Portable Troubleshooting Relay Electric Testing Device

An electrical relay testing device that provides color-coded indicator lights to test vehicle circuit boards for any 12 volt or 24 volt systems, drawing 15 to 150 amps. The device contains an internal relay, standard relay terminal connections, and at least two external indicator lights. Once the device is plugged into a vehicle circuit board, if the relay terminals are properly working on the board, both lights will illuminate. This device greatly simplifies the process of troubleshooting electrical and electronic systems of vehicles.

FIELD OF THE INVENTION

The subject invention is a quick, simple, and portable electrical relay testing device that provides color-coded indicator lights to test vehicle circuit boards, for use by professional mechanics.

BACKGROUND OF INVENTION

Electromechanical relays are used extensively in low voltage vehicle electrical systems. A typical vehicle can help 20 or more relays. A relay is a remote control switch that is operated electrically rather than mechanically. Relays permit a small current flow circuit to control a higher current circuit.

Electro-mechanical relays work by activating an electromagnet to pull a set of contacts to make or break an internal circuit.

A copper coil wrapped around an iron core forms the electromagnet within the relay. This electromagnet is held in a frame to a hinged soft iron bar, or armature. One end of the armature is connected to a tension spring that pulls the other end of the armature up. This is the relay in its de-energized state or at rest with no voltage applied. The coil and contacts are then connected to various terminals on the outside of the relay.

When a voltage is supplied to the coil (by switching on the relay), it creates a small magnetic field around it, this magnetic field overcomes the pulling force provided by the spring and moves the hinged armature down onto, or away from, the contact, such that the circuit is either now either broken or connected. This completes the current circuit between the terminals and the relay is energized. When voltage is removed from the coil terminal the spring pulls the armature back into it's rest position and breaks the circuit between the terminals. So, by applying or removing power to the coil, the relay switches the high current circuit on or off. If the armature/contact is broken with the relay at rest, then the relay is referred to as Normally Open (NO). If the armature/contact is closed with the relay at rest, then the relay is referred to as Normally Closed (NC). These relays are known as Make & break relays or Single Pole Single Throw (SPST).

Electromechanical relays are used widely in vehicle electrical systems due to relatively low cost, and the ability to deploy a large number of relays together to carry out complex functions.

Electromechanical relays are typically not equipped with self-monitoring equipment. In a system with multiple interconnected relays, any malfunction of one of the relays can lead to a complete system failure. When the system malfunctions, it can be significantly cumbersome for maintenance personnel to trace the faulty relay. Often, it can be difficult to diagnose and correct any electrical issues since the circuit boards show no signs of failure. A trial and error method may be employed, that replaces each relay before powering up and running the system to verify if the relay problem has been resolved. If the failed relay is unresolved, the process is repeated. Thus, the troubleshooting process can be time consuming and expensive.

Therefore, there exists a need to provide a quick, inexpensive, easy-to-use system to test individual relays within complex vehicle electrical systems for failure.

SUMMARY OF THE INVENTION

The subject invention discloses a relay testing device comprising: a portable handheld housing comprising a plurality of protruding male pins operatively connected to internal terminals; an internal switch assembly comprising an electromagnetic coil and an armature, wherein the electromagnetic coil and armature energize the relay testing device upon successful voltage applied from a circuit board; a first external light source on the housing, wherein the first light source illuminates upon voltage received by the electromagnetic coil; and a second external light source on the housing, wherein the second light source illuminates upon energization of the relay testing device.

The subject invention also discloses a relay testing device comprising: a portable handheld housing comprising a plurality of protruding male pins operatively connected to internal terminals; an internal switch assembly comprising an electromagnetic coil and an armature, wherein the electromagnetic coil and armature energize the relay testing device upon successful voltage applied from a circuit board; a first external light source on the housing, wherein the first light source illuminates upon an absence voltage applied, but not received by the electromagnetic coil; a second external light source on the housing, wherein the second light source illuminates upon voltage received by the electromagnetic coil; and a third external light source on the housing, wherein the third light source illuminates upon energization of the relay testing device.

The subject invention also discloses a relay testing device comprising: a portable handheld housing comprising a plurality of protruding male pins operatively connected to a plurality of internal terminals; an internal switch assembly that energizes the relay testing device upon successful voltage applied from a circuit board; a first external light source on the housing that illuminates upon voltage received by the testing device; and a second external light source on the housing, wherein the second light source illuminates upon energization of the relay testing device.

