EP1668660B1 - Electric starter for a motor vehicle, comprising a hybrid contactor with a solid-state relay built into the cap - Google Patents

Abstract

The invention relates to a hybrid contactor which is intended for an electric starter and which includes a solid-state relay (21) comprising a semiconductor, which is housed in a slot (40c) in the cap (40) and which is electrically connected to the first connector terminal of the battery, the second power terminal of the motor and the third control terminal of the coil. The aforementioned cap (40) is provided with (i) a boss (40a) which defines the slot (40c) and (ii) at least one metal through hole, thereby enabling the solid-state relay (21) to be connected to the coil when the cap (40) is being crimped on to the container for the electromagnet.

Description

Technical field of the invention

• un électroaimant ayant au moins une bobine de commande et un noyau mobile d'actionnement du contact mobile,
• une première borne de connexion à la batterie,
• une deuxième borne d'alimentation du moteur électrique du démarreur,
• une troisième borne de commande de la bobine,
• une paire de contacts fixes en liaison avec la première borne et la deuxième borne, et coopérant avec le contact mobile pour établir le circuit électrique de puissance à l'intérieur d'un capot,
• et un relais auxiliaire d'alimentation de la bobine pour l'excitation de l'électroaimant.

The invention relates to an electric starter of a motor vehicle equipped with a control contactor comprising:

• an electromagnet having at least one control coil and a mobile actuating core of the movable contact,
• a first connection terminal to the battery,
• a second power terminal of the electric motor of the starter,
• a third control terminal of the coil,
• a pair of fixed contacts in connection with the first terminal and the second terminal, and cooperating with the movable contact to establish the electrical power circuit inside a hood,
• and an auxiliary relay supplying the coil for energizing the electromagnet.

State of the art

The figure 1 represents the classic diagram of a motor vehicle starter. The starter 10 comprises a contactor CT intended to actuate the launcher 11 via a lever 12 pivoting, and to supply the electric motor M with the aid of a movable core 13 driving the movable contact 14 cooperating with contacts fixed 15, 16 of the main circuit of the CT contactor. The contacts 15, 16 and 14 are housed in an insulating cover 40. The magnetic attraction forces of the CT contactor are generated by a or more annular coils 17 surrounding the movable core 13, and the fixed core 43. Due to the importance of these forces, the excitation coils 17 must be supplied with a high current from the battery B. The intensity of the Inrush current is in the range of 30A to 50A at the start of operation, and that of the holding current is 8A to 10A after closing the CT contactor. The ignition key 18 which drives the starter 10 is provided with a mechanical switch sufficiently sized to support such currents.

On the figure 2 , it is known to control the starter 10 not directly by the ignition key 18, but through an electronic control unit 19, including the electronic management unit of the engine. The key 18 can be replaced by a push button or by an electronic identification card. The control signal SC of the starter from the electronic control unit 19 is a few milliamperes. It is then essential to interpose one or more power relays 20 to be able to deliver to the coils 17 the excitation current necessary for the operation of the contactor CT. This intermediate relay, besides its specific cost, requires an additional wiring circuit, additional connection members, and additional space.

Other solutions are known, in particular that consisting in implanting the auxiliary relay 20 directly on the outer casing of the starter. But this involves the use of relays able to withstand physicochemical aggression specific to the environment of the starter, including vibration, heat, humidity, dust, spray water and various liquids. These constraints lead to additional design cost of the contactor, and the size of this additional relay can interfere with the mounting of the starter on the engine.

According to the document FR 2762135 of the applicant, it is known to integrate an auxiliary electromagnetic relay in the contactor housing with lugs adapted to the connection terminals. The auxiliary relay is housed at the bottom of the contactor cover, and is fixed by the terminals of the cover of the contactor. The cover protects the relay against some of the physicochemical attacks, but the large size of the cover is a disadvantage to house such a relay manufactured specifically for this purpose.

