A dustproof auxiliary switch

Abstract

This invention relates to the field of power equipment technology, specifically disclosing a dustproof auxiliary switch. This dustproof auxiliary switch, testing device, and testing method utilize a sealing component between the square shaft and the cover plate, a labyrinthine dustproof channel in the contact box assembly, and an integrated dustproof structure to prevent sand and dust infiltration. Furthermore, it uses the sliding friction between the contact plate group and the insert group to dynamically clean the contacts, solving the problem of ineffective sealing in the multi-layer gaps of traditional switches. The accompanying testing device can simulate real-world scenarios, and the graded testing and self-cleaning linkage method can verify the dustproof effect, locate faults, and ultimately improve the switch's dustproof capability and operational stability, extend its lifespan, and enhance product reliability.

Description

Technical Field

[0001] This invention relates to the field of power equipment technology, and in particular to a dustproof auxiliary switch. Background Technology

[0002] In power systems, auxiliary switches, as key supporting components of core power equipment such as high-voltage or medium-voltage circuit breakers and disconnectors, undertake the important functions of feedback on equipment operating status, control secondary circuits, and improve circuit safety and reliability. Their structure is mainly composed of components such as contacts, springs, contacts, and guide rods. They are widely used in many fields such as machinery, electronics, manufacturing, chemical industry, and power transmission, and are key components to ensure the stable operation of power equipment.

[0003] From an installation perspective, auxiliary switches are typically integrated inside power equipment cabinets. While these cabinets offer basic protection, in practical applications, especially during the installation and commissioning of outdoor substations in Northwest my country, frequent opening of the cabinet doors for equipment calibration and parameter settings is necessary. High concentrations of sand and dust can easily penetrate the cabinet's temporary protective barrier and intrude into the interior. More critically, traditional auxiliary switches generally suffer from insufficient resistance to particulate contaminants. Their protection rating is mostly IP40, which only meets basic dustproof requirements and cannot effectively resist the fine particulate dust unique to the Northwest desert regions—dust particles often less than 10μm in diameter. These particles not only easily penetrate the cavity through switch gaps but also continuously accumulate around the contacts under the influence of the electric field, leading to increased contact resistance, poor connection, and in severe cases, even switch jamming and signal interruption. This directly affects the normal operation of main equipment such as circuit breakers, posing a significant threat to power grid dispatching and power supply reliability.

[0004] Analysis of the current industry situation reveals significant differences in the manufacturing processes of auxiliary switches on the market. Products from different manufacturers vary considerably in material selection, sealing structure design, and contact machining precision, making it difficult to establish a unified standard for overall protection strength and operational stability. While some products may meet routine usage requirements in non-dust-prone environments, the shortcomings of traditional auxiliary switches are further amplified in complex conditions such as the Gobi Desert and other desert environments in Northwest China.

[0005] On the one hand, the probability of failure caused by sand and dust intrusion increases significantly. On the other hand, the oxidation of contacts and dust accumulation caused by sand and dust will accelerate the aging of switching components, shorten the overall life of equipment, and increase the operation and maintenance costs and power outage frequency of substations. This is seriously inconsistent with the needs of unattended, long-term stable operation of new energy bases in Northwest my country (such as wind power and photovoltaic power stations).

[0006] Further investigation into the root cause of the failure revealed that the design flaws of traditional auxiliary switches are mainly reflected in three aspects:

[0007] Firstly, the sealing structure is simple, relying mostly on simple gap seals, which cannot prevent the continuous penetration of fine sand and dust.

[0008] Secondly, the contact system lacks self-cleaning ability, and sand and dust cannot be removed by normal operation of the switch after they adhere to it;

[0009] Third, insufficient assembly precision of components, such as the joint between conductive sheets and insulating parts, and the transmission gap between square shafts and bushings, can easily create channels for sand and dust to enter. Furthermore, component displacement under vibration conditions will further widen the gap, exacerbating the risk of failure.

[0010] With the continuous advancement of power construction in Northwest my country, especially the large-scale deployment of ultra-high-voltage transmission lines and new energy power plants, the reliability requirements for power equipment in dusty environments are increasingly stringent. As the nerve endings of circuit breakers, the particulate contaminant resistance of auxiliary switches directly determines the operational safety of main equipment and the power grid's stability. However, currently, the industry lacks unified technical standards and testing specifications for the particulate contaminant resistance of auxiliary switches. This lack of effective product design basis and the inability to verify the actual protection capabilities of products through standardized testing results in a market shortage of dedicated auxiliary switches truly suited to the dusty environments of Northwest China. Therefore, developing auxiliary switch structures with high-efficiency particulate contaminant resistance and establishing corresponding performance testing methods has become an urgent need to address the operational pain points of power equipment in dusty areas of Northwest China and ensure the safe and stable operation of the power grid. Summary of the Invention

[0011] In view of this, embodiments of the present invention provide a dustproof auxiliary switch to solve the technical problem that the gaps between the multi-layer structure of traditional switches are not effectively sealed, and sand and dust can easily penetrate into the contact cavity.

[0012] This invention provides a dustproof auxiliary switch, comprising:

[0013] A square shaft and a first cover plate and a second cover plate disposed at both ends of the square shaft, wherein at least one contact box assembly is provided between the first cover plate and the second cover plate;

[0014] The contact box assembly includes a first box and a second box with identical structures. The two ends of the first box and the second box are respectively provided with a first protrusion and a first recess. When the first box and the second box are connected, they are installed by the first protrusion and the first recess, and a labyrinth-like dustproof channel is formed between the first protrusion and the first recess to prevent particulate contaminants from entering the interior of the contact box assembly.

[0015] Preferably, the contact box assembly further includes a group of inserts disposed between the first box body and the second box body;

[0016] The first and second boxes are further provided with a second protrusion and a second recess, as well as a slot for accommodating the insert assembly;

[0017] The slot and the second recess are connected through a communication port. The communication port is provided with a dustproof groove. The bottom of the first box and the second box at the position that matches the dustproof groove is provided with a dustproof protrusion that fits the dustproof groove. The first box and the second box are prevented from entering the interior of the first box and the second box through the cooperation of the dustproof groove and the dustproof protrusion.

[0018] A sealing baffle is also provided on the outside of the junction of the first box and the second box. The sealing baffle is attached to the outside of the contact box assembly and covers the gap at the junction of the first box and the second box.

[0019] Preferably, the contact box assembly further includes a contact piece group disposed between the first box body and the second box body;

[0020] The contact assembly includes a first contact and a second contact with identical structures. The first contact and the second contact include a first contact arm and a second contact arm, and the ends of the first contact arm and the second contact arm are arranged in an arc shape.

[0021] The first and second contact pieces are installed in a back-to-back abutting manner so that the first and second contact arms of the first contact piece abut against the ends of the second and first contact arms of the second contact piece. This allows the contact piece assembly to exert pressure on the contact surface and surrounding area through the contact with the insert assembly during the rotation of the square shaft, thereby scraping off particulate contaminants on the contact point.

[0022] Preferably, both the first cover plate and the second cover plate are provided with sealing bushings at the junction with the square shaft, and the sealing bushings are provided with sealing grooves;

[0023] A sealing ring is provided in the sealing groove. The two sides of the sealing ring abut against the side walls of the sealing groove and the first cover plate and the second cover plate, respectively, to prevent particulate contaminants from entering the contact box assembly through the connection between the first cover plate and the second cover plate and the square shaft.

[0024] Preferably, the bottom of the first cover plate is provided with a sealing surface and sealing protrusions adapted to the plurality of the communication ports;

[0025] The sealing protrusion is used to close the communication port on the first box body adjacent to the first cover plate, so as to prevent particulate contaminants from entering the interior of the contact box assembly through the communication port of the first box body adjacent to the first cover plate.

