EP3496126A1 - Power relais for a vehicle - Google Patents

Power relais for a vehicle Download PDF

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Publication number
EP3496126A1
EP3496126A1 EP19154808.0A EP19154808A EP3496126A1 EP 3496126 A1 EP3496126 A1 EP 3496126A1 EP 19154808 A EP19154808 A EP 19154808A EP 3496126 A1 EP3496126 A1 EP 3496126A1
Authority
EP
European Patent Office
Prior art keywords
housing
power relay
contact bridge
formed
contact
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP19154808.0A
Other languages
German (de)
French (fr)
Inventor
Markus Birner
Manuel ENGEWALD
Helmut Kraus
Ricardo Pimenta
Sebastian Rothmayr
Matthias Schwarz
Erwin Singer
Wolfgang Weiss
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ellenberger and Poensgen GmbH
Original Assignee
Ellenberger and Poensgen GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to DE102014007459.5A priority Critical patent/DE102014007459A1/en
Application filed by Ellenberger and Poensgen GmbH filed Critical Ellenberger and Poensgen GmbH
Priority to PCT/EP2015/001032 priority patent/WO2015176818A2/en
Priority to EP15728403.5A priority patent/EP3146553B1/en
Publication of EP3496126A1 publication Critical patent/EP3496126A1/en
Application status is Pending legal-status Critical

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Classifications

    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00Details of electromagnetic relays
    • H01H50/02Bases; Casings; Covers
    • H01H50/04Mounting complete relay or separate parts of relay on a base or inside a case
    • H01H50/047Details concerning mounting a relays
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H1/00Contacts
    • H01H1/60Auxiliary means structurally associated with the switch for cleaning or lubricating contact-making surfaces
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H47/00Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current
    • H01H47/22Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current for supplying energising current for relay coil
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00Details of electromagnetic relays
    • H01H50/02Bases; Casings; Covers
    • H01H50/023Details concerning sealing, e.g. sealing casing with resin
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00Details of electromagnetic relays
    • H01H50/02Bases; Casings; Covers
    • H01H50/04Mounting complete relay or separate parts of relay on a base or inside a case
    • H01H50/041Details concerning assembly of relays
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00Details of electromagnetic relays
    • H01H50/12Ventilating; Cooling; Heating
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00Details of electromagnetic relays
    • H01H50/16Magnetic circuit arrangements
    • H01H50/18Movable parts of magnetic circuits, e.g. armature
    • H01H50/20Movable parts of magnetic circuits, e.g. armature movable inside coil and substantially lengthwise with respect to axis thereof; movable coaxially with respect to coil
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00Details of electromagnetic relays
    • H01H50/16Magnetic circuit arrangements
    • H01H50/36Stationary parts of magnetic circuit, e.g. yoke
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H9/00Details of switching devices, not covered by groups H01H1/00 - H01H7/00
    • H01H9/02Bases, casings, or covers
    • H01H9/04Dustproof, splashproof, drip-proof, waterproof, or flameproof casings
    • H01H9/042Explosion-proof cases
    • H01H9/043Explosion-proof cases with pressure-relief devices
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00Details of electromagnetic relays
    • H01H50/44Magnetic coils or winding
    • H01H2050/446Details of the insulating support of the coil, e.g. spool, bobbin, former
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2231/00Applications
    • H01H2231/026Car
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2235/00Springs
    • H01H2235/01Spiral spring
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H47/00Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current
    • H01H47/001Functional circuits, e.g. logic, sequencing, interlocking circuits
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H47/00Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current
    • H01H47/002Monitoring or fail-safe circuits
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H47/00Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current
    • H01H47/22Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current for supplying energising current for relay coil
    • H01H47/226Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current for supplying energising current for relay coil for bistable relays
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00Details of electromagnetic relays
    • H01H50/02Bases; Casings; Covers
    • H01H50/021Bases; Casings; Covers structurally combining a relay and an electronic component, e.g. varistor, RC circuit
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00Details of electromagnetic relays
    • H01H50/14Terminal arrangements
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00Details of electromagnetic relays
    • H01H50/16Magnetic circuit arrangements
    • H01H50/18Movable parts of magnetic circuits, e.g. armature
    • H01H50/30Mechanical arrangements for preventing or damping vibration or shock, e.g. by balancing of armature
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00Details of electromagnetic relays
    • H01H50/54Contact arrangements
    • H01H50/546Contact arrangements for contactors having bridging contacts

Abstract

A power relay (1) for a vehicle, in particular a commercial vehicle, is specified. The power relay (1) comprises a housing (2) which is formed from a connection socket (3) and a housing pot (4) mounted thereon, wherein two connection bolts (10) for contacting a load circuit are introduced into the connection socket (3). The power relay (1) further comprises a coil assembly (20) arranged in the housing (2) and comprising a magnet coil (30) and a magnet armature (24). The magnet armature (24) is in this case coupled via a force transmission member (23) with a contact bridge (22) and under the action of a magnetic coil (30) generated magnetic field in the housing (2) displaceable, that the contact bridge (22) reversible between a Closed position in which the contact bridge (22) the connecting pin (10) bridges electrically conductive, and an open position in which the contact bridge (22) is dekontaktiert of the terminal bolt (10) is movable. The housing pot (4) is designed as a plastic injection molding component.

