Holder-Type Moving Contact Head for Transformer Tap Switches
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Solution Overview
Problem
Existing transformer tap switches face challenges in carrying high voltage and large current due to incomplete contact between moving and static contact points, leading to increased resistance and reduced lifespan, and existing methods to enhance current capacity are limited by pressure constraints and structural issues.
Innovation Solution
A moving contact head design featuring a holder-type configuration with multiple parallel single moving contact heads and a leaf spring component, where the leaf spring applies pressure to each contact head through leaf claws, ensuring effective contact and insulation, allowing for increased current capacity while maintaining a compact structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If two or more contact points are arranged at one contact head end to increase current-conducting capability, then the current capacity should be improved, but the contact points cannot completely contact with the static contact head due to external force and internal stress, resulting in larger contacting resistance and heat generation
Solution Approach 1:
The moving contact head is divided into multiple independent single moving contact heads arranged in parallel, each with its own contact points. This segmentation allows each contact point to independently establish reliable contact with the static contact head, avoiding the collective contact failure that occurs in unified multi-contact-point designs.
Solution Approach 2:
A leaf spring component is introduced to dynamically adjust and maintain the contact pressure between the moving contact head unit and the static contact head. The elastic deformation of the leaf spring compensates for manufacturing tolerances and wear, ensuring consistent contact pressure and low contacting resistance throughout the operational life of the switch.
2Quantity of substance
If spring pressure is increased to enhance contact pressure and current capacity, then the current-conducting capability is improved, but the pressure increase is limited and excessive pressure adversely affects the changeover between contact heads
Solution Approach 1:
Instead of using a single high-pressure spring system, the design distributes the contact pressure across multiple contact points with a moderate spring force. The leaf spring's elastic properties allow it to maintain optimal contact pressure (a specific parameter range) that is sufficient for low resistance contact but not excessive to hinder mechanical changeover operations.
3Quantity of substance
If multiple contact points are arranged in parallel to increase current capacity, then the conductive capability should be enhanced, but the structure becomes more complex and the contact head size increases
Solution Approach 1:
Multiple single moving contact heads are merged into a unified holder-type moving contact head assembly that rotates with the switch main shaft. This combining approach achieves the current capacity of multiple contact points while maintaining a compact, integrated structure that rotates as a single unit, reducing overall structural complexity compared to independent mechanisms for each contact point.
4Quantity of substance
If multiple contact points are arranged in parallel to increase current capacity, then the conductive capability is improved, but the contact head occupies more space
Solution Approach 1:
The holder-type moving contact head components are nested within a compact rotary bracket structure that rotates with the switch main shaft. The upper and lower moving contact head components are positioned vertically one above the other, utilizing vertical space efficiently. This nesting arrangement accommodates multiple contact points in a minimized volume, achieving high current capacity without proportionally increasing the contact head volume.
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 design enhances the conductive capability of transformer tap switches, enabling the handling of higher currents, including 1000 A working current, 20000 A short-circuit current, and 50 KA peak current, while maintaining a compact and efficient structure.
Implementation Method 1
a leaf spring component arranged on the moving contact head component. A pressing force is applied to the moving contact head unit by the leaf spring component
Data Source
AI summary
A moving contact head for tap switches comprises a moving contact head installation plate component (200) rotating with a switch main shaft (100), and a holder-type moving contact head (300) arranged on the moving contact head installation plate component (200). The holder-type moving contact head (300) is divided into two sets of upper and lower moving contact head components, which are connected to each other and formed a holder shape; wherein, each moving contact head component comprises a moving contact head unit (320) consisting of a plurality of single moving contact heads (321) in parallel, and a leaf spring component (330) arranged on the moving contact head component (320); both ends of each single moving contact head (321) are provided with a contact point, respectively. A contacting ring (500) is clamped at one ends of the two moving contact head units (320), and a static contact head (600) is clamped the other ends of the two moving contact head units to deform a leaf spring (331) in the leaf spring component (330). However, the reaction force by the leaf spring (331) causes the moving contact head unit (320) to contact with the contacting ring (500) and the static contact head (600) to achieve on-state of large current.