On-Load Tap Changer Torque Monitoring via Acoustic Correlation
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Solution Overview
Problem
Existing methods for monitoring on-load tap changers fail to accurately determine torque at the on-load tap changer due to non-constant mathematical relationships between motor-drive unit torque and actual torque, influenced by temperature, aging, and mechanical wear, leading to unreliable torque transmission over the device's long operating life.
Innovation Solution
A device comprising a motor-drive unit, a monitoring unit, and a sensor that acquires acoustic signals to determine the torque curve in the on-load tap changer by correlating the acoustic signal with a reference envelope, allowing for precise conversion of motor-drive unit torque to on-load tap changer torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If torque is monitored at the motor-drive unit, then monitoring is simplified and accessible, but torque measurement accuracy at the on-load tap changer deteriorates due to non-constant transmission relationships
Solution Approach 1:
Acoustic signals serve as an intermediary medium to transfer information about the actual torque at the on-load tap changer to the monitoring system. The acoustic emission sensor captures vibrations generated by the torque action, which are then processed to determine the torque curve at the target location without direct mechanical contact or complex transmission modeling.
Solution Approach 2:
The patent replaces direct mechanical torque measurement at the on-load tap changer with an acoustic field-based measurement system. Instead of using mechanical sensors that would require direct installation at the torque application point, the system uses acoustic emission sensing to indirectly measure torque through vibration analysis, substituting mechanical measurement with acoustic field analysis.
2Device complexity
If traditional torque monitoring methods are used, then device complexity is reduced, but reliability deteriorates due to temperature, aging, and wear influences
Solution Approach 1:
The system replaces mechanical torque transmission and measurement paths with acoustic field-based detection. By monitoring acoustic emissions rather than relying on mechanical torque transmission through the drive shaft train, the system eliminates sensitivity to mechanical wear, bearing degradation, and temperature-induced transmission variations, thereby improving reliability without significantly increasing complexity.
Solution Approach 2:
The on-load tap changer itself generates the measurement signal through its normal operation. The torque action during switching operations naturally produces acoustic emissions that carry the torque information, eliminating the need for separate measurement devices or additional energy input. The system uses the operational characteristics of the device being monitored as the measurement source.
3Measurement precision
If acoustic signal acquisition is added, then torque measurement accuracy improves, but device complexity increases
Solution Approach 1:
Acoustic signals act as an information intermediary that bridges the gap between the motor-drive unit torque and the actual torque at the on-load tap changer. The acoustic emission sensor captures these signals, and through signal processing and correlation analysis, the system accurately determines the torque curve at the target location with minimal additional hardware complexity.
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 accurate and reliable monitoring of torque curves in on-load tap changers, allowing for precise detection of diverter switch actions and retrofitting of old systems, ensuring accurate and stable torque measurement over time.
Implementation Method 1
a sensor (6) for acquiring an acoustic signal
Data Source
AI summary
A device (1) for monitoring an on-load tap changer (2), comprising: —a motor drive (4); —a monitoring unit (11); and —a sensor (6) for acquiring an acoustic signal; wherein —the monitoring unit (11) determines a torque curve in the on-load tap changer (2) on the basis of a torque curve on the motor drive (4) and the acoustic signal of the sensor (6).