Patent Publication Number: US-11657996-B2

Title: Relay contactor dual linear actuator module system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a division of U.S. application Ser. No. 16/270,364 filed Feb. 7, 2019, the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     The following description relates to relay contactors and, more particularly, to a relay contactor with a dual linear actuator module system. 
     The present standard for high amperage relays or contactors is to have a single linear motor actuator with an armature mechanically connected to movable electrical contacts by way of a shaft assembly. The armature and the shaft assembly are supported only on the side of the motor and the movable electrical contacts are provided on a free, unsupported end of the shaft assembly. 
     The single linear motor actuator includes a stator with a coil winding or windings. The armature passes through the single linear motor actuator structure on bushings and with linkages, including springs and other similar features, on the end of the shaft assembly, which is provided as a cantilever structure, and which is connected to the movable electrical contacts. 
     As amperage increases in power levels to 1000&#39;s of amperes at steady state (the present aerospace production component high amperage is around 450A), the electrical connections have to significantly increase in size in order to handle the amperage power flow. As such, the electrical movable contact masses (i.e., combined mechanical and electrical elements are increased. With the high mass electrical movable contacts provided on the free end of a shaft assembly, the armature, the shaft assembly and the electrical movable contacts become mechanically difficult to hold in vibratory modes and to move to achieve high speed switching. 
     BRIEF DESCRIPTION 
     According to an aspect of the disclosure, a relay contactor is provided and includes input and output leads, a shaft assembly, an actuator and first and second bearing assemblies. The shaft assembly includes a shaft, a plate disposed on the shaft and an elastic element. The shaft and the plate are movable between an open position at which the plate is displaced from the input and output leads and a closed position at which the plate contacts the input and output leads. The actuator is coupled to the shaft at a first side of the plate and is configured to selectively move the shaft and the plate into the closed position in opposition to bias applied by the elastic element. The first and second bearing assemblies are disposed to movably support the shaft at the first side and at a second side of the plate, respectively. 
     In accordance with additional or alternative embodiments, a housing houses the input and output leads, the shaft assembly, the actuator and the first and second bearing assemblies. 
     In accordance with additional or alternative embodiments, the input and output leads include first and second conductive elements, respectively, and the plate includes third and fourth conductive elements that are disposed to contact the first and second conductive elements, respectively, when the shaft and the plate are moved into the closed position. 
     In accordance with additional or alternative embodiments, the shaft extends through a space defined between the input and output leads, the actuator and the first bearing assembly are disposed on a first side of the input and output leads and the plate and the second bearing assembly are disposed on a second side of the input and output leads. 
     In accordance with additional or alternative embodiments, the elastic element is anchored at opposite ends thereof to the actuator and the shaft or the plate. 
     In accordance with additional or alternative embodiments, the actuator includes a linear actuator. 
     In accordance with additional or alternative embodiments, the actuator includes an armature through which the shaft extends, coils surrounding the armature and an actuator housing supportive of the first bearing assembly and configured to house the armature and the coils. 
     According to an aspect of the disclosure, a relay contactor is provided and includes input and output leads, a shaft assembly, first and second actuators and first and second bearing assemblies. The shaft assembly includes a shaft, a plate disposed on the shaft and an elastic element. The shaft and the plate are movable between an open position at which the plate is displaced from the input and output leads and a closed position at which the plate contacts the input and output leads. The first and second actuators are coupled to the shaft at first and second sides of the plate, respectively, and are configured to selectively move the shaft and the plate into the closed position in opposition to bias applied by the elastic element. The first and second bearing assemblies are disposed to movably support the shaft at the first and second sides of the plate, respectively. 
     In accordance with additional or alternative embodiments, a housing houses the input and output leads, the shaft assembly, the first and second actuators and the first and second bearing assemblies. 
     In accordance with additional or alternative embodiments, the input and output leads include first and second conductive elements, respectively, and the plate includes third and fourth conductive elements that are disposed to contact the first and second conductive elements, respectively, when the shaft and the plate are moved into the closed position. 
     In accordance with additional or alternative embodiments, the first, second, third and fourth conductive elements are disposed at an angle. 
     In accordance with additional or alternative embodiments, the first, second, third and fourth conductive elements are hemispherical. 
     In accordance with additional or alternative embodiments, the shaft extends through a space defined between the input and output leads, the first actuator and the first bearing assembly are disposed on a first side of the input and output leads and the plate, the second actuator and the second bearing assembly are disposed on a second side of the input and output leads. 
     In accordance with additional or alternative embodiments, the elastic element includes a first elastic element anchored at opposite ends thereof to the first actuator and the shaft and a second elastic element anchored at opposite ends thereof to the second actuator and the shaft or the plate. 
     In accordance with additional or alternative embodiments, the first and second actuators are independently or dependently operable. 
