EP3086351A1 - Power relay for a vehicle - Google Patents

Abstract

The invention relates to a power relay (1) for a vehicle, comprising a housing (2) into which two connection bolts (10) are made for contacting a load circuit, and a coil assembly (16) arranged in the housing (2) a magnetic coil (21) and a magnet armature (19) which is coupled via a force transmission member (23) with a reversibly movable between a closed position and an open position contact bridge (17) and under the action of a magnetic coil (21) generated magnetic field in the housing (2) is displaceable, wherein the contact bridge (17) carries two contact elements (34) which form a first contact pair (33, 34) and a second contact pair (33, 34) with mating contacts (33) of the connecting bolt (10) the contact pairs (33, 34) in the closed position form a three-point support.

Description

The invention relates to a power relay for a vehicle, in particular for a commercial vehicle, according to the preamble of claim 1. Such a power relay is for example from the DE 10 2010 018 738 A1 known.

Generic power relays are used in vehicle technology, especially in commercial vehicles. The power relays are used to electrically disconnect the vehicle battery from the electrical system. In addition, such relays are used to drive electric motors of actuators, e.g. a hydraulic pump or a lifting platform, to switch. Such a power relay must be able to switch currents up to a current of about 300 amperes at low voltage of typically 12 volts to 24 volts and is therefore correspondingly massive. Conventional relays used for this purpose typically consist of a cup-shaped body of metal (e.g., iron or steel) in which a magnetic coil and a magnetic yoke and a magnet armature connected to a double contact contact bridge are received.

For connection of the power relay to a load circuit to be switched in the vehicle, the power relay usually comprises solid connecting bolts (threaded bolts) made of metal, which typically have a diameter of 0.5 cm to 1 cm. Cable lugs of the connection lines of the load circuit to be switched are fixed in a contacting manner by means of nuts (contact nuts) on these connection pins.

In the installed state of the relay, especially in a vehicle, for example in a truck, are operational vibrations that affect the power relay transmitted, practically unavoidable. This can lead to an unwanted increase in the contact resistance between the movable contact bridge and the housing-fixed connecting bolt. Although this problem could be countered by increasing the contact pressure. However, this would require a stronger magnet system, which is undesirable.

The object of the invention is to specify a power relay suitable for reliable contacting for a vehicle, in particular a commercial vehicle.

This object is achieved by the features of claim 1. Advantageous embodiments and further developments are the subject of the dependent claims.

The power relay has a housing preferably formed of a housing pot and a connection socket, in which two connecting bolts are introduced for contacting with a load circuit. In the housing, a coil assembly is arranged, which comprises a magnetic coil and a magnet armature, which is coupled via a force transmission member with a contact bridge and displaceable under the action of a magnetic field generated by the magnetic coil in the housing.

The contact bridge is reversible between a closed position, in which the contact bridge bridges the connecting pins electrically conductive, and an open position in which the contact bridge is dekontaktiert of the connecting pins, movable. The contact bridge carries two contact elements, which form a first and a second contact pair with subsequently referred to as mating contacts mating contact elements of the connecting bolt, wherein the contact pairs in the closed position form a three-point support or three-point system. In this case, suitably have the mating contacts (mating contact elements) of the connecting bolt on a flat surface or contact surface.

In an advantageous embodiment, the first contact pair is designed such that it has only a single defined (local or local limited) support point (contact point). This support point is suitably provided centrally in the contact bridge-side contact element of the first contact pair and as punctiform as possible with respect to the locally limited contact surface. This is suitably achieved by the contact bridge-side contact element of the first contact pair has a convexly curved to the bolt-side mating contact element contact area. This is expediently produced by secant-like polished sections of the preferably plate-like contact element. Suitably, thus, the convex, d. H. with respect to the contact surface outwardly curved contact area in the bridge longitudinal direction to form a centrally raised contact area for providing the support point along the contact bridge-side contact element.

In a further advantageous embodiment, the second contact pair is designed such that it has two defined contact point (contact point). With reference to the bolt-side mating contact element, in this case suitably the contact-bridge-side contact element of the second contact pair has a concave vaulted, d. H. based on the contact surface retracted contact area. Expediently, the concave, arched contact region extends in the bridge longitudinal direction along the contact bridge-side contact element. This embodiment is preferably also produced by a corresponding grinding process.

