Elementary Relay Failure Prediction Using Contact Voltage Noise
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for predicting the failure of elementary relays are inadequate, as laboratory tests only provide a general 'B10 value' that does not account for specific load conditions, leading to unnecessary replacements and early failures.
Innovation Solution
A method involving the recording and monitoring of contact voltage drops during switching cycles, specifically analyzing the noise length and amplitude of contact voltage noise, which serves as a characteristic feature to predict imminent failures by comparing it to a reference curve from a new relay, allowing for timely replacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laboratory tests with B10 values are used to predict relay failure, then a general reliability assessment is provided, but specific failure prediction for individual relays under actual load conditions is not possible
Solution Approach 1:
The patent replaces mechanical contact wear analysis with electrical signal analysis. Instead of physically examining contact degradation, the invention uses acoustic emission signals (noise measurements) during relay switching to detect and predict contact wear and impending failure, enabling non-intrusive, real-time monitoring of relay health
Solution Approach 2:
The patent implements a feedback mechanism where relay operation parameters (contact voltage, noise levels) are continuously measured and fed back to a monitoring system. This feedback loop enables the system to track relay degradation over time and predict failure before it occurs, allowing for proactive maintenance scheduling based on actual relay condition rather than fixed intervals
2Reliability
If all relays are replaced based on B10 values and switching cycle counts, then early failures are prevented, but unnecessarily many switching cycles are wasted and operational efficiency decreases
Solution Approach 1:
The patent performs preliminary detection of relay degradation through noise measurement before actual failure occurs. By identifying relays showing signs of contact wear early in their degradation process, the system allows for planned replacement during scheduled maintenance windows rather than unexpected failures, maximizing relay utilization while preventing failures
Solution Approach 2:
The patent transitions from static replacement schedules to dynamic, condition-based monitoring. The system continuously adapts its assessment of relay health based on real-time noise measurements and operational conditions, allowing relay replacement timing to be optimized based on actual wear rates and usage patterns rather than fixed intervals
3Reliability
If continuous monitoring of contact voltage is performed to detect noise, then early failure detection is improved, but measurement complexity and processing requirements increase
Solution Approach 1:
The patent extracts only the relevant failure indicator signal (noise component) from the complex contact voltage waveform. By using bandpass filtering and noise measurement techniques to isolate the acoustic emission signals from normal switching operations, the system simplifies the monitoring task to detecting specific noise characteristics rather than analyzing the entire voltage signal
Data Source
AI summary
The disclosure relates to a method for predicting the failure of an elementary relay having a switch for switching a load contact of a load circuit and an excitation coil for actuating the switch. The method may include exciting the excitation coil in order to switch on the load contact; detecting a time characteristic of a contact voltage at the load contact when switching on the load contact; extracting a characteristic feature from the time characteristic of the contact voltage; and monitoring the characteristic feature during operation of the elementary relay.