Self-configuring Relay Tester for Automotive Diagnostics
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Solution Overview
Problem
Current relay testers require specific relay sockets and adapters to test different types of relays, making it difficult to quickly and easily test relays without knowing the terminal configurations, especially in live automotive circuits where access is limited.
Innovation Solution
A self-configuring relay tester with a controller, electronic switches, voltage dividers, analog-to-digital converters, and intuitive LED indicators that can quickly identify and test 4-terminal or 5-terminal relays without needing to know the terminal designations, using a battery or external power source for operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If relay testers use specific relay sockets and adapters to test different types of relays, then testing accuracy is improved, but device complexity and ease of operation deteriorate
Solution Approach 1:
The patent implements a universal relay testing system that can test multiple relay types (4-terminal and 5-terminal relays with different configurations) using a single device without requiring separate sockets or adapters. The controller automatically detects relay terminal configurations and adjusts testing parameters accordingly, eliminating the need for multiple physical fixtures while maintaining testing accuracy across different relay types.
Solution Approach 2:
The relay tester automatically detects and identifies relay terminal configurations without requiring user input or manual setup. The controller performs self-configuration by detecting which terminals are connected and determining the relay type, then automatically adjusts the testing sequence and parameters. This self-service capability eliminates the need for users to select adapters or configure settings manually.
2Measurement precision
If relay testers use specific relay sockets and adapters, then measurement precision is improved, but ease of operation worsens
Solution Approach 1:
The relay tester automatically detects and identifies relay terminal configurations without requiring user input or manual setup. The controller performs self-configuration by detecting which terminals are connected and determining the relay type, then automatically adjusts the testing sequence and parameters. This self-service capability eliminates the need for users to select adapters or configure settings manually.
Solution Approach 2:
The controller dynamically changes testing parameters based on detected relay configurations. When a relay is connected, the system detects the terminal arrangement and automatically adjusts voltage levels, measurement sequences, and contact testing patterns to match the specific relay type, maintaining measurement precision while requiring no manual parameter adjustment from the user.
3Measurement precision
If relay testers require knowing terminal configurations, then measurement precision is improved, but productivity deteriorates
Solution Approach 1:
The controller performs preliminary detection of relay terminal configurations automatically as soon as the relay is connected to the tester. This preliminary action identifies the relay type and terminal arrangement before the actual testing sequence begins, allowing the system to pre-configure the optimal testing path and parameters, thereby maintaining measurement precision while eliminating time-consuming manual setup steps.
Solution Approach 2:
The relay tester automatically detects and identifies relay terminal configurations without requiring user input or manual setup. The controller performs self-configuration by detecting which terminals are connected and determining the relay type, then automatically adjusts the testing sequence and parameters. This self-service capability eliminates the need for users to select adapters or configure settings manually.
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
Enables quick and accurate testing of relays with easy-to-use controls, providing clear pass/fail indications, and can operate with either a vehicle battery or on-board battery, simplifying the testing process across various relay configurations.
Implementation Method 1
power is applied to the coil causing a magnetic field to be created about the coil's longitudinal axis which in turn attracts the ferrous metal pole piece
Implementation Method 2
a magnetic field to be created about the coil's longitudinal axis which in turn attracts the ferrous metal pole piece
Implementation Method 3
at least five voltage dividers, at least five analog-to-digital converters
Data Source
AI summary
A tester for a relay comprises an enclosure, a testing circuit that includes a controller, electronic switch components, a power source, indicator LEDs, a test start switch, a relay type switch, and five electric leads each connected with one terminal of the relay. With the relay type switch set to the type of relay being tested, with power supplied to each lead, and with the test start switch actuated, the controller can set each lead to ground, in turn, and then count the number of other leads that are grounded as a result. The controller then illuminates the at least one indicator to indicate either the passing relay test or the failed relay test based on the counts measured. Once the leads connected to the relay coil are identified, cyclic testing of the relay can be performed.