Apparatus, method, appliance, and computer program product for operating a relay

Contacts of a relay may glue together during operation. This state may be measured and a controller may issue a pulse width-modulated signal at a certain duty cycle and frequency in order to vibrate the relay contacts to make them open again. Once this is the case, the process is stopped. This process may be repeated a certain number of times, and if successfully degluing is not possible, a notification may be generated. Also after a certain number of degluing cycles, a signal may be generated to indicate replacement of the relay.

In environments where reliability is of utmost importance, often parts are used that in the past have proven to be long-term stable and to be operable on a long term basis without failure. Such parts are often available on the market manufactured by different suppliers, they are available with various technical parameters and specifications, and thus the provision of a second source is not a problem. Parts like that are e.g. relays that are often used in industrial applications. Their reliability is important and their complexity has to be kept on a basic level in order to keep the costs at a low level and the service-ability easy.

In household environments, relays are often used in switching is applications where a considerable amount of power has to be switched reliably and frequently. Applications there are conceivable in washing machines, dishwashers and kitchen ovens. A field of use in a kitchen environment is the operation of a relay in a duty cycle power control. Such duty cycle power controts are often used to control electric heaters, such as used in kitchen ovens or in cooktops, such as glass ceramic fields.

However, a known problem with power switching using relays is that due to the light arc building when the contact bridge is closed, relay contacts may stick to each other, a phenomenon also known as gluing of the contacts. If the contacts stick together instead of opening, as required according to a control command, then problems may arise due to the overload of a device being switched by the load circuit of the relay that is not designed to withstand high power for a long period of time. As such, glued contacts in a relay may cause significant damage and lead to destruction of major components of the appliance where they are used. Light arcs may weld the contacts together in a small area and thus prevent the opening of the contacts once the current through the coil that operates the load circuit of the relay is switched off and spring force is applied to the contacts, which should lead to the opening of the contact-bridge formed by the relay contacts.

In the German publication document DE 10 2012 011251 A1, a device with an electromechanical relay is discussed. In the load circuit of the relay, a preheater in the air duct of a vehicle is operated. A voltage drop in the load circuit is measured when the load circuit is opened. If this is not the case, a sequence of pulses is applied in order to open the contact bridge. A control light is switched on to indicate malfunction.

The invention is based on the problem to improve the usability of a relay in a household appliance while at the same time extending service intervals.

This problem is solved by an apparatus for operating a relay according to claim1, a method for operating a relay according to claim9, a household appliance according to claim14and a computer program product according to claim15.

Further developments of the invention are given in the dependent claims.

Advantageously, according to an embodiment of the apparatus according to the present invention, the duty cycle of the driver of the relay is controlled in dependency of a verification signal. This allows it to switch from a normal duty cycle of the relay to a duty cycle that allows a degluing of the relay contacts in an efficient way.

Beneficially, the dependency on the verification signal according to this embodiment allows it to only maintain a degluing duty cycle as long as the contacts of the load circuit of the relay actually stick together.

Beneficially, according to a further development of an embodiment of the apparatus according to the present invention, in case of a wrong switching state, the controller is adapted to operate the controlled duty cycle for a limited period of time as the load for the relay can be kept to a minimum; and the period of time reflects results of experiments that have been guided in practice, which have shown that after a certain amount of time and a particular degluing duty cycle in most cases the relay contacts are deglued and open again.

Advantageously, according to a further development of an embodiment of the apparatus according to the present invention, the controller is adapted to control the duty cycle with certain duty cycle parameters that have proven to optimally deglue relay contacts in a test environment. In this manner, the reliability is improved, the time needed for the maintenance of the relay is reduced and the operational lifetime of the relay is extended.

Beneficially, according to a further development of an embodiment of the apparatus according to the present invention, the driver operates the coil at a certain frequency. In this manner, an optimum frequency can be applied to the coil with a certain duty cycle that allows it to deglue the relay contacts in an optimum fashion.

Beneficially, according to a further development of an embodiment of the apparatus according to the present invention, particular frequencies are applied from the driver to the coil of the relay in order to optimally deglue the contacts. In this manner, frequencies can be provided that cause vibrations that optimally vibrate the contact surfaces and break occasional welding connections in a reliable manner.

Favorably, according to a further development of an embodiment of the apparatus according to the present invention, the controller is adapted to repeat a degluing time interval, a plurality of times in case the verification signal indicate no opening of the contact bridge in the load circuit. Thus, an automated degluing process is implemented that more reliably deglues contacts in a predefined number of cycles that increase the probability of degluing the contacts.

Beneficially, a delay or break is provided between the different cycles in order to allow the mechanical stress respectively thermal load to decrease before the next cycle is applied.

Advantageously, according to a further development of an embodiment of the apparatus according to the present invention, the number of cycles where the degluing duty cycle is applied to the relay is counted by a counter of the apparatus as in this case after a certain number corrective measures a notification can be provided.

