Electromagnetic switch state detection and health management device
By integrating electromagnetic switch drive voltage and current detection components, the problem of electromagnetic switch status misjudgment is solved, health management is achieved, and equipment stability and operation and maintenance efficiency are improved.
Patent Information
- Application Number
- CN202521894292.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-03
- Publication Date
- 2026-08-25
- Estimated Expiration
- 2035-09-03
AI Technical Summary
In existing technologies, electromagnetic switch status detection is prone to misjudgment due to contact adhesion, and lacks a health management mechanism, leading to unplanned equipment downtime and increased operation and maintenance costs.
The system integrates electromagnetic switch drive voltage detection components and drive current detection components, and combines them with auxiliary contact signals to construct a multi-dimensional collaborative judgment mechanism. This mechanism monitors voltage and current changes in real time, enabling accurate status identification and health warnings.
Accurately identify switch status, avoid misjudgment, reduce equipment failure, improve operating efficiency, and reduce maintenance costs.
Smart Images
Figure CN224682367U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of magnetic switch status technology, specifically relating to a magnetic switch status detection and health management device. Background Technology
[0002] In the integrated automation control of industrial production processes in the field of advanced manufacturing and automation, electromagnetic switches, as key components for realizing circuit switching and equipment control, directly affect the stable operation and equipment efficiency of the entire automation system through the accuracy of their status detection and health management capabilities. Currently, there are significant shortcomings in the industry's status detection and health management solutions for electromagnetic switches. Existing detection methods are prone to misjudgments due to issues such as contact adhesion, failing to accurately identify abnormalities during switch engagement and disengagement. Furthermore, the lack of a systematic analysis and health assessment mechanism for switch operating data makes it difficult to predict the expected lifespan of switches, leading to repairs only after a failure occurs. This results in increased unplanned equipment downtime and fails to meet the automation control requirements for switch status reliability and forward-looking health management, thus hindering the operational efficiency and stability of integrated automation control systems for industrial production processes. Utility Model Content
[0003] To address the technical problems of the existing detection methods, this utility model provides an electromagnetic switch status detection and health management device.
[0004] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows: An electromagnetic switch status detection and health management device includes a drive circuit for the electromagnetic switch under test, an auxiliary contact for electromagnetic switch linkage, a protection device, an electromagnetic switch drive switch, an electromagnetic switch drive voltage detection component, and an electromagnetic switch drive current detection component. The auxiliary contact for electromagnetic switch linkage is electrically connected to the protection device. The electromagnetic switch drive voltage detection component and the electromagnetic switch drive current detection component are disposed within the protection device. The electromagnetic switch drive voltage detection component is electrically connected to the drive circuit for the electromagnetic switch under test, and the electromagnetic switch drive current detection component is also electrically connected to the drive circuit for the electromagnetic switch under test. Both the electromagnetic switch drive voltage detection component and the electromagnetic switch drive current detection component are grounded.
[0005] The electromagnetic switch drive voltage detection component includes the electromagnetic switch drive voltage to be detected, a single-phase rectifier bridge, a first high-precision voltage divider resistor, a first drive power supply voltage level selection jumper, a second high-precision voltage divider resistor, a second drive power supply voltage level selection jumper, a third high-precision voltage divider resistor, a fourth high-precision voltage divider resistor, a first linear optocoupler, and a first analog quantity detection circuit. The detected electromagnetic switch drive voltage is electrically connected to the single-phase rectifier bridge, the single-phase rectifier bridge is electrically connected to the first high-precision voltage divider resistor, the first high-precision voltage divider resistor is electrically connected to the second high-precision voltage divider resistor, the second high-precision voltage divider resistor is electrically connected to the third high-precision voltage divider resistor, the third high-precision voltage divider resistor is electrically connected to the fourth high-precision voltage divider resistor, and the fourth high-precision voltage divider resistor is electrically connected to the single-phase rectifier bridge.
[0006] The first high-precision voltage divider resistor is connected in parallel with a first drive power supply voltage level selection jumper, and the second high-precision voltage divider resistor is connected in parallel with a second drive power supply voltage level selection jumper.
[0007] The first linear optocoupler is connected in parallel across the fourth high-precision voltage divider resistor, and the first linear optocoupler is electrically connected to the first analog signal detection circuit.
[0008] The electromagnetic switch drive current detection component includes the electromagnetic switch drive current to be detected, a Hall current sensor, a fifth high-precision resistor, a second linear optocoupler, and a second analog quantity detection circuit. The electromagnetic switch drive current to be detected is electrically connected to the Hall current sensor, the Hall current sensor is electrically connected to the second linear optocoupler, and the second linear optocoupler is electrically connected to the second analog quantity detection circuit.
[0009] The fifth high-precision resistor is connected in parallel across the Hall current sensor.
