Multi-Relay Current Sensor Switching for Broad Range Protection
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Solution Overview
Problem
Existing relays are limited to either low or high current ranges, leading to potential overload or damage when used outside their designated current levels, and lack compatibility across a broad load current range, making them difficult to install correctly, especially by non-experts, and resulting in delayed responses or equipment damage.
Innovation Solution
A multi-relay system comprising a first relay switch operable over a low current range and a second relay switch operable over a high current range, connected in parallel, with a current sensor that detects input current and activates the appropriate relay switch without software components, allowing operation across both ranges and enabling installation on either side of the load relative to the power source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single relay is designed for high current operation, then it can handle high current loads, but it has delayed response time due to ramp up time
Solution Approach 1:
The relay system is segmented into two separate relay switches: a first relay switch optimized for low current operation with fast response, and a second relay switch optimized for high current operation. The current sensor divides the monitoring function between these two relays, allowing each to operate in its optimal current range without compromise to response time or current handling capability.
2Speed
If a relay is designed for low current operation, then it has short response time, but it cannot handle high current inputs
Solution Approach 1:
The relay system achieves universality by combining multiple relay switches with different current ratings in parallel configuration. The first relay switch handles low current operations with fast response, while the second relay switch handles high current operations. The current sensor enables the system to universally accommodate both low and high current inputs by automatically selecting the appropriate relay switch based on the detected current level.
3Reliability
If special care is taken to select the proper relay for each application, then equipment damage is prevented, but installation time increases and complexity arises
Solution Approach 1:
The relay system performs self-service by automatically selecting the appropriate relay switch based on the detected input current level. The current sensor continuously monitors the input current and automatically activates either the first relay switch for low current or the second relay switch for high current, eliminating the need for manual selection or expert intervention. This self-configuring capability simplifies installation and reduces the risk of improper relay selection.
4Adaptability or versatility
If multiple relays are utilized in different portions of an application, then current range coverage is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple relay switches with different current ratings into a single integrated relay system with parallel configuration. Instead of distributing multiple relays across different portions of an application, the invention combines them into one unified device with a shared current sensor and control circuitry. This merging approach maintains broad current range coverage while reducing overall system complexity and improving ease of installation.
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 multi-relay system provides reliable operation across a broad current range, reducing the risk of damage and enabling early response to changing currents by activating the appropriate relay switch, thus enhancing compatibility and ease of installation.
Implementation Method 1
a current sensor configured to: detect an input current
Data Source
AI summary
A multi-relay including a first relay switch operable over a first current range; a second relay switch operable over a second current range; and a current sensor configured to: detect an input current; in response to the input current being within the first current range, activate the first relay switch; and in response to the input current being within the second current range, activate the second relay switch.