Magnetic-Sensing Contactor Backup Fuse for Switch Open Failure
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Solution Overview
Problem
Existing electric and hybrid vehicle power circuits face challenges in rapidly detecting and responding to malfunctions, particularly in high-voltage environments, which can pose safety risks to passengers due to the potential for delayed disconnection of electrical loads during events like collisions.
Innovation Solution
A contactor system with a magnetic sensor and controller that measures high-voltage currents, detects overcurrent conditions, and autonomously opens a primary switch or blows a fuse if the switch fails to open, ensuring rapid disconnection without relying on external communication, thereby enhancing safety and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a contactor system uses a primary switch controlled by an external processor to disconnect electrical loads, then the device complexity is reduced, but the response time to detect and respond to malfunctions increases
Solution Approach 1:
The patent implements a feedback mechanism where the contactor system sends diagnostic information about its switch status back to the external processor. This allows the external processor to make informed decisions about disconnecting electrical loads, improving response time while maintaining reduced device complexity through intelligent feedback loops
Solution Approach 2:
The patent introduces a communication interface as an intermediary between the contactor system and the external processor. This intermediary handles the exchange of diagnostic information and control commands, enabling rapid response to malfunctions without requiring complex direct integration between the contactor and processor
2Reliability
If the contactor system relies on external communication to detect malfunctions, then the device complexity is minimized, but the reliability of rapid malfunction detection decreases
Solution Approach 1:
The patent implements preliminary diagnostic actions where the contactor system proactively monitors and reports its status before malfunctions occur. By continuously assessing switch status and communicating diagnostic information to the external processor, the system can detect and respond to malfunctions more rapidly and reliably
Solution Approach 2:
The feedback mechanism enables the external processor to receive real-time diagnostic information about switch status, allowing for reliable and rapid malfunction detection without requiring increased device complexity in the contactor system itself
3Productivity
If the contactor integrates current measurement and switch control capabilities, then the productivity of current monitoring is improved, but the device complexity increases
Solution Approach 1:
The patent combines multiple functions including current measurement, switch control, and diagnostic monitoring into an integrated contactor system. This merging of functions improves productivity by enabling comprehensive current monitoring and control within a single device, while the modular architecture manages the associated complexity
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 system enables rapid and reliable disconnection of electrical loads, reducing the risk of damage and improving safety by shortening feedback loops and integrating diagnostic capabilities within the contactor, thus extending its lifetime and ensuring timely intervention in emergency situations.
Implementation Method 1
a magnetic sensor configured for measuring a primary current flowing through the electrical conductor portion
Data Source
AI summary
A contactor includes: a first and second power terminal; a sub-circuit connected between this first and second power terminal and comprising the following three elements connected in series: an electrical conductor portion, a primary switch, and a fuse. The primary switch has a movable part driven by an actuator. The contactor further has a magnetic sensor for measuring a primary current flowing through the electrical conductor portion, and a controller connected to the magnetic sensor and to the actuator. The controller has a communication port for receiving commands. The contactor can detect whether the primary switch is actually open. The controller is configured for: (i) receiving a command to open the switch; (ii) operating the actuator, (iii) detecting if the primary switch is actually open; and (iv) blowing the fuse if the switch is not open.