Patent Application
20080094156
The present invention relates to a method for safe operation of a switching device as claimed in the precharacterizing clause of claims 1 and 3, and to a corresponding apparatus as claimed in the precharacterizing clause of claims 8 and 10.
Switching devices, in particular low-voltage switching devices, can be used to switch the current paths between an electrical supply device and loads, and therefore to switch their operating currents. This means that the switching device opens and closes current paths, allowing the connected loads to be safely connected and disconnected.
An electrical low-voltage switching device, such as a contactor, a circuit breaker or a compact starter, has one or more so-called main contacts, which can be controlled by one or else more control magnets, in order to switch the current paths. In principle, in this case, the main contacts comprise a moving contact link and fixed contact pieces, to which the loads and the supply device are connected. In order to close and open the main contacts, an appropriate connection or disconnection signal is passed to the control magnets, in response to which their armatures act on the moving contact links such that the latter carry out a relative movement with respect to the fixed contact pieces, and either close or open the current paths to be switched.
Appropriately designed contact surfaces are provided in order to improve the contact between the contact pieces and the contact links at points at which the two meet one another. These contact surfaces are composed of materials such as silver alloys, which are applied at these points both to the contact link and to the contact pieces, and have a specific thickness.
The materials of the contact surfaces are subject to wear during every switching process. Factors which can influence this wear are:
This results in the operating currents no longer being safely switched, which can lead to current interruptions, contact heating or to contact welding.
For example, particularly as the contact erosion increases, the thickness of the materials applied to the contact surfaces will decrease. The switching movement between the contact surfaces of the contact link and the contact pieces therefore becomes longer, thus in the end reducing the contact force on closing. As the number of switching processes increases, this results in the contacts no longer closing correctly. The resultant current interruptions or else the increased connection bouncing can then lead to contact heating and thus to increasing melting of the contact material, which can in turn then lead to welding of the contact surfaces of the main contacts.
If a main contact of the switching device has become worn or even welded, the switching device can no longer safely disconnect the load. In particular in the case of a welded contact, at least the current path with the welded main contact will still continue to carry current and will still be live, despite the disconnection signal, so that the load is not completely isolated from the supply device. Since, in consequence, the load remains in a non-safe state, the switching device represents a potential fault source.
The protective function can thus be blocked, for example, in the case of compact starters according to IEC 60 947-6-2, in which an additional protection mechanism acts on the same main contacts as the control magnet during normal switching.
Fault sources such as these must therefore be avoided for safe operation of switching devices and thus for protection of the load and of the electrical installation.
European Laid-Open Specification EP 1 002 325 A1 discloses a relatively complex method for identification of the remaining electrical life of contacts, in which contact welding during disconnection of the switching device is identified by existing or additional means. The risk resulting from major electrical faults for loads and electrical installations is thus overcome by emitting a message and/or by ceasing switching operation, in particular after short-circuit switching operations.
European Laid-Open Specification EP 0 832 496 A1 discloses a method in which contact welding in the switching device is detected by monitoring the switching device drive. A series-connected second switching device is operated in order to interrupt the circuit when the switching device drive does not reach its normal disconnected position during the disconnection process.
The object of the present invention is to identify such potential fault sources, and to react appropriately to them.
This object is achieved by the method having the features of claims 1 and 3 and by the apparatus having the features of claims 8 and 10. A suitable switching device is specified in claims 15 and 16. Dependent claims 2, 4 to 7, 9, 11 to 14 and 17 contain advantageous developments of the method and of the apparatuses.
The present invention makes it possible to identify a welded contact during connection and disconnection of the switching device, and then to break open the welded contact, with little complexity.
The invention relates to a method and an apparatus for safe operation of a switching device having at least one main contact which can be connected and disconnected and has contact pieces and a moving contact link. The switching device has at least one control magnet with a moving armature, with the armature acting on the contact link during connection and disconnection such that the corresponding main contact is closed and opened. A switching contact is provided, which has an ON state and an OFF state corresponding to a closed position and an open position of the armature.
According to the invention, in a first step, an electrical drive signal is produced for initiation of a contact breaking-open means on connection and/or disconnection of the control magnet, with the drive signal being emitted such that it is outside the ON state of the switching contact during normal operation of the switching device. In a second step, in the event of a fault, in particular in the event of at least one main contact of the switching device being welded, the contact breaking-open means is initiated if the switching contact remains or has remained in the ON state on connection or disconnection of the control magnet, in that the switching contact passes on the drive signal in order to initiate the contact breaking-open means.
