A relay is a switch that opens and closes a circuit either electromechanically or electronically. Relays control one electrical circuit by opening and closing contacts in another circuit.
A relay contact can be Normally Open (NO), there is an open contact when the relay is not energized or Normally Closed (NC), there is a closed contact when the relay is not energized. In either case, applying electrical current to the contacts will change their state.
Different relays have different constructions, components and different operating parameters and are therefore used for specific functions. This also explains why relays have different performance characteristics, lifecycles and failure modes.
If we use an automobile as an example, there are a variety of relays delivering various features and enabling specific functions, such as; warning systems, seatbelt usage, or hazard-sensing, headlights, turn signals, windshield wipers, interior lighting, alarm systems.
The two main types of relay construction are mechanical and solid state. Mechanical relays, such as electromechanical relays and reed relays have shorter lifetimes than solid-state relays. The reason for this is that they simply wear out as they cycle.
As with all components, relays fail, and for a variety of reasons; over current, heat, vibrations, manufacturing defects, and others are simply end-of-life failures.
Customers use our equipment to test the relays that are part of their products; from submarines to satellites Nexeya’s test solutions are deployed to verify and validate fabrication, production, assembly and performance life cycle mapping and asset management.
In addition to testing relays in customer products our suite of test benches and solutions also deploy relays. Based on the performance and lifecycle required our equipment will utilise either mechanical and / or solid state relays. Relays, in our application enable us to quickly and accurately apply current and voltages to a product to detect and pinpoint faults. Software applications, such as Mass HiPot, take advantage of relay configurations to drastically reduce test times in high point count scenarios.
The testing of high point count cables and harnesses requires relays to ensure that the cables can be tested quickly and that all the test scenarios are covered and executed. In order to verify and validate a cable the cable is connected to a relay switch card which assigns a relay to each point or connection on the cable. A test program then turns relays ‘on’ and ‘off’ to apply current and voltage in order to fully test the harness and to identify and pinpoint faults.
These relay cards are the work horse of any electrical test bench and it’s critical that proper maintenance and calibration protocols be followed, that test programs respect the operating parameters of the system and that replacement boards are kept on hand to minimize downtime related to relay failures.
Nexeya’s Studio Software is an ideal command and control application to help monitor and maintain your test equipment while delivering exception test capabilities.
There is no substitute to Nexeya's MPT product line when it comes to testing cables and harnesses with thousands, yes thousands of test points.
To find out more about cables and harness testing, relay or component validation of the products you build or, to better understand your current test equipment or test needs please contact us at NexeyaCanada@Nexeya.com.
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