Description

  • The invention relates to a power relay for a vehicle, in particular a commercial vehicle.
  • Generic power relays are used in vehicle technology, especially in commercial vehicles. The power relays are here used on the one hand to electrically disconnect the vehicle battery from the electrical system. On the other hand, such relays are used to switch electric motors of adjusting devices (e.g., hydraulic pump or lifting platform). Such a power relay must be able to switch currents up to a current of about 300 amperes at low voltage, typically 12 to 24 volts, and must be solidly built accordingly. 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, a magnetic yoke, and a magnet armature connected to a contact bridge (double contact) are housed.
  • To connect the power relay to a load circuit to be switched in the vehicle, the power relay typically includes solid metal studs (threaded bolts) typically 0.5 to 1 cm in diameter. 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.
  • Such power relays are in particular made DE 10 2010 018 755 A1 and DE 10 2010 018 738 A1 known.
  • Disadvantageously, the conventional power relays are comparatively heavy and expensive to manufacture. Another problem of the power relays conventionally used is that currently a variety of different construction variants are used, which are different distances of the Connection bolts and different mounting options for the relay housing (eg laterally on the housing pot, on the connection side or on the opposite to this bottom of the relay housing) differ.
  • In order to be able to serve the market comprehensively, in particular to be able to service existing commercial vehicles with different on-board network configuration and, if necessary, retrofit with new power relays, a large number of different types of power relay must be provided, which leads to considerable manufacturing and storage costs.
  • The invention has for its object to provide a particularly rationally manufacturable and easy-to-build power relay for a vehicle, especially a commercial vehicle.
  • This object is achieved by the features of claim 1. The power relay according to the invention comprises a housing which is formed from a connection socket and a housing pot mounted thereon. Two connection bolts are inserted in the connection socket, via which the power relay can be contacted with connecting cables of an external load circuit to be connected. The power relay further comprises a coil assembly arranged in the housing with a magnet coil and a corresponding magnet armature. The armature is in this case coupled via a force transmission member with a contact bridge and under the action of a magnetic field generated by the magnetic field displaceable in the housing, that the contact bridge is reversibly movable between a closed position and an open position. The closed position is in this case characterized in that the contact bridge bridges the connecting pins in an electrically conductive manner, as a result of which the power relay is switched on. The open position, however, is characterized in that the contact bridge is dekontaktiert of the terminal bolt, so that there is no conductive connection between the terminal bolt and the power relay is thus switched off.
  • According to the invention, the housing pot is designed as a plastic injection-molded part. This allows for a significant reduction in manufacturing and material costs as well as significant weight savings as compared to conventional power relays provided with a metal can. The connection socket is also preferably a plastic injection-molded component.
  • In the case of the power relay according to the invention, this can optionally be a bistable relay which permanently maintains both the closed position and the open position in the de-energized state of the magnet coil, or it can be a monostable relay. In the latter case, the power relay can be designed as normally open or normally closed, wherein the relay automatically assumes the open position when the solenoid coil is not energized, and the closed position in the latter design. Preferably, both bistable and monostable designs of the power relay are realized according to the construction principle of the invention.
  • In a preferred embodiment, the coil assembly further comprises a magnetic yoke. In order to achieve a high stability of the housing despite low weight and compact design, the yoke expediently comprises a torsionally stable structure which is rotatably received in this over the entire axial height of the housing pot. The axial height here is the extension of the housing pot along the housing top axis perpendicular to the bottom of the housing pot. The torsionally stable structure of the magnetic yoke is formed in an expedient embodiment by a one-piece, U-shaped angled bracket whose legs surround the magnetic coil parallel to its coil axis. In order to be able to take up the torsion-stable structure of the magnetic yoke, in particular the yoke, the housing pot preferably has an at least approximately rectangular cross-section at least in its interior, the magnet yoke, in particular the yoke, extending parallel to two of the four sidewalls in the manner of a crossbeam and supported on both sides by the two remaining side walls.
  • Due to the rotationally fixed receiving the magnetic yoke, the housing pot initiates a torque acting on it, which is caused for example by tightening the contact nuts, in the torsion stable running magnetic yoke. In a torsion of the housing pot, therefore, the yoke, in particular the bracket must always be twisted, which in turn relieves the housing pot. As a result, material fatigue or even breakage of the housing pot is counteracted.
  • In order to further improve the torsional stability of the housing, the terminal base is preferably also coupled to the magnetic yoke so as to be secure against rotation, for example by virtue of the magnet yoke engaging in form-fitting manner with corresponding projections in corresponding recesses of the terminal socket. In this way, if necessary, torques exerted on the connection socket are not transferred to the magnetic yoke, but only indirectly via the housing pot. Rather, at least a portion of these torques is introduced directly from the terminal socket in the magnetic yoke, which in turn relieves the housing pot, and in particular the connection between the housing pot and the terminal socket.
  • In principle, the power relay in the context of the invention can be a purely electromechanical component, in which the magnetic coil is activated (energized) solely on the basis of external control signals and deactivated (switched off). Preferably, however, the power relay additionally comprises a control electronics accommodated in the housing for controlling the magnetic coil. In this case, the control electronics converts external control signals (which in this case can also be output, for example, as pulse signals, in particular in digital form) into a corresponding control current for the magnetic coil. Optionally, the control electronics further includes other functions, such as current or voltage measurement between the terminal pins and / or protection functions, a forced shutdown of the power relay in case of over- and / or undervoltage, overload or - in multi-pole versions of the power relay - a fault current or an asymmetrical current distribution effect.
  • Both in purely electromechanical designs as well as in electronic designs, the power relay comprises a number of signal terminals, each of which is in each case connectable to an external signal line. The signal connections are expediently, as well as the connection bolts for the load current, fixed in the connection socket.
  • The signal terminals serve to supply at least one electrical control signal to the power relay and / or to output at least one electrical state signal by the power relay. Optionally, at least one of the signal terminals for supplying an electrical supply voltage or an electrical reference potential, in particular ground, also provided. In a purely electromechanical design of the power relay, the signal connections are in this case contacted directly with the magnetic coil. In electronic designs of the power relay regularly at least some of the signal terminals, however, are connected to the control electronics. This control electronics provides additional functions (for example, measuring functions, protective functions, bus communication, etc.). The signal supplied via the signal terminals are used in the latter case usually only indirectly to control the solenoid.
  • Generic power relays are regularly used in harsh environments where these relays are exposed to water, oil, dust and other contaminants. As a rule, the housing of such power relays must be dust and liquid-tight (especially with IP6K7 or IP6K9K protection rating). In order to guarantee the required tightness with respect to the connection of the housing pot with the connection socket, the connection socket is preferably connected in a fluid-tight manner to the housing pot by means of a hardening potting compound, for example an epoxy resin. In order to allow a simple and durable Vergießung this connection point, the housing pot in an advantageous embodiment, the opening side on a circumferential shoulder on which rests the terminal base with a circumferential radial web. The housing pot engages on the outside with a collar the radial web of the connection socket around, wherein the collar projects axially beyond the radial web. The collar of the housing pot thus surrounds the molded onto the terminal base radial bar in the manner of a balustrade. Thus, a trough-like receptacle (hereinafter referred to briefly as "tub") is formed by the collar and the connection socket for the potting compound. In the assembled state of the power relay, this tub is completely or at least partially filled with the potting compound.
