EP3146553B1 - Relais de puissance pour un véhicule - Google Patents
Relais de puissance pour un véhicule Download PDFInfo
- Publication number
- EP3146553B1 EP3146553B1 EP15728403.5A EP15728403A EP3146553B1 EP 3146553 B1 EP3146553 B1 EP 3146553B1 EP 15728403 A EP15728403 A EP 15728403A EP 3146553 B1 EP3146553 B1 EP 3146553B1
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- EP
- European Patent Office
- Prior art keywords
- power relay
- housing
- connection
- housing pot
- radial
- Prior art date
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Images
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H50/00—Details of electromagnetic relays
- H01H50/02—Bases; Casings; Covers
- H01H50/023—Details concerning sealing, e.g. sealing casing with resin
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H50/00—Details of electromagnetic relays
- H01H50/02—Bases; Casings; Covers
- H01H50/04—Mounting complete relay or separate parts of relay on a base or inside a case
- H01H50/047—Details concerning mounting a relays
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H1/00—Contacts
- H01H1/60—Auxiliary means structurally associated with the switch for cleaning or lubricating contact-making surfaces
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- 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
- H01H47/22—Circuit 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
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H50/00—Details of electromagnetic relays
- H01H50/02—Bases; Casings; Covers
- H01H50/04—Mounting complete relay or separate parts of relay on a base or inside a case
- H01H50/041—Details concerning assembly of relays
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H50/00—Details of electromagnetic relays
- H01H50/12—Ventilating; Cooling; Heating
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H50/00—Details of electromagnetic relays
- H01H50/16—Magnetic circuit arrangements
- H01H50/18—Movable parts of magnetic circuits, e.g. armature
- H01H50/20—Movable parts of magnetic circuits, e.g. armature movable inside coil and substantially lengthwise with respect to axis thereof; movable coaxially with respect to coil
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- 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
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H9/00—Details of switching devices, not covered by groups H01H1/00 - H01H7/00
- H01H9/02—Bases, casings, or covers
- H01H9/04—Dustproof, splashproof, drip-proof, waterproof, or flameproof casings
- H01H9/042—Explosion-proof cases
- H01H9/043—Explosion-proof cases with pressure-relief devices
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H50/00—Details of electromagnetic relays
- H01H50/44—Magnetic coils or windings
- H01H2050/446—Details of the insulating support of the coil, e.g. spool, bobbin, former
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H2231/00—Applications
- H01H2231/026—Car
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H2235/00—Springs
- H01H2235/01—Spiral spring
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- 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
- H01H47/001—Functional circuits, e.g. logic, sequencing, interlocking circuits
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- 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
- H01H47/002—Monitoring or fail-safe circuits
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- 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
- H01H47/22—Circuit 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
- H01H47/226—Circuit 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
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H50/00—Details of electromagnetic relays
- H01H50/02—Bases; Casings; Covers
- H01H50/021—Bases; Casings; Covers structurally combining a relay and an electronic component, e.g. varistor, RC circuit
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H50/00—Details of electromagnetic relays
- H01H50/14—Terminal arrangements
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H50/00—Details of electromagnetic relays
- H01H50/16—Magnetic circuit arrangements
- H01H50/18—Movable parts of magnetic circuits, e.g. armature
- H01H50/30—Mechanical arrangements for preventing or damping vibration or shock, e.g. by balancing of armature
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H50/00—Details of electromagnetic relays
- H01H50/54—Contact arrangements
- H01H50/546—Contact arrangements for contactors having bridging contacts
Definitions
- 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.
- 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.
- the power relay 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 JP 2006 019148 A .
- the conventional power relays are comparatively heavy and expensive to manufacture.
- Another problem of conventionally. used power relay is that currently a variety of different building variants are used, which are different distances of the CONFIRMATION COPY 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.
- 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.
- the power relay 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 magnet 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 opening pitch.
- 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 is characterized in that the contact bridge is de thumbiert of the terminal bolt, so that there is no conductive connection between the terminal bolt and the power relay is thus switched off.
- 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.
- 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.
- 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.
- both bistable and monostable designs of the power relay are realized according to the construction principle of the invention.
- the coil assembly further comprises a magnetic yoke.
- 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.
- the housing pot 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.
- the yoke, in particular the bracket must always be twisted, which in turn relieves the housing pot.
- material fatigue or even breakage of the housing pot is counteracted.
- 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.
- 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.
- 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).
- the power relay additionally comprises a control electronics accommodated in the housing for controlling the magnetic coil.
- 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.
- 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.
- 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.
- 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.
- at least one of the signal terminals for supplying an electrical supply voltage or an electrical reference potential, in particular ground, also provided.
- the signal connections are in this case contacted directly with the magnetic coil.
- the 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.
- the housing pot engages on the outside with a collar around the radial web of the connection socket, 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.
- 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.
- connection conductor which is preferably formed by a bent sheet metal stamped part
- connection conductors is in this case preferably passed through in the region of the tub through 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.
- 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.
- 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.
- the radial contour is designed as a latching nose, which engages over the radial web and thus latched to the housing pot.
- 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.
- 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).
- the overpressure protection but in the housing (and in particular in the housing pot) integrally integrated, in particular to the housing molded.
- 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.
- the breaking point tab 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- the forced shutdown is triggered directly by the bursting of the predetermined breaking point.
- 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 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.
- 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.
- 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 ,
- 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 ,
- 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.
- a coupling rod is provided in an expedient embodiment of the power relay, which extends along a coil axis of the magnetic coil.
- the coupling rod is slidably mounted in a central part of the magnetic yoke.
- the contact bridge is attached to the coupling rod.
- 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.
- 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.
- 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.
- 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.
- 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.
- control electronics are preferably connected to the terminal bolts.
- the control electronics are set up to pick up the electrical voltage dropping between the connecting bolts and to detect them by measurement.
- a supply voltage for the control electronics is preferably tapped off via the connection bolts.
- 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).
- connection bolts 10 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.
- 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).
- 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.
- the connection bolts 10 are fixed in the connection socket 3 by extrusion coating with the plastic material of the connection socket 11.
- 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.
- the terminal base 3 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 schraubheftiert 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 connection conductors 14 are in this case inserted between the terminal base 3 and the housing pot 4 or also by Encapsulation held in the connection socket 3.
- 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.
- the power relay 1 is a bistable relay.
- the pole shoes 28 and the leg ends of the bracket 27 are each two platelet-shaped permanent magnets 29 interposed.
- 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.
- the permanent magnets 29 are completely replaced by ferromagnetic material.
- 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.
- 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.
- 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.
- 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.
- a defined gap width between the magnetic yoke 25 and the armature 24 is set.
- the 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.
- 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
- 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.
- 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.
- the coil assembly 20 is clipped from below onto the previously completed in an injection molding connection socket 3.
- 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.
- 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.
- 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.
- 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.
- 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.
- the housing pot 4 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.
- connection base 3 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.
- connection conductors 14 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.
- 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.
- the potting compound 74 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.
- the power relay 1 is multi-pin, in particular two-pole or three-pole formed.
- 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.
- a separate circuit board 21 may be provided for each coil assembly 20 or a common circuit board for all coil assemblies 20.
- 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.
- 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 (detrustiert), so that there is no electrically conductive connection between the terminal pins 10.
- the magnetic coil 30 is energized.
- 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.
- 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 thus produced. Closed position of the power relay 1 is formed via the contact bridge 22, a conductive connection between the connecting bolt 10.
- the magnetic coil 30 is energized with reverse polarity.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- control electronics 63 optionally has a contact cleaning function.
- 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.
- 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.
- 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.
- 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.
- the control electronics 63 puts the power relay 1 in a safe state.
- 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.
- 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.
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- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Electromagnets (AREA)
- Switch Cases, Indication, And Locking (AREA)
- Fuses (AREA)
- Control Of Transmission Device (AREA)
Description
Die Erfindung bezieht sich auf ein Leistungsrelais für ein Fahrzeug, insbesondere ein Nutzfahrzeug.The invention relates to a power relay for a vehicle, in particular a commercial vehicle.
Gattungsgemäße Leistungsrelais werden in der Fahrzeugtechnik, insbesondere bei Nutzfahrzeugen verwendet. Die Leistungsrelais werden hier zum einen dazu eingesetzt, um die Fahrzeugbatterie vom Bordnetz elektrisch zu trennen. Andererseits werden solche Relais eingesetzt, um elektrische Motoren von Stellvorrichtungen (z.B. Hydraulikpumpe oder Hubbühne) zu schalten. Ein solches Leistungsrelais muss bei Niedrigspannung von typischerweise 12 bis 24 Volt in der Lage sein, Ströme bis zu einer Stromstärke von etwa 300 Ampere zu schalten und muss entsprechend massiv gebaut sein. Übliche, für diesen Zweck verwendete Relais bestehen in der Regel aus einem topfförmigen Körper aus Metall (z.B. Eisen oder Stahl), in dem eine Magnetspule, ein Magnetjoch und ein mit einer Kontaktbrücke (Doppelkontakt) verbundener Magnetanker aufgenommen sind.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.
Zum Anschluss des Leistungsrelais an einen zu schaltenden Laststromkreis in dem Fahrzeug umfasst das Leistungsrelais üblicherweise massive Anschlussbolzen (Gewindebolzen) aus Metall, die typischerweise einen Durchmesser von 0,5 bis 1cm haben. Auf diesen Anschlussbolzen werden bestimmungsgemäß Kabelschuhe der Anschlussleitungen des zu schaltenden Laststromkreises mittels Schraubenmuttern (Kontaktmuttern) kontaktierend festgelegt.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.