The subject invention also discloses a relay testing device comprising: a portable handheld housing comprising a plurality of protruding male pins operatively connected to a plurality of internal terminals; an internal switch assembly that energizes the relay testing device upon successful voltage applied from a circuit board; a first external light source on the housing that illuminates upon voltage applied, but not received by the testing device; a second external light source on the housing that illuminates upon voltage received by the testing device; and a third external light source on the housing, wherein the second light source illuminates upon energization of the relay testing device.

The subject invention also discloses a relay testing device comprising: a portable handheld housing; a first terminal within the housing operatively connected to a first protruding male pin external to the housing, wherein the first terminal is operatively connected to a first external light source on the housing, further wherein the first light source illuminates upon voltage received by the testing device from a female socket in a circuit board; a second terminal within the housing operatively connected to a second protruding male pin external to the housing; a third terminal within the housing operatively connected to a third protruding male pin external to the housing, wherein the third terminal is operatively connected to a second external light source on the housing; a fourth terminal within the housing operatively connected to a fourth protruding male pin external to the housing; an electromagnetic coil within the housing operatively connected to at the first and second terminal, wherein the electromagnetic coil emits a small magnetic field upon receive voltage from the first terminal; and an armature within the housing operatively connected on a first end to the third terminal, wherein the armature is configured to move an uncontacted second end to contact the fourth terminal upon application of the small magnetic field from the electromagnetic coil, further wherein the second light source illuminates upon successful contact of the second end of the armature to the fourth terminal.

The subject invention also discloses a relay testing device comprising: a portable handheld housing; a first terminal within the housing operatively connected to a first protruding male pin external to the housing, wherein the first terminal is operatively connected to a first external light source and a second external light source on the housing, further wherein the first light source illuminates upon voltage applied, but not received by the testing device from a female socket in a circuit board, wherein the second light source illuminates upon voltage received by the testing device from the circuit board; a second terminal within the housing operatively connected to a second protruding male pin external to the housing; a third terminal within the housing operatively connected to a third protruding male pin external to the housing, wherein the third terminal is operatively connected to a third external light source on the housing; a fourth terminal within the housing operatively connected to a fourth protruding male pin external to the housing; an electromagnetic coil within the housing operatively connected to at the first and second terminal, wherein the electromagnetic coil emits a small magnetic field upon receive voltage from the first terminal; and an armature within the housing operatively connected on a first end to the third terminal, wherein the armature is configured to move an uncontacted second end to contact the fourth terminal upon application of the small magnetic field from the electromagnetic coil, further wherein the third light source illuminates upon successful contact of the second end of the armature to the fourth terminal.

In a further embodiment of the subject invention, the relay testing device is re-useable for testing multiple circuit boards.

In a further embodiment of the subject invention, the light sources each comprise light emitting diodes.

In a further embodiment of the subject invention, the light sources may visible red or green light.

In a further embodiment of the subject invention, the light indication may be provided in a single window on the exterior of the housing.

In a further embodiment of the subject invention, the light indication may be provided in two windows on the exterior of the housing.

In a further embodiment of the subject invention, the relay testing device may comprise a housing and pins substantially similar to relay DIN 72552.

In a further embodiment of the subject invention, the circuit board may comprise a 12 volt or 24-volt board from vehicle electrical systems.

In embodiments of the subject invention, the relays may be used with systems using 10 to 100 amperage.

There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. These together with other objects of the invention, along with the various features of novelty, which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

FIGS. 1-4illustrate a standard make and break, or Single Pole Single Throw (SPST) relay11with four Terminals/Pins for operating a vehicle circuit component12(such as the control circuit for automobile headlights, horn, fuel pump, and electric fan). The relay11has a generally cuboid shape casing13with four protruding male Terminals/Pins85,86,87, and30. The Terminals/Pins85,86,87, and30are taken from DIN 72552. This is a German automotive industry standard that has been widely adopted and allocates a numeric code to various types of electrical terminals found in vehicles. The relay11is operatively attached to a vehicle circuit board by inserting the four protruding male Terminals/Pins85,86,87, and30into four female sockets on the board.