[0026] The dustproof auxiliary switch, the switch testing device, and the testing method provided by this invention have the following beneficial effects:

[0027] In this invention, the combination of sealing bushing, sealing groove and sealing ring between the square shaft and the cover plate can block the sand and dust infiltration path at the connection between the shaft and the cover plate; the first protrusion and the first recess of the first box body and the second box body in the contact box assembly form a labyrinth-like dustproof channel. With the fitting of the dustproof groove and the dustproof protrusion, it can block sand and dust from entering the contact cavity from the source of the interlayer gap. At the same time, the contact contaminants can be dynamically scraped off by the sliding friction of the contact plate group and the insert group, further ensuring the cleanliness of the contacts and completely solving the problem of no effective sealing of the gaps in the multi-layer structure of traditional switches. Attached Figure Description

[0028] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the embodiments of the present invention will be briefly introduced below. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort, and these are all within the protection scope of the present invention.

[0029] Figure 1 This is a structural diagram of a dustproof auxiliary switch;

[0030] Figure 2 This is a top view of a dustproof auxiliary switch;

[0031] Figure 3 yes Figure 2 Cross-sectional view at point AA;

[0032] Figure 4 yes Figure 3 Schematic diagram of the structure at point A;

[0033] Figure 5 This is an exploded view of the contact box assembly;

[0034] Figure 6 This is a schematic diagram of the bottom structure of the first cover plate;

[0035] Figure 7 This is a schematic diagram of the bottom structure of the first box;

[0036] Figure 8 This is a schematic diagram of the contact assembly structure;

[0037] Figure 9 This is a schematic diagram of the test device for the auxiliary switch;

[0038] Figure 10 This is a schematic diagram of the test device for the auxiliary switch;

[0039] Parts and component numbers in the diagram:

[0040] 100-Auxiliary switch;

[0041] 200 - Square shaft, 210 - Sealing bushing, 211 - Sealing groove, 212 - Sealing ring, 220 - Insulating shell;

[0042] 310-First cover plate, 311-Sealing surface, 312-Sealing protrusion, 313-Fixing groove, 320-Second cover plate;

[0043] 400-Contact box assembly, 410-First box body, 420-Second box body, 421-First protrusion, 422-First recess, 423-Dustproof channel, 430-Insertion group, 431-Second protrusion, 432-Second recess, 433-Slot, 434-Connecting port, 435-Dustproof groove, 436-Dustproof protrusion, 437-Sealing baffle, 440-Contact group, 441-First contact piece, 442-Second contact piece, 443-First contact arm, 444-Second contact arm, 445-Rivet hole, 446-Rivet post, 447-Support arm, 448-Support protrusion;

[0044] 510-Dust box, 520-Vibrator, 530-Dust fan, 540-Drive motor, 550-Coupling. Detailed Implementation

[0045] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. In the description of the present invention, it should be understood that the terms "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements, but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Unless otherwise specified, the element defined by the phrase "comprising..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element. Where there is no conflict, embodiments of the present invention and the various features thereof can be combined with each other, all of which are within the scope of protection of the present invention.

[0046] Example 1

[0047] Please see Figure 1 This invention provides a dustproof auxiliary switch. In power systems, the auxiliary switch 100, as a core component of high-voltage / medium-voltage circuit breakers, plays a crucial role in providing feedback on equipment status and ensuring the stability of secondary circuits, and is widely used in substations and other similar environments. However, in substation environments with frequent sandstorms, such as the Gobi Desert and other areas, traditional auxiliary switches 100 have significant shortcomings: their protection level is mostly only IP40, their sealing structure is simple, and they cannot resist the continuous penetration of fine sand particles. Sand easily enters the cavity through the gaps between multi-layer components, the drive between the square shaft 200 and the bushing, and the junction of the conductive sheet and the insulating component, leading to faults such as dust accumulation at the contacts, increased contact resistance, and signal interruption; affecting the continuous and reliable operation of substation equipment. Therefore, there is an urgent need to develop an auxiliary switch 100 with efficient dustproof sealing and self-cleaning functions to meet the usage requirements of substations in sandy areas.

[0048] Please see Figure 1 and Figure 5In this embodiment, a dustproof auxiliary switch 100 is provided. The auxiliary switch 100 includes a square shaft 200 and a first cover plate 310 and a second cover plate 320 disposed at both ends of the square shaft 200. At least one contact box assembly 400 is provided between the first cover plate 310 and the second cover plate 320. The contact box assembly 400 includes a first box body 410 and a second box body 420 with the same structure. The two ends of the first box body 410 and the second box body 420 are respectively provided with a first protrusion 421 and a first recess 422. When the first box body 410 and the second box body 420 are connected, they are installed by the first protrusion 421 and the first recess 422, and a labyrinthine dustproof channel 423 is formed between the first protrusion 421 and the first recess 422 to prevent particulate pollutants from entering the interior of the contact box assembly 400.

[0049] When fine dust particles pass through, the dustproof channel 423 forces the dust to change direction multiple times, increasing the difficulty of entry. The channel also provides multiple bends to prevent the dust from penetrating inwards. The back of the cover plate mates with the front of the first-layer contact box assembly 400, similarly forming multiple bends in the blocking channel. The final-layer contact box assembly 400 mates with the plate, also forming multiple bends in the blocking channel.

[0050] Please see Figure 2 , Figure 4 and Figure 5 Before use, the two ends of the square shaft 200 are first assembled with the first cover plate 310 and the second cover plate 320, and then at least one contact box assembly 400 is installed between the two cover plates to form the main frame of the switch. The first cover plate 310 and the second cover plate 320 are both provided with fixing grooves 313. After the square shaft 200, the first cover plate 310, the contact box assembly 400 and the second cover plate 320 are installed, they are fastened by setting long screws in the fixing grooves 313 to form a whole.

[0051] When assembling the contact box assembly 400, the first box body 410 and the second box body 420 with the same structure are connected. The first protrusion 421 and the first recess 422 at both ends of the two are used to cooperate to complete the splicing and fixing of the contact box assembly 400. When assembling several contact box assemblies 400, the first box body 410 and the second box body 420 of each pair of contact box assemblies 400 are connected to achieve assembly to form a multi-layer structure.

[0052] When the switch is in operation, the square shaft 200 can drive the internal components to rotate, realizing the switching function; during this process, the assembled structure will continue to play a dustproof role, preventing pollutants from entering the interior.

[0053] Please see Figure 4 and Figure 7When the first housing 410 and the second housing 420 are connected, the cooperation of the first protrusion 421 and the first recess 422 forms a labyrinthine dustproof channel 423, which can effectively prevent particulate pollutants from entering the contact box assembly 400, solving the problem of ineffective sealing of gaps and easy infiltration of sand and dust in the multi-layer structure of traditional switches. The cooperation of the first protrusion 421 and the first recess 422 not only achieves dust prevention, but also improves the connection tightness between the first housing 410 and the second housing 420, reduces the risk of component loosening, and ensures long-term stable operation of the switch.

[0054] Specifically, this maze-like dustproof channel 423 is designed with a continuously turning channel structure on the mating surfaces of the components, using the misalignment and extension of geometric shapes to form a non-linear path.

[0055] When pollutants such as dust and water vapor in the external environment attempt to penetrate through the gap, the channel will physically block them, forcing the pollutants to constantly change their direction of movement during the process, increasing their penetration resistance.

[0056] Meanwhile, the inner wall of the channel can further interfere with the movement trajectory of pollutants through tiny uneven textures. Some pollutants will settle due to inertial impact on the channel wall and will not be able to continue to penetrate, thereby significantly reducing the probability of pollutants entering the contact box assembly 400 and improving the operational reliability of the auxiliary switch 100 in windy and dusty environments.

[0057] Furthermore, the square shaft 200 is configured as a metal shaft and is fitted with an insulating shell on the outside.

[0058] The metal shaft transmits driving force to control the mechanical action of the switch. Utilizing the high rigidity and stability of the metal material, it ensures that deformation does not easily occur during long-term rotation, thus maintaining the accuracy of the switch's on / off operation. The surface of the metal shaft can be treated with processes such as electroplating to enhance its corrosion resistance, extend the service life of the square shaft 200, and indirectly improve the reliability of the entire switchgear.

