Collimated Beam Alignment for Disconnect Switch Insulators
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Solution Overview
Problem
Conventional methods for aligning insulators in blade-type electric power disconnect switches rely on repetitive manual adjustments, which are difficult and time-consuming, leading to potential misalignment and electrical issues such as loose connections and arcing.
Innovation Solution
A camera-assisted collimated beam alignment system is used to align the insulators of a blade-type electric power disconnect switch, where an emitter stage, an aperture stage, and a target stage are temporarily attached to the insulators, and a camera captures images of the alignment indicator projected onto the aperture plate, allowing a technician to adjust the alignment from a remote location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If repetitive manual adjustment is used to align insulators, then alignment can be achieved, but the process becomes difficult and time-consuming
Solution Approach 1:
The patent replaces the manual mechanical adjustment process with an optical alignment system using a laser emitter, aperture plate with alignment aperture, and target. The laser beam provides a visual reference that guides insulator alignment, eliminating the need for repetitive manual adjustments and significantly reducing alignment time while maintaining precision.
Solution Approach 2:
The patent introduces intermediate alignment tools including a laser emitter that projects a reference beam, an aperture plate with a precisely positioned alignment aperture, and a target. These intermediaries serve as mediators between the insulators, providing visual and physical references that simplify the alignment process and reduce the time required to achieve precise alignment.
2Manufacturing precision
If multiple technicians are required for alignment, then alignment can be performed, but operational efficiency decreases
Solution Approach 1:
The alignment system is designed to be self-guiding through the laser emitter that projects a visible beam and the aperture plate that provides a clear alignment reference. A single technician can observe the laser alignment and make adjustments independently without requiring multiple technicians to manually position and align components, thereby improving operational efficiency while maintaining alignment precision.
3Ease of manufacture
If misalignment occurs, then electrical connection can be established, but loose connections and arcing damage may occur
Solution Approach 1:
The patent implements preliminary alignment action by using the laser emitter and aperture plate system to establish precise insulator alignment before the electrical connection is made. The laser beam provides a visual guide that ensures proper positioning of the contact relative to the jaws, preventing misalignment issues that could lead to loose connections or arcing damage, thereby improving electrical connection reliability.
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
The system enables precise and efficient alignment of insulators, reducing the risk of misalignment and electrical issues, and allows a single technician to perform the alignment, improving operational efficiency.
Implementation Method 1
An emitter stage (42) including a collimated beam emitter (61)
Data Source
AI summary
A camera-assisted collimated beam alignment system for aligning first, second and third insulators of an electric power disconnect switch. An emitter stage including an emitter is temporarily attached to the first insulator. An aperture stage including an aperture plate with alignment aperture is temporarily attached to the second insulator. A target stage including an alignment target is temporarily attached to the third insulator. A camera is positioned to capture an image of the aperture plate displays an alignment indicator projected by the emitter onto the aperture plate. A camera viewer spaced apart from the camera displays the image captured by the camera to assist a technician when adjusting alignment of the insulators.