Voltage Regulator Switching Module With Decoupled Prime Movers
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Solution Overview
Problem
Existing tap changer systems for voltage regulators are complex and costly due to mechanical linkages and the need for multiple vacuum interrupters, which complicates manufacturing, assembly, and maintenance, and increases costs.
Innovation Solution
A simplified switching subassembly for load tap changers using a single vacuum interrupter with two bypass switches and separate prime movers for each switch, eliminating complex mechanical linkages and reducing component count, and utilizing power electronic switches and electronic control systems for actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex mechanical linkages are used to synchronize the tap selector, bypass switches and vacuum interrupter, then reliable switching operation is achieved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent divides the switching system into independent modular units: a tap selector switch with its own prime mover, and a switching subassembly with bypass switches and vacuum interrupter actuated by a secondary prime mover. This segmentation eliminates the need for complex mechanical linkages to synchronize components, as each module operates independently through its own drive system while achieving coordinated switching through electronic control.
Solution Approach 2:
The patent replaces complex mechanical linkages with electronic control systems. The controller receives signals and actuates the prime movers electronically, substituting the need for mechanical synchronization mechanisms. This allows reliable switching operation to be achieved through electronic coordination rather than mechanical coupling.
2Reliability
If multiple vacuum interrupters are used to actuate each moving contact of the tap selector mechanism, then switching reliability is improved, but cost and device complexity increase
Solution Approach 1:
The patent merges the functions of multiple vacuum interrupters into a single vacuum interrupter within the switching subassembly. The single vacuum interrupter, combined with bypass switches, performs the load-breaking function that would otherwise require multiple interrupters. This consolidation reduces component count and cost while maintaining reliability through the coordinated operation of the switching subassembly.
Solution Approach 2:
The switching subassembly with its single vacuum interrupter and bypass switches is designed to perform multiple functions: load breaking, voltage regulation, and protection. This multi-functional design replaces the need for multiple specialized vacuum interrupters, reducing overall system complexity while maintaining comprehensive switching capability.
3Stability of the object's composition
If vacuum interrupters and bypass switches are built into one large assembly, then synchronized operation is achieved, but manufacturing and assembly processes become more complex
Solution Approach 1:
The patent segments the voltage regulator into distinct modular assemblies: the tap selector switch assembly and the switching subassembly. Each module can be manufactured, tested, and assembled independently, then integrated into the final system. This modular approach maintains synchronized operation through electronic control while dramatically simplifying manufacturing and assembly processes compared to a single large integrated assembly.
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 solution reduces manufacturing complexity and costs while maintaining reliability and improving switching performance by decoupling subsystems and using simpler drive systems, allowing for more efficient packaging and easier assembly.
Implementation Method 1
Vacuum interrupters have been used in load tap changers to regulate the voltage in power transformers for several decades
Implementation Method 2
a first prime mover coupled to the tap selector switch and configured to actuate the tap selector switch
Data Source
AI summary
The present disclosure provides techniques for an improved switching module for voltage regulators or transformers with voltage regulating taps. The switching module disclosed herein includes a first bypass switch and a second bypass switch coupled to the first bypass switch, at least one prime mover coupled to and configured to actuate at least one of the first bypass switch and the second bypass switch, and at least one load breaking switch coupled between the first and second bypass switches. In certain example embodiments, a separate prime move is configured to actuate each of the bypass switches and the load breaking switch. In certain other example embodiments, one or more of the bypass switches and the load breaking switch is actuated by a shared prime mover.