     In accordance with additional or alternative embodiments, the first and second actuators each include a linear actuator. 
     In accordance with additional or alternative embodiments, the first actuator includes a first armature through which the shaft extends, first coils surrounding the first armature and a first actuator housing supportive of the first bearing assembly and configured to house the first armature and the first coils and the second actuator includes a second armature through which the shaft extends, second coils surrounding the second armature and a second actuator housing supportive of the second bearing assembly and configured to house the second armature and the second coils. 
     According to another aspect of the disclosure, a relay contactor is provided and includes first and second pairs of input and output leads, a shaft assembly, first and second actuators and first and second bearing assemblies. The shaft assembly includes a shaft, a plate disposed on the shaft and an elastic element. The shaft and the plate are movable between first and second positions at which the plate is positioned at first and second positions with respect to the first and second pairs of the input and output leads, respectively. The first and second actuators are coupled to the shaft at first and second sides of the plate, respectively, and are configured to selectively move the shaft and the plate between the first and second positions in opposition to bias applied by the elastic element. The first and second bearing assemblies are disposed to movably support the shaft at the first and second sides of the plate, respectively. 
     In accordance with additional or alternative embodiments, the first position is characterized in that the plate is displaced from the first pair of the input and output leads and in contact with the second pair of the input and output leads and the second position is characterized in that the plate is displaced from the second pair of the input and output leads and in contact with the first pair of the input and output leads. 
     In accordance with additional or alternative embodiments, the first position is characterized in that the plate is displaced from the first and second pairs of the input and output leads and the second position is characterized in that the plate is in contact with the first and second pairs of the input and output leads. 
     These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The subject matter, which is regarded as the disclosure, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the disclosure are apparent from the following detailed description taken in conjunction with the accompanying drawings in which: 
         FIG.  1    is a schematic view of an aircraft power distribution system with a generator and a module with an integrated relay contactor; 
         FIG.  2    is a top elevation view of a portion of a primary power distribution board shown in  FIG.  1    with an integrated relay contactor; 
         FIG.  3    is a side schematic illustration of a relay contactor for use with the aircraft distribution system of  FIG.  1    and the primary power distribution board of  FIG.  2    in accordance with embodiments; 
         FIG.  4    is a side schematic illustration of a relay contactor for use with the aircraft distribution system of  FIG.  1    and the primary power distribution board of  FIG.  2    in accordance with alternative embodiments; 
         FIG.  5    is a side schematic illustration of a relay contactor for use with the aircraft distribution system of  FIG.  1    and the primary power distribution board of  FIG.  2    in accordance with alternative embodiments; and 
         FIG.  6    is an axial schematic illustration of a relay contactor for use with the aircraft distribution system of  FIG.  1    and the primary power distribution board of  FIG.  2    in accordance with alternative embodiments. 
     
    
    
     These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings. 
     DETAILED DESCRIPTION 
     While a single linear actuator motor is now provided as an industry standard, it is characterized as having movable electrical contacts at a free, unsupported end of a shaft with high masses to handle the high power requirements of aerospace applications. This leads to the armature and the shaft being difficult to move during high-speed switching and to the armature and shaft having a tendency to vibrate. Thus, as will be described below, a linear motor design is provided in which the armature is supported on both ends of the shaft. In an exemplary case, a contactor or a large relay actuator system is provided with moveable electrical contacts between two or dual separate linear motor coil actuator assemblies, so that the actuator armature and shaft system is mechanically supported on both ends. This dual motor actuator configuration can allow the armature, springs, insulators and sliding bearings to be configured to optimize the movable structure for large electrical conductors (high amperage) in high vibration environments. 
     With reference to  FIGS.  1  and  2   , an aircraft power distribution system  10  includes a primary power distribution box  12  that receives power from a generator  14  through power leads  28 . The primary power distribution box  12  provides power through supply leads  46  to a secondary power distribution box  16 , which distributes power to first and second loads  18  and  20 , for example. 
     The primary power distribution box  12  includes a board  24  that is arranged within a housing  22 . The board  24  supports plug-in pins  26  that are connected to the power leads  28 . Mechanical contactors  30  act as switches to selectively electrically connect the power leads  28  to the supply leads  46 . Circuit breakers  48  are supported by the board  24  to selectively disconnect the supply leads  46  from power in response to an overload. The board  24  also supports a connector  32  that communicates with a control  34  through a harness  36 . The control  34  provides commands to the board  24  and/or a secondary circuit board  38  and receives feedback regarding various functions related to the aircraft power distribution system  10 . The secondary circuit board  38  is mounted on the board  24  and is connected to the connector  32  and contactors  30  through connections  39 . The secondary circuit board  38  includes protection circuitry  40  and secondary power distribution circuitry  42 . The protection circuitry  40  monitors the current provided by the generator  14 , for example, to prevent the secondary power distribution box  16  from exposure to undesired currents. The secondary power distribution circuitry  42  commands the contactors  30  between open and closed positions. 
