IP Library Granted Patent US 12704562
Granted Patent B2
US 12704562 · App. 18/646,293 · Granted Aug 11, 2026

Method and apparatus for determining the status of a contactor

Inventors: Connor Benjamin Taylor (Norman, OK); David Keith Howland (Yukon, OK)
Assignee: Cox Automotive, Inc.
G01R31/66
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Quick Facts
Patent No.
US 12704562
App. No.
18/646,293
Granted
Aug 11, 2026
Kind
B2
Abstract

System and method for determining a status of a contactor is provided. An excitation signal is generated. The excitation signal is propagated towards a contactor. A a peak value of a resulting signal resulting from a reflected signal reflected from the contactor and the excitation signal is detected. The peak value is compared with a predetermined value. The contactor is determined as welded in response to determining that the peak value is greater than the predetermined value.

Claims (42)

1 . An apparatus for determining a status of a contactor, the apparatus comprising:

a controller comprising a signal generator, wherein the signal generator is configured to generate an excitation signal;

an isolator connected to the controller, wherein the isolator is configured to propagate the excitation signal to a contactor;

a low pass filter connected between the signal generator and the isolator, wherein the low pass filter is configured to convert the excitation signal into a sine wave signal;

a peak detector connected to the controller, wherein the peak detector detects a peak value of a resonant signal resulting from reflection of the excitation signal from the contact; and

wherein the controller is configured to:

compare the peak value with a predetermined value, and

determine a status of the contactor based on the comparison.

2 . The apparatus of claim 1 , wherein the controller being configured to determine the status of the contact based on the comparison comprises the controller being configured to:

determine that the contact is welded when the peak value is greater than the predetermined value.

3 . The apparatus of claim 1 , wherein the controller being configured to determine the status of the contact based on the comparison comprises the controller being configured to:

determine that the contact is not welded when the peak value is not greater than the predetermined value.

4 . The apparatus of claim 1 , wherein the isolator comprises a galvanic transformer.

5 . The apparatus of claim 1 , wherein the apparatus is connected across the contact.

6 . The apparatus of claim 1 , wherein the controller further comprises an analog to digital convertor, and wherein the analog to digital convertor is connected to the peak detector.

7 . The apparatus of claim 1 , wherein the isolator comprises a transformer, wherein a first output terminal of the transformer is connected to a first node of the contact, wherein a second output terminal of the transformer is connected to a second node of the contact, wherein a first input terminal of the transformer is connected to the controller, and wherein a second input terminal of the transformer is connected to the ground.

8 . The apparatus of claim 1 , wherein the isolator comprises a first capacitor, a second capacitor, and a transformer, wherein a first terminal of the first capacitor is connected to a first node of the contact, wherein a first terminal of the second capacitor is connected to a second node of the contact, wherein a second terminal of the first capacitor is connected to a first output terminal of the transformer, wherein a second terminal of the second capacitor is connected to a second output terminal of the transformer, wherein a first input terminal of the transformer is connected to the controller, and wherein a second input terminal of the transformer is connected to the ground.

9 . A contact weld detector comprising:

a controller comprising a signal generator, wherein the signal generator is configured to generate an excitation signal;

a transformer configured to propagate the excitation signal to a contact, wherein a first output terminal of the transformer is connected to a first node of the contact, wherein a second output terminal of the transformer is connected to a second node of the contact, wherein a first input terminal of the transformer is connected to the controller, and wherein a second input terminal of the transformer is connected to the ground;

a low pass filter connected between the signal generator and the transformer, wherein the low pass filter is configured to convert the excitation signal into a sine wave signal; and

a peak detector connected to the controller and transformer, wherein the peak detector detects a peak value of a resonant signal resulting from reflection of the excitation signal from the contact, wherein the controller is configured to determine a status of the contact based on the peak value.

10 . The contact weld detector of claim 9 , the controller being configured to determine the status of the contact based on the peak value comprises the controller being configured to:

determine that the contact is welded when the peak value is greater than a predetermined value.

11 . The contact weld detector of claim 9 , the controller being configured to determine the status of the contact based on the peak value comprises the controller being configured to:

determine that the contact is not welded when the peak value is not greater than a predetermined value.

12 . The contact weld detector of claim 9 , wherein the controller further comprises an analog to digital convertor, and wherein the analog to digital convertor is connected to the peak detector.

13 . The contact weld detector of claim 9 , further comprising a first capacitor and a second capacitor, wherein the first capacitor is connected between the first output terminal of the transformer and the first node of the contact, wherein the second capacitor is connected between the second output terminal of the transformer and the second node of the contact.

14 . The contact weld detector of claim 9 , further comprising a third capacitor connected between the first input terminal of the transformer and the controller.

15 . A method of determining a status of a contact, the method comprising:

generating, a signal generator, an excitation signal;

propagating, through an isolator connected to the signal generator, the excitation signal towards a contactor;

converting, by a low pass filter connected between the signal generator and the isolator, the excitation signal into a sine wave signal

detecting, through a peak detector, a peak value of a resulting signal resulting from a reflected signal reflected from the contactor and the excitation signal;

comparing, by a controller, the peak value with a predetermined value; and

determining, by the controller, that the contactor is welded in response to determining that the peak value is greater than the predetermined value.

16 . The method of claim 15 , wherein detecting the peak value comprises detecting an amplitude of the resonant signal.

17 . The method of claim 15 , further comprising:

determining that the contact is not welded in response to determining that the peak value is not greater than the predetermined value.

18 . The method of claim 15 , wherein the excitation signal comprises a sine wave signal.

19 . The contact weld detector of claim 9 , wherein the transformer comprises a galvanic transformer.

20 . The contact weld detector of claim 9 , wherein the controller further comprises an analog to digital convertor, and wherein the analog to digital convertor is connected to the peak detector.