Electrical Switch Element With Control Module Between Coil And Yoke
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Solution Overview
Problem
Electrical switch elements in electric vehicles and hybrid vehicles face challenges in reducing size and structural space requirements while managing high starting power levels and minimizing energy reversal and thermal input.
Innovation Solution
The electrical switch element incorporates a coil member, a yoke with at least one yoke member, and a control module positioned between the coil member and the yoke, which reduces structural space by limiting power to maintain the switch position and minimizing thermal input through pulse width modulation and switching between low- and high-resistance windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high starting power levels are used for switching operation, then the switch element can be actuated reliably, but the power necessary to retain the switch element in the switched position increases and thermal input increases
Solution Approach 1:
The patent applies dynamics by transitioning the coil from a static high-power state to a dynamic two-state system. The coil can be in a first state (high current) for actuation and a second state (low current) for maintaining position, allowing the system to adapt its power consumption dynamically based on operational requirements rather than continuously consuming high power.
Solution Approach 2:
The control module implements periodic action through pulse width modulation (PWM), where the coil is supplied with pulsed currents rather than continuous DC. By controlling the duty cycle of these pulses, the system achieves reliable switching during the high-current phases while reducing average power consumption during the maintain phase, effectively separating the actuation and retention functions in time.
2Loss of energy
If a control module is used to reduce power after switching, then energy reversal and thermal input are reduced, but the structural space and drive system complexity increase
Solution Approach 1:
The control module is integrated directly into the coil assembly, merging the control electronics with the electromagnetic actuator. This integration allows the control module to directly manage the coil's power supply without requiring separate external control circuitry, reducing overall system complexity while maintaining the ability to implement PWM and reduce power consumption after switching.
Solution Approach 2:
The control module enables the coil system to self-regulate its power consumption. By incorporating the control functionality within the coil assembly, the system can autonomously transition between high-power actuation mode and low-power maintenance mode without requiring complex external control systems, effectively making the drive system self-managing.
3Volume of moving object
If the coil size is reduced to conserve structural space, then the switch element becomes more compact, but the power density and thermal management requirements increase
Solution Approach 1:
Pulse width modulation uses periodic action to deliver high power in short bursts for actuation, then reduces power for maintenance. This temporal separation allows the coil to be smaller since it doesn't need to continuously dissipate high power, and the thermal management burden is reduced because the average power input is lower even though peak power density increases during switching pulses.
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 configuration effectively reduces the size of electrical switch elements, conserves structural space, and minimizes energy reversal and thermal input, enabling more compact designs for electric vehicle systems.
Implementation Method 1
The electrical switch element has a coil member 3
Implementation Method 2
the thermal input by the magnetic coil into the environment substantially reduced
Data Source
AI summary
An electrical switch element is disclosed. The electrical switch element has a coil member, a yoke having at least one yoke member, and a control module. The control module is disposed between the coil member and the yoke member.