The invention relates to a power relay for a vehicle, in particular a utility vehicle.
Power relays in accordance with the generic type are used in automotive engineering, in particular for utility vehicles. In this case, the power relays are used on the one hand so as to electrically separate the vehicle battery from the on-board power system. On the other hand, such relays are used so as to connect electric motors of adjusting devices (for example a hydraulic pump or lifting platform). In the case of a low voltage of typically 12 to 24 volt, such a power relay must be able to switch currents up to a current strength of approximately 300 ampere and must be of an accordingly robust construction. Relays usually used for this purpose are generally embodied from a pot-shaped body of metal (for example iron or steel) in which are accommodated a magnetic core, a magnetic yoke and a magnetic armature that is connected to a contact bridge (double contact).
In order to connect the power relay to a load current circuit that is to be switched in the vehicle, the power relay generally contains solid connection bolts (threaded bolts) that are embodied from metal and typically have a diameter of 0.5 to 1 cm. These connection bolts at which in the proper manner cable lugs of the connection lines of the load current circuit that is to be connected are defined in a contacting manner by screw nuts (contact nuts) are generally formed by special turned parts that are comparatively complex and consequently expensive to produce.
Power relays of the above described type are known in particular from published, non-prosecuted Germen patent applications DE 10 2010 018 755 A1 (corresponding to U.S. patent publication No. 2011/0267158), DE 10 2010 018 738 (corresponding to U.S. patent publication No. 2011/0267157)A1, DE 39 33 493 A1 (corresponding to U.S. Pat. No. 4,969,844) and U.S. Pat. No. 4,595,811.
German utility model DE 90 01 337 U1 discloses a further power relay in which the connection bolts are formed in each case by a screw having a hexagonal screw head. The screws are inserted from the housing interior into the through-going apertures of a housing socket so that each of the screws protrude outwards with their threaded shaft through the housing socket, whereas the hexagonal head lies in a corresponding receiving arrangement of the housing socket.
The object of the invention is to provide a power relay that can be produced in a particularly rational manner for a vehicle, in particular a utility vehicle.
This object is achieved in accordance with the invention by means of the features of the main claim. The power relay in accordance with the invention contains a housing that is formed from a connection socket and a housing pot that is placed thereon. Two connection bolts are inserted into the housing socket and by way of the connection bolts contact can be made between the power relay and the connection lines of an external load current circuit that is to be connected. In accordance with the invention, the connection bolts are formed by standard screws, in particular in accordance with ISO 4014 (or DIN 931-1) or ISO 4017 (or DIN 933). As is generally the case with screws, each connection bolt contains a threaded shaft—which is to be provided with a metal thread—and a screw head that is wider with respect to said connection bolt.
By virtue of using standard screws as the connection bolts, the production outlay and the production costs for the power relay are considerably reduced. Standard screws are commercially available as mass-produced items.
In order to be able to tighten the contact nuts in a simple manner as they make contact with the load current circuit, the respective screw head of the connection bolts preferably contains a non-circular outer contour. In particular, the screw head is formed in this case as a hexagonal head. The non-circular screw head holds the respective connection bolt in a non-rotatable manner in the connection socket by forming a form-locking connection with the connection socket. A form-locking connection is a connection based on the shape of the parts interacting with each other (e.g. a ball and socket).
In accordance with the invention, the connection bolts having the respective screw head lie loosely in a respective corresponding receiving arrangement of the connection socket. The term “loosely” is understood in this case to mean to such an extent that the connection bolts are not directly connected to the material of the connection socket. The connection bolts can as a result move slightly in particular with respect to the connection socket.
Each of the connection bolts is held in an expedient embodiment by a connecting conductor that is preferably formed by a bent sheet metal stamped part. Each of the connecting conductors is fixed in the connection socket and encompasses the outer face of the screw head so that the respective connection bolt is held in a loss-proof manner in the connection socket. The connecting conductors are used simultaneously to conduct the load current into the housing inner space.
In order to hold the respectively allocated connection bolt in the connection socket, each of the connecting conductors contains in an expedient construction a bore hole in a central section and the allocated connection bolt is guided with its threaded shaft through said bore hole. Each of the connecting conductors contains in an expedient manner on both sides of this central section in each case a fixing limb that is bent at 90° in particular with respect to the central section. The connecting conductor is fixed by the fixing limbs in the connection socket. In terms of a particularly simple process of producing the power relay, each of the connecting conductors is pressed by the fixing limbs in particular into the connection socket.
