Bistable Relay Protection Control for Low-Voltage Contact Reliability
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Solution Overview
Problem
The reliability and service life of relay protective apparatuses in engineering machinery, such as excavators, are compromised due to continuous coil powering, leading to heat generation, reduced contact performance, and difficulty in detecting relay failures, which affects the overall electrical system reliability.
Innovation Solution
A relay protective apparatus with a bistable relay and a central controller that alternately powers the pull-in and release coils when the output voltage is between specific thresholds, causing the contact to oscillate, reducing foreign object accumulation and improving contact performance, while also integrating a fault indicator and storage capacitors for enhanced reliability and fault detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coil is continuously powered to maintain relay contact in the closed state, then the relay protection function is ensured, but heat is generated and the service life of the relay is reduced
Solution Approach 1:
The patent employs periodic action by using a control unit to alternately drive the pull-in coil and release coil in periodic intervals. Instead of continuous powering, the control unit detects the contact state and periodically activates the appropriate coil to maintain the contact in the closed state, thereby reducing continuous heat generation and extending relay service life while ensuring protection function.
Solution Approach 2:
The patent applies dynamics by transitioning from a static continuous-powering mode to a dynamic periodic control mode. The control unit dynamically adjusts the coil driving state based on real-time contact state detection, switching between pull-in coil activation (when contact opens) and release coil activation (when contact closes), optimizing both reliability and service life.
2Reliability
If foreign objects accumulate on the relay contact, then contact performance deteriorates, but detecting and removing these objects is difficult
Solution Approach 1:
The patent utilizes mechanical vibration by causing the contact to oscillate through periodic activation of the pull-in and release coils. This vibration effect prevents foreign objects from accumulating on the contact surface and facilitates their removal, thereby maintaining contact performance without requiring complex detection mechanisms.
Solution Approach 2:
The relay system performs self-maintenance by using its own coils to generate contact vibration that automatically prevents or removes foreign object accumulation. The control unit monitors contact state and triggers coil activation sequences that serve both the primary function of maintaining contact closure and the secondary function of cleaning the contact surface.
3Productivity
If the relay contact is kept closed through continuous coil powering, then the electrical system remains operational, but energy consumption increases and heat generation reduces reliability
Solution Approach 1:
The control unit implements periodic action by detecting the contact state and activating coils only when necessary to maintain closure. This intermittent powering approach significantly reduces energy consumption compared to continuous powering, while the contact remains functionally closed to maintain electrical system operation and productivity.
4Device complexity
If a traditional monostable relay is used, then the structure is simple, but the relay cannot maintain state without continuous power and requires constant coil activation
Solution Approach 1:
The patent transitions from a static monostable relay to a dynamic bistable relay system where the relay can maintain its state (either open or closed) without continuous power to the coils. The control unit dynamically manages the two stable states by selectively activating pull-in or release coils, reducing energy consumption while maintaining structural simplicity.
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 effectively prolongs the service life of the relay protective apparatus and improves the reliability of the electrical system by reducing heat generation, maintaining contact performance, and enabling automatic fault diagnosis and prompt notification.
Implementation Method 1
the pull-in coil and the release coil to be alternately driven to enable the contact to oscillate
Implementation Method 2
the contact to oscillate, reducing foreign object accumulation and improving contact performance
Data Source
AI summary
The present invention relates to a relay protective device, a construction machine, a relay protection control method and apparatus, and a computer readable storage medium. The relay protective device includes: a power supply input contact; a relay protective module comprising a bistable relay and an output contact, wherein the bistable relay comprises a contact, a pull-in coil, and a release coil; an input terminal of the contact, an input terminal of the pull-in coil, and an input terminal of the release coil are connected to the power supply input contact; an output terminal of the contact is connected to the output contact; and a central control unit comprising a first port connected to the output contact, a second port connected to an output terminal of the pull-in coil, and a third port connected to an output terminal of the release coil; the central control unit is used for controlling the pull-in coil and the release coil to be alternately powered on so as to oscillate the contact when a voltage of the output contact is less than a first threshold and is not less than a second threshold, wherein the first threshold is less than a standard working voltage of the bistable relay, and the second threshold is the minimum allowable working voltage of the bistable relay.