A synchronous self-locking control method for a quick-assembly-and-disassembly direct-acting pole-mounted circuit breaker

Abstract

The application provides a kind of quick combination and separation direct-acting pole circuit breaker synchronous self-locking control method, comprising: identifying the engagement depth of locking tooth surface by micro-displacement sensing head, identifying the tooth surface contact posture by tooth surface angle detection probe, obtaining real-time engagement depth and real-time tooth surface contact posture;According to the real-time engagement depth and real-time tooth surface contact posture, analyze the dislocation direction of locking tooth surface and the degree of deviation of the fitting area, obtain the comprehensive cumulative tolerance;According to the release force optimization conclusion and the requirement of stable locking, refine the excitation current application form, obtain the final excitation current application form;The electromagnetic iron is driven by the final excitation current application form to perform the tripping operation, and whether the tripping operation enters the reliable tripping interval is evaluated, and the tripping success is confirmed under the condition of tolerance accumulation.

Description

Technical Field

[0001] This invention relates to the field of information technology, and in particular to a synchronous self-locking control method for a direct-acting pole-mounted circuit breaker that can be quickly opened and closed. Background Technology

[0002] In the field of power equipment, the synchronous self-locking control technology of circuit breakers is a crucial link in ensuring the safe operation of the power grid. Its core lies in ensuring stable locking and timely release of the equipment under various operating conditions to prevent the escalation of faults. This technology is directly related to the reliability and safety of the power system, and therefore receives considerable attention in its design and application, especially in direct-acting pole-mounted circuit breakers with fast closing and opening functions, where the performance of self-locking control is critical. However, some existing methods optimize locking or releasing functions from a single perspective when dealing with complex operating conditions, neglecting the combined influence of various factors during equipment operation. Particularly when facing practical problems such as component machining tolerances, installation deviations, and long-term wear, it is difficult to guarantee the balance between locking and releasing, leading to equipment malfunction under certain extreme conditions and potential safety hazards. The intention of designing the engagement depth is to enhance the locking strength and prevent accidental disengagement under vibration or impact. However, when the engagement depth increases, if the contact angle deviates due to accumulated tolerances, the force required for release will be interfered with by additional resistance. This resistance increases significantly with the severity of the angle deviation, ultimately making it impossible for the release device to provide sufficient force to overcome the resistance under standard excitation, resulting in the risk of release failure. Specifically, in real-world business scenarios, suppose that after long-term operation, the contact angle of the latch in a pole-mounted circuit breaker deviates from the design value due to component tolerances and installation deviations. If the engagement depth is too large, the release device may fail to operate in time due to excessive resistance when an emergency circuit disconnection is needed, resulting in the circuit not being cut off and potentially causing equipment damage or more serious safety accidents. This difficulty in release caused by the interaction between engagement depth and contact angle deviation persists throughout the entire lifecycle of the equipment. Therefore, how to balance the engagement depth of the latch to simultaneously meet the requirements of stable locking and reliable release under the complex conditions of accumulated component tolerances and contact angle deviations becomes a key problem that this research urgently needs to solve. Summary of the Invention

[0003] This invention provides a synchronous self-locking control method for a direct-acting pole-mounted circuit breaker capable of rapid opening and closing, comprising: The engagement depth of the locking teeth is identified by a micro-displacement sensor head, and the tooth surface contact posture is identified by a tooth surface angle detection probe, thus obtaining the real-time engagement depth and the real-time tooth surface contact posture. Based on the analysis of the real-time engagement depth and the real-time tooth surface contact posture, the misalignment direction of the locking tooth surface and the degree of skewness of the contact area are obtained to obtain the comprehensive cumulative tolerance. The angle between the tripping direction and the tooth surface normal is extracted by the tooth surface angle detection probe, and it is determined whether the angle exceeds the preset contact direction of the tooth surface to obtain the reduction posture of the tripping force in the contact area. The current electromagnet output force is collected by the electromagnet output force sensing head, and the degree of aggravation of tooth surface friction resistance is deduced based on the effect of the current electromagnet output force and the tripping force in the contact area to reduce the posture, thereby obtaining the real-time meshing posture, and the comprehensive resistance torque is extracted based on the real-time meshing posture. Based on the comprehensive cumulative tolerance, it is determined whether the comprehensive resistance torque exceeds the rated output force of the electromagnet. If the comprehensive resistance torque exceeds the rated output force of the electromagnet, the excitation current application mode is determined based on the real-time engagement posture, and the electromagnet adjustment output force corresponding to the excitation current application mode is obtained. Based on the current electromagnet output force and the comprehensive resistance torque, the tripping release force optimization conclusion is obtained. Based on the optimization conclusions of the tripping release force and the requirements for stable locking, the excitation current application mode is adjusted to obtain the final excitation current application mode. The electromagnet is driven to perform a tripping operation based on the final excitation current applied, and it is determined whether the tripping operation enters the preset tripping range to obtain a successful tripping confirmation result.

[0004] Furthermore, the step of identifying the engagement depth of the locking teeth using a micro-displacement sensor head and identifying the tooth surface contact posture using a tooth surface angle detection probe to obtain the real-time engagement depth and real-time tooth surface contact posture includes: The current position displacement data of the locking tooth surface is collected by the micro-displacement sensor head, the difference between the current position displacement data and the meshing reference position is calculated, and the offset of the locking tooth surface relative to the meshing reference position is obtained. Based on the geometric correspondence between the offset and the locking tooth structure, the axial distance of the tooth surface embedding into the opposite locking buckle is determined, and the real-time engagement depth is obtained. The angle of the spatial tilt direction of the locking tooth surface is detected by the tooth surface angle detection probe, and the tilt angle and rotation azimuth angle values ​​of the tooth surface normal relative to the reference axis corresponding to the meshing reference position are extracted. The orientation distribution of the tooth surface contact area in space is determined based on the tilt angle value and the rotation azimuth angle value, and continuous areas where the contact pressure between the tooth surfaces is greater than a preset pressure threshold are identified to obtain the real-time tooth surface contact posture.

[0005] Furthermore, the step of analyzing the misalignment orientation of the locking tooth surface and the degree of skewness of the contact area based on the real-time engagement depth and the real-time tooth surface contact posture to obtain the comprehensive cumulative tolerance includes: Calculate the difference between the real-time engagement depth and the standard engagement depth, and extract the engagement depth offset; Based on the engagement depth offset, the tilt angle value and rotation azimuth angle value in the real-time tooth surface contact posture, the spatial deviation direction of the tooth surface relative to the standard contact position is identified, and the misalignment orientation of the locking tooth surface is obtained. Based on the misalignment orientation of the locking teeth, the distribution range of the tooth contact area in the misalignment direction is extracted. The overlap between the actual boundary of the distribution range and the standard contact boundary is compared to obtain the skew angle of the contact area relative to the standard position, and the degree of skewness of the contact area is obtained. Based on the degree of skewness between the misalignment of the locking teeth and the mating area, the combined deviation of machining tolerance and installation deviation is determined, and the combined cumulative tolerance is obtained.

[0006] Furthermore, the step of extracting the angle between the tripping direction and the tooth surface normal using the tooth surface angle detection probe, and determining whether the angle exceeds the preset contact orientation of the tooth surface to obtain the reduction posture of the tripping force in the contact area, includes: The force direction is obtained by the tooth surface angle detection probe, and the spatial orientation of the current tooth surface normal is extracted. The vector dot product of the applied force direction and the spatial direction is performed and converted into an angle value to obtain the angle between the tripping action direction and the tooth surface normal. Compare the included angle with the permissible angle of the fitting orientation. If the included angle exceeds the permissible angle of the fitting orientation, then an orientation violation state is determined. The deviation amount of the included angle exceeding the permissible angle of the fitting orientation is extracted based on the out-of-bounds orientation state; By mapping the deviation amount to the bonding area, the percentage of the area not covered by the tripping force is obtained, and the reduction posture of the tripping force in the bonding area is obtained.

[0007] Furthermore, the step of mapping the deviation amount to the contact area, obtaining the percentage of the area not covered by the tripping force, and thus obtaining the reduction posture of the tripping force in the contact area, includes: Retrieve the value corresponding to the angle between the tripping action direction and the tooth surface normal, and decompose the value corresponding to the angle according to the horizontal and vertical directions to obtain the horizontal azimuth deflection angle and the vertical azimuth deflection angle. The horizontal azimuth deflection angle and the vertical azimuth deflection angle are vector-synthesized to obtain the degree of skewness of the fitting orientation. By comparing the degree of deviation of the bonding orientation with the tooth surface separation limit angle, if the degree of deviation of the bonding orientation exceeds the tooth surface separation limit angle, the angle difference between the degree of deviation of the bonding orientation and the separation orientation is extracted to determine the extent of the deviation. Based on the aforementioned deviation range, extract the percentage of the force component transmitted along the tooth surface normal direction of the tripping force; By comparing the force component ratio with the standard coverage of the contact area, the range of the gap in the contact area not covered by the tripping force is obtained, and the degree of force transmission reduction and the coverage gap are obtained. The insufficient force transmission corresponding to the degree of force transmission reduction and the insufficient bonding area corresponding to the covering gap are calculated according to the weighted summation algorithm to obtain the comprehensive insufficient effect of the release force in the bonding area, and to obtain the reduction posture of the release force in the bonding area.

