Vacuum switch with pre-insertion contact

A vacuum switching device with pre-insertion contact arrangement is disclosed. The vacuum switch includes first and second contact systems. The first contact system includes an annular stationary contact and an annular moving contact retained on a moving contact drive rod. A second contact system includes a moving contact retained on an end of the moving contact drive rod and a floating contact retained along the same axis as the second moving contact. Both contact systems are enclosed in a vacuum envelope. A mechanical adjustment system is provided for the floating contact, which allows it to be positioned so that the secondary moving contact and floating moving contact may engage at a set interval before the annular moving contact engages the annular stationary contact. A resistor or inductor is connected between the second contact system and a load to prevent a current in-rush into the load.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the field of high voltage vacuum switches and circuit interrupting devices and more particularly to a vacuum switch with a pre-insertion resistor or inductor arrangement to limit transient in-rush currents and or voltage transients during the closing and opening of a power distribution circuit containing capacitor banks.

2. Discussion of the Prior Art

A number of vacuum and non-vacuum prior art arrangements are directed to pre-insertion resistors or inductors for circuit interrupting devices wherein a resistor or inductor is either inserted in series with a high voltage switch or in parallel with a switch gap during the closing movement of the switch or interrupting unit to reduce audible and electrical noise and to limit transient in-rush current and/or voltages incident to completion of the circuit by the switch or interrupting unit. For example pre-insertion resistors of this type are shown in the following U.S. Pat. Nos. 3,588,406; 3,576,414; 3,566,061; 3,590,186; 3,763,340; 4,069,406; 4,072,836; 4,324,959; 4,695,918 and 4,788,390. Without the pre-insertion resistor, as the circuit interrupting device is closed, the in-rush current may reach values of 10 to 30 thousand amperes, where the interrupting device is used in conjunction with back to back capacitor banks. Additionally, during energization of a single capacitor bank, large voltage transients may also be produced. Such transient current and/or voltages can produce undesirable noise both audible and electrical and can, of course, also lead to distress or damage to equipment connected to the circuit. With the pre-insertion resistor, the in-rush current arising from switching back to back capacitor banks is limited to much lower values, perhaps in the range of 1.5 to 4 thousand amperes, which can be carried by the circuit without undue distress. Since the pre-insertion resistor or inductor is in the circuit only briefly during the closing of the circuit interrupting device, the pre-insertion resistor or inductor is not required to carry the continuous current of the circuit except during the portion of the insertion time after the in-rush. The vacuum devices of this type rely on complex and costly external switching techniques, while the non-vacuum devices rely on an air switch, which is quite noisy and bulky or SF6 devices, which are now creating environmental concerns due to the affect of escaped SF6 gas on the ozone layer.

Another approach to damping or limiting the current in-rush incident to the completion of the capacitor bank circuit by a high voltage switch is the continuous, permanent connection of an inductor in the circuit. However, such an arrangement does have its drawbacks since the inductor must be designed to carry continuous load currents and fault currents. In addition, there are ongoing costs associated with power losses in the inductor on a continuous basis as well as a reduction in the effectiveness of the capacitor bank to which it is connected.

Vacuum interrupters have been used in series combinations or with other circuit interrupting devices to provide a pre-insertion means. U.S. Pat. No. 3,708,638 illustrates two vacuum circuit breakers connected in series with an electronic control system to close one breaker before the other. This results in an arrangement that is complex and costly. U.S. Pat. No. 4,383,150 illustrates a vacuum interrupter combined with an SF6 interrupter. The combination of the two interrupters results in a switching device, which is also complex, costly and has the aforementioned environmental concerns associated with SF6 gas.

Prior art electronically controlled vacuum switches have allowed for precise closing on a voltage zero which minimizes the in-rush current and voltage transients as is illustrated in U.S. Pat. No. 6,921,989 B2. The electronic control employees a feedback circuit to determine the exact location and speed of the contact operating means so that the vacuum switch can be closed on a voltage zero of the sinusoidal waveform of the electric supply line. This type of vacuum switch is quite complex and costly, and can be difficult to set up when utilized in three phase applications.

Other prior art vacuum interrupters utilize multiple contact systems in an axial configuration as illustrated in U.S. Pat. Nos. 6,255,615 B1, 6,720,515 B2 and patent application US 2008/0245772 A1. These vacuum interrupters engage one set of contacts by having the contact operating means move in one direction and engage a second set of contacts when the contact operating means moves in the opposite direction. This configuration is suitable for providing a means to ground the electric circuit in which the vacuum switch or interrupter is employed, but because the contact means is not capable of engaging both sets of contacts by moving in one direction, the vacuum interrupters do not provide a pre-insertion means.

