# US 11,114,840 B2 · System, method, and apparatus for power distribution in an electric mobile application using a combined breaker and relay

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- Number: US 11,114,840 B2
- Document ID: US11114840B2
- Status: Granted
- Kind: B2
- Application number: 16/712,692
- Filed: 2019-12-12
- Published: 2020-04-16
- Granted: 2021-09-07
- Earliest claimed: 2017-11-08
- Assignees: Eaton Intelligent Power Limited
- Applicants: Eaton Intelligent Power Limited
- Inventors: Brandon William Fisher
- Web page: https://patentgrep.com/patent/US11114840B2

## CPC

- B60L 3/04: Cutting off the power supply under fault conditions (protective devices and circuit arrangements in general H01H; H02H)
- H02H 7/085: against excessive load {(H02H6/00 takes precedence)}
- B60L 3/0023: {Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train}
- H01H 9/106: {fuse and switch being connected in parallel}
- H01H 50/12: Ventilating; Cooling; Heating (for operating electrothermal relays H01H61/013)
- H01H 71/32: having permanently magnetised part
- H01H 89/00: Combinations of two or more different basic types of electric switches, relays, selectors and emergency protective devices, not covered by any single one of the other main groups of this subclass
- H02H 1/0007: {concerning the detecting means (in general G01R or other subclasses of G01; reed switches H01H71/2445)}
- H02H 3/087: for DC applications
- H02M 7/003: {Constructional details, e.g. physical layout, assembly, wiring or busbar connections}
- H02P 29/68: based on the temperature of a drive component or a semiconductor component
- H05K 7/2089: {for power electronics, e.g. for inverters for controlling motor}
- B60K 6/22: characterised by apparatus, components or means specially adapted for HEVs
- B60Y 2200/91: Electric vehicles
- B60Y 2200/92: Hybrid vehicles
- H01H 9/52: Cooling of switch parts (cooling of contacts H01H1/62)
- H01H 50/14: Terminal arrangements {(for coils H01H50/443)}
- H01H 50/54: Contact arrangements
- H01H 50/64: Driving arrangements between movable part of magnetic circuit and contact (structurally associated with contact spring sets H01H50/58)
- Y02T 10/64: Electric machine technologies in electromobility
- Y02T 90/16: Information or communication technologies improving the operation of electric vehicles
- B60L: PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES (arrangements or mounting of electrical propulsion units or of plural diverse prime-movers for mutual or common propulsion in vehicles B60K1/00, B60K6/20; arrangements or mounting of electrical gearing in vehicles B60K17/12, B60K17/14; preventing wheel slip by reducing power in rail vehicles B61C15/08; dynamo-electric machines H02K; control or regulation of electric motors H02P); SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES (electric coupling devices combined with mechanical couplings of vehicles B60D1/64; electric heating for vehicles B60H1/00); ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL (control or regulation of electric motors H02P); MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- H02H: EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS (indicating or signalling undesired working conditions G01R, e.g. G01R31/00, G08B; locating faults along lines G01R31/08; emergency protective devices H01H)
- H01H: ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES (contact cables H01B7/10; electrolytic self-interrupters H01G9/18; emergency protective circuit arrangements H02H; switching by electronic means without contact-making H03K17/00)
- H02M: APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF (transformers H01F; dynamo-electric converters H02K47/00; controlling transformers, reactors or choke coils, control or regulation of electric motors, generators or dynamo-electric converters H02P)
- H02P: CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- B60K: ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60Y: INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

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.

## Claims

### Claim 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.

### Claim 2 (depends on 1)

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.

### Claim 3 (depends on 1)

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.

### Claim 4 (depends on 1)

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.

### Claim 5 (depends on 4)

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.

### Claim 6 (depends on 4)

The mobile application of claim 4, wherein the standard on/off circuit comprises one of a keyswitch voltage and a keyswitch indicator.

### Claim 7 (depends on 1)

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.

### Claim 8 (depends on 1)

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.

### Claim 9 (depends on 1)

The mobile application of claim 1, further comprising a charging circuit, and wherein the breaker/relay is further positioned on the charging circuit.

### Claim 10 (depends on 9)

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.

### Claim 11 (depends on 10)

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.

### Claim 12 (depends on 1)

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.

### Claim 13 (depends on 1)

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.

### Claim 14 (depends on 1)

The mobile application of claim 1, wherein the power storage device comprises a rechargeable device.

### Claim 15 (depends on 1)

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.

### Claim 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.

### Claim 17 (depends on 16)

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.

### Claim 18 (depends on 17)

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.

### Claim 19 (depends on 17)

The breaker/relay of claim 17, wherein the standard on/off circuit comprises one of a keyswitch voltage and a keyswitch indicator.