[0008] Furthermore, the current electromagnet output force is collected by the electromagnet output force sensing head, and the degree of aggravation of tooth surface frictional resistance is deduced based on the effect of the current electromagnet output force and the tripping force in the contact area to obtain the real-time meshing posture. The comprehensive resistance torque is extracted based on the real-time meshing posture, including: The output force value is collected in real time by the electromagnet output force sensing head, and the instantaneous thrust value is obtained to obtain the current electromagnet output force; Calculate the product of the current electromagnet output force and the attenuation ratio in the reduced action posture to obtain the actual transmitted force value; The degree of aggravation of tooth surface friction resistance is obtained based on the actual transmitted force value and the tooth surface friction characteristic parameters. Based on the degree of aggravation of the tooth surface friction resistance, and combined with the axial embedment amount corresponding to the real-time meshing depth and the orientation deflection amount corresponding to the real-time tooth surface contact posture, the real-time meshing posture is obtained. Based on the real-time engagement posture, the embedding resistance and frictional resistance in the disengagement direction are extracted, and the corresponding lever arm distances are multiplied to obtain the resistance torque components. The combined resistance torque is obtained by superimposing the various resistance torque components.

[0009] Furthermore, the step of determining whether the comprehensive resistance torque exceeds the rated output force of the electromagnet based on the comprehensive cumulative tolerance, and if the comprehensive resistance torque exceeds the rated output force of the electromagnet, then determining the excitation current application mode based on the real-time engagement posture, obtaining the electromagnet adjustment output force corresponding to the excitation current application mode, and obtaining the tripping release force optimization conclusion based on the current electromagnet output force and the comprehensive resistance torque, includes: By comparing the combined resistance torque with the electromagnet's rated output torque, if the combined resistance torque exceeds the electromagnet's rated output torque, then a resistance over-limit gap is determined. Based on the resistance over-limit gap and the real-time meshing posture, extract the compensation requirements corresponding to the meshing depth offset and orientation deflection. Increase the amplitude of the excitation current and extend the application time according to the compensation requirements to obtain the excitation current application pattern; The electromagnet's output force is obtained based on the excitation current application pattern and the electromagnet's output characteristics. Calculate the difference between the output force of the electromagnet after it is converted into output torque and the comprehensive resistance torque, and obtain the restraint margin of the output torque relative to the comprehensive resistance torque; If the restraint margin exceeds the release margin threshold, then the optimized release force of the tripping force is obtained.

[0010] Furthermore, obtaining the optimized tripping release force conclusion includes: The resistance over-limit gap is obtained by calculating the difference between the comprehensive resistance torque and the rated output torque of the electromagnet, and the excitation current compensation range is determined based on the value of the resistance over-limit gap. Based on the resistance over-limit gap and the excitation current compensation amplitude, combined with the tooth surface misalignment orientation and the degree of deviation of the contact area in the real-time meshing posture, the excitation current amplitude increment corresponding to the tooth surface misalignment orientation and the application time increment corresponding to the degree of deviation of the contact area are extracted. The excitation current application pattern is obtained by superimposing the excitation current amplitude increment and the application duration increment to the reference excitation current parameter; Obtain the electromagnet adjustment output force corresponding to the excitation current application mode, calculate the difference between the electromagnet adjustment output force converted into output torque and the comprehensive resistance torque, and determine the restraint margin of the output torque on the comprehensive resistance torque; By comparing the restraint margin with the release margin threshold, the degree of trip release margin compensation is determined; The optimization conclusion of trip release force is determined based on the restraint margin and the degree of compensation for trip release margin. The optimization conclusion of trip release force includes sufficient trip release force compensation and insufficient trip release force compensation.

[0011] Furthermore, adjusting the excitation current application pattern based on the optimized tripping release force conclusion and the stable locking requirements to obtain the final excitation current application pattern includes: Based on the optimization conclusion of the tripping release force, if the conclusion is that the compensation is sufficient, then the excitation current application mode is maintained. If the conclusion is that the compensation is insufficient, then the amplitude increment and duration increment are added to the excitation current application mode, while the increment amplitude is limited within the locked safety threshold range to obtain the adjusted excitation current application mode. Based on the adjusted excitation current application mode, the adjusted amplitude and duration are extracted as the final output parameters to obtain the final excitation current application mode.

[0012] Furthermore, the step of driving the electromagnet to perform a tripping operation based on the final excitation current application mode, and determining whether the tripping operation enters a preset tripping range to obtain a successful tripping confirmation result, includes: The electromagnet is driven to perform the tripping operation according to the final excitation current application pattern; Collect the actual disengagement displacement and disengagement time of the latch during the release process; The actual disengagement displacement and the disengagement time are compared with a preset reliable tripping interval, which is the displacement range and time range of the latch in a normal tripping state, to determine whether the tripping operation enters the reliable tripping interval. Based on the judgment result of the reliable tripping interval, if both the actual tripping displacement and the tripping time are within the reliable tripping interval, then the tripping is determined to be successful.

[0013] The technical solutions provided by the embodiments of the present invention may include the following beneficial effects: This invention discloses a synchronous self-locking control method for a direct-acting pole-mounted circuit breaker capable of rapid opening and closing. Addressing the complex influences of latching tooth engagement depth, contact posture, and tripping force under tolerance accumulation, it proposes a comprehensive diagnostic and optimized control solution. This invention uses a micro-displacement sensor and a tooth surface angle detection probe to acquire engagement depth and contact posture in real time, analyzes tooth misalignment orientation and contact area skew, and assesses the force reduction posture by combining the angle between the tripping force direction and the tooth surface normal, thereby deriving frictional resistance and comprehensive resistance torque. Based on this, the invention dynamically refines the excitation current application pattern according to the relationship between resistance torque and electromagnet output force, ensuring that the tripping release force still functions reliably under tolerance accumulation conditions, ultimately achieving reliable tripping operation. The core innovation of this invention lies in solving the interference of tolerance accumulation on tripping reliability through real-time posture diagnosis and current optimization, significantly improving the synchronous self-locking and rapid opening and closing performance of the circuit breaker under complex operating conditions. Attached Figure Description

[0014] Figure 1 This is a flowchart of a synchronous self-locking control method for a direct-acting pole-mounted circuit breaker that can be quickly opened and closed according to the present invention.

[0015] Figure 2 This is a schematic diagram of a synchronous self-locking control method for a direct-acting pole-mounted circuit breaker that can be quickly closed and opened according to the present invention.

[0016] Figure 3 This is another schematic diagram of a synchronous self-locking control method for a direct-acting pole-mounted circuit breaker that can be quickly closed and opened according to the present invention. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and thoroughly described below with reference to the accompanying drawings. The described embodiments are merely some embodiments of the present invention.

[0018] like Figures 1-3 This embodiment of a synchronous self-locking control method for a direct-acting pole-mounted circuit breaker capable of rapid opening and closing may specifically include: Step S101: The engagement depth of the locking tooth surface is identified by the micro-displacement sensor head, and the tooth surface contact posture is identified by the tooth surface angle detection probe to obtain the real-time engagement depth and the real-time tooth surface contact posture.

[0019] The current position of the locking tooth surface is acquired by a micro-displacement sensor. The displacement data is compared with the preset meshing reference position to obtain the offset δ of the locking tooth surface relative to the meshing reference. Based on the geometric correspondence between the offset and the locking tooth structure, the axial distance d of the tooth surface embedding into the opposite locking latch is determined. The calculation formula is d=δ / tan(θ), where θ is the tilt angle of the tooth profile and δ is the offset in millimeters. Substituting these values ​​into the formula, d is calculated to obtain the real-time meshing depth. The spatial tilt direction of the locking tooth surface is detected by a tooth surface angle detection probe. The tilt angle and rotation azimuth angle values ​​of the tooth surface normal relative to the reference axis corresponding to the meshing reference position are extracted. Based on the tilt angle and rotation azimuth angle values, the orientation distribution of the tooth surface contact area in space is determined. The tooth surface contact area is defined as a continuous area where the contact pressure between the tooth surfaces is greater than a preset pressure threshold. Its boundary is identified by an image segmentation method where the tilt angle difference is less than the preset tilt angle threshold. The area is calculated using an integral method to obtain the tooth surface contact posture.

[0020] In the locking mechanism of the pole-mounted circuit breaker, a micro-displacement sensor head is installed at a lateral position on the locking tooth surface, with its detection end pointing towards the embedding direction of the tooth surface. The micro-displacement sensor head adopts an eddy current detection method, outputting a corresponding voltage signal based on the change in distance between the induction coil and the metal surface of the locking tooth surface. This voltage signal is converted into a displacement value after calibration.

[0021] In one embodiment, the engagement reference position is set based on the standard engagement depth of the locking teeth in the fully locked state.

