Design of Automatic Test System for Load-Breaking Performance of Hermetically Sealed Electromagnetic Relay Contact System

Load-breaking performance of the contact systems in Hermetically Sealed Electromagnetic Relay (HSER) significantly impacts their overall reliability. To ensure the reliability and safety of HSER, a novel test system is designed for evaluating the load-breaking performance. A multifunctional mechanical clamping part is designed to fix contact systems. A pushing process dynamic simulation model is established to calculate key parameters such as speed, displacement and acceleration. For highly accuracy, a linear motor and control model are selected to achieve fully simulating the actuary motion of the movement of relay’s rod. High-speed cameras and oscilloscopes are employed to capture dynamic images of the reed movement and arcing waveform. A typical 1/2 crystal HSER is set to be an example to verify the function of this system under different reed-breaking conditions (different material, load and speed). Proper accuracy, push speed range of 0–1500 mm/s and error margin less than 5% are verified. This system can be used providing theoretical and practical support for optimizing the relay’s contact system design and reliability analysis.