Linear-Guided Tap Changer Contact Unit for Low-Wear Engagement
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Solution Overview
Problem
Existing contact systems for on-load tap changers face challenges in providing a stable and reliable mechanism with low wear and stress, particularly due to force concentrations and complexity in installation.
Innovation Solution
A contact unit with a connector body, contact holders, and drive and guiding means, including linear bearings and a spring, allows for linearly guided movement of contact elements, reducing friction and mechanical stress while enabling secure electrical engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rotational lever mechanism with contacts placed on a static holder is used, then the contact system can provide voltage transfer at multiple tap positions, but force concentrations occur at the engaging contacts leading to wear and stresses
Solution Approach 1:
The patent inverts the conventional rotational lever mechanism by replacing it with a linearly guided contact element that moves parallel to the contact surface rather than rotating around a pivot. This inversion eliminates the force concentration at the pivot point and distributes the mechanical stress along the linear guidance path, reducing wear at the engaging contacts while maintaining reliable voltage transfer across multiple tap positions
Solution Approach 2:
The patent substitutes the rotational mechanical lever system with a linearly guided movement system using bearings and guiding means. This replacement transforms the mechanical stress distribution from concentrated forces at pivot points to distributed forces along linear guides, reducing wear and improving contact engagement reliability
2Manufacturing precision
If a rotational lever mechanism with precise alignment is used, then correct contact engagement can be provided, but complexity and difficulty occur during installation phase
Solution Approach 1:
The patent employs a dynamically adjustable linear guidance system that can accommodate minor misalignments through the inherent movement freedom of the contact element within its linear guides. This dynamic capability eliminates the need for extremely precise static alignment during installation, reducing installation complexity while maintaining contact engagement precision
Solution Approach 2:
The patent changes the movement parameter from rotational angular displacement to linear translational displacement. This parameter change simplifies the alignment requirements during installation, as linear guidance can be more easily implemented with standard bearings and guides, reducing installation complexity while maintaining the necessary contact precision
3Power
If conventional contact systems with rotational movement are used, then voltage transfer can be achieved, but friction and mechanical stress increase during engagement processes
Solution Approach 1:
The patent inverts the movement direction from rotational to linear, allowing the contact element to slide parallel to the contact surface rather than pivot. This inversion reduces friction by eliminating the rotational pivot point and distributes mechanical stress along the linear guidance path, maintaining voltage transfer capability while reducing overall force requirements
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
The contact unit achieves a stable and reliable electrical engagement with reduced wear and stress, facilitating easier assembly and operation by allowing for linear guidance and retraction of contact elements.
Implementation Method 1
The drive and guiding means comprise at least one linear bearing and an axis arranged inside the bearing which are configured to provide linearly guided movement of the contact element of the contact unit
Implementation Method 2
allows for linearly guided movement of the contact element, reducing friction and mechanical stress
Implementation Method 3
The contact unit further comprises a spring configured to act as a driving means for the contact element in the direction away from the connector body
Data Source
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AI summary
A contact unit (10) for an on-load tap changer comprises a connector body (11) and a contact holder (12) coupled to each other, wherein the connector body (11) is configured to connect the contact holder (12) to a contact (2) of the on-load tap changer. The contact unit (10) further comprises a contact element (17) coupled to the contact holder (12) and configured to make electrical contact to a contact element (31) of a contact device (30) for the on-load tap changer. The contact unit (10) further comprises drive and guiding means (13, 15, 16) coupled to the contact holder (12) such that the contact element (17) is movable driven and linearly guided in a direction (T1, T2) away from the connector body (11) .