Contactor Pull-In Control Using Abnormal Current Drop Detection
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Solution Overview
Problem
Existing contactor systems face challenges in maintaining stable attraction under non-ideal operating conditions, such as high temperatures or low supply voltages, leading to unstable operation and increased power consumption, without cost-effective solutions like redesigning or replacing components.
Innovation Solution
A method to control the power supply time of contactors by determining abnormal current drops and extending the power supply time when necessary, using processors and memory to adjust power supply voltage based on set thresholds and current change curves, ensuring stable attraction without redesigning or replacing contactors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power supply voltage is increased to ensure stable contactor attraction, then the reliability of contactor attraction is improved, but the power consumption increases
Solution Approach 1:
The patent applies dynamics by making the power supply time dynamic rather than fixed. The control method adjusts the power supply time based on real-time detection of current drop characteristics, allowing the system to adapt to varying operating conditions. This resolves the contradiction by providing just enough power for stable attraction without excessive power consumption.
Solution Approach 2:
The patent implements feedback by continuously monitoring the current change characteristics during the power supply process. The control device detects whether an abnormal current drop occurs and uses this feedback information to adjust the power supply time accordingly. This feedback mechanism enables the system to maintain reliable attraction while minimizing power consumption by avoiding unnecessarily extended power supply.
2Reliability
If the power supply time is extended to ensure stable contactor attraction, then the reliability of contactor attraction is improved, but the power consumption increases
Solution Approach 1:
The patent makes the power supply time dynamic by baseing it on detected current characteristics rather than using a fixed extended duration. The power supply time is adjusted in real-time according to whether abnormal current drop is detected, resolving the contradiction between ensuring reliable attraction and minimizing unnecessary power supply duration.
Solution Approach 2:
The control device uses feedback from current monitoring to determine the appropriate power supply time. By detecting abnormal current drop characteristics and responding accordingly, the system extends power supply only when necessary for stable attraction, avoiding excessive duration while maintaining reliability.
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 patent applies self-service by enabling the existing contactor system to adjust its own operation through intelligent control. The control device monitors current characteristics and automatically adjusts power supply time to ensure stable attraction, allowing the system to solve its own reliability issues without requiring redesign or replacement of the contactor hardware, thus avoiding increased costs.
Solution Approach 2:
The patent changes operational parameters (power supply time) rather than hardware parameters. By adjusting the power supply time based on detected current characteristics, the system achieves reliable attraction through parameter optimization instead of hardware redesign or replacement, maintaining cost-effectiveness while improving reliability.
4Adaptability or versatility
If the power supply voltage is adjusted dynamically, then the adaptability to varying conditions is improved, but the device complexity increases
Solution Approach 1:
The patent uses feedback from simple current monitoring to trigger power supply time extension only when abnormal current drop is detected. This feedback-based approach provides adaptability to varying operating conditions while keeping the control logic relatively simple, as it relies on detecting specific current characteristics rather than complex real-time adjustments.
Solution Approach 2:
The patent changes the power supply time parameter based on detected current characteristics. This parameter adjustment provides adaptability to different operating conditions (such as high temperature or low voltage) while maintaining relatively simple control logic, as it involves extending or maintaining power supply time rather than complex multi-parameter adjustments.
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 under varying conditions while reducing power consumption and costs by timely adjustment of power supply time, avoiding costly redesigns or replacements.
Implementation Method 1
determining whether to extend a first power supply time for providing a first power supply voltage to the contactor based on a detection result of whether an abnormal current drop process occurs during a attraction process of the contactor
Implementation Method 2
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
Data Source
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Figure 4b~5
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.