     The contactors  30  are illustrated with control traces  50  and power traces  66  which are supported by the board  24  and connected to the secondary circuit board  38  and secondary power distribution connectors  44 , respectively. The board  24  is relatively thick to accommodate the current flowing through the power traces  66 . The contactors  30  are connected to the plug-in pins  26  by first bands  52  and second bands (not shown). The power traces  66  are selectively provided with power when a plate  60  is moved into a closed position connecting first and second contacts. The plate  60  is moved between open and closed positions by a linear motor and shaft assembly to be described below. The linear motor and shaft assembly is mounted to the board  24  and is commanded by the secondary power distribution circuitry  42  through the control traces  50 . The current flowing through the power traces  66  is monitored by the protection circuitry  42  through the control traces  50 . 
     With reference to  FIG.  3   , a relay contactor  301  is provided for use in or as the contactors  30  of  FIGS.  1  and  2   . As shown in  FIG.  3   , the relay contactor  301  includes an input lead  310  that is configured to carry current supplied from the power leads  28  of  FIG.  2   , an output lead  320  that is configured to carry current to the power traces  66  of  FIG.  2   , a shaft assembly  330 , first and second actuators  340  and  350  and first and second bearing assemblies  360  and  370 . The relay contactor  301  may further include a housing  380 , which is configured to house respectively portions of the input lead  310  and the output lead  320 , the shaft assembly  330 , the first and second actuators  340  and  350  and the first and second bearing assemblies  360  and  370 . 
     The input lead  310  includes an electrically conductive body that extends to an exterior of the housing  380  and a first electrical contact  311  at a proximal end of the electrically conductive body within the housing  380 . The output lead  320  includes an electrically conductive body that extends to an exterior of the housing  380  and a second electrical contact  321  at a proximal end of the electrically conductive body within the housing  380 . 
     The shaft assembly  330  includes a shaft  331  that can span the housing  380 , a plate  332  that is disposed on the shaft  331 , shaft isolation sleeve  3320  that is interposed between the shaft  331  and the plate  332  and an elastic element  333 . The plate  332  includes an electrically conductive body and third and fourth electrical contacts  334  and  335  at opposite ends of the electrically conductive body. The shaft  331  and the plate  332  are movable together along a longitudinal axis of the shaft  331  between an open position and a closed position. At the open position, the third and fourth electrical contacts  334  and  335  of the plate  332  are displaced from electrical contact with the first electrical contact  311  of the input lead  310  and from electrical contact with second electrical contact  321  of the output lead  320 , respectively, such that the input lead  310  and the output lead  320  are not electrically communicative with one another (i.e., current from the power leads  28  is not transmitted to the power traces  66 ). At the closed position, the third and fourth electrical contacts  334  and  335  of the plate  332  are disposed in electrical contact with the first electrical contact  311  of the input lead  310  and in electrical contact with second electrical contact  321  of the output lead  320 , respectively, such that the input lead  310  and the output lead  320  are electrically communicative (i.e., current from the power leads  28  is transmitted to the power traces  66 ). The shaft isolation sleeve  3320  serves to electrically insulate or isolate the plate  332  from the shaft  331 . The elastic element  333  can be disposed to apply a bias to the shaft  331  and the plate  332  which urges the shaft  331  and the plate  332  toward assumption of the open position. 
     In accordance with embodiments, the first and second electrical contacts  311  and  321  and the third and fourth electrical contacts  334  and  335  can be hemispherical or otherwise curved, flat-faced or otherwise configured to form reliable electrical contacts. 
     The first actuator  340  is coupled to the shaft  331  at a first side  3321  of the plate  332 . The second actuator  350  is coupled to the shaft  331  at a second side  3322  of the plate  332 . The first and second actuators  340  and  350  are configured to be independently or dependently operable so as to selectively move the shaft  331  and the plate  332  into the closed position in opposition to bias applied by the elastic element  333 . 
     In accordance with embodiments, the first actuator  340  may include or be provided as a linear actuator. In this or other cases, the first actuator  340  may include a first armature  341  through which the shaft  331  extends, first coils  342  surrounding the first armature  341  and a first actuator housing  343  that is supportive of the first bearing assembly  360  and configured to house the first armature  341  and the first coils  342 . In accordance with similar embodiments, the second actuator  350  may include or be provided as a linear actuator. In this or other cases, the second actuator  350  may include a second armature  351  through which the shaft  331  extends, second coils  352  surrounding the second armature  351  and a second actuator housing  353  that is supportive of the second bearing assembly  370  and configured to house the second armature  351  and the second coils  352 . 
     Electrical insulation (isolation) of the plate  332  from the shaft assembly  330  can be achieved, for example, by material selection of the shaft isolation sleeve  3320 . 
