Relay Control Circuit Voltage Switching for Power Reduction

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Solution Overview

Problem

Conventional relay control methods dissipate excessive power due to the need for high pick-up voltage to energize relays, while lower hold-up voltage is sufficient to maintain them in an energized state, which is inefficient, especially under Energy Star and DOE guidelines for energy efficiency.

Innovation Solution

A relay control circuit that provides a first voltage for a short period to energize the relay and then switches to a lower second voltage, which is sufficient to maintain the relay in an energized state, using a switch, diode, and pulse generator to manage the voltage levels and duration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high pick-up voltage is continuously applied to energize the relay, then the relay remains reliably in an energized state, but excessive power is dissipated

Engineering Contradiction:

Improverelay energized state stabilityVSAvoidpower dissipation

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent applies periodic action by using a pulse generator to provide high voltage only during the brief moment needed to energize the relay coil, then switching to low voltage for holding. The control circuit periodically switches between high voltage (for energizing) and low voltage (for holding), eliminating continuous high power consumption while maintaining reliable relay operation.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent implements dynamics by making the voltage supply adaptive rather than static. The control circuit dynamically adjusts the voltage level based on the relay's operational state: high voltage when the relay needs to be energized, and low voltage when the relay is already energized and needs to be held. This dynamic voltage adjustment resolves the contradiction between reliability and energy loss.

Inventive Principle:

Principle #15Dynamics

2Reliability

If high voltage is applied to the relay coil, then the relay energizes reliably from a de-energized state, but power consumption increases significantly

Engineering Contradiction:

Improverelay pick-up reliabilityVSAvoidrelay coil power consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent applies segmentation by dividing the voltage supply into two distinct segments: a high voltage segment for the brief pick-up phase when the relay needs to be energized, and a low voltage segment for the extended hold phase when the relay is already energized. This segmentation allows the system to use high voltage only when necessary for reliable pick-up, while minimizing power consumption during the longer holding period.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements parameter changes by varying the voltage parameter over time based on the relay's operational requirements. The control circuit changes the voltage parameter from high to low after the relay is energized, and from low to high when re-energization is needed. This dynamic parameter adjustment resolves the contradiction between pick-up reliability and ongoing power consumption.

Inventive Principle:

Principle #35Parameter changes

3Loss of energy

If low hold-up voltage is used to maintain the relay, then power dissipation is reduced, but the relay may not energize from a de-energized state

Engineering Contradiction:

Improvepower dissipationVSAvoidrelay pick-up capability

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

Inventive Principle:

Principle #19Periodic action

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 approach reduces power dissipation by using the full pick-up voltage only when necessary and a lower hold-up voltage for extended periods, potentially utilizing one-fourth the power of conventional methods, thereby enhancing energy efficiency.

Implementation Method 1

a first input to receive a first voltage capable of energizing the relay from a de-energized state... a second input to receive a second voltage capable of maintaining the relay in an energized state

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS10256065B2Systems and methods for controlling relays

Publication Date: 2019.04.09 SCHNEIDER ELECTRIC IT CORP

AI summary

A relay control circuit for use with a relay having a coil voltage input. The relay control circuit includes a first input to receive a first voltage capable of energizing the relay from a de-energized state, a second input to receive a second voltage, less than the first voltage, that is capable of maintaining the relay in an energized state, and means, responsive to a relay control signal having one of a first state and a second state, for switchably coupling the coil voltage input to the first input for a period of time sufficient to energize the relay in response to the relay control signal having the first state, and for switchably coupling the coil voltage input to the second input in response to expiration of the period of time.