Relay Controller with Commutation Winding for Energy Efficiency
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Solution Overview
Problem
Existing relay systems face high current consumption, high costs, and slow commutation due to high inductance in excitation windings, leading to premature wear and increased CO2 emissions in automotive applications.
Innovation Solution
A relay controller that controls the excitation current by providing a pull-in current followed by a lower holding current, using a commutation device to manage the current flow and voltage, and integrating a temperature sensor to reduce power consumption, allowing for efficient energy dissipation and extended relay lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high-side or low-side switch is used to connect the excitation winding to the operating voltage, then the relay can be operated, but high current consumption occurs after switch-on
Solution Approach 1:
The patent applies periodic action by implementing two distinct operational phases: a pull-in phase with high current to activate the relay, and a holding phase with reduced current to maintain the relay state. This temporal separation of current levels reduces overall energy consumption while ensuring reliable relay operation.
Solution Approach 2:
The patent implements dynamics by making the excitation current adjustable and time-dependent. The current is dynamically changed from a high pull-in current to a lower holding current based on the relay's operational state, optimizing energy consumption throughout the relay's lifecycle.
2Strength
If the excitation winding has many windings with thin wire to achieve high impedance, then the coil resistance is increased, but the inductance becomes high making commutation difficult
Solution Approach 1:
The patent introduces an intermediary commutation winding that assists in the commutation process. This additional winding acts as a mediator to speed up the collapse of the magnetic field in the excitation winding, enabling faster commutation without changing the excitation winding's resistance characteristics.
3Reliability
If a diode is used for commutation purposes, then the commutation current can flow through the diode, but only a low commutation voltage is permitted resulting in slow commutation
Solution Approach 1:
The commutation winding serves as an intermediary element that enables faster commutation by providing an additional path for current decay. It works in conjunction with the diode to accelerate the commutation process without exceeding the diode's voltage limitations.
Solution Approach 2:
The patent changes the commutation parameters by introducing the commutation winding, which modifies the current decay characteristics. This allows the system to achieve faster commutation speeds while maintaining compatibility with the diode's operational constraints.
4Speed
If a zener diode is used for commutation purposes, then the commutation current can flow through the zener diode undergoing breakdown, but very high power loss occurs
Solution Approach 1:
The commutation winding acts as an intermediary that reduces the burden on the zener diode. By providing an additional current path, it decreases the current that must flow through the zener diode, thereby reducing power loss while maintaining fast commutation speed.
Solution Approach 2:
Instead of relying entirely on the zener diode for commutation, the patent uses partial action by combining the zener diode with the commutation winding. This shared approach reduces the excessive current demand on the zener diode, lowering power loss while achieving adequate commutation speed.
5Speed
If a resistor is used for commutation purposes, then a high voltage can be applied to the excitation winding for rapid commutation, but a high voltage pulse arises shortly after turn-off requiring expensive high-voltage semiconductor switches
Solution Approach 1:
The commutation winding serves as an intermediary that enables rapid commutation without requiring high-voltage switches. It works together with the diode or zener diode to achieve fast current decay, eliminating the need for expensive high-voltage semiconductor switching components.
6Speed
If a resistor is used for commutation purposes, then current flows through the resistor when the relay is switched on, but this increases power consumption
Solution Approach 1:
The commutation winding acts as an intermediary that enables the system to use a higher-value resistor for commutation without significantly increasing power consumption during normal operation. The commutation winding provides the necessary current path during switching transitions, allowing the resistor to have minimal impact on steady-state power consumption.
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 solution reduces current consumption, minimizes wear on relay contacts, and extends the service life of relays while reducing CO2 emissions by optimizing current flow and energy dissipation in automotive systems.
Implementation Method 1
a first terminal 501, which is connected to an excitation winding 310 of the relay 300... when the relay 300 is turned on, the excitation current through the excitation winding 310 of the relay 300 is controlled in such a way that through the excitation winding 310 there flows firstly a pull-in current
Implementation Method 2
when the relay 300 is switched off, a commutation current that flows through the excitation winding 310 is fed to a commutation device 400 through the first terminal 501 and through the second terminal 502 of the relay controller 500
Data Source
AI summary
The invention relates to a relay controller (500) for controlling an excitation current of a relay (300), wherein the relay controller (500) is designed, upon the energization of the relay (300) by means of a switch (210, 211, 221), to control the excitation current through the excitation winding (310) of the relay (300) in such a way that through the excitation winding (310) there flows firstly a pull-in current and, after a pull-in time has elapsed, through the excitation winding there flows a holding current that is lower than the pull-in current, and wherein the relay controller (500) is designed, upon the switching-off of the relay by means of the switch (210, 211, 221), to feed a commutation current that flows through the excitation winding (310) to the commutation device (400) through the first terminal (501) and through the second terminal (502) of the relay controller (500).