Fig. 1

in perspektivischer Ansicht von schräg oben ein Leistungsrelais mit einem Anschlusssockel,

Fig. 2

das Leistungsrelais in einem Längsschnitt mit geöffneten Kontakten und Gegenkontakten im Anschlusssockel,

Fig. 3

den Anschlusssockel in perspektivischer Darstellung mit Blick auf eine die Kontakte (Kontaktelemente) tragenden Kontaktbrücke,

Fig. 4

in perspektivischer Darstellung die Kontaktbrücke mit gewölbt ausgeführten Kontaktelementen zur Bildung einer Dreipunktauflage mit den Gegenkontakten,

Fig. 5

den Anschlusssockel in einer Schnittdarstellung,

Fig. 6

eine Schnittdarstellung entlang der Linie VI-VI in Fig. 5 mit konvex ausgewölbtem kontaktbrückenseitigem Kontaktelement,

Fig. 7

eine Schnittdarstellung entlang der Linie VII-VII in Fig. 5 mit konkav eingewölbtem kontaktbrückenseitigem Kontaktelement,

Fig. 8

die Kontaktbrücke in Seitenansicht,

Fig. 9

eine Schnittdarstellung entlang der Linie IX-IX in Fig. 8 entlang des konvex gewölbten Kontaktelements, und

Fig. 10

eine Schnittdarstellung entlang der Linie X-X in Fig. 8 entlang des konkav gewölbten Kontaktelements.

An embodiment of the invention will be explained in more detail with reference to a drawing. Show:

Fig. 1

in perspective view obliquely from above a power relay with a connection socket,

Fig. 2

the power relay in a longitudinal section with opened contacts and mating contacts in the connection socket,

Fig. 3

the connection socket in perspective view of a contacts (contact elements) bearing contact bridge,

Fig. 4

in a perspective view of the contact bridge with curved executed contact elements to form a three-point support with the mating contacts,

Fig. 5

the connection socket in a sectional view,

Fig. 6

a sectional view taken along the line VI-VI in Fig. 5 with a convexly curved contact bridge-side contact element,

Fig. 7

a sectional view taken along the line VII-VII in Fig. 5 with a concave vaulted contact bridge-side contact element,

Fig. 8

the contact bridge in side view,

Fig. 9

a sectional view taken along the line IX-IX in Fig. 8 along the convexly curved contact element, and

Fig. 10

a sectional view taken along the line XX in Fig. 8 along the concave contact element.

Corresponding parts all figures are always provided with the same reference numerals.

That in the Fig. 1 and 2 shown power relay 1 comprises a housing 2, which is formed of two parts, namely a terminal socket 3 and a housing pot 4. Both the terminal base 3 and the housing pot 4 are preferably formed here as injection molded plastic parts.

The terminal base 3 limits the housing 2 to a connection side, at which the power relay 1 can be contacted with an external load circuit and with external control lines. This connection side is hereinafter - regardless of the actual orientation of the power relay 1 in the enclosed space - also referred to as the top 5. The housing pot 4 encloses with four side walls 6 and a housing bottom 7, the remaining sides of an approximately cuboid housing interior 8 (FIGS. Fig. 2 ). The housing bottom 7 in this case closes off the housing 2 from an underside 9 facing away from the upper side 5, wherein the term "lower side" is also used independently of the actual orientation of the power relay 1 in the enclosed space.

For connecting two connecting lines of the load circuit to be connected, three solid connecting bolts 10 are fixed in the connecting base 3, each protruding out of the housing 2 with a threaded shaft 11 to the outside. The connecting bolt 10 are solid turned parts made of metal which, for example, have a diameter of 0.8 cm in the region of the threaded shaft 11. To connect the respective connection line of the load circuit, an end-side cable lug of this connection line is placed on the associated threaded shaft 11 and screw-contacted by means of a nut (contact nut). Alternatively, the connection bolts 10 may also be formed by sleeves, each with a threaded bore. Instead of contact nuts contact screws for contacting the leads are provided in this case, which are screwed into the threaded holes. As in particular from Fig. 2 As can be seen, the connection bolts 10 are fixed in the connection socket 3 by extrusion coating with the plastic material of the connection socket 11.

To exclude an electrical flashover or other short circuit between the terminal bolt 10 and the connection lines of the load circuit optionally attached thereto, a partition wall 12 is formed on the outside of the terminal base 3, which projects into the gap formed between the terminal pin 10.