In a simple but simultaneously expedient embodiment, each connecting conductor also forms a fixed contact of the (main) switching device that is formed within the power relay for switching the load current circuit. For this purpose, one contact end is formed on at least one of the fixing limbs of each connecting conductor and the respective connecting conductor protrudes with the contact end into the housing inner space. The contact end supports a contact element of the switching device. It is preferred that in each case both fixing limbs of the connecting conductor is provided with contact ends that protrude into the housing inner space and support in each case a contact element. Consequently, each fixed contact is formed in a redundant manner by two parallel switched part contacts. In cooperation with a contact bridge, which forms the movable contact of the main switching device and in a closed position bridges the fixed contacts in an electrically conductive manner so as to close the load current circuit, a four-point contact is consequently produced in which the load current circuit is closed by way of a series connection of two respectively parallel connected contact point pairs. In comparison to a conventional two-point contact in which both fixed contacts are formed in each case only in a simple manner, a reduced transition resistance is achieved by this four-point contact in the through-connected (electrically conductive) state of the power relay.
It is preferred that each of the two contact ends of each connecting conductor is bent away from the adjacent fixing limb in such a manner that the contact elements that are arranged in each case on the contact ends are orientated in an inclined manner with respect to the housing axis. The mutually opposite contact elements of the fixed contacts are as a consequence in particular facing one another in an inclined manner. The inclined contact ends of the connecting conductors thus correspond to a contact bridge that is formed bent in the shape of the letter V or contains bridge ends that are at least bent in an inclined manner. The inclined position of the contact ends ensures that the contact elements of all four contact ends make contact with corresponding mating contact elements of the contact bridge.
In one expedient embodiment variant, the two contact ends of each connecting conductor are bent in each case towards one another. With the central section, the fixing limbs that are bent away from the central section, and the contact ends that are in turn bent with respect to the fixing limbs, each connecting conductor thus contains in simplified manner the shape of a frame that is slotted on one side and encompasses a spatial volume on four sides.
In order on the one hand to be able to insert, in particular press in, the connecting conductor that is configured in this manner into the connection socket, but in order on the other hand to prevent a hollow space, which would otherwise impair the stability of the power relay, from remaining within the connection socket, a filler element is allocated in an advantageous embodiment to each connecting conductor, wherein the filler element is embodied as a separate part from the connection socket and completely fills or at least fills around the edge of the volume that is encompassed by the connecting conductor. The filler element is used in this case in particular also so as to stabilize the allocated connecting conductor. It is preferred that the filler element is inserted into the respective connecting conductor during the production of the power relay. The component that is formed by the connecting conductor and the filler element is then pressed into the connection socket—after the allocated connection bolt has been inserted.
The connection socket is preferably a component that is injection molded from a synthetic material.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a power relay for a vehicle, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
Mutually corresponding parts are always provided in all figures with like reference numerals.
Referring now to the figures of the drawings in detail and first, particularly to
The connection socket 3 delimits the housing 2 with respect to a connection face and the power relay 1 can be connected on a connection face to an external load current circuit. This connection side is subsequently also referred to as the upper face 5—irrespective of the actual orientation of the power relay 1 in the surrounding space. The housing pot 4 encompasses with four side walls 6 and a housing base 7 the remaining faces of an approximately cuboid-shaped housing inner space 8 (see
In order to connect two connection lines of the load current circuit that is to be connected, two solid connection bolts 10 are fixed in the connection socket 3 and the connection bolts protrude with a threaded shaft 11 outwards in each case from the housing 2. In order to connect the respective connection line of the load current circuit, an end-face cable lug of this connection line is placed on the allocated threaded shaft 11 and is contacted by the thread of a screw nut (contact nut).
In order to prevent an electrical flashover or any other short circuit between the connection bolt 10 and the connection lines of the load current circuit that are possibly fastened thereto, a partition wall 12 is formed on the outer face of the connection socket 3 and the partition wall protrudes into the intermediate space that is formed between the connection bolts 10.
In order to control the power relay 1, in other words to initiate the switching processes by which the power relay 1 is to be switched in—by virtue of producing inside the housing an electrically conductive connection between the connection bolts 10—or to be switched out—by virtue of separating this electrically conductive connection, multiple connections 13 are formed on the housing pot 4 and corresponding external signal lines can be connected in a clamped manner to the power relay 1 by way of the multiple signal connections. The signal lines are used so as to direct at least one electrical control signal to the power relay 1 and/or so as to output at least one electrical state signal by the power relay 1. As an option, at least one of the signal connections 13 is also provided so as to supply an electrical supply voltage, in particular ground. The signal connections 13 are embodied as contacts of a plug connector 14 that is formed as one piece on the wall of the housing pot 4.
The coil assembly 20 contains a contact bridge 22 that is mechanically coupled by way of a coupling rod 23 to a magnetic armature 24 of a magnetic circuit, the magnetic armature being bent in the interior of the coil assembly 20 and only visible in
The power relay 1 can be embodied in particular as a bi-stable relay. In this case, in each case one or multiple permanent magnets are arranged between the pole shoes 28 and the limb ends of the bracket 27. In the case of mono-stable variants of the power relay 1, the permanent magnets are replaced by a ferromagnetic material.