Derartige Leistungsrelais sind insbesondere aus
Nachteiligerweise sind die herkömmlichen Leistungsrelais vergleichsweise schwer und aufwändig in der Herstellung. Ein weiteres Problem der herkömmlicherweise. verwendeten Leistungsrelais besteht darin, dass derzeit vielfältige unterschiedliche Bauvarianten eingesetzt werden, die sich durch verschiedene Abstände der
BESTÄTIGUNGSKOPIE Anschlussbolzen und verschiedene Montagemöglichkeiten für das Relaisgehäuse (z.B. seitlich am Gehäusetopf, über die Anschlussseite oder über den zu dieser entgegengesetzten Boden des Relaisgehäuses) unterscheiden.Disadvantageously, the conventional power relays are comparatively heavy and expensive to manufacture. Another problem of conventionally. used power relay is that currently a variety of different building variants are used, which are different distances of the
CONFIRMATION COPY 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.
Um den Markt umfassend bedienen zu können, insbesondere um bestehende Nutzfahrzeuge mit unterschiedlicher Bordnetzkonfiguration warten und ggf. mit neuen Leistungsrelais nachrüsten zu können, müssen daher eine Vielzahl unterschiedlicher Bauformen des Leistungsrelais vorgehalten werden, was zu einem erheblichen Herstellungs- und Lageraufwand führt.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.
Der Erfindung liegt die Aufgabe zugrunde, ein besonders rationell fertigbares und leicht bauendes Leistungsrelais für ein Fahrzeug, insbesondere ein Nutzfahrzeug, anzugeben.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.
Diese Aufgabe wird erfindungsgemäß gelöst durch die Merkmale des Anspruchs 1. Das erfindungsgemäße Leistungsrelais umfasst ein Gehäuse, das aus einem Anschlusssockel und einem darauf aufgesetzten Gehäusetopf gebildet ist. In den Anschlusssockel sind zwei Anschlussbolzen eingebracht, über die das Leistungsrelais mit Anschlussleitungen eines anzuschließenden externen Laststromkreises kontaktierbar ist. Das Leistungsrelais umfasst weiterhin eine in dem Gehäuse angeordnete Spulenbaugruppe mit einer Magnetspule und einem korrespondierenden Magnetanker. Der Magnetanker ist hierbei über ein Kraftübertragungsglied mit einer Kontaktbrücke gekoppelt und unter Wirkung eines mittels der Magnetspule erzeugten Magnetfeldes derart in dem Gehäuse verschiebbar, dass die Kontaktbrücke reversibel zwischen einer Schließstellung und einer Öffnungssteilung bewegbar ist. Die Schließstellung ist hierbei dadurch gekennzeichnet, dass die Kontaktbrücke die Anschlussbolzen elektrisch leitend überbrückt, wodurch das Leistungsrelais angeschaltet ist. Die Öffnungsstellung ist dagegen dadurch gekennzeichnet, dass die Kontaktbrücke von den Anschlussbolzen dekontaktiert ist, so dass zwischen den Anschlussbolzen keine leitende Verbindung besteht und das Leistungsrelais somit abgeschaltet ist.This object is achieved by the features of
Erfindungsgemäß ist der Gehäusetopf als Kunststoff-Spritzgießteil ausgebildet. Dies ermöglicht, im Vergleich zu herkömmlichen, mit einem Gehäusetopf aus Metall versehenen Leistungsrelais eine wesentliche Reduzierung des Herstellungs- und Materialaufwands sowie außerdem eine entscheidende Gewichtseinsparung. Auch bei dem Anschlusssockel handelt es sich vorzugsweise um ein Kunststoff-Spritzgießbauteil.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.
Bei dem erfindungsgemäßen Leistungsrelais kann es sich hierbei wahlweise um ein bistabiles Relais, das sowohl die Schließstellung als auch die Öffnungsstellung in unbestromtem Zustand der Magnetspule dauerhaft aufrechterhält, oder um ein monostabiles Relais handeln. In letzterem Fall kann das Leistungsrelais als Schließer oder Öffner ausgebildet sein, wobei das Relais selbsttätig bei unbestromter Magnetspule in der erstgenannten Bauform die Öffnungsstellung, und in der letztgenannten Bauform die Schließstellung einnimmt. Vorzugweise sind sowohl bistabile als auch monostabile Bauformen des Leistungsrelais nach dem erfindungsgemäßen Bauprinzip realisiert.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 bevorzugter Ausgestaltung umfasst die Spulenbaugruppe weiterhin ein Magnetjoch. Um trotz geringem Gewicht und trotz kompakter Bauweise eine hohe Stabilität des Gehäuses zu erreichen, umfasst das Magnetjoch zweckmäßigerweise eine torsionsstabile Struktur, die über die gesamte axiale Höhe des Gehäusetopfs drehfest in diesem aufgenommen ist. Als axiale Höhe ist hierbei die Ausdehnung des Gehäusetopfs entlang der senkrecht auf den Boden des Gehäusetopfs stehenden Gehäusetopfachse bezeichnet. Die torsionsstabile Struktur des Magnetjochs ist in zweckmäßiger Ausgestaltung durch einen einstückigen, U-förmig gewinkelten Bügel gebildet, dessen Schenkel die Magnetspule parallel zu ihrer Spulenachse umgreifen. Um die torsionsstabile Struktur des Magnetjochs, insbesondere den Bügel, drehfest aufnehmen zu können, hat der Gehäusetopf vorzugsweise zumindest in seinem Innenraum einen zumindest näherungsweise rechteckigen Querschnitt, wobei sich das Magnetjoch, insbesondere der Bügel, nach Art eines Querträgers parallel zu zwei der vier Seitenwände erstreckt und beidseitig an den zwei verbleibenden Seitenwänden abgestützt ist.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.
Durch die drehfeste Aufnahme des Magnetjochs leitet der Gehäusetopf ein auf ihn wirkendes Drehmoment, das beispielsweise durch das Anziehen der Kontaktmuttern verursacht ist, in das torsionsstabil ausgeführte Magnetjoch ein. Bei einer Torsion des Gehäusetopfs muss daher das Magnetjoch, insbesondere der Bügel, stets mit tordiert werden, wodurch wiederum der Gehäusetopf entlastet wird. Hierdurch wird einer Materialermüdung oder sogar einem Bruch des Gehäusetopfs entgegengewirkt.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.
Um die Torsionsstabilität des Gehäuses weiter zu verbessern, ist vorzugsweise auch der Anschlusssockel verdrehsicher mit dem Magnetjoch gekoppelt, beispielsweise indem das Magnetjoch mit ausgeformten Vorsprüngen formschlüssig in entsprechende Vertiefungen des Anschlusssockels eingreift. Auf diese Weise werden gegebenenfalls auf den Anschlusssockel ausgeübte Drehmomente nicht lediglich mittelbar über den Gehäusetopf auf das Magnetjoch übertragen. Vielmehr wird zumindest ein Teil dieser Drehmomente direkt von dem Anschlusssockel in das Magnetjoch eingeleitet, wodurch wiederum der Gehäusetopf, und insbesondere die Verbindung zwischen dem Gehäusetopf und dem Anschlusssockel entlastet werden.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.
Grundsätzlich kann es sich bei dem Leistungsrelais im Rahmen der Erfindung um ein rein elektromechanisches Bauteil handeln, bei dem die Magnetspule ausschließlich aufgrund externer Steuersignale aktiviert (bestromt) und deaktiviert (stromlos geschaltet) wird. Vorzugsweise umfasst das Leistungsrelais zusätzlich aber eine in dem Gehäuse aufgenommene Steuerelektronik zur Ansteuerung der Magnetspule. Die Steuerelektronik setzt hierbei externe Steuersignale (die in diesem Fall beispielsweise auch als Pulssignale, insbesondere in digitaler Form, abgegeben werden können) in einen entsprechenden Steuerstrom für die Magnetspule um. Optional umfasst die Steuerelektronik darüber hinaus weitere Funktionen, beispielsweise Strom- oder Spannungsmessung zwischen den Anschlussbolzen und/oder Schutzfunktionen, die eine Zwangsabschaltung des Leistungsrelais bei Über- und/oder Unterspannung, Überlast oder - bei mehrpoligen Ausführungen des Leistungsrelais - einem Fehlerstrom oder einer unsymmetrischen Stromverteilung bewirken.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.
Sowohl bei rein elektromechanischen Bauformen als auch bei elektronischen Bauformen umfasst das Leistungsrelais eine Anzahl von Signalanschlüssen, von denen jeder jeweils an eine externe Signalleitung anschließbar ist. Die Signalanschlüsse sind zweckmäßigerweise, ebenso wie die Anschlussbolzen für den Laststrom, in dem Anschlusssockel fixiert.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.
Die Signalanschlüsse dienen hierbei zur Zuführung mindestens eines elektrischen Steuersignals an das Leistungsrelais und/oder zur Abgabe mindestens eines elektrischen Zustandssignals durch das Leistungsrelais. Optional ist zudem mindestens einer der Signalanschlüsse zur Zuführung einer elektrischen Versorgungsspannung oder eines elektrischen Bezugspotentials, insbesondere Masse, vorgesehen. In einer rein elektromechanischen Bauform des Leistungsrelais sind die Signalanschlüsse hierbei unmittelbar mit der Magnetspule kontaktiert. Bei elektronischen Bauformen des Leistungsrelais sind regelmäßig zumindest einige der Signalanschlüsse dagegen mit der Steuerelektronik verbunden. Diese Steuerelektronik stellt hierbei Zusatzfunktionen (z.B. Messfunktionen, Schutzfunktionen, Buskommunikation, etc.) zur Verfügung. Die über die Signalanschlüsse zugeführten Signale dienen in dem letzteren Fall in der Regel nur mittelbar zur Ansteuerung der Magnetspule.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.
