Relay testing device and methods for testing relays

• US 9,423,462 B1
• Filed: 04/21/2013
• Issued: 08/23/2016
• Est. Priority Date: 05/07/2012
• Status: Active Grant

• Current Assignee: KMC Electronics LLC
• Original Assignee: Kevin M. Curtis
• Inventors: Curtis, Kevin M
• Primary Examiner(s): Nguyen, Tung X
• Assistant Examiner(s): Pothen, Feba
• Application Number:
  US13/867,105
• Time in Patent Office: 1,220 Days
• US Class Current: 1/1
• CPC Class Codes: G01R 31/327 Testing of circuit interrupters, switches or circuit-breakers
• CPC Class Codes: G01R 31/3278 of relays, solenoids or reed switches measuring contact resistance G01R27/205; high voltage magnetic switches G01R31/3271, G01R31/333; testing electric windings G01R31/72; monitoring of fail safe circuits H01H47/002

Abstract

A testing device for a relay includes an enclosure for containing a circuit that includes at least one electrical socket adapted for selective engagement with a connector of the relay, a power source, a testing indicator LED adapted to convey a testing results indication, a power switch, and a testing IC adapted to run a series of tests on the relay when the relay is engaged with the at least one socket. In use, with the connector of the relay engaged with the at least one socket, power may be applied to the circuit such that the testing IC runs the series of tests on the relay by alternately activating and deactivating the coil power lines and measuring the resulting state of the armature line, the normally open signal line, and if available the normally closed signal line of the relay.

Claims

1. A testing device for a relay of the type having an electrical connector that includes at least a pair of coil power lines, an armature signal line, and a normally open signal line, the testing device comprising:

an enclosure;

a circuit contained substantially within the enclosure and including a plurality of electrical sockets adapted for selective engagement with the connector of the relay, the plurality of electrical sockets disposed within the enclosure such that the electrical connector of the relay is configured to extend through the enclosure into one of the plurality of electrical sockets, a power source, a testing indicator adapted to convey a testing results indication to outside of the enclosure, and a testing IC adapted to run a series of tests on the relay when the relay is engaged with one of the plurality of electrical sockets; and

a relay type indicator switch for indicating the relay either having or not having a normally closed signal line, the relay type indicator switch being a user-operable mechanical switch, wherein when the relay being tested does have the normally closed signal line, the testing IC performs additional tests and measurements of the normally closed signal line to determine whether the relay is functioning correctly;

whereby with the electrical connector of the relay engaged with one of the plurality of electrical sockets, power is applied to the circuit such that the testing IC runs the series of tests on the relay by alternately activating and deactivating the coil power lines and measuring the resulting state of the armature line and normally open signal line of the relay, whereupon if all tests indicate a properly working relay then the testing indicator conveys a positive testing results indication, or alternately if any of the tests indicate an improperly working relay then the testing indicator conveys a negative testing result indication;

wherein each socket of the plurality of electrical sockets mutually connected in parallel with each other to the circuit.

2. The testing device of claim 1 wherein each of the plurality of electrical sockets being a unique type adapted for selective engagement with one of a number of different types of relays.

3. The testing device of claim 1 wherein the power source is a battery contained within the enclosure.

4. The testing device of claim 1 wherein the power source is an external power source supplied to the circuit through a power line traversing the enclosure.

5. The testing device of claim 4 wherein the power line includes a distal end terminating in at least one power connector for attaching to the external power source.

6. The testing device of claim 1 wherein the testing indicator is an LED for indicating the testing results by color or the power state of the LED.

7. The testing device of claim 6 wherein the LED is a tri-color LED, wherein the color red indicates at least one failed test and an improperly working relay, and the color green indicates all tests passed and a properly working relay.

8. The testing device of claim 7 wherein the color yellow indicates that testing of the relay has not yet been completed.

9. The testing device of claim 1 further including a power switch that activates the circuit by connecting power from the power source thereto.

10. The testing device of claim 9 wherein the relay includes a normally closed signal line.

11. A method of testing a relay of the type having an electrical connector that includes at least a pair of coil power lines, an armature signal line, and a normally open signal line, the method comprising the steps:

providing an enclosure and a circuit contained substantially within the enclosure, the circuit including a plurality of electrical sockets connected in parallel, one of the plurality of electrical sockets adapted for selective engagement with the connector of the relay, the plurality of electrical sockets disposed within the enclosure such that the electrical connector of the relay is configured to extend through the enclosure into one of the plurality of electrical sockets, a power source, a testing indicator adapted to convey a testing results indication to outside of the enclosure, and a testing IC adapted to run a series of tests on the relay when the relay is engaged with the socket and when power from the power source is applied to the circuit;

connecting the connector of the relay to the at least one electrical socket of the device;

switching a relay type indicator switch for indicating the relay either having or not having a normally closed signal line, the relay type indicator switch being a user-operable mechanical switch;

applying power to the circuit from the power source;

the testing IC alternately activating and deactivating the coil power lines and measuring the resulting state of the armature line and normally open signal line of the relay to determine if the state of the armature line and the normally open signal line of the relay are working properly, and, when the relay being tested does have the normally closed signal line, the testing IC performs additional tests and measurements of the normally closed signal line to determine whether the relay is functioning correctly; and

the circuit causing the testing indicator to convey a positive testing results indication if all tests indicate a properly working relay, or alternately causing the testing indicator to convey a negative testing results indication.

12. A testing device for a relay of the type having an electrical connector that includes at least a pair of coil power lines, an armature signal line, and a normally open signal line, the testing device comprising:

an enclosure;

a circuit contained substantially within the enclosure;

a plurality of electrical sockets, electrically connected in parallel to the circuit and adapted for selective engagement with the connector of the relay, the plurality of electrical sockets disposed within the enclosure such that the electrical connector of the relay is configured to extend through the enclosure into one of the plurality of electrical sockets;

a battery contained within the enclosure, the battery providing a power source for the testing device;

a testing indicator adapted to convey a testing results indication to outside of the enclosure;

a testing IC adapted to run a series of tests on the relay when the relay is engaged with one of the plurality of electrical sockets; and

a relay type indicator switch for indicating the relay either having or not having a normally closed signal line, the relay type indicator switch being a user-operable mechanical switch, wherein when the relay being tested does have the normally closed signal line, the testing IC performs additional tests and measurements of the normally closed signal line to determine whether the relay is functioning correctly;

whereby with the electrical connector of the relay engaged with one of the plurality of electrical sockets, power is applied to the circuit such that the testing IC runs the series of tests on the relay by alternately activating and deactivating the coil power lines and measuring the resulting state of the armature line and normally open signal line of the relay, whereupon if all tests indicate a properly working relay then the testing indicator conveys a positive testing results indication, or alternately if any of the tests indicate an improperly working relay then the testing indicator conveys a negative testing result indication.

13. The testing device of claim 12 wherein each of the plurality of electrical sockets being a unique type adapted for selective engagement with one of a number of different types of relays, each socket of the plurality of electrical sockets mutually connected in parallel with each other to the circuit.

14. The testing device of claim 12 wherein the testing indicator is an LED for indicating the testing results by color or the power state of the LED.

15. The testing device of claim 14 wherein the LED is a tri-color LED, wherein the color red indicates at least one failed test and an improperly working relay, and the color green indicates all tests passed and a properly working relay.

16. The testing device of claim 15 wherein the color yellow indicates that testing of the relay has not yet been completed.

17. The testing device of claim 12 further including a power switch that activates the circuit by connecting power from the power source thereto.