  • Each of the signal connections described above is in each case connected via an associated connection conductor (which is preferably formed by a bent sheet metal stamped part) to the magnet coil or the control electronics which may be connected upstream of this. Each of the connection conductors is in this case preferably passed through in the region of the tub through the connection socket. Thus, when the housing is cast, each of the connection conductors is also embedded in the potting compound, as a result of which the passage of the connection conductors through the connection socket is also sealed, without the need for separate measures for this.
  • In order to further stabilize the connection between the housing pot and the connection socket, the collar of the housing pot is provided in the region of the tub with at least one radial contour. The or each radial contour of the collar can be formed by a radial recess (which reduces the material thickness of the collar) or a radial projection (which increases the material thickness of the collar). Corresponding to the or each radial contour at least one mating contour is formed on the connection socket in the region of the trough. In this case, the radial contour and the corresponding mating contour form a form-locking connection with the potting compound, by means of which the connection socket and the housing pot are locked together in the circumferential direction, ie tangentially to the axis of the magnet coil and of the housing pot. As a result of this locking a rotation of the terminal socket is blocked relative to the housing pot also effectively by the potting compound. Preferably, the radial contour and the corresponding mating contour continue to undercuts, due to which the housing pot and the connection socket by form-locking the potting compound with the radial contour and the mating contour in the radial Direction are locked together. In this way, a radial curvature of the housing pot, due to which the collar of the housing pot would at least locally detach from the radial web of the connection socket, is prevented by the casting compound. In a preferred embodiment variant, the radial contour is designed as a latching nose, which engages over the radial web and thus latched to the housing pot.
  • It is known that when switching a generic relay, especially in the case of short circuit, regularly a high gas pressure in the interior of the housing, which could lead under unfavorable circumstances to explosion or at least uncontrolled bursting of the relay housing. The cause of the high gas pressure may in this case consist in the warming-related expansion of the air in the housing interior and / or in the evaporation of residual moisture of the air taken up in the housing interior. The cause of the air heating can in turn be a switching arc or the heating of the current-carrying parts due to the current flow (in particular a short-circuit current). The explosion or the uncontrolled bursting of the housing can lead to dangerous situations, in particular a short circuit of live parts with mass and an associated risk of fire or personal injury, and must therefore be excluded. To ensure this safety requirement in a compact and easy to build power relay, an overpressure protection is provided in an advantageous embodiment of the power relay in the housing - and this preferably in the housing pot - which releases a gas discharge opening in the case of a critical overpressure in the housing, and thus a controlled Ensures pressure equalization with the environment. The overpressure protection can be formed by a separately manufactured and inserted into the housing pot (or possibly in the connection socket) valve, in particular by a spring-loaded ball valve or a tearing in the overpressure membrane (optionally semi-permeable by nature, ie gas-permeable, but not liquid permeable can).
  • Preferably, the overpressure protection but in the housing (and in particular in the housing pot) integrally integrated, in particular to the housing molded. In this embodiment, the overpressure protection is formed in particular by a predetermined breaking point, which bursts in the overpressure case and thus releases the gas ejection opening to relieve the remaining housing areas. The predetermined breaking point preferably has a curved, for example U-shaped, V-shaped, or trapezoidal, shape and thus surrounds from three sides a tab-like portion (hereinafter "flap") of the housing, which forms the closure of the overpressure protection. The fourth side of this tab is expediently designed as a film joint along a connecting line extending between the ends of the predetermined breaking point. By the framed by the breaking point tab in this case a gas discharge opening is formed with a defined shape and size. The film joint connecting the predetermined breaking point allows the tab to be bent outwardly from the housing wall when the predetermined breaking point bursts open, but prevents the tab from tearing off in an uncontrolled manner, thereby counteracting possible personal injury or damage to adjacent parts. In a particularly advantageous embodiment variant, the predetermined breaking point in particular has a keyhole shape, that is to say it is of U-shaped design with a circularly prepared base.
  • Since the housing of the power relay after the bursting of the predetermined breaking point is no longer tight, a replacement of the power relay is required in this case regularly. To rule out that the power relay is still operated, the power relay is provided in an expedient development with a safety function that generates a warning signal after the failure of the predetermined breaking point and / or the power relay forcibly switches to a safe state. In one embodiment of the power relay, the safety function comprises a forced shutdown, by means of which the power relay permanently shuts off - by decontacting the contact bridge from the terminal bolts - and is thus irreversibly shut down. For certain embodiments, the fuse function of the power relay - in adaptation to the particular application - but also include the switching of the power relay. For example, a power relay used as a battery switch in a commercial vehicle must remain switched on even in the event of a fault, since otherwise the electrical supply of the vehicle electrical system - if necessary while driving - would collapse.
  • In principle, it can be provided within the scope of the invention that the forced shutdown detects the overpressure case independently of the state of the predetermined breaking point, for example by a separate overpressure sensor which is triggered in a critical overpressure case. Preferably, however, the forced shutdown is triggered directly by the bursting of the predetermined breaking point. For this purpose, in an expedient embodiment, an electrical safety line is mechanically coupled to the predetermined breaking point such that the safety line is severed in the event of failure of the predetermined breaking point. The fuse line is here - directly or indirectly - in operative connection with the solenoid, so that their severance causes the forced shutdown of the power relay. The fuse line may be part of the power supply of the solenoid or part of a signal circuit connected to the possibly existing control electronics, for example. In principle, it is also conceivable within the scope of the invention that the fuse line is electrically switched through in the case of failure of the predetermined breaking point, in which case the connection (ie the emergence of a conductive connection via the fuse line), the forced shutdown triggers, or that the state of the predetermined breaking point another sensor is controlled.
  • In order to simplify the assembly of the power relay, the coil assembly is preferably designed as a self-stable (stable in itself) and contiguous structural unit. The coil assembly is thus designed such that it holds together without the surrounding parts of the housing. This makes it possible to assemble the coil assembly outside the housing, which in particular accommodates an automated manufacturing, and to use as a whole in the housing.
  • Core element of the self-stable coil assembly is in an advantageous embodiment of the power relay a trained by a plastic injection molded part, one-piece support body on which the magnetic coil is wound directly. Furthermore, the carrier body preferably also carries the magnet armature, which for this purpose is slide-mounted directly in the carrier body.
  • In an expedient embodiment, the carrier body comprises at least one pocket which serves to receive a pole shoe of the magnetic yoke and, if present, at least one permanent magnet. Permanent magnets are provided here in bistable designs of the power relay.
  • On the inside, the or each pocket preferably has a wall with a defined wall thickness between 0.2 mm and 0.5 mm, in particular at about 0.3 mm, by which the corresponding pole piece of the magnetic yoke is spaced from the guided inside the support body magnet armature , By this integrally formed with the support body wall, an effective magnetic flux is achieved within the magnetic circuit formed from the yoke and the magnet armature, at the same time the magnetic conditions can be adjusted within this magnetic circuit with high precision and high temporal stability.
  • Preferably, a holder or at least installation space for at least one freewheeling diode and / or a holder for a thermal fuse and / or a holder for a switching position contact for detecting the switching position of the power relay are further formed on the carrier body. As a thermal fuse is here an electrical or electronic component understood that opens by melting or mechanical movement under the influence of external heat generation (unlike a fuse so not under the effect of flowing through the component current) and thus interrupts the guided over the thermal fuse circuit. As a result of the holders described above, which are preferably provided in combination on the carrier body, this carrier body is designed as a multi-functional part that can be used unchanged in a variety of different types of power relay, especially in types with and without freewheeling diodes, designs with and without thermal fuse as well as designs with and without switch position contact. The brackets are thus on the support body in particular also formed in designs of the power relay, in which the respective functional component, ie the freewheeling diode, the thermal fuse or the signal contact are not provided. Thus, a particularly high degree of prefabrication is achieved for different types of power relay.