Alternatively, according to the invention, an electrical drive pulse for possible initiation of a contact breaking-open means on connection and/or disconnection of the control magnet is produced in a first step, with the respective time duration of the drive pulse being designed such that it occurs at a time within the OFF state of the switching contact during normal operation of the switching device. In a second step, the contact breaking-open means is initiated in that the switching contact passes on the drive pulse for initiation of the contact breaking-open means if the switching contact remains or has remained in the ON state on connection or disconnection of the control magnet.
The essence of the invention is the production of suitable electrical signals which allow the initiation of a contact breaking-open means.
The particular advantage of the invention is that the presence of at least one welded main contact in the switching device can be checked for during every switching operation. In the event of a fault, the at least one welded main contact can be broken open by initiation of a contact breaking-open means. Additionally or alternatively, appropriate warning signals can be produced, which indicate that operation of the switching device is not safe.
The method according to the invention and the apparatus according to the invention therefore ensure safe operation of a multipole switching device, such as a contactor, a circuit breaker or a compact outgoer and, in particular, safe operation of a three-pole switching device.
In particular, the electrical drive pulse is delayed by a predetermined value during disconnection of the switching device. This delay may, for example, be produced by an OFF-delayed break contact.
Alternatively, the electrical drive pulse can also be produced by means of an electronic circuit. At least one pulse generator, such as a monostable multivibrator or a so-called monoflop, and a time delay element can be provided for this purpose in order to produce the time delay for the electrical drive pulse and, if required, for the time delay.
Furthermore, further operation of the switching device can be interrupted once the contact breaking-open means has been initiated. The blocking of normal switching can be indicated and/or processed further by means of a display, by a mechanical indication and reset element, by a signaling contact or via a data bus.
Further advantageous embodiments and preferred developments of the invention are specified in the dependent claims.
The invention as well as advantageous embodiments of it will be described in more detail in the following text, with reference to the following figures, in which:
As illustrated in
In the alternative method according to the invention, the following steps are both essentially carried out:
This ensures that at the end of the life of the switching device, that is to say when the contact materials on the contact surfaces have in particular been worn away to such an extent that at least one main contact has become welded, this welded contact can be broken open, thus ensuring safe operation of the switching device.
The method according to the invention is used for switching devices whose normal switching is carried out by controllable drives, such as remotely operated switches, contactors or circuit breakers.
The initiation process unlocks a force energy store, such as a latching mechanism, by which means the welded contacts are broken open. Furthermore, an electrically operated force element may be provided in order to break open the welded contacts. In order to disconnect the current flow to the load in the event of strong contact welding which cannot be broken open by the latching mechanism, the latching mechanism can operate a further contact opening mechanism which allows the switching contacts to be opened independently of one another. This results in the contacts that are not welded being opened by the latching mechanism, and in the current flow being interrupted.
The pulse delay and the drive pulse can be provided in a known manner by mechanical, electromechanical or electronic means, and the electrical energy that is required can be provided by an electrical energy store, for example by means of a capacitor or a coil. The control voltage for the circuit breaker can be used for electrical charging of the energy store.
The apparatus according to the invention will be described in more detail in the following text with reference, by way of example, to two exemplary embodiments.
For example,
The example in
During connection of the electromagnetic drive or of the control magnet for the switching device, the armature moves in the closing direction, provided that the contacts are not welded, once the magnetic force has increased above the level of the force difference comprising the spring opening force of the armature and the contact load on the moving contacts. After a closing movement of a few millimeters, for example 4 mm, the moving contacts, which are coupled to the armature via mechanical operating elements, strike the fixed contacts of the switching device. The pressure required for a secure contact force on the switching contacts is built up by the further closing movement of the armature. The overall armature movement from the start of armature movement to the connected position may, for example, be 6 mm. A typical closing time of 10 to 30 milliseconds with a closing speed of between 0.5 and 2 m/s is achieved in the case of switching devices, such as contactors, during the accelerated closing movement of the armature from the disconnected position to the connected position. During this process, the majority of the closing time is taken up by the movement from the disconnected position of the moving contacts to the point at which they touch the fixed contacts. The operation of the electrical contact 4 is linked to the movement of the armature, with the electrical contact 4 being open in the armature open position and being closed at a specific armature position during the armature closing movement. This armature position is defined such that this contact 4 will undoubtedly be closed in the event of contact welding and when the control magnet is disconnected.
