Remote Reset Switch Actuation for Energized Transformer Panels
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Solution Overview
Problem
Resetting a load tap changer on an energized transformer is dangerous and costly due to the need for de-energizing the transformer, which causes customer outages and incurs significant installation and maintenance costs for portable substations.
Innovation Solution
A portable device with a housing and electromagnetic actuator that magnetically attaches to a control panel, allowing a technician to remotely operate the reset switch from a safe distance using a remote control device, eliminating the need for de-energizing the transformer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the transformer is de-energized before resetting the load tap changer, then worker safety is ensured, but customer outages occur and significant costs are incurred for portable substation installation and maintenance
Solution Approach 1:
A portable resetting device with an extended rod acts as an intermediary tool, allowing the reset switch to be operated from a safe distance without requiring direct contact with energized components. The device includes a housing with an opening, a rod that extends through the opening to contact the reset switch, and a actuator that moves the rod between retracted and extended positions, enabling remote operation while maintaining safety boundaries
Solution Approach 2:
The manual mechanical operation of the reset switch is replaced with an automated actuating mechanism. The actuator automatically moves the rod to the extended position to contact and operate the reset switch, then retracts the rod, eliminating the need for manual intervention near energized equipment and reducing exposure time to hazardous conditions
2Loss of time
If a worker manually operates the reset switch on an energized transformer, then the load tap changer can be reset quickly, but the worker is exposed to dangerous voltages of 15 kV and above
Solution Approach 1:
The portable resetting device serves as a protective intermediary between the worker and the energized transformer. The device allows the worker to stand at a safe distance while the extended rod contacts the reset switch on the energized equipment, completely eliminating direct exposure to high voltage hazards while maintaining operational efficiency
Solution Approach 2:
The resetting operation is segmented into distinct functional components: a housing that provides structural support and safety isolation, a rod that provides the physical contact interface with the reset switch, and an actuator that provides the actuating force. This segmentation allows the dangerous function of contacting energized equipment to be separated from the safe function of worker operation
3Productivity
If a portable substation is installed to prevent customer outages during transformer resetting, then service continuity is maintained, but costs exceeding $200,000 per installation are incurred
Solution Approach 1:
The portable resetting device is a low-cost, simple tool that can be easily deployed and removed as needed, replacing the expensive portable substation infrastructure. The device includes basic components (housing, rod, actuator) that can be manufactured at minimal cost compared to the $2,500,000+ portable substation, yet achieves the same operational goal of maintaining service continuity during reset operations
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
Improves worker safety by enabling remote operation of the reset switch from a safe distance, reducing the need for costly portable substations and associated downtime.
Implementation Method 1
An actuator is attached to the housing and is configured to move the rod between the retracted and extended positions in response to a control signal received from a remote device
Implementation Method 2
The housing includes at least one magnet, and the housing is magnetically attached to the control panel via the at least one magnet
Data Source
AI summary
A system for remotely operating a control panel reset switch for electrical equipment includes a remote control device, and a portable apparatus in communication with the remote control device. The portable apparatus includes a housing configured to be removably attached to the control panel and an electromagnetic actuator attached to the housing. The electromagnetic actuator includes a solenoid with a plunger. A rod is attached to the plunger and is movable through an opening in the housing from a retracted position to an extended position when the solenoid is energized. The rod contacts and operates the reset switch when in the extended position. The portable apparatus includes a camera that acquires images of the rod and reset switch during operation. The remote control device includes a switch for operating the electromagnetic actuator and at least one display configured to display operational messages and images from the camera.