  • In order to further simplify assembly, the coil assembly is preferably attached to the terminal socket, wherein a snap connection is preferably used for this attachment. This makes it possible to mount all electrically and by mechanical movement cooperating parts of the power relay outside of the housing.
  • For mechanical coupling of the magnet armature with the contact bridge, a coupling rod is provided in an expedient embodiment of the power relay, which extends along a coil axis of the magnetic coil. Conveniently, the coupling rod is slidably mounted in a central part of the magnetic yoke. On the anchor remote side, the contact bridge is attached to the coupling rod. In order to ensure precise guidance of the contact bridge, the coupling rod is in this case, in an advantageous embodiment of the invention, slidably mounted on its armature-distant side (thus in the region of the contact bridge) in the connection base. The coupling rod dives in particular with a - in the connection base slidably mounted - bearing section through the contact bridge.
  • In electronic construction variants of the power relay, the control electronics present in this case are preferably arranged outside the magnetic yoke, and in this case in particular parallel to one of the side faces of the housing pot. By the magnetic yoke, the control electronics are shielded by the heat generated by the energization of the magnetic coil. The control electronics is thus arranged in the cold area of the power relay, whereby the control electronics is spared.
  • In addition to single-pole embodiments with only two terminal bolts and a single associated coil assembly also multipolar embodiments of the power relay are preferably provided. These multipolar versions of the power relay are used in particular to switch multiphase load circuits simultaneously or to switch single-phase load circuits through several switching units in parallel. The latter has the particular advantage that the load acting on the relay during switching can be distributed over several poles. Multipole embodiments of the power relay are hereby advantageously realized in that a plurality of coil assemblies are fastened together on one and the same terminal base, said terminal base carries two connecting bolts for each coil assembly.
  • In order to realize different mounting positions with one and the same design of the power relay, the housing pot preferably carries both on a side surface and at its bottom each have a mounting surface which is provided with screw holes for receiving fastening screws. On each of these mounting surfaces, the power relay can either be mounted directly or - to adapt to different hole distances of the installation environment - via adapter plates by screwing. The respectively provided in the mounting surfaces of the housing pot screw openings are preferably realized by threaded sleeves made of metal, which are pressed into openings of the plastic material of the housing pot or encapsulated with the material of the housing pot.
  • In an advantageous further development of an electronic construction variant of the power relay, the control electronics provided in this case are provided with a contact cleaning function. In this case, the control electronics are set up to control the magnetic coil several times at short intervals in a contact cleaning mode. Due to the multiple control thus an artificial contact bouncing is generated in which the contact bridge repeatedly beats against the connecting bolt. In this way, optionally adhering to the contact points contaminants are abraded, whereby low contact resistance can be achieved or maintained. In a particularly advantageous embodiment of this contact cleaning function, the control electronics causes the contact cleaning only when there is no electrical voltage across the terminal bolt, so that the artificial contact bouncing is done without load. To this Way switching arcs are excluded in the contact cleaning function.
  • In electronic designs of the power relay, the control electronics are preferably connected to the terminal bolts. In this case, the control electronics are set up to pick up the electrical voltage dropping between the connecting bolts and to detect them by measurement. Furthermore, a supply voltage for the control electronics is preferably tapped off via the connection bolts.
  • Embodiments 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 for a truck,
    Fig. 2
    in a perspective view obliquely from below the power relay,
    Fig. 3
    in an exploded view, four subassemblies of the power relay, namely a terminal socket, a housing pot, a coil assembly and a control electronics supporting board,
    Fig. 4
    in a perspective view obliquely from above the coil assembly of the power relay,
    Fig. 5
    in a perspective view obliquely from below the coil assembly according to Fig. 4 .
    Fig. 6
    in a perspective view obliquely from above a magnetic circuit of the power relay with a magnetic yoke and a magnet armature and with a coupling rod over which the armature acts on a (not shown here) contact bridge,
    Fig. 7
    in a perspective view obliquely from above a support body of the coil assembly,
    Fig. 8
    in a perspective view obliquely from below the carrier body according to Fig. 7 .
    Fig. 9
    in a cross-section IX-IX according to Fig. 7 the carrier there,
    Fig. 10
    in a perspective view from above the power relay in a non-cast pre-assembled state,
    Fig. 11
    in an enlarged section XI out Fig. 10 a detail of the housing of the power relay,
    Fig. 12
    in a longitudinal section XII-XII according to Fig. 1 and 2 the local power relay,
    Fig. 13
    in a longitudinal section XIII-XIII according to Fig. 1 and 2 the local power relay,
    Fig. 14
    in a cross section XIV-XIV according to Fig. 1 and 2 the local power relay, and
    Fig. 15
    in perspective view obliquely from above the housing pot of the power relay.
  • Corresponding parts all figures are always provided with the same reference numerals.
  • That in the Fig. 1 and 2 Power relay 1 shown as a whole comprises a housing 2, which is formed from two parts, namely a terminal socket 3 and a housing pot 4. Both the terminal base 3 and the housing pot 4 are in this case formed 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. 12 to 14 ). 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. 13 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 intermediate space 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 held by encapsulation in the connection socket 3. Towards the top 5, the signal connections 13 are protected against contact by a separate, snap-on plastic cover 15.
  • Fig. 3 shows the power relay 1 in partially dismounted state. It can be seen from this representation that the power relay 1 is formed from four subassemblies which are in each case connected in one another. In addition to the housing parts already described, namely the terminal base 3 with the attached connecting pins 10 and signal terminals 13 and next to the housing pot 4, the power relay 1 accordingly comprises a coil assembly 20 and a hereinafter referred to as board 21 line carrier.
  • In the Fig. 4 Coil assembly 20 shown enlarged comprises a contact bridge 22, which is connected via a coupling rod 23 with a magnet armature 24 of an in Fig. 6 separately shown magnetic circuit is mechanically coupled. As can be seen in particular from this illustration, the magnetic circuit comprises in addition to the armature 24, a magnetic yoke 25, said magnetic yoke 25 by a central, the coupling rod 23 concentrically surrounding hollow cylindrical core 26, a U-shaped bent bracket 27 and two of the leg ends of Ironing of successive pole pieces 28 is formed. The pole pieces 28 in this case include the magnet armature 24 between them. The armature 24 and the components of the magnetic yoke 15 are formed of ferromagnetic material.
  • In the illustrated embodiment, the power relay 1 is a bistable relay. In this case, the pole shoes 28 and the leg ends of the bracket 27 are each two platelet-shaped permanent magnets 29 interposed. Depending on the design of the power relay 1, however, one or two of the permanent magnets 29 assigned to a pole shoe 28 may also be replaced by ferromagnetic plates of the same size. In a (not shown) monostable variant of the power relay 1, the permanent magnets 29 are completely replaced by ferromagnetic material.
  • As an eponymous component, the coil assembly 20 comprises a magnetic coil 30 (FIG. Fig. 4 ), which rests in the framed by the magnetic yoke 25 volume. The magnet coil 30 concentrically surrounds the core 26 of the magnet yoke 25 and is itself framed by the yoke 27 and the pole shoes 28.
  • As in particular from Fig. 5 As can be seen, the coil assembly 20 further comprises a number of electrical functional elements, namely
    • a switch position contact 31 with two fixed contacts 32 and a coupled to the coupling rod 23 moving contact 33,
    • two free diodes 34, which serve to protect against inductive surges when switching and
    • a thermal fuse 35, which causes a forced shutdown of the power relay 1 in case of overheating.
  • Further, the coil assembly 20 comprises two auxiliary conductors 36, each formed of a bent stamped sheet metal part, a damping element 37 and two compression rods surrounding the coupling rod 23, namely a return spring 38 and a contact pressure spring 39 (FIGS. Fig. 12 and 13 ).
  • The above enumerated components of the coil assembly 20 are in this case mechanically held together by a carrier body 40 which in the Fig. 7 to 9 is shown isolated. The carrier body 40 is a one-piece, multifunctional injection molding component made of plastic.
