Relay switching apparatus

Claim 2

A switching circuit for selectively coupling a load to an A.C. power source, said switching circuit comprising: (a) a master relay including a master relay contact and a master relay coil; (b) a pilot relay including a pilot relay and a pilot relay coil, said master and pilot relay contacts being coupled in series with each other and being coupled between said load and said power source to cause said power source to be coupled to said load whenever both said master and pilot relay contacts are closed; and to cause said power source to be completely disconnected from said load whenever at least said pilot relay contact is open; said pilot relay contact being devoid of any additional conductive element thereacross; (c) a single commutating diode coupled in parallel only with said master relay contact; and (d) timing and control circuit means for performing a switching operation in which: (1) said master relay contact is opened during a first half-cycle of the A.C. waveform of said power source during which said single commutating diode is forward-biased; (2) the state of said pilot relay contact is changed during a second half-cycle of said A.C. waveform, said second half-cycle being that half-cycle of said A.C. waveform immediately following said first half-cycle, and during which said single commutating diode is reverse-biased. (3) said master relay contact is closed during a third half-cycle of said A.C. waveform, said third half-cycle being that half-cycle of said A.C. waveform immediately following said second half-cycle.

Claim 3

A switching circuit according to claim 1, wherein said timing and control circuit means further includes means for: (a) disabling a flow of current through said master relay coil at a time interval ΔT before said master relay contact is to be opened; (b) changing the state of current flow through said pilot relay coil at a time interval ΔT' before the state of said pilot relay contact is to be changed; and (c) enabling a flow of current through said master relay coil at a time interval ΔT before said master relay contact is to be reclosed; wherein the time interval ΔT is the response time of said master relay and the time interval ΔT' is the delay time of said pilot relay.

Claim 4

A switching circuit according to claim 1, wherein said timing and control circuit means includes means for closing said master relay contact at the middle of said first half-cycle of said A.C. waveform, for changing state of said pilot relay contact at the middle of said second half-cycle of said A.C. waveform, and for reclosing said master relay contact at the middle of said third half-cycle of said A.C. waveform.

Claim 5

A switching circuit according to claim 1, wherein said timing and control circuit means includes means for monitoring both said A.C. waveform and a control signal which indicates whether said power supply is to be coupled to, or removed from, said load; said timing and control means being adapted for initiating said switching operation responsive to a change in the state of said control signal.

Claim 6

The switching circuit of claim 4, wherein said timing and control circuit means includes a zero-cross-detect circuit receiving only the A.C. waveform from said source and used to determine the phase of said source A.C. waveform.

Claim 7

The switching circuit of claim 5, wherein said zero-cross-detect circuit outputs a signal for at least each source A.C. waveform zero crossing in a selected direction, and said timing and control circuit further includes a flip-flop which stores the state of said control signal and receives the zero-cross-detect circuit output to initiate said switching operation responsive to the next detect circuit output signal after said control signal changes state.

Claim 8

The switching circuit of claim 6, wherein said flip-flop has a data input and a clock input, said data input receiving said control signal, said clock input receiving said output signal from said zero-cross-detect circuit.

Claim 9

A switching circuit for selectively coupling any combination of a plurality N of loads, where N is an integer greater than 1, to an A.C. power source, said switching circuit comprising: (a) a master relay including a master relay contact and a master relay coil; (b) a plurality N of pilot relays, each of said pilot relays including a pilot relay contact and a pilot relay coil, each of said pilot relay contacts being coupled in series with a respective one of said N loads; said master relay contact being coupled in series with all of said pilot relay contacts to said power source insuch manner that each individual one of said N loads is connected to said power source only when both said master relay and the pilot relay contact associated with that individual one of said N loads are closed; (c) a single commutating diode coupled in parallel only with said master relay contact; each of said pilot relay contacts being devoid of any additional conductive element thereacross; (d) timing and control circuit means for performing a switching operation in which: (1) said master relay contact is opened during a first half-cycle of the A.C. waveform of said power source during which said single commutating diode is forward-biased; (2) the state of at least one of said pilot relay contacts is changed during a second half-cycle of said A.C. waveform, said second half-cycle being that half-cycle of said A.C. waveform immediately following said first half-cycle, during which second half-cycle said single commutating diode is reverse-biased; and (3) said master relay contact is closed during a third half-cycle of said A.C. waveform, said third half-cycle being that half-cycle of said A.C. waveform immediately following said second half-cycle.

