WO2007028321A1 - Contact a commande numerique faible puissance et systeme de controle constitue de contacts - Google Patents

Contact a commande numerique faible puissance et systeme de controle constitue de contacts Download PDF

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Publication number
WO2007028321A1
WO2007028321A1 PCT/CN2006/002210 CN2006002210W WO2007028321A1 WO 2007028321 A1 WO2007028321 A1 WO 2007028321A1 CN 2006002210 W CN2006002210 W CN 2006002210W WO 2007028321 A1 WO2007028321 A1 WO 2007028321A1
Authority
WO
WIPO (PCT)
Prior art keywords
power
low
contactor
iron core
permanent magnet
Prior art date
Application number
PCT/CN2006/002210
Other languages
English (en)
French (fr)
Inventor
Jinping Liu
Ronggao Chen
Original Assignee
Jinping Liu
Ronggao Chen
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
Application filed by Jinping Liu, Ronggao Chen filed Critical Jinping Liu
Priority to US12/066,235 priority Critical patent/US8093969B2/en
Publication of WO2007028321A1 publication Critical patent/WO2007028321A1/zh

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H47/00—Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current
    • H01H47/02—Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current for modifying the operation of the relay
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00—Details of electromagnetic relays
    • H01H50/16—Magnetic circuit arrangements
    • H01H50/36—Stationary parts of magnetic circuit, e.g. yoke
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H51/00—Electromagnetic relays
    • H01H51/01—Relays in which the armature is maintained in one position by a permanent magnet and freed by energisation of a coil producing an opposing magnetic field
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H47/00—Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current
    • H01H47/02—Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current for modifying the operation of the relay
    • H01H47/04—Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current for modifying the operation of the relay for holding armature in attracted position, e.g. when initial energising circuit is interrupted; for maintaining armature in attracted position, e.g. with reduced energising current
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H51/00—Electromagnetic relays
    • H01H51/22—Polarised relays
    • H01H51/2209—Polarised relays with rectilinearly movable armature

Definitions

  • the present invention relates to a switch device, and more particularly to a contactor core and a contactor drive.
  • AC contactor Since its inception, the AC contactor has been widely used in industrial process control automation and low-voltage terminal power supply, and has a solid market foundation. AC contactor
  • the main disadvantages of the flow contactor are: poor controllability of motion, high drive power, high energy consumption, easy to cause coil burnout, and short service life; new intelligent contactor drive unit with advanced electronic circuit and control chip, The real-time control of the entire dynamic process has improved its performance, but there are still problems such as complex drive circuit and large startup power.
  • the control system with the AC contactor as the main body has the characteristics of simple control circuit, strong driving force and low cost.
  • PLC programmable logic control device
  • a special control circuit is required to reduce the power consumption during the pull-in, which restricts the application and development of the control system.
  • the technical problem to be solved by the present invention is to provide a core structure suitable for a 100 ⁇ 800A high-power AC contactor; the present invention further provides a low-power numerical control contactor constructed by using the above-mentioned iron core, and the low-power numerical control A control system consisting of contactors.
  • the low-power numerical control contactor of the present invention comprises an excitation coil, a moving iron core and a static iron core, wherein the static iron core is laminated by a silicon steel sheet; the static iron core is embedded with a permanent magnet; the permanent magnet is embedded at the distance The farthest position of the iron core;
  • the static iron core is an E-shaped iron core, and the bottoms of the two grooves of the E-shaped iron core are respectively embedded with permanent magnets;
  • the static iron core is a U-shaped iron core, and the bottom of the U-shaped iron core groove is inlaid with a permanent magnet;
  • the permanent magnet is a neodymium iron boron permanent magnet;
  • the low-power numerical control contactor has a built-in driving circuit; the driving circuit is connected to the exciting coil; and the driving circuit is configured to connect an external power source and a control signal to drive the exciting coil;
  • the driving circuit is connected to an external power source and a control signal through three terminals; the three terminals are: a power terminal, a control terminal and a common terminal;
  • the driving circuit drives the exciting coil in a single pulse manner
  • the drive circuit is composed of a relay, a capacitor, and a charge/discharge circuit thereof.
  • the control system of the present invention includes a power source, a controller, and at least one low power digitally controlled contactor; the power source is coupled to the low power digitally controlled contactor and the controller; and the low power digitally controlled contactor is coupled to the controller.
  • the power source is a switching power supply; the controller is a PLC or a PLD.
  • the beneficial effects of the invention are:
  • the contactor has low power consumption, is easy to drive, and has a long service life.
  • the power supply range is wide AC85 ⁇ 264V, the energy saving effect is very significant, and the switching power supply is also It can supply power to low-power CNC contactor from a long distance (500m), and the line connection is flexible and convenient, and the operation is safe.
  • the control terminal of the drive circuit can be directly driven by programmable logic control devices such as integrated circuit, single chip microcomputer, PLD, LOGO, PLC.
  • the invention breaks the boundary between "strong power” and "weak electricity” in the control system, and overcomes the inherent shortcomings of the AC contactor.
  • Figure 1 is a schematic view of Embodiment 1;
  • Figure 2 is a cross-sectional view taken along line A-A of the static iron core of Figure 1;
  • Figure 3 is a schematic view of Embodiment 2;
  • Figure 4 is a cross-sectional view taken along line B-B of the static iron core of Figure 3;
  • Figure 5 is a schematic diagram of the driving circuit of the embodiment 3.
