Abstract

In order to meet the requirement of electric vehicle to the high power direct current (dc) contactor, this paper investigates the structural optimization design method of actuator and proposes a novel energy-saving control strategy. The operating principles and structural design processes of electromagnetic actuator are demonstrated in detail. The influences of the electromagnetic parameters including the coil skeleton, the wire diameter and the spring pre-pressure are compared and analyzed and then optimized to obtain the optimal combination by orthogonal test method. A new energy-saving control strategy is proposed by adopting pulse width modulation technology to control the holding current at a smaller value after the movable iron reaches to the closed position. A co-simulation coupling magnetic field, machinery and circuit is carried out with the Maxwell and Circuit Editor software. A prototype of 600 A/750 V dc contactor is manufactured according to the optimized parameters. The experimental results validate the effectiveness of the structural optimization design method and the proposed energy-saving control strategy.

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