Heat-Deformable Insulating Cap for Early Load Test Failure Detection

Solution Overview

Problem

Conventional load test devices for generators face challenges in early detection of failures due to high voltage currents, which can lead to undetected issues until they cause significant heat generation, making it difficult to identify problems promptly.

Innovation Solution

A load test device with a resistor unit and an insulating cap that deforms and detaches at elevated temperatures, along with a transparent cover and detection units for temperature, humidity, sound, vibration, and discharge voltage, allowing for early visual and auditory indication of failures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high voltage current flows through the load test device, then the generator can be tested effectively, but failures are difficult to detect early

Engineering Contradiction:

Improvefailure detection capabilityVSAvoidtime to detect failure

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The cap includes a temperature-sensitive color change element that changes color when the resistor generates excessive heat indicating a loose connection or failure. This allows visual detection of abnormalities without interrupting the high voltage testing operation.

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The cap acts as an intermediary indicator component that translates internal thermal conditions (caused by high voltage current flow) into external visual signals. The cap is attached to the resistor and provides visual feedback about the resistor's thermal state without being part of the high voltage circuit itself.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the nut is loose, then the resistor generates more heat, but this condition is difficult to recognize from the outside

Engineering Contradiction:

Improveabnormality detection accuracyVSAvoidvisibility of terminal condition

Core Design Contradiction:

ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

The cap includes a temperature-sensitive color change element that changes color when the resistor generates excessive heat indicating a loose connection or failure. This allows visual detection of abnormalities without interrupting the high voltage testing operation.

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The invention transforms the detection of terminal abnormalities from an internal electrical/thermal parameter space to an external visual dimension. By attaching the cap to the terminal and using color change elements, the system makes internal thermal conditions visible from the outside without requiring direct inspection of the terminal connection.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If the cap is composed of heat-deformable material, then heat generation can be visually detected, but the cap structure becomes more complex

Engineering Contradiction:

Improvevisual indication capabilityVSAvoidcap structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cap includes a temperature-sensitive color change element that changes color when the resistor generates excessive heat indicating a loose connection or failure. This allows visual detection of abnormalities without interrupting the high voltage testing operation.

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The cap serves multiple functions: it provides insulation, mechanical support, and visual indication of thermal conditions. By integrating the color change element into the cap structure, the invention combines multiple functions into a single component rather than adding separate indication devices.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables early detection of failures through visual and auditory cues, preventing damage by stopping power supply and notifying external devices of abnormalities, thus ensuring timely maintenance and reducing downtime.

Implementation Method 1

The cap is composed of a material that is deformed by heat. When a temperature of the terminal becomes equal to or higher than a first temperature, the cap is deformed by the heat and detached from the terminal.

Methodology Applied

Scientific EffectThermal deformation: Thermal Expansion

Implementation Method 2

a first detection unit that acquires information regarding at least one of a temperature, a humidity, a sound, a vibration, an impact, a discharge voltage, or a smell of a region where the terminal and the cap are located inside the frame

Methodology Applied

Scientific EffectTemperature detection:

Data Source

PatentUS12140636B2Load test device and cap of load test device

Publication Date: 2024.11.12 TATSUMI CORP

AI summary

A load test device includes: a resistor unit that includes a plurality of resistors that receive supplied power and a wall (holding frame) that holds opposite ends of each of the plurality of resistors; and an insulating cap that is attached to a portion of a terminal of the resistor that protrudes from the wall. The cap is composed of a material that is deformed by heat. When a temperature of the terminal becomes equal to or higher than a first temperature, the cap is deformed by heat and detached from the terminal.