Relay Processor Voltage Sensing Economizer Circuit
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Solution Overview
Problem
Conventional electrical relays require complex and costly auxiliary circuits to manage power efficiency and diagnostics, with existing solutions either lacking confirmation of proper armature closure or increasing manufacturing complexity.
Innovation Solution
Incorporating voltage sensors to monitor voltages at both main contacts and coil control terminals, allowing for optimized control and continuous diagnostics, which enables the elimination of auxiliary circuits by using processor-controlled coil management and voltage sensing circuits to determine relay states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If an auxiliary relay contact is used to implement the economizer circuit, then power consumption is reduced, but device complexity increases due to the need for simultaneous operation calibration
Solution Approach 1:
The patent replaces the mechanical auxiliary relay contact system with an electronic processor-based control system. The processor monitors the state of main contacts and controls the economizer circuit electronically, eliminating the need for mechanically linked auxiliary contacts and their complex calibration procedures while achieving the same power-saving function.
Solution Approach 2:
The patent introduces a processor as an intermediary between the main contacts and the economizer circuit. This processor acts as a smart mediator that senses the contact state and intelligently controls the coil power, replacing the direct mechanical coupling of traditional auxiliary contacts and enabling more flexible and reliable power management.
2Device complexity
If a timing circuit is used to implement the economizer circuit, then auxiliary switch complexity is reduced, but reliability decreases due to lack of armature closure confirmation
Solution Approach 1:
The patent implements a feedback mechanism where the processor continuously monitors the state of main contacts and uses this feedback information to confirm proper armature closure before activating the economizer circuit. This feedback loop ensures reliable operation verification while maintaining simple circuit implementation.
Solution Approach 2:
The processor performs preliminary monitoring and verification of contact closure state before activating the economizer circuit. This preliminary action ensures that the armature has properly closed and is functioning correctly before the system transitions to power-saving mode, enhancing reliability without adding mechanical complexity.
3Use of energy by moving object
If two separate coil windings are used to maintain relay closed state, then power consumption is minimized, but manufacturing cost increases
Solution Approach 1:
The patent applies partial action by using a single coil winding that is selectively controlled in two distinct operational modes: full power mode for contact closure and reduced power mode for maintaining the closed state. The processor dynamically adjusts the coil activation level based on the operational phase, achieving effective two-winding functionality with a single winding and reducing manufacturing costs.
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 simplifies relay design, reduces manufacturing costs, and provides reliable diagnostics and power management, eliminating the need for mechanical adjustments and auxiliary circuits while ensuring efficient operation and health monitoring of relays.
Implementation Method 1
a relatively large magnetic field is generated to provide sufficient force to overcome the inertia of the armature mechanism and, also, to build up enough flux in the open air gap of its solenoid
Implementation Method 2
a relatively smaller coil current is needed to sustain the force needed to hold the main contacts 10 together
Data Source
Figure 1~3B
Figure 4~6
Figure 7~8
AI summary
A relay (141; 241; 341) includes a first terminal (A1), a second terminal (A2), a third terminal (X1), a fourth terminal (X2), separable contacts (10) electrically connected between the first and second terminals, an actuator coil comprising a first winding (6) and a second winding (8;150), the first winding electrically connected between the third and fourth terminals, the second winding electrically connected between the third and fourth terminals, a processor (142), an output (154), a first voltage sensing circuit (20; 50; 60; 90; 110) cooperating with the processor to determine a first voltage between the first and second terminals, and a second voltage sensing circuit (20; 50; 60; 90; 110) cooperating with the processor to determine a second voltage between the third and fourth terminals. The processor determines that the separable contacts are closed when the first voltage does not exceed a first predetermined value and the second voltage exceeds a second predetermined value and responsively outputs a corresponding status to the output.