Integrated DC Contactor With Synchronous Dual-Line Switching
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Solution Overview
Problem
High-voltage direct current contactors in new energy vehicle charging systems require higher voltage and current levels, leading to increased volume and cost, and existing designs struggle with synchronizing the opening and closing of positive and negative electrode contacts, resulting in high contactor resistance and on-state current loss.
Innovation Solution
A direct current contactor design that uses two pairs of contacts to connect/disconnect electrode lines, with a single drive mechanism and flexible cables, reducing contactor resistance by half and drive power consumption, and employing magnets to extinguish arcs without a ceramic isolation wall, simplifying the structure and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate high-voltage direct current contactors are installed in positive electrode and negative electrode lines, then safety isolation distance is ensured, but total contactor costs and total volume increase significantly
Solution Approach 1:
The patent merges two separate contactors into a single integrated contactor that controls both positive and negative electrode lines. The housing contains two pairs of contacts (first and second fixed contacts, first and second moving contacts) that are simultaneously controlled by a single drive mechanism, achieving space and cost reduction while maintaining safety isolation through proper structural design
2Reliability
If two separate contactors are used in positive and negative electrode lines, then safety is ensured, but drive mechanism complexity and synchronization difficulty increase
Solution Approach 1:
The patent combines two independent drive mechanisms into a single integrated drive mechanism that simultaneously controls both pairs of contacts. The drive component includes a drive shaft that rotates to simultaneously actuate the first and second moving contacts through connected rods, ensuring synchronized opening and closing of all contacts while reducing mechanical complexity
Solution Approach 2:
The single drive mechanism serves multiple functions: it controls the first moving contact for the positive electrode line, controls the second moving contact for the negative electrode line, ensures synchronized operation, and maintains electrical isolation between the two electrode lines through the insulating housing structure
3Power
If conventional contactor designs are used with higher voltage and current levels, then power distribution capability is improved, but contactor volume and manufacturing costs increase
Solution Approach 1:
The patent integrates two contactor functions into one compact device, handling both positive and negative electrode lines with higher voltage and current levels (up to 1000Vdc and 400A) within a single housing, thereby reducing overall volume while maintaining or enhancing power distribution capability
Solution Approach 2:
The patent uses flexible cables to connect the connecting bars to the moving contacts, allowing for compact internal arrangement of high-current conductors while maintaining external connectivity, which helps reduce the overall contactor volume for high power applications
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 design reduces total contactor resistance and on-state current loss, simplifies the structure, and decreases manufacturing costs by using fewer components, while ensuring reliable connection and arc extinction without increasing the risk of short circuits.
Implementation Method 1
a magnetic coil configured to surround the first iron core and the second iron core
Implementation Method 2
the drive component includes a drive rod... a magnetic coil configured to surround the first iron core and the second iron core
Implementation Method 3
a first magnet and a second magnet that are disposed on two opposite sides of an outer sidewall of the housing, where the first magnet is configured to extinguish an electric arc between the first fixed contact and the first moving contact, and the second magnet is configured to extinguish an electric arc between the second fixed contact and the second moving contact
Data Source
AI summary
This application provides a direct current contactor which includes a housing, and a first fixed contact and a second fixed contact that are fastened into the housing; a first moving contact and a second moving contact that are located in the housing; a drive mechanism, including: an insulation rod connected to the first moving contact and the second moving contact, and a drive component that drives the insulation rod to drive the first moving contact and the second moving contact to synchronously move toward the first fixed contact and the second fixed contact; and a pressing component configured to push the moving contact firmly against the fixed contact. Only two pairs of contacts are used to implement connection/disconnection of two electrode lines, so that a total contactor resistance is reduced by half compared with that in the conventional technology.