Relay Armature Position Sensing to Prevent Stuck Switching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electromagnetic relays in automated control systems can become stuck, leading to potential electrical damage due to improper switching states, which existing technologies fail to reliably detect and prevent.
Innovation Solution
Incorporating built-in position sensors and current sensors within relays to monitor the armature's position and electrical current, enabling controllers to accurately determine the relay's state and prevent hot switching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing relay technology is used without position sensors, then the device complexity is low, but the reliability is insufficient because relays can become stuck and improper switching states cannot be detected
Solution Approach 1:
The patent combines the position sensor and current sensor directly into the relay structure, merging the monitoring function with the switching function. This integration allows the relay to self-monitor its state without requiring external monitoring components, thereby improving reliability while minimizing the increase in device complexity.
Solution Approach 2:
The position sensor provides real-time feedback on the armature position to the controller, enabling the system to detect whether the relay is properly opened or closed. This feedback mechanism allows for immediate detection of stuck relays and prevents improper switching states, directly addressing the reliability issue.
2Measurement precision
If position sensors and current sensors are integrated into the relay, then measurement precision of relay state is improved, but the device complexity increases
Solution Approach 1:
The position sensor serves multiple functions: it detects armature position, determines relay switching state, and provides feedback to the controller. This multi-functionality approach allows a single component to achieve precise measurement while minimizing the overall complexity by avoiding multiple separate monitoring components.
3Object-affected harmful factors
If relays are used in safety-critical applications without monitoring, then the device complexity is low, but harmful factors increase due to potential electrical damage from improper switching
Solution Approach 1:
The position sensor and current sensor continuously monitor the relay state before switching operations are commanded, ensuring the relay is in the correct state. This preliminary monitoring prevents hot switching and electrical damage by detecting improper states before they can cause harm, directly addressing the harmful factors issue.
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
Enhances the reliability of relays by ensuring they are properly opened or closed, minimizing board space requirements, and preventing electrical damage in safety-critical applications.
Implementation Method 1
the position sensor is arranged to monitor the position of the armature by sensing the position of the permanent magnet
Implementation Method 2
a solenoid that is disposed inside the housing enclosure and arranged to actuate the armature between the disengaged position and the engaged position
Implementation Method 3
a current sensor that is disposed inside the housing enclosure and configured to measure a level of electrical current through the armature
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3C
AI summary
A relay 100, 200, 300, 400, comprising: a housing enclosure; a first terminal; a second terminal; an armature 104, 206, 310, 4026 arranged to assume one of an engaged and disengaged position, such that when the armature is in the engaged position the first terminal is electrically coupled to the second terminal by the armature, and when the armature is in the disengaged position, the first terminal is electrically isolated from the second terminal as a result of the armature being removed from at least one of the first terminal and/or the second terminal; a solenoid 130, 318, 318, 418 that is disposed inside the housing enclosure and arranged to actuate the armature between the disengaged position and the engaged position; and a position sensor 142A, 142B, 142C, 142D, 222, 322, 323, 325, 422, 429, 431, 452 that is disposed inside the housing enclosure, the position sensor being arranged to monitor a position of the armature and output an indication of whether the armature is in the disengaged position or the engaged position.