  • Figure 6 is a voltage waveform diagram of the exciting coil when sucking
  • Figure 7 is a voltage waveform diagram of the exciting coil at the time of breaking
  • Figure 8 is a schematic structural view of a control system of Embodiment 4.
  • Embodiment 9 is a schematic structural view of a control system of Embodiment 5.
  • FIG. 10 is a schematic structural view of a power supply system of Embodiment 6. detailed description
  • the low-power numerical control contactor of the invention selects a core formed by stacking silicon steel sheets, and embeds a permanent magnet in the static iron core, which increases the suction force of the static iron core to the moving iron core, reduces the requirement for the magnetic force of the exciting coil, and reduces the requirement.
  • the excitation coil drives the current to reduce the drive power. After the low-power digital contactor is pulled in, the magnetic field of the permanent magnet does not need to maintain the current, and the low-power digital contactor can maintain the contact state, further reducing the energy consumption.
  • the low-power digital control contactor of the invention has a built-in driving circuit, adopts various means for reducing consumption and improving reliability, and has a clever circuit structure.
  • the entire driver circuit is mounted in a low-power CNC contactor base, integrated with a low-power digitally controlled contactor, and connected to an external power supply and control signal via a three-terminal interface to drive the excitation coil.
  • the driving current of the low-power CNC contactor excitation coil is driven by a single pulse current.
  • the pulse current duration is 50ms regardless of the breaking and closing.
  • a permanent magnet is embedded in the static iron core, and a magnetic source is added to the magnetic circuit, so that the process of sucking, holding and breaking the low-power digital control contactor has a new feature.
  • Pull-in feature The embedding of the permanent magnet increases the suction force of the static iron core to the moving iron core.
  • the single-pulse current excitation mode is adopted to greatly reduce the starting power of the low-power digital control contactor.
  • the suction of the low-power digital contactor is accomplished by the combination of electromagnetic force and permanent magnet force. This composite magnetic force eliminates the drawbacks of contactor contact jitter.
  • the holding process is divided into suction holding and breaking holding.
  • the excitation coil has no holding current.
  • the magnetic force of the permanent magnet maintains a stable suction state, and the permanent magnet magnetic force is required to be as strong as possible. If a mis-sucking action occurs, the magnetic force is required to be as weak as possible. It has been proved that the magnetized permanent magnet not only has the residual magnetization, but also can be magnetized by the external magnetic field to generate the induced magnetization. When the low-power numerical control contactor is operated, the magnetic properties of the permanent magnet will be repeatedly excited and broken. The effect of changes in the magnetic field of the coil.
  • the magnetic field generated by the excitation coil current during the suction process is the same as the magnetic field of the permanent magnet itself, so that the permanent magnet generates an induced magnetization, which is a magnetization process for the permanent magnet and enhances the magnetic field strength of the permanent magnet.
  • the magnetic field generated in the excitation coil at the time of breaking is a process of demagnetization for the permanent magnet. Demagnetizing potential makes the magnetic field strength of the permanent magnet in the area of the return line Change within.
  • the invention selects a neodymium iron boron permanent magnet with relatively stable performance. The alternating change of magnetization and demagnetization does not change the magnetic stability of the permanent magnet, but enables the permanent magnet to have a strong magnetic force when the suction is held. The magnetic force is relatively weak when the breaking is maintained.
  • Breaking feature Due to the embedding of the permanent magnet, a reverse current is applied to the exciting coil during the breaking to overcome the attraction of the permanent magnet to the moving iron core.
  • the single-pulse current driving method makes the contactor breaking time have good controllability.
  • NdFeB is the core component of the permanent magnet mechanism. Its magnetic properties are affected by many factors such as environment, temperature and time. In order to ensure the long-term stable operation of the permanent magnet mechanism, we have developed a perfect foundation based on full exploration. Manufacturing, processing and assembly processes.
  • the low-power digital control contactor achieves low starting power.
  • the technical measure is to charge the storage capacitor within a predetermined time.
  • the capacitor provides the energy required for starting.
  • the operating frequency of the low-power digital contactor is hourly. 600 times, 1200 times, 2400 times, the charging current is 300mA, 400mA, 500mA respectively.
  • the power supply voltage is DC24V
  • the corresponding starting power consumption is 7.2W, 9.6W, 12W
  • the power consumption is 0.12W when sucking.
  • the built-in drive circuit consumes power
  • the low-power digitally controlled contactor consumes only as much as a typical medium-power transistor, making it fully compatible with low-voltage electronic circuits, providing a very practical choice for automated engineering.
  • the technical measures for low-temperature digital contactor to achieve low temperature rise are: Since the core, excitation coil and drive circuit are sealed in the base of the low-power digital control contactor, the performance of NdFeB and electrolytic capacitor is susceptible to temperature. Therefore, the control of temperature rise is extremely important.
  • the device that generates the heat source has a core (the impact of the moving and static iron cores when closed), the excitation coil, and the current limiting element in the drive circuit.
  • the control of the above-mentioned links enables the low-power digital control contactor to operate at a frequency of 2,400 times/hour under uninterrupted working conditions, and when the ambient temperature is 30 ,, the measured temperature rises by 6K.
  • Figure 1 shows a schematic view of a ⁇ -type core structure.
  • 1 is a permanent magnet
  • 2 is a static iron core
  • 3 is an exciting coil
  • 4 is a moving iron core.
  • the static iron core 2 has a ⁇ -type structure
  • the movable iron core 4 has an I-type structure.
  • the low-power digital contactor core is laminated from silicon steel sheets, as shown in cross-sectional view 2.