Once inserted, a switch14, with a power source15controls the relay11through the relay switch power lead Terminal/Pin86. The relay11then provides a direct connection from a battery16through a fuse17to Terminal/Pin30to the relay power lead Terminal/Pin87which provides power to the component12. The lead Terminal/Pin85separately grounds18the relay11from the ground19of the component12. Terminals/Pins85and86are connected to an internal electromagnetic coil20. Terminal/Pin87is connected to the Normally Open (NO) contact21of the armature22. The internal electromagnetic coil20is fed with +12V or +24V to Terminal/Pin86and grounded via Terminal/Pin85. The amperage of such electrical systems may be 10 to 100 amps. This electromagnet coil20is held in a frame to the armature22. One end of the armature22is connected to a tension spring that pulls the other end, or the Normally Open (NO) contact21of the armature22up. This is the relay1in its de-energized state or at rest with no voltage applied.

As illustrated inFIG. 4, when the Switch13is activated, a voltage is supplied to the coil20through Terminal/Pin86, which creates a small magnetic field around the coil20. This magnetic field overcomes the pulling force provided by the spring and moves the hinged armature22down onto Normally Open (NO) contact21. This connects the battery16through Terminal/Pin87to the component12through Terminal/Pin30, so that the circuit is now connected. This completes the current circuit between Terminals/Pins85,86,87, and30and the relay11is energized.

As illustrated inFIG. 3, when the Switch13is de-activated, a voltage is removed from the coil20through Terminal/Pin86, which ends the small magnetic field around the coil20. The spring moves the hinged armature22back away from Normally Open (NO) contact21, breaking the circuit. This dis-connects Terminal/Pin87and Terminal/Pin30, disconnecting the battery16from component12. The relay11is now dis-energized.

FIGS. 5-7illustrate a standard make and break, or Single Pole Single Throw (SPST) relay23with six Terminals/Pins for operating a vehicle circuit component (such as the control circuit for automobile headlights, horn, fuel pump, and electric fan). The relay23has a generally cuboid shape casing24with six protruding male Terminals/Pins1,2,3,4,5, and6. The relay23is operatively attached to a vehicle circuit board by inserting the six protruding male Terminals/Pins1,2,3,4,5, and6into six female sockets on the board. Terminals/Pins1and3are connected to an internal electromagnetic coil25. Terminal/Pins2and4form the Normally Open (NO) contact26. Terminal/Pins5and6form the Normally Closed (NC) contact27. The internal electromagnetic coil25is fed with +12V or +24V to Terminal/Pin1and grounded via Terminal/Pin3. The amperage of such electrical systems may be 10 to 100 amps. The relay23may also be used on electrical systems that are AC 120 volts and 10 to 30 amps.

As illustrated inFIG. 6, when the relay23is de-activated, a voltage is removed from the coil25through Terminal/Pin3, which ends the small magnetic field around the coil25. This breaks contact between Terminal/Pins2and4from Normally Open (NO) contact26, breaking the circuit. The relay23is now dis-energized.

As illustrated inFIG. 7, when the relay23is activated, a voltage is supplied to the coil25through Terminal/Pin1, which creates a small magnetic field around the coil25. This magnetic field brings contact between Terminal/Pins2and4from Normally Open (NO) contact26so that the circuit is now connected.

Embodiments of the subject invention are disclosed inFIGS. 8-11. The first embodiment of a troubleshooting relay device28tests four Terminal/Pin relays11. The troubleshooting relay device28has a generally cuboid shape casing29with four protruding male Terminals/Pins85,86,87, and30, substantially similar to relay11. In embodiments of the subject invention, the outer casing29may be composed of a strong, durable plastic, such as high density polyethylene or polypropylene

In the troubleshooting relay device28, Terminals/Pins85and86are connected to an internal electromagnetic coil31. Terminal/Pin87is connected to Normally Open (NO) contact32of an armature33. Terminal/Pin30is connected to armature33. This electromagnetic coil31is held in a frame to the armature33. One end of the armature33is connected to a tension spring that pulls the other end, or the Normally Open (NO) contact32of the armature33up. This is the troubleshooting relay device28in its de-energized state or at rest with no voltage applied.