To control the power relay 1, that is to trigger switching processes by which the power relay 1 - by making an in-house electrically conductive connection between the terminal bolt 10 - turned on or - by disconnecting this electrically conductive connection - is turned off, are on the terminal base 3 further a plurality of (three exemplary here) signal terminals 13 are formed, via the three corresponding external control lines can each be schraubkontaktiert with an end-side cable lug with the power relay 1. Each signal terminal 13 is electrically connected to the housing interior 8 via a connecting conductor 14 in the form of a bent stamped sheet metal part. The connecting conductors 14 are in this case inserted between the terminal base 3 and the housing pot 4 or also by encapsulation held in the terminal socket 3. Towards the top 5, the signal connections 13 are protected against contact by a separate, snap-on plastic cover 15.

In addition to the housing parts already described, namely the terminal base 3 with the attached connecting bolts 10 and signal terminals 13 and in addition to the housing pot 4, the power relay 1 comprises a in Fig. 2 illustrated coil assembly 16. A line carrier in the form of a populated with components of an electronic control board is also provided, but in Fig. 2 not visible.

The illustrated coil assembly 16 comprises a contact bridge 17 which is arranged in the inner region of the connection base 3 and which is mechanically coupled via a coupling rod 18 to a magnet armature 19 of a magnetic circuit. The magnetic circuit includes in addition to the armature 19, a magnetic yoke 20. Their components are not detailed components are a central, the coupling rod 18 concentrically surrounding hollow cylindrical core, a U-shaped bent bracket and two of the leg ends of the bracket converging pole pieces, which the magnet armature 19th between them. The armature 19 and the components of the magnetic yoke 20 are formed of ferromagnetic material.

Furthermore, the coil assembly 16 comprises a magnetic coil 21, which rests in the framed by the magnetic yoke 20 volume. The magnetic coil 21 in this case surrounds the core of the magnetic yoke 20 concentrically and in turn is framed by the bracket and the pole shoes. Further, the coil assembly 16 comprises two auxiliary conductors 22, each formed of a bent stamped sheet metal part, and two compression springs surrounding the coupling rod 18, namely a return spring 23 and a contact pressure spring 24.

The above enumerated components of the coil assembly 20 are mechanically held together by a carrier body 25. The carrier body 25 is a one-piece, multi-functional injection molded plastic component. The carrier body 25 carries the magnetic coil 21 and supports the magnetic yoke 20 and the armature 19. The magnet armature 19 and the core of the magnetic yoke 20 are for this purpose received in the interior of the carrier body 25. The magnet armature 19 is in this case slide-mounted directly on the carrier body 20.

The coil assembly 16 is clipped on the finished in an injection molding connection socket 3. For this purpose, the connection socket 3 is at its bottom with molded snap hooks 26 (FIG. Fig. 3 ) Mistake.

The auxiliary conductors 22 are soldered to (Spannungsabgriffs-) terminals 27. The connections 27 are in this case assigned in pairs to the connecting bolt 10. One of the terminals 27 is thus contacted with one of the connecting bolts 10, while the other terminal 27 is contacted with the other connecting bolt 10. For this purpose, the connections 27 are welded in advance to the respective associated connection bolt 10 and are encapsulated together with this with the plastic material of the connection socket 3.

After mounting the coil assembly 16 and possibly the board to the terminal base 3, the housing pot 4 is slipped over the coil assembly 16 and locked to the terminal base 3 and screwed, whereby the housing 2 is closed. In the closed state of the housing 2, the connection socket 3 rests with a circumferential radial web 28 on a peripheral shoulder 29 in the wall of the housing pot 4. The housing pot 4 engages in this case with a circumferential, limiting its opening collar 30 on the outside around the radial web 28 of the connection socket 3 around and beyond this. The collar 30 thus surrounds the top of the radial web 28 as a balustrade and forms together with the terminal base 3 a trough-shaped structure or trough 31. For liquid and gas-tight sealing of the connection between the terminal base 3 and the housing pot 4, this trough 31 with an initially filled with liquid and curing in the course of a curing phase potting compound 32. In particular, a two-component system consisting of an epoxy resin and a mixed hardener is used as potting compound 32.

With the potting compound 32 and the bushings of the connection conductors 14 are further sealed. The connection conductors 14 are guided for this purpose in the region of the trough 31 through the connection base 3. The passages of the connecting bolt 10 through the terminal base 3 are sealed separately from the trough 31 by potting compound 32.

The connection bolts 10 each also form fixed contacts of the main switching device of the power relay 1 provided for switching the load circuit. The ends of the connection bolts 10 projecting from the underside of the connection socket 3 into the housing interior 8 are each provided with a contact element designated below as a countercontact 33. The corresponding moving contact of the main switching device forms the contact bridge 17 which, in contrast to each of the mating contacts 33, comprises a contact element 34, which is also referred to below as a contact.

