Method and terminal for predicting service life of a relay

Abstract

The application discloses a kind of relay service life prediction method and terminal, in working process, real-time monitoring storage relay action process current, voltage, action completion time, environmental data, working time and the charging end event caused by relay opening or closing, obtain working data;After work, in combination with historical working data, the cumulative calculation relay normal on-off times, relay action hysteresis response times, in the large current state of exceeding preset threshold value Large current relay off times and the cumulative conversion on-off times obtained by working time conversion on-off times;According to relay normal on-off times, large current relay off times, relay action hysteresis response times and cumulative on-off times, the used life of relay is weightedly calculated;It can more accurately assess the used life of relay, to remind maintenance personnel to replace or repair charging pile relay in time.

Description

Technical Field

[0001] This invention relates to the field of equipment condition prediction technology, and in particular to a method and terminal for predicting the service life of a relay. Background Technology

[0002] With the rapid development and popularization of new energy vehicles, the safety requirements for the charging process and the entire vehicle are becoming increasingly stringent, comprehensive, and systematic. Relays are a key component of DC fast charging stations, providing reliable and rapid power transfer from the charging station to the electric vehicle battery. However, charging stations frequently open and close relays during use. This frequent operation can affect the mechanical and electrical lifespan of the relays. To prevent damage to the life and property of vehicle owners caused by worn-out relays failing to open or close during charging, accurately predicting the remaining lifespan of relays is a crucial issue that needs to be addressed.

[0003] Generally, charging stations only detect relay malfunctions during charging by checking the high or low level of the relay's feedback pin to determine if the relay has properly opened or closed. However, there's a possibility that a worn-out relay might fail to open or close properly during charging, potentially causing harm to the vehicle owner's life and property.

[0004] For example, the patent application with application number CN202311345705.2, entitled "A Method, Device and Medium for Calculating the Remaining Life of a Relay", predicts the remaining life of the relay based on the change in the current relay release time parameter when the circuit breaker is short-circuited, and can make relevant fault response pairs in advance based on hardware boundaries.

[0005] However, it only considers the aging of the relay's action response over a long period of time. In actual use scenarios, there are many more influencing factors, making it impossible to better predict the remaining service life of the relay. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to provide a method and terminal for predicting the service life of a relay, which can more accurately predict the service life of a relay.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0008] A method for predicting the lifespan of a relay includes the following steps:

[0009] S1. During operation, monitor and store the current, voltage, operation completion time, environmental data, working duration, and charging termination events caused by relay opening or closing in real time to obtain working data.

[0010] S2. After the work is completed, based on historical work data, calculate the cumulative number of times the relay is normally switched on and off, the number of times the relay has delayed response, the number of times the relay is disconnected under high current conditions exceeding the preset threshold, and the cumulative number of switching on and off obtained by converting the working time into the number of switching on and off.

[0011] S3. Calculate the service life of the relay by weighting the number of normal on / off cycles, the number of times the relay is disconnected by high current, the number of times the relay has delayed response, and the cumulative on / off cycles.

[0012] To solve the above-mentioned technical problems, another technical solution adopted by the present invention is as follows:

[0013] A terminal for predicting relay lifespan includes a processor, a memory, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it performs the following steps:

[0014] S1. During operation, monitor and store the current, voltage, operation completion time, environmental data, working duration, and charging termination events caused by relay opening or closing in real time to obtain working data.

[0015] S2. After the work is completed, based on historical work data, calculate the cumulative number of times the relay is normally switched on and off, the number of times the relay has delayed response, the number of times the relay is disconnected under high current conditions exceeding the preset threshold, and the cumulative number of switching on and off obtained by converting the working time into the number of switching on and off.

[0016] S3. Calculate the service life of the relay by weighting the number of normal on / off cycles, the number of times the relay is disconnected by high current, the number of times the relay has delayed response, and the cumulative on / off cycles.