FIGS. 8 and 9illustrate a first embodiment of the troubleshooting relay device28. In this embodiment, a connection34is made between Terminal/Pin86and Terminal/Pin85. This connection34contains a first light emitting diode (LED)35and a resistor36. If Terminal/Pin86receives voltage from switch4, then connection34provides power to the first LED35to illuminate a first color on the exterior of the troubleshooting relay device28casing29. Another connection37is made between Terminal/Pin87and Terminal/Pin30. This connection37contains a second LED38and a resistor39. If the coil31receives voltage, a small magnetic field around the coil31overcomes the pulling force provided by the spring and moves the hinged armature33down onto Normally Open (NO) contact32. The connection37is made between Terminal/Pin87and Terminal/Pin30, powering the second LED38to illuminate a second color on the exterior of the troubleshooting relay device28casing29.

To troubleshoot, or quickly test, the functionality of a relay1or a vehicle circuit board using this first embodiment of the troubleshooting relay device28, the relay1is removed from the four female sockets. The troubleshooting relay device28is then inserted onto the vehicle circuit board by inserting its four protruding male Terminals/Pins85,86,87, and30into four female sockets on the board. The troubleshooting relay device28may be used on an electrical system that is 12 volts to 24 volts, and 10 amps to 100 amps.

Once inserted, if the board is working properly, the switch4will provide power to the troubleshooting relay device28Terminal/Pin86. Once the voltage is received through Terminal/Pin86, the connection34is made to power the first LED35to illuminate a first color on the exterior of the troubleshooting relay device28casing29. This first illuminated LED35quickly informs the user that the relay connection is properly receiving power from the board. If the coil31receives power from Terminal/Pin86, a small magnetic field around the coil31overcomes the pulling force provided by the spring and moves the hinged armature33down onto Normally Open (NO) contact32to make connection37is made between Terminal/Pin87and Terminal/Pin30. This powers the second LED38to illuminate a second color on the exterior of the troubleshooting relay device28casing29. This second illuminated LED38quickly informs the user that the internal coil of the relay connection is properly receiving power from the board.

Once the test is complete the troubleshooting relay device28is removed from the four female sockets, and used on the next relay1site to be tested. This enables a user to quickly and efficiently insert and re-insert the troubleshooting relay device28, and look for the two illuminated LEDs35and38to test the relays1of the vehicle electrical system.

In embodiments of the subject invention, the first LED35and the second LED38illuminate distinctly colored lights, preferably a red color for LED35and a green color for LED38.

FIGS. 10 and 11illustrate a second embodiment of the troubleshooting relay device70for use with six Terminal/Pin relays. In this embodiment, a first connection40is made between Terminal/Pin1and Terminal/Pin3. This first connection40contains a first light emitting diode (LED)41and a resistor42. If Terminal/Pin1receives voltage from switch4, then connection40provides power to the first LED41to illuminate a first color on the exterior of the troubleshooting relay device70. A second connection42is made between Terminal/Pins2and4, the Normally Open (NO) contact43, and Terminal/Pin3. This second connection42contains a second LED44and a resistor45. If a coil46receives voltage, the second connection42is made between Terminal/Pins2,4, and3powering the second LED44to illuminate a second color on the exterior of the troubleshooting relay device70. A third connection47is made between Terminal/Pins5and6, the Normally Closed (NC) contact48, and Terminal/Pin3. This third connection47contains a third LED49and a resistor50. If the coil46does not receive a voltage, the third connection47is made between Terminal/Pins5and6, the Normally Closed (NC) contact48, and Terminal/Pin3, powering the third LED49to illuminate a third color on the exterior of the troubleshooting relay device70.

Once this embodiment of the device is inserted in a board to be tested, if the board is working properly, the switch4will provide power to the troubleshooting relay device70Terminal/Pin1.

Once the voltage is received through Terminal/Pin1, the first connection40contains powers the first light emitting diode (LED)41to illuminate a first color on the exterior of the troubleshooting relay device70. This first illuminated LED41quickly informs the user that the relay connection is properly receiving power from the board. If a coil46receives voltage, the second connection42powers the second LED44to illuminate a second color on the exterior of the troubleshooting relay device70. This second illuminated LED44quickly informs the user that the internal coil of the relay connection is properly receiving power from the board. If the coil46does not receive a voltage, the third connection47powers the third LED49to illuminate a third color on the exterior of the troubleshooting relay device70. This third illuminated LED49quickly informs the user that the internal coil of the relay connection is properly receiving power from the board.

