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ABSTRACT
In electrical system, circuit breaker is used to make or break current for different power system equipments like transformers,
reactors, transmission lines, capacitor banks etc. in normal as well as abnormal (short circuits, over voltages and many more)
conditions. These conditions create switching over voltages. This can be substantially damped by inserting pre-insertion resistor
in circuit. The existing electrically parallel pre-insertion resistor is to be converted in to a new simple and easily controllable
electrically series pre insertion resistor mechanism with mechanical feasibility. The mechanism is comprised of two electrical
contacts and certain means for controlling the motion of the electrical contact. The motion of two electrical contacts should be
controlled to insert the resistor for 10 ms as soon as the circuit breaker is closed and bypass the resistor while opening the
circuit breaker. Five different concepts are developed from scratch to insert resistor. Dynamic motion analyses of concepts are
carried out in MSC ADAMS for various control parameters. Stress analysis of critical components of final concept which
fulfills the requirement of insertion is carried out and subsequent shape modification is followed by final dynamic analysis
which aligns with the requirement.
1 INTRODUCTION
A circuit breaker (CB) is an apparatus in electrical a system that has the capability to, in the shortest possible time,
switch from being an ideal conductor to an ideal insulator and vice-versa. The most important task of a drive operated
circuit breaker is to interrupt fault currents and thus protect electric and electronic equipment [1]. The interruption and
the
Fig 1: Schematic of circuit showing the process of inserting resistor (R) in series with main contacts
Subsequent reconnection is called opening and closing respectively. Switching operations create transient voltages
which can be damped by inserting a particular value of resistor for certain duration in the circuit during connection [1].
Many switch like mechanisms which insert resistor in series during closing are used in industries. Fig 1 shows
completely open position initially. In open position, PIR contacts 1 and main circuit breaker contacts 2 are open. For
inserting resistor R in circuit, main breaker contacts 2 are closed first, whereas PIR contact 1 remains open.
Resistor R is bypassed after closing PIR contacts 1.
Freeman, Froelich and Johnson [2] developed a switch like mechanism (1 in Fig. 1) using a linearly moving roller.
The roller engages a crank arm that is pivotally connected to movable pre-insertion resistor (PIR) contact of switch
mechanism. Variable mechanical advantage obtained from angle between roller and crank causes the PIR contacts to
close at high speed just after main circuit breaker contacts (2 in Fig. 1) to insert resistor during closing. A piston
cylinder coupling establishing rectilinear connection between main circuit breaker contacts and PIR contacts was
devised by Muller and Talir [3]. Coupling was designed to provide closing and opening delay of PIR contacts to insert
resistor and bypass resistor respectively. Michel Perret [4] invented a switch like mechanism with both PIR contacts
movable. Initial pressure suction is used to maintain gap between PIR contacts. This initial maintenance of gap
provides closing delay of PIR contacts to insert resistor. Opening delay is provided by resistance provided to motion of
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PIR contact via separate spring damper system. Considering the inventions, there is a need to develop a mechanism
which can be controlled easily for insertion time.
The present work focuses on development of an easy to control mechanism for closing and opening where insertion
time can be controlled easily. The specifications to insert a resistor in series for 10 milliseconds (ms) are as under
1. Gap of at least 35 mm should be maintained between PIR contacts until main circuit breaker contacts close; 2.
2. PIR contacts should close at 65.9 ms i.e. after 10 ms of main circuit breaker closing as shown in Fig. 2;
3. PIR contacts should open at 469.2 ms i.e. after 300 ms of main circuit breaker opening as shown in Fig. 2
Fig 2: Input motion curve shows instants of closing and opening of main circuit breaker and PIR switch
2. METHODOLOGY
The concepts for new switch mechanisms are developed based on three central ideas which are as under.
1. Only one contact of mechanism is movable, the other is fixed.
2. Both the contacts moving, where motion of one contact is controlled by input motion and the other is controlled
by spring.
3. Both the contacts moving, where motion of one contact is controlled partially by input motion and partially by
spring damper, the other is controlled by spring.
