Beruflich Dokumente
Kultur Dokumente
Robert Foster
Application Engineer
Megger
Paradise, CA 95969
Abstract
Time and travel analysis is the most important test used to determine the
correct operation of a circuit breaker. Although the majority of technicians
perform timing measurements; travel analysis, or motion measurements,
are often ignored. The motion measurement of the contacts and
mechanism in circuit breakers provide a variety of important information
when performing routine testing and maintenance; however it is a
practice that is marginalized due to its apparent difficulty and complexity.
Bypassing this measurement and its results can lead to a catastrophic
failure in the circuit breaker.
This paper will illustrate common best practices that simplify the
installation of the transducers and will explain the minimum amount of
information required for a test plan to obtain meaningful results. Speed
calculation points, conversion constants and conversion tables for
different manufactures will also be examined. In addition, there will be
graphical example results of different transducer attachment points on
the same breaker to show and analyze the effects of transducer
mountings on travel results.
This paper will enable the reader to have a better understanding of where
to install the transducer, how to properly set up the test plan, and it shall
give guidance for instances where the manufacturer provides a minimal
amount of data on travel analysis setup.
Introduction
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Many parameters are determined from the transducer but the most
important measurement is the stroke of the circuit breaker, in fact all
other parameters are derived from the stroke of the circuit breaker. The
stroke is defined as the total travel distance of the contacts from resting
position in one state, e.g. Closed, to the resting position in the other state
i.e. Open or vice versa. It is imperative that one is diligent in connecting
the transducer to the manufacturer’s recommended attachment point on
the circuit breaker and correcting for any multiplication factors if a direct
connection to the contacts cannot be made. At the very least the
technician must be consistent in measuring the stroke through periodic
maintenance in order to trend the results. If the circuit breaker is gang
operated i.e. it has one mechanism operating all 3 three phases then
only one transducer is needed, if the circuit breaker has separate
operating mechanisms for each phase, then an individual transducer
should be used for each mechanism.
Once the stroke of the circuit breaker is determined you can derive the
velocity of the contacts in different regions of the travel. The most
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By observing the closing time along with the travel measurement the
penetration or contact wipe can be determined, this is how far the
contacts are engaged. Penetration is the length measured from initial
contact touch to the final resting position after the operation. Overtravel is
measured directly from the travel curve and is the maximum
displacement past the resting position that the contacts reach during the
operation. Similarly, Rebound is measured from minimum displacement,
after the maximum displacement (Overtravel), to the final resting position
of the contacts. See Figure 1 for examples of the different parameters
that can be measured with a travel transducer. Other parameters can be
determined as well but they are all derivatives of the actual stroke
measurement of the contacts so it is important to connect the transducer
correctly and to accurately measure the stroke of the circuit breaker.
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There are two types of transducers used to measure the contacts of the
circuit breaker, linear or rotary. A linear transducer will measure a value
of length typically in either inches or millimeters whereas a rotary
transducer will measure a value of angle, typically degrees, which then
must be converted to inches or millimeters. There are various designs of
transducers such as resistive, optical, magnetic etc. but they generally
give an analog or digital output. Linear transducers are available in a
wide variety of lengths ranging from 25 mm or less, commonly used for
vacuum circuit breakers, all the way up to 1000 mm or more, typical
lengths are from 225-300 mm for SF6 dead tank circuit breakers and
500-600 mm for bulk oil circuit breakers. When first setting up for motion
measurements, the type of transducer to be used, rotary or linear, must
be selected. Although a lot of breakers allow you to use either type of
transducer, the manufacturer generally will specify a preference and it is
always recommended to use the manufacturer’s specified attachment
point, transducer type, and conversion factor (if needed).
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Rotary transducers have the advantage of being relatively small and with
a few accessories one kit can hook up to many different styles or types of
circuit breakers. The disadvantage of the rotary transducer is that you
need to know the conversion factor or table in order to calculate the
correct parameters of your circuit breaker. If the conversion factor or
table is not provided in the manual, the breaker manufacturer should be
contacted. Rotary transducers are most common on live tank SF6 circuit
breakers but are also used on certain types of dead tank SF6 breakers,
bulk oil circuit breakers and generator circuit breakers. See Figure 4 and
Figure 5 for examples of rotary transducer connections.
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factor applied to each transducer. The results are shown in Figure 12,
Figure 13, Figure 14, and Figure 15.
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From the results above it can be seen that even with three different
transducer attachment points and two different types of transducers, that
all three produce very similar results as long as the correct conversion
factor is applied. The maximum difference between stroke values is 0.2
mm on the close operation and 0.5 mm upon opening. Penetration,
overtravel, and rebound are very close for the three different
measurements too. One interesting observation is that the travel trace of
Linear A, the linear transducer connected directly to the mechanism, has
an oscillation throughout the entire movement, and Linear C, the linear
transducer connected to the end of the linkage, has a slight oscillatory
movement at the beginning and the end of travel. Most likely the flex in
the travel rod and the connection of the rod to the transducer is causing
some of this movement. Additionally since Linear A is connected directly
to the mechanism, the vibrations of the mechanism are affecting the
motion throughout the entire travel.
