Spring-Loaded Contact Elements for High Voltage Switches
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Solution Overview
Problem
Existing high or medium voltage switches, particularly DC switches, face challenges in simplifying the assembly of conducting elements onto their carriers and improving the carrier material for enhanced performance and reliability.
Innovation Solution
The switch design features a first and second set of contact elements with insulating carriers and spring-loaded pins for secure mounting, allowing for a glue-free connection and improved current conduction, using a carrier frame made from epoxy material reinforced with aramid fibers for superior performance, and conducting elements made from high conductivity materials with rounded edges for reduced electrical field exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conducting elements are mounted onto carriers using traditional methods (glue or mechanical fastening), then the connection is secure, but the assembly process is complex and time-consuming
Solution Approach 1:
The conducting element is segmented into a main body and separate contact faces, allowing the contact faces to be independently positioned and secured using spring-loaded pins. This segmentation enables simplified assembly where components can be independently manufactured and then easily combined without complex mounting procedures.
Solution Approach 2:
The spring-loaded pins automatically secure the conducting elements to the carriers through elastic engagement. The pins are resiliently mounted in recesses and automatically engage with the conducting elements, eliminating the need for external fastening mechanisms or complex assembly procedures. The system self-secures through the inherent elasticity of the pins.
2Loss of energy
If conducting elements have sharp edges, then manufacturing is simpler, but electrical field exposure increases causing higher loss of energy
Solution Approach 1:
The contact faces of the conducting elements are designed with rounded edges and curved surfaces instead of sharp edges. This curvature reduces electrical field concentration at the contact points, minimizing energy loss and improving electrical performance. The rounded geometry is directly formed during manufacturing, adding minimal complexity to the fabrication process.
3Loss of substance
If conducting elements are rigidly fixed to carriers, then positioning is precise, but the connection creates hetero-material interfaces increasing loss of substance
Solution Approach 1:
The spring-loaded pins are made from the same material as the conducting elements, creating a homogeneous connection without hetero-material interfaces. This eliminates galvanic corrosion and material incompatibility issues while maintaining secure mechanical attachment. The pins are resiliently mounted in recesses of the same material family, ensuring chemical and physical compatibility.
Solution Approach 2:
The spring-loaded pins act as intermediary elements between the conducting elements and the carrier. These pins provide a flexible mechanical connection that maintains precise positioning while allowing for thermal expansion and contraction. The pins are resiliently mounted to provide continuous contact pressure, ensuring stable electrical connection without rigid fixation.
4Reliability
If contact elements use simple mounting structures, then assembly is easier, but reliability of connection decreases
Solution Approach 1:
The spring-loaded pins are pre-loaded with elastic force to provide continuous contact pressure between the conducting elements and the carrier. This beforehand cushioning ensures reliable electrical connection by maintaining constant mechanical pressure, compensating for manufacturing tolerances and thermal expansion. The resilient mounting absorbs stress and prevents loose connections without requiring complex adjustment mechanisms.
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
This design simplifies assembly, enhances current conduction, and improves the switch's reliability and performance in high voltage applications by reducing material interactions and electrical field exposure, while maintaining high dielectric withstand levels and fast switching times.
Implementation Method 1
with the positions of the conducting elements being such that in a first mutual position of the contact elements the conducting elements form at least one conducting path between the first terminal and the second terminal... with the conducting elements mounted onto the carrier part are locked into their operating position by one or more spring-loaded pins
Data Source
Figure 1
Figure 2
Figure 3A~4C
AI summary
A medium or high voltage switch has a first set of contact elements (13a, 13b, 13c) and a second set of contact elements (14a, 14b, 14c). Each contact element consists of an insulating carrier (15) carrying conducting elements (16). In the closed state of the switch, the conducting elements (16) align to form one or more current paths between terminals (8, 9) of the switch along an axial direction (A). For opening the switch, the contact elements are mutually displaced by means of two drives (18, 19) along a direction (D) perpendicular to the axial direction (A) with the conducting elements (16) mounted onto the contact elements by means of springloaded pins (161,162).