Another prior art interrupter utilizes multiple contact systems wherein one set of contacts drives another as illustrated in U.S. Pat. No. 2,863,026. In this case the operating spring for the driven contact is mounted inside the interrupter and is subject to annealing during the brazing together of the interrupter. While work hardening will result in the return of some of the spring force characteristics, its final force characteristics will be uncontrolled. Additionally, this device is not suitable as a pre-insertion device as no means is provided to precisely position the driven contact or to adjust out the tolerance accumulation between the multiple parts.

While the aforementioned prior art arrangements may be suitable for their intended use in accordance with their respective defined applications, as discussed hereinbefore, it would be desirable to provide an efficient and compact pre-insertion contact arrangement contained within a vacuum switch module to limit transient in-rush currents and voltage transients.

SUMMARY OF THE INVENTION

Accordingly, it is the principal object of the present invention to provide a single vacuum switch module with pre-insertion contacts activated by the motion of the main contacts and a resistor or inductor arrangement that effectively limits transient in-rush currents and/or voltages during operation of the device and does not require high energy dissipation, complex mechanical or electronic switching systems or precise insertion timing.

In the practice of the invention, the primary contact system has an annular stationary contact, which is engaged by a disc shaped moving contact. Both contacts are of copper-tungsten material, which is generally used for switching applications. The base of the stationary contact is supported between two tubular insulators, which are preferably made of ceramic and form the main portion of the interrupter housing. One of these insulators contains the first contact system. The end of this insulator is closed off by a stainless steel or monel end-cup which has an opening for the contact drive rod. The contact rod is made of copper with a stainless steel reinforcing rod to prevent a reduction in length due to repeated impact. A flexible stainless steel bellows is used to allow motion of the drive rod and allow for sealing of the end-cup. The drive rod for the moving contact disc extends through the disc and annular stationary contact into the region of the second insulator. A second moving contact disc is mounted on the end of the drive rod and is engaged by a floating contact disc mounted on a floating contact rod. These contacts are also of copper-tungsten material and the floating contact rod is also copper with a stainless steel reinforcing rod. This contact rod is mounted on the other end of the second insulator using a bellows and end-cup arrangement to allow sealing and free motion of the floating contact. The floating contact is driven by the motion of the second moving contact, which is directly coupled to the first contact system.

A mechanism is mounted on the end-cup that supports the floating contact and allows the tolerance accumulation of the components to be adjusted out and the floating contact positioned so that the second moving contact and floating contact can close before the primary contacts. The mechanism also has the capability of controlling the range of motion of the floating contact so that it may be contacted by the second moving contact for a set time before the primary contacts close.

The mechanism includes an annular housing with two long slots along the main axis spaced 180 degrees apart. The length of these slots is the sum of the length of the slots in the threaded adjuster described below plus the full range of tolerance accumulation of all parts that determine the spacing between the primary and secondary contacts. This allows the mechanism to have the capability of adjusting-out the tolerance build-up in the system. The housing also has an internal thread to allow the insertion of the threaded adjuster. The floating contact rod for the floating contact has a cross-hole placed in a position to allow the threaded adjuster to move through its required range within the housing. A fixturing pin is inserted through a hole in the floating contact rod and passes through both slots cut into the housing. In this manner, when the interrupter is processed through a brazing cycle, the relationship between the floating contact rod and housing is established and the housing can also be used as a bellows anti-twist device. After the interrupter is brazed, the fixturing pin is removed and an annular adjuster with external thread is screwed into the housing. The threaded adjuster has six slots spaced 60 degrees apart and of a length that is calculated to provide the desired time that the secondary contact system engages before the primary contact system, plus a small amount of over travel to accommodate any erosion or compression of the primary contacts. The threaded adjuster also has a counter-bore into which a compression spring or series of Bellville washers may be inserted. With the primary contacts held together and the secondary contacts in contact with each other, the threaded adjuster is rotated so that the top of the slot is above the cross-hole in the floating contact rod by the planned over-travel distance. The multiple slots in the threaded adjuster allows for a finer adjustment in determining this setting. Once the adjustment is complete, a pin is inserted so that it passes through the housing, floating contact rod and threaded adjuster and is secured with washers and retaining rings at both ends. A compression spring or series of Bellville washers of appropriate design to provide the required contact pressure for the secondary contacts and return force for the floating contact is placed in the counter-bore of the threaded adjuster and is secured in place with a threaded cap. This forces the pin through the floating contact rod to the lower portion of the adjuster slot and establishes the setting so the secondary contacts engage before the moving contacts.