2.1 Generation of concepts based on first idea
2.1.1 Concept 1
The concept simplifies and replaces the spring with that of damper of the switch mechanism invented by Muller &
Talir and patented as US5814782 [3]. As shown in Fig. 3, piston cylinder is used to couple main circuit breaker
contacts to PIR contacts. The gap between pistoncylinder walls d1 will delay motion of PIR contacts during opening
and closing. Spring used in patented mechanism will only aid to control the closing but the same spring will not control
the motion of movable contact during opening. The damper used in concept 1 will control the motion of movable
contact while opening and closing both.
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2.1.2 Concept 2
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Fig.11 Gap between PRI contacts and main circuits breaker contacts v/s time superimposed
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Fig 12: Gap between PIR contacts and main circuit breaker contacts v/s time superimposed
As shown in Fig 12 insertion time of 7.7 ms and opening delay of 3 ms is obtained for crank radius of 90.5 mm, back
spring stiffness and damping of 2 N/mm and 0.050 Ns/mm respectively, horizontal distance between onset of cam and
hinge of collapsible link (striking distance) of 2 mm and overlap of 37 mm. All the moving parts are assumed of
Aluminum material. Adams contact parameters are taken as of concept 1 for analysis. Insertion time of 10 ms can be
obtained by setting back spring stiffness but maximum opening delay obtainable here is 15.6 ms. It is difficult to
achieve opening delay of 300 ms, hence concept 4 is dropped here.
3.3 Dynamic Analysis of Contact 5
Parameters like back spring stiffness, crank radius and striking distance (horizontal distance between onset of cam and
hinge of collapsible link) are critical parameters to control insertion time. These parameters are varied to understand
their effect on travel of back contact.
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From above results, for least impact, maximum possible crank radius considering space is 75 mm. To avoid vertical
reaction force in system, appropriate striking distance is 0mm. For analysis, crank radius of 75 mm and striking
distance of 0 mm is taken. Setting these two parameters, whole system depends on back contact spring stiffness.
Fig.15 Effect of striking distance on travel of back contact
To get 10 ms insertion time of resistor, spring stiffness of 6.9 N/mm is obtained from dynamic analysis. Thus stiffness
can be varied to obtain variety of insertion time. Opening delay can be easily controlled by opening spring stiffness and
damping. As the requirement of insertion time and opening delay can be fulfilled in concept 5, it is selected for further
design and analysis.
3.4 Design of Mechanism based on Concept 5
To design the mechanism various forces acting on joints as well as inertia forces are obtained from analysis of concept
5.
Fig 16 shows loads on connecting link (as shown in Fig 10) from which stresses at various sections are obtained. The
link needs to be non-conducting for electrical feasibility.
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Fig.19 Gap between PIR contacts and main circuit breaker contacts v/s time superimposed
4. Conclusion
Five concepts are developed for inserting resistor in series. Two concepts are dropped due to mechanical and electrical
feasibility. Dynamic analyses of three concepts are carried out in MSC ADAMS. Two more concepts are dropped as
they cannot fulfill specific requirement. Concept 5 is selected for final design of mechanism after analysis. After
modifying shapes according to stresses and using the material proposed final dynamic analysis is carried out. Final
dynamic analysis gives insertion time of 10 ms, opening delay of 300 ms and maintains gap of 51 mm between PIR
contacts until the main contacts are closed. Thus, mechanism based on concept 5 can be used to insert resistor in series.
Moreover in concept 5, variety of insertion time can be obtained by just adjusting back spring stiffness. Thus, Concept 5
is very easy to control mechanism.
References
[1] http://www.abb.com/global/scot/scot245.nsf/veritydisplay/_le/buyers guide hv live tank circuit breaker sed5en.pdf
accessed on 29th, April, 2013.
[2] W. B. Freeman, K. Froelich, D. S. Johnson, Modular Closing Resistor, US5245145, 1993.
[3] R. Muller, J. Talir, Rower circuit breaker having closing resistor, US5814782, 1998.
[4] M. Perret, Interrupter with resistor insertion system having long insertion time, US6239399, 2001.
[5] W. Daniel, Contact Modeling, Benelux ADAMS User Meeting, 2012.
[6] C. Pereira, A. Ramalho, J. Ambrsio, a Critical Overview of Internal and External Cylinder Contact Force Models.
[7] V. Bhandari, Design of Machine Elements, 2004.
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