[0059] The insulating shell prevents the square shaft 200 from making conductive contact with surrounding components during rotation, ensuring electrical safety during switch operation. Made of high-temperature resistant and aging-resistant polymer material, the insulating shell maintains stable insulation performance over long-term use, while providing excellent support and protection for the square shaft 200, reducing frictional losses during rotation, and extending its service life.

[0060] Further, please see Figure 8 The contact box assembly 400 further includes a insert group 430 disposed between the first box body 410 and the second box body 420;

[0061] The first box 410 and the second box 420 are further provided with a second protrusion 431 and a second recess 432, as well as a slot 433 for accommodating the insert assembly 430.

[0062] The slot 433 and the second recess 432 are connected through a connecting port 434. The connecting port 434 is provided with a dustproof groove 435. The bottom of the first box 410 and the second box 420 at the position that matches the dustproof groove 435 is provided with a dustproof protrusion 436 that fits into the dustproof groove 435. The first box 410 and the second box 420 are prevented from entering the interior of the first box 410 and the second box 420 through the cooperation of the dustproof groove 435 and the dustproof protrusion 436.

[0063] A sealing baffle 437 is provided on the outside of the junction of the first box body 410 and the second box body 420. The sealing baffle 437 is attached to the outside of the contact box assembly 400 and covers the gap at the junction of the first box body 410 and the second box body 420.

[0064] In specific implementation, slots 433 adapted to the insert assembly 430 are first pre-set inside the first housing 410 and the second housing 420. At the same time, a second protrusion 431 and a second recess 432 are machined inside the housing, and a connecting port 434 is opened to connect the slots 433 and the second recess 432. Next, a dustproof groove 435 is opened at the connecting port 434, and a dustproof protrusion 436 is machined at the bottom position of the first housing 410 and the second housing 420 that is adapted to the dustproof groove 435 to ensure that the two can fit precisely during installation. Finally, after the first housing 410 and the second housing 420 are spliced, the sealing baffle 437 is attached and fixed to the splicing gap outside the contact box assembly 400 to complete the overall assembly.

[0065] The core function of this structure is to build a multi-layered dustproof barrier. The fitting of the dustproof groove 435 and the dustproof protrusion 436 can directly block particles from entering the communication port 434 from the slot 433, thereby preventing them from entering the interior of the contact box assembly 400; the sealing baffle 437 blocks the gaps in the box assembly from the outside, forming a secondary protection to prevent sand and dust from seeping in from the external gaps, further improving the sealing and dustproof capability of the contact box assembly 400.

[0066] In addition, the second protrusion 431 and the second recess 432 not only help to position the insert assembly 430 and ensure that the insert assembly 430 is installed firmly in the slot 433, but also enhance the connection strength between the first housing 410 and the second housing 420, reducing the risk of dustproof structure failure due to loose parts. At the same time, the design of the slot 433 also provides convenience for the installation and replacement of the insert assembly 430, taking into account both dustproof performance and maintenance convenience.

[0067] Further, please see Figure 5 The contact box assembly 400 further includes a contact piece group 440 disposed between the first box body 410 and the second box body 420;

[0068] The contact assembly 440 includes a first contact 441 and a second contact 442 with identical structures. The first contact 441 and the second contact 442 include a first contact arm 443 and a second contact arm 444, and the ends of the first contact arm 443 and the second contact arm 444 are arc-shaped.

[0069] The first contact piece 441 and the second contact piece 442 are installed in a back-to-back abutting manner so that the first contact arm 443 and the second contact arm 444 of the first contact piece 441 abut against the ends of the second contact arm 444 and the first contact arm 443 of the second contact piece 442. This allows the contact piece group 440 to generate pressure on the contact surface and surrounding area through the contact between the contact piece group 440 and the insert group 430 during the rotation of the square shaft 200, thereby scraping off particulate contaminants and oxide layers on the contact point.

[0070] In specific implementation, the first contact piece 441 and the second contact piece 442 with the same structure are first assembled in a back-to-back abutting manner, so that the ends of the first contact arm 443 and the second contact arm 444 of the first contact piece 441 abut with the ends of the second contact arm 444 and the first contact arm 443 of the second contact piece 442 respectively, forming a complete contact piece group 440; then the assembled contact piece group 440 is installed between the first housing 410 and the second housing 420, and it is ensured that the contact piece group 440 is linked with the square shaft 200, while ensuring that the contact arm of the contact piece group 440 can make effective contact with the installed insert group 430.

[0071] The core function of this part of the structure is to achieve dynamic self-cleaning of the contacts. When the square shaft 200 drives the contact assembly 440 to rotate, the contact arm of the contact assembly 440 contacts the insert assembly 430 and generates pressure. The arc-shaped contact arm end can scrape off particulate contaminants on the contact surface and surrounding area of ​​the insert assembly 430 during the contact process, avoiding the accumulation of contaminants that affect the contact conductivity. This makes up for the shortcomings of traditional sealing structures that can only passively prevent dust and cannot clean up internal micro-contaminants.

[0072] Furthermore, the installation of the first contact piece 441 and the second contact piece 442 ensures that the contact piece group 440 and the insert piece group 430 are subjected to uniform force when in contact, thus improving the stability of the contact point. The back-to-back abutting installation method can enhance the overall structural strength of the contact piece group 440, reduce the risk of contact arm deformation, and at the same time, the curved end can reduce wear during contact, extend the service life of the contact piece group 440 and the insert piece group 430, and balance the cleaning effect and component durability.

[0073] Please see Figure 5 The insert also has a slot that matches the structure of the dustproof groove. During assembly, the dustproof protrusion 436 is embedded in the dustproof groove 435 and the slot on the insert to prevent sand and dust from entering the joint. The cooperation between the dustproof protrusion 436 and the groove and dustproof groove 435 increases the friction, making it less likely for the insert and the box to shift relative to each other when impacted by sand and dust or when the equipment vibrates, further blocking the intrusion of sand and dust.

[0074] During the rotation of the square shaft 200, the moving contact plate slides in contact with the stationary contact plate, making it more stable in performing the dust scraping function during opening and closing. When opening and closing, the moving contact plate exerts pressure on the contact surface and surrounding area through elastic deformation, effectively scraping off sand particles, dust and foreign objects, and oxide film layer generated by electric arc erosion on the contact, keeping the contact clean and ensuring good electrical contact.

[0075] The first contact piece 441 and the second contact piece 442 are moving contacts, and the insert piece is a stationary contact.

[0076] Further, please see Figure 8 The first contact piece 441 is arranged in an annular shape, with a first contact arm 443 and a second contact arm 444 at opposite ends. A riveting hole and a riveting post are provided between the first contact arm 443 and the second contact arm 444 for riveting the first contact piece 441 and the second contact piece 442 back to back. In order to ensure the flatness of the riveting of the first contact piece 441, a grid-like indentation treatment is performed on the surface of the contact piece.

[0077] The grid-shaped indentation treatment involves pressing grid-like indentations with a spacing of 0.5 mm and a depth of 0.05 mm onto the surface of the contact piece. This treatment increases the surface friction of the moving contact piece, allowing it to fit better during riveting, reducing displacement, ensuring riveting flatness, and ensuring that the tightness of the clamping parts is consistent after riveting two contact pieces together, guaranteeing the same clamping force and making the contact resistance value between the moving and stationary contact pieces stable and reliable.

[0078] Furthermore, to facilitate assembly and repair, the movable contact piece is specially equipped with a pair of bent support arms to restrict the other movable contact piece within a preset range of motion. These arms precisely engage with the central circular boss to form a rotary friction pair, achieving accurate positioning and smooth rotation. The movable contact piece also has two sets of support protrusions to reduce frictional contact between pairs of movable contact pieces.

[0079] Further, please see Figure 3 and Figure 4 The first cover plate 310 and the second cover plate 320 are both provided with sealing bushings 210 at the junction with the square shaft 200, and the sealing bushings 210 are provided with sealing grooves 211.

[0080] A sealing ring 212 is provided in the sealing groove 211. The two sides of the sealing ring 212 abut against the side walls of the sealing groove 211 and the first cover plate 310 and the second cover plate 320, respectively, to prevent particulate pollutants from entering the contact box assembly 400 through the connection between the first cover plate 310 and the second cover plate 320 and the square shaft 200.

