Disconnect Switch Linkage Alignment for Faster Closed-Position Calibration

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Solution Overview

Problem

Conventional three-phase disconnect switches face challenges in precisely calibrating the linkage for the fully closed switch position, requiring manual adjustments of multiple calibration points and leading to a time-consuming and error-prone process.

Innovation Solution

A line-of-sight quick-alignment linkage is introduced, featuring a quick-alignment straight edge aligned with the line-of-sight from the pivot point of the drive pipe to the actuator arm, aiding in setting the linkage for the fully closed switch position, and potentially including a visual indicator for alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional linkage calibration methods are used, then the switch can be closed properly, but the calibration process is time-consuming and requires multiple trial-and-error adjustments

Engineering Contradiction:
Improvecalibration speedVSAvoidtime for calibration adjustments
Core Design Contradiction:
ProductivityVSLoss of time

Solution Approach 1:

A laser alignment tool is introduced as an intermediary device to project a visual reference line that mediates between the mechanical components and the operator. The laser line serves as a mediator that shows the exact alignment needed between the drive pipe and actuator arm, eliminating the need for operators to manually measure and calculate alignment angles. This intermediary visual aid dramatically reduces calibration time and trial-and-error adjustments.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces traditional mechanical measurement and alignment methods with an optical system (laser). Instead of using physical rulers, protractors, and manual angle measurements, the laser projection system provides visual feedback for alignment. This substitution of mechanical measurement systems with optical visualization systems streamlines the calibration process and reduces the complexity of manual adjustments.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If multiple calibration points are adjusted manually, then precise alignment can be achieved, but the process becomes complex and error-prone

Engineering Contradiction:
Improvealignment precisionVSAvoidcalibration process complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent extracts the alignment reference function from the complex mechanical calibration process and isolates it into a separate laser alignment tool. By taking out the alignment reference creation from the manual measurement process, the system simplifies the overall calibration procedure. The laser tool independently provides the reference line, separating the alignment reference generation from the mechanical adjustment tasks.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The laser alignment tool provides self-aligning visual feedback that guides the operator automatically. The laser line self-adjusts to show the correct alignment position without requiring the operator to perform complex calculations or multiple measurement steps. The system serves itself by providing real-time visual indication of proper alignment, reducing the need for complex manual calibration procedures.

Inventive Principle:
Principle #25Self-service

Data Source

PatentUS12266497B2Line-of-sight quick-alignment linkage for a three-phase electric disconnect switch
Publication Date: 2025.04.01 SOUTHERN STATES
  • US12266497B2 patent drawing
  • US12266497B2 patent drawing
  • US12266497B2 patent drawing

AI summary

A line-of-sight quick-alignment linkage for a three-phase electric disconnect switch interconnects a drive pipe, actuator arm, and a calibration mechanism of the switch. The linkage includes a quick-alignment straight edge configured to be aligned with the line-of-sight from the pivot point of the drive pipe to the actuator arm when the drive pipe is in the fully closed drive pipe position. The calibration mechanism, the actuator arm, and other phase operating levers of the other phases are then set to their fully closed positions to calibrate the linkage. The quick-alignment straight edge may be positioned on the calibration mechanism along with a visual indicator parallel to quick-alignment straight edge.