Another solution described in the document FR 2736099 of the applicant, consists in integrating an electronic circuit in the contactor between the magnetic circuit of the electromagnet, and the cover of the contactor. The electronic circuit requires a printed circuit receiving the electronic components, and to be soldered to the outputs of the contactor coil. Connections through the hood are welded after crimping and allow power and control of the electronic circuit. This circuit can provide various functions, including those of protection of the starter against overloads, automatic shutdown, delay. This circuit also offers the advantage of being able to be controlled by very small currents, for example of the order of 5 to 20 milliamperes, which are much lower than the currents required for the control of the electromagnetic auxiliary relays as previously described. This system has a very good compatibility with the existing electronic control units on the vehicles. Its disadvantage is to have an expensive electronic circuit, and to require a contactor specific to the integration of such a system. Another solution is also known from the document FR 2,770,023 .

All these known solutions require additional wiring and electrical connections to connect the relay or electronic components to the contactor, and a large footprint.

Object of the invention

The object of the invention is to provide a motor vehicle electric starter having a hybrid contactor to reduce the size and facilitate the electrical connection.

The starter according to the invention is characterized in that the auxiliary relay is a static relay without printed circuit, housed in a cell of the cover, and being in electrical connection with the first battery connection terminal, the second motor power supply terminal, and the third coil control terminal, and that the cover is provided with at least one metal passage opening, allowing the connection of the static relay with the coil when crimping the cover on the electromagnet tank.

• montage du capot sur la bobine du contacteur avec traversée des fils d'extrémité à travers les orifices de passage métalliques,
• sertissage de la cuve du contacteur sur le capot,
• soudure des fils de bobines sur les rivets creux constituant les orifices de passage métalliques
• mise à la masse.

The cover thus equipped with the static relay according to the invention, assembles with the contactor in the same way as a conventional hood:

• mounting of the cover on the coil of the contactor through which the end wires pass through the metal through-holes,
• crimping the contactor tank on the hood,
• welding of the bobbin threads on the hollow rivets constituting the metal through-holes
• Grounding.

According to a preferred embodiment, the solid state relay comprises at least one semiconductor power component, in particular of the MOSFET or IGBT type. To avoid polarity reversal errors, the first terminal in connection with the battery is connected to the anode of a protection diode connected in series with the semiconductor component. The solid state relay cooperates with means for monitoring overheating, overcurrent and / or overvoltage to protect the semiconductor component and the coil.

• les moyens de surveillance et le composant semi-conducteur de puissance du relais statique sont logés dans un même boîtier électronique ;
• les extrémités des bobines sont reliées au capot par des connexions internes du type fiches à pression ou connecteurs auto-dénudables ;
• la mise à la masse du relais statique est réalisée au moyen d'un élément élastique, notamment un ressort sollicité en pression contre une partie du circuit magnétique de l'électroaimant ;
• l'alvéole de logement du relais statique est remplie d'une pâte d'enrobage permettant, après gélification, d'assurer l'isolation électrique, l'étanchéité et la protection mécanique dudit relais ;
• l'alvéole est obturé par un opercule pour protéger le circuit électronique du relais.

Other features may be used singly or in combination:

• the monitoring means and the semiconductor power component of the solid state relay are housed in the same electronic box;
• the ends of the coils are connected to the cover by internal connections of the type pressure plugs or self-stripping connectors;
• the static relay is grounded by means of an elastic element, in particular a spring biased against a part of the magnetic circuit of the electromagnet;
• the housing of the static relay is filled with a coating paste allowing, after gelling, to ensure the electrical isolation, sealing and mechanical protection of said relay;
• the cell is closed by a cover to protect the electronic circuit relay.

