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How is contact gap related to electrical life in a relay?

Hilbert–Huang transform

Contact resistance

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The contact gap in a relay plays a crucial role in determining its electrical life. A larger contact gap aids in extinguishing AC arcs, which can erode relay contacts and shorten their lifespan . On the other hand, the gap and malposition of relay contacts heavily influence their life, with proper inspection and maintenance being essential for enhancing relay quality . Additionally, the electrical properties of contact materials, such as contact resistance, play a key role in relay reliability, with silver-based materials widely used due to their good conductivity and thermal properties . Moreover, a relay design incorporating a regulating connecting pressure gap can optimize electrical connections, leading to a longer service life and improved performance . Therefore, maintaining an optimal contact gap is vital for ensuring the longevity and efficiency of relay operation.

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Patent Relay constituting of regulating connecting pressure gap Wu Songren 06 Jun 2001 1 Citations	The contact gap in the relay regulates the contact pressure between points, ensuring optimum electrical connection, leading to a long service life due to maintaining effective electrical connections.
Proceedings Article•DOI Research on the influence of contact gap on AC arc duration of electromagnetic relay Xuerong Ye, Han Zhao, Huimin Liang, Guofu Zhai - Show less +3 more 01 Aug 2014	Increasing contact gap in a relay accelerates arc extinguishment, shortens arc duration, and enhances relay lifespan by reducing contact erosion, as studied in the paper.
Journal Article•DOI Research on the Electric Life Prediction of Relay Contact Based on Harris Hawk Optimized 01 Jan 2022-IEEE Transactions on Instrumentation and Measurement 3 Citations	The contact gap influences contact pressure, which is calculated from contact resistance. This pressure-based criterion predicts the electrical life of a relay effectively.
Journal Article•DOI Automated Visual Inspection of Contact Gap and Contact Malposition of Automotive Relay Chen Huei Hsieh, Chi-Sheng Tsai, Ting Yu Tseng, Yi Sheng Wong, Shi Zhen Zhou - Show less +4 more 01 Jul 2012-Applied Mechanics and Materials 1 Citations	The gap and malposition of the contact in an automotive relay significantly impact its life. Automated visual inspection can enhance quality by detecting these issues efficiently during manufacturing.
Open access•Journal Article•DOI Performance degradation comparisons and failure mechanism of silver metal oxide contact materials in relays application by simulation Zhaobin Wang, Weiyan Li, Shang Shang, Zhan Wang, Chunyang Han - Show less +4 more 10 Dec 2019-Eksploatacja I Niezawodnosc-maintenance and Reliability 8 Citations	The contact gap in relays affects electrical life by influencing factors like contact resistance, arc energy conversions, and mechanical stress, impacting overall reliability and performance.

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