  • The carrier body 40 carries on the one hand the magnetic coil 30, which is wound directly on a central column 41 of the carrier body 40 for this purpose. On the other hand, the carrier body 40 holds the magnetic yoke 25 and the magnet armature 24. The armature 24 and the core 26 of the magnetic yoke 25 are for this purpose in the interior of the hollow column 41 of the carrier body 40 received (see. Fig. 12 to 14 ). The magnet armature 24 is in this case slide-mounted directly on the carrier body 40. The yoke 27 of the magnetic yoke 25 is placed on an upper platform 42 of the carrier body 40, so that its legs laterally outside of the magnet coil 30 after protrude down. The pole shoes 28 and the permanent magnets 29 of the magnetic yoke 25 are in two opposite in a lower platform 43 of the carrier body 40 introduced pockets 44 a. As in particular from Fig. 9 shows, each of the two pockets 44 on the inside - thus the hollow interior of the column 41 through - limited by a thin wall 45 of the support body 40, which has a defined, everywhere constant wall thickness of 0.3 mm. Through the walls 45 in this case a defined gap width between the magnetic yoke 25 and the armature 24 is set.
  • Furthermore, the carrier body 40, as in particular Fig. 8 it can be seen
    • Mounts 46 for the fixed contacts 32 of the switch position contact 31,
    • Space 47 for the freewheeling diodes 34 (the free-wheeling diodes 34 are supported only indirectly via coil connection conductors on the carrier body 40 in the illustrated embodiment),
    • Mounts 48 for the thermal fuse 35,
    • Mounts 49 for the auxiliary conductor 36 and
    • Mounts 50 for the damping element 37th
    on. As intended, identical carrier bodies 40 are used for different types of power relay 1. The carrier body 40 thus has the respectively molded holders 46 to 50, even if not all of the above-described functional components (ie the switch position contact 31, the free diodes 34, the thermal fuse 35, the auxiliary conductor 36 or the damping element in a particular design of the power relay 1 37) are present.
  • In the Fig. 3 shown board 21 is formed of two sections 60 and 61, which are hingedly connected to each other via a film hinge 62 and therefore from a plain initial state in the in Fig. 3 shown L-shaped arrangement are bendable. In the illustrated electronic design of the power relay 1, the portion 60 carries a control electronics 63. The section 61 includes mainly contact points for making electrical contact with the fixed contacts 32 of Switch position contact 31, the coil terminals with the freewheeling diodes 34, the thermal fuse 35, the auxiliary conductor 36 and the solenoid 30th
  • In purely electromechanical designs of the power relay 1, the board 21 is optionally also available. However, it carries in this case, no control electronics 63, but only traces for contacting the magnetic coil 30 and the possibly existing electrical functional elements with the signal terminals 13. Alternatively, the board 21 is replaced with purely electromechanical types of power relay 1 by wire conductor.
  • In the course of mounting the power relay 1, the carrier body 40 is first with the solenoid 30, the yoke 25, the armature 24 connected to the coupling rod 23 and the compression springs 38, 39, the contact bridge 22 and the optional electrical functional components (ie the switch position contact 31st , the free-wheeling diodes 34, the thermal fuse 35 and / or the auxiliary conductors 36) and equipped with the damping element 37. The coil assembly 20 is thus completed as a self-stable (self-supporting) assembly.
  • In this form, the coil assembly 20 is clipped from below onto the previously completed in an injection molding connection socket 3. For this purpose, the terminal base 3 is at its bottom with molded snap hooks 64 ( Fig. 3 ), which engage on both sides under the upper platform 42 of the carrier body 40. In the state of the coil assembly 20 fastened to the connection base 3, the yoke 27 of the magnetic yoke 25 continues to engage with two shaped projections 65 (FIG. Fig. 3 and 4 ) positively into complementary shaped recesses on the underside of the terminal socket 3 a. Thus, the bracket 27 of the magnetic yoke 25 in the clipped state rotationally fixed with respect to a rotation about the axis of the magnetic coil or the respective axis of the connecting bolt 10 is connected to the terminal socket 3.
  • After, before or simultaneously with the clipping of the coil assembly 20, the board 21 is mounted. For this purpose, on the one hand connection points in the area of the section 60 soldered to the connecting conductors 14 of the signal terminals 13. On the other hand, connection points in the region of the section 61 are soldered to terminals of the magnet coil 30 as well as the existing electrical functional elements (ie optionally the fixed contacts 32 of the switch position contact 31, the freewheeling diodes 34, the thermal fuse 35 and / or the auxiliary conductor 36). In its mounting position, the board 21 extends with its portion 60 parallel to a leg of the bracket 27, wherein the portion 60 is disposed outside of the bracket 27. With its portion 61, the board 21 extends perpendicular to the coil axis, wherein it engages under the yoke 25 and the armature 24.
  • Further, the auxiliary conductors 36 are provided with (voltage tap) terminals 66 (FIG. Fig. 3 and 13 ) soldered. The connections 66 are in this case assigned in pairs to the connection bolt 10. One of the terminals 66 is thus contacted with one of the connecting bolts 10, while the other terminal 66 is contacted with the other connecting bolt 10. For this purpose, the connections 66 are welded in advance to the respective associated connection bolt 10 and, together with this, are encapsulated with the plastic material of the connection socket 3.
  • After mounting the coil assembly 20 and the board 21 to the terminal base 3, the housing pot 4 is slipped over the coil assembly 20 and the board 21 and locked with the terminal base 3 and screwed, whereby the housing 2 is closed. The bracket 27 of the magnetic yoke 25 is in such a way in the housing pot 4 that extend its legs in the manner of cross beams between two opposite side walls 6 of the housing pot 4 and parallel to the remaining side walls 6 over the entire width of the housing interior 8. The bracket 27 is thus over the entire - measured in the direction of the coil axis and the axis of the housing pot 4 - height of the housing pot 4 rotatably received in this. The bracket 27 thus stiffened due to its torsionally stable structure the housing pot 4 against axial torques, as they are exercised in particular when tightening the contact nuts on the connecting bolt 10.
  • In the closed state of the housing 2, the connection base 3 is provided with a circumferential radial web 70 (FIG. Fig. 3 . 12 and 13 ) on a circumferential shoulder 71 ( Fig. 3 . 12 and 13 ) in the wall of the housing pot 4. The housing pot 4 engages in this case with a circumferential, limiting its opening collar 72 ( Fig. 3 . 12 and 13 ) on the outside around the radial web 70 of the terminal socket 3 around and beyond this. The collar 72 thus surrounds the upper side of the radial web 70 like a balustrade and forms together with the connection base 3 a - from the Fig. 12 and 13 apparent - trough-shaped structure, which is referred to below as trough 73. For liquid-tight and gas-tight sealing of the connection between the terminal base 3 and the housing pot 4, this trough 73 is filled with a first liquid and curing in the course of a curing phase potting compound 74. In particular, a two-component system consisting of an epoxy resin and a mixed hardener is used as potting compound 74.
  • With the potting compound 74, the feedthroughs of the connection conductors 14 are also sealed. For this purpose, the connection conductors 14 are guided through the connection base 3 in the region of the trough 73. The passages of the connecting bolts 10 through the terminal socket 3 are sealed separately from the trough 73 by potting compound.
  • In order to additionally secure the connection between the terminal base 3 and the housing pot 4, along the inside of the collar 72 - and here in particular in the straight sections of the collar 72 - a number of radial projections 80 (FIG. Fig. 3 . 10 and 11 ), which protrude from the inner wall of the collar 72 inwards. The radial projections 80 act on the one hand as locking lugs which engage around the radial web 70 of the connection socket 3 and thus latch in its mounting position. Furthermore, each radial projection 80 is provided on both sides with an undercut 81, so that each radial projection (80) has a dovetail-shaped contour when viewed from above. Due to the undercuts 81, the radial projections 80 dig into the potting compound 74, whereby both a rotation of the Housing pot 4 relative to the terminal base 3 and a radial bulge of the side walls 6 of the housing pot 4 is prevented.
  • In order to prevent that under the action of forces acting on the side walls 6 of the housing pot 4 the potting compound 47 is entrained with the housing pot 4 and thereby dissolves from the outside of the terminal socket 3, a number of counter contours are in shape on the top of the terminal socket 3 formed by protrusions 82. The respective inner edges of these projections in turn here forms an undercut 83, which digs into the potting compound 74.
  • In (not shown) alternative designs, the power relay 1 is multi-pin, in particular two-pole or three-pole formed. In this case, one of the number of poles corresponding number of coil assemblies 20 are connected to a common terminal socket 3, wherein in the connection socket 3 in this case, each 2 connector pin 10 are fixed for each coil assembly. Depending on the design, a separate circuit board 21 may be provided for each coil assembly 20 or a common circuit board for all coil assemblies 20. In multipole designs of the power relay 1 is preferably a - preferably partitioned by transverse walls - housing pot 4 for common recording of all coil assemblies 20 is provided.