The coil assembly 20 contains furthermore a magnetic coil 29 that lies in the volume that is framed by the magnetic yoke 25. The magnetic coil 29 surrounds the core 26 of the magnetic yoke 25 in a concentric manner and for its part is framed by the bracket 27 and the pole shoes 28.
The circuit board 21 is formed from two sections 30 and 31 that are connected to one another in an articulated manner by way of a film hinge 32 and can therefore be bent out of an original planar state into the L-shaped arrangement that is illustrated in
As an alternative to the illustrated electronic construction of the power relay 1, purely electromechanical constructions of the power relay 1 are provided. In the case of these constructions, the circuit board 21 is preferably likewise provided. However, in this case, the circuit board does not support an electronic control system 33 but rather it only supports conductor tracks so as to connect the magnetic coil 29 and the possibly provided electrical functioning elements to the signal connections 13. As an alternative, the circuit board 21 is replaced by wire conductors in the case of purely electromechanical constructions of the power relay 1.
The auxiliary conductor 41 is used in this case to provide an electrical contact between the allocated connection bolt 10 and the housing inner space 8. As is particularly evident in
The filler pieces 42 are components that are injection molded. Each filler piece 42 is shaped on an outer face 56 in such a manner that it can be inserted with this outer face 56 in such a manner that it fits precisely into the volume that is encased by the associated connecting conductor 41. On an inner face 57 that lies opposite the outer face 56, a receiving arrangement 58 is formed in each of the two filler pieces 42 and so as to produce a form closure the hexagonal head 40 of the associated connection bolt 10 can be inserted into the receiving arrangement in such a manner that it fits precisely or with a small amount of play with slightly half of its circumference.
The auxiliary conductors 43 are bent sheet metal stamped parts that extend lengthwise.
In accordance with
In order to mount the power relay 1, the coil assembly 20 is clipped from below onto the previously assembled connection socket 3. For this purpose, the connection socket 3 is provided on its lower face with injection-molded snap-in hooks 61 (
The circuit board 21 is mounted after, prior to or simultaneously with clipping on the coil assembly 20. In particular, the auxiliary conductors 43 and the coil connections (not explicitly illustrated) of the magnetic coil 29 are soldered to the corresponding contact sites on the section 31 of the circuit board 21. Subsequently, the housing pot 4 is placed over the coil assembly 20 and the circuit board 21 and screwed to the connection socket 3, as a consequence of which the housing 2 is closed. In order to seal the housing 2, a casting compound 65 (
As is evident in
So as to match the arrangement of the contact elements 55, the contact bridge 22 also contains a V-shaped or roof-shaped structure with ends that are bent in an inclined manner so that the mating contact elements 60 are arranged parallel to the corresponding contact elements 55. The inclined position of the contact elements 55 and the corresponding mating contact elements 60 facilitates in this manner a good contact connection of all four contact elements 55 with the corresponding mating contact elements 60.
In order to switch off the power relay 1, the magnetic coil 29 is energized with the reversed polarity. Under the influence of the magnetic flux that is generated in the magnetic yoke 25, the holding force that is generated by the permanent magnets 29 is compensated for, as a result of which the magnetic armature 24 is separated from the core 26 by a restoring spring 67 (
In the illustrated bi-stable construction of the power relay 1, each of the two switching positions of the power relay 1 is also stable in the non-energized state of the magnetic coil 29. In this case, it is only necessary to energize the magnetic coil 29 temporarily.
A supply voltage for the electronic control system 33 is supplied to the circuit board 21 by way of the auxiliary conductor 43. Furthermore, when the power relay 1 is in the switched-on state, the electronic control system 33 uses the potential that is tapped by way of the auxiliary conductor 43 to ascertain the voltage that is dropping between the connection bolts 10 as a measurement for the current strength of the load current that is flowing through the power relay 1 in order to automatically switch off the power relay 1 in the event of an overload or short circuit.
The invention is particularly clarified with reference to the above described exemplary embodiment but nonetheless is not limited to this exemplary embodiment. On the contrary, numerous further embodiments of the invention can be derived from the claims and the above description.
The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention:
Number | Date | Country | Kind |
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10 2014 007 457 | May 2014 | DE | national |
This is a continuation application, under 35 U.S.C. § 120, of copending international application No. PCT/EP2015/001031, filed May 21, 2015, which designated the United States; this application also claims the priority, under 35 U.S.C. § 119, of German patent application No. 10 2014 007 457.9, filed May 21, 2014; the prior applications are herewith incorporated by reference in their entireties.
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Number | Date | Country |
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101113711 | Jan 2008 | CN |
102113078 | Jun 2011 | CN |
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Number | Date | Country | |
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20170069451 A1 | Mar 2017 | US |
Number | Date | Country | |
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Parent | PCT/EP2015/001031 | May 2015 | US |
Child | 15357181 | US |