Brief description of the drawings

• la figure 1 est une vue en coupe d'un démarreur électrique équipé d'un contacteur de l'art antérieur ;
• la figure 2 montre le schéma électrique d'un démarreur de l'art antérieur dont la bobine du contacteur est alimentée par un relais de puissance intermédiaire ;
• la figure 3 représente le schéma électrique d'un démarreur équipé d'un contacteur hybride selon l'invention ;
• la figure 4 illustre un exemple de réalisation du relais statique destiné à être intégré dans le capot du contacteur hybride ;
• la figure 5 montre une vue extérieure en perspective du capot avec sa connectique ;
• la figure 6 représente une vue interne du capot après insertion du relais statique ;
• les figures 7 et 8 sont des coupes selon les lignes respectives 7-7 et 8-8 de la figure 6.

Other advantages and features will emerge more clearly from the following description of an embodiment of the invention given by way of non-limiting example, and represented in the appended drawings in which:

• the figure 1 is a sectional view of an electric starter equipped with a contactor of the prior art;
• the figure 2 shows the circuit diagram of a starter of the prior art whose contactor coil is powered by an intermediate power relay;
• the figure 3 represents the circuit diagram of a starter equipped with a hybrid contactor according to the invention;
• the figure 4 illustrates an embodiment of the solid state relay intended to be integrated in the hybrid contactor cover;
• the figure 5 shows an external perspective view of the hood with its connectors;
• the figure 6 represents an internal view of the cover after insertion of the static relay;
• the Figures 7 and 8 are cuts along the respective lines 7-7 and 8-8 of the figure 6 .

Description of a preferred embodiment

On the figure 3 , the starter 10 is controlled by a hybrid CT contactor, further comprising mechanical contacts 14, 15, 16, a static relay 21 for supplying the coil or coils 17. The static relay 21 comprises a semiconductor, for example example of the MOSFET or IGBT type, preferably with an electronic control and protection circuit integrated in the same housing. A protective diode D protects the solid state relay 21 against battery polarity inversions B.

• Une liaison L1 avec une première borne B1 du démarreur, elle-même reliée au pôle positif de la batterie B. Cette liaison L1 sert à l'alimentation du relais statique 21 et de la bobine 17 du contacteur CT lorsque le relais statique 21 est à l'état passant. La diode D de protection peut être placée dans cette liaison L1. La deuxième borne B2 d'alimentation du moteur M est au potentiel du contact fxe 16.
• Une liaison L2 avec la troisième borne de commande B3 du démarreur.
• Une liaison L3 avec la masse pour l'alimentation du semi-conducteur.
• Une liaison L4 connectée à la patte 30 pour alimenter le double bobinage d'appel et de maintien 17 du contacteur CT.

The semiconductor of the static relay 21 is integrated in the cover of the contactor CT, and has at least the following connections:

• A link L1 with a first terminal B1 of the starter, itself connected to the positive pole of the battery B. This link L1 serves to supply the static relay 21 and the coil 17 of the contactor CT when the static relay 21 is at the passing state. The protective diode D can be placed in this link L1. The second power supply terminal B2 of the motor M is at the potential of the fixed contact 16.
• A link L2 with the third control terminal B3 of the starter.
• A link L3 with the ground for the power supply of the semiconductor.
• A link L4 connected to the lug 30 for supplying the call and hold dual winding 17 of the contactor CT.

A resistor R may advantageously be arranged between the control lug of the link L2 and the ground, so as to avoid inadvertent control following magnetically or electrostatically induced voltages. The electronic control unit 19 which delivers the start signal SC, is connected by a connecting wire 29 to the terminal B3.

• Un élévateur et régulateur de tension pour assurer la polarisation de l'élément de commutation à l'état passant.
• Un capteur de température pour la protection thermique.
• Un capteur de courant pour la mesure du courant délivré aux bobines 17 d'excitation.
• Un capteur de tension pour les protection de surtension.
• Un circuit logique permettant de mettre en oeuvre les différentes protections destinées à protéger le semi-conducteur et la bobine 17.