[0022] Specifically, during the circuit breaker's factory commissioning phase, the latching mechanism is adjusted to the standard locking position specified in the design. At this time, the displacement value collected by the micro-displacement sensor is stored in the detection device as the engagement reference position. When the latch position changes during circuit breaker operation, the micro-displacement sensor collects the current displacement value in real time and compares it with the preset engagement reference position to obtain the offset.

[0023] For example, the geometric correspondence of the locking tooth surfaces is established based on the contour parameters of the tooth structure. The locking tooth surfaces typically adopt a trapezoidal or arc-shaped contour, and there is a fixed proportional relationship between the axial distance of the tooth surface embedded in the opposite locking latch and the offset. This proportional relationship is determined by the inclination angle of the tooth profile and the width of the meshing surface. Based on the offset and geometric correspondence, the actual axial distance of the tooth surface embedded in the opposite locking latch can be determined, thereby obtaining the real-time engagement depth. The tooth surface angle detection probe is mounted on a fixed bracket of the locking mechanism, with its detection end facing the tooth surface normal direction. The tooth surface angle detection probe employs a dual-axis tilt sensing method, the process of which is as follows: First, a laser beam with a wavelength of 650nm is emitted to the tooth surface, and the intensity distribution of the reflected signal is collected; then, a Fourier transform algorithm is applied to process the signal, with the input being the reflected spectrum data and the output being the angle components. The tilt angle value I (in degrees) is calculated using the formula I=arctan(Sy / Sx), where Sy and Sx are the y-axis and x-axis signal components, respectively; the rotational azimuth angle value R (in degrees) is calculated using the formula R=atan2(Sy,Sx). In the example, if Sy=0.5 and Sx=0.866, then I=30 degrees and R=30 degrees. The tilt angle value characterizes the degree of deflection of the tooth surface in the vertical plane, and the rotational azimuth angle value characterizes the degree of torsion of the tooth surface in the horizontal plane. If the tilt angle exceeds a preset threshold of 5 degrees, an alarm is triggered.

[0024] In one possible implementation, the reference axis corresponds to the meshing reference position, and its direction is perpendicular to the mounting plane of the locking mechanism. Based on the tilt angle and rotation azimuth angle values, the orientation distribution of the tooth surface contact area in space is determined, thus obtaining the tooth surface contact posture. This tooth surface contact posture reflects the direction and magnitude of the tooth surface's deviation from the ideal contact state under the current operating conditions.

[0025] It should be noted that the integration of the real-time engagement depth and the tooth surface contact posture is accomplished by superposition in the same coordinate system. The axial embedding amount corresponding to the real-time engagement depth is taken as the longitudinal component in the coordinate system, and the orientation deflection amount corresponding to the tooth surface contact posture is decomposed into a lateral component and a rotational component. The three are vector superimposed in the coordinate system to obtain a comprehensive spatial positioning description of the locking tooth surface under the current working condition, thus obtaining the real-time engagement depth and the real-time tooth surface contact posture.

[0026] Step S102: Analyze the misalignment direction of the locking tooth surface and the degree of skewness of the contact area based on the real-time engagement depth and real-time tooth surface contact posture to obtain the comprehensive cumulative tolerance.

[0027] The real-time engagement depth is compared with the preset standard engagement depth to extract the engagement depth offset. Combined with the tilt angle and rotation azimuth angle values ​​in the real-time tooth surface contact posture, the spatial deviation direction of the tooth surface relative to the ideal contact position is identified, yielding the locking tooth surface misalignment orientation. Based on the locking tooth surface misalignment orientation, the distribution range of the tooth surface contact area in the misalignment direction is extracted. The overlap of the actual boundary of the contact area with the standard contact boundary is compared to obtain the skew angle of the contact area relative to the standard position, thus obtaining the degree of skewness of the contact area. Based on the locking tooth surface misalignment orientation and the degree of skewness of the contact area, the engagement depth offset and the skew angle of the contact area are superimposed under the same reference to obtain the comprehensive deviation of the part machining tolerance and installation deviation under the current working conditions, thus obtaining the comprehensive cumulative tolerance.

[0028] During the operation of the pole-mounted circuit breaker's locking mechanism, the machining tolerances and installation deviations of the parts gradually accumulate over time, causing the actual meshing state of the gear teeth to deviate from the design standards. The comprehensive accumulated tolerance is used to quantify this deviation. The comprehensive deviation magnitude D = ∑(Ti + Di), where Ti is the machining tolerance of each part and Di is the installation deviation, provides a reference for tripping control. The specific process is as follows: input the real-time monitored values ​​of Ti and Di, and calculate D using a weighted summation algorithm; if D exceeds a preset threshold of 0.5 mm, an output signal triggers the tripping mechanism to ensure system safety.

[0029] In one embodiment, the standard engagement depth is set based on the design drawings of the locking mechanism.

[0030] Specifically, the standard engagement depth corresponds to the theoretical axial distance at which the latch teeth engage with the opposite latch in a fully locked state. This distance is calibrated and stored in the detection device at the time of circuit breaker manufacturing. The real-time engagement depth is obtained through a displacement sensor. The input is the real-time signal when the latches are closed, and the axial engagement distance is calculated using a laser ranging algorithm. The output is a numerical value, such as 2.0 mm. When the real-time engagement depth is compared with the standard engagement depth, the difference is the engagement depth offset. A positive value indicates excessive engagement, while a negative value indicates insufficient engagement.

[0031] For example, the identification of the misalignment orientation of the locking tooth surface is based on the tilt angle and rotational azimuth angle values ​​in the tooth surface contact posture. The tooth surface contact posture is acquired using a 3D laser scanner. The specific process is as follows: scanning the tooth surface point cloud data, fitting the tooth surface normal vector, and calculating the tilt angle value θ (in degrees, reflecting the pitch deflection of the tooth surface in the vertical plane) and the rotational azimuth angle value φ (in degrees, reflecting the lateral sway of the tooth surface in the horizontal plane). θ and φ are then vector-synthesized, and the calculation formula is the total deviation angle. The deviation direction β = atan2(φ, θ), where atan2 is the arctangent function, α represents the total deviation of the normal, and β represents the deviation direction. Obtaining α and β of the tooth surface normal relative to the ideal vertical direction, β represents the misalignment orientation of the locking tooth surface, characterizing the direction in which the tooth surface has deviated in space.

[0032] For example, when θ = 5 degrees and φ = 3 degrees, α ≈ 5.83 degrees and β ≈ 30.96 degrees. Based on the above misalignment orientation of the locking teeth, the skew angle of the mating area is further determined.

[0033] It should be noted that the contact area refers to the effective area of ​​actual contact between the locking tooth surface and the opposite locking tooth, and its boundary is determined by the geometric contour of the tooth surface and the contact posture.

[0034] In one possible implementation, the actual boundary of the mating area is projected onto a two-dimensional plane, and the overlap is compared with the projection of the standard mating boundary. The smaller the proportion of the overlapping area to the standard mating boundary, the greater the degree of skewness. The standard mating boundary is derived from the part design drawings and generated by CAD software simulating an ideal meshing state. The input is the part's geometric parameters, and the output is a two-dimensional boundary profile. The skew angle is determined by the angle between the line connecting the center point of the actual boundary and the center point of the standard boundary and the reference axis. In the process of forming the comprehensive cumulative tolerance, the meshing depth offset and the mating area skew angle are superimposed in the same reference coordinate system. The superposition method is to first normalize the axial offset d (in millimeters) and the skew angle θ (in degrees), and then calculate d. norm =d / 5 (assuming a maximum offset of 5 mm) and θ norm =θ / 30 (assuming the maximum angle is 30 degrees), then the weighted composite deviation amplitude A = 0.6 × d norm +0.4×θ norm The weights are determined based on empirical testing. This comprehensive deviation range reflects the overall impact of part machining tolerances and installation deviations under current operating conditions.

[0035] Step S103: The angle between the tripping action direction and the tooth surface normal is further extracted by the tooth surface angle detection probe. The angle is evaluated to determine whether it exceeds the contact orientation required for effective disengagement of the tooth surface, and the reduction posture of the tripping force in the effective contact area is obtained.

[0036] The direction of the tripping force is obtained by a tooth surface angle detection probe, and the spatial direction of the current tooth surface normal is extracted. The force direction and the spatial direction of the tooth surface normal are vector-producted and converted into an angle value to obtain the angle between the tripping direction and the tooth surface normal. This angle is compared with a preset permissible contact angle. If the angle exceeds the permissible contact angle, the tripping direction is determined to have exceeded the required contact angle range for effective tooth surface disengagement, indicating an out-of-bounds state. Based on this out-of-bounds state, the deviation of the angle from the permissible contact angle is extracted and mapped to the coverage area of ​​the contact area. The percentage of the area not covered by the tripping force within the contact area is obtained, thus determining the reduction posture of the tripping force within the effective contact area.

[0037] During the tripping process of a pole-mounted circuit breaker, the angle between the direction of the tripping force and the normal to the tooth surface directly affects the transmission efficiency. The direction of the applied force is determined by the axis direction of the push rod of the electromagnet tripping device, and the normal to the tooth surface is determined by the direction perpendicular to the locking tooth surface.

