Vacuum Interrupter Reconditioning With Getter Plug Vacuum Restoration
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Solution Overview
Problem
Vacuum interrupters in electrical systems degrade over time, leading to costly replacements and difficulties in finding direct replacements due to numerous models and ratings, necessitating a method to extend their service life.
Innovation Solution
A reconditioning method for vacuum interrupters involves cleaning and electropolishing internal components, using getter plugs to maintain vacuum integrity, and testing for suitability, which includes assessing contact resistance and erosion to determine remaining life and suitability for reconditioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum interrupters are replaced when they degrade, then system reliability is maintained, but replacement costs increase and downtime occurs due to difficulty in finding direct replacements
Solution Approach 1:
The patent changes the physical-chemical parameters of the vacuum interrupter by introducing cleaning solutions through holes in the endcap, performing electropolishing to restore contact surfaces, and replacing getter material to rejuvenate the vacuum environment. These parameter changes restore the interrupter's performance to near-original conditions, extending its service life and avoiding replacement downtime while maintaining system reliability
Solution Approach 2:
The patent recovers the vacuum interrupter from a degraded state by selectively replacing only the consumable getter material and cleaning/restoring components rather than discarding the entire device. This recovery process extends the interrupter's life by 50-100 years, eliminating the need for immediate replacement and associated downtime
2Reliability
If vacuum interrupters are replaced when they degrade, then operational safety is ensured, but replacement costs increase due to difficulty in acquiring direct replacements
Solution Approach 1:
The patent restores the vacuum interrupter's operational parameters through electropolishing of contact surfaces, replacement of getter material, and cleaning of internal components. This restoration maintains operational safety by ensuring contacts meet resistance specifications while avoiding the high costs of purchasing new interrupters, particularly for obsolete models
Solution Approach 2:
The patent recovers value from degraded vacuum interrupters by replacing only the consumable getter material and restoring components through cleaning and electropolishing. This selective recovery approach reduces replacement costs by keeping functional interrupters in service rather than purchasing new ones, addressing the cost issue while maintaining safety standards
3Loss of substance
If vacuum interrupters continue to be used after degradation, then replacement costs are reduced, but vacuum integrity deteriorates leading to failure
Solution Approach 1:
The patent recovers vacuum interrupters from degraded states by replacing the getter material and restoring vacuum integrity through controlled re-evacuation and sealing. This recovery process extends service life by 50-100 years while maintaining vacuum integrity, allowing continued use without premature replacement
Solution Approach 2:
The patent restores vacuum integrity by changing the vacuum environment parameters through getter replacement and controlled re-evacuation to achieve pressures below 10^-6 Torr. This parameter restoration maintains reliable operation while avoiding replacement costs
4Ease of operation
If cleaning solutions are introduced through holes in the endcap, then internal components are effectively cleaned, but vacuum integrity is compromised during the process
Solution Approach 1:
The patent performs preliminary cleaning actions by introducing cleaning solutions through holes in the endcap before final vacuum restoration. The cleaning process includes flushing, electropolishing, and drying steps that prepare components for vacuum re-establishment, ensuring thorough cleaning while planning for subsequent vacuum integrity restoration
Solution Approach 2:
The patent uses the holes in the endcap as intermediary access points that allow cleaning solutions to enter and exit the vacuum envelope without permanent compromise. These same holes serve as conduits for re-evacuation and sealing, mediating between the cleaning process and final vacuum restoration while maintaining a pathway for both operations
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 method effectively extends the service life of vacuum interrupters, potentially up to 50-100 years, reducing replacement costs and avoiding downtime by revitalizing suitable units for continued use.
Implementation Method 1
The cleaning of components of the vacuum interrupter inside the vacuum envelope is performed by introducing at least one cleaning solution into the interior of the vacuum envelope through the at least one hole in the endcap
Implementation Method 2
installing a plug in the at least one hole, wherein the plug has getter material on a surface thereof facing the interior of the vacuum envelope, and vacuum sealing the plug to the at least one hole such that a vacuum is re-established in the interior of the vacuum envelope
Implementation Method 3
the plug has getter material on a surface thereof facing the interior of the vacuum envelope
Implementation Method 4
The cleaning of components of the vacuum interrupter inside the vacuum envelope may be performed by baking the vacuum interrupter
Data Source
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Figure 2A
Figure 2B
AI summary
Disclosed is a method of reconditioning a vacuum interrupter comprising determining whether the vacuum interrupter is suitable for reconditioning. Where the vacuum interrupter is suitable for reconditioning, the method comprises optionally reducing pressure inside vacuum interrupter using magnetron pumping, and/or forming at least one hole in an endcap of a vacuum envelope of the vacuum interrupter, cleaning components of the vacuum interrupter inside the vacuum envelope by introducing at least one cleaning solution into the interior of the vacuum envelope through the at least one hole in the endcap, removing the cleaning solution from the interior of the vacuum envelope, installing a plug in the at least one hole, wherein the plug has getter material on a surface thereof facing the interior of the vacuum envelope, and vacuum sealing the plug to the at least one hole such that a vacuum is re-established in the interior of the vacuum envelope.