[0017] The beneficial effects of this invention are as follows: In addition to real-time monitoring of the relay feedback pin and counting the number of relay actions, the method and terminal for predicting the service life of a relay can more accurately assess the service life of the relay by monitoring the magnitude of the current when the relay disconnects, the response time of the relay switching action, and the cumulative switching count obtained by converting the working time into the number of switching times. This facilitates timely reminders to maintenance personnel to replace or repair the charging pile relay, preventing economic losses and safety hazards caused by the aging and damage of the charging pile relay. Attached Figure Description

[0018] Figure 1 This is a flowchart illustrating a method for predicting the lifespan of a relay according to an embodiment of the present invention;

[0019] Figure 2This is a structural diagram of a relay lifespan prediction terminal according to an embodiment of the present invention;

[0020] Label Explanation:

[0021] 1. A terminal for predicting the lifespan of a relay; 2. A processor; 3. A memory. Detailed Implementation

[0022] To explain in detail the technical content, objectives, and effects of the present invention, the following description is provided in conjunction with the embodiments and accompanying drawings.

[0023] Please refer to Figure 1 A method for predicting the lifespan of a relay includes the following steps:

[0024] S1. During operation, monitor and store the current, voltage, operation completion time, environmental data, working duration, and charging termination events caused by relay opening or closing in real time to obtain working data.

[0025] S2. After the work is completed, based on historical work data, calculate the cumulative number of times the relay is normally switched on and off, the number of times the relay has delayed response, the number of times the relay is disconnected under high current conditions exceeding the preset threshold, and the cumulative number of switching on and off obtained by converting the working time into the number of switching on and off.

[0026] S3. Calculate the service life of the relay by weighting the number of normal on / off cycles, the number of times the relay is disconnected by high current, the number of times the relay has delayed response, and the cumulative on / off cycles.

[0027] As can be seen from the above description, the beneficial effects of the present invention are as follows: The method and terminal for predicting the service life of a relay of the present invention, in addition to real-time monitoring of the relay feedback pin and counting the number of relay actions, can also more accurately assess the service life of the relay by monitoring the magnitude of the current when the relay disconnects, the response time of the relay switching action, and the cumulative switching count obtained by converting the working time into the number of switching times. This facilitates timely reminders to maintenance personnel to replace or repair the charging pile relay, preventing economic losses and safety hazards caused by the aging and damage of the charging pile relay.

[0028] Furthermore, the environmental data includes ambient temperature and ambient humidity;

[0029] The calculation of the cumulative number of on / off cycles in step S2 is as follows:

[0030] S21. For each operation, obtain the actual duration t of the relay closing operation, and calculate the average values ​​of the ambient temperature and the ambient humidity in the current operation to obtain the average temperature and average humidity.

[0031] S22. Calculate the number of on / off cycles based on the average temperature, the average humidity, and a preset reference table for the number of on / off cycles adjusted according to the relay operating conditions;

[0032] S23. The working time of each task is converted into the number of on / off cycles and accumulated to obtain the cumulative converted number of on / off cycles.

[0033] As described above, based on the ambient temperature and humidity of the equipment, and referring to the relay operating condition correction reference table, the duration of relay closure is converted into the number of relay on / off cycles.

[0034] Furthermore, step S3 specifically includes:

[0035] The weighted average service life Y of the relay is calculated based on the number of normal on / off cycles A, the number of high-current disconnections B, the number of relay hysteresis responses C, and the cumulative on / off cycles D.

[0036] Y = A*α + B*β + C*θ + T*γ;

[0037] Wherein, α, β, θ and γ are all correction coefficients, with α ranging from 0.35 to 0.5, γ ranging from 0.5 to 0.65, β ranging from 1.1 to 1.3, and θ ranging from 1.1 to 1.2.

[0038] As described above, the accumulated number of relay on / off cycles, calculated based on the number of normal on / off cycles of the relay, the number of high-current disconnection cycles of the relay, the number of relay action delay responses, and the number of relay on / off cycles converted from the working time, is combined with a correction factor to calculate the service life.