[0081] In specific implementation, the sealing bushing 210 is first fitted and fixed at the connection positions of the square shaft 200 and the first cover plate 310 and the second cover plate 320, respectively, to ensure that the bushing is fitted to the square shaft 200 and the cover plate; then, a suitable sealing ring 212 is embedded in the pre-set sealing groove 211 of the sealing bushing 210. During assembly, it is necessary to ensure that the sealing ring 212 completely fills the sealing groove 211, and that its two sides can tightly abut against the inner wall of the sealing groove 211 and the side wall of the cover plate, respectively, to form a gapless sealing structure, thus completing the sealing assembly at the connection between the square shaft 200 and the cover plate.

[0082] The core function of this structure is to block the path of sand and dust infiltration through the gap between the shaft and the cover plate. The sealing ring 212, through double contact with the sealing groove 211 and the side wall of the cover plate, can directly seal the gap between the square shaft 200 and the cover plate when it rotates, preventing external sand and dust from entering the switch through the gap as the square shaft 200 rotates. This prevents contaminants from entering the contact box assembly 400 and affecting the contact performance, and supplements the protection range of the dustproof structure of the contact box assembly 400 itself, forming a dustproof closed loop for the entire switch.

[0083] Meanwhile, the sealing bushing 210 also supports the rotating square shaft 200, reducing radial wobble during rotation and improving the stability of the switch operation. The combination design of the sealing groove 211 and the sealing ring 212 facilitates the installation and subsequent replacement and maintenance of the sealing ring 212, and can also adapt to the slight vibration of the square shaft 200 through the elastic deformation of the sealing ring 212, maintaining the sealing effect for a long time, thus balancing protective performance and structural practicality.

[0084] Further, please see Figure 6 The bottom of the first cover plate 310 is provided with a sealing surface 311 and a sealing protrusion 312 adapted to the plurality of the communication ports 434;

[0085] The sealing protrusion 312 is used to close the communication port 434 on the first box body 410 adjacent to the first cover plate 310, so as to prevent particulate contaminants from entering the interior of the contact box assembly 400 through the communication port 434 of the first box body 410 adjacent to the first cover plate 310.

[0086] In specific implementation, a flat sealing surface 311 is first machined at the bottom of the first cover plate 310, and a matching sealing protrusion 312 is integrally formed or fixedly installed according to the number, position and size of the connecting openings 434 on the adjacent first box body 410. During assembly, the first cover plate 310 is placed on the adjacent first box body 410, so that the sealing protrusion 312 is precisely embedded in the corresponding connecting opening 434, and at the same time, the sealing surface 311 at the bottom of the first cover plate 310 is tightly fitted with the surface of the first box body 410. When multiple contact box assemblies 400 are spliced ​​in sequence, it is ensured that the joints of the first box bodies 410 of two adjacent contact box assemblies 400 are completely fitted, and a closed sealing cavity is naturally formed after the joint by utilizing the structure of the box body itself or by adding a sealing strip.

[0087] The core function of this structure is to fill the dustproof gaps at the junction of the switch end and the component. The sealing protrusion 312 directly seals the connection port 434 between the first cover plate 310 and the adjacent box body, preventing contaminants from entering through the end connection port 434. The sealing surface 311 further enhances the fit and sealing between the cover plate and the box body, reducing gaps. The sealing cavity formed by the mating of the adjacent first box bodies 410 isolates the working area of ​​the contact box assembly 400 from the outside, preventing wind and sand from seeping in through the component joint gaps, and forming all-round protection in conjunction with other dustproof structures.

[0088] Furthermore, the fitting design of the sealing protrusion 312 and the connecting port 434 enables precise sealing without the need for additional complex fasteners, simplifying the assembly process. The natural formation of the sealing cavity utilizes the existing box structure without increasing the cost of additional components. At the same time, the flat sealing surface 311 also improves the connection stability between the first cover plate 310 and the box, reducing the risk of dustproof failure caused by component loosening, thus balancing dustproof effect with structural economy and stability.

[0089] Further, please see Figure 3 After the first box body 410 is connected to the first box body 410 of the first group of contact box assembly 400, a sealed cavity is also formed to prevent wind and sand from entering the working area of ​​the contact box assembly 400.

[0090] Example 2

[0091] Please see Figure 9 and Figure 10This invention provides a testing device for a dustproof auxiliary switch. Currently, most testing devices for auxiliary switches 100 in the industry can only meet conventional IP protection level testing or electrical performance testing, lacking dedicated simulation and testing capabilities adapted to sandstorm environments. In sandstorm scenarios such as Gobi substations, traditional testing devices cannot accurately reproduce the combined working conditions of sandstorms and vibrations of different intensities, making it difficult to simulate the dynamic intrusion process of sand and dust onto the auxiliary switch 100. Furthermore, existing devices mostly use single-channel data acquisition, unable to independently monitor the performance of multiple contact box assemblies 400, resulting in an inability to comprehensively evaluate the switch's protection effect and component reliability in sandstorm environments. In addition, due to the lack of a unified sandstorm environment testing standard, test results from different manufacturers lack comparability, making it difficult to support the R&D optimization and quality control of sandstorm-resistant auxiliary switches 100. Therefore, there is an urgent need to construct a dedicated testing device that can accurately simulate sandstorm scenarios and collect data from multiple dimensions. This includes:

[0092] The environmental simulation system includes a dust box 510, a vibrator 520, a dust fan 530, and a drive motor 540, wherein the drive motor 540 is connected to the square shaft 200 via a coupling 550.

[0093] The signal acquisition and control system includes a signal acquisition module for acquiring environmental simulation system and switch information, and a controller for controlling test parameters;

[0094] The test parameters include the motor speed, number of operations, rotation direction, vibration intensity of the vibration generator, and speed of the dust-generating fan 530.

[0095] The dust chamber 510 is set as a sealed environment and has an observation window on the top. The dust chamber 510 is made of transparent plexiglass and has an internal mounting bracket to fix the switch and drive motor 540 to be tested.

[0096] The signal acquisition and control system connects the signal acquisition module to the switch to acquire the open and closed state of the switch, as well as whether the switch signal is abnormal when it is closed. The acquired signal is then transmitted to the host computer for processing and to determine whether particulate contaminants are causing the contact to not conduct.

[0097] In use, the test preparation is carried out first. The dustproof auxiliary switch 100 to be tested is fixed in the mounting bracket inside the dust box 510. At the same time, the drive motor 540 is fixed and connected to the switch square shaft 200 through the coupling 550. After checking the airtightness of the dust box 510, the corresponding level of sand and dust is added into the box. The box door is closed and the transparent plexiglass observation window is kept clear. Then, the signal acquisition and control system is connected. The signal acquisition module is connected to the switch. The controller establishes communication with the drive motor 540, vibrator 520, and dust fan 530. The test parameters such as motor speed, number of operations, vibration intensity, and fan speed are preset.

[0098] Next, the test process is started. The environmental simulation system is started through the controller. The dust fan 530 runs to generate a sandstorm environment, the vibrator 520 simulates outdoor vibration conditions, and the drive motor 540 drives the switch square shaft 200 to rotate to simulate the actual operation of the switch. During the test, the situation inside the box is observed through the transparent window. The signal acquisition and control system collects data such as the switch's opening and closing status and whether the signal is abnormal when closed in real time. At the same time, the environmental simulation parameters are recorded, and all data is synchronously transmitted to the host computer.

[0099] Finally, the results are analyzed. The host computer processes the collected data and compares the switch performance data under normal operating conditions and wind and sand vibration conditions to determine whether there is a problem of contact non-conductivity caused by particulate pollutants. If it is necessary to test different wind and sand levels, the above process can be repeated by adjusting the parameters through the controller. After completing the multi-dimensional test, a complete performance evaluation report is generated, which provides a basis for judging the dustproof effect and reliability of the switch.

