Modular DC Switch Layout for Arc Isolation and Low Mounting Height
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Solution Overview
Problem
Existing DC switches for new energy vehicles are not suitable due to high mounting height and complex assembly, and the impact of arcs on electromagnetic systems, making it difficult to meet the requirements of limited space and high rated current.
Innovation Solution
A switching device with a modular design that integrates a contact module and electromagnetic system, featuring a contact module housing with static and moving contacts, arc-extinguishing chambers, and a magnetic blowing structure using permanent magnets to guide arcs into extinguishing chambers, reducing overall height and enhancing arc-extinguishing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the contact mechanism is directly mounted in the switch housing, then the assembly is compact, but the assembly and replacement become more complicated
Solution Approach 1:
The switching device is divided into distinct modules: an electromagnetic system module and a contact mechanism module. The contact mechanism is mounted on a separate mounting plate that can be independently assembled and replaced, while the electromagnetic system remains in the switch housing. This segmentation allows the contact mechanism to be easily serviced without disturbing the electromagnetic components.
2Length of stationary object
If the contact mechanism is mounted close to the electromagnetic system, then the overall height is reduced, but the arc generated by the contact mechanism has greater impact on the electromagnetic system
Solution Approach 1:
The contact mechanism is extracted from direct integration with the electromagnetic system and mounted on a separate mounting plate positioned at the end of the switch housing. This spatial separation removes the harmful arc effects generated during contact operation away from the electromagnetic components, while still maintaining a compact overall structure through optimized layout.
3Power
If the switch housing is designed with separate mounting cavities for electromagnetic system and contact module, then the rated current capacity is increased, but the device complexity increases
Solution Approach 1:
The mounting plate serves multiple functions: it supports the contact mechanism, provides structural reinforcement, and acts as an arc-extinguishing barrier. By combining these functions into a single component, the design achieves high rated current capacity through proper spatial separation of electromagnetic and contact components without proportionally increasing overall device 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 solution allows for a compact design that supports higher rated currents while prolonging product life and improving arc-extinguishing efficiency, suitable for new energy vehicles with limited space.
Implementation Method 1
a magnetic blowing structure using permanent magnets to guide arcs into extinguishing chambers
Implementation Method 2
the electromagnetic system comprises an electromagnetic coil, a static iron core and a moving iron core; the moving iron core is connected to the moving contact through a linkage member to drive the moving contact to move in a straight line
Data Source
AI summary
A switching device includes a switch housing and an electromagnetic system including an electromagnetic coil, a static iron core and a moving iron core. The switch housing includes an electromagnetic mounting cavity, in which the electromagnetic system resides, and a contact module mounting cavity, in which a contact module resides. The contact module includes a static contact, a moving contact and an arc-extinguishing chamber in the contact module housing. The moving iron core is connected to the moving contact and drives the moving contact in a straight line. The contact module housing has a first linkage hole through which a linkage member passes to connect the moving iron core with the moving contact. The contact mechanism is encapsulated, and mounted in the switch housing to reduce, the overall height of the switch, and the influence of an arc on the electromagnetic system.