[0039] Furthermore, it also includes the following steps:

[0040] S4. Obtain the initial lifespan of the relay, calculate the remaining lifespan of the relay based on the initial lifespan and the already used lifespan, determine whether the remaining lifespan is greater than the preset replacement setting value, and if not, initiate a replacement alarm.

[0041] As described above, when the remaining lifespan of the relay is low, an alarm should be issued in a timely manner to remind the user to replace it.

[0042] Please refer to Figure 2 A terminal for predicting the lifespan of a relay includes a processor, a memory, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it performs the following steps:

[0043] S1. During operation, monitor and store the current, voltage, operation completion time, environmental data, working duration, and charging termination events caused by relay opening or closing in real time to obtain working data.

[0044] S2. After the work is completed, based on historical work data, calculate the cumulative number of times the relay is normally switched on and off, the number of times the relay has delayed response, the number of times the relay is disconnected under high current conditions exceeding the preset threshold, and the cumulative number of switching on and off obtained by converting the working time into the number of switching on and off.

[0045] S3. Calculate the service life of the relay by weighting the number of normal on / off cycles, the number of times the relay is disconnected by high current, the number of times the relay has delayed response, and the cumulative on / off cycles.

[0046] As can be seen from the above description, the beneficial effects of the present invention are as follows: The method and terminal for predicting the service life of a relay of the present invention, in addition to real-time monitoring of the relay feedback pin and counting the number of relay actions, can also more accurately assess the service life of the relay by monitoring the magnitude of the current when the relay disconnects, the response time of the relay switching action, and the cumulative switching count obtained by converting the working time into the number of switching times. This facilitates timely reminders to maintenance personnel to replace or repair the charging pile relay, preventing economic losses and safety hazards caused by the aging and damage of the charging pile relay.

[0047] Furthermore, the environmental data includes ambient temperature and ambient humidity;

[0048] The calculation of the cumulative number of on / off cycles in step S2 is as follows:

[0049] S21. For each operation, obtain the actual duration t of the relay closing operation, and calculate the average values ​​of the ambient temperature and the ambient humidity in the current operation to obtain the average temperature and average humidity.

[0050] S22. Calculate the number of on / off cycles based on the average temperature, the average humidity, and a preset reference table for the number of on / off cycles adjusted according to the relay operating conditions;

[0051] S23. The working time of each task is converted into the number of on / off cycles and accumulated to obtain the cumulative converted number of on / off cycles.

[0052] As described above, based on the ambient temperature and humidity of the equipment, and referring to the relay operating condition correction reference table, the duration of relay closure is converted into the number of relay on / off cycles.

[0053] Furthermore, step S3 specifically includes:

[0054] The weighted average service life Y of the relay is calculated based on the number of normal on / off cycles A, the number of high-current disconnections B, the number of relay hysteresis responses C, and the cumulative on / off cycles D.

[0055] Y = A*α + B*β + C*θ + D*γ;

[0056] Wherein, α, β, θ and γ are all correction coefficients, with α ranging from 0.35 to 0.5, γ ranging from 0.5 to 0.65, β ranging from 1.1 to 1.3, and θ ranging from 1.1 to 1.2.

[0057] As described above, the accumulated number of relay on / off cycles, calculated based on the number of normal on / off cycles of the relay, the number of high-current disconnection cycles of the relay, the number of relay action delay responses, and the number of relay on / off cycles converted from the working time, is combined with a correction factor to calculate the service life.

[0058] Furthermore, it also includes the following steps:

[0059] S4. Obtain the initial lifespan of the relay, calculate the remaining lifespan of the relay based on the initial lifespan and the already used lifespan, determine whether the remaining lifespan is greater than the preset replacement setting value, and if not, initiate a replacement alarm.

[0060] As described above, when the remaining lifespan of the relay is low, an alarm should be issued in a timely manner to remind the user to replace it.

