High-Power and Digital Relays: Reshaping the Future of Industrial Automation

Highlights

• Introduction
• Innovations in relay technology
• The dynamic potential of digital and wireless relays
• Recent developments in the industry

A relay is an electromechanical device that regulates the flow of electricity between circuits. It comprises components such as a coil, an armature, and one or more sets of contacts. When an electric current flows through the coil, it generates a magnetic field that attracts the armature, resulting in the opening or closing of the contacts. This mechanism enables the relay to switch electrical circuits on or off, thereby managing the current flow. Relays are essential in numerous applications, including industrial automation, telecommunications, automotive systems, and power distribution.

The growing usage of electronic devices, telecommunications equipment, and data centers is fueling the expansion of the relay industry. Relays used in process control systems for manufacturing and industrial automation are expected to see increased demand in the landscape of relay. The industry is projected to showcase a noticeable CAGR of 6.9% by 2032. The latest relay models involve general-purpose relays, monitor and control relays, time relays, and protection relays. 

The role of advanced materials and miniaturization in optimizing the relay’s performance

The transition from traditional electromechanical relays (EMRs) to solid-state relays (SSRs) and numerical relays has been substantial. SSRs offer benefits like faster switching speeds, lower power consumption, and extended lifespans. Numerical relays, enhanced by computer technology, provide integrated control, protection, and metering abilities, making them increasingly popular in industrial applications.

Furthermore, relay components are becoming smaller and more compact, facilitating easier integration into modern electronic devices and circuit boards. This wave of miniaturization is supported by the need for more efficient space utilization in applications such as automotive and telecommunications. 

On the other hand, advancements in materials have resulted in new coatings that lower contact resistance in relays. Research into complex metallic alloys focuses on improving performance, especially in low-power applications where minimizing contact losses is essential. Additionally, innovations in arc management materials are designed to endure repeated arcing without significant degradation.

The integration of digital and wireless relays in modern smart factories

Relays are required for the development and operation of smart grid technology, improving the efficiency, reliability, and safety of power systems. Modern smart grids need advanced protection mechanisms to maintain reliable power delivery. Relay protection systems have evolved to incorporate ultra-high-speed fault discrimination and coordination principles, adapting to the complexities of diverse power networks. These advancements enable rapid fault detection and isolation, reducing service interruptions and improving the overall stability of the grid.

The incorporation of digital technology into relays has significantly enhanced their functionality. Digital relays process large volumes of data in real time, allowing them to conduct complex calculations and analyses for fault detection and system monitoring. This capability is necessary for maintaining the integrity of the smart grid, as it facilitates rapid responses to disturbances and supports better decision-making based on real-time data.

Moreover, recent advancements in wireless technology, including wirelessly powered relays, are projected to improve smart grid applications. These relays function without wired power sources, enabling more flexible and efficient deployment of sensors and communication devices across the grid. This innovation supports the increasing demand for smart factories and connected environments, where seamless communication and power delivery are essential.

Omron’s high-power PCB relays

Omron Electronic Components introduced the latest high-power PCB relay in July 2024. The product is designed for AC wall boxes used in EV charging stations. The G9KC relay features reduce contact resistance and generate less heat at the load terminals during operation compared to other similar devices. This improvement allows EV charger designers and manufacturers to develop systems that offer faster, more efficient charging with enhanced reliability and longer expected lifetimes.

Omron’s G9KC relay, with its double break contact and mechanically coupled design, is ideal for demanding pedestal chargers and AC wall boxes in workplaces, homes, industries, and commercial settings.

Siemens introduced the new SIRIUS 3UG5 line monitoring relays

Siemens unveiled a new generation of line monitoring relays in August 2023. The SIRIUS 3UG5 relays integrate established technology with enhanced features and applications. Grid monitoring relays are essential in settings such as hospitals and the process industry, where a reliable and fail-safe power supply is important. They are also integrated into cranes, elevators, air compressors, air-conditioning systems, and the timber industry.

The new SIRIUS 3UG5 line monitoring relays offer optimal protection for mobile machinery and equipment, as well as for unstable grids. They enable early detection and reporting of grid and voltage faults, helping to prevent significant subsequent damage.

To conclude, the relay industry is evolving with advancements in materials, miniaturization, and digital technology, enhancing performance and integration in modern systems. Moreover, the growth is driven by innovations like solid-state relays, advanced coatings, and wireless technology. Additionally, new high-power and line monitoring relays also show ongoing improvements in functionality and reliability for various uses.

For more details on the applications of relays across multiple industries, contact our experts today!

Related Post