Relay Safety System with Sticking Detection Circuit
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Solution Overview
Problem
Existing relay systems in robotic arms and electromechanical equipment face issues with contact sticking due to temperature and electrical conditions, leading to abnormal states that cannot be effectively addressed by existing detection methods, particularly when both relays are faulty, as they do not provide a solution for disconnecting power and require redesigns that increase size, making them unsuitable for limited spaces.
Innovation Solution
A relay safety system comprising an emergency stop device, trigger detection circuit, sticking detection circuit, and power-off circuit that generates an emergency stop signal to determine sticking abnormalities and disconnects the relay's power supply when issues are detected, ensuring safety and reliability by using a combination of circuits and switches to manage power effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If relay contact status is monitored and power is cut off when abnormality is detected, then safety is improved, but device complexity increases due to additional detection circuits
Solution Approach 1:
The detection circuits are integrated within the existing relay module structure, with the trigger detection circuit connected to the relay coil and the sticking detection circuit embedded in the control circuit path. This nested arrangement allows safety functions to be added without significantly increasing overall device complexity.
Solution Approach 2:
The trigger detection circuit acts as an intermediary between the emergency stop device and the sticking detection circuit, converting the emergency stop signal into a trigger signal that enables the sticking detection function. This intermediary approach allows modular addition of safety features.
2Reliability
If separate power disconnection paths for control voltage and high voltage are implemented, then safety is improved, but device complexity increases
Solution Approach 1:
The power disconnection function is segmented into two independent paths: one path controls the internal control low-voltage source through the power-off circuit, and the other path controls the high-voltage voltage source separately. This segmentation allows each voltage source to be disconnected independently, improving safety while maintaining manageable circuit complexity through modular design.
3Reliability
If relay contact sticking is detected through control loop interruption, then reliability is improved, but ease of operation deteriorates due to inability to restart
Solution Approach 1:
The system dynamically responds to different fault conditions: when a single relay abnormality is detected, the control system issues an alarm and prohibits restart to prevent further issues; when both relays are abnormal, the power-off circuit automatically disconnects power to ensure safety. This dynamic response strategy balances reliability with operational flexibility.
Data Source
AI summary
The relay safety system provided by the present invention includes a relay, an emergency stop device, a trigger detection circuit, a sticking detection circuit, and a power-off circuit. The emergency stop device is used to generate an emergency stop signal. The trigger detection circuit connects the relay and the emergency stop device, and is used to convert the emergency stop signal into a trigger signal. The sticking detection circuit is connected to the trigger detection circuit and the relay, and is used to detect the sticking signal generated by the relay, and generate a power-off signal according to the trigger signal and the sticking signal. The power-off circuit is connected to the emergency stop device, the relay and the sticking detection circuit, and receives the power-off signal, and disconnects the power of the relay according to the power-off signal.