High-Voltage Contactor Weld State Detection via Actuator Coil Analysis
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Solution Overview
Problem
Conventional systems fail to effectively detect welded and partially welded contacts in high-voltage contactors, leading to undetected issues and restricted use in various contactor designs, which can result in undesirable conditions.
Innovation Solution
The method involves utilizing actuator coil current and voltage measurement characteristics during contactor actuation to determine the weld state, comparing these characteristics to those of a reference contactor, and applying a weighted model based on contactor design to identify normal, partially welded, or welded states, providing an advanced warning for vehicle systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional current rise time detection is used, then welded contactors can be detected in some instances, but many welded and partially welded contactors remain undetected
Solution Approach 1:
The patent segments the detection process into multiple independent measurement components: current rise time analysis, maximum derivative calculation, sign change counting, and weighted scoring. Each segment evaluates a specific aspect of the actuator current waveform, and their combined results provide comprehensive weld detection coverage that overcomes the limitations of any single detection method.
Solution Approach 2:
The patent transforms the detection approach by changing multiple parameters simultaneously: it analyzes not just current rise time but also the maximum derivative of current, the number of sign changes in the derivative, and applies weighted scoring based on contactor design characteristics. This multi-parameter analysis enables detection across diverse contactor designs and weld states.
2Adaptability or versatility
If conventional detection methods are used, then detection is restricted to limited contactor designs, but broader applicability is needed
Solution Approach 1:
The patent creates a universal detection system that functions across multiple contactor designs by incorporating design-specific weighting factors. The system maintains a reference database of characteristics from normally operating contactors and applies weighted scoring that adapts to different contactor designs, enabling accurate detection across diverse applications while preserving design-specific nuances.
Solution Approach 2:
The detection system dynamically adapts to different contactor designs by adjusting weighting factors based on reference characteristics specific to each design type. Rather than using fixed thresholds, the system dynamically compares measured characteristics against design-specific references and applies appropriate weights to generate accurate weld state determinations for various contactor configurations.
3Measurement precision
If multiple current characteristics are analyzed with weighted scoring, then detection accuracy across various designs improves, but system complexity increases
Solution Approach 1:
The patent performs preliminary actions by pre-establishing reference databases of characteristics from normally operating contactors for various designs. These reference values and weighting factors are determined beforehand, allowing the detection system to operate with straightforward comparisons during actual weld detection without requiring complex real-time calculations or adaptive learning algorithms.
Solution Approach 2:
The system incorporates feedback mechanisms where the measured characteristics are compared against reference values, and the weighted scoring provides feedback on the likelihood of weld states. This feedback loop enables accurate classification of contactor states (normal, partially welded, welded) while maintaining computational efficiency through structured comparison and scoring rather than complex iterative analysis.
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
This approach allows for the detection of welded and partially welded contacts across various designs, enabling advanced warnings to vehicle operators and systems, enabling operation in a limited mode until repairs are made and preventing complete contactor welds.
Implementation Method 1
receiving current information from a current sensor and voltage information from a voltage sensor associated with an actuator coil of the contactor
Data Source
AI summary
Systems and methods are disclosed for determining a weld state of a contactor (e.g., normal, partially welded, and/or welded states) based on a variety of actuator coil characteristics during actuation. In some embodiments, the disclosed systems and methods may be utilized in connection with determining contactor weld states in a variety of contactor designs. In further embodiments, the disclosed systems and methods may utilize a probability weighted score accounting for contactor design characteristics and information obtained from a reference contactor to identify a weld state associated with a contactor device.