Gattungsgemäße Leistungsrelais werden regelmäßig in rauen Einsatzumgebungen eingesetzt, in denen diese Relais Wasser, Öl, sowie Staub und anderweitigen Verschmutzungen ausgesetzt sind. Das-Gehäuse solcher Leistungsrelais muss daher in der Regel staub- und flüssigkeitsdicht (insbesondere nach Schutzart IP6K7 oder IP6K9K) sein. Um hinsichtlich der Verbindung des Gehäusetopfs mit dem Anschlusssockel die erforderliche Dichtheit zu garantieren, ist der Anschlusssockel mittels einer aushärtenden Vergussmasse, beispielsweise einem Epoxidharz fluiddicht mit dem Gehäusetopf verbunden. Um hierbei eine einfache und haltbare Vergießung dieser Verbindungsstelle zu ermöglichen, weist der Gehäusetopf öffnungsseitig einen umlaufenden Absatz auf, auf dem der Anschlusssockel mit einem umlaufenden Radialsteg aufliegt. Der Gehäusetopf greift hierbei außenseitig mit einem Kragen um den Radialsteg des Anschlusssockels herum, wobei der Kragen den Radialsteg axial überragt. Der Kragen des Gehäusetopfs umrandet somit den an den Anschlusssockel angeformten Radialsteg nach Art einer Balustrade. Somit wird durch den Kragen und den Anschlusssockel eine wannenartige Aufnahme (nachfolgend kurz als "Wanne" bezeichnet) für die Vergussmasse gebildet. In dem Montagezustand des Leistungsrelais ist diese Wanne mit der Vergussmasse ganz oder zumindest teilweise ausgefüllt.Generic power relays are regularly used in harsh environments where these relays are exposed to water, oil, dust and other contaminants. The housing of such power relays must therefore normally be dust and liquid-tight (in particular with IP6K7 or IP6K9K protection). In order to guarantee the required tightness with regard to the connection of the housing pot to the terminal socket, the terminal socket is 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 on the opening side on a peripheral shoulder on which rests the connection socket with a circumferential radial web. The housing pot engages on the outside with a collar around the radial web of the connection socket, 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.
Jede der vorstehend beschriebenen Signalanschlüsse ist jeweils über einen zugeordneten Anschlussleiter (der vorzugsweise durch ein gebogenes Blechstanzteil gebildet ist) mit der Magnetspule oder der ggf. dieser vorgeschalteten Steuerelektronik verbunden. Jeder der Anschlussleiter ist hierbei vorzugsweise im Bereich der Wanne durch den Anschlusssockel hindurchgeführt. Somit wird beim Vergießen des Gehäuses auch jeder der Anschlussleiter in die Vergussmasse eingebettet, wodurch auch die Durchführung der Anschlussleiter durch den Anschlusssockel abgedichtet wird, ohne dass es hierfür gesonderter Maßnahmen bedürfte.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.
Um die Verbindung zwischen dem Gehäusetopf und dem Anschlusssockel weiter zu stabilisieren, ist der Kragen des Gehäusetopfs im Bereich der Wanne mit mindestens einer Radialkontur versehen. Die oder jede Radialkontur des Kragens kann hierbei durch eine radialen Ausnehmung (die die Materialstärke des Kragens verringert) oder einen radialen Vorsprung (der die Materialstärke des Kragens vergrößert) gebildet sein. Korrespondierend mit der oder jeder Radialkontur ist am Anschlusssockel im Bereich der Wanne mindestens eine Gegenkontur ausgebildet. Die Radialkontur und die korrespondierende Gegenkontur bilden hierbei mit der Vergussmasse eine Formschlussverbindung, durch die der Anschlusssockel und der Gehäusetopf in Umfangsrichtung, d.h. tangential zur Achse der Magnetspule und des Gehäusetopfs, aneinander arretiert sind. Infolge dieser Arretierung wird eine Verdrehung des Anschlusssockels relativ zu dem Gehäusetopf auch durch die Vergussmasse wirksam blockiert. Vorzugsweise weisen die Radialkontur und die korrespondierende Gegenkontur weiterhin Hinterschneidungen auf, aufgrund welcher der Gehäusetopf und der Anschlusssockel durch Formschlussbildung der Vergussmasse mit der Radialkontur und der Gegenkontur auch in radialer Richtung aneinander arretiert sind. Auf diese Weise wird eine radiale Aufwölbung des Gehäusetopfs, aufgrund der sich der Kragen des Gehäusetopfs zumindest lokal von dem Radialsteg des Anschlusssockels ablösen würde, durch die Vergussmasse unterbunden. In einer bevorzugten Ausgestaltungsvariante ist die Radialkontur als Rastnase ausgebildet, die den Radialsteg übergreift und somit an dem Gehäusetopf verrastet.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.
Erkanntermaßen entsteht beim Schalten eines gattungsgemäßen Relais, insbesondere im Kurzschlussfall, regelmäßig ein hoher Gasdruck im Innenraum des Gehäuses, der unter ungünstigen Umständen zur Explosion oder zumindest zum unkontrollierten Aufplatzen des Relaisgehäuses führen könnte. Die Ursache für den hohen Gasdruck kann hierbei in der erwärmungsbedingten Ausdehnung der Luft im Gehäuseinnenraum und/oder in der Verdampfung von Restfeuchte der im Gehäuseinnenraum aufgenommenen Luft bestehen. Die Ursache für die Lufterwärmung kann wiederum ein Schaltlichtbogen oder die Aufheizung der stromführenden Teile aufgrund des Stromflusses (insbesondere eines Kurzschlussstroms) sein. Die Explosion oder das unkontrollierte Aufplatzen des Gehäuses kann zu Gefahrensituationen, insbesondere einem Kurzschluss stromführender Teile mit Masse und einer damit einhergehenden Brandgefahr oder einer Personengefährdung, führen und muss daher ausgeschlossen werden. Um diese Sicherheitsanforderung bei einem möglichst kompakten und leicht bauenden Leistungsrelais sicherzustellen, ist in einer vorteilhaften Ausführungsform des Leistungsrelais im Gehäuse - und hierbei vorzugsweise im Gehäusetopf - eine Überdrucksicherung vorgesehen, die im Falle eines kritischen Überdrucks in dem Gehäuse eine Gasausstoßöffnung freigibt, und somit einen kontrollierten Druckausgleich mit der Umgebung sicherstellt. Die Überdrucksicherung kann durch ein separat gefertigtes und in den Gehäusetopf (oder ggf. in den Anschlusssockel) eingesetztes Ventil gebildet sein, insbesondere durch ein federbelastetes Kugelventil oder eine im Überdruckfall reißende Membran (die optional von Haus aus semipermeabel, d.h. gasdurchlässig, aber nicht flüssigkeitsdurchlässig sein kann).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).
Vorzugsweise ist die Überdrucksicherung aber in das Gehäuse (und hier insbesondere in den Gehäusetopf) einstückig integriert, insbesondere an das Gehäuse angespritzt. In dieser Ausführung ist die Überdrucksicherung insbesondere durch eine Sollbruchstelle gebildet, die im Überdruckfall aufplatzt und somit zur Entlastung der übrigen Gehäusebereiche die Gasausstoßöffnung freigibt. Die Sollbruchstelle hat vorzugsweise eine gebogene, beispielsweise U-förmige, V-förmige, oder trapezförmige, Form und umgibt somit von drei Seiten einen laschenartigen Abschnitt (nachfolgend kurz "Lasche") des Gehäuses, der den Verschluss der Überdrucksicherung bildet. Die vierte Seite dieser Lasche ist zweckmäßigerweise entlang einer zwischen den Enden der Sollbruchstelle verlaufenden Verbindungslinie als Filmgelenk ausgebildet. Durch die von der Sollbruchstelle umrahmte Lasche wird hierbei eine Gasausstoßöffnung mit definierter Form und Größe gebildet. Das die Sollbruchstelle verbindende Filmgelenk ermöglicht dabei, dass die Lasche beim Aufplatzen der Sollbruchstelle definiert aus der Gehäusewand ausgebogen wird, verhindert aber, dass die Lasche hierbei unkontrolliert abreißt, wodurch einer möglichen Personengefährdung oder einer Beschädigung benachbarter Teile entgegengewirkt wird. In einer besonders vorteilhaften Ausgestaltungsvariante hat die Sollbruchstelle insbesondere eine Schlüssellochform, ist also U-förmig mit einem kreisförmig aufbereiteten Grund ausgebildet.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.
Da das Gehäuse des Leistungsrelais nach dem Aufplatzen der Sollbruchstelle nicht mehr dicht ist, ist in diesem Fall regelmäßig ein Austausch des Leistungsrelais erforderlich. Um auszuschließen, dass das Leistungsrelais dennoch weiter betrieben wird, ist das Leistungsrelais in einer zweckmäßigen Weiterbildung mit einer Sicherheitsfunktion versehen, die nach dem Versagen der Sollbruchstelle ein Warnsignal erzeugt und/oder das Leistungsrelais zwangsweise in einen sicheren Zustand schaltet. Die Sicherheitsfunktion umfasst in einer Ausführungsform des Leistungsrelais eine Zwangsabschaltung, durch die das Leistungsrelais - durch Dekontaktierung der Kontaktbrücke von den Anschlussbolzen - permanent abschaltet und somit unumkehrlich außer Betrieb genommen wird. Für bestimmte Ausführungsformen kann die Sicherungsfunktion des Leistungsrelais - in Anpassung an den jeweiligen Einsatzzweck - aber auch die Einschaltung des Leistungsrelais umfassen. So muss beispielsweise ein als Batterieschalter in einem Nutzfahrzeug eingesetztes Leistungsrelais auch im Fehlerfall eingeschaltet bleiben, da ansonsten die elektrische Versorgung des Bordnetzes - gegebenenfalls während der Fahrt - zusammenbrechen würde.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.
