Testable Sealed Relay With Multimeter Terminals And LED Diagnostics
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Solution Overview
Problem
Current relay technologies lack a direct method for testing and self-diagnosis while installed in vehicles, requiring removal for testing, which is time-consuming and costly, and do not provide clear indications of operational status.
Innovation Solution
A testable sealed relay with accessible terminals for multimeter testing and a self-diagnosing relay using LED indicators to validate relay operation, allowing for in-situ testing and fault identification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If relay testing is performed by removing the relay from the vehicle, then testing can be conducted, but time is lost and repair efficiency decreases
Solution Approach 1:
The patent incorporates testable terminals and LED indicators into the relay design beforehand, enabling direct testing without removal. The terminals are pre-positioned to allow multimeter probe access, and LED circuits are pre-wired to provide visual feedback, eliminating the need for removal-based testing procedures
Solution Approach 2:
The patent introduces intermediary testing elements (testable terminals and LED indicators) that mediate between the relay's internal components and the external testing environment. These intermediaries allow technicians to test relay functionality through the housing without disassembly, bridging the gap between sealed construction and testing requirements
2Ease of operation
If relay terminals are made accessible for testing, then in-situ testing becomes possible, but relay sealing and protection may be compromised
Solution Approach 1:
The patent applies local quality by providing testable terminals at specific locations on the relay housing that are accessible for testing while maintaining the sealed construction of the main relay body. The terminals are strategically positioned to allow testing without compromising the overall sealing integrity
Solution Approach 2:
The patent implements a nested structure where testable terminals are integrated within or on the surface of the sealed housing. The terminals are nested in such a way that they provide testing access while remaining protected by the housing structure, allowing the relay to maintain its sealed protective enclosure
3Loss of information
If LED indicators are added for self-diagnosis, then fault identification is improved, but device complexity increases
Solution Approach 1:
The patent implements feedback by incorporating LED indicators that provide real-time visual information about relay operational status. The LEDs are connected to monitor coil energization and contactor activation, providing immediate feedback on whether the relay is functioning correctly without requiring external diagnostic equipment
Solution Approach 2:
The patent enables self-service by allowing the relay to diagnose its own operational status through the LED indicators. The relay monitors its own coil and contactor circuits and provides visual feedback about its state, eliminating the need for external diagnostic tools or complex testing procedures
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 efficient troubleshooting by allowing relay testing without removal and providing visual feedback on relay and circuit operation, reducing diagnosis time and improving repair efficiency.
Implementation Method 1
The coil is magnetized with the current and attracts or repels a plunger (a rod passed through the coil), either connecting two switching contacts in the relay or separating them
Implementation Method 2
A contact circuitry in electrical connection to the components is provided having at least two light-emitting diodes (LEDs)
Data Source
AI summary
Testable sealed and/or self-diagnosing electromagnetic or solid-state relays simplify troubleshooting of electrical circuits. The testable relay comprises a relay housing with terminals adapted to connect to a circuit and an opposing top wall with testable terminals formed as projections being flush with or extending from the top wall and being exposed for testing the relay by applying a multimeter device. A self-diagnosing relay comprises a relay housing with terminals adapted to connect to a circuit, and at least two light-emitting diodes (LEDs). One of the LED indicates the relay is energized, and another LED light is a diagnostic LED and indicates if the relay is damaged.