Research And Application Of Energy Saver IC For AC Contactor

AC contactor is common electrical equipment in modern industrial production, and it is an electronic switch that has a large capacity and a wide range. The working principle is that AC current flows through the coil to produce a magnetic field and electromagnetic attraction, so the contact terminals close to operate electrical device load (electrical motor)with large current. According to the working principle of AC contactor, when at the state of close, the AC current flowing through the coil of contactor will consume probably tens of watts of energy. in our country, because the number of medium and large-capacity contactors is very large, the total power consumption is huge.One of the energy-saving technology for this contactor enables the DC energy in the economy mode operation, not only save energy, significantly reduce noise and temperature, but also extends the life of AC contactor. The Energy-saving technology for AC contactor has a very large economic and social benefit. At present, there are varieties of energy-saving technologies for AC contactor in the market. But there are many disadvantages that are not well resolved. So it limits the promotion of energy-saving technology, and the utility rate of energy-saving technology for AC contactor is not high.In this paper, based on the research of AC contactor producers and users nationwide, we design an ASIC ZDLX for energy saver for AC contactors, which is using the technology by changing the duty cycle itself. This technology has many advantages like small chip volume, low cost, good energy-saving effect, easy installation and not taking up the additional contact terminals. So it is very easy to improve the traditional AC contactors. Meanwhile, this chip can overcome the weakness of being susceptible to strong electromagnetic interference in MCU. So it has a value of application promotion.The main advantages of ZDLX in this paper are shown below:1. Meet the National Standard for AC Contactor Saver GB8871-2001.2. Low cost and not sensitive to environmental interference resulting in internal program execution errors, compared with MCU.3. Application circuit is simple, and size is small. It can be directly installed in the AC contactors, so it is easy to improve the traditional AC contactors.4. Good energy saving effect. It can reduce the power consumption of AC contactors down to the original 5%-15%.5. Low power consumption. There is 400uA static current in the chip and the power consumption is only 2mW.6. High reliability. Chip can normally work in the environment temperature from-25℃to 85℃.ZDLX was fabricated in Wuxi Shanghua 0.5um mix-signal standard CMOS process. And the test result shows all the parameters of the chip meet the specifications. Meanwhile this paper designs the application circuit for ZDLX, and reachs the performance according to the National Standard.