Insulating Support Flange for Current Loop Isolation
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Solution Overview
Problem
Self-powered gate driver systems (SPGDSs) in power control systems experience delays in operation and response time due to insufficient charge in capacitors during transitions, leading to current and torque surges that can cause wear on system components.
Innovation Solution
An insulating support flange is designed to isolate current loop conductors from current transformers, creating a fixed open air space that reduces the possibility of discharge, and a pre-charge circuit continuously delivers a small current to maintain the SPGDS in a ready state, ensuring sufficient energy reserves without delays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If self-powered gate driver systems are used to eliminate dedicated power supplies, then system cost and component count are reduced, but operation delays and response time increase due to insufficient capacitor charge during transitions
Solution Approach 1:
The pre-charge circuit performs preliminary charging of the capacitor bank before the main operation begins. By continuously delivering a small current through the current loop conductor, the capacitor is pre-charged to the required voltage level, ensuring that when the motor controller needs to operate, the gate drivers have sufficient charge immediately available without delay.
Solution Approach 2:
The pre-charge circuit maintains continuous charging of the capacitor through the current loop conductor during normal operation. This continuous action ensures the capacitor remains charged and ready, eliminating interruptions or delays in the gate driver operation while the motor controller is running.
2Ease of operation
If current loop conductor is in direct contact with current transformers, then electrical connection is established, but partial discharge occurs causing wear on system components
Solution Approach 1:
The insulating support flange acts as an intermediary component between the current loop conductor and the current transformers. It provides mechanical support and positioning while maintaining electrical isolation, preventing direct contact that would cause partial discharge. The flange allows the conductor to pass through while keeping the current transformers at a safe electrical distance.
Solution Approach 2:
The insulating support flange extracts the support and positioning function from the electrical connection itself. By separating the mechanical support function (performed by the flange) from the electrical connection function (performed by the conductor and transformers), the design eliminates the harmful direct contact while maintaining the necessary electrical connectivity where needed.
Data Source
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Figure 3
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AI summary
The present invention relates generally to systems and methods for isolating a current loop conductor of a current loop system of a pre-charge circuit from a plurality of current transformers disposed around the current loop conductor. In particular, the embodiments described herein include an insulating support flange having a first tubular section, a second tubular section radially disposed around the first tubular section and connected to the first tubular section via a solid annular section extending radially outward from the first tubular section to a first end of the second tubular section, an annular base extending radially outward from a second end of the second tubular section, and a plurality of prongs extending axially from or near to an outer circumference of the annular base, wherein each of the prongs comprises an end face that is angled toward the second tubular section. The insulating support flanges are configured to mate with each other along an axial direction of the current loop conductor. In addition, each of the plurality of current transformers is installed (i.e., held in place) between the prongs, annular base, and second annular section of its respective insulating support flange. As such, a fixed open air space between the first and second annular sections of the insulating support flanges isolates the current transformers from the current loop conductor, thereby reducing the possibility of discharge between the current transformers and the current loop conductor.