  • the permanent magnet 1 is made of neodymium iron boron permanent magnet. In this example, a double permanent magnet structure is used. Yong The magnet 1 is embedded in the middle of the bottom of the groove of the E-type static iron core 2.
  • the permanent magnet 1 is inlaid at this position for easy processing and installation, and does not affect the mechanical strength of the static iron core due to the machining of the static iron core and the installation of the permanent magnet.
  • the magnetic resistance of each branch from the position of the permanent magnet 1 to the junction of the moving and static iron cores is similar, and the static magnetic field distribution between the joints is balanced. Since the permanent magnet 1 is far from the moving iron core 4, the suction strength of the moving iron core 4 is relatively weak, and even when the moving iron core is disturbed by a certain degree of external force, no mis-sucking action occurs, and the low-power numerical control contactor When sucking, it can follow the low reluctance magnetic circuit generated when the static iron core is closed, and maintain a stable suction state.
  • the EI core can match the DC drive circuit well, which is the first choice for the low-power CNC contactor core structure.
  • the core structure of this example is U1 type
  • the static iron core 2 is U-shaped structure
  • the moving iron core 4 is of type I structure.
  • the permanent magnet 1 is embedded in the middle of the bottom of the groove of the U-shaped static iron core 2
  • Fig. 4 shows a cross-sectional view of the static iron core of the present example.
  • This low power CNC contactor uses a double excitation coil.
  • the UI type core is suitable for large low-power CNC contactors of 300 ⁇ 800A.
  • the single permanent magnet structure of this example simplifies the design of the magnetic circuit.
  • the parallel driving or synchronous driving of the double excitation coil can effectively solve the problem that the large contactor is difficult to start when the nominal voltage DC24V is used, and the structure superiority is highlighted.
  • Other structural features of this example are the same as those of the first embodiment.
  • Fig. 5 shows a schematic diagram of the driving circuit of this example.
  • the drive circuit is mounted in the base of the low-power CNC contactor and is integrated with the low-power CNC contactor.
  • the exciting coil KM is connected to the power source through the changeover switch JK2 and the changeover switch JK3.
  • the transfer switch JK2 is the contact of relay J2, and the changeover switch JK3 is the contact of relay J3.
  • the capacitor C5 and the capacitor C6 connected in series with the relay J2 and the relay J3 are controlled by the switch JK1-1 and the switch JK1-2.
  • the switch JK1-1 and the switch JK1-2 are controlled by the relay J1, and the relay J1 is controlled by an external control signal.
  • C is connected to an external control signal
  • Vcc is connected to an external positive power supply
  • G is a common ground.
  • the power supply circuit has three relatively independent power supply branches, which are responsible for each The task of powering, breaking, and controlling the power of the circuit.
  • the external power source is connected to the constant current source circuit composed of the resistor R1, the light-emitting diode D1, the capacitor C1, the transistor Q1, the resistor R3, and the resistor R4, and charges the storage capacitor C4 to form a pull-in power source; the external power source passes through the diode D3.
  • Resistor R5 charges capacitor C7 to form a divided power supply; external power supply charges capacitor C3 via diode D2 to form a control power supply.
  • the resistor R1, the resistor R3, the transistor Q1, and the diode D1 constitute a conventional constant current source circuit, and the control capacitor C4 is charged.
  • the value of the constant current is determined by the resistor R1.
  • the function of the capacitor C1 in the figure is to delay the conduction of the transistor Q1 when the capacitor C4 is discharged.
  • the function of the resistor R4 is to make the voltage of the capacitor C4 charge to the power supply voltage, and the transistor Q1 is turned off after the charging process ends, thereby reducing the loss of Q1; When the storage capacitor C4 is discharged through the resistor R4 and the external power source.
  • the exciting coil KM switches the direction of the current flowing through the exciting coil KM through the changeover switch JK2 and the changeover switch JK3, so as to control the suction, hold, and break of the low-power numerical control contactor.
  • the working process of the circuit is as follows: After the power is turned on, both ends of the exciting coil KM are grounded through the normally closed point of the switching switch JK2 and the switching switch JK3, and the contactor is in a standby state.
  • the control terminal C is "0" (low level)
  • the relay J1 is sucked, the charging current of the capacitor C5 causes the relay J2 to be sucked, and the exciting coil KM is energized by the switching switch JK2 normally open, and the electric energy stored by the capacitor C4 is driven.
  • Low-power CNC contactor pull-in The LC circuit consisting of capacitor C5 and relay J2 is released after the delay, the relay J2 is released, the excitation coil KM is de-energized, the residual voltage in KM is released through the normally closed point of JK2, and the low-power numerical control contactor is kept closed by the permanent magnet force. status.
  • the voltage waveform in the excitation coil KM is shown in Fig. 6. It can be seen that the current is a single pulse (ignoring the oscillating voltage in the excitation coil), and the pulse duration is 50 ms.
  • the capacitor C6 is discharged through the closed loop formed by the normally open point of the JK1-2, the resistor R6, and the diode D5.
  • the relay J1 When the control terminal C is "1" (high level), the relay J1 is released, the charging current of the capacitor C6 causes the relay J3 to be sucked, and the exciting coil KM is reversed by the normally open point of the switching switch JK3, and the electric energy stored by the capacitor C7 Drive low power CNC contactor to break.
  • the LC circuit composed of capacitor C6 and relay J3 is released after the delay, and the excitation coil KM is de-energized.
  • the breaking state is maintained by the supporting spring.