[0038] In one embodiment, the vector dot product operation is used to obtain the angle between two directions.

[0039] Specifically, the direction of force application and the tooth surface normal are represented as unit direction vectors. A dot product is performed on the two unit vectors, and the result is the cosine of the angle between the two vectors. The cosine value is then converted into an angle value using an inverse cosine function. This angle value is the angle between the tripping direction and the tooth surface normal, representing the degree to which the tripping force deviates from the perpendicular direction of the tooth surface.

[0040] For example, the preset allowable contact angle is determined based on the disengagement mechanical characteristics of the locking mechanism. The force transmission efficiency is highest when the direction of the tripping force completely coincides with the tooth surface normal; as the angle gradually increases, the component of the force in the tooth surface normal direction gradually decreases. The allowable contact angle corresponds to the critical angle at which the tripping force can normally push the lock to disengage. This angle is calibrated during the circuit breaker design phase based on the lock tooth profile parameters and the tripping force margin. The specific calibration process is as follows: input tooth profile parameters such as tooth angle α (unit: °) and tripping force margin m (coefficient range: 0.8-1.2), and calculate using the formula θ=arctan(m×tan(α)), where θ is the allowable contact angle. An example output is θ=10° when α=10° and m=1.0. Based on the comparison between the above angle and the allowable contact angle, the out-of-bounds state of the orientation is further determined.

[0041] It should be noted that if the included angle θ does not exceed the permissible angle θ of the fit direction. p For example, at 30°, the component of the tripping force F in the direction normal to the tooth surface is F nSufficient to push the latch off, of which F n The calculation takes F and θ as inputs and uses the formula F. n =Fcosθ output component values; if the included angle θ exceeds θ p If this occurs, the transmission of the tripping force will be skewed, and part of the force will be decomposed into the tangential direction F of the tooth surface. t It cannot be converted into separation thrust, of which F t The calculation takes F and θ as inputs and uses the formula F. t =Fsinθ outputs the component values. Here, θ is the included angle. p Let F be the allowable angle, and F be the force applied. n For the normal component, F t This is the tangential component.

[0042] In one possible implementation, the process of mapping the deviation to the coverage area of ​​the contact region is based on geometric projection relationships. Taking the deviation *d*, where the included angle exceeds the permissible angle of the contact orientation, as input, and based on the geometry of the contact region of the locking teeth, an algorithm such as projective transformation is used to calculate the projected coverage area *A* of the disengagement force in the contact region. p With standard coverage area A s The ratio, i.e., ratio = A p / A s The percentage of uncovered areas (1-ratio) is a quantitative representation of the reduced action posture, reflecting the degree of insufficient force applied by the tripping force in the effective contact area.

[0043] For example, if d = 5 degrees, A p =80 square millimeters, A s =100 square millimeters, then ratio=0.8, and proportion 0.2.

[0044] The degree of deviation of the contact orientation of the tripping action direction relative to the tooth surface normal is retrieved. It is then identified whether the degree of deviation exceeds the effective disengagement limit of the tooth surface and deviates from the reliable separation orientation. The reduction of the tripping force on the tooth surface and the effective coverage gap under the condition of contact orientation exceeding the limit are analyzed to obtain the reduction posture of the tripping force in the effective contact area.

[0045] The angle between the tripping direction and the tooth surface normal is retrieved. This angle is decomposed into horizontal and vertical azimuth angles. Based on the vector synthesis of these angles, the degree of contact orientation deviation is determined. This deviation is compared to a preset tooth surface separation limit angle. If the deviation exceeds this limit, the tripping direction is deemed to have exceeded the separation limit. The angle difference between the deviation and the reliable separation orientation is further extracted to determine the deviation range. Based on this deviation, the proportion of the force component transmitted along the tooth surface normal is extracted. This proportion is compared to the standard coverage area of ​​the contact region to obtain the gap in the contact region not covered by the tripping force, thus determining the force transmission reduction and coverage gap. Based on the degree of force transmission reduction and the coverage gap, the insufficient force transmission corresponding to the degree of force transmission reduction and the insufficient bonding area corresponding to the coverage gap are weighted and summed under the same benchmark to obtain the comprehensive insufficient effect of the tripping force in the bonding area, and thus obtain the reduction posture of the effect of the tripping force in the effective bonding area.

[0046] In the tripping control process of a pole-mounted circuit breaker, the degree of deviation of the tripping force direction relative to the tooth surface normal directly affects the transmission efficiency of the tripping force. The degree of deviation represents the comprehensive angular magnitude of the deviation of the tripping force direction from the tooth surface normal. When this deviation exceeds the tooth surface disengagement limit, the component of the tripping force in the tooth surface normal direction will be significantly reduced, causing the latch to fail to disengage normally.

[0047] In one embodiment, the angle between the tripping direction and the tooth surface normal is obtained by the tooth surface angle detection probe and then further decomposed into two components: horizontal azimuth angle and vertical azimuth angle.

[0048] Specifically, the horizontal azimuth deflection angle represents the deflection angle of the tripping action direction in the horizontal plane relative to the projection of the tooth surface normal, while the vertical azimuth deflection angle represents the deflection angle of the tripping action direction in the vertical plane relative to the projection of the tooth surface normal. Treating the horizontal and vertical azimuth deflections as two orthogonal components on a two-dimensional plane, a composite angle value is obtained through vector synthesis. This composite angle value represents the degree of misalignment in the contact direction.

[0049] For example, the vector synthesis process is completed based on vector operations in a Cartesian coordinate system. The tangents of the horizontal azimuth angle h and the vertical azimuth angle v are used as the x-axis and y-axis components, respectively, to synthesize the skew angle. This synthesis method comprehensively reflects the overall magnitude of the deviation of the tripping action direction from the tooth surface normal in three-dimensional space, rather than focusing on deflection in only a single direction. Based on the aforementioned degree of contact orientation deviation, it is further compared with the preset tooth surface disengagement boundary angle.

[0050] It should be noted that the tooth surface disengagement limit angle is pre-calibrated based on the disengagement mechanical characteristics of the locking mechanism, and represents the critical deflection angle at which the triggering force can normally push the lock to disengage. When the degree of deflection in the contact direction is less than the tooth surface disengagement limit angle, the component of the triggering force in the tooth surface normal direction is sufficient to overcome the locking resistance; when the degree of deflection in the contact direction exceeds the tooth surface disengagement limit angle, it is determined to be an out-of-limit state.

[0051] In one possible implementation, the reliable separation orientation refers to the ideal force direction range corresponding to the stable separation of the locking tooth surface during the disengagement process. The reliable separation orientation extends outward from the tooth surface normal at a certain angle, forming a conical region where all force directions within this region can achieve reliable disengagement. When the degree of deviation in the contact orientation exceeds the tooth surface disengagement limit angle, the angle difference between this deviation and the reliable separation orientation boundary is further calculated. This difference is the deviation amplitude, characterizing the severity of the deviation of the disengagement action direction from the reliable separation region. Based on the deviation amplitude, the proportion of the force component transmitted along the tooth surface normal direction during the disengagement process is extracted.

[0052] Specifically, when the direction of the tripping force forms an angle with the tooth surface normal, the force decomposes into an effective thrust component along the tooth surface normal and an ineffective friction component along the tooth surface tangentially. The proportion of the force components is characterized by the cosine of the angle; the greater the deviation beyond the limit, the smaller the cosine value, and the lower the proportion of the effective thrust component to the total force. Furthermore, the proportion of the force components is compared with the standard coverage area of ​​the contact region. The standard coverage area refers to the area of ​​the tooth surface contact region that the tripping force can completely cover under the ideal application direction. When the proportion of the force components decreases, the application intensity of the tripping force in the contact region decreases accordingly, and some contact areas cannot be effectively pushed due to insufficient application intensity, forming a coverage gap. The range of the coverage gap is obtained by inversely multiplying the proportion of the force components by the standard coverage area, representing the proportion of the contact area that the tripping force failed to effectively cover.

[0053] Preferably, the force transmission attenuation degree is defined as the transmission loss caused by the force component proportion being lower than the ideal value, calculated using the formula R=(1-P)×F, where R is the attenuation degree, P is the force component proportion (range 0 to 1), and F is the total applied force. The weighted sum of R and the covering gap G is determined based on the mechanical priority during the latch disengagement process. In the weighted summation process, the force transmission deficiency corresponding to input R is assigned a weight of 0.7; the contact area deficiency corresponding to input G is assigned a weight of 0.3. The weight ratio is calibrated by simulating the disengagement critical condition of the latch mechanism, for example, adjusting the ratio when the critical force is 50N. The calculation process is as follows: the deficiency is multiplied by the weight and then summed, i.e., the total deficiency T=0.7×(R×F)+0.3×G, and the output T is the comprehensive deficiency of the disengagement force in the contact area.

