Fault Closure Lockout Electrical Connector Piston
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Solution Overview
Problem
Conventional high voltage electrical connectors, such as bushing inserts, suffer from catastrophic failure and potential explosion during fault closure, leading to the inability to reset the piston-contact element, resulting in incomplete engagement during subsequent fault closures.
Innovation Solution
Incorporating a piston lockout member that engages a stop ring within the electrical connector, preventing the piston-contact element from resetting to its original position after a fault closure, thereby ensuring it remains locked in the advanced position to prevent further engagement issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the piston is reset by forcing it back into its original position before fault closure, then the electrical connector appears as if it has not endured a fault closure, but during a subsequent fault closure the female contact will not completely engage the male contact and the fault closure will not be completed
Solution Approach 1:
The lockout member is positioned in advance to engage the stop ring, preventing the piston from returning to its original position after fault closure. This preliminary mechanical constraint ensures that even if someone attempts to reset the piston by forcing it back, the lockout mechanism will prevent complete return to the initial position, thereby maintaining reliability for subsequent fault closure operations.
2Reliability
If the piston moves forward to engage contacts during fault closure, then arc formation is eliminated, but the female contact is damaged and will not perform during subsequent fault closure
Solution Approach 1:
The lockout member is pre-positioned to prevent the piston from returning to its original position after the protective forward movement during fault closure. This ensures that the damaged female contact remains in its protected position and cannot be inadvertently reset, preventing incomplete engagement during subsequent fault closure attempts.
Solution Approach 2:
The electrical connector is designed as a single-use component that performs its protective function during the first fault closure and then becomes permanently locked in the advanced position. Rather than allowing repeated use of a damaged contact, the system treats the connector as a disposable safety device that must be replaced after one fault event.
3Ease of operation
If the piston is forced back into original position, then resetting is achieved, but the electrical connector appears functional while actually being compromised
Solution Approach 1:
The lockout member is positioned in advance to engage the stop ring, creating a permanent mechanical record of the fault closure event. This preliminary constraint prevents any attempt to reset the piston, thereby preserving the information that a fault closure has occurred and the connector is no longer suitable for use.
Solution Approach 2:
The lockout mechanism creates a visible, permanent change in the physical state of the connector. The piston remains in the advanced position with the lockout member engaged, providing a clear visual indication that the connector has endured a fault closure and should not be reset or reused, preventing loss of operational history information.
Data Source
AI summary
An electrical connector, such as a bushing insert, with a fault-closure lockout feature includes a housing with an inner bore having opposite ends. One end has an opening providing access to the inner bore. A piston-contact element is movable between first and second axially spaced positions within the inner bore. During fault conditions, the piston-contact element moves from the first position to the second position to accelerate connection with a male contact of another electrical connector, such as a cable connector, thereby inhibiting the formation of flashover or electrical arc. After fault closure, a lockout member on the piston-contact element prevents moving the piston-contact element from the second position to the first position.