[0100] Example 3

[0101] Please see Figures 1-10 This invention provides a testing method for a dustproof auxiliary switch. Current testing methods for the auxiliary switch 100 mainly focus on conventional electrical performance (such as switching reliability and contact resistance), lacking a systematic testing process for sandstorm environments. This is because they fail to classify sandstorm levels to fit actual scenarios (such as light, moderate, and heavy sandstorms in a Gobi substation) and lack a closed-loop testing logic of "environmental simulation - data acquisition - performance matching - fault handling." Furthermore, traditional methods cannot determine whether a fault is caused by temporary sand adhesion or seal failure, and it is difficult to accurately locate the damaged contact box assembly 400. These limitations prevent the scientific evaluation of the long-term reliability of the auxiliary switch 100 in sandstorm environments and hinder the provision of accurate data support for product optimization. Therefore, there is an urgent need to develop a testing method that combines the characteristics of sandstorm scenarios and covers all performance dimensions of the switch.

[0102] In this embodiment, a test method for a dustproof auxiliary switch is provided, the test method comprising:

[0103] The switch is tested under initial operating conditions and its initial reference value is obtained.

[0104] Specifically, under initial operating conditions, the dustproof auxiliary switch 100 to be tested is fixed in a clean environment within a dust chamber 510; that is, there is no dust in the dust chamber 510, the particulate matter concentration is ≤0.01g / m³, and the vibrator 520 is turned off. The drive motor 540 of the testing device drives the switch square shaft 200 to complete 500 opening and closing operations at a frequency of approximately 2 times / min. At the same time, the multi-channel module of the signal acquisition and control system is activated and connected to the output terminal of each group of contact box assemblies 400 of the switch, recording the closing and closing operations of each group of assemblies in real time. The contact resistance in the closed state was sampled at 10ms intervals each time the switch was closed, and the average value was taken. The insulation resistance in the open state was sampled at 10ms intervals each time the switch was opened, and the minimum value was taken. The signal response time during 500 consecutive opening and closing processes was accurate to 1ms, and the maximum value was taken. The combination of parameters recorded above, with contact resistance ≤10mΩ, insulation resistance ≥200MΩ, response time ≤30ms, and no abnormal signals, was determined as the initial reference value of the switch, which served as the benchmark standard for performance comparison in subsequent wind and sand level tests.

[0105] The switch is subjected to a dustproof test according to the preset first-level wind and sand parameters, and the actual working data of different contact box components 400 under the corresponding wind and sand parameters are obtained during the test.

[0106] Specifically, based on the preset first-level wind and sand parameters corresponding to a light wind and sand scenario at a Gobi substation, with a dust concentration of 0.8-1.5 g / m³, the dust-suppressing fan 530 maintains a speed of 800 r / min, a vibration intensity of 20-40 Hz, and the drive motor 540 operates at a frequency of approximately 2 times / min, reciprocating at a speed of 1080° / s, stopping for 30 seconds. The switch to be tested is placed in a sealed environment within the dust chamber 510, and the dust-suppressing fan 530 and vibrator 520 are started. After the environmental parameters have stabilized for 20 minutes, the drive motor is turned on. During operation, the drive motor 540 drives the switch square shaft 200 to complete approximately 500 opening and closing operations. Simultaneously, the multi-channel module of the signal acquisition and control system is connected to the output terminal of each group of contact box assembly 400 to monitor and record in real time the contact resistance during closing, the insulation resistance during opening, the signal response time of nearly 500 consecutive opening and closing operations, as well as the occurrence and frequency of abnormal signals. All data is stored in categories according to "component number-parameter type-time stamp" to form the actual working data of each group of contact box assembly 400 under the first level of wind and sand parameters.

[0107] Specifically, the rotating mechanism of the moving contact uses a low-speed drive, taking approximately 29 seconds to reach the position where it contacts the stationary contact. This design aims to maintain an extremely low linear velocity throughout the approach process, significantly reducing mechanical impact and particle disturbance caused by friction between the structures. Slow rotation effectively prevents instantaneous impact on the guide structure, bushing structure, and labyrinth seal structure before contact, helping to maintain the integrity of the contact plating, reducing material fatigue and deformation caused by high-speed contact, and providing a better stress environment for the components.

[0108] After the moving contact reaches the contact position, the actual contact time between it and the stationary contact is set to approximately 0.5 seconds. During this short steady-state interval, key parameters such as on-resistance, noise amplitude, and steady-state current are collected. This short contact time effectively limits the duration of the contact arc, reducing arc erosion and thermal damage to the contact surface, while preventing additional friction and wear or the pushing of particles into the contact interface caused by prolonged conduction. Furthermore, the fixed and brief contact window ensures consistent test conditions for each operation, resulting in good comparability of data from each cycle and improving the accuracy of determining conduction abnormalities, particle jamming, and sealing performance degradation.

[0109] Furthermore, to accommodate the needs of different application environments, the "29-second proximity time" and "0.5-second contact time" set in this embodiment can be appropriately adjusted according to the operating load, contact material, contact pressure, or durability requirements. For example, the proximity time can be set within the range of 10 to 60 seconds to match different lifespan levels of testing, while the contact time can be adjusted to 0.1 to 2 seconds according to changes in the carrying current. Through the setting of the above parameters, this embodiment achieves consistent, stable, and repeatable test conditions for subsequent continuity performance sampling and failure location while maintaining contact lifespan, controlling wear, and limiting the impact of arcing.

[0110] The actual working data of different contact box assemblies 400 are matched with the initial reference value. If all matches are successful, the next level of dustproof test is performed. If the matching fails, the auxiliary switch 100 is used for failure location.

[0111] Specifically, the actual working data of each group of contact box components 400 under the first-level sandstorm parameters are exported from the signal acquisition and control system. The contact resistance, insulation resistance, signal response time and abnormal signal standards of each component are compared with the initial reference value and the abnormal signal standard. If all parameters of all components meet the reference threshold and there is no abnormal signal, it is determined that all matching is successful. Then the current sandstorm environment parameter is turned off and the test is switched to the next level of sandstorm parameters according to the preset process. If any parameter of at least one group of components exceeds the threshold or an abnormal signal occurs, it is determined that the matching is unsuccessful. After the matching fails, the drive motor 540 can be controlled to drive the square shaft 200 to rotate alternately in forward and reverse directions. The sliding friction between the contact group 440 and the insert group 430 can clear the contact and surrounding particles. It is seen whether this action can make the contact group 440 and the insert group 430 conduct smoothly again. Alternatively, the test can be paused and the failure location of the auxiliary switch 100 can be started to locate the failed component.

[0112] After the switch is located for failure, repeat the steps of "performing dustproof tests on the switch in progressive steps according to different sandstorm levels, and obtaining actual working data of the contact box assembly 400 under different sandstorm levels during the tests";

[0113] Specifically, after the failure location is completed, the environmental simulation system of the sand and dust chamber 510 is restarted. The parameters are set according to the original sand and dust level that failed to match. After the sand and dust distribution stabilizes, a 4-hour test cycle is maintained. The drive motor 540 drives the switch square shaft 200 to complete about 480 opening and closing operations. At the same time, the multi-channel module of the signal acquisition and control system independently monitors each group of contact box components 400 again, and records the contact resistance, insulation resistance, signal response time and abnormal signals in real time. The data is stored in the format of "component number-parameter-timestamp" to form the actual working dataset after self-cleaning. The process is consistent with the first test of this level.

[0114] The actual working data of different contact box assemblies 400 are matched with the initial reference value. If all matches are successful, the dustproof test is completed. If the matching fails, the contact box assembly 400 that fails to match is located.

[0115] Specifically, after failure location, the actual working data of each group of contact box components 400 are exported. The contact resistance, insulation resistance, signal response time and abnormal signal standards are compared with the initial reference values ​​and abnormal signal standards one by one according to the component number. If all parameters of all components meet the reference threshold and there is no abnormal signal, it is determined that all matching is successful and the dustproof test is completed. If any parameter of at least one group of components exceeds the threshold or an abnormal signal occurs, it is determined that the matching is failed. Then the group isolation function of the signal acquisition and control system is activated to activate each group of components individually for continuity and disconnection tests. The specific contact box component 400 that failed to match is located by combining the abnormal signal characteristics and its number and corresponding abnormal parameters are marked.