[0061] The present invention provides a method and terminal for predicting the service life of relays, which is applicable to relay service life monitoring scenarios, especially relay service life monitoring scenarios in new energy vehicle charging piles.

[0062] Please refer to Figure 1 Embodiment 1 of the present invention is as follows:

[0063] A method for predicting the lifespan of a relay includes the following steps:

[0064] S1. During operation, monitor and store the current, voltage, operation completion time, environmental data, working duration, and charging termination events caused by relay opening or closing in real time to obtain working data.

[0065] The environmental data includes ambient temperature and ambient humidity.

[0066] In this embodiment, a charging pile relay is used as an example. There are three main relays in a charging pile: a main positive relay, a main negative relay, and an auxiliary power relay. The main positive relay will be used as an example for explanation; the following description will focus directly on the relay itself.

[0067] To avoid affecting users' normal charging, parameters related to the relays, such as voltage and current changes during charging, operation completion time, ambient temperature and humidity of the charging station, and charging termination due to relay disconnection or closure faults, are recorded and saved before charging is completed. These parameters are then analyzed and evaluated to determine whether the remaining lifespan and reliability of the relays need to be adjusted.

[0068] S2. After the work is completed, based on historical work data, calculate the cumulative number of times the relay normally switches on and off, the number of times the relay has delayed response, the cumulative working time, and the number of times the relay is disconnected under high current conditions exceeding the preset threshold.

[0069] In this embodiment, the following parameters are calculated: the number of normal on / off cycles A, the number of times the relay is disconnected by high current B, the number of times the relay's action response is delayed C, and the cumulative on / off cycle D, which is obtained by converting the on / off cycle count to the operating time. The cumulative on / off cycle D is obtained by converting the relay's closed operating time.

[0070] Normal switching count A refers to the number of switching actions performed by the relay when the current passing through the relay is less than or equal to 80% of the rated current.

[0071] The number of times the high-current disconnect relay is B refers to the count of the relay performing a disconnect operation when the current passing through the relay is greater than 80% of the rated current.

[0072] The action response lag count refers to the time from the on / off state of the control relay to the relay feedback indicating the completion of its action exceeding 20% ​​of the relay's factory test time. The charging pile program records the moment the control relay action is initiated (t1) and the moment the relay feedback signal changes to the moment the action is completed (t2); thus, it calculates the relay action response time t = t2 - t1.

[0073] The calculation of the cumulative number of on / off cycles can be found below.

[0074] The calculation of the cumulative number of on / off cycles in step S2 is as follows:

[0075] S21. For each operation, obtain the actual duration t of the relay closing operation, and calculate the average values ​​of the ambient temperature and the ambient humidity in the current operation to obtain the average temperature and average humidity.

[0076] S22. Calculate the number of on / off cycles based on the average temperature, the average humidity, and a preset reference table for the number of on / off cycles adjusted according to the relay operating conditions;

[0077] S23. The working time of each task is converted into the number of on / off cycles and accumulated to obtain the cumulative converted number of on / off cycles.

[0078] The following is a reference example for calculating the number of on / off cycles under relay operating conditions:

[0079] Table 1. Reference Table for Relay Operating Conditions and the Number of On / Off Cycles

[0080]

[0081]

[0082]

[0083] S3. Calculate the service life of the relay by weighting the number of times the relay is normally switched on and off, the number of times the relay is disconnected by high current, the number of times the relay has delayed response, and the cumulative working time.

[0084] Step S3 is as follows:

[0085] The weighted average service life Y of the relay is calculated based on the number of normal on / off cycles A, the number of high-current disconnections B, the number of relay hysteresis responses C, and the cumulative on / off cycles D.

[0086] Y = A*α + B*β + C*θ + D*γ;

[0087] Wherein, α, β, θ and γ are all correction coefficients, with α ranging from 0.35 to 0.5, γ ranging from 0.5 to 0.65, β ranging from 1.1 to 1.3, and θ ranging from 1.1 to 1.2.

