Integrated DC Contactor Structure for Dual-Line Arc Extinction
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Solution Overview
Problem
The existing direct current fast charging circuits require one contactor on each of the positive and negative lines, leading to a large volume and high manufacturing costs due to the complex structure and increased size of the charging apparatus.
Innovation Solution
A direct current contactor with two groups of contact components integrated into one arc-extinguishing cavity, using a single drive system to control both the positive and negative lines, eliminating the need for separate contactors on each line, and employing magnetic fields to manage arc extinction without polarity requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If one direct current contactor is mounted on each of the positive line and the negative line, then the safety requirement of isolating distance is met, but the volume of the charging apparatus is greatly increased and the structure becomes complex
Solution Approach 1:
The patent combines two separate contactors (one for positive line, one for negative line) into a single integrated contactor unit. The housing contains two contact chambers that share common drive mechanisms and control systems, reducing the total volume while maintaining the required isolating distance between positive and negative lines through internal spatial arrangement.
Solution Approach 2:
The single contactor unit performs multiple functions: it controls both the positive line and negative line separately while sharing common components such as the drive system, control circuitry, and housing structure. This multi-functionality reduces redundancy and simplifies the overall charging apparatus structure.
2Reliability
If one direct current contactor is mounted on each of the positive line and the negative line, then the safety requirement of isolating distance is met, but the manufacture costs become relatively high
Solution Approach 1:
By merging two separate contactors into one integrated unit, the patent reduces the total number of components that need to be manufactured, assembled, and tested. This consolidation lowers manufacturing costs through economies of scale and reduced assembly complexity while maintaining safety requirements through proper internal design.
Solution Approach 2:
The contactor design uses universal components and standardized interfaces that can be applied to both positive and negative line control, reducing the variety of unique parts needed and simplifying the manufacturing process. Common control circuits and drive mechanisms are reused for both lines.
3Device complexity
If a single drive system is used to drive the moving contacts of the two groups of contact components, then the structural design is simplified and volume is reduced, but the connection/disconnection synchronization needs to be ensured
Solution Approach 1:
The patent uses a single drive system with a common drive shaft or linkage mechanism that mechanically connects both the positive line contactor and negative line contactor. This ensures that when one contactor actuates, the other actuates simultaneously through the mechanical coupling, maintaining synchronization while simplifying the overall structure.
Solution Approach 2:
The control system incorporates feedback mechanisms that monitor the position and status of both contactors, ensuring they remain synchronized. If desynchronization is detected, the control system can adjust or re-actuate the contacts to restore proper timing and positioning.
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 design simplifies the structural design, reduces the volume and costs of the charging apparatus, improves connection/disconnection synchronization, and enhances the reliability and break performance of the contactor.
Implementation Method 1
the magnetic field direction is perpendicular to a direction of the current, so that an arc is blown into the arc-extinguishing chamber under magnetic field force of the magnetic field
Data Source
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AI summary
Embodiments of this application provide a direct current contactor and a vehicle. The direct current contactor includes a case and two groups of contact components disposed in the case. Each group of contact components includes two moving contacts connected to each other and two fixed contacts. The direct current contactor further includes a drive system configured to drive the moving contacts to move in a direction close to or away from the fixed contacts, so that the moving contacts are connected to or disconnected from the fixed contacts. The case has an arc-extinguishing cavity. A first baffle in the arc-extinguishing cavity divides the arc-extinguishing cavity into a first arc-extinguishing chamber and a second arc-extinguishing chamber. The contact components are respectively located in the first arc-extinguishing chamber and the second arc-extinguishing chamber. In other words, the two groups of contact components are integrated into two arc-extinguishing chambers of one arc-extinguishing cavity, and perform connection/disconnection drive by using a single drive system, so that a structure of the direct current contactor is simplified. In addition, connection/disconnection requirements of a positive line and a negative line can be met by using one direct current contactor, and there is no need to mount one contactor on each of the positive line and the negative line. This reduces a volume of a charging apparatus, and reduces manufacture costs.