[0054] It is understandable that the aforementioned insufficient combined effect is a quantitative representation of the reduction in the effect of the tripping force in the effective contact area. This reduction reflects the decrease in the force exerted by the tripping force relative to the ideal working condition under the conditions of tolerance accumulation and angle deviation, and can provide a reference for the compensation and adjustment of the tripping release force.

[0055] Step S104: The current output force of the electromagnet is collected by the electromagnet output force sensing head. Combined with the effect of the tripping force in the effective contact area, the degree of aggravation of tooth surface friction resistance is deduced to obtain the real-time meshing posture, and the comprehensive resistance torque corresponding to the real-time meshing posture is analyzed.

[0056] The output force of the electromagnet is collected in real time by an electromagnet output force sensing head to obtain the instantaneous thrust value of the electromagnet under the current excitation current condition, thus obtaining the current output force of the electromagnet. Based on the reduced action posture of the current electromagnet output force and the tripping force in the effective contact area, the current output force is multiplied by the attenuation ratio corresponding to the insufficient force transmission in the reduced action posture to obtain the actual transmitted force value of the tripping force in the tooth surface normal direction. Based on the actual transmitted force value and preset tooth surface friction characteristic parameters, the degree of tooth surface friction resistance is obtained. Based on the degree of tooth surface friction resistance, combined with the real-time engagement depth and tooth surface contact posture, the axial embedment amount corresponding to the engagement depth, the orientation deflection amount corresponding to the tooth surface contact posture, and the degree of friction resistance are comprehensively characterized to obtain the real-time engagement posture. Based on the real-time engagement posture, the embedding resistance caused by the engagement depth and the frictional resistance caused by frictional hindrance are extracted from the locking tooth surface in the disengagement direction. The embedding resistance and the frictional resistance are multiplied by their respective lever arm distances to obtain the resistance torque components. The two resistance torque components are superimposed and summed to obtain the comprehensive resistance torque corresponding to the real-time engagement posture.

[0057] In the tripping control process of a pole-mounted circuit breaker, the electromagnet acts as the tripping actuator, and its output force directly determines the release capability of the latch. The electromagnet output force sensing head is installed at the output end of the electromagnet push rod, and the output thrust of the push rod is detected in real time through strain gauges or piezoelectric sensing.

[0058] In one embodiment, the electromagnet output force sensing head adopts a strain gauge structure. The strain gauge is attached to the surface of the push rod. When the push rod is subjected to force, the strain gauge deforms, and this deformation is converted into a change in resistance. After passing through a signal conditioning circuit, a voltage signal proportional to the push force is output. After calibration, the current output force of the electromagnet can be obtained from the voltage signal.

[0059] For example, the attenuation ratio corresponding to the insufficient force transmission in the reduced action posture is determined based on the aforementioned analysis results. The reduced action posture includes a quantified value of the overall insufficient force, which characterizes the decrease in the tripping force's ability to exert force relative to the ideal operating condition. Converting the overall insufficient force into a percentage, this percentage represents the attenuation ratio, indicating the proportion of the tripping force lost during transmission. Multiplying the current electromagnet output force by the complement of the attenuation ratio yields the actual transmitted force value of the tripping force in the tooth surface normal direction. Based on this actual transmitted force value, the degree of aggravation of tooth surface frictional resistance is further deduced.

[0060] It should be noted that the tooth surface friction characteristic parameter refers to the friction coefficient of the locking tooth surface material and the friction correction amount corresponding to the surface roughness. This parameter is pre-calibrated based on the characteristics of the locking material during the circuit breaker design stage. When the actual transmitted force is applied to the tooth surface, due to the deviation in the contact direction, part of the force is converted into tangential frictional force on the tooth surface. This frictional force is related to the tooth surface friction characteristic parameter. The larger the actual transmitted force and the greater the degree of deviation, the greater the frictional force generated, and the more obvious the aggravation of tooth surface frictional resistance.

[0061] In one possible implementation, the comprehensive characterization of the real-time meshing posture is based on three dimensions. The axial embedment amount corresponding to the real-time meshing depth characterizes the depth to which the locking tooth surface is embedded in the opposite locking latch; a larger embedment amount results in greater embedding resistance to be overcome during disengagement. The orientation deflection amount corresponding to the tooth surface contact posture characterizes the spatial tilt of the tooth surface relative to its ideal position; a larger deflection amount indicates a more severe deviation in the force transmission direction. The degree of frictional resistance aggravation characterizes the increase in tooth surface friction relative to normal operating conditions; a higher aggravation degree results in greater frictional resistance during disengagement. Combining the quantified values ​​of these three dimensions into a vector form provides the comprehensive description of the real-time meshing posture.

[0062] Specifically, the embedding resistance and frictional resistance are generated by different physical mechanisms. Embedding resistance originates from the geometric fit of the locking teeth. When the teeth are embedded in the opposite locking surface, the reverse movement of the teeth along the embedding direction during disengagement is geometrically blocked by the opposite teeth. This blocking force is the embedding resistance, and its magnitude is related to the embedding depth and tooth profile angle. Frictional resistance originates from the contact friction in the tooth contact area. When the disengagement force pushes the teeth to move, the frictional force generated in the contact area hinders the movement. This frictional force is the frictional resistance, and its magnitude is related to the normal force and friction coefficient of the contact area. Furthermore, the lever arm distance is determined based on the geometry of the locking mechanism. The locking mechanism rotates around a pivot to achieve the disengagement action, with the embedding resistance and frictional resistance acting at different positions in the tooth contact area. The lever arm distance corresponding to the embedding resistance is the vertical distance from the center of the pivot to the point of application of the embedding resistance, and the lever arm distance corresponding to the frictional resistance is the vertical distance from the center of the pivot to the point of application of the frictional resistance. Multiplying each resistance by its corresponding lever arm distance yields the resistance torque component generated by each resistance.

[0063] Preferably, the summation of the resistance torque components is performed using a unidirectional superposition method. Both the resistance torque component generated by the embedding resistance and the resistance torque component generated by the frictional resistance impede the disengagement rotation of the latch, and their directions are consistent; therefore, their direct addition yields the comprehensive resistance torque. This comprehensive resistance torque characterizes the overall resistance torque required to overcome for the latch to disengage under the current real-time engagement posture, and is a key basis for evaluating whether the release force is sufficient.

[0064] It is understandable that the combined resistance torque comprehensively reflects the hindering effect of multiple factors such as engagement depth, contact posture, and frictional resistance on the disengagement of the latch. Under the combined influence of tolerance accumulation and contact angle deviation, the value of the combined resistance torque will be significantly larger than that under ideal working conditions, placing higher demands on the output force margin of the electromagnet.

[0065] Step S105: Based on the comprehensive cumulative tolerance analysis, determine whether the comprehensive resistance torque exceeds the rated output force of the electromagnet. If so, refine the excitation current application mode according to the real-time engagement posture, obtain the electromagnet output force corresponding to the excitation current application mode, evaluate the relationship between the current electromagnet output force and the comprehensive resistance torque, and obtain the optimized conclusion of the tripping release force.

[0066] Based on the comprehensive cumulative tolerance and comprehensive resistance torque, the comprehensive resistance torque is compared with the rated output torque of the electromagnet. If the comprehensive resistance torque exceeds the rated output torque, the current operating condition is determined to be in a resistance overrun state, and the resistance overrun gap is identified. Based on the resistance overrun gap and the real-time meshing posture, the compensation requirements of the meshing depth offset and orientation deflection for the excitation current are extracted. According to the compensation requirements, the amplitude of the excitation current is increased proportionally and the application time is extended to obtain the adjusted excitation current application pattern. Based on the excitation current application pattern and the output characteristics of the electromagnet under the corresponding current, the adjusted electromagnet output force is obtained. Based on the adjusted electromagnet output force and comprehensive resistance torque, the adjusted electromagnet output force is converted into output torque and then the difference is calculated with the comprehensive resistance torque to obtain the restraint margin of the output torque relative to the comprehensive resistance torque. If the restraint margin exceeds the preset release margin threshold, the tripping release force is determined to meet the requirements, and the tripping release force optimization conclusion is obtained.

[0067] During the tripping control of a pole-mounted circuit breaker, when the combined resistance torque exceeds the rated output torque of the electromagnet, the output force of the electromagnet under the standard excitation current cannot overcome the locking resistance. To enhance the tripping capability, the excitation current is compensated and adjusted. The specific process is as follows: Input the combined resistance torque M... r and rated output torque M n Calculate the compensation coefficient k=(M) r -M n ) / M n If k > 0.2, then increase the current amplitude I. c =k×standard current I s For example, when the standard current is 5A and k=0.3, the compensated current is 6.5A, ensuring that the output torque meets the tripping requirements.

[0068] In one embodiment, the resistance overshoot gap refers to the difference between the total resistance torque and the rated output torque of the electromagnet.

[0069] Specifically, the difference between the overall resistance torque and the rated output torque is the resistance over-limit gap, which represents the insufficient tripping force under the current operating condition. The larger the resistance over-limit gap, the higher the compensation requirement of the excitation current.

