Vehicle Battery Contactor Arc Prevention via Sensor Feedback
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Solution Overview
Problem
Manual interruption of the electrical connection between a vehicle's battery and load in contactors can cause electric arcs, damaging contacts and interfering with the electrical wiring system, especially when high currents pass through or bouncing effects occur.
Innovation Solution
A contactor with mechanical means for interrupting the electrical connection and a sensor to detect actuation before mechanical interruption, controlled by a microcontroller to ensure the mobile contact is displaced into the open position, preventing electric arcs by managing the electromagnetic control device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual mechanical interruption is used to disconnect the electrical connection, then the device can be operated manually, but electric arcs are generated that damage contacts and interfere with the electrical wiring system
Solution Approach 1:
The sensor detects the actuation of mechanical means before the contacts are actually interrupted, and the control device activates the electromagnetic control device in advance to open the contacts. This preliminary action ensures that the electrical connection is broken before the mechanical interruption occurs, preventing electric arcs from forming during the disconnection process.
Solution Approach 2:
A sensor is implemented to detect the actuation of mechanical means and provide feedback to the control device. This feedback mechanism allows the system to respond automatically by activating the electromagnetic control device to open the contacts before the mechanical interruption takes place, thereby preventing harmful electric arcs.
2Object-affected harmful factors
If the electromagnetic control device is used to disconnect contacts, then electric arcs are prevented, but the device requires continuous electrical power to maintain the disconnected state
Solution Approach 1:
The electromagnetic control device is activated periodically or temporarily only when needed - specifically, when the sensor detects actuation of the mechanical means. After the contacts are opened and the mechanical means complete their action, the electromagnetic control device can be deactivated. This periodic action reduces electrical consumption compared to continuous operation, while still preventing electric arcs during the critical disconnection moment.
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
Prevents electric arcs and ensures safe operation by controlling the electromagnetic control device to disconnect the mobile contact before manual mechanical interruption, reducing interference and damage to the electrical system.
Implementation Method 1
an electromagnetic control device designed to produce a force that recalls the shaft towards an operative second position
Implementation Method 2
a sensor configured for detecting an actuation of the mechanical means before these effectively interrupt the electrical connection between the fixed contacts
Data Source
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AI summary
A contactor comprising: a stationary casing (12, 14, 16) bearing at least two fixed contacts (162), at least one mobile contact (144) co-operating with the fixed contacts (162), and at least one electromagnetic control device (142) coupled to a respective mobile contact (144), and wherein said electromagnetic control device (142) is configured for pushing the mobile contact (162) selectively into an operative first position or into an operative second position, and mechanical means (242-254) designed to interrupt the electrical connection between the fixed contacts (162). In particular, when the mobile contact (144) is in the operative first position, the mobile contact (144) and the fixed contacts (162) are connected electrically, and when the mobile contact (144) is in the operative second position, the mobile contact (144) and the fixed contacts (162) are disconnected. The contactor further comprises a sensor (1468) for detecting actuation of the mechanical means (24, 242-254) before these interrupt the electrical connection between the fixed contacts (162), and a control device (1462, 1466, 1470) configured for driving the electromagnetic control device (142) in such a way that the mobile contact (144) is pushed into the operative second position when the sensor (1468) indicates that the mechanical means (24, 242-254) have been operated.