Claim 10

A switching circuit for selectively coupling any combination of a plurality N of loads, where N is an integer greater than 1, to an A.C. power source, said switching circuit comprising: (a) a master relay including a master relay contact and a master relay coil; (b) a plurality N of pilot relays, each of said pilot relays including a pilot relay contact and a pilot relay coil, each of said pilot relay contacts being coupled in series with a respective one of said N loads; said master relay contact being coupled in series with all of said pilot relay contacts to said power source insuch manner that each individual one of said N loads is connected to said power source only when both said master relay and the pilot relay contact associated with that individual one of said N loads are closed; (c) a single commutating diode coupled in parallel only with said master relay contact; each of said pilot relay contacts being devoid of any additional conductive element thereacross; (d) timing and control circuit means for performing a switching operation in which: (1) said master relay contact is opened during a first half-cycle of the A.C. waveform of said power source during which said single commutating diode is forward-biased; (2) the state of at least one of said pilot relay contacts is changed during a second half-cycle of said A.C. waveform, said second half-cycle being that half-cycle of said A.C. waveform immediately following said first half-cycle, during which second half-cycle said single commutating diode is reverse-biased; and (3) said master relay contact is closed during a third half-cycle of said A.C. waveform, said third half-cycle being that half-cycle of said A.C. waveform immediately following said second half-cycle.

Claim 11

A switching circuit according to claim 8, wherein said timing and control circuit means includes means for (a) disabling a flow of current through said master relay coil at a time interval ΔT before said master relay coil is to be opened; (b) changing the state of current flowing through said pilot relay coils associated with said at least one pilot relay contact at a time interval ΔT' before the state of said at least one pilot relay contact is to be changed; and (c) enabling a flow of current through said master relay coil at a time interval ΔT before said master relay contact is to be reclosed; the time interval ΔT being the response time of said master relay and the time interval ΔT' being the delay time of each of said pilot relays.

Claim 12

A switching circuit according to claim 8, wherein said timing and control circuit means includes means for closing said master relay contact at the middle of said first half-cycle of said A.C. waveform, for changing state of said at least one pilot relay contact at the middle of said second half-cycle of said A.C. waveform, and for reclosing said master relay contact at the middle of said third half-cycle of said A.C. waveform.

Claim 13

A switching circuit according to claim 8, wherein said timing and control circuit means includes means for monitoring both said A.C. waveform and a plurality of control signals indicative of whether said power supply is to be coupled to or removed from respective ones of said loads; and means for initiating said switching operation responsive to a change in the state of at least one of said control signals and a next subsequent zero-crossing of said A.C. waveform thereafter.

Claim 14

The switching circuit of claim 8, further including a fuse coupled in series with said single commutating diode, said series-connected fuse and diode being connected in parallel with said master relay contact.

Claim 15

The switching circuit of claim 8, further including fail-safe circuit means for determining that either said commutating diode or said master relay contact is operating improperly and then for halting said switching operation.

Claim 16

The switching circuit of claim 13, wherein said fail-safe circuit means includes first means for determining whether said commutating diode and said master relay contact are operating properly during said first half-cycle of said A.C. waveform; and second means for halting said switching operation before said second half-cycle of said A.C. waveform whenever said first means provides an output indicative of either said commutating diode or said master relay contact operating improperly.

Claim 17

The switching circuit of claim 14, wherein said fail-safe circuit means first means includes first test means for determining if said master relay contact is operating properly; and second test means for determining if said commutating diode is operating properly.

Claim 18

The switching circuit of claim 8, further including means for storing a plurality of binary bits, each of said binary bits indicating whether power is to be coupled to or removed from a respective one of said loads.

Claim 19

The switching circuit of claim 16, wherein new information is read into said storage means at a predetermined frequency; and further including watchdog circuit means for removing power to all of said loads whenever it is determined that information is not properly being read into said storage means.