  • The Fig. 12 to 14 show the power relay 1 in the fully assembled state. It can be seen from these illustrations that the connection bolts 10 also each form fixed contacts of the main switching device of the power relay 1 provided for switching the load circuit. The protruding from the bottom of the terminal socket 3 in the housing interior 8 ends of the connecting bolts 10 are each provided with a contact element 90 for this purpose. The corresponding moving contact of the main switching device forms the contact bridge 22, which in each case comprises a counter contact element 91 in opposition to each of the contact elements 90. The mating contact elements 91 are electrically short-circuited within the contact bridge 22.
  • The Fig. 12 and 13 show the power relay 1 in an open position in which the mating contact elements 91 are lifted from the contact elements 90 (dekontaktiert), so that there is no electrically conductive connection between the terminal pins 10. To turn on the power relay 1, the magnetic coil 30 is energized. As a result, a magnetic flux is generated in the magnetic yoke 25, through which the magnet armature 24 is attracted against the core 26 of the magnetic yoke 25. With the magnet armature 24, the contact bridge 22 is thereby deflected upward through the intermediary of the coupling rod 23, so that the counter contact elements 91 abut against the corresponding contact elements 90. 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 22.
  • To switch off the power relay 1, the magnetic coil 30 is energized with reverse polarity. Under the effect of the magnetic flux generated in this case in the magnetic yoke 25, the holding force generated by the permanent magnets 29 is compensated, so that the magnet armature 24 withdrawn by the return spring 38 of the core 26 and thus in the open position according to Fig. 12 and 13 is pressed. The armature 24 in this case takes over the coupling rod 23 again with the contact bridge 22, whereby the counter contact elements 91 - are disconnected from the corresponding contact elements 90 - with separation of the electrical connection between the connecting pins 10. The attached at the lower end of the support body 40 damping element 37 intercepts this movement and thus prevents springing back of the formed from the armature 24, the coupling rod 23 and the contact bridge 22 unit in the direction of the closed position. In addition, the play of the components of the coil assembly 20 is reduced by the damping element 37.
  • 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 30. The magnetic coil 30 must be energized only temporarily.
  • In a (not explicitly shown) construction variant of the power relay 1, the coupling rod 23 protrudes with a bearing portion upwards, ie beyond the armature remote side of the contact bridge 22 addition. The bearing section emerges here in an aligned bearing opening 92 of the connection socket 3, so that the coupling rod 23 is also slidably mounted in the connection socket 3. As a result, a particularly stable and precise positioning of the contact bridge 22 is ensured.
  • As in particular from Fig. 12 shows, the portion 60 of the board 21 in the assembled state of the power relay 1 between a leg of the bracket 27 and the adjacent side wall 6 of the housing pot 4 is arranged. The arranged on the portion 60 control electronics 63 is thus shielded by the bracket 27 thermally opposite to the heat generated during the energization of the magnetic coil 30. Thus, the control electronics 36 is in a cold area of the housing 2, whereby premature aging of the control electronics 63 is prevented.
  • The control of the solenoid 30 is carried out either directly via the signal terminals 14 or via the control electronics 63, which in turn is supplied in the illustrated embodiment, via the terminals 66 and the auxiliary conductor 36 with voltage. The control electronics 63 controls the solenoid 30 in response to external or internal control commands, which are supplied to the control electronics 63 via the signal terminals 13. Via the connections 66, the electronic control unit 63 furthermore determines, in the switched-on state of the power relay 1, the voltage dropped across the connection bolt 10 as a measure of the load current flowing through the power relay 1 or for the detection of the relay position. In this case, the electronic control unit 63 optionally implements an overload shutdown and a short-circuit shutdown by automatically moving the power relay 1 into the open position when the detected load current exceeds predetermined threshold values. In the case of multi-pole designs of the power relay 1, the control electronics 63 optionally also comparatively evaluate the voltages that drop over the connecting pins 10 of the individual poles to the power relay 1 - depending on the design - to switch off on detection of a fault current or an asymmetrical current distribution.
  • Finally, the control electronics 63 optionally has a contact cleaning function. In a corresponding contact cleaning mode, the control electronics 63 controls the solenoid 30 at regular time intervals several times at short time intervals successively, so that an artificial contact bounce is generated. In this case, the contact bridge 22 abuts against the connecting bolts 10 several times, as a result of which any adhering impurities to the contact elements 90 and the mating contact elements 91 are rubbed off. The control electronics 63 in this case first checks the electric voltage applied across the terminal bolt 10 and only switches to the contact cleaning mode when this voltage has a vanishing amount, and the power relay 1 can thus be switched load-free.
  • In particular, when switching off the power relay 1 in overload or short circuit occurs due to the heating of the live parts and due to a resulting switching arc regularly to a high pressure in the housing interior 8. Under unfavorable circumstances, this pressure can assume a value of the stability of the housing. 2 , in particular of the housing pot 4 or the connection between the terminal base 3 and the housing pot 4 endangered. In order to prevent exploding or uncontrolled bursting of the housing 2 under these circumstances, the housing pot 4 is therefore provided with an overpressure safety device 100,
  • How out Fig. 15 can be seen, this overpressure 100 is formed by a curved groove, which reduces the material thickness of the housing bottom 7 locally and thereby acts as a predetermined breaking point 101. Due to the predetermined breaking point 101, an approximately keyhole-shaped tab 102 is delimited from the housing bottom 7 from three sides. Between the ends of the predetermined breaking point 100, thus at the narrow end of the keyhole-shaped tab 102, a further groove extends, which has a smaller groove depth compared to the predetermined breaking point 101 and therefore acts as a film hinge 103. The predetermined breaking point 101 is dimensioned such that they bursts when the pressure in the housing interior 8 exceeds a critical limit of, for example, about 2 to 3 bar. In this case, the tab 102 is bent outwardly about the film hinge 103 and thus releases a gas outlet opening, via which a pressure equalization with the environment takes place.
  • In a preferred embodiment of the power relay 1 is on the inner wall of the housing bottom 7 across the predetermined breaking point 101 and the tab 102 (not explicitly shown) laid electrical signal line in the form of a vapor-deposited or glued trace whose electrical resistance is queried by the control electronics 36. The signal line is thereby automatically cut when bursting the predetermined breaking point 100, which is detected by the control electronics 63 due to the sudden increased volume resistance. In this case, the control electronics 63 puts the power relay 1 in a safe state. In a design variant suitable for many applications, the control electronics 63 triggers a permanent forced shutdown of the power relay 1 in order to force an exchange of the power relay 1.
  • How out Fig. 2 shows, two alternative mounting options are given for the power relay 1. Thus, the housing pot 4 bears on the outside both on a side wall 6 and on the housing bottom 7 each have a mounting surface 110. Each mounting surface 110 four screw holes 111 are introduced at which the power relay 1 as intended mounted either directly or via an intermediate adapter plate by means of corresponding mounting screws can be. The screw holes 101 are preferably formed by threaded sleeves made of metal, which are pressed or screwed into associated recesses (blind holes) in the plastic material of the housing pot 4 or encapsulated with the plastic material.
  • The invention will be particularly apparent in the embodiments described above, but is not limited to these embodiments. Rather, numerous other embodiments of the invention may be inferred from the claims and the foregoing description.
  • 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
    20
    coil assembly
    21
    circuit board
    22
    Contact bridge
    23
    coupling rod
    24
    armature
    25
    yoke
    26
    core
    27
    hanger
    28
    pole pieces
    29
    permanent magnet
    30
    solenoid
    31
    Switch position contact
    32
    fixed contact
    33
    moving contact
    34
    Freewheeling diode
    35
    thermal fuse
    36
    auxiliary circuit
    37
    damping element
    38
    Return spring
    39
    Contact pressure spring
    40
    support body
    41
    pillar
    42
    (upper) platform
    43
    (lower) platform
    44
    bag
    45
    wall
    46
    holder
    47
    holder
    48
    holder
    49
    holder
    50
    holder
    60
    section
    61
    section
    62
    film hinge
    63
    control electronics
    64
    snap hooks
    65
    head Start
    66
    (Spannungsabgriffs-) Connection
    70
    radial web
    71
    paragraph
    72
    collar
    73
    tub
    74
    potting compound
    80
    radial projection
    81
    undercut
    82
    head Start
    83
    undercut
    90
    contact element
    91
    Contact element
    92
    bearing opening
    100
    Overpressure protection
    101
    Breaking point
    102
    flap
    103
    film hinge
    110
    mounting surface
    111
    screw opening