  • the breaking current waveform is shown in Fig. 7, and is also a single pulse with a pulse width of 50ms.
  • the capacitor C5 is discharged through the closed loop formed by the normally closed point of the switch JK1-2, the resistor R6, and the diode D4.
  • relay Jl in the interface circuit improves the anti-interference energy of the low-power digital control contactor
  • the force, the resistor R2 and the capacitor C2 are an energy-saving connection, which enables the relay J1 to work stably for a long time.
  • Relay J1 can be directly driven by programmable logic control devices such as integrated circuit, single chip microcomputer, PLD, LOGO, PLC, etc.
  • the function of overheat protection, overload protection and delay of contactor can be realized through interface circuit to make low power
  • the plug-in function expansion module of the numerical control contactor is electronic.
  • the electrical life of relay J2 and relay J3 directly affects the service life of the low-power digital contactor. It is known from the technical parameters of the relay that the electrical life of this type of relay is 100,000 times and the mechanical life is 10 million times. If no technical measures are added, the electrical life of relay J2 is less than 80,000 times. The reason for the damage is that when the relay is disconnected, the arc generated in the contact gap causes the contact to burn. After the technical measures such as the constant current source charging circuit are adopted, when the normally open contact of the relay J2 is closed, the LC loop current composed of the capacitor C4 and the exciting coil KM cannot be abruptly changed, and no arc is generated; the contact is broken after about 80 ms delay.
  • Relay J3 works the same way.
  • the electrical life of relay J2 and relay J3 has been increased from 100,000 to 2 million.
  • the service life of the low power digital control contactor of the invention is improved.
  • the low-power numerical control contactor of the invention has good motion controllability, and various technical indicators are at the international leading level. Taking the 105A low-power numerical control contactor as an example, the service life is 1 million times, and the operating frequency is 2400 times/hour. The startup power consumption is 12W.
  • the low power digitally controlled contactor of the present invention relates to a specification of 100 to 800A.
  • the control system constructed by the low power consumption numerical control contactor of the present invention will be described below in conjunction with an application example of the low power numerical control contactor.
  • the control system shown in Fig. 8 is an application example of the low power digitally controlled contactor of the present invention connected to an external switching power supply and a control signal.
  • a 50W switching power supply is used to supply power to four low-power digitally controlled contactors (105A) and programmable controller PLC-221.
  • the power of the switching power supply can be increased or decreased according to specific tasks; the programmable logic of this example
  • the control device is PLC, its input terminal is controlled by switches K1-K6, and the output terminals Q0, Ql, Q2, Q3 are respectively connected with the control terminals C of four low-power digital control contactors to form a commercial hardware platform.
  • the corresponding functions can be expanded according to the specific situation, and the corresponding control program can be compiled.
  • the industrial control system of this example provides a new mode of operation for the technical transformation of traditional industries.
  • Figure 9 is an application example of the low-power digital control contactor of the present invention in an industrial field.
  • 16 low-power digital control contactors and PLC-226 are connected with a 300W switching power supply.
  • the input terminals of the built-in decoding circuit of the low-power digital control contactors K1 to K16 are connected to the output end of the encoding circuit via a connecting line.
  • the coding circuit is connected to the output of the PLC, and the input of the PLC is connected to the input switch.
  • the highlight of this example is: Using a centralized power supply method, it supplies power to multiple low-power digital contactors from a long distance (500m), which fully utilizes the technical advantages of safe and efficient switching power supply.
  • This example uses a two-wire encoding and decoding control circuit, which greatly simplifies the connection and wiring of the control system.
  • This example demonstrates the broad application prospects of low-power CNC contactors from the other side while demonstrating a distributed industrial control system.
  • FIG. 10 is an application example of the low-power digital control contactor of the present invention for synchronously closing a low-voltage terminal power supply system.
  • the low-power numerical control contactor, PLC-222, electronic arc-extinguishing module and switching power supply connection the control end of low-power digital control contactor and electronic arc-extinguishing module are respectively connected with the output end of PLC-222, PLC-222
  • the input end is connected with the control switch and the synchronous signal detecting circuit
  • the synchronous signal detecting circuit is connected with the input power source R, S, T
  • the three poles of the contactor are used in parallel with the number of the electronic arc extinguishing module, and one end is respectively connected with the input power source R, S , T is connected, and the other end is connected to the output power sources 11, V, W, respectively.
  • the technical features of this example are: It is intended to suppress the generation of surge voltage and current when inputting into the power system; avoid the closure at the point where the maximum hazardous phase angle is generated, and achieve the purpose of improving the quality of the power and the life of the contactor itself.
  • This technical solution can not only play the role of the original arc extinguishing device of the contactor, but also reduce the control precision of the driving circuit from microsecond to millisecond.
  • the three-pole low-power digital control contactor is used in parallel, supplemented by an electronic arc-extinguishing module, which is used as a pole for independent control of the power supply system.
  • the synchronization of the power supply system is controlled by the PLC.
  • the control process is as follows: switch K1 when closing The issued command is input to the PLC together with the synchronization signal, and is controlled by the PLC at the specified phase angle, and the electronic arc extinguishing module is sequentially turned on, and then the low-power numerical control contactor is turned on in turn, and the electronic arc extinguishing is performed when the low-power numerical control contactor is fully turned on.
  • the module is closed; K2 sends an instruction to the PLC when it is opened, controlled by the PLC, first turns on the electronic arc extinguishing module, and then breaks the low-power numerical control contactor, at low power consumption After the control contactor is disconnected, the electronic arc extinguishing module is turned off in turn; the basis for achieving the synchronous closing is the good motion controllability of the low power numerical control contactor.
