Working Principle and Fault Detection Method of Relay Indicator Light Module

Fault of Relay Indicator Light Module

The failure rate of relays in the vehicle electronic control system is also relatively high. In order to quickly and accurately determine which relay is faulty, we connect an indicator light module in parallel at both ends of the relay coil to display the power gain and loss status of the relay, which is often encountered during use. Because the relay fault indicator light causes the circuit breaker to trip, which leads to many bad events such as the train clearing off the assembly line.

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The relay indicator module is composed of light-emitting diodes and bidirectional transient voltage stabilizer diodes (TVS), which are connected in parallel with the relay coil, and the light-emitting diodes are used to display the gain and loss of the relay.

When there is an instantaneous surge voltage in the loop, the bidirectional voltage regulator tube will break down quickly, change from high resistance state to low resistance state, shunt and clamp the surge voltage, so as to protect the components in the circuit from being damaged by the instantaneous surge voltage.

The surge pulse voltage is damaged, so that the voltage at both ends of the relay is stabilized within the standard voltage range, and the freewheeling diode D2 is used to absorb the instantaneous back electromotive force generated during the process of turning on to cutting off the coil, thereby effectively protecting related components.

During the debugging process, we often encounter the tripping of the circuit breaker due to the instantaneous increase of the current caused by the damage of the internal Zener tube or diode.

Whenever we encounter this situation, we find out by pulling the wires one by one. This method not only It is time-consuming and laborious, but also greatly reduces work efficiency. Below, I will find a quick detection method based on the internal schematic diagram of the indicator light module.

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Reasons and detection methods of subway relay fault indicator light

Taking the trip of the zero-speed circuit breaker (ZVRCB) of a subway project as a column to analyze the reasons and the detection and processing method of fault indicator light, the ZVRCB tripping phenomenon occurred in the second column of a subway project during the debugging process.

The resistance value of the lower end of the circuit breaker to the negative line is found to be infinite, which indicates that the gap is not caused by the short circuit of the positive and negative lines. Since it is the second train, the reason for the small capacity selection of the circuit breaker is also ruled out.

Under normal circumstances, as long as the braking system detects that the train is in a stopped state, the braking system outputs a zero-speed signal, that is, the ZVRTC and ZVRM relays are energized and their normally open contacts are closed, so that the ZVR1-ZVR5 zero-speed relays are energized.

Now the trip is definitely caused by a fault indicator light from ZVR1 to ZVR5, but which fault indicator light is the specific fault indicator light. Normally, we can find out by pulling the wires all the way.

This is not only time-consuming and laborious, but also seriously affects the work efficiency.

Its principle shows that when the coil is energized, due to the reverse cut-off effect of the diode D1, the protection circuit is regarded as an open circuit, that is, the current does not pass through the protection circuit, that is, it does not pass through D2 and DZ1;

At this time, the voltage regulator tube (DZ1) is reversely broken down to absorb the instantaneous high voltage, and the ordinary diode D2 is used for freewheeling.

Even if the Zener tube is in a failed state due to thermal breakdown short-circuit, it can continue to flow through the diode D2, which only reduces the ability of the circuit to eliminate arcs, but does not short-circuit the entire circuit, so the reason for the jump switch is due to D1. , D2 or DZ1 breakdown causes the current in the circuit to increase instantaneously, so we can directly measure the tube voltage drop between T1 and T2, T2 and T3, the normal value of the tube voltage drop is (0.5-0.7v) to judge the end Which LED module is damaged.

If there is forward conduction and reverse cut-off between T1 and T2, that is, the diode between T1 and T2 is normal, otherwise the diode fault indicator light, that is, the fault indicator light of this channel, if there is a tube voltage drop between T2 and T3, the module is damaged.

The time meter pen can be measured in reverse to more accurately determine whether D2 or DZ1 is damaged.

Under normal circumstances, the tube pressure drop between T2 and T3 is infinite. If there is a tube pressure drop between T2 and T3 and the circuit is damaged, we can directly short-circuit T1 and T2 to skip the indicator module to quickly Excluding the fault indicator light, this method can not only quickly determine the fault point but also greatly improve the work efficiency.

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Summarize

With the continuous development of technology, the domestic new urban rail vehicle systems all use high-performance vector control or direct torque control AC drive systems, which have excellent speed regulation performance and power utilization performance; the train bus control system is widely used, which greatly reduces the The internal wiring of the vehicle is improved, and the reliability of the vehicle operation is improved; Automatic Train Operation (ATO)。

Automatic Train Protection (ATP) and Automatic Train Monitoring (ATS) have become the basic configuration standards, which greatly improves the reliability and safety of train operation. , reducing the labor intensity of drivers and dispatchers.

The high-performance analog electro-pneumatic braking system is widely used, which realizes seamless air-electric joint control and excellent anti-skid and anti-idling performance. Each system is closely connected, and each link is related to the safety of the train.

From the perspective of commissioners, we It is necessary to understand the working principles of its internal systems, and to actively improve and study the systems and components that have hidden dangers. Only in this way can the safety of subway vehicles be better ensured, the reliability of subway vehicles can be improved, and the safe and fast operation of urban rail vehicles can be ensured.

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