We initiated development of our own data processing software for laser microscope data with C# language. This software is provided with volume calculation function of a target portion, based on a new calculation algorithm that can precisely handle the volume calculation of the portion located on a tilted surface or on a distorted surface. In this paper, this algorithm and some exemplary results obtained thereby, as well as some further development aims, are briefly described.

The three major failures of electrical contacts for automotive relay applications are: contact welding (or contact sticking), high contact resistance and severe contact erosion due to switching arcing. With the demand of high power and multiple functions of automotive vehicles, the switching current has be dramatically increased, it results in higher failing rate, in particular for contact welding. On the other hand, the miniaturization of electromechanical relays has lead to the reduction of mechanical spring force. This not only results in the earlier contact welding but also makes the relay more susceptible to the contact resistance and arc erosion failures. This paper is a review of most recent studies on these three failure aspects. It describes the progress in the understanding of contact welding caused by short arcing and high contact resistance due to contamination of particles and films in relay manufacturing process and also it review the material transfer due to switching arcing. At the end, the brief considerations of electromechanical relays used in 42 volts have also been given.

A new scheme for evaluation of shapes of pips and craters formed by arc discharges on electrical contact surfaces is proposed. Measuring a height of a pip or a depth of a crater as well as an average diameter thereof with a scanning laser microscope and then putting a plot having the measured values as its vertical and horizontal coordinates enable us to numerically and briefly evaluate shapes of those pips and craters on arc-damaged contact surfaces. Some exemplary results obtained by this evaluation scheme are presented here.

Telecom- and Signal Relays with gastight plastic sealed housings enables the usage of inert and highly insulating gases. Although plastic sealed housings are used, optimized designs can keep the gas during the entire life of more than 25 years. The application of this technology allows the application of highly insulting gases like SF6 and result in a significant reduction of the relay size as reduced physical dimensions can be applied. With unchanged distances a significantly better dielectric performance can be achieved, without a relevant cost increase. Furthermore the inert switching atmosphere increases the switching characteristics or reduces the consumption of precious metals for the contacts. Even the usage of less precious metals like tungsten or ruthenium might be possible for switching typical telecommunication signals.

The authors have been interested in a Scanning Laser Microscope (SLM) and applied it to studies of contact phenomena. In particular, a digital SLM is being currently used, and confirmed to be a successful tool for investigating the contact phenomena. In this paper, the theory and mechanism of a digital SLM are briefly explained, and some actual data obtained with the digital SLM are presented for demonstrating its usefulness for studies of contact phenomena.

Arc discharge between electrodes of relays and switches often causes contact surface damage through material transfer and arc erosion. Especially, material transfer sometimes occurs and brings serious failure even under lower load that is quite smaller than the minimum arc current value of contact material. In this paper, contact surface configuration, material transfer, and arc erosion characteristics of Ag and AgPd 60 contacts were experimentally studied after 0.5 or 1 million switching operations at various load levels. The followings can be made clear. Firstly, it was confirmed that the arcs and material transfer occurred even under such current that was lower than the minimum arc current. Therefore, the definition of the arc occurrence boundary current was newly determined. Secondly, the relation between load conditions (current and power supply voltage) and contact surface configuration (craters and pips) caused by material transfer was studied. The arc erosion behaviors of tested samples could be classified into two types: material transfer type and wear-out type. As one of the primary factors of transition from the former type to the latter one, contact activation was considered. The influences of load conditions and organic gas emitted from relay structure on arc characteristics was experimentally examined. The results indicated that load current greatly influenced the amount of material transfer and that power supply voltage affected the occurrence of the wear-out type significantly. The activation behavior of the contact surface could be found through observing the bridge voltage waveform.