Grundsätzlich kann hierbei im Rahmen der Erfindung vorgesehen sein, dass die Zwangsabschaltung den Überdruckfall unabhängig von dem Zustand der Sollbruchstelle detektiert, beispielsweise durch einen separaten Überdrucksensor, der in einem kritischen Überdruckfall ausgelöst wird. Vorzugsweise wird die Zwangsabschaltung aber unmittelbar durch das Aufplatzen der Sollbruchstelle ausgelöst. Hierzu ist in zweckmäßiger Ausführung eine elektrische Sicherungsleitung derart mechanisch mit der Sollbruchstelle gekoppelt, dass die Sicherungsleitung im Versagensfall der Sollbruchstelle durchtrennt wird. Die Sicherungsleitung steht hierbei - unmittelbar oder mittelbar - mit der Magnetspule in Wirkverbindung, so dass ihre Durchtrennung die Zwangsabschaltung des Leistungsrelais bewirkt. Die Sicherungsleitung kann hierbei beispielsweise Teil der Stromversorgung der Magnetspule oder Teil eines mit der ggf. vorhandenen Steuerelektronik verschalteten Signalstromkreises sein. Grundsätzlich ist im Rahmen der Erfindung ferner auch denkbar, dass die Sicherungsleitung im Versagensfall der Sollbruchstelle elektrisch durchgeschaltet wird, wobei in diesem Fall die Durchschaltung (also das Zustandekommen einer leitfähigen Verbindung über die Sicherungsleitung), die Zwangsabschaltung auslöst, oder dass der Zustand der Sollbruchstelle durch einen sonstigen Sensor kontrolliert wird.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.
Um die Montage des Leistungsrelais zu vereinfachen, ist die Spulenbaugruppe vorzugsweise als selbststabile (in sich stabile) und zusammenhängende Baueinheit ausgebildet. Die Spulenbaugruppe ist also derart gestaltet, dass sie auch ohne die umgebenden Teile des Gehäuses zusammenhält. Dies ermöglicht es, die Spulenbaugruppe außerhalb des Gehäuses zusammenzubauen, was insbesondere einer automatisierten Fertigung entgegenkommt, und als Ganzes in das Gehäuse einzusetzen.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.
Kernelement der selbststabilen Spulenbaugruppe ist in zweckmäßiger Ausgestaltung des Leistungsrelais ein durch ein Kunststoff-Spritzgießteil ausgebildeter, einstückiger Trägerkörper, auf den die Magnetspule unmittelbar aufgewickelt ist.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.
Des Weiteren trägt der Trägerkörper vorzugsweise auch den Magnetanker, der hierzu unmittelbar in dem Trägerkörper gleitgelagert ist.Furthermore, the carrier body preferably also carries the magnet armature, which for this purpose is slide-mounted directly in the carrier body.
In einer zweckmäßigen Ausgestaltung umfasst der Trägerkörper mindestens eine Tasche, die zur Aufnahme eines Polschuhs des Magnetjochs sowie - falls vorhanden - mindestens eines Permanentmagneten dient. Permanentmagnete sind hierbei bei bistabilen Bauformen des Leistungsrelais vorgesehen.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.
Innenseitig hat die oder jede Tasche vorzugsweise eine Wand mit einer definierten Wandstärke zwischen 0,2 mm und 0,5 mm, insbesondere bei ca. 0,3 mm, durch die der entsprechende Polschuh des Magnetjochs von dem im Inneren des Trägerkörpers geführten Magnetanker beabstandet ist. Durch diese einstückig mit dem Trägerkörper ausgebildete Wand wird ein effektiver magnetischer Fluss innerhalb des aus dem Magnetjoch und dem Magnetanker gebildeten Magnetkreises erzielt, wobei gleichzeitig die magnetischen Verhältnisse innerhalb dieses Magnetkreises mit hoher Präzision und hoher zeitlicher Konstanz eingestellt werden können.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.
Vorzugsweise sind an dem Trägerkörper weiterhin eine Halterung oder zumindest Bauraum für mindestens eine Freilaufdiode und/oder eine Halterung für eine Thermosicherung und/oder eine Halterung für einen Schaltstellungskontakt zur Erkennung der Schaltstellung des Leistungsrelais eingeformt. Als Thermosicherung wird hierbei ein elektrisches oder elektronisches Bauteil verstanden, das durch Aufschmelzen oder mechanische Bewegung unter Einfluss externer Wärmeerzeugung (anders als eine Schmelzsicherung also nicht unter Wirkung des durch das Bauteil fließenden Stroms) öffnet und somit den über die Thermosicherung geführten Stromkreis unterbricht. Infolge der vorstehend beschriebenen Halterungen, die vorzugsweise in Kombination an dem Trägerkörper vorgesehen sind, ist dieser Trägerkörper als Multifunktionsteil ausgebildet, das unverändert bei einer Vielzahl von unterschiedlichen Bauformen des Leistungsrelais eingesetzt werden kann, insbesondere bei Bauformen mit und ohne Freilaufdioden, Bauformen mit und ohne Thermosicherung sowie Bauformen mit und ohne Schaltstellungskontakt. Die Halterungen sind somit an dem Trägerkörper insbesondere auch bei Bauformen des Leistungsrelais ausgebildet, bei denen das jeweilige Funktionsbauteil, also die Freilaufdiode, die Thermosicherung bzw. der Signalkontakt nicht vorgesehen sind. Somit wird ein besonders hoher Vorfertigungsgrad für unterschiedliche Bauformen des Leistungsrelais erzielt.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.
Im Sinne einer weiteren Montagevereinfachung ist die Spulenbaugruppe vorzugsweise an dem Anschlusssockel befestigt, wobei für diese Befestigung vorzugsweise eine Schnappverbindung zum Einsatz kommt. Hierdurch wird ermöglicht, alle elektrisch sowie durch mechanische Bewegung zusammenwirkenden Teile des Leistungsrelais außerhalb des Gehäuses zu montieren.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.
Zur mechanischen Kopplung des Magnetankers mit der Kontaktbrücke ist in zweckmäßiger Ausführung des Leistungsrelais eine Koppelstange vorgesehen, die sich entlang einer Spulenachse der Magnetspule erstreckt. Zweckmäßigerweise ist die Koppelstange in einem zentralen Teil des Magnetjochs gleitgelagert. An der ankerfernen Seite ist an der Koppelstange die Kontaktbrücke befestigt. Um eine präzise Führung der Kontaktbrücke sicherzustellen, ist die Koppelstange hierbei in einer vorteilhaften Ausführungsform der Erfindung auf ihrer ankerfernen Seite (somit im Bereich der Kontaktbrücke) in dem Anschlusssockel gleitgelagert. Die Koppelstange taucht hierbei insbesondere mit einem - in dem Anschlusssockel gleitgelagerten - Lagerabschnitt durch die Kontaktbrücke hindurch.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.
Bei elektronischen Bauvarianten des Leistungsrelais ist die in (diesem Fall vorhandene) Steuerelektronik vorzugsweise außerhalb des Magnetjochs, und hierbei insbesondere parallel zu einer der Seitenflächen des Gehäusetopfs angeordnet. Durch das Magnetjoch wird die Steuerelektronik hierbei von der durch die Bestromung der Magnetspule entstehenden Wärme abgeschirmt. Die Steuerelektronik ist somit im kalten Bereich des Leistungsrelais angeordnet, wodurch die Steuerelektronik geschont wird.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.
Neben einpoligen Ausführungsformen mit lediglich zwei Anschlussbolzen und einer einzigen zugehörigen Spulenbaugruppe sind vorzugsweise auch mehrpolige Ausführungsformen des Leistungsrelais vorgesehen. Diese mehrpoligen Ausführungen des Leistungsrelais dienen insbesondere dazu, mehrphasige Laststromkreise simultan zu schalten oder einphasige Laststromkreise durch mehrere Schalteinheiten parallel zu schalten. Letzteres hat hierbei insbesondere den Vorteil, dass die auf das Relais beim Schalten wirkende Belastung auf mehrere Pole verteilt werden kann. Mehrpolige Ausführungsformen des Leistungsrelais werden hierbei vorteilhaft dadurch realisiert, dass mehrere Spulenbaugruppen gemeinsam an ein und demselben Anschlusssockel befestigt werden, wobei dieser Anschlusssockel für jede Spulenbaugruppe jeweils zwei Anschlussbolzen trägt.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.
