Contactor Coil Control for Stable Attraction Under Current Drop
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing contactor systems face challenges in maintaining stable attraction under non-ideal operating conditions, such as high temperatures or low power supply voltages, leading to unstable operation and increased energy consumption, without cost-effective solutions like redesigning or replacing components.
Innovation Solution
A method to control contactors by determining abnormal current drop processes and extending the power supply time based on set thresholds, using processors and memory to ensure stable attraction without redesigning or replacing the contactor, thereby reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power supply time is extended to ensure stable attraction, then the reliability of contactor attraction is improved, but the energy consumption increases
Solution Approach 1:
The power supply time is dynamically adjusted based on real-time current monitoring. When abnormal current drop is detected, the controller extends the power supply time adaptively, rather than using a fixed time duration. This dynamic adjustment ensures reliable attraction when needed while minimizing unnecessary energy consumption during normal operation.
Solution Approach 2:
The system implements closed-loop feedback by continuously monitoring the coil current and comparing it against expected values. When the current deviates from the normal range (indicating abnormal drop), the feedback mechanism triggers an extension of power supply time. This feedback-based control resolves the contradiction by using energy only when the feedback indicates it is necessary for reliable operation.
2Reliability
If the power supply voltage is increased to ensure stable attraction, then the reliability of contactor attraction is improved, but the risk of damage to the contactor increases
Solution Approach 1:
The system performs preliminary detection of abnormal current drop during the power supply process. By detecting current anomalies early, the controller can extend the power supply time in advance to ensure stable attraction, rather than waiting for attraction failure and then applying higher voltage. This preliminary action prevents the need for high-voltage compensation while ensuring reliable operation.
Solution Approach 2:
Instead of changing the voltage parameter to ensure stable attraction, the system changes the time parameter by extending the power supply duration. When abnormal current drop is detected, the controller maintains the original safe voltage level but extends the供电 time, achieving reliable attraction through time extension rather than voltage increase. This parameter substitution resolves the contradiction by avoiding voltage-related damage risks.
3Reliability
If the contactor is redesigned or replaced to improve attraction stability, then the reliability is improved, but the cost increases
Solution Approach 1:
The contactor system performs self-diagnosis and self-adjustment through the controller that monitors coil current and automatically extends power supply time when abnormal drop is detected. This self-service capability improves attraction stability without requiring external intervention, redesign, or replacement of the contactor hardware, thereby maintaining low cost while achieving high reliability.
Solution Approach 2:
The system replaces potential mechanical redesign solutions (such as redesigning the contactor structure or replacing components) with an electronic control solution. By using the controller to monitor current and adjust power supply time, the patent achieves improved attraction stability through software/control logic rather than hardware changes, avoiding the costs associated with redesign or replacement.
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
Ensures stable contactor attraction in non-ideal environments with reduced power consumption and costs, enhancing flexibility and timeliness without the need for redesign or replacement.
Implementation Method 1
A contactor is a widely used switching appliance used to switch on, switch off, and control current in an electrical circuit
Data Source
AI summary
The present disclosure relates to a method for controlling a contactor, wherein power is supplied to the contactor by a power supply external to the contactor. The method includes: in response to determining that a power supply voltage of the power supply is greater than a first voltage threshold, determining whether an abnormal current drop process occurs; and in response to determining that the abnormal current drop process occurs, controlling a first power supply time, during which a first power supply voltage for the contactor is supplied, to be extended from a preset first value to a second value, wherein the abnormal current drop process indicates that the contactor fails to attract as expected. The present disclosure also relates to a contactor system, a computer program product and a computer-readable storage medium.