Electromagnetic Relay Life Prediction for Replacement Timing

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Solution Overview

Problem

Mechanical electromagnetic relays in electronic systems have a short service life, making it difficult to uniformly set the timing for replacement due to varying actual use conditions, which affects the overall system's longevity.

Innovation Solution

An electronic system that calculates the remaining service life of mechanical electromagnetic relays based on the number of operations and electric power applied, using a processor to determine the relay's condition and notify users when replacement is necessary.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mechanical electromagnetic relays are used to switch contacts, then the electronic system can achieve reliable switching function, but the service life of the relay becomes short and replacement timing cannot be uniformly determined

Engineering Contradiction:

Improveswitching functionVSAvoidservice life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The system performs preliminary monitoring of operating conditions (number of operations, electric power applied, temperature) and calculates remaining service life before the relay actually fails. This allows proactive replacement scheduling based on predicted lifespan rather than reactive replacement after failure, resolving the contradiction by maintaining reliability while optimizing the service life utilization.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors actual operating conditions of the relay and feeds this information back to the processor, which recalculates remaining service life based on accumulated usage data. This feedback mechanism allows dynamic adjustment of replacement timing, ensuring the relay operates reliably throughout its actual service life while enabling optimized replacement scheduling.

Inventive Principle:

Principle #23Feedback

2Ease of operation

If replacement timing is set uniformly, then maintenance scheduling becomes simple, but it cannot account for varying actual use conditions and may lead to premature or delayed replacement

Engineering Contradiction:

Improvemaintenance schedulingVSAvoidreplacement timing accuracy

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system transitions from static uniform replacement scheduling to dynamic condition-based scheduling. The processor continuously updates remaining service life calculations based on actual operating conditions (number of operations, electric power, temperature), allowing the replacement timing to adapt dynamically to each relay's actual usage pattern while maintaining simple automated scheduling through the notification system.

Inventive Principle:

Principle #15Dynamics

3Reliability

If early replacement is performed to ensure reliability, then system uptime is maintained, but resource waste increases due to replacing relays that could have continued operating

Engineering Contradiction:

Improvesystem uptimeVSAvoidresource waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The system uses parameter changes in operating conditions (number of operations, electric power applied, temperature) to dynamically adjust the replacement decision. By monitoring how these parameters evolve over time and comparing them against the calculated remaining service life, the system determines the optimal replacement moment that maintains reliability while avoiding premature replacement and resource waste.

Inventive Principle:

Principle #35Parameter changes

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

Optimizes the timing of mechanical electromagnetic relay replacement by understanding the actual use conditions, extending the system's service life and improving maintenance efficiency.

Implementation Method 1

a mechanical electromagnetic relay configured to mechanically switch a contact according to application of current to a coil

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250292982A1Electronic system, electronic method, and non-transitory computer readable medium

Publication Date: 2025.09.18 FUJIFILM BUSINESS INNOVATION CORP

AI summary

An electronic system includes: a mechanical electromagnetic relay configured to mechanically switch a contact according to application of current to a coil; and a processor configured to calculate, based on a number of operations of the contact of the mechanical electromagnetic relay and an index of electric power applied to the coil, a remaining service life of the mechanical electromagnetic relay; and transmit a notification indicating the calculated remaining service life of the mechanical electromagnetic relay.