Claims (10)

  1. Power relay (1) for a vehicle, in particular a commercial vehicle,
    - With a housing (2), which is formed from a terminal socket (3) and a housing pot mounted thereon (4),
    - With two in the terminal base (3) introduced connection bolt (10) for contacting with a load circuit,
    - With a in the housing (2) arranged coil assembly (20) comprising a magnetic coil (30) and a magnet armature (24), wherein the armature (24) via a force transmission member (23) coupled to a contact bridge (22) and Effect of a magnetic field by means of the magnetic coil (30) generated magnetic field in the housing (2) is displaceable, that the contact bridge (22) reversibly between a closed position in which the contact bridge (22) electrically bridges the connecting pins (10), and an open position in which the contact bridge (22) is decontacted by the connecting pins (10) is movable,
    wherein the housing pot (4) is designed as a plastic injection molding component, wherein the housing (2) has an overpressure safety device (100) which releases a gas ejection opening in the case (2) in the event of a critical overpressure.
  2. Power relay (1) according to claim 1,
    wherein the overpressure safety device (100) is formed by a separately manufactured valve inserted into the housing pot (4) or the connection base (3), in particular a spring-loaded ball valve or a membrane.
  3. Power relay (1) according to claim 1,
    wherein the overpressure safety device (100) is formed by a predetermined breaking point (101) formed in the housing (2).
  4. Power relay (1) according to claim 3,
    wherein the predetermined breaking point (101) surrounds a tab-like portion (102) of the housing (3) from three sides, and wherein the fourth side of the tab-like portion (104) extends along a connecting line between the ends of the predetermined breaking point (101) as a film hinge (103). is trained.
  5. Power relay (1) according to claim 1 or 2,
    wherein an electrical safety line is so mechanically coupled to the predetermined breaking point (101) that the fuse line in case of failure of the predetermined breaking point (101) is severed or electrically connected, wherein the fuse line is so in operative connection with the magnetic coil (30) that in case of failure of the Predetermined breaking point (101) or cut through the fuse line causes a permanent electrical forced shutdown of the power relay (1).
  6. Power relay (1) for a vehicle, in particular a commercial vehicle,
    - With a housing (2), which is formed from a terminal socket (3) and a housing pot mounted thereon (4),
    - With two in the terminal base (3) introduced connection bolt (10) for contacting with a load circuit,
    - With a in the housing (2) arranged coil assembly (20) comprising a magnetic coil (30) and a magnet armature (24), wherein the armature (24) via a force transmission member (23) coupled to a contact bridge (22) and Effect of a magnetic field by means of the magnetic coil (30) generated magnetic field in the housing (2) is displaceable, that the contact bridge (22) reversibly between a closed position in which the contact bridge (22) electrically bridges the connecting pins (10), and an open position in which the contact bridge (22) is decontacted by the connecting pins (10) is movable,
    wherein the housing pot (4) is designed as a plastic injection molding component, wherein the coil assembly (20) is formed as a self-stable and coherent structural unit, and wherein the coil assembly (20) has a carrier body (40) which is formed as a one-piece plastic injection molded part, and on which the magnetic coil (30) is wound directly.
  7. Power relay (1) according to claim 6,
    wherein on the support body (40) has a holder (48) for a thermal fuse (35) for protecting the power relay (1) is formed from overheating.
  8. Power relay (1) according to claim 6 or 7,
    wherein on the carrier body (40) at least one holder for a fixed contact (32) of a switching position contact (31) for signaling the position of the contact bridge (22) is formed.
  9. Power relay (1) for a vehicle, in particular a commercial vehicle,
    - With a housing (2), which is formed from a terminal socket (3) and a housing pot mounted thereon (4),
    - With two in the terminal base (3) introduced connection bolt (10) for contacting with a load circuit,
    - With a in the housing (2) arranged coil assembly (20) comprising a magnetic coil (30) and a magnet armature (24), wherein the armature (24) via a force transmission member (23) coupled to a contact bridge (22) and Effect of a magnetic field by means of the magnetic coil (30) generated magnetic field in the housing (2) is displaceable, that the contact bridge (22) reversibly between a closed position in which the contact bridge (22) electrically bridges the connecting pins (10), and an open position in which the contact bridge (22) is decontacted by the connecting pins (10) is movable,
    wherein the housing pot (4) is formed as a plastic injection molding, with control electronics (63) which is adapted to the magnetic coil (30) in a contact cleaning mode several times at short time intervals to drive, so that the contact bridge (22) repeatedly against the connecting pins (10) strikes.
  10. Power relay (1) for a vehicle, in particular a commercial vehicle,
    - With a housing (2), which is formed from a terminal socket (3) and a housing pot mounted thereon (4),
    - With two in the terminal base (3) introduced connection bolt (10) for contacting with a load circuit,
    - With a in the housing (2) arranged coil assembly (20) comprising a magnetic coil (30) and a magnet armature (24), wherein the armature (24) via a force transmission member (23) coupled to a contact bridge (22) and Effect of a magnetic field by means of the magnetic coil (30) generated magnetic field in the housing (2) is displaceable, that the contact bridge (22) reversibly between a closed position in which the contact bridge (22) electrically bridges the connecting pins (10), and an open position in which the contact bridge (22) is decontacted by the connecting pins (10) is movable,
    wherein the housing pot (4) is designed as a plastic injection molding component, with a control electronics (63) which is contacted with the connecting bolt (10), and wherein the control electronics (63) is adapted to the falling between the terminal bolt (10) electrical To determine voltage.
EP19154808.0A 2014-05-21 2015-05-21 Power relais for a vehicle Pending EP3496126A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
DE102014007459.5A DE102014007459A1 (en) 2014-05-21 2014-05-21 Power relay for a vehicle
PCT/EP2015/001032 WO2015176818A2 (en) 2014-05-21 2015-05-21 Power relay for a vehicle
EP15728403.5A EP3146553B1 (en) 2014-05-21 2015-05-21 Relais de puissance pour un véhicule