For cost reasons, the semiconductor of the solid-state relay 21 is constituted by a standard component in the semiconductor manufacturers. Advantageously, the semiconductor of the static relay 21 comprises:

• An elevator and voltage regulator for biasing the switching element in the on state.
• A temperature sensor for thermal protection.
• A current sensor for measuring the current delivered to the excitation coils 17.
• A voltage sensor for overvoltage protection.
• A logic circuit making it possible to implement the various protections intended to protect the semiconductor and the coil 17.

On the figure 4 an example of mounting of the static relay 21 comprises a diode D whose cathode is connected to a base 21a. The anode of the diode D is connected to a connecting lug 21b. As the base 20a of the semiconductor of the solid state relay 21 serves as a current, simply mount these two components back to back, and assemble them with a rivet 26 to obtain a compact electronic block. A metal plate 28 can be interposed between the diode D and the static relay 21 to increase the thermal inertia and the cooling capacity of the electronic components. Lateral extensions of this plate, not shown, can reinforce the aforementioned thermal effects and can also be used to position the electronic block in the cover of the contactor CT. The tabs, after being cut to the desired length and arched, are used to receive the resistor R and the connecting wires 29, 30 respectively for the control signal and output to the coils 17. The wire 30 corresponds to the L4 link. The ground lug 20b of the link L3, also receives by welding, a spring 27 of steel having a surface treatment compatible with the weld. This gives a complete electronic subassembly, without printed circuit, having all its input and output terminals.

• La première borne B1 servant à recevoir le câble CB (figure 3) venant du pôle positif de la batterie B. Cette borne B1 est reliée par une connexion C1 à un rivet creux 38 faisant office de passage métallique vers l'intérieur du capot 40. Ce passage du rivet 38 reçoit l'extrémité de la patte 21 b de la diode D.
• La deuxième borne B2 destinée à recevoir la tresse d'alimentation du moteur électrique M. Elle est reliée par une connexion C2 à un rivet creux 37 faisant office de passage métallique vers l'intérieur du capot 40. Ce passage reçoit le fil de sortie de la bobine d'appel 17.
• La troisième borne B3 de commande du démarreur. Elle est reliée à une connexion C3 permettant la soudure du fil de sortie 30 du bloc électronique.
• Un rivet creux 32 recevant les fils d'entrée des bobines 17 d'appel et de maintien. Une cosse (33) permet la soudure du fil 29 du bloc électronique de la figure 4.

On the Figures 5 to 8 , the cover 40 of the contactor comprises a cell delimited by a boss 40a to serve as a housing for the electronic subassembly of the figure 4 , with a connector having the same location and the same size as the conventional contactors connectors:

• The first terminal B1 serving to receive the cable CB ( figure 3 ) This terminal B1 is connected by a connection C1 to a hollow rivet 38 acting as a metal passage towards the inside of the cover 40. This passage of the rivet 38 receives the end of the tab 21 b of the diode D.
• The second terminal B2 intended to receive the power supply braid of the electric motor M. It is connected by a connection C2 to a hollow rivet 37 acting as a metal passage towards the inside of the cover 40. This passage receives the lead of the call coil 17.
• The third control terminal B3 of the starter. It is connected to a connection C3 allowing the welding of the output wire 30 of the electronic block.
• A hollow rivet 32 receiving the input son of the coil 17 call and hold. A lug (33) allows the welding of the wire 29 of the electronic block of the figure 4 .

A boss 40a of the cover 40 defines an internal housing for receiving the static relay 21. Each of the two connecting son 29 and 30 passes through the cover 40 by holes 40b whose diameter is slightly greater than that of the son. The spring 27 connected to the ground lug is guided in a cell 40c of the cover 40, and protrudes a few millimeters from the bearing face of the cover. The cell 40c is filled with a coating paste 39 which, after gelation, provides electrical isolation, sealing and mechanical protection of the electronic block. On the figure 6 , we notice the fixed contacts 15, 16 and the hexagonal head of the terminal B3,

It is also possible to protect the relay component 21 by a cover closing the opening of the cell 40c.