[0070] For example, the compensation adjustment of the excitation current is determined based on the engagement depth offset and orientation deflection in the real-time engagement posture. The real-time engagement posture is measured by collecting data in real-time using displacement and angle sensors mounted on the latch, and the engagement depth offset D and orientation deflection A are calculated, where D is the difference between the actual depth and the standard depth in millimeters, and A is the difference between the actual angle and the standard angle in degrees. A larger engagement depth offset D indicates a deeper latch insertion, greater insertion resistance during disengagement, and a higher increase in the corresponding excitation current amplitude. A larger orientation deflection A indicates a more severe deviation in the force transmission direction, greater frictional resistance during disengagement, and a higher extension of the corresponding excitation current application time. The engagement depth offset D is mapped to an amplitude increase coefficient K1 = 0.1 × D, where D ranges from 0 to 10, and K1 ranges from 0 to 1. The orientation deflection A is mapped to a duration extension coefficient K2 = 0.05 × A, where A ranges from 0 to 20, and K2 ranges from 0 to 1. The adjusted amplitude I1 is obtained by multiplying the original excitation current amplitude I0 by (1+K1), and the adjusted duration T1 is obtained by multiplying the original application duration T0 by (1+K2), thus obtaining the adjusted excitation current application mode.

[0071] For example, when D=5 and A=10, K1=0.5 and K2=0.5. If I0=2 amperes and T0=1 second, then I1=3 amperes and T1=1.5 seconds. Based on the above adjusted excitation current application pattern, the adjusted electromagnet output force is further determined.

[0072] It should be noted that the output characteristics of an electromagnet refer to the relationship between the output thrust generated by the electromagnet push rod under different excitation currents. This relationship is obtained through calibration testing at the factory and stored in the control device. By referring to the output characteristic table based on the adjusted excitation current amplitude, the corresponding output force value of the electromagnet can be obtained.

[0073] In one possible implementation, the restraint margin is obtained by calculating the difference between the output torque and the combined resistance torque. The adjusted electromagnet output force F is multiplied by the lever arm distance L to convert it into an output torque T, where L is defined as the perpendicular distance from the electromagnet's point of action to the lock's rotation center. This torque is calculated using an algorithm by inputting the lock's geometric parameters, such as the coordinates of the point of action (x1, y1) and the rotation center (x0, y0). For example, when x1 = 0.05 meters, y1 = 0, x0 = 0, and y0 = 0, L = 0.05 meters. Subtracting the combined resistance torque from T = F × L gives the restraint margin. The release margin threshold is preset based on the reliability requirements of the locking mechanism, typically taken as 0.2 times the combined resistance torque. If the restraint margin exceeds the release margin threshold, the release force is deemed to meet the reliable release requirements, and the release force optimization conclusion is passed. If the restraint margin does not exceed the release margin threshold, the release force is deemed insufficient, and the release force optimization conclusion is that further adjustment is needed.

[0074] The excess notch of the comprehensive resistance torque relative to the rated output force of the electromagnet is extracted. The effect of tooth misalignment orientation and contact area deviation on the excitation current under real-time meshing posture is analyzed. The restraint margin of the electromagnet output force on the comprehensive resistance torque and the degree of compensation for tripping release margin under the refined shape are evaluated, and the optimization conclusion of tripping release force is obtained.

[0075] Based on the combined resistance torque and the electromagnet's rated output torque, the difference between the combined resistance torque and the electromagnet's rated output torque is obtained. This difference represents the excess distance between the combined resistance torque and the electromagnet's rated output torque. The excitation current compensation amplitude is determined based on the magnitude of this excess distance. Based on the excess distance and the excitation current compensation amplitude, and considering the tooth misalignment orientation and the degree of misalignment in the real-time meshing posture, the amplitude increment of the excitation current corresponding to the tooth misalignment orientation and the application duration increment corresponding to the misalignment in the contact area are extracted. These amplitude increments and duration increments are superimposed on the reference excitation current parameters to obtain a refined excitation current application pattern. Based on this refined excitation current application pattern, the electromagnet output force corresponding to the refined pattern is obtained. This output force is converted into output torque and then compared with the combined resistance torque to obtain the restraint margin of the output torque relative to the combined resistance torque. This restraint margin is compared with a preset release margin threshold to determine the degree of tripping release margin compensation. Based on the restraint margin and the degree of compensation for trip release margin, if the restraint margin exceeds the release margin threshold, it is determined that the trip release force compensation is sufficient; if the restraint margin does not exceed the release margin threshold, it is determined that the trip release force compensation is insufficient, thus obtaining the trip release force optimization conclusion.

[0076] During the tripping control of a pole-mounted circuit breaker, when the combined resistance torque exceeds the rated output torque of the electromagnet, the standard excitation current cannot provide sufficient tripping force. In this case, refined compensation of the excitation current is required to meet the tripping requirements. The aforementioned boundary gap represents the difference between the combined resistance torque and the rated output torque of the electromagnet; the larger this difference, the higher the compensation requirement of the excitation current.

[0077] In one embodiment, the excitation current compensation amplitude is determined by a graded mapping based on the magnitude of the boundary gap. The boundary gap is defined as the difference between the actual excitation current and a preset threshold of 0.5A. The calculation formula is G=Ia-It, where G is the boundary gap, Ia is the actual current, and It is the threshold.

[0078] Specifically, the out-of-bounds gap is divided into three intervals, each corresponding to a compensation level. The larger the out-of-bounds gap, the higher the compensation level, and the larger the corresponding increase in excitation current. For example, 0-2 corresponds to level 1 with an increase of 0.1A, 2-5 corresponds to level 2 with an increase of 0.2A, and 5 and above corresponds to level 3 with an increase of 0.3A. The hierarchical mapping relationship is established through calibration tests during the circuit breaker commissioning phase and stored in the control device for use during operation.

[0079] For example, the impact of tooth surface misalignment on the increase in excitation current amplitude stems from the deviation of the force transmission direction. Tooth surface misalignment is defined as the deviation angle θ between the actual position of the tooth surface and its ideal position. The ideal position refers to the coincidence of the tooth surface normal and the force transmission axis. Measurement is performed by using a laser scanner to obtain the three-dimensional coordinates of the tooth surface and calculating θ = arccos(the dot product of the actual normal vector and the ideal axis vector). When the tooth surface is misaligned relative to the ideal position, the component of the tripping force in the tooth surface normal direction decreases, and some of the force is converted into ineffective tangential friction. The greater the deviation of the tooth surface misalignment from the ideal direction, the lower the force transmission efficiency, requiring a higher instantaneous thrust to compensate for the transmission loss, and the larger the corresponding increase in excitation current amplitude. A linear mapping relationship is established between the deviation angle of the tooth surface misalignment and the amplitude increment, with the formula ΔI = k × θ, where ΔI is the current amplitude increment in A; k is the mapping coefficient, with an example value of 0.5 A / degree; and θ is the deviation angle in degrees.

[0080] For example, if the input θ = 10 degrees, then ΔI = 0.5 × 10 = 5A. Based on the above method for determining the amplitude increment, the influence of the skewness of the fitting area on the application duration increment is further analyzed.

[0081] It should be noted that the misalignment of the contact area reduces the contact area of ​​the tooth surface, resulting in incomplete force coverage of the disengagement force within the contact area. Some areas fail to disengage synchronously due to insufficient thrust. In this situation, simply increasing the amplitude of the excitation current cannot solve the problem of insufficient coverage; it is necessary to extend the application time of the excitation current so that the push rod applies force continuously for a longer period, gradually pushing each contact area to disengage sequentially. The greater the degree of misalignment of the contact area, the larger the gap in force coverage, and the longer the corresponding increment in application time.

[0082] In one possible implementation, the reference excitation current parameter refers to the amplitude and duration of the excitation current when the electromagnet performs a tripping operation under standard operating conditions. This parameter is predetermined during the circuit breaker design phase based on the electromagnet's characteristics and the mechanical requirements for latching disengagement. By superimposing the amplitude increment onto the reference excitation current amplitude and the duration increment onto the reference application duration, the refined form of the adjusted excitation current application can be obtained. This refined form includes two elements: the adjusted excitation current amplitude and the adjusted application duration. Further, the corresponding electromagnet output force is obtained based on the refined excitation current application form. The electromagnet generates different output thrusts under different excitation currents, and there is a corresponding relationship between the two. This relationship is usually non-linear, with the thrust increasing rapidly at lower currents and slowing down at higher currents. The correspondence table is established through experimental measurements and is a two-dimensional table. The first column is the excitation current amplitude I (unit: A), and the second column is the corresponding output thrust F (unit: N). Example data points: When I=1, F=5; when I=2, F=15; when I=3, F=25; when I=4, F=32; when I=5, F=38; when I=6, F=42; when I=7, F=45; when I=8, F=47; when I=9, F=48; when I=10, F=49. Query method: Input the adjusted excitation current amplitude I. Use the linear interpolation algorithm to calculate. If I is between two points in the table, then F=(F2-F1) / (I2-I1)×(I-I1)+F1, where I1 and I2 are adjacent current values, and F1 and F2 are the corresponding thrusts. This will give you the electromagnet output force value corresponding to the refined configuration.

