System, method, and apparatus for power distribution in an electric mobile application using a combined breaker and relay
A mobile application including a motive power circuit including a power storage device and an electrical load, where the power storage device and the electrical load are selectively electrically coupled through a power bus; a power distribution unit (PDU) electrically interposed between the power storage device and the electrical load, wherein the PDU comprises a breaker/relay including: a fixed contact electrically coupled to the power bus; a movable contact selectively electrically coupled to the fixed contact; an armature operationally coupled to the movable contact; a first biasing member biasing the armature; a contact force spring operationally interposed between the armature and the movable contact; and a means for adjusting an opening velocity of the moveable contact during a run-time operation of the power bus, wherein the opening velocity comprises an initial velocity of the moveable contact away from the fixed contact in response to a physical opening response.
1. A mobile application, comprising:
a motive power circuit, the motive power circuit comprising a power storage device and an electrical load, wherein the power storage device and the electrical load are selectively electrically coupled through a power bus; and
a power distribution unit (PDU) electrically interposed between the power storage device and the electrical load, wherein the PDU comprises a breaker/relay positioned on one of a high side and a low side of the power storage device; wherein the breaker/relay comprises:
a fixed contact electrically coupled to the power bus;
a movable contact selectively electrically coupled to the fixed contact, and wherein the movable contact allows power flow through the power bus when electrically coupled to the fixed contact, and prevents power flow through the power bus when not electrically coupled to the fixed contact, wherein the movable contact comprises a moving mass value;
wherein the fixed contact and the movable contact comprise a contactor area when electrically coupled;
an armature operationally coupled to the movable contact, such that the armature in a first position prevents electrical coupling between the movable contact and the fixed contact, and the armature in a second position allows electrical coupling between the movable contact and the fixed contact;
a first biasing member biasing the armature into one of the first position or the second position;
a contact force spring operationally interposed between the armature and the movable contact, such that in response to the armature being in the second position, the contact force spring is at least partially compressed; and
a means for adjusting an opening velocity of the movable contact during a runtime operation of the power bus, wherein the opening velocity comprises an initial velocity of the movable contact away from the fixed contact in response to a physical opening response.
2. The mobile application of claim 1 , wherein the means for adjusting the opening velocity of the movable contact comprise a contact area, a contact force, and a mass value of the movable contact configured to move the movable contact away from the first position at the initial velocity in response to a current value exceeding a threshold current value.
3. The mobile application of claim 1 , further comprising:
a standard on/off circuit having at least two states, wherein the standard on/off circuit in a first state provides an actuating signal and in a second state prevents the actuating signal; and
a current response circuit structured to determine a current in the power bus, and further structured to block the actuating signal of the standard on/off circuit in response to the current in the power bus indicating a high current value; and
wherein the armature is responsive to the actuating signal to electrically couple the movable contact to the fixed contact.
4. The mobile application of claim 1 , wherein the breaker/relay further comprises an auxiliary off circuit structured to interpret an auxiliary command, and further structured to block an actuating signal of a standard on/off circuit in response to the auxiliary command indicating that the movable contact should not be electrically coupled to the fixed contact.
5. The mobile application of claim 4 , wherein the auxiliary command comprises at least one command selected from the commands consisting of: an emergency shutdown command, a service event indicator, a maintenance event indicator, an accident indicator, a vehicle controller request, and a device protection request.
6. The mobile application of claim 4 , wherein the standard on/off circuit comprises one of a keyswitch voltage and a keyswitch indicator.
7. The mobile application of claim 1 , wherein the contact force spring is configured such that a Lorentz force acting between the fixed contact and the movable contact further compresses the contact force spring in response to a selected current value.
8. The mobile application of claim 1 , wherein the movable contact comprises a body extending away from the fixed contact, wherein the body of the movable contact is disposed within a plurality of splitter plates, and wherein the plurality of splitter plates are at least partially disposed within a permanent magnet.
9. The mobile application of claim 1 , further comprising a charging circuit, and wherein the breaker/relay is further positioned on the charging circuit.
10. The mobile application of claim 9 , wherein the charging circuit comprises a quick charging circuit having a higher current throughput value than a rated current for operations of the electrical load.
11. The mobile application of claim 10 , further comprising:
a standard on/off circuit having at least two states, wherein the standard on/off circuit in a first state provides an actuating signal and in a second state prevents the actuating signal; and
a current response circuit structured to determine a current in the power bus, and further structured to block the actuating signal of the standard on/off circuit in response to the current in the power bus indicating a high current value;
wherein the current response circuit is further structured to utilize a first threshold current value for the high current value in response to the motive power circuit powering the electrical load, and to utilize a second threshold current value for the high current value in response to the charging circuit coupled to a quick charging device; and
wherein the armature is responsive to the actuating signal to electrically couple the movable contact to the fixed contact.
12. The mobile application of claim 1 , wherein the electrical load comprises at least one load selected from the loads consisting of: a motive power load, a regeneration load, a power take-off load, an auxiliary device load, and an accessory device load.
13. The mobile application of claim 1 , further comprising a second breaker/relay disposed on the other of the high side or the low side of the power storage device.
14. The mobile application of claim 1 , wherein the power storage device comprises a rechargeable device.
15. The mobile application of claim 1 , wherein the power storage device comprises at least one device selected from the devices consisting of: a battery, a capacitor, and a fuel cell.
16. A breaker/relay, comprising:
a fixed contact electrically coupled to a power bus;
a movable contact selectively electrically coupled to the fixed contact, and wherein the movable contact allows power flow through the power bus when electrically coupled to the fixed contact, and prevents power flow through the power bus when not electrically coupled to the fixed contact, wherein the movable contact comprises a moving mass value;
wherein the fixed contact and the movable contact comprise a contactor area when electrically coupled;
an armature operationally coupled to the movable contact, such that the armature in a first position prevents electrical coupling between the movable contact and the fixed contact, and the armature in a second position allows electrical coupling between the movable contact and the fixed contact;
a first biasing member biasing the armature into one of the first position or the second position;
a contact force spring operationally interposed between the armature and the movable contact, such that in response to the armature being in the second position, the contact force spring is at least partially compressed; and
a physical response opening adjustment circuit for adjusting an opening velocity of the movable contact during a run-time operation of the power bus, wherein the opening velocity comprises an initial velocity of the movable contact away from the fixed contact in response to a physical opening response.
17. The breaker/relay of claim 16 , further comprising an auxiliary off circuit structured to interpret an auxiliary command, and further structured to block an actuating signal of a standard on/off circuit in response to the auxiliary command indicating that the movable contact should not be electrically coupled to the fixed contact.
18. The breaker/relay of claim 17 , wherein the auxiliary command comprises at least one command selected from the commands consisting of: an emergency shutdown command, a service event indicator, a maintenance event indicator, an accident indicator, a vehicle controller request, and a device protection request.
19. The breaker/relay of claim 17 , wherein the standard on/off circuit comprises one of a keyswitch voltage and a keyswitch indicator.