[0010] Compared with the prior art, the advantages of this utility model are: 1. This utility model integrates an electromagnetic switch drive voltage detection component and a drive current detection component within the protection device, and combines them with the electromagnetic switch linkage auxiliary contact signal to construct a multi-dimensional collaborative judgment mechanism for voltage and current contact actions. During the pull-in phase, it can accurately identify the peak current maintenance characteristics and auxiliary contact action after the drive voltage reaches the pull-in voltage. During the disconnection phase, it can monitor the current decay to zero and the synchronization of contact action in real time, completely solving the problem of misjudgment caused by contact adhesion and asynchronous action of main and auxiliary contacts in existing technologies. This provides reliable switch status feedback for automated control systems, avoiding circuit faults or equipment safety hazards caused by misjudgment, and achieving high-quality status detection of the electromagnetic switch.
[0011] 2. This utility model stores and analyzes key parameters such as drive current, engagement voltage, and disengagement voltage, as well as their changing trends, during each engagement and disengagement process of the switch in real time, enabling dynamic tracking of the switch's health status. When a deterioration in the switch's health status is detected, a timely health warning can be issued, helping maintenance personnel to predict the switch's expected lifespan in advance. Based on this, they can rationally plan equipment maintenance time, avoid unplanned downtime caused by sudden faults, effectively reduce equipment idle time, significantly increase effective equipment operating time, and lower emergency maintenance costs.
[0012] 3. The combination design of the high-precision voltage divider resistor and the drive power supply voltage level selection jumper in the voltage detection component of this utility model can flexibly adapt to electromagnetic switch drive power supplies of different voltage levels; the current detection component adopts Hall current sensor and linear optocoupler to ensure current detection accuracy and signal stability, and effectively improve the reliability of detection data. Attached Figure Description
[0013] To more clearly illustrate the embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.
[0014] The structures, proportions, sizes, etc. illustrated in this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed herein, and are not intended to limit the implementation conditions of this utility model. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportional relationships, or adjustments to the size, without affecting the effects and purposes that this utility model can produce, should still fall within the scope of the technical content disclosed in this utility model.
[0015] Figure 1 This is the circuit diagram of this utility model; Figure 2 This is a circuit diagram of the electromagnetic switch drive voltage detection component of this utility model; Figure 3 This is a circuit diagram of the electromagnetic switch drive current detection component of this utility model.
[0016] Wherein: 1 is the electromagnetic switch drive circuit to be tested, 2 is the electromagnetic switch linkage auxiliary contact, 3 is the protection device, 4 is the electromagnetic switch drive switch, 5 is the electromagnetic switch drive voltage detection component, 6 is the electromagnetic switch drive current detection component, 51 is the electromagnetic switch drive voltage to be tested, 52 is the single-phase rectifier bridge, 53 is the first high-precision voltage divider resistor, 54 is the first drive power supply voltage level selection jumper, 55 is the second high-precision voltage divider resistor, 56 is the second drive power supply voltage level selection jumper, 57 is the third high-precision voltage divider resistor, 58 is the fourth high-precision voltage divider resistor, 59 is the first linear optocoupler, 510 is the first analog quantity detection circuit, 61 is the electromagnetic switch drive current to be tested, 62 is the Hall current sensor, 63 is the fifth high-precision resistor, 64 is the second linear optocoupler, and 65 is the second analog quantity detection circuit. Detailed Implementation
[0017] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions in the embodiments of this utility model will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. These descriptions are only for further illustrating the features and advantages of this utility model, and not for limiting the claims of this utility model. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0018] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate this utility model, but are not intended to limit its scope.
[0019] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.
[0020] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.
[0021] like Figure 1-3As shown, this embodiment provides a magnetic switch status detection and health management device. First, signal acquisition is performed. The driving voltage of the electromagnetic switch drive circuit 1 to be detected is transmitted to the electromagnetic switch drive voltage detection component 5. The electromagnetic switch drive voltage 51 to be detected is first processed by a single-phase rectifier bridge 52, and then divided by a first high-precision voltage divider resistor 53, a second high-precision voltage divider resistor 55, a third high-precision voltage divider resistor 57, and a fourth high-precision voltage divider resistor 58. During this process, different voltage levels can be selected using the first drive power supply voltage level selection jumper 54 and the second drive power supply voltage level selection jumper 56. The voltage signal after voltage division is transmitted to the first analog quantity detection circuit 510 via the first linear optocoupler 59 and finally fed back to the protection device 3. At the same time, the drive current of the electromagnetic switch drive circuit 1 under test is transmitted to the electromagnetic switch drive current detection component 6. The electromagnetic switch drive current 61 under test is detected by the Hall current sensor 62. The fifth high-precision resistor 63 assists in signal processing. The current signal is transmitted to the second analog quantity detection circuit 65 via the second linear optocoupler 64 and also fed back to the protection device 3. The electromagnetic switch drive switch 4 cooperates to realize the on-off control of the drive circuit.
[0022] Next, the engagement state is determined. When the protection device 3 detects that the driving voltage of the electromagnetic switch drive circuit 1 under test reaches the engagement voltage through the electromagnetic switch drive voltage detection component 5, it immediately monitors the driving current through the electromagnetic switch drive current detection component 6. If the driving current reaches the engagement current value and maintains the engagement for the corresponding time before dropping to the holding current value within a specified time, and at the same time, the electromagnetic switch linkage auxiliary contact 2 is detected to have a corresponding action within a specified time, then the protection device 3 determines that the electromagnetic switch in the electromagnetic switch drive circuit 1 under test is normally engaged. If the driving current does not meet the above change pattern, or the electromagnetic switch linkage auxiliary contact 2 does not have a corresponding action, any failure to meet either condition will be determined as an engagement failure.