  • the low-power digital contactor of the invention breaks through the traditional design concept of the contactor, and expands the space for the survival and development of the contactor in a new way of thinking and excellent performance.

Description

说明书
低功耗数控接触器及其组成的控制系统 技术领域
本发明涉及一种开关装置，特别涉及接触器铁心以及接触器驱动 背景技术
交流接触器自问市以来，在工业过程控制自动化、低压终端供电 两大领域的应用十分广泛，有着扎实的市场基础。交流接触器的吸合、 认
保持、分断过程是一个变化规律十分复杂的动态过程。现有技术的交 本
流接触器的主要缺点是： 运动可控性差， 驱动功率大、 能耗高、 易造 成线圈烧损， 使用寿命短； 新型智能化接触器的驱动装置， 配有先进 的电子电路及控制芯片，对整个动态过程实时控制，使其性能有所提 高， 但仍存在驱动电路复杂， 启动功率大等问题。 以交流接触器为主 体的控制系统， 具有控制电路简单、驱动力强、 成本低廉的特点， 在 可编程逻辑控制器件（PLC)驱动大型交流接触器时， 需要经过中间 级放大才能实现，而且还需专设控制电路降低吸合时的功耗， 制约了 控制系统的应用与发展。
发明内容
本发明所要解决的技术问题， 就是提供一种适用于 100〜800A 大功率交流接触器的铁心结构；本发明进一步提供了采用上述铁心构 成的低功耗数控接触器， 以及所述低功耗数控接触器组成的控制系 统。
本发明的低功耗数控接触器， 包括励磁线圈， 动铁心和静铁心， 所述静铁心由硅钢片叠成； 所述静铁心中镶嵌有永磁体； 所述永磁体 镶嵌在距离所述动铁心最远的位置；
所述静铁心为 E型铁心， 所述 E型铁心两个凹槽底部分别镶嵌 有永磁体；
所述静铁心为 U型铁心，所述 U型铁心凹槽底部镶嵌有永磁体； 所述永磁体为钕铁硼永磁体； 所述低功耗数控接触器内置驱动电路；所述驱动电路与励磁线圈 连接；所述驱动电路用于连接外部电源和控制信号对励磁线圈进行驱 动；
所述驱动电路通过 3个接线端子与外部电源和控制信号连接；所 述 3个接线端子分别为： 电源端子， 控制端子及公共端子；
所述驱动电路以单脉冲方式驱动励磁线圈；
所述驱动电路由继电器、 电容器及其充 /放电回路构成。
本发明的控制系统包括电源、控制器以及至少一台低功耗数控接 触器； 所述电源与低功耗数控接触器和控制器连接； 所述低功耗数控 接触器与控制器连接。
所述电源为开关电源； 所述控制器为 PLC或 PLD。
本发明的有益效果是： 接触器功耗低， 易驱动， 使用寿命长。低 功耗数控接触器可以直接采用标称 DC24V的小功率开关电源 （V= 18〜24V、 I=0.4〜1A、 10W)供电， 电源适用范围宽 AC85〜264V， 节能效果十分显著， 开关电源还可以远距离地 （500m) 向低功耗数 控接触器供电， 线路连接灵活方便、操作安全； 驱动电路的控制端子 可直接由集成电路、 单片机、 PLD、 LOGO, PLC等可编程逻辑控制 器件驱动。 本发明打破了控制系统中 "强电"与 "弱电"的界线， 克 服了交流接触器固有缺点。
附图说明
图 1是实施例 1的示意图；
图 2是图 1中静铁心的 A-A剖视图；
图 3是实施例 2的示意图；
图 4是图 3中静铁心的 B-B剖视图；
图 5是实施例 3驱动电路原理图；
图 6是吸合时励磁线圈的电压波形图；
图 7是分断时励磁线圈的电压波形图；
图 8是实施例 4控制系统结构示意图；
图 9是实施例 5控制系统结构示意图；
图 10是实施例 6供电系统结构示意图。 具体实施方式
下面结合附图及实施例， 详细描述本发明的技术方案。
本发明的低功耗数控接触器，选用硅钢片叠成的铁心， 并在静铁 心中嵌入永磁体，增加了静铁心对动铁心的吸合力， 降低了对励磁线 圈磁力的要求， 减小了励磁线圈驱动电流， 降低驱动功率。低功耗数 控接触器吸合后， 由于永磁体磁场的作用， 不需要维持电流， 低功耗 数控接触器就可以保持接触状态， 进一步降低了能耗。
本发明低功耗数控接触器，其内置驱动电路，采用了多种降耗措 施及提高可靠性的手段， 电路结构巧妙。整个驱动电路全部安装在低 功耗数控接触器基座内，与低功耗数控接触器集成在一起， 通过三端 接口与外部电源及控制信号连接，对励磁线圈进行驱动。低功耗数控 接触器励磁线圈的驱动电流， 采用单脉冲电流驱动， 无论分断吸合， 脉冲电流持续时间均 50ms。
静铁心中嵌入永磁体，在磁路中新增了一个磁源， 使得低功耗数 控接触器的吸合、 保持、 分断过程有了新的特征。
