Self-configuring relay tester with automatic terminal detection
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Solution Overview
Problem
Current relay testers require specific relay sockets and adapters to test different types of relays, making them cumbersome and time-consuming, especially in automotive circuits where access to test points is limited, and they cannot automatically determine relay malfunctions.
Innovation Solution
A self-configuring relay tester with an intuitive interface that automatically detects and tests 4-terminal or 5-terminal relays without requiring specific socket alignment, using a controller, voltage dividers, analog-to-digital converters, and LEDs to indicate pass or fail results, and can switch between 12V and 24V power sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional relay testers use specific relay sockets and adapters for different relay types, then testing capability is provided, but device complexity and ease of operation deteriorate due to multiple fixtures and alignment requirements
Solution Approach 1:
The patent implements a universal relay testing system where a single five-position socket can accommodate multiple relay types (4-terminal and 5-terminal relays) through self-configuring circuitry. The controller automatically detects relay terminal configurations and adjusts testing parameters accordingly, eliminating the need for multiple specialized sockets and adapters while maintaining full testing capability across different relay types.
2Reliability
If traditional relay testers require specific socket alignment, then controlled testing is achieved, but ease of operation and time consumption worsen due to manual alignment requirements
Solution Approach 1:
The relay testing system employs self-configuring circuitry that automatically detects the relay's terminal configuration when placed in the five-position socket. The controller identifies which terminals are connected and configures the testing circuit accordingly without requiring manual intervention or specific alignment procedures. This self-service approach maintains reliable controlled testing while dramatically improving ease of operation.
3Measurement precision
If DMM is used for circuit testing, then voltage and current measurements are obtained, but productivity and time efficiency worsen due to manual measurement processes
Solution Approach 1:
The patent replaces the manual mechanical operation of a DMM with an automated electronic testing system. The controller automatically performs voltage and current measurements across all relay terminals, processes the data, and determines relay functionality without manual intervention. This substitution maintains measurement precision while dramatically improving productivity by eliminating the time-consuming manual measurement process.
4Measurement precision
If traditional relay testers require knowledge of terminal configurations, then accurate testing is possible, but ease of operation deteriorates due to prior knowledge requirements
Solution Approach 1:
The system performs preliminary automatic detection of relay terminal configurations before the actual testing begins. When the relay is placed in the socket, the controller immediately identifies which terminals are connected and configures the testing sequence accordingly. This preliminary action eliminates the need for users to have prior knowledge of terminal configurations while maintaining testing accuracy through automated configuration detection.
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 selector switch, and five electric leads each connected with one terminal of the relay. With the relay selector switch toggled to indicate the type of relay being tested, with power supplied to each lead, and with the test start switch actuated, the controller sets 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.