Favorably, according to a further development of an embodiment of the apparatus according to the present invention, as a corrective measure a notification signal can be generated or the number of cycles can be limited to a certain predefined number.

Advantageously, according to the method according to the present invention, it is verified if contacts of the relay are glued together; and if this is the case, a duty cycle at a switching frequency is provided in order to deglue the contacts.

Advantageously, according to a further development of the method according to the present invention, a certain period of time under which the relay is exposed a degluing duty cycle is repeated in order to securely deglue the relay contacts or in order to provide several passes in case the first pass was not successful in degluing the relay contacts.

Beneficially, a delay is provided between the different passes in order to allow excess mechanical or thermal stress to disappear.

Advantageously, according to a further development of an embodiment of the method according to the present invention, five passes are counted, and if in this case the relay contacts are not open, a notification signal is generated in order to inform an operator that a maintenance activity is required respectively to cut the power to the load circuit in order to avoid overload of the load.

Advantageously, according to a further development of an embodiment of the method of the present invention, certain parameters are maintained for the duty cycle, the frequency applied to the coil and thus to the relay contacts of the contact bridge and the duty cycle in order to maximize the effect of the method according to the present invention while at the same time protecting the circuitry and the load maximally.

Advantageously, according to a further development of an embodiment of the method according to the present invention, the number of successful degluing of a certain relay is counted and after the predetermined number of degluing cycles has been successfully completed, a change signal is generated in order to provide for the change the relay.

In this manner, beneficially, a total failure of the relay can be prevented in time and the relay can be serviced without causing a device to fail in which the apparatus is built into.

Beneficially, a household appliance according to the present invention comprises an apparatus for operating a relay, because such a household appliance will be reliable technically, simple and easy to manufacture.

Beneficially, a computer program product according to the present invention will allow servicing the apparatus in the field by easily updating the parameters of the controller, while at the same time also being able to allow easy adaptation of the apparatus to different relays.

AsFIG. 1shows, a basic configuration of a preferred embodiment of an apparatus according to the present invention consists of a minimum number of components which are depicted in this Figure. E.g. there is a power supply1700that is connected to a load1600, which is part of a load circuit that is switched by a relay1500to which the load circuit is connected at contacts1530and1540. The load circuit also contains a measuring device1800that gathers properties of the load circuit and generates a verification signal1810according to the detected results respectively properties of the load circuit.

The circuit is referred by reference1710. The relay1500, e.g. a commonly available part, comprises a magnetic coil that is spring-loaded in the fashion that in case the coil is not energized, which takes place over contact1510and1520, the contact bridge closing the circuit1710between contact1530and1540of the load circuit switched by the relay is open. However, there are also relays that once de-energized close the contact bridge, and thus the circuit design of the apparatus may be adapted accordingly.

The apparatus1000also comprises a controller1100that controls the energization of the magnetic coil of the relay1500via power lines1120and1130of a control circuit. Beneficially, the controller1100is provided with a verification signal1810from the device1800and thus is informable about the properties of the load circuit1710. The controller1100may comprise a memory1150that is loadable e.g. with instructions and parameters and controls the operation of the controller. In particular, the switching properties of the relay1500may be controlled by a program stored in the memory1150.

Also shown is a computer program product1800that comprises a memory chip or the like for storing instructions and code1810.

Such a computer program product may be inserted into the controller or is connected by wire or wirelessly in order to communicate with the memory1150of the controller1100and to provide appropriate instructions to the controller or e.g. gather information stored in the controller.

In a common operation case, the load circuit will be closed, which means that the contact bridge between contacts1530and1540of the relay is closed. The device1800measures the property of the load circuit and detects that the load circuit is closed and that the current is flowing through the load once the power supply1700is connected and operational. The status of the load circuit is communicated via the verification line1810to the controller1100. As required, the controller may deenergize the coil of the relay1500in order to cause it to open the contact bridge between contracts1530and1540.

As mentioned above, the inverse operation may also be possible. The device1800detects the parameters of the load circuit, and if the load circuit1710is open, the corresponding parameters are communicated to the controller1100. However, in the course of plural open and closed cycles of the contact bridge of the relay1500, it may happen that the contacts on the relay tongue due to light arcs forming when switching may be welded to each other, a phenomenon that is called gluing. In this case, if the load circuit is to be opened, a corresponding activity will be instructed by the controller1100to the relay1500. But the spring load will not be sufficient to open the relay contacts. In this case, corresponding parameters respectively a voltage drop, or corresponding parameters will not be measured by the device1800, and the corresponding result will be notified via verification line1810to the controller1100. If this is the case, the controller1100will beneficially cause vibrations on the relay contact by energizing the coil of the relay via lines1120and1130according to a certain duty cycle.