The contact elements 34, which are electrically short-circuited within the contact bridge 17, each form a contact pair 33, 34 with the opposing mating contacts 33.

Fig. 2 shows - as well as Fig. 5 - The power relay 1 in an open position in which the contact elements 34 are lifted from the mating contacts 33 (dekontaktiert), so that there is no electrically conductive connection between the terminal pin 10. To turn on the power relay 1, the magnetic coil 21 is energized. As a result, a magnetic flux is generated in the magnetic yoke 20, through which the magnet armature 19 is attracted against the core of the magnetic yoke 20. With the magnet armature 19, the contact bridge 17 is thereby deflected upward by means of the coupling rod 18, so that the contact elements 34 abut against the corresponding counter contact elements 33. In the closed position of the power relay 1 produced in this way, a conductive connection between the connecting pins 10 is formed via the contact bridge 17. The contact elements 34 and the opposing counter contacts 33 in each case form two contact pairs 33, 34th

To switch off the power relay 1, the magnetic coil 21 is energized with reverse polarity. Under the effect of the magnetic flux generated in this case in the magnetic yoke 20, the holding force generated by permanent magnets is compensated, so that the armature 19 is withdrawn by the return spring 23 from the core and thus pressed into the open position. The magnet armature 19 in this case takes over the coupling rod 18 again with the contact bridge 17, whereby the contact elements 34 are dekontaktiert under separation of the electrical connection between the terminal pins 10 of the corresponding mating contacts 33. An attached at the lower end of the support body 25 damping element can intercept this movement, so that a spring back of the formed from the armature 19, the coupling rod 18 and the contact bridge 17 unit is prevented in the direction of the closed position.

In the illustrated, bistable design of the power relay 1, each of the two switching positions of the power relay 1 is stable even in the de-energized state of the solenoid 21. The magnetic coil 21 must be energized only temporarily. The control of the solenoid 21 is carried out either directly via the signal terminals 14 or via the control electronics, which controls the solenoid coil 21 in response to external or internal control commands, which are supplied to the control electronics via the signal terminals 13. About the terminals 27, the control electronics further determined in the on state of the power relay 1, the voltage drop across the terminal pin 10 voltage as a measure of the current flowing through the power relay 1 load current or to detect the relay position.

Fig. 3 shows the terminal socket in relation to the illustration in Fig. 1 rotated position overlooking the therein einliegen or einitzende contact bridge 17 without coupling rod 18th

Fig. 4 shows the contact bridge 17 in opposite Fig. 3 turn rotated position facing the two contact elements 34. The in Fig. 4 left contact element 34 forms with the corresponding mating contact 33 a first contact pair, while that in FIG. 4 right contact element 34 forms a second contact pair with the corresponding mating contact 33. The contact element 34 of the first contact pair has a convexly curved contact region 34a, which extends in the longitudinal direction 35 of the contact bridge 17.

This bulged (convex) contact region 34a is formed on both sides of the bulged contact region 34a, for example, by corresponding, secant-like, grinding surfaces 34b, viewed transversely to the longitudinal direction 35. The shape of the bulged contact region 34a is designed such that in its central region and thus in the central region of the contact surface 36 of the contact element 34, a locally limited, suitably practically punctiform application or contact point 37 is formed.

The contact element 34 of the second contact pair has a vaulted (concave) contact region 34c which likewise extends in the longitudinal direction 35 of the contact bridge 17. As a result - seen again transversely to the longitudinal direction 35 - secant-like, raised contact surface regions 34d are formed on both sides of this contact region 34c, for example again by suitable grinding technology. The contact surface regions 34d in turn preferably form centrally or centrally raised or exposed abutment or abutment points 38, 39, which, like the defined bearing point 37 of the contact element 34 of the first contact pair, are indicated by a small circle for illustration purposes.

The contact elements 34 thus form a total contact bridge side with the three support points 37, 38, 39 a defined three-point support or three-point system with the two bolt-side mating contacts 33. With this construction, an improved contact behavior even in the case of vibration of the power relay 1 achieved in its intended installation state.

Fig. 6 shows the contact-bridge-side contact element 34 of the first contact pair with its convexly curved to form the defined support point 27 contact region 34a, while Fig. 7 the contact element 34 of the second contact pair with its under the formation of the other two defined support points 38 and 39 vaulted contact area 34c shows.

