Relay Temperature Sensing for ISO 26262 Safety Cost Reduction
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Solution Overview
Problem
Current relays used in safety applications for battery electric vehicles (BEVs) are overly expensive due to being designed for worst-case scenarios, which exceeds their actual performance needs, and lack direct safety measures, necessitating a cost-effective solution that meets safety standards like ISO 26262.
Innovation Solution
Incorporating temperature sensing elements such as NTC or PTC thermistors to monitor the relay's operation, allowing for real-time temperature input in overcurrent monitoring, reducing the need for excessive design robustness and enabling cost-effective production while maintaining safety standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If relays are designed for worst-case scenarios to meet safety standards, then safety reliability is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent applies dynamics by making the relay's performance characteristics adjustable through temperature-dependent resistance changes. The coil resistance automatically adapts to temperature conditions, allowing the relay to maintain safety reliability across varying thermal environments without requiring an overly robust fixed design, thereby reducing manufacturing costs.
Solution Approach 2:
The patent utilizes parameter changes by incorporating temperature sensing elements that detect coil temperature and provide feedback to adjust the control signal. This dynamic parameter adjustment allows the relay to meet safety standards under actual operating conditions rather than requiring design for extreme worst-case scenarios, reducing unnecessary manufacturing costs.
2Reliability
If relays are designed with higher performance specifications, then safety performance is improved, but device cost increases
Solution Approach 1:
The patent implements feedback by using temperature sensing elements to monitor coil temperature and adjusting the control signal accordingly. This feedback mechanism ensures the relay maintains safety performance under actual operating conditions without requiring overly complex high-performance specifications, thereby reducing device cost.
Solution Approach 2:
The relay performs self-service by automatically compensating for temperature effects through its own temperature sensing elements and control circuitry. This self-regulation ensures safety performance without requiring external monitoring systems or overly robust design specifications, reducing device complexity and cost.
3Ease of manufacture
If standard relays are used without direct safety measures, then device cost is reduced, but safety reliability deteriorates
Solution Approach 1:
The patent enables standard relays to provide their own safety measures through integrated temperature sensing elements and control circuitry that automatically monitor and adjust operation. This self-service approach maintains safety reliability without requiring expensive external safety systems or overly robust relay designs.
Solution Approach 2:
The relay incorporates feedback mechanisms where temperature sensing elements monitor coil temperature and provide information to the control circuit, which adjusts the control signal to maintain safe operation. This feedback ensures safety reliability in standard relays without requiring expensive additional safety measures.
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 significantly reduces the cost of relays while ensuring they meet safety requirements, allowing for the use of lower-performance relays that are still effective in safety-critical situations, thereby improving the cost-performance ratio.
Implementation Method 1
Incorporating temperature sensing elements such as NTC or PTC thermistors to monitor the relay's operation
Implementation Method 2
Incorporating temperature sensing elements such as NTC or PTC thermistors to monitor the relay's operation
Implementation Method 3
a coil for actuating the circuit breaker according to a current flowing through the coil
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention refers to a relay suitable for use in safety applications, a relay system and a method for operating the latter, the relay comprising: a first main connector configured for getting connected with a first conductor; a second main connector configured for getting connected with a second conductor; a first busbar connected with the first main connector; a second busbar connected with the second main connector; a circuit breaker moveable between a closed position and an open position, wherein in the closed position, the circuit breaker is in contact to both, the first busbar and the second busbar, and in the open position, the circuit breaker is spaced apart from both, the first busbar and the second busbar; a coil for driving the circuit breaker; a first temperature sensing element is arranged on or at the first busbar.