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Since the close operation requires more energy, closing the breaker and
charging the opening spring, this effect is more apparent on the close
operation.
One interesting note is that the velocity is different for each connection,
this is in part due to the calculation points being based on contact touch
and separation so the variance in the timing will affect where on the
curve the velocity is calculated. On Linear A the vibrations will also affect
the velocity calculations, if one of the speed calculation points rests on
the crest of an oscillation and the other speed calculation point rests on
the trough of an oscillation, the speed can vary dramatically compared to
points taken on a neutral part of the oscillation. This effect can be seen
by examining several operations in a row and observing that the velocity
of Linear A can vary by 0.16 m/s or 3%, whereas the other two
connections vary by a magnitude less. Play in the linkages will have
some effect on the velocity calculations. One last thing to consider is that
a linear conversion factor was assumed, i.e. a conversion constant was
used. Comparing Rotary B to Linear C, they align better at the beginning
and a the end of travel, in the middle of the movement they diverge
slightly, since this is the portion of the curve that velocity is calculated, it
follows that the speeds would diverge slightly as well. If the geometries
were analyzed and a conversion table was built for both connections,
they would most likely overlap throughout most of the travel and the
velocities would align more closely.
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Once again all three traces are very similar with a variance in stroke of
only 1.2 mm between the shortest and the longest phase. A few things to
note are that A phase begins to move approximately 0.5 ms before
phases B and C which can be expected since it is the closest connection
to the mechanism. Both A and C phase produce very smooth traces
throughout the motion but B phase has some oscillations in the first 20
ms of travel. These oscillations are most likely due to a mechanical
delay, B phase is pushed by the linkage from A phase and then it has to
push the linkage to phase C. Any mechanical play within the connections
between B and the other two phases will result in small perturbations.
The velocities of A and C are fairly close but B phase is 0.2 m/s slower.
This is most likely caused by two different factors, first the oscillations in
the trace can cause different speed points to be taken as mentioned
above, secondly the timing of the three phases is slightly different and
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All three traces practically lay on top of each other with no deviation until
the contacts reach the closed position. The stroke of the different phases
is closer with only a 0.5 mm difference between the shortest and the
longest phase. Once again the velocities of the three phases are different
but observing the contact times and speed calculation points shows that
the velocity is calculated at slightly different points on each curve thus
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changing the values slightly. If the speed calculation points are changed
to reference below closed and a differential, then B and C travel at the
same velocity while A phase travels slightly slower due to it having to
push the other two phases.
The first thing to look for in deciding where to connect the transducer is if
connection directly to the contacts or actuating arm of the contacts is
possible. Then a linear transducer can be connected and the correct
stroke, velocities and other parameters will be measured without the
need of a conversion table. If direct connection to the contacts is not
possible, which is often the case, then a spot that is very close to the
contacts with the minimal amount of linkages between the connection
point and the contacts should be selected; either a linear or rotary
transducer can be used. Per IEC 62271-100, the mechanical
characteristics can be recorded with a travel transducer at “convenient
locations on the drive to the contact system where there is a direct
connection, and a representative image of the contact stroke can be
achieved”. Connecting directly to the mechanism can cause unwanted
vibrations and influence the results, if possible this should be avoided. If
an indirect connection is used then there are two options, create a
conversion table/factor, or measure the absolute value of the motion, in
either length or angle, and trend the results with the transducer
connected in the same spot during future testing. If a conversion factor or
table is to be used, the connection points and linkages can be examined
and measured to develop a trigonometric function that relates the
transducer movement to the contact motion. The function can also be
determined from the mechanical drawings of the circuit breaker.
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If the stroke of the contacts are known, another, less accurate, method of
creating a conversion factor is to assume a linear relationship between
the connection point and the contacts. The known stroke of the contacts
can be divided by the measured stroke of the transducer to create the
conversion factor. This value can then be used to measure the travel
characteristics for initial fingerprint measurements and future testing. It
should be noted that if the relationship between the connection point and
the contacts is not linear, the other stroke dependent parameters such as
velocity, overtravel, rebound etc. may not be correct. Additionally, if this
measurement is made when there are issues with the circuit breaker i.e.
the stroke is not correct, the subsequent measurements will also be
incorrect. If there are other circuit breakers of the same type available it
is beneficial to compare measurements to verify the correction factor.
Conclusion
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Even if the original measurement points that the manufacturer used are
not known, valuable data will still be measured with a transducer as long
as it is placed in a sensible location. In fact, even if motion is measured
at different points on the circuit breaker, as long as the correct
conversion factor is applied, the results will come out very similar.
Lastly, once one type of connection and conversion factor is chosen, all
future measurements should be made using the same setup in order to
correctly trend the results.
Bibliography
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