Hybrid Relay Drive Waveform for Fast Low-Noise Switching
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Solution Overview
Problem
Hybrid relays face challenges in reducing acoustic noise and achieving fast switching times while maintaining a long operational life, with existing solutions either introducing delays or requiring significant thermal dissipation.
Innovation Solution
A method for operating hybrid relays using a digital-to-analog converter to shape a drive signal with a waveform that includes a vertical segment, a linear ramp, and another vertical segment, optimizing the closing time while keeping noise levels low, and incorporating an acoustical sensor for auto-learning and self-adaptation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the electrical contacts are moved slower to reduce switching noise, then noise level is reduced, but switching time increases significantly
Solution Approach 1:
The drive signal is divided into periodic phases: a first phase with slowly increasing voltage to move contacts silently, and a second phase with rapidly increasing voltage to complete closing quickly. This periodic variation in voltage application rate resolves the contradiction between slow silent movement and fast overall switching.
Solution Approach 2:
The drive signal dynamically changes its characteristics during operation - starting with a slow ramp-up phase and transitioning to a fast increase phase. This dynamic adjustment of voltage application rate allows the system to adapt between noise reduction and speed requirements at different moments in the switching process.
2Object-generated harmful factors
If a linear ramp drive signal is used to move contacts slowly and silently, then noise is reduced, but the time required for contacts to travel from open to closed position increases to 5-10 seconds
Solution Approach 1:
The drive signal uses periodic action with two distinct phases: first a slow linear ramp for silent contact movement, then a rapid voltage increase to complete closing. This periodic structure allows the system to achieve both silent operation during contact travel and fast overall switching completion.
Solution Approach 2:
The first phase of slowly increasing voltage performs the preliminary action of moving contacts silently to near-closed position, preparing them for the final rapid closing action in the second phase. This preliminary silent movement prevents noise while setting up for fast completion.
3Productivity
If the relay switching operation is made faster, then productivity is improved, but acoustic noise increases significantly
Solution Approach 1:
The switching operation is segmented into two distinct phases with different voltage application rates. The first segment handles silent contact movement, while the second segment achieves rapid closing. This segmentation allows the system to combine both slow silent operation and fast overall switching.
Solution Approach 2:
The drive signal dynamically transitions from a slow increasing phase to a rapid increase phase, allowing the system to adapt between noise reduction and speed requirements. This dynamic adjustment resolves the contradiction between fast switching and noise reduction.
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
Significantly reduces overall closing time and noise levels, accommodating performance variability and ensuring optimal operation throughout the relay's life, with noise reduction up to 18dB and improved reliability.
Implementation Method 1
a drivable coil, and at least a movable contact that can be alternatively switched between a closed position and an open position
Data Source
AI summary
x A hybrid relay (1) comprises an electromechanical part (10) with a movable contact (103), a solid state relay (11) and a control unit (2) for applying a drive signal (S',S") to the drivable coil (101) of the electromechanical part. A method for operating the hybrid relay comprises steps of determining a first minimum voltage (V1) for the drive signal above which the movable contact (103) starts to move away from an open position (P o ) and a second minimum voltage (V2) for the drive signal above which the movable contact (103) reaches the closed position (P c ), and a step of shaping a waveform (W) for the drive signal comprising a portion (W1) consisting of a vertical segment jumping from zero to the first minimum voltage value, a portion (W2) wherein the voltage gradually increases from the first minimum value to the second minimum voltage value, and a portion (W3) consisting of another vertical segment jumping from the second minimum voltage value to an upper voltage boundary (V sup ).