Once the test is complete the troubleshooting relay device70is removed from the six female sockets, and used on the next relay1site to be tested. This enables a user to quickly and efficiently insert and re-insert the troubleshooting relay device39, and look for the three illuminated LEDs41,44, and49to test the relays1of the vehicle electrical system. The troubleshooting relay device70may also be used on electrical systems that are AC 120 volts and 10 to 30 amps.

In embodiments of the subject invention, the three illuminated LEDs41,44, and49illuminate distinctly colored lights.

FIGS. 12-18illustrate embodiments of a tester51for Telemecanique® or Schneider Electric® limit switches. The tester51has a generally cuboid shape casing52with four female pin receptors1,2,3, and4. Female pin receptors2and3are connected to the Normally Closed (NC) contact71. Female pin receptors2and3are connected to the Normally Closed (NC) contact71. Female pin receptor4is attached to hinged armature53. Female pin receptor1is connected to the Normally Open (NO) contact54of the armature53. The armature53is connected to a tension spring that pulls the other end, or the Normally Open (NO) contact54of the armature53. This is the tester51in its de-energized state or at rest with no voltage applied. As illustrated inFIG. 14, when the tester51is activated, a switch moves the hinged armature54down onto Normally Open (NO) female pin receptor1. This completes the circuit between and the tester51is energized.

FIGS. 15 and 16illustrate an embodiment of the troubleshooting tester device51. In this embodiment, a connection55is made between pin receptor2and 3-volt battery56. This connection55contains a first light emitting diode (LED)72. If tester51receives voltage from battery56, then connection55provides power to the first LED72to illuminate a first color on the exterior of the tester51. Another connection57is made between female pin receptor1and battery56. This connection57contains a second LED58. If tester51receives voltage, a switch moves the hinged armature53down onto Normally Open (NO) contact54. The connection57is made between female pin receptor1and battery56, powering the second LED58to illuminate a second color on the exterior of the tester51.

FIG. 17illustrates another embodiment of the troubleshooting tester device51. In this embodiment, a connection73is made between pin receptor1and pin receptor3. This connection73contains a first light emitting diode (LED)74and a resistor75. If tester51receives voltage from coil60, then connection73provides power to the first LED74to illuminate a first color on the exterior of the tester51. Another connection61is made between female pin receptor1and pin receptor2. This connection61contains a second LED62, and a resistor63. If tester51receives voltage, the connection61is made between female pin receptor1and pin receptor2, powering the second LED62to illuminate a second color on the exterior of the tester51. The troubleshooting relay device51may also be used on electrical systems that are AC 120 volts and 10 to 30 amps.

FIG. 18illustrates a further embodiment of the troubleshooting tester device51. In this embodiment, a connection73is made between pin receptor1and pin receptor3. This connection73contains a first light emitting diode (LED)74and a resistor75. If tester51receives voltage from coil60, then connection73provides power to the first LED7to illuminate a first color on the exterior of the tester51. Another connection61is made between female pin receptor1and pin receptor2. This connection61contains a second LED62, and a resistor63. If tester51receives voltage, the connection61is made between female pin receptor1and pin receptor2, powering the second LED62to illuminate a second color on the exterior of the tester51. A third connection64is made between female pin receptor1, pin receptor4, and a pin receptor5. This connection64contains a third LED65, and a resistor66. If tester51receives voltage, the connection64is made between female pin receptor1and pin receptor4, powering the third LED65to illuminate a third color on the exterior of the tester51. The troubleshooting relay device51may also be used on electrical systems that are AC 120 volts and 10 to 30 amps.

In embodiments of the subject invention, the term “substantially” is defined as at least close to (and can include) a given value or state, as understood by a person of ordinary skill in the art. In one embodiment, the term “substantially” refers to ranges within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.1% of the given value or state being specified.

The many aspects and benefits of the invention are apparent from the detailed description, and thus, it is intended for the following claims to cover such aspects and benefits of the invention, which fall within the scope, and spirit of the invention.

In addition, because numerous modifications and variations will be obvious and readily occur to those skilled in the art, the claims should not be construed to limit the invention to the exact construction and operation illustrated and described herein. Accordingly, all suitable modifications and equivalents should be understood to fall within the scope of the invention as claimed herein.