Relay welding detector, relay equipment incorporating the same, and relay welding detecting method

• US 9,581,648 B2
• Filed: 12/27/2013
• Issued: 02/28/2017
• Est. Priority Date: 11/28/2013
• Status: Active Grant

• Current Assignee: Lite-On Electronics Company Limited (Lite-On Technology Corporation), Lite-On Technology Corporation
• Original Assignee: Lite-On Electronics Company Limited (Lite-On Technology Corporation), Lite-On Technology Corporation
• Inventors: Wu, Zhi-Feng
• Primary Examiner(s): Kitov, Zeev V
• Application Number:
  US14/141,656
• Publication Number:
  US 20150146333A1
• Time in Patent Office: 1,159 Days
• US Class Current: 1/1
• 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
• CPC Class Codes: H01H 2047/003 Detecting welded contacts and applying weld break pulses to coil
• CPC Class Codes: H01H 2300/052 Controlling, signalling or testing correct functioning of a switch see also H01H2300/056 - H01H2300/066 and H01H11/0062
• CPC Class Codes: H01H 47/002 Monitoring or fail-safe circuits

Abstract

A relay welding detector is adapted for detecting welding fault of a relay. The relay has a first electrical contact coupled to a neutral terminal of an alternating current (AC) power source through a first power line, and a second electrical contact coupled to a load through a second power line. The relay welding detector includes a signal generator generating a test signal, a current transformer wound with a portion of one of the power lines and generating an induced signal based on the test signal, and a determining unit determining, based on the induced signal, whether the electrical contacts of the relay are welded to each other.

Claims

1. A relay welding detector adapted for detecting welding fault of a relay that is coupled between an alternating current (AC) power source and a load, the AC power source having a grounded earth terminal and a neutral terminal coupled to the earth terminal, the relay having a first electrical contact coupled to the neutral terminal of the AC power source through a first power line, and a second electrical contact coupled to the load through a second power line, said relay welding detector comprising:

a signal generator for generating a test signal;

a current transformer coupled to said signal generator for receiving the test signal therefrom, configured to generate an induced signal based on the test signal, and adapted to be wound with a portion of one of the first and second power lines; and

a determining unit coupled to said current transformer, wherein said determining unit is configured to pre-store a predetermined threshold value, and is further configured to compare an amplitude of the induced signal from said current transformer with the predetermined threshold value, and is further configured to determine, based on a result of the comparison, whether the first and second electrical contacts of the relay are welded to each other;

wherein said determining unit determines that said first and second electrical contacts of said relay are welded to each other when the result of the comparison indicates that the amplitude of the induced signal is smaller than the threshold value.

2. The relay welding detector of claim 1, further comprising a switch operable between an ON state and an OFF state, and adapted to be coupled between ground and the second power line, such that at least the relay, the portion of said one of the first and second power lines and said switch form a closed electrical loop when electrical connection between the first and second electrical contacts of the relay is established and said switch operates in the ON state.

3. The relay welding detector of claim 1, wherein said current transformer is adapted to be wound with the portion of the first power line.

4. The relay welding detector of claim 1, wherein said current transformer is adapted to be wound with the portion of the second power line.

5. A relay equipment system adapted to be coupled between an alternating current (AC) power source and a load, the AC power source having a grounded earth terminal and a neutral terminal coupled to the earth terminal, said relay equipment system comprising:

a relay having a first electrical contact adapted to be coupled to the neutral terminal of the AC power source through a first power line, and a second electrical contact adapted to be coupled to the load through a second power line; and

a relay welding detector including

a signal generator for generating a test signal,

a current transformer coupled to said signal generator for receiving the test signal therefrom, configured to generate an induced signal based on the test signal, and adapted to be wound with a portion of one of the first and second power lines, and

a determining unit coupled to said current transformer, wherein said determining unit is configured to pre-store a predetermined threshold value, and is further configured to compare an amplitude of the induced signal from said current transformer with the predetermined threshold value, and is further configured to determine, based on a result of the comparison, whether said first and second electrical contacts of said relay are welded to each other;

wherein said determining unit determines that said first and second electrical contacts of said relay are welded to each other when the result of the comparison indicates that the amplitude of the induced signal is smaller than the threshold value.

6. A relay welding detecting method for detecting, using a relay welding detector, welding fault of a relay that is coupled between an alternating current (AC) power source and a load, the AC power source having a grounded earth terminal and a neutral terminal coupled to the earth terminal, the relay having a first electrical contact coupled to the neutral terminal of the AC power source through a first power line, and a second electrical contact coupled to the load through a second power line, the relay welding detector including a signal generator, a current transformer coupled to the signal generator and wound with a portion of one of the first and second power lines, and a determining unit coupled to the current transformer, said relay welding detecting method comprising:

(A) generating, by the signal generator of the relay welding detector, a test signal;

(B) generating, by the current transformer of the relay welding detector, an induced signal based on the test signal;

(C) comparing an amplitude of the induced signal with a predetermined threshold value pre-stored in the determining unit of the relay welding detector; and

(D) determining, by the determining unit of the relay welding detector, based on a result of the comparison, whether the first and second electrical contacts of the relay are welded to each other;

wherein in (D), the first and second electrical contacts of the relay are determined to be welded to each other when the result of the comparison indicates that the amplitude of the induced signal is smaller than the threshold value.

7. The relay welding detecting method of claim 6, the relay being operable between an ON state and an OFF state, the relay welding detector further including a switch operable between an ON state and an OFF state and coupled between ground and the second power line, such that at least the relay, the portion of said one of the first and second power lines and the switch form a closed electrical loop when electrical connection between the first and second electrical contacts of the relay is established and the switch operates in the ON state, said relay welding detecting method further comprising, prior to (A):

configuring the relay to operate in the OFF state; and

configuring the switch of the relay welding detector to operate in the ON state.