Modular Load Testing Device for High Voltage Safety
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Solution Overview
Problem
Existing dry-type load testing machines face complexity in managing multiple resistance units when testing power supplies with large voltages, requiring increased unit size or series connections, which complicates management and increases the risk of electrical shock during testing.
Innovation Solution
Connecting resistor groups in series across resistance units in the y-direction, allowing for a single resistance unit group to handle voltages twice that of a single unit while maintaining sufficient isolation and simplifying control, using insulators and connection cables to ensure safety and ease of use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plurality of resistance units are connected in series to handle high voltage, then the voltage handling capability is improved, but the device complexity and management difficulty increase
Solution Approach 1:
The resistance unit is divided into multiple independent modules (first resistance unit to sixth resistance unit), each capable of handling lower voltage individually. These modules can be connected in series to handle higher voltages when needed, providing flexibility without permanently increasing system complexity.
Solution Approach 2:
The connection configuration between resistance units is made dynamic through switching devices, allowing the system to reconfigure from parallel to series connections based on voltage requirements. This enables the same physical components to adapt to different voltage levels, improving versatility without fixed complexity increases.
2Reliability
If the size of resistance unit is increased to handle high voltage, then the voltage handling capability is improved, but the transportation and installation difficulty increase
Solution Approach 1:
Instead of creating one large resistance unit for high voltage, the system segments the resistance functionality into multiple smaller, standardized modules. Each module maintains manageable dimensions for easy transportation and installation, while combining multiple modules achieves the required high voltage handling capability.
3Reliability
If more resistors are used to increase resistance value, then the voltage handling capability is improved, but the management complexity increases
Solution Approach 1:
The total resistance requirement is segmented across multiple resistance units, each containing a manageable number of resistors. This distribution simplifies individual unit management while achieving the cumulative resistance value needed for high voltage applications.
Solution Approach 2:
Switching devices enable dynamic reconfiguration of resistor connections, allowing the system to achieve different total resistance values by selectively connecting resistance units in series or parallel, rather than requiring all possible resistor combinations to be permanently wired.
4Adaptability or versatility
If connection cables are used to connect resistance units, then the versatility for different voltage tests is improved, but the risk of electrical shock increases
Solution Approach 1:
Switching devices serve as intermediaries between the resistance units and test circuits, providing controlled connection and disconnection points. This intermediary mechanism allows for safe configuration changes and reduces direct exposure to high voltage connections, mitigating electrical shock risk while maintaining versatility.
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 straightforward load testing on high-voltage power supplies with improved safety and reduced complexity, allowing for efficient management and transportation of the load testing machine.
Implementation Method 1
an insulator to be used has specifications which consider a voltage to be applied to one resistance unit group
Implementation Method 2
A dry-type load testing machine has been proposed that uses a resistance unit including an alignment of rod-shaped resistors
Implementation Method 3
the first to sixth resistance units and the first to sixth cooling fans
Data Source
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AI summary
An object of the present invention is to provide a load testing machine capable of conducting a load test with a simple controlling. The load testing machine according to the present invention includes: six resistance units; six cooling fans; insulators between the resistance units and the cooling fans; and connection cables, in which: each of the resistance units includes a plurality of steps of resistor groups arranged in a z-direction and each formed of a plurality of rod-shaped resistors parallel to a x-direction connected together in series arranged at predetermined intervals in a y-direction; the six cooling fans face the resistance units, respectively, in the z-direction; the connection cables are cables used for serially and detachably connecting resistor groups next to each other in the y-direction of two resistance units next to each other in the y-direction with an interval of not smaller than a second distance in between; and the insulators each have a size corresponding to the rated voltage of a target power supply of a power supply load test to be conducted using a resistance unit group, the resistance unit group having serially connected resistors of two resistance units next to each other in the y-direction with the second distance in between.