Relay Switch Control with Randomized Startup Delay
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Solution Overview
Problem
Conventional contactors in climate control systems fail due to arcing, contamination, and simultaneous startup issues, leading to reduced reliability and potential electrical grid overload during power restoration.
Innovation Solution
A relay switch control system with a processor and sealed relay, capable of randomizing startup delays and incorporating a lockout selection device, to prevent arcing, contamination, and manage simultaneous startup demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional contactors are used to connect and disconnect system components, then the basic switching function is achieved, but arcing and contamination occur leading to reduced reliability
Solution Approach 1:
The patent replaces the mechanical contactor system with an electronic relay controlled by a microprocessor. This substitution eliminates the mechanical contacts that generate arcs and contamination, using solid-state switching instead. The relay is substantially enclosed in a seal to prevent contamination, and the electronic control provides precise timing capabilities to avoid arcing issues inherent in mechanical contactors.
2Productivity
If multiple climate control systems start up simultaneously after power restoration, then all systems resume operation quickly, but electrical grid overload occurs
Solution Approach 1:
The patent implements a random startup delay feature that activates when line power is detected. The microprocessor generates a randomized time delay before energizing the relay, causing systems to start up at staggered intervals rather than simultaneously. This preliminary randomization action prevents the synchronized startup surge that would otherwise overload the electrical grid while still allowing all systems to resume operation.
3Reliability
If a sealed relay is used to prevent contamination, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines the relay and its protective seal into a single integrated unit. The relay is substantially enclosed in a seal that prevents contamination while maintaining a compact design. This merging of the protective function into the relay structure itself avoids adding separate complex protection systems, thereby improving reliability without proportionally increasing device complexity.
Data Source
AI summary
Exemplary embodiments are disclosed of a relay switch control configured for connection between a power source and a load. The control includes a processor having a clock upon which an operating frequency of the processor is based, and a sealed relay operable by the processor to electrically connect or disconnect the power source and the load. The relay switch control can start power to the load through the relay after a randomized time delay determined by the processor using a value of a counter of the processor. The counter is updated as a function of cycles of the clock.