     With the first and second actuators  340  and  350  configured as described above, the first bearing assembly  360  is disposed to movably support the shaft  331  at the first side  3321  of the plate  332  and the second bearing assembly  370  is disposed to movably support the  331  shaft at the second side  3322  of the plate  332 . The first bearing assembly  360  can include bearing elements that are secured in the first actuator housing  343  to permit movements of the shaft  331  along the longitudinal axis of the shaft  331  and the second bearing assembly can include bearing elements that are secured in the second actuator housing  353  to permit the movement of the shaft along the longitudinal axis of the shaft  331 . 
     As shown in  FIG.  3   , the proximal ends of the electrically conductive bodies of the input and output leads  310  and  320  define or form a space or opening through which the shaft  331  extends, the first actuator  340  and the first bearing assembly  360  are disposed on a first side of the input and output leads  310  and  320  and the plate  332 , the second actuator  350  and the second bearing assembly  370  are disposed on a second side of the input and output leads  310  and  320 . In addition, as shown in  FIG.  3   , the elastic element  333  can include a first elastic element  3331 , which is anchored at opposite ends thereof to the first actuator  340  and the shaft  331 , and a second elastic element  3332 , which is anchored at opposite ends thereof to the second actuator  350  and the shaft  331  or the plate  332 . 
     During an operation of the relay contactor  301 , the first and second coils  342  and  352  of the first and second actuators  340  and  350  can be independently or dependently energized to thus generate magnetic flux which brings the shaft  331  and the plate  332  into the closed position in opposition to the bias applied by the elastic element  333 . To this end, the first and second coils  342  and  352  can be disposed in parallel or in series within an energization circuit and the elastic element  333  can be optimized for use with the various components of the first and second actuators  340  and  350 . 
     Although  FIG.  3    has been illustrated with first and second actuators  340  and  350 , it is to be understood that this is not required. For example, certain embodiments exist in which the second actuator  350  is not included in the relay contactor  301 . In these or other cases, the second bearing assembly  370  could include bearing elements that are secured to the housing  380  at the second side  3322  of the plate  332  and the second elastic element  3332  could be anchored at the opposite ends thereof to the housing  380  and the shaft  331  or the plate  332 . 
     The elastic elements  3331  and  3332  can be electrically isolated from the plate  332  by the shaft isolation sleeve  3320 . 
     With reference to  FIG.  4   , the relay contactor  301  is illustrated in accordance with alternative embodiments in which the first and second electrical contacts  311  and  321  and the third and fourth electrical contacts  334  and  335  are disposed at an angle with respect to the longitudinal axis of the shaft  331 . 
     With reference to  FIGS.  5  and  6   , the relay contactor  301  is illustrated in accordance with alternative embodiments in which the input and output leads  310  and  320  are provided as first and second pairs of input and output leads  310  and  320  and  310 ′ and  320 ′ and the shaft  331  and the plate  332  are movable between first and second positions at which the plate  332  is positioned at first and second positions with respect to the first and second pairs of the input and output leads  310  and  320  and  310 ′ and  320 ′. As shown in  FIG.  5   , the first position is characterized in that the plate  332 , which has additional third and fourth electrical contacts  334 ′ and  335 ′, is displaced from the first pair of the input and output leads  310  and  320  and in electrical contact with the second pair of the input and output leads  310 ′ and  320 ′ and the second position is characterized in that the plate  332  is displaced from the second pair of the input and output leads  310 ′ and  320 ′ and in electrical contact with the first pair of the input and output leads  310  and  320  (i.e., one of the first and second pairs of input and output leads  310  and  320  is normally open and the other of the first and second pairs of input and output leads  310 ′ and  320 ′ is normally closed). As shown in  FIG.  6   , the first position is characterized in that the plate  332  is displaced from the first and second pairs of the input and output leads  310  and  320  and  310 ′ and  320 ′ and the second position is characterized in that the plate  332  is in electrical contact with the first and second pairs of the input and output leads  310  and  320  and  310 ′ and  320 ′ (i.e., both the first and second pairs of input and output leads  310  and  320  and  310 ′ and  320 ′ are either normally open or closed). 
     Technical effects and benefits of the features described herein are the provision of a dual linear motor actuator with a compact size, capacity to handle heavy movable electrical contracts for small motor assemblies and a spring system optimized for an armature structure, electrical conductive material mass and dual coil (motor) power. 
     While the disclosure is provided in detail in connection with only a limited number of embodiments, it should be readily understood that the disclosure is not limited to such disclosed embodiments. Rather, the disclosure can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the disclosure. Additionally, while various embodiments of the disclosure have been described, it is to be understood that the exemplary embodiment(s) may include only some of the described exemplary aspects. Accordingly, the disclosure is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.