• Montage du capot 40 sur la bobine 17, les fils d'extrémité passant par les rivets creux 32, 37 et 38.
• Sertissage de la cuve du contacteur CT sur le capot 40.
• Soudure des fils de bobines 17 sur les rivets creux 32, 37.

The hood 40 thus prepared assembles in the same way as a conventional hood:

• Mounting the cover 40 on the coil 17, the end son passing through the hollow rivets 32, 37 and 38.
• Crimping of the tank of the contactor CT on the cover 40.
• Welding of the coil wires 17 on the hollow rivets 32, 37.

During crimping, the cover 40 is pressed against the fixed core 43 (see figure 1 ) of the magnetic circuit of the contactor CT. The spring 27 is therefore compressed by the magnetic circuit, and thus ensures electrical ground continuity with the electronic circuit of the static relay 21, despite the dimensional variations that may occur in the life of the starter (differential expansion, vibration wear). , ....). The spring 27 is a compression spring, or any other elastic means.

The CT contactor according to the invention retains a size similar to conventional contactors. The preparation of the cover 40 is simple and does not require specific processes or investments other than small tooling for soldering iron. This results in a low cost of this hybrid contactor.

Claims (10)

1. Electric stator for a motor véhicle equipped with a contacted comprising:

   - an electromagnet which has at least one control coil (17) and a mobile core (13) for activation of the mobile contact (14);

   - a first terminal (B1) for connection to the battery (B);

   - a second terminal (B2) for supply of the electric motor (M) of the starter;

   - a third terminal (B3) for control of the coil (17);

   - a pair of fixed contacts (15, 16) which are connected to the first terminal (B1) and the second terminal (B2), and co-operate with the mobile contact (14) in order to establish the electric power circuit inside a cover (40); and

   - an auxiliary to supply the coil (17) for excitation of the electromagnet, the auxiliary relay being a static relay (21) without a printed circuit, which is accommodated in a receptacle of the cover, and is connected electrically to the first terminal (B1) for connection to the battery (B), the second terminal (B2) for supply of the motor (M), and the third terminal (B3) for control of the coil (17), and characterised in that the cover (40) is provided with at least one metal passage aperture (32) which permits connection of the static relay (21) to the coil (17) during fastening of the cover (40) onto the body of the electromagnet, and in the passage aperture of the cover (40) comprises a hollow rivet (32) which allows the ends of the wires of the coils (17) to be welded on the exterior of the cover (40).
2. Starter according to claim 1, characterised in that the static relay (21) comprises at least one semiconductor power component, in particular of the MOSFET or IGBT type.
3. Starter to claim 2, characterised in that the first first terminal (B1) is connected to the anode of a protection diode (D) which is fitted in series with the semiconductor component.
4. Stater according to claim 2, characterised in that the relay (21) co-operates with means for monotoring of heating, excess current and/or excess voltage, in order to protect the semiconductor component and the coil (17).
5. Starter according to claim 4, characterised in that the monitoring means and the semiconductor power component of the static relay (21) are accommodated in a single electronic box.
6. Starter according to claim 1, characterised in first the ends of the coils (17) are connected to the cover (40) by means of internal connections (C2, C3, 33) of the pressure plug or self-cleaning connector type.
7. Starter according to claim 2, characterised in that the static relay (21) in earthed by means of a resilient element, and in particular a spring (27) which present against a part of the magnetic circuit of the electromagnet.
8. Starter according to claim 1, characterised in that the receptacle (40c) for accommodation of the static relay (21) is filled with a coating paste (39) which, after gelling has taken place, makes it possible to assure the electrical insulation, the sealing and the mechanical protection of the said relay.
9. Starter according to claim 1, characterised in that the receptacle (40c) is closed by means of a cap in order to protect the electronic circuit of the relay (21).
10. Starter according to any one of the preceding claims, characterised in that the receptacle is delimited by a boss (40a) of the cover (40).

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