[0116] Perform fault analysis on switches that fail to match;

[0117] Specifically, for the contact box assembly 400 that failed to match, the switch was first disassembled and the assembly removed. An optical microscope was used to observe whether the first protrusion 421 and the first recess 422 of the first box 410 and the second box 420 were worn or deformed. If the dustproof channel 423 widened, it could indicate sand intrusion. The sealing baffle 437 was checked for tightness; sand accumulation in the gaps indicated a seal failure. The fit between the dustproof groove 435 and the dustproof protrusion 436 was also checked; residual particles in the groove indicated poor sealing. The contact arm arc surface of the contact piece assembly 440 was observed for wear, and the surface of the insert assembly 430 for scratches, which could lead to poor contact. For assemblies near the square shaft 200, the sealing ring 212 of the sealing sleeve 210 was checked for aging or the sealing groove 211 for deformation. Finally, based on the abnormal data, the cause of the fault was determined and the location of the fault point was recorded. Finally, a corresponding treatment plan was developed based on the cause of the fault.

[0118] Furthermore, the step of conducting a dustproof test on the switch according to preset first-level wind and sand parameters, and obtaining actual working data of different contact box assemblies 400 under corresponding wind and sand parameters during the test, includes:

[0119] Based on the substation's usage scenario, a first-level wind and sand parameter is set, and the environmental simulation system is controlled by the controller to conduct a dustproof test on the switch using the first-level wind and sand parameter.

[0120] Specifically, based on the daily use scenario of light sandstorms at the Gobi substation, the first-level sandstorm parameters were set to correspond to normal light wind weather, where sand and dust can easily enter through equipment gaps but are not carried by strong winds: the sand and dust concentration of 0.8-1.5 g / m³ matched the average daily sand and dust suspension amount under this scenario; the vibration intensity of 20-40 Hz simulated the mechanical vibration frequency of the transformer and circuit breaker in the substation during operation; the operating frequency of the drive motor 540 was about 2 times / min, which matched the typical daily opening and closing frequency of the switch; then, the controller of the test device issued a command to start the dust fan 530 in the environmental simulation system and adjust it to 800 r / min, the vibrator 520 output vibration at 20-40 Hz, and the drive motor 540 drove the switch square shaft 200 to rotate. At the same time, the sand and dust box 510 door was closed to form a sealed test environment. After the system ran for 20 minutes to ensure that the sand and dust were evenly distributed and the parameters were stable, the dustproof test of the switch was officially carried out.

[0121] The switch will complete the preset test actions during the test cycle of the first level of wind and sand parameters;

[0122] Specifically, during a test period of 4 hours with stable operation of the first-level wind and sand parameters, the controller controls the drive motor 540 to rotate the switch square shaft 200 at a frequency of approximately 2 times / min, so that the switch continuously completes the opening and closing test actions, accumulating approximately 480 times. During the process, the environmental parameters inside the sand and dust box 510 are monitored in real time to ensure that the wind and sand concentration and vibration intensity do not fluctuate. At the same time, the transparent observation window confirms that there is no structural displacement or jamming of the switch, ensuring that each opening and closing action conforms to the actual operating conditions of the substation and covers the typical daily operating load of the switch.

[0123] By using the multi-channel module of the signal acquisition and control system, the output of each group of contact box assembly 400 is connected to an independent channel to monitor the performance of each group individually and obtain the actual working data of each group of contact box assembly 400.

[0124] Specifically, the signal acquisition and control system is started and the multi-channel module is debugged. The current output terminal and voltage feedback terminal of each group of contact box assembly 400 of the switch are connected to the independent channel of the module through dedicated shielded cables; for example, assembly 1 corresponds to channel 1, assembly 2 corresponds to channel 2, ensuring that the wiring of each group has good contact and no signal interference. During the monitoring process, the system samples the closing contact resistance and opening insulation resistance of each group of components at 10ms intervals, and records the signal response time of each opening and closing. If a group of components has a contact resistance >10mΩ, insulation resistance <200MΩ, or response time >30ms, the system automatically marks it as an abnormal signal and records the occurrence time and frequency. All monitoring data are stored in the system database in real time, and sorted by "component number-parameter type-time stamp", finally forming a complete actual working dataset of each group of contact box assembly 400 under the first level of wind and sand parameters.

[0125] Furthermore, the process of matching the actual operating data of different contact box assemblies 400 with the initial reference value, and if all matches are successful, proceeding to the next level of dustproof testing; if the matching fails, the auxiliary switch 100 performs failure location, including:

[0126] The matching threshold of each group of contact box assemblies 400 is set with reference to the initial benchmark value;

[0127] Specifically, the initial reference value of the switch with contact resistance ≤10mΩ, insulation resistance ≥200MΩ, signal response time ≤30ms, and no abnormal signals under initial operating conditions is used as the core reference. Combined with the actual fault tolerance requirements of the Gobi substation in the windy and sandy environment, the matching thresholds of each group of contact box components 400 are set: the contact resistance threshold is maintained at ≤10mΩ, the insulation resistance threshold is maintained at ≥200MΩ, and the signal response time threshold is relaxed to ≤35ms. At the same time, an abnormal signal matching standard is added, that is, the frequency of abnormal signals of a single component within the test cycle must be ≤2 times, and there should be no situation where abnormality occurs in 3 consecutive opening and closing operations. The above parameter thresholds and abnormal standards are integrated into a unified matching judgment system, which serves as the basis for matching the actual working data of each group of contact box components 400 with the initial reference value.

[0128] Based on the actual working data obtained from each group of contact box components 400, each one is compared with the corresponding matching threshold;

[0129] Specifically, the actual working data of all contact box components 400 under the first-level wind and sand parameters are exported from the signal acquisition and control system, and each group of data is retrieved in sequence according to the component number; for example, the data corresponding to component 1 includes the average contact resistance, minimum insulation resistance, maximum signal response time and frequency of abnormal signals within a 4-hour test cycle; then, based on the set standards of contact resistance ≤10mΩ, insulation resistance ≥200MΩ, signal response time ≤35ms, and frequency of abnormal signals ≤2 times with no three consecutive abnormal matching thresholds, each parameter of each group of components is compared one by one;

[0130] First, check if the average contact resistance is within the threshold range. Then, confirm if the minimum insulation resistance meets the standard. Next, check if the maximum signal response time meets the requirements. Finally, count whether the frequency and continuity of abnormal signals meet the standards. After each set of comparisons is completed, record the matching result of the component immediately. If all parameters meet the standard, it is considered a "single set of matching success". If any parameter does not meet the standard, it is considered a "single set of matching failure". Mark the specific value of the non-compliant parameter to provide a basis for judging the overall matching result.

[0131] Furthermore, please set the second and third level parameters based on the first level wind and sand parameters.

[0132] If all contact box components 400 are successfully matched, the test for the current sandstorm level is deemed passed and the current environmental simulation parameters are turned off. The test then proceeds to the next sandstorm level according to the preset procedure. If at least one set of components fails to match, the failure location of the current test start switch is immediately paused.

[0133] Specifically, after comparing all contact box components 400 one by one, the matching results of each group are summarized. If all components meet the standards of "contact resistance ≤10mΩ, insulation resistance ≥200MΩ, signal response time ≤35ms, abnormal signal frequency ≤2 times and no three consecutive abnormalities", the current first-level sandstorm level test is determined to be passed. Then, the controller sends a command to shut down the dust fan 530, vibrator 520 and drive motor 540 of the sand and dust box 510, and stop the output of the current sandstorm environment simulation parameters. After the equipment stops, the next level of sandstorm parameters are reset in the controller according to the preset sandstorm level progression process, and the next level of dustproof test is prepared to be started. If the summary results show that at least one group of components does not meet the standards, the matching is determined to be a failure. The controller immediately cuts off the power of the environmental simulation system to suspend the test, and at the same time triggers the switch failure location program to locate the failure location or failure component of the auxiliary switch 100.