[0083] Specifically, the restraint margin is obtained by calculating the difference between the output torque and the combined resistance torque. The combined resistance torque T res It consists of frictional torque and spring torque, and the frictional force F is measured by a sensor. fric The formula for calculating the lever arm r, spring stiffness k, and angle theta is: T res =F fric ×r+k×theta×r, where F fric The unit is Newton, r is in meters, k is in Newton-meters-radians, and theta is in radians. For example, F fric When =5, r=0.1, k=10, and theta=0.5, T res =1.0. Multiply the electromagnet's output force by the lever arm distance to convert it into output torque, then subtract the combined resistance torque. The difference is the restraint margin. The restraint margin characterizes the margin between the adjusted electromagnet's output torque and the combined resistance torque. A positive restraint margin indicates that the output torque is greater than the combined resistance torque, and the latch can disengage; a negative restraint margin indicates that the output torque is still less than the combined resistance torque, and the latch cannot disengage.

[0084] Preferably, the preset release margin threshold is determined based on the reliable disengagement requirements of the latching mechanism. The release margin threshold is taken as 0.2 to 0.3 times the comprehensive resistance torque M as a safety margin, where M is the comprehensive resistance torque. This ratio is determined during the circuit breaker design phase using the following calibration method: inputting the latching material strength S, the operating condition fluctuation range R, and the reliability requirement P, the threshold T = k × M is calculated using a finite element analysis algorithm, where k is a proportionality coefficient, obtained by weighting S, R, and P, with weights of 0.4, 0.3, and 0.3, respectively.

[0085] For example, if M=100Nm and k=0.25, then T=25Nm. By comparing the restraint margin with the release margin threshold, the degree of trip release margin compensation can be determined. The degree of compensation characterizes whether the current compensation scheme meets the reliable tripping requirements.

[0086] Understandably, the optimization conclusion of the tripping release force is based on the comparison between the restraint margin and the release margin threshold. If the restraint margin exceeds the release margin threshold, the optimization conclusion is that the tripping release force compensation is sufficient, and the current refined form of the excitation current application meets the reliable tripping requirements; if the restraint margin does not exceed the release margin threshold, the optimization conclusion is that the tripping release force compensation is insufficient, and it is necessary to further increase the excitation current amplitude or extend the application time to enhance the tripping capability.

[0087] Step S106: Based on the optimization conclusion of the tripping release force and the requirement of balancing stable locking, refine the excitation current application mode to obtain the final excitation current application mode.

[0088] Based on the optimization conclusion of the tripping release force, if the conclusion indicates sufficient compensation, the current refined excitation current application pattern is maintained; if the conclusion indicates insufficient compensation, the amplitude increment and duration increment are increased proportionally based on the refined pattern, while the increment amplitude is limited within a preset locking safety threshold range, resulting in an adjusted excitation current application pattern. Based on the adjusted excitation current application pattern, the adjusted amplitude and duration are used as the final output parameters to determine the final excitation current application pattern.

[0089] In the tripping control process of a pole-mounted circuit breaker, the final determination of the excitation current application mode needs to consider both the tripping release capability and the stable locking of the latch. The optimized tripping release force provides directional guidance for the adjustment of the excitation current, while the locking safety threshold sets boundary constraints for the adjustment range.

[0090] In one embodiment, the locking safety threshold is preset based on the locking and retaining mechanical characteristics of the locking mechanism. The specific setting process is as follows: First, the locking and retaining force F (in N) and the reference current I are obtained through mechanical testing. b (Unit: A), then calculate the threshold T = 0.8 × F / I. bWhere T is the threshold and 0.8 is the safety factor. In the example, F is 100N, I b If the current is 4A, then the amplitude threshold T is 20.0A, and the duration threshold is set to 10.0s. The locking safety threshold represents the upper limit of the excitation current increment. When the excitation current increment exceeds this threshold, the electromagnet may generate a false thrust in the non-disengaged state, affecting the stable locking state of the latch. The amplitude increment and duration increment are compared with their respective locking safety thresholds. If they exceed the threshold, the current is truncated to the threshold boundary to ensure that the adjusted excitation current application pattern does not affect the stability of the normal locking state.

[0091] For example, the final excitation current application pattern is determined using parameters constrained by a threshold as the final output. The adjusted amplitude and adjusted duration are combined to form a complete description of the excitation current application pattern, which includes two elements: the peak amplitude of the excitation current and the duration of continuous application, serving as the control basis for the electromagnet tripping execution.

[0092] Step S107: Drive the electromagnet to perform a tripping operation by applying the final excitation current, evaluate whether the tripping operation has entered the reliable tripping range, and obtain confirmation of successful tripping under the tolerance accumulation condition.

[0093] The electromagnet is driven to perform a tripping operation by applying the final excitation current. The actual disengagement displacement and time of the latch during the tripping process are collected and compared with a preset reliable tripping interval. The reliable tripping interval is the displacement and time range of the latch under normal tripping conditions. It is then determined whether the tripping operation has entered the reliable tripping interval. Based on the determination result of the reliable tripping interval, if both the actual disengagement displacement and time are within the reliable tripping interval, the tripping is considered successful under tolerance accumulation conditions, thus confirming successful tripping under tolerance accumulation conditions.

[0094] In the tripping control process of a pole-mounted circuit breaker, after the final excitation current application mode is determined, the electromagnet performs the tripping operation according to this mode. The execution result of the tripping operation is evaluated by the actual disengagement state of the latch to determine whether reliable tripping has been achieved under tolerance accumulation conditions.

[0095] In one embodiment, the reliable tripping interval is pre-calibrated based on the normal tripping characteristics of the latching mechanism. The reliable tripping interval includes two elements: a displacement range and a time range. The displacement range refers to the standard displacement interval from the latch moving from the locked position to the fully disengaged position, and the time range refers to the standard time interval from the application of the excitation current to the complete disengagement of the latch. This interval is determined through calibration testing during the circuit breaker's factory commissioning phase and stored in the control device.

[0096] For example, the actual disengagement displacement and disengagement time are acquired using a latch position sensor and a timer. The acquired actual disengagement displacement is compared with a preset displacement range, and the actual disengagement time is compared with a preset time range. If both are within their respective reliable disengagement intervals, the disengagement is considered successful under the tolerance accumulation condition, thus confirming successful disengagement. If either parameter exceeds the reliable disengagement interval, the disengagement is considered unsuccessful, requiring troubleshooting or parameter readjustment.

[0097] The above description is merely an example and illustration of the structure of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the structure of the invention or exceed the scope defined in the claims, all of which should fall within the protection scope of the present invention.

Claims

1. A synchronous self-locking control method for a direct-acting pole-mounted circuit breaker capable of rapid opening and closing, characterized in that, include: The engagement depth of the locking teeth is identified by a micro-displacement sensor head, and the tooth surface contact posture is identified by a tooth surface angle detection probe, thus obtaining the real-time engagement depth and the real-time tooth surface contact posture. Based on the analysis of the real-time engagement depth and the real-time tooth surface contact posture, the misalignment direction of the locking tooth surface and the degree of skewness of the contact area are obtained to obtain the comprehensive cumulative tolerance. The angle between the tripping direction and the tooth surface normal is extracted by the tooth surface angle detection probe, and it is determined whether the angle exceeds the preset contact direction of the tooth surface to obtain the reduction posture of the tripping force in the contact area. The current electromagnet output force is collected by the electromagnet output force sensing head, and the degree of aggravation of tooth surface friction resistance is deduced based on the effect of the current electromagnet output force and the tripping force in the contact area to reduce the posture, thereby obtaining the real-time meshing posture, and the comprehensive resistance torque is extracted based on the real-time meshing posture. Based on the comprehensive cumulative tolerance, it is determined whether the comprehensive resistance torque exceeds the rated output force of the electromagnet. If the comprehensive resistance torque exceeds the rated output force of the electromagnet, the excitation current application mode is determined based on the real-time engagement posture, and the electromagnet adjustment output force corresponding to the excitation current application mode is obtained. Based on the current electromagnet output force and the comprehensive resistance torque, the tripping release force optimization conclusion is obtained. Based on the optimization conclusions of the tripping release force and the requirements for stable locking, the excitation current application mode is adjusted to obtain the final excitation current application mode. The electromagnet is driven to perform a tripping operation based on the final excitation current applied, and it is determined whether the tripping operation enters the preset tripping range to obtain a successful tripping confirmation result.