吸合特征： 永磁体的嵌入增加了静铁心对动铁心的吸合力，配合 电容储能式驱动电路，采用单脉冲电流励磁方式， 使低功耗数控接触 器的启动功率大幅度降低。低功耗数控接触器的吸合在电磁力和永磁 力的共同作用下完成， 这种复合磁力消除了接触器触头抖动的弊端。
保持特征： 保持过程分为吸合保持与分断保持， 吸合保持时励磁 线圈无维持电流，靠永磁体的磁力保持稳定的吸合状态，要求永磁体 磁力尽可能强； 而分断保持时为避免产生误吸合动作， 则要求其磁力 尽可能弱。 实践证明， 经磁化的永磁体不但具有剩余磁化强度， 而且 还能被外磁场磁化产生感应磁化强度，低功耗数控接触器动作时，永 磁体的磁性能， 会反复受到吸合、 分断时励磁线圈磁场变化的影响。 吸合过程中励磁线圈电流产生的磁场， 与永磁体本身磁场方向相同， 使永磁体产生感应磁化强度，对永磁体是一个充磁的过程， 增强了永 磁体的磁场强度。当励磁电流消除，永磁体仍然以较强的磁力保持动 铁心处于吸合状态。分断时励磁线圈中产生的磁场，对于永磁体而言 是一个退磁的过程。去磁磁动势使永磁体的磁场强度，在回复线的区 间内变化。 本发明选用了性能比较稳定的钕铁硼永磁体， 这种充磁、 退磁的交替变化不会改变永磁体的磁稳定性，却能使永磁体在吸合保 持时具有较强的磁力， 在分断保持时其磁力相对较弱。
分断特征： 由于永磁体的嵌入， 分断时需向励磁线圈施加反向电 流， 以克服永磁体对动铁心的吸力。采用单脉冲电流的驱动方式， 使 得接触器分断时间具有良好的可控性。
钕铁硼是永磁机构的核心部件， 其磁性能会受到环境、温度、 时 间等诸多因素的影响， 为了保证永磁机构能长期稳定地运行， 我们在 充分探索的基础上、 制定了完善的制造、 加工及装配工艺。
低功耗数控接触器实现低启动功率的技术措施是：在预定的时间 内， 完成对储能电容的充电， 由电容提供启动时所需能量， 低功耗数 控接触器的动作频率在每小时 600次、 1200次、 2400次时， 充电电 流取值分别为 300mA、 400mA, 500mA， 当电源电压为 DC24V时， 对应启动功耗分别为 7.2W、 9.6W、 12W, 吸合时功耗 0.12W (内置 驱动电路耗电）， 同比现有的智能接触器的线圈损耗启动时 162W, 吸合时 9.8W有了很大的改进。 低功耗数控接触器的功耗仅相当于一 只普通的中功率晶体管，使之完全兼容于低压电子电路， 为自动化工 程设计提供了一种非常实用的选择。
低功耗数控接触器实现低温升的技术措施是： 由于铁心、励磁线 圈及驱动电路均密闭在低功耗数控接触器基座内，而钕铁硼、 电解电 容的性能， 易受温度的影响， 因此对温升的控制极为重要， 在低功耗 数控接触器中，产生热源的器件有铁心（动、静铁心在闭合时的撞击）、 励磁线圈、 驱动电路中的限流元件， 通过对上述环节的控制， 使低功 耗数控接触器在不间断工作条件下， 动作频率 2400次 /小时， 环境温 度 30Ό时， 实测温升 6K。
实施例 1
图 1示出了一种 ΕΙ型铁心结构的示意图。 图中 1为永磁体； 2 为静铁心； 3为励磁线圈； 4为动铁心。 静铁心 2为 Ε型结构， 动铁 心 4为 I型结构。本例低功耗数控接触器铁心由硅钢片叠成， 如剖视 图 2所示。永磁体 1选用钕铁硼永磁体， 本例采用双永磁体结构。永 磁体 1镶嵌在 E型静铁心 2凹槽底部中间位置。永磁体 1镶嵌在该位 置加工、安装方便， 不会因加工静铁心和安装永磁体， 而过多影响静 铁心的机械强度。在处于分断状态时， 从永磁体 1的位置到动、静铁 心衔接处各支路的磁阻相近，衔接处之间的静态磁场分布均衡。 由于 永磁体 1距离动铁心 4较远，对动铁心 4的吸力强度相对较弱， 即使 在动铁心受到一定程度的外力干扰时，也不会产生误吸合动作， 当低 功耗数控接触器吸合时，又能沿动、静铁心闭合时产生的低磁阻磁路， 保持稳定的吸合状态。这样的安装位置， 即使永磁体 1的磁场强度在 较大范围内变化时，仍然能够恰到好处地满足要求， 这在工程上具有 重要意义。 EI型铁心能很好地匹配直流驱动电路， 为低功耗数控接 触器铁心结构的首选。
实施例 2
如图 3所示， 本例的铁心结构为 U1型， 静铁心 2为 U型结构， 动铁心 4为 I型结构。永磁体 1镶嵌在 U型静铁心 2的凹槽底部中间 位置， 图 4示出了本例静铁心的剖视图。这种低功耗数控接触器采用 双励磁线圈。 UI型铁心适用于 300〜800A的大型低功耗数控接触器， 本例的单永磁体结构， 简化了磁路的设计。双励磁线圈的并联驱动或 同步驱动， 能够有效地解决大型接触器在采用标称电压 DC24V时启 动难的问题， 凸显其结构的优越性。 本例的其他结构特征与实施例 1 相同。
实施例 3