Um mit ein- und derselben Bauform des Leistungsrelais unterschiedliche Montagepositionen realisieren zu können, trägt der Gehäusetopf vorzugsweise sowohl an einer Seitenfläche als auch an seinem Boden jeweils eine Montagefläche, die mit Schrauböffnungen zur Aufnahme von Befestigungsschrauben versehen ist. An jeder dieser Montageflächen kann das Leistungsrelais entweder direkt oder - zur Anpassung an verschiedene Lochabstände der Einbauumgebung - über Adapterplatten durch Verschraubung montiert werden. Die in den Montageflächen des Gehäusetopfs jeweils vorgesehenen Schrauböffnungen sind vorzugsweise durch Gewindehülsen aus Metall realisiert, die in Öffnungen des Kunststoffmaterials des Gehäusetopfs eingepresst oder mit dem Material des Gehäusetopfs umspritzt sind.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 einer vorteilhaften Weiterentwicklung einer elektronischen Bauvariante des Leistungsrelais ist die in diesem Fall vorgesehene Steuerelektronik mit einer Kontaktreinigungsfunktion versehen. Die Steuerelektronik ist hierbei dazu eingerichtet, in einem Kontaktreinigungsmodus die Magnetspule mehrfach in kurzen zeitlichen Abständen anzusteuern. Durch die mehrfache Ansteuerung wird somit ein künstliches Kontaktprellen erzeugt, bei dem die Kontaktbrücke mehrfach gegen die Anschlussbolzen schlägt. Auf diese Weise werden gegebenenfalls an den Kontaktstellen anhaftende Verunreinigungen abgerieben, wodurch geringe Kontaktwiderstände erzielt bzw. aufrechterhalten werden. In einer besonders vorteilhaften Ausgestaltungsform dieser Kontaktreinigungsfunktion veranlasst die Steuerelektronik die Kontaktreinigung nur dann, wenn über den Anschlussbolzen keine elektrische Spannung anliegt, so dass das künstliche Kontaktprellen lastfrei erfolgt. Auf diese Weise werden Schaltlichtbögen bei der Kontaktreinigungsfunktion ausgeschlossen.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.
Bei elektronischen Bauformen des Leistungsrelais ist die Steuerelektronik vorzugsweise mit den Anschlussbolzen verbunden. Die Steuerelektronik ist hierbei dazu eingerichtet, die zwischen den Anschlussbolzen abfallende elektrische Spannung abzugreifen und messtechnisch zu detektieren. Über die Anschlussbolzen wird des Weiteren vorzugsweise eine Versorgungsspannung für die Steuerelektronik abgegriffen.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.
Nachfolgend werden Ausführungsbeispiele der Erfindung anhand einer Zeichnung näher erläutert. Darin zeigen:
- Fig. 1
- in perspektivischer Ansicht von schräg oben ein Leistungsrelais für einen Lastkraftwagen,
- Fig. 2
- in perspektivischer Ansicht von schräg unten das Leistungsrelais,
- Fig. 3
- in einer Explosionsdarstellung vier Teilbaugruppen des Leistungsrelais, nämlich einen Anschlusssockel, einen Gehäusetopf, eine Spulenbaugruppe sowie eine eine Steuerelektronik tragende Platine,
- Fig. 4
- in perspektivischer Ansicht von schräg oben die Spulenbaugruppe des Leistungsrelais,
- Fig. 5
- in perspektivischer Ansicht von schräg unten die Spulenbaugruppe gemäß
Fig. 4 , - Fig. 6
- in perspektivischer Ansicht von schräg oben isoliert einen Magnetkreis des Leistungsrelais mit einem Magnetjoch und einem Magnetanker sowie mit einer Koppelstange, über die der Magnetanker auf eine (hier nicht dargestellte) Kontaktbrücke wirkt,
- Fig. 7
- in perspektivischer Ansicht von schräg oben einen Trägerkörper der Spulenbaugruppe,
- Fig. 8
- in perspektivischer Ansicht von schräg unten den Trägerkörper gemäß
Fig. 7 , - Fig. 9
- in einem Querschnitt IX-IX gemäß
Fig. 7 den dortigen Trägerkörper, - Fig. 10
- in perspektivischer Ansicht von oben das Leistungsrelais in einem unvergossenen Vormontagezustand,
- Fig. 11
- in einem vergrößert dargestellten Ausschnitt XI aus
Fig. 10 ein Detail des Gehäuses des Leistungsrelais, - Fig. 12
- in einem Längsschnitt XII-XII gemäß
Fig. 1 und2 das dortige Leistungsrelais, - Fig. 13
- in einem Längsschnitt XIII-XIII gemäß
Fig. 1 und2 das dortige Leistungsrelais, - Fig. 14
- in einem Querschnitt XIV-XIV gemäß
Fig. 1 und2 das dortige Leistungsrelais, und - Fig. 15
- in perspektivischer Ansicht von schräg oben den Gehäusetopf des Leistungsrelais.
- 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 and2 the local power relay, - Fig. 13
- in a longitudinal section XIII-XIII according to
Fig. 1 and2 the local power relay, - Fig. 14
- in a cross section XIV-XIV according to
Fig. 1 and2 the local power relay, and - Fig. 15
- in perspective view obliquely from above the housing pot of the power relay.
Einander entsprechende Teile sind allen Figuren stets mit gleichen Bezugszeichen versehen.Corresponding parts all figures are always provided with the same reference numerals.
Das in den
Der Anschlusssockel 3 begrenzt das Gehäuse 2 zu einer Anschlussseite hin, an der das Leistungsrelais 1 mit einem externen Laststromkreis sowie mit externen Steuerleitungen kontaktierbar ist. Diese Anschlussseite ist nachfolgend - unabhängig von der tatsächlichen Orientierung des Leistungsrelais 1 im umgebenen Raum - auch als Oberseite 5 bezeichnet. Der Gehäusetopf 4 umschließt mit vier Seitenwänden 6 und einem Gehäuseboden 7 die übrigen Seiten eines etwa quaderförmigen Gehäuseinnenraums 8 (
Zum Anschluss zweier Anschlussleitungen des anzuschließenden Laststromkreises sind im Anschlusssockel 3 zwei massive Anschlussbolzen 10 fixiert, die jeweils mit einem Gewindeschaft 11 aus dem Gehäuse 2 nach außen hervorragen. Bei dem Anschlussbolzen 10 handelt es sich um massive Drehteile aus Metall, die im Bereich des Gewindeschafts 11 beispielsweise einen Durchmesser von 0,8 cm aufweisen. Zum Anschluss der jeweiligen Anschlussleitung des Laststromkreises wird ein endseitiger Kabelschuh dieser Anschlussleitung auf den zugeordneten Gewindeschaft 11 aufgesetzt und mittels einer Schraubenmutter (Kontaktmutter) schraubkontaktiert. Alternativ hierzu können die Anschlussbolzen 10 aber auch durch Hülsen mit jeweils einer Gewindebohrung gebildet sein. Anstelle von Kontaktmuttern sind in diesem Fall Kontaktschrauben zur Kontaktierung der Anschlussleitungen vorgesehen, die in die Gewindebohrungen eingeschraubt werden. Wie insbesondere aus
Um einen elektrischen Überschlag oder sonstigen Kurzschluss zwischen den Anschlussbolzen 10 und den daran gegebenenfalls befestigten Anschlussleitungen des Laststromkreises auszuschließen, ist außenseitig an dem Anschlusssockel 3 eine Trennwand 12 angeformt, die in den zwischen den Anschlussbolzen 10 gebildeten Zwischenraum hineinragt.To exclude an electrical flashover or other short circuit between the
Zur Ansteuerung des Leistungsrelais 1, also zur Auslösung von Schaltprozessen, durch die das Leistungsrelais 1 - durch Herstellung einer gehäuseinternen elektrisch leitfähigen Verbindung zwischen den Anschlussbolzen 10 - eingeschaltet oder - durch Trennung dieser elektrisch leitenden Verbindung - ausgeschaltet wird, sind an dem Anschlusssockel 3 des Weiteren mehrere (hier beispielhaft drei) Signalanschlüsse 13 ausgebildet, über die drei korrespondierende externe Steuerleitungen jeweils mit einem endseitigen Kabelschuh mit dem Leistungsrelais 1 schraubkontaktiert werden können. Jeder Signalanschluss 13 ist über einen Anschlussleiter 14 in Form eines gebogenen Blechstanzteils mit dem Gehäuseinnenraum 8 elektrisch verbunden. Die Anschlussleiter 14 sind hierbei zwischen dem Anschlusssockel 3 und dem Gehäusetopf 4 eingelegt oder ebenfalls durch Umspritzung in dem Anschlusssockel 3 gehalten. Zur Oberseite 5 hin sind die Signalanschlüsse 13 durch einen separaten, aufrastbaren Kunststoffdeckel 15 gegen Berührung geschützt.To control the
Die in
In dem dargestellten Ausführungsbeispiel handelt es sich bei dem Leistungsrelais 1 um ein bistabiles Relais. In diesem Fall sind den Polschuhen 28 und den Schenkelenden des Bügels 27 jeweils zwei plättchenförmige Permanentmagnete 29 zwischengeordnet. Je nach Auslegung des Leistungsrelais 1 können hierbei allerdings ein oder zwei der einem Polschuh 28 zugeordneten Permanentmagnete 29 auch durch ferromagnetische Plättchen gleicher Größe ersetzt sein. Bei einer (nicht näher dargestellten) monostabilen Variante des Leistungsrelais 1 sind die Permanentmagnete 29 gänzlich durch ferromagnetisches Material ersetzt.In the illustrated embodiment, the
Als namensgebenden Bestandteil umfasst die Spulenbaugruppe 20 eine Magnetspule 30 (
Wie insbesondere aus
einen Schaltstellungskontakt 31 mit zwei Festkontakten 32 und einem mit der Koppelstange 23 gekoppelten Bewegkontakt 33,zwei Freidioden 34, die zum Schutz gegen induktive Spannungsstöße beim Schalten dienen sowieeine Thermosicherung 35, die eine Zwangsabschaltung desLeistungsrelais 1 bei Überhitzung bewirkt.
