contactor structure, sharing common housing, mounting points, and mechanical linkages. The prong of the service disconnect unit interacts directly with the contactor's movable contact, eliminating redundant structural elements and reducing overall weight.
3Reliability
If separate contactor and service disconnect components are used, then safety isolation function is achieved, but cost increases
Solution Approach 1:
The integrated design allows for single-piece or pre-assembled unit manufacturing, reducing assembly steps and labor costs. The service disconnect unit shares common materials, fasteners, and mounting structures with the contactor, simplifying the supply chain and reducing overall component cost.
4Weight of moving object
If integrated contactor/service disconnect assembly is used, then weight and cost are reduced, but device complexity increases
Solution Approach 1:
While integrated, the assembly maintains clear functional segmentation between the contactor portion and service disconnect unit portion. This segmentation allows for modular manufacturing and assembly, where each sub-assembly can be produced and tested separately before final integration, reducing the practical complexity despite the unified design.
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 integrated assembly reduces weight and cost by integrating components, enhances energy storage device reliability, and enables safe servicing of high voltage components by disabling the high voltage current when needed.
Implementation Method 1
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Data Source
AI summary
An integrated contactor/service disconnect assembly according to an exemplary aspect of the present disclosure includes, among other things, a stationary contact, a movable contact selectively movable relative to the stationary contact and a service disconnect unit configured to block the movable contact from contacting the stationary contact.