Visible, the contact elements 34 and the mating contacts or mating contact elements 33 are designed rivet-like. For this purpose, the mating contacts 33 have a contact surface head 33a and a joint 33b. The bridge-side contact elements 34 also have a joining shank 34e and a contact surface head 34f. The mating contacts 33 are joined via their Fügeschäfte 33 b with the respective terminal pin 10 and thus firmly connected to this. Analogously, the contact elements 34 are joined via the Fügeschäfte 34e with the contact bridge 17 and thus firmly connected to this.

While Fig. 8 showing the contact bridge 17 in a side view, show the FIGS. 9 and 10 Sectional views along or through the two contact elements 34. Comparatively clearly visible, the contact element 34 of the first pair of contacts on the convexly curved contact portion 34a. The formation of the bulged contact region 34a performs according to Fig. 9 to the fact that in the central region of the contact surface 36 of the contact element 34, a locally limited, punctiform Auf- or contact point 37 is formed. The contact element 34 of the second contact pair has recognizably the convex (concave) contact region 34c, whereby the raised contact surface regions 34d are formed on both sides of the contact region 34c. These contact surface areas 34d form the exposed abutment points 38, 39.

LIST OF REFERENCE NUMBERS

1

power relay

2

casing

3

connection base

4

housing pot

5

top

6

Side wall

7

caseback

8th

Housing interior

9

bottom

10

connecting bolt

11

threaded shaft

12

partition wall

13

signal connection

14

connecting conductors

15

cover

16

coil assembly

17

Contact bridge

18

coupling rod

19

armature

20

yoke

21

solenoid

22

auxiliary circuit

23

Return spring

24

Contact pressure spring

25

support body

26

snap hooks

27

(Spannungsabgriffs-) Connection

28

radial web

29

paragraph

30

collar

31

tub

32

potting compound

33

bolt-side counter contact / element

33a

Contact surface head

33b

joining shaft

34

contact bridge-side contact element

34a

(convex) contact area

34b

ground surface

34c

(concave) contact area

34d

raised contact surface area

34e

joining shaft

34f

Contact surface head

35

longitudinal direction

36

contact area

37

Up / contact point

38

Up / contact point

39

Up / contact point

Claims (11)

Power relay (1) for a vehicle, in particular commercial vehicle, with a housing (2) into which two connecting bolts (10) for contacting with a load circuit are introduced, and with a in the housing (2) arranged coil assembly (16), the one Magnetic coil (21) and a magnet armature (19) coupled via a force transmission member (23) with a movable between a closed position and an open position contact bridge (17) and under action of a magnetic coil (21) generated magnetic field in the housing (2 ) is displaceable,
characterized,
that the contact bridge (17) carrying two contact elements (34) with mating contacts (33) of the connecting bolt (10) a first pair of contacts (33, 34) and a second pair of contacts (33, 34), wherein the contact pairs (33, 34 ) form a three-point support in the closed position. Power relay (1) according to claim 1,
characterized,
that the first contact pair (33, 34) is designed such that it has only a defined point of support (37). Power relay (1) according to one of Claims 1 to 3,
characterized,
that the contact bridge side contact element (34) of the first contact pair (33, 34) for a bolt-side mating contact (34) convexly curved contact region (34a). Power relay (1) according to claim 3,
characterized,
in that the convexly curved contact region (34a) is provided in the bridge longitudinal direction (35) to provide a centrally raised contact region the support point (37) extends along the contact bridge-side contact element (34). Power relay (1) according to one of claims 1 to 4,
characterized,
in that the second contact pair (33, 34) is designed such that it has two defined support points (38, 39). Power relay (1) according to one of claims 1 to 5,
characterized,
that the contact bridge-side contact element (34) of the second contact pair (33, 34) - with respect to the bolt-side mating contact (33) - a concave vaulted contact region (34c). Power relay (1) according to claim 6,
characterized,
in that the concave, arched contact region (34c) extends in the longitudinal direction (21) of the bridge along the contact bridge-side contact element (34) to form two adjacent and raised contact regions (34d). Power relay (1) according to one of claims 1 to 7,
characterized,
that the bolt-side mating contacts (33) have a planar support surface. Power relay (1) according to one of claims 1 to 8,
characterized,
in that the mating contacts (33) and / or the contact elements (34) have a joining shaft (33b, 34e) and a circular, preferably plate-like, contact surface head (33a, 34f). Power relay (1) according to one of claims 1 to 9,
characterized,
in that the housing (2) comprises a housing pot (4) and a connection socket (3) which is joined to it or can be partially inserted in it and into which the connection bolts (10) are introduced. Power relay (1) according to claim 10,
characterized,
that in the assembled state, the contact bridge (17) at least partially in the terminal socket (3) is seated.

Images