图 5示出了本例的驱动电路原理图。驱动电路安装在低功耗数控 接触器的基座内， 与低功耗数控接触器构成一个整体。 图 5中， 励磁 线圈 KM通过转换开关 JK2、 转换开关 JK3与电源连接。 转换开关 JK2为继电器 J2的触点， 转换开关 JK3为继电器 J3的触点。 与继电 器 J2、 继电器 J3串联的电容 C5、 电容 C6的充放电由开关 JK1-1、 开关 JK1-2控制， 开关 JK1-1、 开关 JK1-2受继电器 J1控制， 继电器 J1由外部控制信号控制。图 3中 C与外部控制信号连接， Vcc与外部 正电源连接， G为公共地。
图 5 中电源电路有三个相对独立的电源支路， 分别担负着向启 动、 分断及控制电路供电的任务。 图 5中， 外部电源经电阻 Rl、 发 光二极管 Dl、 电容 Cl、 三极管 Ql、 电阻 R3、 电阻 R4组成的恒流 源电路，向储能电容 C4充电，构成吸合电源；外部电源经二极管 D3、 电阻 R5向电容 C7充电，组成分断电源； 外部电源经二极管 D2向电 容 C3充电组成控制电源。 图 5中， 电阻 Rl、 电阻 R3、 三极管 Ql、 二极管 D1组成常规恒流源电路， 控制电容 C4的充电， 恒流电流的 取值由电阻 R1决定。图中电容 C1的作用是当电容 C4放电时延缓三 极管 Q1的导通，电阻 R4的作用是使电容 C4的电压可充至电源电压， 充电过程结束后三极管 Q1截止， 降低了 Q1的损耗； 关机时， 储能 电容 C4经电阻 R4及外部电源放电。
图 5中， 励磁线圈 KM通过转换开关 JK2和转换开关 JK3切换 流经励磁线圈 KM的电流方向，达到控制低功耗数控接触器吸合、保 持、 分断的目的。 电路工作过程为： 接通电源后， 励磁线圈 KM的两 端经切换开关 JK2和转换开关 JK3的常闭点接地， 接触器处于待命 状态。 当控制端 C为 "0" (低电平） 时， 继电器 J1 吸合， 电容 C5 的充电电流使继电器 J2吸合， 励磁线圈 KM经切换开关 JK2常开点 得电， 电容 C4所储电能驱动低功耗数控接触器吸合。 由电容 C5、 继 电器 J2组成的 LC电路， 经延时后继电器 J2释放， 励磁线圈 KM断 电， KM中的残余电压经 JK2的常闭点释放， 低功耗数控接触器靠永 磁力保持吸合状态。励磁线圈 KM中的电压波形如图 6所示，可以看 出， 电流为一个单脉冲 （忽略励磁线圈中的震荡电压）， 脉冲持续时 间 50ms。 与此同时电容 C6经 JK1-2的常开点、 电阻 R6、 二极管 D5形成的闭合回路放电。 当控制端 C为 " 1 " (高电平） 时， 继电器 J1释放， 电容 C6的充电电流使继电器 J3吸合， 励磁线圈 KM经切 换开关 JK3常开点反向得电， 电容 C7所储电能驱动低功耗数控接触 器分断。 电容 C6、 继电器 J3组成的 LC电路， 经延时后继电器 J3释 放， 励磁线圈 KM断电， 分断状态靠支撑弹簧保持， 分断电流波形如 图 7所示， 也是一个脉冲宽度 50ms 的单脉冲。 与此同时电容 C5 经开关 JK1-2的常闭点、 电阻 R6、 二极管 D4形成的闭合回路放电。 在接口电路中使用继电器 Jl， 提高了低功耗数控接触器的抗干扰能 力， 电阻 R2、 电容 C2是一种节能接法， 能使继电器 J1长期稳定地 工作。 继电器 J1可以由集成电路、 单片机、 PLD、 LOGO, PLC等可 编程逻辑控制器件直接驱动，除此之外可以通过接口电路实现接触器 的过热保护、 过载保护、延时等功能扩展， 使低功耗数控接触器的外 挂功能扩展模块电子化。
图 5中， 继电器 J2、 继电器 J3的电寿命， 直接影响到低功耗数 控接触器使用寿命， 从继电器的技术参数中得知， 该型号继电器的电 寿命为 10万次、 机械寿命 1000万次， 如果不加任何技术措施， 继电 器 J2的电寿命实测不足 8万次， 损坏的原因是继电器分断时， 触头 间隙中产生的电弧造成触头烧损。在采用恒流源充电电路等技术措施 后，继电器 J2的常开点触头闭合时， 电容 C4与励磁线圈 KM组成的 LC回路电流不能突变， 不会产生电弧； 经约 80ms延时触头分断， 此时储能电容 C4经放电后电压值近似为零（参见图 6)， 也不会产生 电弧， 延长了继电器 J2触点 JK2的电寿命。 继电器 J3工作过程与此 相同。 继电器 J2及继电器 J3的电寿命由 10万次提高到了 200万次。 提高了本发明低功耗数控接触器的使用寿命。
本发明的低功耗数控接触器具有良好的运动可控性，各项技术指 标处于国际领先水平， 以 105A低功耗数控接触器为例， 使用寿命 100万次， 动作频率 2400次 /每小时， 启动功耗为 12W。 本发明的低 功耗数控接触器涉及规格为 100〜800A。
下面结合低功耗数控接触器的应用实例，说明采用本发明的低功 耗数控接触器构成的控制系统。
实施例 4