Especially, a duty cycle of about 80% will be applied by a switching frequency of 20 Hz to the contacts in order to deglue the contacts. This frequency has been proven to be appropriate with said power cycle once applied for about a period of time that is chosen to be preferable one second. However, there is a range of parameters conceivable, such as the duty cycle may be preferably between 60 and 90%, more preferably between 70 and 85% or precisely 80%.

On the other hand, the pulse-width modulated signal may be applied with a frequency of 15 to 25 Hz or preferably 17 to 22 Hz or most preferably with a frequency of 20 Hz. It has been observed by the inventors that degluing can be efficiently effected by applying such a degluing duty cycle for a period of one second. On the other hand, the period can be preferably 1.5 seconds, or more preferably 2 seconds, but most preferably it is 1 second.

The controller1100may comprise a counter realized in hardware or in software or in firmware that counts a number of degluing cycles.

As a degluing cycle here, the operation of a duty cycle power control for the period of e.g. 1 second will be defined or a comparable operation of the duty cycle of 80%, a pulse-width modulation of 20 Hz for a predetermined time period. In the case of the application of this degluing cycle, if the contacts will open, this will be detected by the device1800and corresponding parameters will be communicated over the verification line1810. In this case, preferably no further actions will be taken. On the other hand, if the contacts are still closed, the controller may apply another degluing cycle after e.g. a certain delay in order to allow mechanical and thermal stress to rebuild. Such a delay may preferably be in the range of 2 seconds.

Beneficially, if the relay contacts do not open after a degluing and a reapplication of such a degluing cycle, this procedure may be repeated until 5 cycles preferably are completed. If then the contacts are still not open, a signal may be generated in order to inform a user to replace the relay. On the other hand, if successfully degluing the contacts is possible, the number of times of successfully degluing the relay contacts may be counted; and once a certain number is reached that is predetermined, a notification may be generated by the controller1000in order to effect e.g. the replacement of the relay1500. Here, the relay may then be replaced, once the apparatus is not operational, and thus no defect will be caused during the operation of the apparatus.

Beneficially, the apparatus can be built into a household appliance in order to control e.g. the heater of an oven or a kitchen hob. During a normal operation, the controller1100may operate the heater with a duty cycle in order to e.g. control the heating power of the heater.

FIG. 2shows an example of a degluing cycle according to a preferred embodiment of the present invention. A diagram2000shows an initial state2050where no power is applied and a final state2200where no power is supplied as well. Once a stage2100is reached, e.g. when it has been detected that a faulty contact open-close state is present in the apparatus, the controller may start a degluing cycle over a period of time2500. In this case, beneficially, at a pulse-width modulated frequency of 20 Hz, and at a duty cycle of 80%, contacts of a relay are vibrated. Peaks2110,2150and2170are shown that are followed by respectively valleys2115,2155and2175. Accordingly, corresponding to the duty cycle, the valleys are much smaller in width than the peaks. It has been shown in tests that such a duty cycle with such a pulse-width modulated frequency is suitable to deglue contacts of the relays in question efficiently. However, different frequencies and different duty cycles over a different period of time may also be sufficient to perform the task.

Beneficially, the period at which the degluing duty cycle is applied is 1 second. It may also be preferably 1.5 seconds or 2 seconds as desired. However, it has to be taken into consideration that the operation at such a duty cycle and with such a frequency puts the circuitry and the coil in the relay under thermal and mechanical stress, hence the degluing. Therefore, care should be taken that the relay is not overloaded. The period respectively the duty cycle applied to the relay can be repeated in case it is detected that after 1 second the relay contacts are still not open.

AsFIG. 3shows, multiple degluing cycles having periods2500can be performed one after another. The diagram3000shows an initial phase3100and delays between the degluing cycles3110,3120and3130.

Beneficially, a number of five degluing cycles may be performed in which preferably a duty cycle of 80% is maintained and a pulse-width modulation frequency of 20 Hz is applied by the controller.

Beneficially, five such degluing cycles may be performed in order to effectively deglue relay contacts. Test results have shown that if after five attempts have been conducted after which still no degluing of the contacts took place, preferably the relay should be replaced.

AsFIG. 4shows, a method for operating a relay according to an embodiment of the invention starts in a driver off-state of a relay4100and proceeds to an interrogation4200at which it is determined if the relay contacts are glued. If this is not the case at4210, the method4000is stopped at4500. On the other hand, if the relay contacts are glued, this is determined at4220, relay vibrations are effected at4300. Those vibrations are preferably caused by controlling the relay at a duty cycle of 80% and applying a pulse-width modulated frequency of 20 Hz to the control circuit of the relay to cause the contacts closing the load circuit and being glued to open. If the relay contacts are still not open4250, this is again determined at4200. At4300, it is determined in an interrogation, if the cycle has been repeated five times. Any other predetermined number instead of five may be chosen according to the application and the relay. If this is the case4320, an error signal may be generated4400which may lead to an indication to a user in form of a light written message or any other signal, e.g. a wireless communication to a mobile device.

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