Relay Contact Thermal Imaging for Real-Condition Performance Testing
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Solution Overview
Problem
Existing relay performance testing methods focus on individual parameters like voltage, current, and time, neglecting the assessment of contact performance, which is crucial for intermediate relays, and are inefficient, unsafe, and lack comprehensive evaluation under actual working conditions.
Innovation Solution
A system and method using infrared thermal imaging to test relay contact performance by collecting temperature, closing quantity, and working duration, incorporating a collection device with an infrared thermal imager, timer, and ampere-voltage meter to assess contact performance under simulated working conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional resistance test and voltage-current test methods are used, then individual parameters can be measured, but contact performance cannot be comprehensively evaluated
Solution Approach 1:
The patent replaces traditional mechanical/electrical measurement methods (multimeter, ammeter, regulated power supply) with infrared thermal imaging technology. The infrared thermal imager non-contactly detects temperature changes of relay contacts during operation, substituting direct electrical measurement with thermal field detection to evaluate contact performance comprehensively.
Solution Approach 2:
The patent changes the measurement parameter from direct electrical parameters (resistance, voltage, current) to thermal parameters (temperature). By monitoring temperature changes of contacts during closing and releasing operations, the system evaluates contact performance under actual working conditions, transforming the evaluation dimension.
2Reliability
If manual testing of individual parameters is performed, then testing can be conducted, but testing efficiency is low and manual data recording is required
Solution Approach 1:
The infrared thermal imager automatically captures temperature data without requiring manual intervention. The system self-performs the measurement and data collection process, eliminating manual recording operations and significantly improving testing efficiency while maintaining test validity.
Solution Approach 2:
The patent replaces manual measurement and recording operations with automated infrared thermal imaging. The system automatically captures temperature data during relay contact operations, substituting manual processes with automated optical detection and data acquisition.
3Adaptability or versatility
If regulated power supply circuit is assembled and replaced during testing, then voltage and current can be adjusted, but electric shock risk is posed
Solution Approach 1:
The patent substitutes direct electrical contact and power supply adjustment with non-contact infrared thermal detection. The infrared thermal imager measures temperature from a distance, eliminating the need for physical assembly and replacement of regulated power supply circuits, thereby removing electric shock risks while maintaining testing capability.
Solution Approach 2:
The patent introduces infrared radiation as an intermediary between the relay contact and the measurement device. Instead of directly measuring electrical parameters through electrical contact, the system uses thermal radiation as a mediator to detect contact temperature, eliminating direct electrical exposure and associated hazards.
4Measurement precision
If individual parameter testing is performed, then resistance and voltage can be measured, but actual contact performance under continuous closing and releasing conditions cannot be reflected
Solution Approach 1:
The patent changes the measurement approach from static electrical parameter measurement to dynamic thermal parameter monitoring. By continuously monitoring temperature changes during repeated closing and releasing operations, the system captures actual contact performance under operational conditions rather than isolated parameter values.
Solution Approach 2:
The patent implements continuous temperature monitoring during the entire testing process, including multiple closing and releasing cycles. This continuous detection captures the thermal characteristics of contacts under sustained operation, reflecting actual performance rather than instantaneous parameter values.
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 system provides a safe, efficient, and accurate assessment of relay contact performance, reflecting actual working conditions and identifying potential faults through temperature changes, enhancing safety and testing efficiency.
Implementation Method 1
the collection device comprises an infrared thermal imager... configured to collect a temperature... of the contact
Implementation Method 2
the ampere-voltage meter is configured to detect a value of current flowing through the contact
Data Source
AI summary
The present disclosure provides a system and method for testing performance of a relay contact based on infrared thermal imaging, and relates to the field of performance testing of relay contacts. The system includes a collection device, a testing device, and a time relay. The testing device is separately connected to a tested relay and the time relay, and configured to control closing and release of a contact of the tested relay by using the time relay. The collection device is connected to the testing device, and configured to collect a temperature, a closing quantity, and working duration of the contact of the tested relay. The present disclosure resolves a limitation in existing performance testing methods for intermediate relays, which predominantly concentrate on individual parameters like voltage, current, and time, while overlooking the assessment of contact performance.