Bi-Stable Relay Controller With Boost Converter For Wide Voltage Range
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Solution Overview
Problem
Existing bi-stable solenoid switches have limited operating voltage ranges, leading to issues such as chatter at low voltages and excessive energy consumption and heat at high voltages, resulting in increased relay size and degradation.
Innovation Solution
A bi-stable relay controller with a boost converter to increase the input voltage, coupled with an energy storage device and driver circuits to manage the solenoid's magnetic field, allowing the relay to operate over a wide voltage range with reduced power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a normally open relay operates at low voltage, then the relay can function at lower voltage levels, but the magnetic holding force becomes weak causing chatter
Solution Approach 1:
The patent applies dynamic current control by transitioning from constant current to pulse-width modulated (PWM) driving mode. The controller dynamically adjusts the coil current waveform, delivering high current pulses during switching transitions and reducing to minimal holding current during steady state, thereby maintaining reliable magnetic holding force across the extended voltage range while preventing chatter.
Solution Approach 2:
The patent changes the electrical parameters (current magnitude and waveform) based on operating conditions. By implementing PWM control with adjustable duty cycle and frequency, the system adapts the coil excitation parameters to maintain optimal magnetic field strength across varying supply voltages, ensuring stable operation from 5V to 32V without chatter.
2Adaptability or versatility
If a normally open relay operates at high voltage, then the relay can function at higher voltage levels, but the energy consumption and heat production increase due to constant current flow
Solution Approach 1:
The patent implements periodic pulsed current delivery through PWM control instead of continuous constant current flow. The controller applies high current pulses only during the brief moments when switching action is required, then reduces to minimal or zero current during the majority of the operating cycle, dramatically reducing average power consumption and heat generation while maintaining the ability to switch at high voltages.
Solution Approach 2:
The bi-stable relay mechanism itself provides the energy-saving function by maintaining its switched state without continuous external energy input. Once the coil pulse triggers the mechanical switching action, the relay's inherent bi-stable construction (using spring force and magnetic latching) maintains the contact position without requiring continuous coil excitation, eliminating the need for constant current flow and associated energy consumption.
3Adaptability or versatility
If a normally open relay uses constant current to support high voltage operation, then the relay can operate at high voltages, but the overall relay size increases due to larger coil windings
Solution Approach 1:
The patent uses dynamic PWM current control to deliver high peak currents during switching transitions and then reduces to minimal holding currents, allowing the use of smaller, less massive coil windings. The coil is designed to handle brief high-current pulses rather than requiring continuous high current capability, significantly reducing the size and mass of the coil assembly while maintaining high-voltage switching capability.
Solution Approach 2:
By employing periodic pulsed excitation instead of continuous current flow, the patent reduces the thermal and mechanical stress requirements for the coil windings. This allows the use of smaller gauge wire and reduced coil form factor, as the coil only needs to withstand brief high-current pulses rather than continuous high current, thereby reducing overall relay size and mass.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the bi-stable relay to maintain stable operation across a wide voltage range (5-32V) with reduced chatter, energy consumption, and heat production, extending the relay's lifespan and size efficiency.
Implementation Method 1
the coil windings, which when engaged by a power source, generates a magnetic field
Implementation Method 2
The magnetic coupling member configured to reduce the force needed by the solenoid to remain in an open position when selectively energized
Data Source
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AI summary
Provided herein is an improved bi-stable relay operable with a relay control circuit including a boost converter and an energy storage device, which is used to switch the bi-stable relay. In some embodiments, the bi-stable relay includes a solenoid wound with multiple coil windings. A conductive plate (e.g., a bus bar) may be coupled to a plunger of the solenoid, and is provided with contacts on each end of the conductive plate. The conductive plate is configured to electrically engage and disengage the solenoid upon respective application of power to the solenoid. The control circuit causes the solenoid to remain in an open position when selectively energized by a pulse for moving and retaining the conductive plate of the plunger against the solenoid for allowing wide operating voltage and reduced operating power.