[0134] Furthermore, based on the wind and sand intensity gradient of the Gobi substation, and corresponding to different seasons or weather conditions, second-level and third-level wind and sand parameters are further set on the basis of the first-level parameters.

[0135] The second-level wind and sand parameter corresponds to a moderate wind and sand scenario, such as spring dust storms or intermittent strong winds, with a dust concentration of 2.0-3.0 g / m³, which is recorded by a dust-suppressing fan (530).

[0136] The speed was maintained at 1200 r / min to simulate the enhanced sand-carrying capacity and increased sand settling rate. The vibration intensity was 30-50 Hz, with the vibration frequency and amplitude slightly higher than the first level, simulating the intensified resonance effect of substation equipment under strong winds. The operating frequency of the drive motor 540 was about 2 times / min, the test cycle was 5 hours, and about 600 opening and closing operations were completed in total. This corresponds to the increased demand for power grid load adjustment under sandstorm weather. The test duration was extended to evaluate the dustproof durability under high-frequency operation.

[0137] Level 3 wind and sand parameters correspond to severe wind and sand scenarios, such as sandstorms or continuous strong winds, with a dust concentration of 4.0-6.0 g / m³, as determined by a dust-generating fan (530).

[0138] The speed was maintained at 1800 r / min to simulate the continuous impact of high-concentration sand and dust on the equipment surface; the vibration intensity was 40-60 Hz, and the vibration intensity was further increased, approaching the critical value of equipment structural resonance, testing the vibration resistance of the sealed structure; the operating frequency of the drive motor 540 was 2 times / min, the test cycle was 6 hours, and a total of about 720 opening and closing operations were completed, simulating the emergency operation requirements under extreme weather conditions. The long-term, high-load test verified the extreme dustproof capability of the switch in harsh environments.

[0139] The three-level parameters form a gradient of increasing wind and sand intensity and operating load, gradually approaching the harsh conditions of extreme wind and sand scenarios, which can comprehensively verify the dustproof reliability of the switch from daily to extreme operating conditions.

[0140] Furthermore, the failure location includes:

[0141] Based on the on-resistance, action response time, signal waveform stability and noise jitter parameters of the contact box assembly 400, multi-dimensional data features are extracted for each contact box assembly.

[0142] Specifically, the testing device synchronously acquires the voltage, current, and control signals of each contact box assembly 400 during a single operation using a multi-channel acquisition module, and performs timing alignment of the sampled waveforms in conjunction with the trigger signal of the drive motor 540. The acquired raw waveforms first undergo baseline correction, bandpass filtering, and transient noise suppression processing to eliminate environmental noise, electromagnetic interference, and bias differences between different operations, thereby obtaining a standardized electrical signal that truly reflects the contact state of the contacts.

[0143] After preprocessing, the controller extracts multi-dimensional feature parameters from the processed waveform according to preset rules, including the on-resistance and its change in the closed steady-state segment, the action response time, the number of bounces and the duration of bounces at the moment of closure, the voltage or current noise amplitude (such as RMS value and peak-to-peak value) in the steady-state interval, and the spectral energy distribution obtained through fast Fourier transform. These features can respectively reflect the contact quality of the contact points, the action sensitivity, the stability of moving parts, and the micro-discontinuity phenomenon caused by particulate contamination.

[0144] Through the aforementioned multi-dimensional data feature extraction process, each contact box assembly 400 obtained a set of structured feature vectors under this sandstorm level. These vectors comprehensively cover key parameters such as contact conductivity, mechanical integrity, and signal stability. The feature vectors are uniformly stored in the controller's feature database, providing a reliable data foundation for subsequent anomaly detection, failure classification, and structural weak point location.

[0145] The characteristic parameters of each contact box assembly 400 are compared with the preset threshold and the corresponding parameters of adjacent contact box assemblies to determine the type of abnormal data.

[0146] Specifically, the controller first compares the feature parameters extracted from each contact box assembly 400 with the corresponding preset thresholds item by item. These thresholds are determined by initial reference values ​​or historical statistical data, including the rising limit of on-resistance, the delay limit of action response time, the bounce count threshold, the steady-state noise amplitude threshold, and the spectral energy offset threshold. When any feature parameter exceeds its threshold range, the channel is marked as "preliminary anomaly," and the specific deviation is recorded for further analysis of the anomaly degree and feature type. After completing the comparison with its own thresholds, the system continues to compare the feature parameters of the contact box assembly 400 laterally with the corresponding features of its adjacent contact box assemblies 400 to determine whether the anomaly is caused by local contamination, individual wear, or a common structural problem.

[0147] For example, when the on-resistance of only one contact box suddenly increases while the adjacent channels remain normal, it is mostly due to local contamination or elasticity decay of the contact. However, if two or three adjacent contact boxes simultaneously experience increased resistance or signal jitter, it is more likely to indicate a regional failure of the labyrinth seal structure, dustproof groove, or cover plate sealing protrusion.

[0148] By combining the threshold comparison results with the synchronous change trend of adjacent channels, the controller can further classify abnormal data into categories such as sealing structure failure, contact contamination or particle jamming, moving part misalignment, or bushing seal degradation, thereby providing accurate abnormality type input for subsequent structural weak point location and component replacement strategies.

[0149] Based on the physical position mapping relationship of the contact box assembly 400 in the auxiliary switch 100, the potential dust intrusion path and structural weak parts of the abnormal channel are located.

[0150] include:

[0151] Establish location mapping and intrusion path model

[0152] During the equipment development phase, each contact box assembly is assigned a unique number (e.g., C1...C8...), and a channel-physical location mapping table is established. Examples of fields include channel ID, box number, relative axial distance, proximity to cover / axis side identifier, and a list of adjacent structural components (maze segment, dustproof groove, sealing protrusion, bushing, etc.).

[0153] Simultaneously, a static model of the intrusion path is established, representing possible dust intrusion paths, such as: cover plate connection port → connection port channel → slot; square shaft sleeve gap → shaft side contact box; first protrusion / recess fit gap → maze channel, using a topological graph or directed graph. The nodes of the graph are structural elements, and the edges represent possible particle migration directions with weights. This model serves as a priori knowledge base for localization inference.

[0154] Positioning and Decision Making

[0155] Input the list of abnormal channels, the location mapping table, the intrusion path model, and the abnormal relationship matrix between adjacent channels.

[0156] For each anomalous channel, its nearest neighbor structural elements are retrieved from the mapping table and expanded outward by 1-2 hops in the intrusion path map to generate a set of candidate intrusion paths. Each edge of the candidate path is scored based on observational evidence. If adjacent channels are anomalous along the same path, a higher score is added, indicating that the path has a common problem. If the anomaly is a single point and is a change / interruption in conduction resistance, edges related to contact surface contamination are given higher weight. The path scores are then normalized to a confidence level of 0–1. If the highest confidence level is greater than the preset threshold, the path / structural element is considered a high-confidence location result. If the confidence level is between 0.4 and 0.7, it is considered a medium confidence level; if it is below 0.4, it is considered a low confidence level, and manual review or expanded detection is recommended.

[0157] Examples of typical rules

[0158] Rule 1 (Single point → Contact surface type): If only a single channel is abnormal and the main feature is a sudden increase or momentary interruption of ΔR, and the adjacent channels are normal → the priority for location is "contamination or plating damage to the insert surface / contact surface".

[0159] Rule 2 (Local Multi-point → Sealing): If ≥2 channels in the same box are abnormal at the same time or 2–3 adjacent horizontally arranged boxes are abnormal at the same time, the priority for location is "failure of cover sealing protrusion or maze channel".

[0160] Rule 3 (Shaft-side deterioration with frequency → Bushing type): If the Failure_score of the channel near the shaft side increases with the number of tests, it is identified as "shoulder sleeve seal failure or seal ring aging".

[0161] Rule 4 (Bouncing and vibration spectrum related): If abnormal features are accompanied by high-spectral components and the vibration sensor shows resonance, it is located as "stuck moving parts or loose assembly".