[0088] In this embodiment, the weighted average of the relay's normal on / off cycles (A), the high-current relay disconnection cycles (B), the relay's delayed response cycles (C), and the cumulative calculated on / off cycles (D) is used to calculate the relay's service life (Y). The high-current relay disconnection cycle (B) reflects actions that carry the risk of accelerated aging; while the relay delayed response cycle (C) reflects obvious signs of aging in the relay device. The cumulative calculated on / off cycles (D) takes into account the situation where the relay will also age faster under high temperature and high humidity conditions.

[0089] The correction coefficients α, β, θ, and γ are taken as empirical values ​​and can be adjusted according to the application scenario in actual use. For example:

[0090] In outdoor environments, the γ coefficient can be set to a larger value, such as 0.65; while in indoor environments, it can be set to 0.5.

[0091] In application scenarios such as bus stations, heavy trucks, and mines, it is recommended to take a larger value of 1.3 for the β coefficient; while in home and other scenarios, it is recommended to take a smaller value of 1.1.

[0092] Secondly, when a charging pile reaches a certain number of years of use, a certain number of uses, or a certain threshold of accumulated orders, the α and θ coefficients will be automatically adjusted and increased. For example, for newly manufactured equipment, the coefficient θ can be 1.1, and after reaching the threshold usage conditions, it will automatically change to 1.2.

[0093] S4. Obtain the initial lifespan of the relay, calculate the remaining lifespan of the relay based on the initial lifespan and the already used lifespan, determine whether the remaining lifespan is greater than the preset replacement setting value, and if not, initiate a replacement alarm.

[0094] In this embodiment, the initial lifespan X of the relay is obtained in advance. The remaining lifespan XY of the relay is calculated. Based on the remaining lifespan, it is determined whether it is less than or equal to the replacement threshold that requires the relay to be replaced. If the relay needs to be replaced, the initial lifespan of the main positive relay is updated to the remaining lifespan, and an alarm is issued to remind the staff to replace and repair the fuse.

[0095] Please refer to Figure 2 Embodiment two of the present invention is as follows:

[0096] A terminal 1 for predicting the lifespan of a relay includes a processor 2, a memory 3, and a computer program stored in the memory 3 and executable on the processor 2. When the processor 2 executes the computer program, it implements the steps in the method for predicting the lifespan of a relay according to Embodiment 1 above.

[0097] In summary, the method and terminal for predicting the service life of a relay provided by this invention, in addition to real-time monitoring of the relay feedback pin and counting the number of relay actions, also monitors the magnitude of the current when the relay disconnects, the response time of the relay's on / off action, and the cumulative closing working time. This allows for a more accurate assessment of the relay's service life, facilitating timely reminders to maintenance personnel to replace or repair the charging pile relay, and preventing economic losses and safety hazards caused by the aging and damage of the charging pile relay.

[0098] This invention, without adding detection circuitry, fully utilizes existing hardware and software to detect and warn about the lifespan of charging pile relays. This can prevent economic losses and safety hazards caused by the aging and deterioration of charging pile relays, and promptly remind maintenance personnel to replace or repair the corresponding relays of the charging piles. This reduces the inability to charge or damage to the charging piles caused by failure to replace the corresponding relays in a timely manner, thereby improving the reliability of charging.

