Relay Integrated Control Unit for Coil Current Regulation
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Solution Overview
Problem
Existing relays require an externally supplied precisely defined coil signal for operation, leading to incorrect switching if the signal is too weak or strong, and are not compatible with low-power control systems like on-board vehicle computers that cannot provide the necessary pull-in or drop-out currents.
Innovation Solution
A relay with an integrated control unit that interprets external voltages as control signals, generating a precise coil current, and includes features like undervoltage protection, reverse polarity protection, and a compact design with a round circuit board to ensure reliable and safe operation, including spring-loaded contact pins for vibration resistance and short-circuit proofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an external control system is used to supply coil signal, then the relay structure remains simple, but switching reliability deteriorates when voltage is too weak or too high
Solution Approach 1:
The control unit is integrated directly into the relay housing, merging the control function with the relay switching mechanism. This integration ensures that the control unit can precisely regulate coil current while maintaining a compact overall structure, resolving the contradiction between improved reliability and device complexity.
Solution Approach 2:
The control unit acts as an intermediary between the external control signal and the coil arrangement. It receives external voltage signals, processes them, and generates the precisely defined coil current needed for reliable switching, protecting the system from voltage fluctuations while maintaining structural simplicity.
2Adaptability or versatility
If external control systems are used, then device complexity is reduced, but the relay becomes incompatible with low-power control systems that cannot provide sufficient pull-in or drop-out currents
Solution Approach 1:
The control unit changes the electrical parameters by receiving low-power control voltages and converting them into the high current needed by the coil arrangement. This parameter transformation enables compatibility with low-power control systems like on-board vehicle computers while maintaining the ability to generate sufficient pull-in and drop-out currents.
3Volume of moving object
If the circuit board is made compact to match coil arrangement diameter, then volume is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The circuit board is designed with a round shape matching the coil arrangement geometry. This spherical/symmetric design optimizes space utilization within the cylindrical relay housing, achieving compact volume while the standardized round shape facilitates manufacturing compared to irregular geometries.
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 integrated control unit enhances switching reliability, prevents field failures from overcurrent, and allows for power-free switching, ensuring high electronic safety and compatibility with low-power systems, while maintaining a compact and robust design.
Implementation Method 1
A magnetic flux is generated by the coil current, which moves the armature so that a current flow can either be permitted or interrupted via two connection contacts.
Implementation Method 2
At least one holding means, in particular a permanent magnet, can be provided in the bistable relay, with which the armature can be fixed in one position.
Data Source
Figure 1
Figure 2
AI summary
The relay (10) has a coil housing (14) comprising a movable armature (24) allowing or disconnecting current flow over two main contact terminals (16.1, 16.2) by magnetic flow that is generated in a coil arrangement (22) using coil current. A control unit (26) is provided on the coil housing for controlling the coil current, and is formed on a round board. Spring-mounted contact pins (28.1) are provided for contacting the control unit, and are electrically connected with control electrodes (20.1, 20.2), where coil unloading is examinable by the control unit.