Solid-State Switches for High-Voltage Contactor Arcing Reduction
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Solution Overview
Problem
High-voltage contactors in battery systems degrade over time due to electrical arcing across relay contacts, leading to increased wear and failure.
Innovation Solution
Incorporating solid-state switches in parallel with mechanical contactors to shunt current and limit voltage during contact opening, reducing arcing and degradation by using primary and secondary solid-state switches driven by monostable triggered circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical contactors are used to switch high-voltage battery systems, then the system can be controlled and powered, but the contactor contacts degrade over time due to electrical arcing
Solution Approach 1:
A solid-state switch is introduced as an intermediary component between the mechanical contactor and the battery terminals. The solid-state switch acts as a mediator that handles the high-voltage switching without mechanical contacts, thereby eliminating electrical arcing at the mechanical contactor contacts and preventing their degradation.
Solution Approach 2:
The patent replaces the mechanical switching mechanism with a solid-state electronic switching mechanism. The solid-state switch uses semiconductor devices instead of mechanical contacts, eliminating the physical wear and electrical arcing problems associated with mechanical contactors while maintaining the switching function.
2Reliability
If solid-state switches are added in parallel with mechanical contactors, then contactor degradation is reduced, but device complexity increases
Solution Approach 1:
The switching system is segmented into two distinct functional components: a mechanical contactor for main isolation and a solid-state switch for controlled current interruption. This segmentation allows each component to perform its specialized function optimally, with the solid-state switch handling the arcing-prone switching operations while the mechanical contactor provides robust physical isolation.
Solution Approach 2:
The patent merges the mechanical contactor and solid-state switch into a hybrid switching system where both components work together. The mechanical contactor and solid-state switch are electrically connected in parallel, combining the advantages of both mechanical robustness and solid-state precision to achieve extended cycle life and reduced degradation.
3Object-affected harmful factors
If solid-state switches are used to shunt current during contact opening, then arcing is reduced, but energy loss increases
Solution Approach 1:
The solid-state switch is activated in advance before the mechanical contactor opens. By closing the solid-state switch beforehand, the system prepares an alternative current path, ensuring that when the mechanical contacts separate, the current can immediately transition to the solid-state switch without creating arcs at the mechanical contacts.
Solution Approach 2:
The solid-state switch enables the current to rapidly transition from the mechanical contactor to the alternative path during the switching transition. This rapid current transfer minimizes the time during which arcing could occur at the mechanical contacts, effectively skipping the harmful arcing phase.
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 approach significantly reduces contactor degradation, allows for smaller and more cost-effective contactors, increases cycle life, and decreases noise, vibration, and failure rates associated with arcing, while enabling hot switching of higher power cycles.
Implementation Method 1
a solid-state switch disposed in parallel to the contactor... The solid-state switch may be closed in response to the second signal... shunt current and limit voltage during contact opening
Data Source
AI summary
Systems and methods for switching high-voltage contactors in a battery system with reduced degradation over time are presented. In certain embodiments, a system may include solid-state switches disposed is parallel with the high-voltage contactors. The solid-state switches may be configured to selectively close when the high-voltage contactors are in transition from a closed state to an open state. By closing the solid-state switches during this transition, electrical arcing and associated degradation and/or damage to the contactors may be reduced.