[0099] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent modifications made based on the content of the present invention specification and drawings, or direct or indirect applications in related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A method for predicting the service life of a relay, characterized in that, Including the following steps: S1. During operation, monitor and store the current, voltage, operation completion time, environmental data, working duration, and charging termination events caused by relay opening or closing in real time to obtain working data. S2. After the work is completed, based on historical work data, calculate the cumulative number of times the relay is normally switched on and off, the number of times the relay has delayed response, the number of times the relay is disconnected under high current conditions exceeding the preset threshold, and the cumulative number of switching on and off obtained by converting the working time into the number of switching on and off. S3. Calculate the service life of the relay by weighting the number of normal on / off cycles, the number of times the relay is disconnected by high current, the number of times the relay has delayed response, and the cumulative on / off cycles. The environmental data includes ambient temperature and ambient humidity; The calculation of the cumulative number of on / off cycles in step S2 is as follows: S21. For each operation, obtain the actual duration t of the relay closing operation, and calculate the average values ​​of the ambient temperature and the ambient humidity in the current operation to obtain the average temperature and average humidity. S22. Calculate the number of on / off cycles based on the average temperature, the average humidity, and a preset reference table for the number of on / off cycles adjusted according to the relay operating conditions; S23. The working time of each task is converted into the number of on / off cycles and accumulated to obtain the cumulative converted number of on / off cycles.

2. The method for predicting the service life of a relay according to claim 1, characterized in that, Step S3 is as follows: The weighted average service life Y of the relay is calculated based on the number of normal on / off cycles A, the number of high-current disconnections B, the number of relay hysteresis responses C, and the cumulative on / off cycles D. Y = A*α + B*β + C*θ + D*γ; Wherein, α, β, θ and γ are all correction coefficients, with α ranging from 0.35 to 0.5, γ ranging from 0.5 to 0.65, β ranging from 1.1 to 1.3, and θ ranging from 1.1 to 1.

2.

3. The method for predicting the service life of a relay according to claim 1, characterized in that, It also includes the following steps: S4. Obtain the initial lifespan of the relay, calculate the remaining lifespan of the relay based on the initial lifespan and the already used lifespan, determine whether the remaining lifespan is greater than the preset replacement setting value, and if not, initiate a replacement alarm.

4. A terminal for predicting the lifespan of a relay, comprising a processor, a memory, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it performs the following steps: S1. During operation, monitor and store the current, voltage, operation completion time, environmental data, working duration, and charging termination events caused by relay opening or closing in real time to obtain working data. S2. After the work is completed, based on historical work data, calculate the cumulative number of times the relay is normally switched on and off, the number of times the relay has delayed response, the number of times the relay is disconnected under high current conditions exceeding the preset threshold, and the cumulative number of switching on and off obtained by converting the working time into the number of switching on and off. S3. Calculate the service life of the relay by weighting the number of normal on / off cycles, the number of times the relay is disconnected by high current, the number of times the relay has delayed response, and the cumulative on / off cycles. The environmental data includes ambient temperature and ambient humidity; The calculation of the cumulative number of on / off cycles in step S2 is as follows: S21. For each operation, obtain the actual duration t of the relay closing operation, and calculate the average values ​​of the ambient temperature and the ambient humidity in the current operation to obtain the average temperature and average humidity. S22. Calculate the number of on / off cycles based on the average temperature, the average humidity, and a preset reference table for the number of on / off cycles adjusted according to the relay operating conditions; S23. The working time of each task is converted into the number of on / off cycles and accumulated to obtain the cumulative converted number of on / off cycles.

5. A terminal for predicting the lifespan of a relay according to claim 4, characterized in that, Step S3 is as follows: The weighted average service life Y of the relay is calculated based on the number of normal on / off cycles A, the number of high-current disconnections B, the number of relay hysteresis responses C, and the cumulative on / off cycles D. Y = A*α + B*β + C*θ + D*γ; Wherein, α, β, θ and γ are all correction coefficients, with α ranging from 0.35 to 0.5, γ ranging from 0.5 to 0.65, β ranging from 1.1 to 1.3, and θ ranging from 1.1 to 1.

2.

6. A terminal for predicting the lifespan of a relay according to claim 4, characterized in that, It also includes the following steps: S4. Obtain the initial lifespan of the relay, calculate the remaining lifespan of the relay based on the initial lifespan and the already used lifespan, determine whether the remaining lifespan is greater than the preset replacement setting value, and if not, initiate a replacement alarm.

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