图 8 的所示的控制系统是本发明低功耗数控接触器与外部开关 电源及控制信号连接的应用实例。 图中以一台 50W的开关电源， 为 4台低功耗数控接触器（105A)以及可编程控制器 PLC-221供电， 开 关电源的功率可依据具体任务而增减；本例的可编程逻辑控制器件为 PLC, 其输入端由开关 K1-K6控制， 输出端 Q0、 Ql、 Q2、 Q3分别 与 4台低功耗数控接触器的控制端 C连接，组成一个商品化的硬件平 台。使用时，可根据具体情况扩展相应的功能，编制相应的控制程序， 达到预期的控制目的，本例的工业控制系统为传统工业的技术改造提 供了一个新的运作模式。
实施例 5
图 9 是本发明低功耗数控接触器在工业现场的应用实例。 图中 16台低功耗数控接触器及 PLC-226与一台 300W开关电源连接， 低 功耗数控接触器 K1至 K16的内置解码电路的输入端，经连接线与编 码电路的输出端连接， 编码电路与 PLC的输出端连接， PLC的输入 端， 与输入开关连接。本例的亮点在于： 采用集中供电方式， 远距离 地 （500m) 向多台低功耗数控接触器供电， 它充分发挥了开关电源 安全、 高效的技术优势。本例采用了二线制编码、 译码控制电路， 极 大地简化了控制系统的连接布线。本例在展示一个分布式工业控制系 统的同时， 从另一个侧面揭示了低功耗数控接触器广阔的应用前景。
实施例 6
图 10是本发明低功耗数控接触器在同步关合低压终端供电系统 的应用实例。 图中， 低功耗数控接触器、 PLC-222、 电子灭弧模块与 开关电源连接， 低功耗数控接触器、 电子灭弧模块的控制端分别与 PLC-222的输出端连接， PLC-222的输入端， 与控制开关、 同步信号 检测电路连接， 同步信号检测电路与输入电源 R、 S、 T连接， 接触 器的三极与电子灭弧模块数并联使用， 一端分别与输入电源 R、 S、 T 连接， 另一端分别与输出电源11、 V、 W连接。 本例的技术特征是： 旨在抑制投入电力系统时产生浪涌电压、 电流；避开在产生最大危害 相角处关合，达到提高电能质量及接触器自身使用寿命的目的。这种 技术方案既能发挥接触器原有灭弧装置的作用，又使驱动电路的控制 精确度由微秒级降为毫秒级。本例将低功耗数控接触器的三极并联使 用， 辅以电子灭弧模块， 作为供电系统独立操控的一极， 供电系统的 同步关合由 PLC控制，操控过程如下：合闸时开关 K1发出的指令与 同步信号一起输入给 PLC, 由 PLC控制在指定相角处， 依次开通电 子灭弧模块，再依次开通低功耗数控接触器， 当低功耗数控接触器全 部开通后电子灭弧模块关闭； 分闸时 K2向 PLC发出指令， 由 PLC 控制， 先开通电子灭弧模块， 再分断低功耗数控接触器， 在低功耗数 控接触器分断后， 依次关闭电子灭弧模块； 实现同步关合的基础是低 功耗数控接触器良好的运动可控性。
本发明的低功耗数控接触器， 突破了接触器传统的设计理念， 以 全新的思维方式以及优异的性能拓展了接触器未来生存与发展的空 间。

Claims

权利要求书
1. 低功耗数控接触器， 包括励磁线圈， 动铁心和静铁心， 所述 静铁心由硅钢片叠成； 所述静铁心中镶嵌有永磁体； 其特征在于： 所 述永磁体镶嵌在距离所述动铁心最远的位置。
2. 根据权利要求 1所述的低功耗数控接触器， 其特征在于： 所 述静铁心为 E型铁心， 所述 E型铁心两个凹槽底部分别镶嵌有永磁 体。
3. 根据权利要求 1所述的低功耗数控接触器， 其特征在于： 所 述静铁心为 U型铁心， 所述 U型铁心凹槽底部镶嵌有永磁体。
4. 根据权利要求 1所述的低功耗数控接触器， 其特征在于： 所 述永磁体为钕铁硼永磁体。
5. 根据权利要求 1、 2、 3或 4所述的低功耗数控接触器， 其特 征在于：所述低功耗数控接触器内置驱动电路；所述驱动电路与励磁 线圈连接；所述驱动电路用于连接外部电源和控制信号对励磁线圈进 行驱动。
6. 根据权利要求 5所述的低功耗数控接触器， 其特征在于： 所 述驱动电路通过 3个接线端子与外部电源和控制信号连接；所述 3个 接线端子分别为： 电源端子， 控制端子及公共端子。
7.根据权利要求 5或 6所述的低功耗数控接触器，其特征在于: 所述驱动电路以单脉冲方式驱动励磁线圈。
8. 根据权利要求 7所述的低功耗数控接触器， 其特征在于： 所 述驱动电路由继电器、 电容器及其充 /放电回路构成。
9. 由权利要求 5所述低功耗数控接触器组成的控制系统， 包括 电源、控制器以及至少一台低功耗数控接触器；所述电源与低功耗数 控接触器和控制器连接； 所述低功耗数控接触器与控制器连接。
10. 根据权利要求 9所述的控制系统， 其特征在于： 所述电源为 开关电源； 所述控制器为 PLC或 PLD。
PCT/CN2006/002210 2005-09-09 2006-08-28 Contact a commande numerique faible puissance et systeme de controle constitue de contacts WO2007028321A1 (fr)

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