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With the rapid development of industrial automation, automotive electronics, and information industry, higher performance requirements are imposed on the development of electromagnetic relays. A single load type can no longer meet the needs of people's daily life. We often need relays to control different types of load. Such as: resistive load, lamp load, inductive load, capacitive load and motor load, these loads have different current characteristics. Therefore, it is particularly important to select the contact material for the contact system to control the load execution location.
Here are some typical load current characteristics
Lamp load: Taking incandescent lamps as an example, since the incandescent lamp tungsten wire has a small cold current, the inrush current at the instant of turn-on will be as high as 15 times the steady state current. Such a large surge current will quickly ablate the contacts, so the frequent failure phenomenon is instantaneous bonding, that is, 'fusion welding' accident.
Motor load: When the motor is at rest, the input impedance is small, and the current at the start is very large. After the current is injected, the interaction between the current and the magnetic field produces a torque. When the motor starts, it will generate an internal electromotive force, which will reduce the contact current. When the switch is turned off, a counter electromotive force will be generated between the contacts, which often causes arcing and causes contact ablation.
Resistive load: When the resistive load is turned on, no inrush current is generated, and the on current is the steady state current. After working for a period of time, the resistance will rise due to the increase of temperature, which will cause the current to decrease, but the effect is small and can be ignored.
Inductive loads: Inductors, chokes, electromagnets, contactor coils, etc. are all inductive loads. When the inductor and the yoke are turned on, the electromagnetic coil has a function of suppressing the rise of the current, and no inrush current occurs; when the electromagnet or the contact coil is turned on, a surge current occurs. However, when the four loads are turned off, the electromagnetic energy stored in the coil is consumed by the arc between the contacts, which is prone to contact ablation, metal material transfer, and bonding failure.
Capacitive load: The charging current of the capacitive load circuit is very large, generally 20-40 times the steady-state current. At the moment of startup, the capacitor is similar to a short circuit and its current is only affected by the line resistance.
In summary, the current waveforms of different kinds of loads are very different. The inrush current of some loads is several times of the steady-state current, while some loads have no inrush current. The magnitude of the inrush current greatly affects the reliability and life of the contacts, so it is important to select the appropriate contact material depending on the type of load.
The characteristics of several contact materials widely used in the relay industry are described below.
AgNi:
The silver-nickel contact has the characteristics of good electrical conductivity, good thermal conductivity, high ablation resistance, small contact resistance and good processing performance. However, its ability to withstand surge currents is poor. When there is a surge current in the circuit, it is easy to cause instantaneous adhesion failure of the contacts. Therefore, the most suitable control load for silver-nickel contacts is a resistive load.
AgCdO:
The silver cadmium oxide material has good resistance to electric abrasion and fusion welding, and has low contact resistance and stable characteristics, and has a certain effect on the resistance of the surge current. However, due to the different thermal stability requirements of MeO, the low current requires MeO to be easily decomposed to consume a large amount of arc energy. AgCdO meets this requirement. Therefore, AgCdO contact materials are more suitable for controlling motors, inductors and resistive loads.
AgSnO2:
Tin oxide has a high melting point and boiling point, and has a relatively high hardness, so that the alloy has high resistance to material transfer, fusion welding and wear resistance. At the same time, it has the characteristics of high thermal stability when MeO is required to suppress the occurrence of spatter, so it can adapt to high inrush current. AgSnO2 is more suitable for controlling loads with large inrush currents such as lamp load, inductive load and capacitive load.
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