- a
switch position contact 31 with two fixed contacts 32 and a coupled to thecoupling 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 thepower relay 1 in case of overheating.
Ferner umfasst die Spulenbaugruppe 20 zwei Hilfsleiter 36, die jeweils aus einem gebogenen Blechstanzteil gebildet sind, ein Dämpfungselement 37 sowie zwei die Koppelstange 23 umgebende Druckfedern, nämlich eine Rückstellfeder 38 und eine Kontaktdruckfeder 39 (
Die vorstehend aufgezählten Bestandteile der Spulenbaugruppe 20 werden hierbei mechanisch zusammengehalten von einem Trägerkörper 40, der in den
Der Trägerkörper 40 trägt zum einen die Magnetspule 30, die hierzu unmittelbar auf eine zentrale Säule 41 des Trägerkörpers 40 aufgewickelt ist. Zum anderen haltert der Trägerkörper 40 das Magnetjoch 25 und den Magnetanker 24. Der Magnetanker 24 und der Kern 26 des Magnetjochs 25 sind hierzu im Inneren der hohlen Säule 41 des Trägerkörpers 40 aufgenommen (vgl.
Weiterhin weist der Trägerkörper 40, wie insbesondere aus
Halterungen 46 für die Festkontakte 32 des Schaltstellungskontakts 31,Bauraum 47 für die Freilaufdioden 34 (dieFreilaufdioden 34 sind in dem dargestellten Ausführungsbeispiel nur indirekt über Spulenanschlussleiter andem Trägerkörper 40 gehaltert),Halterungen 48 für dieThermosicherung 35,Halterungen 49 für dieHilfsleiter 36 sowieHalterungen 50für das Dämpfungselement 37
-
Mounts 46 for the fixed contacts 32 of theswitch position contact 31, -
Space 47 for the freewheeling diodes 34 (the free-wheelingdiodes 34 are supported only indirectly via coil connection conductors on thecarrier body 40 in the illustrated embodiment), -
Mounts 48 for thethermal fuse 35, -
Mounts 49 for theauxiliary conductor 36 and -
Mounts 50 for the damping element 37th
Die in
Bei rein elektromechanischen Bauformen des Leistungsrelais 1 ist die Platine 21 optional ebenfalls vorhanden. Sie trägt in diesem Fall allerdings keine Steuerelektronik 63, sondern lediglich Leiterbahnen zur Kontaktierung der Magnetspule 30 und der ggf. vorhandenen elektrischen Funktionselemente mit den Signalanschlüssen 13. Alternativ hierzu ist die Platine 21 bei rein elektromechanischen Bauformen des Leistungsrelais 1 durch Drahtleiter ersetzt.In purely electromechanical designs of the
Im Zuge der Montage des Leistungsrelais 1 wird zunächst der Trägerkörper 40 mit der Magnetspule 30, dem Magnetjoch 25, dem mit der Koppelstange 23 verbundenen Magnetanker 24 und den Druckfedern 38, 39, der Kontaktbrücke 22 sowie den gegebenenfalls vorhandenen elektrischen Funktionsbauteilen (also dem Schaltstellungskontakt 31, den Freilaufdioden 34, der Thermosicherung 35 und/oder den Hilfsleitern 36) sowie mit dem Dämpfungselement 37 bestückt. Die Spulenbaugruppe 20 ist damit als selbststabile (selbsttragende) Baueinheit fertiggestellt.In the course of mounting the
In dieser Form wird die Spulenbaugruppe 20 von unten auf den zuvor in einem Spritzgießprozess fertiggestellten Anschlusssockel 3 aufgeklipst. Hierzu ist der Anschlusssockel 3 an seiner Unterseite mit angespritzten Schnapphaken 64 (
Nach, vor oder gleichzeitig mit dem Aufklipsen der Spulenbaugruppe 20 wird die Platine 21 montiert. Hierzu werden einerseits Anschlussstellen im Bereich des Abschnitts 60 mit den Anschlussleitern 14 der Signalanschlüsse 13 verlötet. Andererseits werden Anschlussstellen im Bereich des Abschnitts 61 mit Anschlüssen der Magnetspule 30 sowie der vorhandenen elektrischen Funktionselemente (also gegebenenfalls der Festkontakte 32 des Schaltstellungskontakts 31, der Freilaufdioden 34, der Thermosicherung 35 und/oder der Hilfsleiter 36) verlötet. In ihrer Montagestellung erstreckt sich die Platine 21 mit ihrem Abschnitt 60 parallel zu einem Schenkel des Bügels 27, wobei der Abschnitt 60 außerhalb des Bügels 27 angeordnet ist. Mit ihrem Abschnitt 61 erstreckt sich die Platine 21 senkrecht zur Spulenachse, wobei sie das Magnetjoch 25 und den Magnetanker 24 untergreift.After, before or simultaneously with the clipping of the
Ferner werden die Hilfsleiter 36 mit (Spannungsabgriffs-)Anschlüssen 66 (
Nach der Montage der Spulenbaugruppe 20 und der Platine 21 an dem Anschlusssockel 3 wird der Gehäusetopf 4 über die Spulenbaugruppe 20 und die Platine 21 gestülpt und mit dem Anschlusssockel 3 verrastet und verschraubt, wodurch das Gehäuse 2 geschlossen wird. Der Bügel 27 des Magnetjochs 25 liegt dabei derart in dem Gehäusetopf 4 ein, dass sich seine Schenkel nach Art von Querträgern zwischen zwei gegenüberliegenden Seitenwänden 6 des Gehäusetopfs 4 sowie parallel zu den verbleibenden Seitenwänden 6 über die gesamte Breite des Gehäuseinnenraums 8 erstrecken. Der Bügel 27 ist somit über die gesamte - in Richtung der Spulenachse und der Achse des Gehäusetopfs 4 gemessenen - Höhe des Gehäusetopfs 4 drehfest in diesem aufgenommen. Der Bügel 27 versteift somit aufgrund seiner torsionsstabilen Struktur den Gehäusetopf 4 gegenüber axialen Drehmomenten, wie sie insbesondere beim Anziehen der Kontaktmuttern auf den Anschlussbolzen 10 ausgeübt werden.After mounting the
In geschlossenem Zustand des Gehäuses 2 liegt der Anschlusssockel 3 mit einem umlaufenden Radialsteg 70 (
Mit der Vergussmasse 74 werden weiterhin auch die Durchführungen der Anschlussleiter 14 abgedichtet. Die Anschlussleiter 14 sind hierzu im Bereich der Wanne 73 durch den Anschlusssockel 3 hindurch geführt. Die Durchführungen der Anschlussbolzen 10 durch den Anschlusssockel 3 werden separat von der Wanne 73 durch Vergussmasse abgedichtet.With the potting
Um die Verbindung zwischen dem Anschlusssockel 3 und dem Gehäusetopf 4 zusätzlich zu sichern, sind entlang der Innenseite des Kragens 72 - und hier insbesondere in den geraden Abschnitten des Kragens 72 eine Anzahl von Radialvorsprüngen 80 (
Um zu verhindern, dass unter Wirkung von auf die Seitenwände 6 des Gehäusetopfs 4 wirkenden Kräften die Vergussmasse 74 mit dem Gehäusetopf 4 mitgerissen wird und sich hierbei von der Außenseite des Anschlusssockels 3 löst, sind auf der Oberseite des Anschlusssockels 3 eine Anzahl von Gegenkonturen in Form von Vorsprüngen 82 ausgebildet. Die jeweils innenliegenden Kanten dieser Vorsprünge bildet hierbei wiederum eine Hinterschneidung 83, die sich mit der Vergussmasse 74 verkrallt.In order to prevent that under the action of forces acting on the
In (nicht dargestellten) alternativen Bauformen ist das Leistungsrelais 1 mehrpolig, insbesondere zweipolig oder dreipolig ausgebildet. Hierbei werden eine der Polzahl entsprechende Anzahl von Spulenbaugruppen 20 mit einem gemeinsamen Anschlusssockel 3 verbunden, wobei in dem Anschlusssockel 3 in diesem Fall für jede Spulenbaugruppe 20 jeweils 2 Anschlussbolzen 10 fixiert sind. Je nach Bauform kann hierbei für jede Spulenbaugruppe 20 eine separate Platine 21 vorgesehen sein oder eine gemeinsame Platine für alle Spulenbaugruppen 20. Bei mehrpoligen Bauformen des Leistungsrelais 1 ist vorzugsweise ein - zweckmäßigerweise durch Querwände unterteilter - Gehäusetopf 4 zur gemeinsamen Aufnahme aller Spulenbaugruppen 20 vorgesehen.In (not shown) alternative designs, the
Die
Die
Zum Abschalten des Leistungsrelais 1 wird die Magnetspule 30 mit umgekehrter Polung bestromt. Unter Wirkung des hierbei im Magnetjoch 25 erzeugten Magnetflusses wird die durch die Permanentmagneten 29 erzeugte Haltekraft kompensiert, so dass der Magnetanker 24 durch die Rückstellfeder 38 von dem Kern 26 abgezogen und somit in die Öffnungsstellung gemäß
In der dargestellten, bistabilen Bauform des Leistungsrelais 1 ist jede der beiden Schaltstellungen des Leistungsrelais 1 auch in unbestromtem Zustand der Magnetspule 30 stabil. Die Magnetspule 30 muss hierbei nur vorübergehend bestromt werden.In the illustrated, bistable design of the
In einer (nicht explizit dargestellten) Bauvariante des Leistungsrelais 1 ragt die Koppelstange 23 mit einem Lagerabschnitt nach oben, also über die ankerferne Seite der Kontaktbrücke 22 hinaus. Der Lagerabschnitt taucht hier in eine fluchtend angeordnete Lageröffnung 92 des Anschlusssockels 3 hinein, so dass die Koppelstange 23 auch in dem Anschlusssockel 3 gleitgelagert ist. Hierdurch wird eine besonders stabile und präzise Positionierung der Kontaktbrücke 22 gewährleistet.In a (not explicitly shown) construction variant of the
Wie insbesondere aus
