Abstract
Electromechanical switching devices such as relays may be surprisingly forgiving to occasional, but temporary, electrical stress beyond specification. Consequently delayed openings due to welded contacts on the order of milliseconds usually have been unnoticed and hence have not been reason for concern. However, as electrical systems of vehicles are getting smarter and more and more diagnostic routines are being implemented, even such short delay times may be translated as errors. Pre-conditioning contact surfaces has been explored as a measure to increase the welding resistance and eliminate contact opening delays. The 20-A-class relay investigated has been optimized to break occasional current peaks up to 80 ADC.
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