A portion of the floating contact rod extends through the cap that captures the compression springs to which a flexible lead or other current exchange method (garter springs or multi-lam current transfer devices) may be attached. A pre-insertion resistor or inductor of appropriate design is attached from the established current exchange to a load terminal located on the base of the stationary contact of the primary set of contacts. A current exchange is also required for the moving contact rod for the primary set of contacts as this is a source terminal for the vacuum switch. As the primary contact rod moves to the closed position, it can be seen that the secondary contacts will close first which will allow current to flow from the source terminal connected to the primary rod, through the secondary contacts and pre-insertion resistor or inductor and out to the load terminal at the base of the stationary contact. As the primary contact rod continues its motion, the second moving contact pushes the floating contact, compressing the spring contained in the adjustment mechanism until the primary contacts engage. Once the primary contacts engage they short out the circuit consisting of the secondary contacts and pre-insertion resistor or inductor and thus effectively remove the pre-insertion resistor or inductor from the circuit. Current then flows unimpeded from the source terminal through the primary contacts to the load terminal. This motion allows the pre-insertion resistor or inductor to be momentarily connected in a capacitor bank application and then removed to allow efficient flow of the capacitor bank load current. As the moving contact rod is moved to the open position, the previously charged spring in the adjustment mechanism now discharges and forces the secondary contacts to remain engaged for a time after the primary contacts part. This reduces arcing on the primary contacts and places the pre-insertion resistor or inductor momentarily in series with the capacitor bank to reduce transients when the secondary contacts break the circuit. The invention described above is suitable for use in oil or SF6 switchgear.

A ramification of the invention allows the vacuum switch to be encapsulated. This is facilitated by the addition of a housing, which prevents the encapsulation material from contacting the moving components of the threaded adjuster. The housing consists of a metallic cylinder with a top made of insulating material. The portions of the housing are held in place by screws, which engage insulators, which are secured to studs that are brazed to the end-cup of the interrupter. A flexible lead transfers current from the floating contact rod to a terminal, which exists out the top of the housing. A terminal rod is extended out from the stationary contact and a current exchange utilizing a multi-lam construction and bellows anti-twist means is utilized with the primary moving contact. A terminal rod is extended out from this current exchange, in the opposite direction to that on the stationary contact to maximize terminal dielectric clearances. This configuration may be encapsulated using the various techniques established in prior art. Once encapsulated, the pre-insertion resistor or inductor may be mounted externally between the top terminal and the terminal connected to the stationary contact.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1discloses a vacuum switch with pre-insertion contact (vacuum switch)1. The vacuum switch1includes a vacuum envelope2. The major part of the vacuum envelope2includes a pair of insulating cylinders4A and4B preferably fabricated from alumina ceramic and joined end-to-end by way of two stainless steel or monel triple point shields6A and6B and a stationary contact support ring8preferably fabricated from copper. A threaded hole in the stationary contact support ring8allows the attachment of a terminal rod10preferably fabricated from copper to facilitate electrical connection to the load line. The opposite ends of the ceramic cylinders are enclosed by two end cups12A and12B preferably fabricated from stainless steel or monel.

A second set of triple point shields14A and14B preferably fabricated from stainless steel or monel are attached to the end cups12A and12B. A generally tubular internal shield16A and16B is provided within each insulating cylinder4A and4B spaced from the interior wall and overlapping the triple point shields14A and14B to prevent any vaporized material from contacting the interior wall.

A primary contact system11includes an annular stationary contact support18preferably fabricated from copper and is attached to the stationary contact support ring8. An annular stationary contact20preferably fabricated from copper tungsten is attached to a lower end of the stationary contact support18. The annular stationary contact20is engaged with an annular moving contact22and also preferably fabricated from copper tungsten.

The annular moving contact22is attached to a disc shaped moving contact support24preferably fabricated from copper. The moving contact support24is reinforced by a moving contact reinforcement cone26preferably fabricated from stainless steel. Both the moving contact support24and the moving contact reinforcement cone26are on a moving contact rod28preferably fabricated from copper. The moving contact rod28is reinforced by a reinforcing rod30preferably fabricated from stainless steel and is sealingly passed through the end cup12A and the triple point shield14A by a bellows32to allow electrical connection to the source line. The bellows32is preferably fabricated from stainless steel. The end of the reinforcing rod30is preferably threaded and extends beyond the lower end of the moving contact rod28to facilitate the attachment of a drive rod from an external drive mechanism (not shown). The bellows32is preferably protected from vaporized material damage by a bellows shield34. The bellows shield34is preferably fabricated from stainless steel.