Die Ansteuerung der Magnetspule 30 erfolgt entweder direkt über die Signalanschlüsse 14 oder über die Steuerelektronik 63, die im dargestellten Ausführungsbeispiel ihrerseits über die Anschlüsse 66 und die Hilfsleiter 36 mit Spannung versorgt wird. Die Steuerelektronik 63 steuert die Magnetspule 30 in Abhängigkeit von externen oder internen Steuerbefehlen an, die der Steuerelektronik 63 über die Signalanschlüsse 13 zugeführt werden. Über die Anschlüsse 66 ermittelt die Steuerelektronik 63 ferner im eingeschalteten Zustand des Leistungsrelais 1 die über den Anschlussbolzen 10 abfallende Spannung als Maß für die durch das Leistungsrelais 1 fließende Laststromstärke oder zur Erkennung der Relaisstellung. Die Steuerelektronik 63 realisiert hierbei optional eine Überlastabschaltung sowie eine Kurzschlussabschaltung, indem sie das Leistungsrelais 1 automatisch in die Öffnungsstellung verfährt, wenn die erfasste Laststromstärke vorgegebene Schwellwerte übersteigt. Bei mehrpoligen Bauformen des Leistungsrelais 1 wertet die Steuerelektronik 63 optional die über den Anschlussbolzen 10 der einzelnen Pole jeweils abfallenden Spannungen auch vergleichend aus, um das Leistungsrelais 1 - je nach Bauform - bei Erkennung eines Fehlerstroms oder einer unsymmetrischen Stromverteilung abzuschalten.The control of the
Schließlich verfügt die Steuerelektronik 63 optional über eine Kontaktreinigungsfunktion. In einem entsprechenden Kontaktreinigungsmodus steuert die Steuerelektronik 63 die Magnetspule 30 in regelmäßigen Zeitabständen mehrfach in kurzen zeitlichen Abständen nacheinander an, so dass ein künstliches Kontaktprellen erzeugt wird. Hierbei schlägt die Kontaktbrücke 22 mehrfach gegen die Anschlussbolzen 10 an, wodurch an den Kontaktelementen 90 und den Gegenkontaktelementen 91 gegebenenfalls anhaftende Verunreinigungen abgerieben werden. Die Steuerelektronik 63 prüft hierbei zunächst die über den Anschlussbolzen 10 anliegende elektrische Spannung und schaltet nur dann in den Kontaktreinigungsmodus, wenn diese Spannung einen verschwindenden Betrag hat, und das Leistungsrelais 1 somit lastfrei geschaltet werden kann.Finally, the
Insbesondere bei Abschaltung des Leistungsrelais 1 im Überlast- oder Kurzschlussfall kommt es aufgrund der Aufheizung der stromführenden Teile sowie aufgrund eines entstehenden Schaltlichtbogens regelmäßig zu einem hohen Überdruck in dem Gehäuseinnenraum 8. Unter ungünstigen Umständen kann dieser Überdruck einen Wert annehmen, der die Stabilität des Gehäuses 2, insbesondere des Gehäusetopfs 4 oder der Verbindung zwischen dem Anschlusssockel 3 und dem Gehäusetopf 4 gefährdet. Um ein Explodieren oder unkontrolliertes Aufplatzen des Gehäuses 2 unter diesen Umständen zu verhindern, ist der Gehäusetopf 4 daher mit einer Überdrucksicherung 100 versehen,In particular, when switching off the
Wie aus
In bevorzugter Ausführung des Leistungsrelais 1 ist an der Innenwand des Gehäusebodens 7 quer über die Sollbruchstelle 101 und die Lasche 102 eine (nicht explizit dargestellte) elektrische Signalleitung in Form einer aufgedampften oder aufgeklebten Leiterbahn gelegt, deren elektrischer Durchgangswiderstand durch die Steuerelektronik 36 abgefragt wird. Die Signalleitung wird hierbei beim Aufplatzen der Sollbruchstelle 100 automatisch durchtrennt, was von der Steuerelektronik 63 aufgrund des schlagartigen erhöhten Durchgangswiderstands erkannt wird. In diesem Fall versetzt die Steuerelektronik 63 das Leistungsrelais 1 in einen sicheren Zustand. In einer für viele Anwendungsfälle zweckmäßigen Bauvariante löst die Steuerelektronik 63 eine permanente Zwangsabschaltung des Leistungsrelais 1 aus, um einen Austausch des Leistungsrelais 1 zu erzwingen.In a preferred embodiment of the
Wie aus
Die Erfindung wird an den vorstehend beschriebenen Ausführungsbeispielen besonders deutlich, ist gleichwohl auf diese Ausführungsbeispiele aber nicht beschränkt. Vielmehr können zahlreiche weitere Ausführungsformen der Erfindung aus den Ansprüchen und der vorstehenden Beschreibung abgeleitet werden.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.
- 11
- Leistungsrelaispower relay
- 22
- Gehäusecasing
- 33
- Anschlusssockelconnection base
- 44
- Gehäusetopfhousing pot
- 55
- Oberseitetop
- 66
- SeitenwandSide wall
- 77
- Gehäusebodencaseback
- 88th
- GehäuseinnenraumHousing interior
- 99
- Unterseitebottom
- 1010
- Anschlussbolzenconnecting bolt
- 1111
- Gewindeschaftthreaded shaft
- 1212
- Trennwandpartition wall
- 1313
- Signalanschlusssignal connection
- 1414
- Anschlussleiterconnecting conductors
- 1515
- Deckelcover
- 2020
- Spulenbaugruppecoil assembly
- 2121
- Platinecircuit board
- 2222
- KontaktbrückeContact bridge
- 2323
- Koppelstangecoupling rod
- 2424
- Magnetankerarmature
- 2525
- Magnetjochyoke
- 2626
- Kerncore
- 2727
- Bügelhanger
- 2828
- Polschuhepole pieces
- 2929
- Permanentmagnetpermanent magnet
- 3030
- Magnetspulesolenoid
- 3131
- SchaltstellungskontaktSwitch position contact
- 3232
- Festkontaktfixed contact
- 3333
- Bewegkontaktmoving contact
- 3434
- FreilaufdiodeFreewheeling diode
- 3535
- Thermosicherungthermal fuse
- 3636
- Hilfsleiterauxiliary circuit
- 3737
- Dämpfungselementdamping element
- 3838
- RückstellfederReturn spring
- 3939
- KontaktdruckfederContact pressure spring
- 4040
- Trägerkörpersupport body
- 4141
- Säulepillar
- 4242
- (obere) Plattform(upper) platform
- 4343
- (untere) Plattform(lower) platform
- 4444
- Taschebag
- 4545
- Wandwall
- 4646
- Halterungholder
- 4747
- Halterungholder
- 4848
- Halterungholder
- 4949
- Halterungholder
- 5050
- Halterungholder
- 6060
- Abschnittsection
- 6161
- Abschnittsection
- 6262
- Filmgelenkfilm hinge
- 6363
- Steuerelektronikcontrol electronics
- 6464
- Schnapphakensnap hooks
- 6565
- Vorsprunghead Start
- 6666
- (Spannungsabgriffs-)Anschluss(Spannungsabgriffs-) Connection
- 7070
- Radialstegradial web
- 7171
- Absatzparagraph
- 7272
- Kragencollar
- 7373
- Wannetub
- 7474
- Vergussmassepotting compound
- 8080
- Radialvorsprungradial projection
- 8181
- Hinterschneidungundercut
- 8282
- Vorsprunghead Start
- 8383
- Hinterschneidungundercut
- 9090
- Kontaktelementcontact element
- 9191
- GegenkontaktelementContact element
- 9292
- Lageröffnungbearing opening
- 100100
- ÜberdrucksicherungOverpressure protection
- 101101
- SollbruchstelleBreaking point
- 102102
- Lascheflap
- 103103
- Filmgelenkfilm hinge
- 110110
- Montageflächemounting surface
- 111111
- Schrauböffnungscrew opening
Claims (15)
- Power relay (1) for a vehicle, in particular a utility vehicle,- having a housing (2) that is formed from a connection socket (3) and a housing pot (4) installed thereon,- having two connection bolts (10) introduced into the connection socket (3) for contacting a load current circuit,- having a coil assembly (20) arranged in the housing (2), said coil assembly (20) comprising a magnetic coil (30) and a magnetic anchor (24), wherein the magnetic anchor (24) is coupled to a contacting bridge (22) via a force transfer member (23) and can be shifted in the housing (2) under the effect of a magnetic field generated by means of the magnetic coil (30) in such a way that the contact bridge (22) can be reversibly moved between a closed position, in which the contact bridge (22) electrically conductively bypasses the connection bolts (10), and an open position, in which the contact bridge (22) is de-contacted by the connection bolts (10),wherein the housing pot (4) is formed as a plastic injection moulded part,
wherein the connection socket (3) is connected to the housing pot (4) in a fluid-tight manner by means of a casting compound (74),
characterised in that
on the side of the opening, the housing pot (4) has a peripheral shoulder (71), on which the connection socket (3) abuts with a peripheral radial web (70),
on the outside, the housing pot (4) surrounds the radial web (70) with a collar (72) and protrudes axially beyond this, such that a trough-like receiver (73) for the casting compound (74) is formed by the collar (72) of the housing pot (4) and the connection socket (3). - Power relay (1) according to claim 1,
wherein the coil assembly (20) has a magnetic yoke (25), which has a torsion-stable structure (27), which is non-rotationally received across the entire axial height of the housing pot (4) in it. - Power relay (1) according to claim 1 or 2,
wherein the connection socket (3) is coupled to the magnetic yoke (25) in a rotationally fixed manner. - Power relay (1) according to one of claims 1 to 3,