Related Parent Applications (2)

Application Number Title Priority Date Filing Date
EP15728403.5A Division-Into EP3146553B1 (en) 2014-05-21 2015-05-21 Relais de puissance pour un véhicule
EP15728403.5A Division EP3146553B1 (en) 2014-05-21 2015-05-21 Relais de puissance pour un véhicule

Publications (1)

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EP15728403.5A Active EP3146553B1 (en) 2014-05-21 2015-05-21 Relais de puissance pour un véhicule

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EP (2) EP3496126A1 (en)
KR (1) KR101937274B1 (en)
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DE (1) DE102014007459A1 (en)
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DE102016105544A1 (en) * 2016-03-24 2017-09-28 Epcos Ag Apparatus for measuring a state of an electrical switch, electrical switch and method for measuring a state of an electrical switch

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KR20170005857A (en) 2017-01-16
EP3146553A2 (en) 2017-03-29
US10366852B2 (en) 2019-07-30
EP3146553B1 (en) 2019-07-03
WO2015176818A2 (en) 2015-11-26
PL3146553T3 (en) 2019-12-31
DE102014007459A1 (en) 2015-11-26
US20170069450A1 (en) 2017-03-09
KR101937274B1 (en) 2019-01-11
CN106463307A (en) 2017-02-22
WO2015176818A3 (en) 2016-02-04
CN106463307B (en) 2018-11-13

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