A bellows anti-twist housing36preferably fabricated from stainless steel is attached to the opposite side of end cup12A and is centered by a circular depression formed in the end cup12A. With reference toFIG. 1a, the bellows anti-twist housing36is indexed to the moving contact rod28by a hardened pin38preferably fabricated from nickel plated steel, which passes through a cross-hole40in the moving contact rod28and slides in a slot42in the bellows anti-twist housing36. Two threaded holes39are formed in the bellows anti-twist housing36to facilitate attachment of a current exchange housing126.

A second contact system13includes the extension of the moving contact rod28, which passes through the moving contact support24. A disc shaped moving contact support44preferably fabricated from copper is attached to an end of the moving contact rod28. A moving contact disc46preferably fabricated from copper tungsten is attached to the moving contact support44. The second contact system13further includes a floating contact48preferably fabricated from copper tungsten, which is attached to an end of a disc-shaped floating contact support50preferably fabricated from copper. The floating contact support50is attached to a floating contact rod52preferably fabricated from copper, which is reinforced by a reinforcing rod54preferably fabricated from stainless steel and sealingly passed through the end cup12B and triple point shield14B by a bellows56. Bellows56is protected from damage by vaporized material by a bellows shield58. The bellows56and the bellows shield58are preferably fabricated from stainless steel. A mechanism housing60preferably fabricated from stainless steel is attached to the opposite side of end cup12B and is centered by the circular depression formed in the end cup. The mechanism housing60is indexed to the floating contact rod52by a hardened pin62preferably fabricated from a nickel plated steel passes through a cross-hole64in the floating contact rod52and slides in a slot66in the mechanism housing60. During a brazing cycle for the vacuum switch pin62; the vacuum switch pin62is replaced by a fixture pin to assure the alignment of these parts.

An operating mechanism for the floating contact15includes the mechanism housing60into which is threaded a threaded adjuster68preferably fabricated of brass. The mechanism housing60has two slots66located at opposite sides of its circumference. The threaded adjuster68preferably has six slots70equally spaced around its perimeter so that pin62can be inserted into any opposite facing pair of slots70during the adjustment process. When threading the threaded adjuster68into the mechanism housing60, the pin62is withdrawn from the mechanism housing60. The threaded adjuster68is positioned so that one pair of slots70line up with the cross hole64in the floating contact rod52. A top of the slot70is preferably 0.031 inch above cross-hole64.

During this adjustment, both the first and second set of contacts must be closed. The pin62is then inserted back through the mechanism housing60, the threaded adjuster68and the floating contact rod52. The pin62is held in place by a pair of retaining rings61A and61B and a pair of washers63A and63B. The retaining rings61A,61B and the pair of washers63A,63B are both preferably fabricated from steel. A compression spring72preferably made of music wire is inserted into a counter-bore in threaded adjuster68and a threaded spring retainer74is tightened. The threaded spring retainer is preferably fabricated from a nickel plated steel. The pin62prevents rotation of the floating contact rod52relative to the mechanism housing60.

The compression spring72forces the pin62to the bottom of the slot70. The length of the slots70in the threaded adjuster68is calculated to provide a desired pre-insertion time based on the speed of the contacts plus an allowance for wear of the contacts. For example, with a contact speed of 3 feet/second and allowable wear of 0.031 inch, the slot70would be approximately 0.187 inch long end to end. The slots66in the mechanism housing60have a minimum length equal to the tolerance build-up between the location of the cross hole64in floating contact rod52and the end of the second moving contact46plus the length of the slots70in the threaded adjuster68. This allows the threaded adjuster68to be able to be adjusted through the full range of possible locations of the cross hole64.

In order to facilitate encapsulation of an end of the vacuum switch1; a cover housing102and cover plate104are placed over the mechanism housing60as shown inFIG. 2. The cover housing102is preferably fabricated from an aluminum material. The cover plate104is preferably fabricated from an insulating material such as GP01 or GP03 fiberglass or G10 epoxy glass.