wherein the collar (72) has at least one radial contour (80) in the form of a radial recess or a radial protrusion in the region of the trough-like receiver (73), and wherein the connection socket (3) has at least one counter contour (82) in the region of the trough-like receiver (73), wherein the housing pot (4) and the connection socket (3) are locked in the peripheral direction by positive lock formation of the casting compound (74) with the radial contour (80) and the counter contour (82) opposite each other. - Power relay (1) according to claim 4,
wherein the radial contour (80) and the counter contour (82) each have at least one undercut (81, 83), such that the housing pot (4) and the connection socket (3) are locked in the radial direction by the positive lock formation of the casting compound (74) with the radial contour (80) and the counter contour (82) opposite each other. - Power relay (1) according to one of claims 1 to 5,
wherein the housing (2) has a pressure relief device (100), which releases a gas emission opening in the event of a critical overpressure in the housing (2). - Power relay (1) according to claim 6,
wherein the pressure relief device (100) is formed by a separately produced valve that is inserted into the housing pot (4) or the connection socket (3), in particular a springloaded ball valve or a membrane. - Power relay (1) according claim 6,
wherein the pressure relief device (100) is formed by a predetermined break point (101) moulded into the housing (2). - Power relay (1) according to claim 8,
wherein the predetermined break point (101) surrounds a tab-like section (102) of the housing (2) on three sides, and wherein the fourth side of the tab-like section (102) is formed along a connection line running between the ends of the predetermined break point (101) as a film joint (103). - Power relay (1) according to claim 8 or 9,
wherein an electric safety line is mechanically coupled to the predetermined break point (101) in such a way that the safety line is severed or electrically through-switched in the event of the predetermined break point (101) failing, wherein the safety line is in operative connection with the magnetic coil (30) in such a way that the severing or through-switching of the safety line that takes place in the event of the predetermined break point (101) failing causes a permanent electric forced disconnection of the power relay (1). - Power relay (1) according to one of claims 1 to 10,
wherein the coil assembly (20) is formed as a self-stable and contiguous subassembly, and wherein the coil assembly (20) has a carrier body (40), which is formed as an integral plastic moulded part, and on which the magnetic coil (30) is directly wound. - Power relay (1) according to claim 11,
wherein a bracket (48) for a thermal fuse (35) to protect the power relay (1) from overheating is moulded on the carrier body (40). - Power relay (1) according to claim 11 or 12,
wherein at least one bracket for a fixed contact (32) of a switching position contact (31) is formed on the carrier body (40) for signalling the position of the contact bridge (22). - Power relay (1) according to one of claims 1 to 13,
having a control electronic system (63) that is set up to control the magnetic coil (30) several times in short temporal intervals in a contacting mode, such that the contact bridge (22) hits against the connection bolts (10) several times. - Power relay (1) according to one of claims 1 to 14,
having a control electronic system (63) that is contacted with the connection bolts (10), and wherein the control electronic system (63) is set up to determine the electric voltage declining between the connection bolts (10).
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PL15728403T PL3146553T3 (en) | 2014-05-21 | 2015-05-21 | Relais de puissance pour un véhicule |
PL19154808T PL3496126T3 (en) | 2014-05-21 | 2015-05-21 | Power relais for a vehicle |
EP19154808.0A EP3496126B1 (en) | 2014-05-21 | 2015-05-21 | Power relais for a vehicle |
Applications Claiming Priority (2)
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 |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP19154808.0A Division EP3496126B1 (en) | 2014-05-21 | 2015-05-21 | Power relais for a vehicle |
EP19154808.0A Division-Into EP3496126B1 (en) | 2014-05-21 | 2015-05-21 | Power relais for a vehicle |
Publications (2)
Publication Number | Publication Date |
---|---|
EP3146553A2 EP3146553A2 (en) | 2017-03-29 |
EP3146553B1 true EP3146553B1 (en) | 2019-07-03 |
Family
ID=53385568
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP19154808.0A Active EP3496126B1 (en) | 2014-05-21 | 2015-05-21 | Power relais for a vehicle |
EP15728403.5A Active EP3146553B1 (en) | 2014-05-21 | 2015-05-21 | Relais de puissance pour un véhicule |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP19154808.0A Active EP3496126B1 (en) | 2014-05-21 | 2015-05-21 | Power relais for a vehicle |
Country Status (8)
Country | Link |
---|---|
US (1) | US10366852B2 (en) |
EP (2) | EP3496126B1 (en) |
KR (1) | KR101937274B1 (en) |
CN (1) | CN106463307B (en) |
DE (1) | DE102014007459A1 (en) |
ES (2) | ES2747992T3 (en) |
PL (2) | PL3146553T3 (en) |
WO (1) | WO2015176818A2 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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DE102019102146A1 (en) * | 2019-01-29 | 2020-07-30 | Song Chuan Precision Co., Ltd. | Relay with cooling function |
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US11239038B2 (en) | 2015-05-18 | 2022-02-01 | Gigavac, Llc | Mechanical fuse device |
US10566160B2 (en) | 2015-05-18 | 2020-02-18 | Gigavac, Llc | Passive triggering mechanisms for use with switching devices incorporating pyrotechnic features |
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DE102016107127A1 (en) * | 2016-01-29 | 2017-08-03 | Epcos Ag | relay |
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 |
CN110945615B (en) * | 2017-07-26 | 2021-11-05 | 三菱电机株式会社 | Opening and closing device |
JP6795552B2 (en) * | 2018-06-26 | 2020-12-02 | 住友電装株式会社 | Power relay device |
FR3085229B1 (en) * | 2018-08-27 | 2021-03-05 | Valeo Equip Electr Moteur | STARTER SWITCH INCLUDING A SEALING DEVICE, AND STARTER MOTOR INCLUDING SUCH A SWITCH |
CN110310865B (en) * | 2019-07-22 | 2024-02-20 | 三友联众集团股份有限公司 | Contact conduction structure for relay |
US11443910B2 (en) | 2019-09-27 | 2022-09-13 | Gigavac, Llc | Contact levitation triggering mechanisms for use with switching devices incorporating pyrotechnic features |
US20210151265A1 (en) * | 2019-11-19 | 2021-05-20 | Gigavac, Llc | Switching devices incorporating rupture disk |
CN113948341A (en) * | 2020-07-16 | 2022-01-18 | 施耐德电器工业公司 | Mechanical operating assembly for bistable relay and bistable relay assembly |
DE102021112268A1 (en) | 2021-05-11 | 2022-11-17 | Bayerische Motoren Werke Aktiengesellschaft | Switching device for a multi-pole high-voltage vehicle electrical system of an electrically driven motor vehicle, electronic control unit and motor vehicle |
CN113506707B (en) * | 2021-05-27 | 2024-06-18 | 中汇瑞德电子(芜湖)有限公司 | Control relay panel clamp plate |
CN113838707B (en) * | 2021-09-01 | 2024-04-05 | 东风时代(武汉)电池***有限公司 | Relay integrated with current collection function and power battery pack |
KR20230149248A (en) * | 2022-04-19 | 2023-10-26 | 샤먼 홍파 일렉트릭 파워 컨트롤즈 컴퍼니 리미티드 | Relay |
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- 2015-05-21 PL PL15728403T patent/PL3146553T3/en unknown
- 2015-05-21 KR KR1020167035207A patent/KR101937274B1/en active IP Right Grant
- 2015-05-21 EP EP15728403.5A patent/EP3146553B1/en active Active
- 2015-05-21 ES ES15728403T patent/ES2747992T3/en active Active
- 2015-05-21 CN CN201580025892.3A patent/CN106463307B/en active Active
- 2015-05-21 ES ES19154808T patent/ES2825724T3/en active Active
- 2015-05-21 WO PCT/EP2015/001032 patent/WO2015176818A2/en active Application Filing
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Also Published As
Publication number | Publication date |
---|---|
CN106463307B (en) | 2018-11-13 |
ES2825724T3 (en) | 2021-05-17 |
PL3496126T3 (en) | 2021-02-08 |
EP3496126B1 (en) | 2020-08-05 |
PL3146553T3 (en) | 2019-12-31 |
KR101937274B1 (en) | 2019-01-11 |
US20170069450A1 (en) | 2017-03-09 |
DE102014007459A1 (en) | 2015-11-26 |
EP3146553A2 (en) | 2017-03-29 |
WO2015176818A3 (en) | 2016-02-04 |
KR20170005857A (en) | 2017-01-16 |
EP3496126A1 (en) | 2019-06-12 |
WO2015176818A2 (en) | 2015-11-26 |
US10366852B2 (en) | 2019-07-30 |
ES2747992T3 (en) | 2020-03-12 |
CN106463307A (en) | 2017-02-22 |
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