Relay-Welding Detection Using ADC Voltage Comparison
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Solution Overview
Problem
Existing relay-welding detection devices rely on additional components like photocouplers and welding relays, which increase costs and reduce reliability, and are prone to switch noise due to frequent switching operations, leading to safety risks from potential relay welding.
Innovation Solution
A relay-welding detection device utilizing analog-digital converters (ADCs) to compare input and output voltages of a relay, eliminating the need for photocouplers and welding relays, and incorporating a central processing unit to determine welding states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photocouplers and welding relays are used to detect relay welding, then relay welding detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the essential detection function from the complex photocoupler-welding relay system and implements it using only an ADC and CPU. The voltage comparison method isolates the core detection capability while removing unnecessary components, achieving welding detection through direct voltage measurement at relay terminals rather than through optical coupling mechanisms.
Solution Approach 2:
The ADC and CPU are used for multiple purposes: they detect relay welding by comparing voltages, measure general electrical parameters, and control charging operations. This multi-functionality eliminates the need for dedicated welding detection components like photocouplers, as the same components perform both charging control and welding detection tasks.
2Reliability
If welding relays are used for detection, then welding detection is achieved, but the risk of relay welding increases
Solution Approach 1:
The patent introduces voltage as an intermediary parameter for detection. Instead of using a welding relay that could itself weld, the system measures voltage at the relay terminals through an ADC. This voltage measurement serves as a safe intermediary that indicates relay state without requiring additional switching components that could fail.
Solution Approach 2:
The patent replaces the mechanical/electrical switching mechanism of welding relays with an electronic voltage measurement system. The ADC and CPU-based voltage comparison eliminates mechanical contacts and optical components that are prone to failure, using purely electronic measurement to detect relay welding states.
3Measurement precision
If frequent switching operations are performed to detect welding states, then detection accuracy is improved, but switch noise increases
Solution Approach 1:
The patent implements periodic voltage sampling at specific charging states (charging start, charging end, and abnormal states) rather than continuous or frequent switching. This periodic measurement approach achieves necessary detection accuracy while minimizing the generation of switch noise by only measuring when critical state transitions occur.
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 solution reduces unit costs, eliminates switch noise, and extends the life of relays by simplifying voltage measurement, thereby enhancing the reliability and safety of the detection process.
Implementation Method 1
a plurality of analog-digital converters (ADCs) outputting an input voltage and an output voltage of the relay
Data Source
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AI summary
The objective of the present invention is to provide a relay-welding detection device and method, the device and method capable of determining, whether a relay is welded, by using an analog-digital converter (ADC). Another relay-welding detection device according to the present invention comprises: a first ADC for measuring a voltage of a relay input terminal; a second ADC for measuring a voltage of a relay output terminal; and a CPU for comparing the voltage of the relay input terminal with the voltage of the relay output terminal and determining whether the relay is welded.