Relay Contactor Movement Detection for Faulty Coil State Diagnosis
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Solution Overview
Problem
Existing relay systems lack effective diagnostics for detecting mechanical shocks and malfunctions, particularly in safety-critical applications like electric vehicle battery disconnect units, which can lead to potential hazards such as electric shock and fire.
Innovation Solution
A fault detection system for relays, utilizing comparators and processing circuitry to generate comparison signals based on coil voltage and current thresholds, detecting unintended movements and generating fault indications when the relay is in a faulty state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If relay systems are used in safety-critical applications without effective diagnostics, then the system can operate simply, but the reliability and safety are compromised due to undetected mechanical shocks and malfunctions
Solution Approach 1:
The patent applies preliminary action by implementing a diagnostics system that proactively monitors relay coil voltage and current before failures occur. The system continuously compares actual electrical parameters against expected thresholds and detects deviations that indicate mechanical shocks or malfunctions, enabling preventive detection rather than reactive response to failures.
Solution Approach 2:
The patent uses an intermediary diagnostics system that mediates between the relay's electrical operations and the control system. The diagnostics circuit acts as a mediator by monitoring coil voltage and current, generating comparison signals, and providing fault indications to the control system without directly interfering with the relay's primary switching function.
2Object-affected harmful factors
If no fault detection system is implemented, then the device complexity remains low, but harmful factors such as electric shock and fire hazards cannot be prevented
Solution Approach 1:
The patent applies preliminary anti-action by implementing a diagnostics system that detects and signals potential hazards before they manifest as dangerous failures. By continuously monitoring coil voltage and current parameters and comparing them against expected thresholds, the system identifies deviations that could lead to mechanical shocks, contactor damage, or safety hazards, enabling preventive action.
Solution Approach 2:
The patent implements feedback by creating a closed-loop monitoring system that continuously measures coil voltage and current, compares actual values against expected thresholds, and provides feedback through fault indication signals when deviations are detected. This feedback mechanism enables the control system to respond to potential failures and take corrective action before hazards occur.
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 fault tolerance of relays by accurately identifying mechanical shocks and malfunctions, ensuring safe operation in critical applications by providing timely fault detection and preventing potential hazards.
Implementation Method 1
generating a comparison signal SP having a first value when a voltage that is applied at one end of a contactor coil of a relay is above a threshold VP and a second value when the voltage is below the threshold VP
Implementation Method 2
detecting whether the relay is in a faulty state based on the comparison signals SP and SD
Data Source
AI summary
A method, comprising: generating a comparison signal SP having a first value when a voltage that is applied at one end of a contactor coil of a relay is above a threshold VP and a second value when the voltage is below the threshold VP; generating a comparison signal SD having the first value when the voltage is above a threshold VD and the second value when the voltage is below the threshold VD; detecting whether the relay is in a faulty state based on the comparison signals SP and SD; and generating an indication of a fault when the relay is detected to be in a faulty state.