[0162] Verification and Feedback

[0163] When outputting the location results, a verification action list is generated simultaneously, such as "Check whether the sealing protrusion of the cover plate of the C3 box is intact; if it cannot be confirmed by visualization, replace the C3 contact box assembly and retest." For high-confidence location, it is directly recommended to replace the corresponding component and retest; for medium / low confidence, it is recommended to increase sensor sampling or perform manual disassembly and inspection before proceeding to root cause analysis. The verification results after each replacement / disassembly and inspection compare the location conclusion with the actual findings and archive them for dynamic updating of intrusion path weights and rules.

[0164] Based on the location results, a corresponding handling strategy is generated. The handling strategy includes replacing the abnormal contact box assembly 400, replacing the contact piece group 440, replacing the insert group 430, or replacing the entire auxiliary switch 100.

[0165] In this embodiment, after the controller completes fault location based on the position mapping relationship and the anomaly type determination result, the system automatically generates a handling strategy that matches the fault type. For abnormal channels determined to be local contact contamination, plating damage, or contact elasticity decay, the controller preferentially recommends replacing the corresponding contact group 440 or insert group 430 to eliminate the impact of performance degradation of a single contact unit and ensure that subsequent tests are not interfered with by wear accumulation factors.

[0166] When an anomaly occurs simultaneously in multiple channels of the same contact box assembly 400, or when the location results point to structural sealing weaknesses such as labyrinthine dustproof channels, dustproof grooves, or sealing baffles, the system will generate a "replace the entire contact box assembly 400" recommendation to ensure the integrity of the sealing structure of the test sample and avoid structural inconsistency caused by local cleaning or repair. If the anomaly spans multiple boxes or the fault type manifests as a global failure such as dust ingress into the bushing or large-scale internal particle accumulation, the controller will directly generate a "replace the entire auxiliary switch 100" instruction to ensure the reliability of the retesting process and the comparability of the results.

[0167] After the aforementioned handling strategy is generated, it is recorded in the test log along with the corresponding abnormal channel number, judgment criteria, and location path. After the replacement operation is performed, it automatically enters the retest process of the same wind and sand level to verify whether the fault is caused by structural defects or local component failure, thereby forming a complete location-handling-retest closed loop, improving the accuracy and traceability of the test.

[0168] Furthermore, the corresponding handling plan formulated based on the cause of the failure includes:

[0169] Specifically, the controller or manual analysis system maps the abnormal parts to their corresponding structural units, including the meshing accuracy of the first protrusion 421 and the first recess 422, the width variation of the dustproof channel 423, the tightness of the sealing baffle 437, the fit of the dustproof groove 435 and the dustproof protrusion 436, the arc surface wear characteristics of the contact plate group 440, the scratches of the insert group 430, and the aging degree of the sealing ring 212 of the sealing bushing 210 near the square shaft 200, thereby clarifying the structural root causes of sand and dust intrusion, poor contact, or abnormal operation.

[0170] After identifying the weak points, this implementation method further develops targeted structural optimization schemes based on the mechanism by which the abnormalities occur.

[0171] For example, when wear or dimensional deviation is found in the first recess 422 or the dustproof channel 423, resulting in the channel widening, optimization solutions may include increasing the surface hardness of the relevant structure, increasing the depth of the labyrinth channel, adjusting the shape accuracy of the protrusions and recesses, or adding a secondary sealing tortuous structure.

[0172] When the sealing baffle 437 is not fully fitted or the sealing groove 211 is deformed, the sealing reliability can be improved by improving the elastic modulus of the material, optimizing the thickness distribution of the baffle, increasing the pre-tightening step, or using a sealing material with higher aging resistance.

[0173] If the contact assembly 440 has uneven wear or the insert assembly 430 has local hard scratches, the contact pressure can be adjusted in the design, the contact guide structure can be improved, or the wear resistance of the contact surface coating can be enhanced.

[0174] Based on the above optimization results, this implementation method records all weaknesses and their corresponding optimization measures into a weakness improvement database for use in the structural iteration and manufacturing process adjustment of subsequent product versions.

[0175] The weak points identified in each sandstorm level test are accumulated into structural reliability statistics. By comparing the frequency and severity of the weak points with the test performance of the improved prototype, the effectiveness of the optimization scheme can be continuously verified and a closed-loop improvement of the structure can be achieved.

[0176] Therefore, the solution in this embodiment is not to repair the faulty component, but to systematically identify the weak points and optimize their design parameters in a targeted manner, thereby fundamentally improving the reliability and lifespan of the auxiliary switch 100 in a sandy environment.

[0177] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A dustproof auxiliary switch, characterized in that, include: A square shaft (200) and a first cover plate (310) and a second cover plate (320) disposed at both ends of the square shaft (200), wherein at least one contact box assembly (400) is provided between the first cover plate (310) and the second cover plate (320). The contact box assembly (400) includes a first box body (410) and a second box body (420) with identical structures. The two ends of the first box body (410) and the second box body (420) are respectively provided as a first protrusion (421) and a first recess (422). When the first box body (410) and the second box body (420) are connected, they are installed by the first protrusion (421) and the first recess (422), and a labyrinth-like dustproof channel (423) is formed between the first protrusion (421) and the first recess (422) to prevent particulate pollutants from entering the interior of the contact box assembly (400). The contact box assembly (400) further includes a insert group (430) disposed between the first box body (410) and the second box body (420). The first box (410) and the second box (420) are also provided with a second protrusion (431) and a second recess (432), as well as a slot (433) for accommodating the insert assembly (430). The slot (433) and the second recess (432) are connected through a connecting port (434). The connecting port (434) is provided with a dustproof groove (435). The bottom of the first box (410) and the second box (420) at the position that matches the dustproof groove (435) is provided with a dustproof protrusion (436) that fits the dustproof groove (435). The first box (410) and the second box (420) are prevented from entering the interior of the first box (410) and the second box (420) through the cooperation of the dustproof groove (435) and the dustproof protrusion (436).

2. The dustproof auxiliary switch according to claim 1, characterized in that, A sealing baffle (437) is provided on the outside of the junction of the first box body (410) and the second box body (420). The sealing baffle (437) is attached to the outside of the contact box assembly (400) and covers the gap at the junction of the first box body (410) and the second box body (420).

3. The dustproof auxiliary switch according to claim 2, characterized in that, The contact box assembly (400) further includes a contact piece group (440) disposed between the first box body (410) and the second box body (420). The contact assembly (440) includes a first contact (441) and a second contact (442) with identical structures. The first contact (441) and the second contact (442) include a first contact arm (443) and a second contact arm (444). The ends of the first contact arm (443) and the second contact arm (444) are arranged in an arc shape. The first contact piece (441) and the second contact piece (442) are mounted in a back-to-back abutting manner so that the first contact arm (443) and the second contact arm (444) of the first contact piece (441) abut against the ends of the second contact arm (444) and the first contact arm (443) of the second contact piece (442). This allows the contact piece assembly (440) to generate pressure on the contact surface and surrounding area and scrape off particulate contaminants on the contact point through the contact between the contact piece assembly (440) and the insert assembly (430) during the rotation of the square shaft (200).

4. The dustproof auxiliary switch according to claim 1, characterized in that, The first cover plate (310) and the second cover plate (320) are both provided with sealing bushings (210) at the junction with the square shaft (200), and the sealing bushings (210) are provided with sealing grooves (211). A sealing ring (212) is provided in the sealing groove (211). The two sides of the sealing ring (212) abut against the side walls of the sealing groove (211) and the first cover plate (310) and the second cover plate (320) respectively, so as to prevent particulate pollutants from entering the contact box assembly (400) through the connection between the first cover plate (310) and the second cover plate (320) and the square shaft (200).

5. The dustproof auxiliary switch according to claim 2, characterized in that, The bottom of the first cover plate (310) is provided with a sealing surface (311) and a sealing protrusion (312) adapted to the plurality of the communication ports (434). The sealing protrusion (312) is used to close the communication port (434) on the first box body (410) which is adjacent to the first cover plate (310) to prevent particulate contaminants from entering the interior of the contact box assembly (400) through the communication port (434) of the first box body (410) which is adjacent to the first cover plate (310).

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