Collimated Beam Insulator Alignment for Disconnect Switches
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Solution Overview
Problem
Conventional blade-type electric power disconnect switches require repetitive manual adjustment for insulator alignment, which is time-consuming and prone to misalignment, leading to loose connections and potential arcing.
Innovation Solution
A collimated beam alignment system comprising an emitter stage, an aperture stage, and a target stage temporarily attached to the insulators, using a visible spectrum collimated beam to indicate proper alignment, allowing for precise adjustment before installation of live components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional manual adjustment methods are used for insulator alignment, then the alignment process can be performed without additional equipment, but the alignment precision is poor and the process is time-consuming
Solution Approach 1:
The patent introduces a collimated beam as an intermediary tool to establish a reference alignment axis. The beam passes through alignment apertures on multiple insulators, providing a visual indicator of proper alignment. This intermediary reference system enables precise alignment measurement without requiring complex measurement equipment or repetitive manual adjustments, directly resolving the contradiction between alignment precision and time consumption
Solution Approach 2:
The alignment apertures are designed to allow visual detection of the collimated beam's position relative to the insulators. When the beam passes through the apertures, it creates a visible indication (through light transmission or shadowing) that shows whether alignment is correct. This visual feedback mechanism enables operators to quickly identify and correct misalignment without time-consuming measurement procedures
2Reliability
If manual adjustment is used for insulator alignment, then no alignment verification system is needed, but misalignment cannot be detected and loose connections may occur
Solution Approach 1:
The collimated beam serves as an intermediary verification tool that provides a simple yet effective method to detect misalignment. By observing whether the beam passes through all alignment apertures, operators can verify proper insulator alignment and ensure reliable electrical connections. This simple verification mechanism significantly improves connection reliability without introducing complex alignment systems
Solution Approach 2:
The alignment apertures and collimated beam system enable self-verification of alignment. The apertures are designed to automatically indicate when alignment is correct through the passage of the collimated beam, allowing operators to verify alignment without requiring additional measurement tools or complex procedures. This self-verifying design ensures reliable connections while maintaining system simplicity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures accurate alignment of insulators, preventing loose connections and arcing, thereby enhancing the reliability and safety of the electrical connection.
Implementation Method 1
The visible spectrum collimated beam may be a laser beam
Implementation Method 2
The visible spectrum collimated beam may be a laser beam, a collimated LED beam
Data Source
AI summary
A collimated beam alignment system for aligning a receiving insulator, a guide insulator and a drive insulator of an electric power disconnect switch. The collimated beam alignment system includes an emitter stage temporarily attached to the receiving insulator, an aperture stage including an alignment aperture temporarily attached to the receiving insulator, and a target stage including an alignment target temporarily attached to the drive insulator. With the drive insulator rotated to a switch-closed position, proper alignment of the receiving insulator, the guide insulator and the drive insulator is indicated by a visible spectrum collimated beam from the emitter stage passing through the alignment aperture and illuminating the alignment target. Once the insulators are aligned, the alignment system is removed and the live components of the disconnect switch are attaches to the insulators.