[0023] Subsequently, the disconnection status is determined. When the protection device 3 detects that the driving voltage of the electromagnetic switch driving circuit 1 under test drops to the disconnection voltage through the electromagnetic switch driving voltage detection component 5, the driving current is continuously monitored through the electromagnetic switch driving current detection component 6. If the driving current drops to zero within a specified time and the electromagnetic switch linkage auxiliary contact 2 is detected to have a corresponding action within a specified time, the protection device 3 determines that the electromagnetic switch is normally disconnected. If the driving current does not drop to zero within a specified time, or the electromagnetic switch linkage auxiliary contact 2 does not have a corresponding action, and either of these conditions is not met, the disconnection fault is determined.
[0024] Finally, health management is achieved. The protection device 3 stores the pull-in voltage and break-out voltage collected by the electromagnetic switch drive voltage detection component 5 and the pull-in current, holding current, and break-out current collected by the electromagnetic switch drive current detection component 6 during each pull-in and break-out process. Based on these parameters, a mathematical model of the electromagnetic switch under test is established, and the parameter change trend is continuously analyzed. When abnormal parameters are detected or the change trend does not conform to the normal pattern, that is, when it is judged that the health status of the electromagnetic switch has deteriorated, the protection device 3 issues a health warning in a timely manner, providing a basis for subsequent equipment maintenance and component replacement.
[0025] The above description only describes the preferred embodiments of the present utility model. However, the present utility model is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present utility model, and all such changes should be included within the protection scope of the present utility model.
Claims
1. An electromagnetic switch status detection and health management device, characterized in that: The device includes a drive circuit (1) for an electromagnetic switch to be tested, an auxiliary contact (2) for electromagnetic switch linkage, a protection device (3), an electromagnetic switch drive switch (4), an electromagnetic switch drive voltage detection component (5), and an electromagnetic switch drive current detection component (6). The auxiliary contact (2) for electromagnetic switch linkage is electrically connected to the protection device (3). The electromagnetic switch drive voltage detection component (5) and the electromagnetic switch drive current detection component (6) are located inside the protection device (3). The electromagnetic switch drive voltage detection component (5) is electrically connected to the drive circuit (1) for the electromagnetic switch to be tested. The electromagnetic switch drive current detection component (6) is electrically connected to the drive circuit (1) for the electromagnetic switch to be tested. Both the electromagnetic switch drive voltage detection component (5) and the electromagnetic switch drive current detection component (6) are grounded.
2. The electromagnetic switch status detection and health management device according to claim 1, characterized in that: The electromagnetic switch drive voltage detection component (5) includes the electromagnetic switch drive voltage to be detected (51), a single-phase rectifier bridge (52), a first high-precision voltage divider resistor (53), a first drive power supply voltage level selection jumper (54), a second high-precision voltage divider resistor (55), a second drive power supply voltage level selection jumper (56), a third high-precision voltage divider resistor (57), a fourth high-precision voltage divider resistor (58), a first linear optocoupler (59), and a first analog quantity detection circuit (510). The voltage divider (51) is electrically connected to the single-phase rectifier bridge (52), the single-phase rectifier bridge (52) is electrically connected to the first high-precision voltage divider resistor (53), the first high-precision voltage divider resistor (53) is electrically connected to the second high-precision voltage divider resistor (55), the second high-precision voltage divider resistor (55) is electrically connected to the third high-precision voltage divider resistor (57), the third high-precision voltage divider resistor (57) is electrically connected to the fourth high-precision voltage divider resistor (58), and the fourth high-precision voltage divider resistor (58) is electrically connected to the single-phase rectifier bridge (52).
3. The electromagnetic switch status detection and health management device according to claim 2, characterized in that: The first high-precision voltage divider resistor (53) is connected in parallel with a first drive power supply voltage level selection jumper (54), and the second high-precision voltage divider resistor (55) is connected in parallel with a second drive power supply voltage level selection jumper (56).
4. The electromagnetic switch status detection and health management device according to claim 3, characterized in that: The first linear optocoupler (59) is connected in parallel across the fourth high-precision voltage divider resistor (58), and the first linear optocoupler (59) is electrically connected to the first analog signal detection circuit (510).
5. The electromagnetic switch status detection and health management device according to claim 1, characterized in that: The electromagnetic switch drive current detection component (6) includes the electromagnetic switch drive current to be detected (61), a Hall current sensor (62), a fifth high-precision resistor (63), a second linear optocoupler (64), and a second analog quantity detection circuit (65). The electromagnetic switch drive current to be detected (61) is electrically connected to the Hall current sensor (62), the Hall current sensor (62) is electrically connected to the second linear optocoupler (64), and the second linear optocoupler (64) is electrically connected to the second analog quantity detection circuit (65).
6. The electromagnetic switch status detection and health management device according to claim 5, characterized in that: The fifth high-precision resistor (63) is connected in parallel across the Hall current sensor (62).