Wide Input Voltage Relay Circuit Design
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Solution Overview
Problem
Relays require multiple catalog numbers to accommodate various supply voltages, leading to increased size, cost, and heat generation, and are prone to reliability issues due to leakage current, especially in small devices.
Innovation Solution
A two-stage regulation circuit that pre-regulates input voltage to a range tolerated by the relay coil and further regulates it to a predetermined level, ensuring coil energization only when a minimum current threshold is met, allowing a single relay to operate over a wide input voltage range from 24V AC/DC to 240V AC/DC.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a relay is designed for only one specific supply voltage, then the relay can operate reliably at that voltage, but a large number of catalog numbers and associated relays need to be manufactured and warehoused
Solution Approach 1:
The patent applies universality by designing a single relay model that can operate across multiple supply voltages (24V, 48V, 120V, 240V AC/DC) through integrated voltage detection and control circuitry. The relay coil is designed with a wide operating voltage range, and the control circuit automatically adjusts operation based on detected input voltage, eliminating the need for multiple voltage-specific relay variants.
Solution Approach 2:
The patent employs parameter changes by dynamically adjusting the relay's operational parameters based on the detected input voltage. The control circuit monitors the supply voltage and modifies the coil energization characteristics accordingly, allowing the same relay hardware to adapt to different voltage conditions without requiring physical redesign or multiple catalog numbers.
2Device complexity
If attempts are made to accommodate devices to operate on more than one supply voltage, then fewer catalog numbers are required, but increased size, cost, and heat generation occur
Solution Approach 1:
The patent applies segmentation by dividing the voltage regulation function into discrete stages: voltage detection circuitry that identifies the input voltage level, and corresponding control logic that activates appropriate coil energization sequences. This segmented approach allows precise control of power delivery to the coil, preventing excessive heat generation while maintaining multi-voltage compatibility.
Solution Approach 2:
The patent implements dynamics through adaptive control circuitry that dynamically adjusts coil energization based on real-time voltage detection. The system transitions between different operational modes depending on the detected voltage level, optimizing power consumption and heat dissipation for each specific voltage condition rather than using a fixed, conservative design that would generate unnecessary heat.
3Volume of moving object
If small size relays are used to reduce physical packaging, then mounting on circuit boards becomes possible, but leakage current from upstream circuitry can cause unwanted coil energization
Solution Approach 1:
The patent applies feedback through voltage detection circuitry that continuously monitors the input voltage level and provides feedback to the control logic. This feedback mechanism enables the system to distinguish between legitimate voltage signals that should trigger relay operation and leakage currents that should be ignored, thereby preventing unwanted energization while maintaining compact dimensions.
Solution Approach 2:
The patent implements preliminary action by incorporating voltage detection and threshold verification before activating coil energization. The control circuit first detects and validates the input voltage level, then decides whether to energize the coil based on predetermined thresholds. This preliminary validation step prevents leakage currents from causing unwanted activation while maintaining the relay's compact form factor.
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 the number of required catalog numbers, enhances relay reliability by controlling coil energization, and effectively operates small relays with limited heat dissipation capabilities across a broad voltage range while minimizing heat generation.
Implementation Method 1
The first regulation stage includes a linear regulator circuit configured to maintain a bus voltage within a predefined voltage range when an input voltage exceeds a predefined input level
Implementation Method 2
A second regulation stage includes a buck converter circuit configured to regulate an average bus voltage to a predetermined load level
Implementation Method 3
Both electromechanical and solid state relays are commonly available... energization of the relay coil
Data Source
AI summary
A wide input voltage power supply circuit for a load includes a first regulation stage and a second regulation stage. The first regulation stage includes a linear regulator circuit configured to maintain a bus voltage within a predefined voltage range when an input voltage exceeds a predefined input level. A second regulation stage includes a buck converter circuit configured to regulate an average bus voltage to a predetermined load level. The second regulation stage includes an under voltage lockout configuration, with the under voltage lockout configured to set a minimum turn-on voltage for the load.