A pair of studs106A and106B preferably fabricated from stainless steel are attached to an outside surface of the end cup12B. An insulating stringer108A and108B preferably fabricated from a filament wound epoxy glass is threaded onto each stud106A and106B. A screw110A and110B preferably fabricated from stainless steel is threaded into an opposite end of each stringer108A and108B to retain the cover plate104and the cover housing102. A split-clamp connector112preferably fabricated from copper is tightened onto an end of floating contact rod52using a bolt114and a nut116. A pair of highly flexible multi-stranded conductors118A and118B preferably fabricated from copper are conductively secured to the split clamp connector112on one end and to a terminal connector120preferably fabricated from copper on the other end thereof. The terminal connector120is preferably threaded onto a lower portion of a pre-insertion terminal122and secured with a jam nut124; creating a current exchange between the floating contact rod52and the pre-insertion terminal122. The terminal connector122is preferably fabricated from copper and the jam nut124from brass.

The opposite end of the vacuum switch1is prepared for encapsulation by installation of the current exchange housing126preferably fabricated from copper and a multi-lam contact128. The current exchange housing126is placed over the bellows anti-twist housing36. The multi-lam contact128provides electrical contact between the moving contact rod28and the current exchange housing126. The current exchange housing126is secured to the bellows anti-twisting housing36with a pair of bolts130A and130B preferably fabricated from stainless steel. A threaded hole133in a perimeter of the current exchange housing126allows the attachment of a terminal rod132preferably fabricated from copper to facilitate electrical connection to a source line.

There are several examples of prior art patents, which show the encapsulation of vacuum modules.FIG. 3indicates one possible way of encapsulating the aforementioned vacuum switch as demonstrated by U.S. Pat. No. 5,917,167. In this case, a substantial portion of the invention202is encased in a tube204and cast in an encapsulation206. The tube204is preferably a silicone rubber and the encapsulation is preferably an epoxy. The result is a three terminal encapsulation with a source terminal208, a load terminal210and a pre-insertion terminal212. A pair of pre-insertion resistors or inductors214A and214B are connected from the pre-insertion terminal212to the load terminal210utilizing [stainless steel] brackets216,218and220, [tin plated phosphor bronze] bolts222A-D and [tin plated phosphor bronze] nuts224A-H. The brackets216-220are preferably stainless steel. The bolts222A-D and nuts224A-H are preferably fabricated from tin plated phosphor bronze. This places the pre-insertion components electrically in series with the aforementioned second contact system and this series combination electrically in parallel with the first contact system.

In operation, the aforementioned encapsulated vacuum switch would be coupled via an operating rod228as shown inFIG. 4with contact pressure spring means230to an operating mechanism (not shown). The closing stroke of the operating mechanism and operating rod228would drive the moving contact rod28upward. Because of the aforementioned adjustment of the threaded adjuster68, when the spring72is installed the pin62is forced to the bottom of the slot66which causes the floating contact rod52to be pushed downward. This causes the second set of contacts to engage in advance of the first set of contacts by preferable dimension of 0.156 inch (the total length of slot66minus the 0.031 wear allowance). Once the second set of contacts46and48engages, electric current flows from the source terminal208, through the second set of contacts and through the pre-insertion resistors or inductors and out the load terminal210. As the moving contact rod28continues its closing stroke, the floating contact rod52is driven upward resulting in the pin62moving upward in slot66and compressing spring72. The closing stroke is completed; when moving contact rod28is driven to the point that the first set of contacts20and22make. At this point, the electric current flows from the source terminal208through the first set of contacts and directly out the load terminal210, bypassing the second set of contacts and the pre-insertion resistors or inductors214A,214B. The operation results in the pre-insertion resistors or inductors214A,214B being in the circuit for approximately ¼ cycle of the 60 cycle wave. During this time, the in-rush current experienced during energizing of parallel bank capacitors (not shown) would be damped.

Upon initiation of the opening stroke, the moving contact rod28moves downward causing the first set of contacts20and22to immediately part. However, the energy stored in the spring72forces the floating contact rod52downward maintaining contact through the second set of contacts46and48. This re-establishes current flow through the pre-insertion resistors or inductors and results in an essentially arc-less parting of the first set of contacts. As moving contact rod28continues its opening stroke, the floating contact rod52continues to move downward, until the pin62is driven to the bottom of slot66. At this point, floating contact rod52is no longer able to follow the contact rod28downward and the second set of contacts46and48begins to part initiating an arc. With the pre-insertion resistors or inductors now back in series with the circuit the transient recovery voltage transient is damped resulting in an efficient interruption of the arc as the moving contact rod28completes its opening stroke and provides the full open gap for the second set of contacts.