2. The method as described in claim 1, characterized in that, The process of identifying the engagement depth of the locking teeth using a micro-displacement sensor head and identifying the tooth surface contact posture using a tooth surface angle detection probe to obtain real-time engagement depth and real-time tooth surface contact posture includes: The current position displacement data of the locking tooth surface is collected by the micro-displacement sensor head, the difference between the current position displacement data and the meshing reference position is calculated, and the offset of the locking tooth surface relative to the meshing reference position is obtained. Based on the geometric correspondence between the offset and the locking tooth structure, the axial distance of the tooth surface embedding into the opposite locking buckle is determined, and the real-time engagement depth is obtained. The angle of the spatial tilt direction of the locking tooth surface is detected by the tooth surface angle detection probe, and the tilt angle and rotation azimuth angle values ​​of the tooth surface normal relative to the reference axis corresponding to the meshing reference position are extracted. The orientation distribution of the tooth surface contact area in space is determined based on the tilt angle value and the rotation azimuth angle value, and continuous areas where the contact pressure between the tooth surfaces is greater than a preset pressure threshold are identified to obtain the real-time tooth surface contact posture.

3. The method as described in claim 1, characterized in that, The method of analyzing the misalignment orientation of the locking tooth surface and the degree of skewness of the contact area based on the real-time engagement depth and the real-time tooth surface contact posture to obtain the comprehensive cumulative tolerance includes: Calculate the difference between the real-time engagement depth and the standard engagement depth, and extract the engagement depth offset; Based on the engagement depth offset, the tilt angle value and rotation azimuth angle value in the real-time tooth surface contact posture, the spatial deviation direction of the tooth surface relative to the standard contact position is identified, and the misalignment orientation of the locking tooth surface is obtained. Based on the misalignment orientation of the locking teeth, the distribution range of the tooth contact area in the misalignment direction is extracted. The overlap between the actual boundary of the distribution range and the standard contact boundary is compared to obtain the skew angle of the contact area relative to the standard position, and the degree of skewness of the contact area is obtained. Based on the degree of skewness between the misalignment of the locking teeth and the mating area, the combined deviation of machining tolerance and installation deviation is determined, and the combined cumulative tolerance is obtained.

4. The method as described in claim 1, characterized in that, The step of extracting the angle between the tripping direction and the tooth surface normal using the tooth surface angle detection probe, and determining whether the angle exceeds the preset contact orientation of the tooth surface to obtain the reduction posture of the tripping force in the contact area, includes: The force direction is obtained by the tooth surface angle detection probe, and the spatial orientation of the current tooth surface normal is extracted. The vector dot product of the applied force direction and the spatial direction is performed and converted into an angle value to obtain the angle between the tripping action direction and the tooth surface normal. Compare the included angle with the permissible angle of the fitting orientation. If the included angle exceeds the permissible angle of the fitting orientation, then an orientation violation state is determined. The deviation amount of the included angle exceeding the permissible angle of the fitting orientation is extracted based on the out-of-bounds orientation state; By mapping the deviation amount to the bonding area, the percentage of the area not covered by the tripping force is obtained, and the reduction posture of the tripping force in the bonding area is obtained.

5. The method as described in claim 4, characterized in that, The step of mapping the deviation amount to the contact area, obtaining the percentage of the area not covered by the tripping force, and determining the reduction posture of the tripping force in the contact area includes: Retrieve the value corresponding to the angle between the tripping action direction and the tooth surface normal, and decompose the value corresponding to the angle according to the horizontal and vertical directions to obtain the horizontal azimuth deflection angle and the vertical azimuth deflection angle. The horizontal azimuth deflection angle and the vertical azimuth deflection angle are vector-synthesized to obtain the degree of skewness of the fitting orientation. By comparing the degree of deviation of the bonding orientation with the tooth surface separation limit angle, if the degree of deviation of the bonding orientation exceeds the tooth surface separation limit angle, the angle difference between the degree of deviation of the bonding orientation and the separation orientation is extracted to determine the extent of the deviation. Based on the aforementioned deviation range, extract the percentage of the force component transmitted along the tooth surface normal direction of the tripping force; By comparing the force component ratio with the standard coverage of the contact area, the range of the gap in the contact area not covered by the tripping force is obtained, and the degree of force transmission reduction and the coverage gap are obtained. The insufficient force transmission corresponding to the degree of force transmission reduction and the insufficient bonding area corresponding to the covering gap are calculated according to the weighted summation algorithm to obtain the comprehensive insufficient effect of the release force in the bonding area, and to obtain the reduction posture of the release force in the bonding area.

6. The method as described in claim 1, characterized in that, The process involves acquiring the current output force of the electromagnet through an electromagnet output force sensing head, and deriving the degree of aggravation of tooth surface frictional resistance based on the effect of the current electromagnet output force and the tripping force in the contact area to obtain the real-time meshing posture. Furthermore, the process extracts the comprehensive resistance torque based on the real-time meshing posture, including: The output force value is collected in real time by the electromagnet output force sensing head, and the instantaneous thrust value is obtained to obtain the current electromagnet output force; Calculate the product of the current electromagnet output force and the attenuation ratio in the reduced action posture to obtain the actual transmitted force value; The degree of aggravation of tooth surface friction resistance is obtained based on the actual transmitted force value and the tooth surface friction characteristic parameters. Based on the degree of aggravation of the tooth surface friction resistance, and combined with the axial embedment amount corresponding to the real-time meshing depth and the orientation deflection amount corresponding to the real-time tooth surface contact posture, the real-time meshing posture is obtained. Based on the real-time engagement posture, the embedding resistance and frictional resistance in the disengagement direction are extracted, and the corresponding lever arm distances are multiplied to obtain the resistance torque components. The combined resistance torque is obtained by superimposing the various resistance torque components.

7. The method as described in claim 1, characterized in that, The step of determining whether the comprehensive resistance torque exceeds the rated output force of the electromagnet based on the comprehensive cumulative tolerance, and if the comprehensive resistance torque exceeds the rated output force of the electromagnet, then determining the excitation current application mode based on the real-time engagement posture, obtaining the electromagnet adjustment output force corresponding to the excitation current application mode, and obtaining the tripping release force optimization conclusion based on the current electromagnet output force and the comprehensive resistance torque, includes: By comparing the combined resistance torque with the electromagnet's rated output torque, if the combined resistance torque exceeds the electromagnet's rated output torque, then a resistance over-limit gap is determined. Based on the resistance over-limit gap and the real-time meshing posture, extract the compensation requirements corresponding to the meshing depth offset and orientation deflection. Increase the amplitude of the excitation current and extend the application time according to the compensation requirements to obtain the excitation current application pattern; The electromagnet's output force is obtained based on the excitation current application pattern and the electromagnet's output characteristics. Calculate the difference between the output force of the electromagnet after it is converted into output torque and the comprehensive resistance torque, and obtain the restraint margin of the output torque relative to the comprehensive resistance torque; If the restraint margin exceeds the release margin threshold, then the optimized release force of the tripping force is obtained.

8. The method as described in claim 7, characterized in that, The optimized conclusion for obtaining the tripping release force includes: The resistance over-limit gap is obtained by calculating the difference between the comprehensive resistance torque and the rated output torque of the electromagnet, and the excitation current compensation range is determined based on the value of the resistance over-limit gap. Based on the resistance over-limit gap and the excitation current compensation amplitude, combined with the tooth surface misalignment orientation and the degree of deviation of the contact area in the real-time meshing posture, the excitation current amplitude increment corresponding to the tooth surface misalignment orientation and the application time increment corresponding to the degree of deviation of the contact area are extracted. The excitation current application pattern is obtained by superimposing the excitation current amplitude increment and the application duration increment to the reference excitation current parameter; Obtain the electromagnet adjustment output force corresponding to the excitation current application mode, calculate the difference between the electromagnet adjustment output force converted into output torque and the comprehensive resistance torque, and determine the restraint margin of the output torque on the comprehensive resistance torque; By comparing the restraint margin with the release margin threshold, the degree of trip release margin compensation is determined; The optimization conclusion of trip release force is determined based on the restraint margin and the degree of compensation for trip release margin. The optimization conclusion of trip release force includes sufficient trip release force compensation and insufficient trip release force compensation.

9. The method as described in claim 1, characterized in that, The step of adjusting the excitation current application mode based on the optimized tripping release force conclusion and the stable locking requirements to obtain the final excitation current application mode includes: Based on the optimization conclusion of the tripping release force, if the conclusion is that the compensation is sufficient, then the excitation current application mode is maintained. If the conclusion is that the compensation is insufficient, then the amplitude increment and duration increment are added to the excitation current application mode, while the increment amplitude is limited within the locked safety threshold range to obtain the adjusted excitation current application mode. Based on the adjusted excitation current application mode, the adjusted amplitude and duration are extracted as the final output parameters to obtain the final excitation current application mode.

10. The method as described in claim 1, characterized in that, The step of driving the electromagnet to perform a tripping operation based on the final excitation current and determining whether the tripping operation enters a preset tripping range to obtain a successful tripping confirmation result includes: The electromagnet is driven to perform the tripping operation according to the final excitation current application pattern; Collect the actual disengagement displacement and disengagement time of the latch during the release process; The actual disengagement displacement and the disengagement time are compared with a preset reliable tripping interval, which is the displacement range and time range of the latch in a normal tripping state, to determine whether the tripping operation enters the reliable tripping interval. Based on the judgment result of the reliable tripping interval, if both the actual tripping displacement and the tripping time are within the reliable tripping interval, then the tripping is determined to be successful.

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