Relay Armature Position Detection Using Dual-Coil Transformer Arrangement
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Solution Overview
Problem
Existing methods for determining the armature position of relays, particularly in compact relay modules, are inadequate for detecting misalignments and faulty contact positions, which can lead to incorrect switching behavior in safety-relevant applications.
Innovation Solution
A multi-coil relay arrangement is used where a first coil and a second coil are mounted on a U-shaped yoke, with a signal transmitter emitting a signal to the first coil and a measuring device detecting a response signal from the second coil to determine the armature position based on transmission properties, such as attenuation or time shifts, allowing for accurate detection of air gap size and misalignments without affecting the relay's operational power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a multi-coil relay arrangement with signal transmitter and measuring device is implemented to determine armature position, then measurement precision of armature position is improved, but device complexity increases
Solution Approach 1:
The patent applies multi-functionality by making the relay coils serve dual purposes: their primary function for relay actuation and a secondary function as transformer windings for position detection. The first and second coils form a transformer arrangement where the first coil acts as primary winding and the second coil as secondary winding, enabling non-contact measurement of armature position through magnetic coupling without requiring separate dedicated sensing components.
Solution Approach 2:
The relay module performs self-diagnosis by using its own internal components (coils and magnetic circuit) to detect its operational state. The measuring device evaluates the transmission behavior of magnetic signals through the relay's own magnetic circuit to determine armature position, allowing the system to monitor itself without external complex measurement equipment.
2Volume of moving object
If compact relay module design with narrow width is used to reduce installation space, then volume of relay module is reduced, but measurement precision of armature position deteriorates
Solution Approach 1:
The patent replaces mechanical position sensing methods with electromagnetic field-based measurement. Instead of using mechanical switches, contactless sensors, or complex mechanical linkages that would require additional space, the system uses magnetic field coupling between the first and second coils to detect armature position. This electromagnetic approach enables accurate measurement within the compact 3-3.5 mm width constraint.
Solution Approach 2:
The system changes the measurement parameter from direct physical contact or optical measurement to magnetic field transmission characteristics. By evaluating how magnetic signals transmit through the magnetic circuit and air gap, the system can determine armature position based on changes in magnetic coupling efficiency, which remains effective even in the narrow 3-3.5 mm form factor.
3Reliability
If additional measurement components are added to detect armature position to improve reliability, then reliability of safety function is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent merges the measurement function with the existing relay structure by integrating the position detection capability into the coil assembly. The first and second coils, already necessary for relay operation, are configured to form a transformer arrangement that simultaneously enables position sensing. This consolidation eliminates the need for separate measurement components and reduces assembly steps while maintaining safety function reliability.
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 method enables precise determination of the armature position in limited space, providing a safety function by detecting misalignments and ensuring correct switching behavior in relay modules, even in narrow configurations like those with a width of 3.5 mm, without interfering with the relay's normal operation.
Implementation Method 1
a signal transmitter electrically connected to the first coil and configured to emit a first signal to the first coil, and a measuring device electrically connected to the second coil and configured to detect a second signal at the second coil, the second signal being a response signal to excitation of the first coil with the first signal
Implementation Method 2
The magnetic transfer behavior between the first and second coils of the relay can depend on the size of the air gap, i.e., the working air gap of the armature, particularly due to the reluctance of the magnetic circuit
Data Source
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AI summary
The invention relates to an arrangement 100 for determining the armature position of a relay 101, wherein the relay 101 comprises a first coil 103 on a first section 105 of a yoke 102 and a second coil 104 on a second section 106 of the yoke 102, wherein an armature 107 of the relay 101 is spaced from the yoke 102 by an air gap 108. The arrangement 100 includes a signal transmitter 109, which is electrically connected to the first coil 103 and configured to send a first signal to the first coil 103, and a measuring device 110, which is electrically connected to the second coil 104 and configured to detect a second signal at the second coil 104, wherein the second signal is a response signal to an excitation of the first coil 103 with the first signal. The arrangement 100 is configured to determine the armature position of the relay 101 based on the second signal. The invention further relates to a method. (Fig. 1)