According to the invention, an electrical drive signal is now emitted in order to initiate the contact breaking-open means 6. This is achieved by the electrical break contact 3 being opened on or shortly after the presence of the connection command, that is to say on the application of the switching voltage Us, before the electrical make contact 4 closes on reaching the switch position of the armature in the area of the contact touching point, during normal switching operation.
On disconnection of the control magnet, the magnetic field is first of all dissipated before the start of the armature opening movement,
until the magnetic armature closing force becomes weaker than the armature opening force. After an opening movement of a few millimeters, the armature or the contact slide which is connected with a force fit to it strikes the moving contacts of the switching device, and opens them, provided that the main contacts are not welded. The make contact 4, which is operated by the armature movement, opens its contact at the predetermined position of the armature, and remains in the disconnected state during the rest of the armature opening movement. The time period from the disconnection command for the switching device to safe disconnection of the make contact 4 governs the minimum duration for the predetermined delay time of the drive signal for driving the initiation unit 5. During normal operation, the drive signal is thus deactivated before or at the end of the delay time during disconnection by means of the make contact 4, and is maintained until the next connection command. During disconnection of the switching device, that is to say on removal of the switching voltage Us, the break contact 3 moves back with the predetermined delay time, such as 100 ms, once the make contact 4 has already been opened again, during normal switching operation. The alternate OFF position of the switching contacts 3 and 4 during normal switching operation means that no current iA can flow to the initiation unit 5 in order to initiate the contact breaking-open means 6.
According to the invention, during faulty operation of the switching means, the contact breaking-open means 6 is now initiated if the switching contact 4 remains or has remained in the ON state on connection or disconnection of the control magnet. This then passes on the drive signal in order to initiate the contact breaking-open means 6, by supplying current iA to the initiation unit 5. The drive signal can in this case be regarded as an enable signal, which is applied to the initiation unit 5 during connection and in the event of a break contact 3 already being closed, in the form of the switching voltage Us and is applied to the initiation unit 5 during disconnection and after the break contact 3 “remains closed” in the form of the buffered switching voltage Us.
Contact welding is thus reliably identified during disconnection of the switching device, and the latching mechanism 6 is unlatched by the initiation unit 5. When the welded contacts are broken open, the circuit to the load is disconnected, and the switching device is inhibited from further normal switching.
The switching device can be used again only after the welded contacts have been broken open or new contacts have been fitted. Current can therefore no longer flow via the switching contacts. If a number of such connection attempts are made, the latching mechanism carries out the same number of additional attempts to break open the welded contacts, by which means it is generally possible to overcome medium-strength welded contacts.
The make contact 4 connects or disconnects the field circuit for the initiation unit, and may also be in an electronic form, switchable by sensor control. The make contact 4 may, for example, be a reed relay, which is made to close and open by a permanent magnet fitted to the armature. The make contact 4 may also be a positively guided mechanical switching element which is operated by the armature or by a mechanical component coupled to it. A mechanical circuit, an electromechanical circuit or an electronic circuit is used to derive a time-delayed drive signal from the disconnection command for the control magnet for the initiation unit 5, which drive signal is fed through the electrical energy store and, if contacts are welded, operates the initiation unit 5 and unlatches the latching mechanism 6 of the switching device. This is described in detail in the next figure,
The signal P is produced by means of a monostable multivibrator 10 or a monoflop 10 as a pulse generator, which reacts to a positive-edge-triggered input signal. In the present case, the input signal is the switching voltage Us. This means that, during connection of the switching device, the monoflop 10 generates a square-wave pulse with a predetermined time duration TP, which is then present in the sum signal S as a drive pulse PL. The time duration TP is therefore designed such that the drive pulse PL has already “passed” before the make contact 4 closes during normal switching operation. On the other hand, the drive pulse TP must be present for a minimum time so that the downstream initiation unit 5 can still be initiated. The initiation mechanism may, for example, be in an electromagnetic, pyrotechnic or motor form. The time duration TP is, for example, in the region of a few milliseconds.
The signal V is delayed by means of a time delay element 12 by a time period TV of a few milliseconds with respect to a signal N. The signal N is in this case generated by means of a further monostable multivibrator 11 or a further monoflop 11, which reacts to a negative-edge-triggered input signal. In the present case, the input signal is once again the switching voltage Us. This means that, during disconnection of the switching device or when there is no switching voltage Us, the monoflop 11 generates a square-wave pulse with a predetermined time duration TN, which is then present in the sum signal S as the drive pulse PL, delayed by the time period TV. The time duration TN is designed such that the drive pulse PL is sufficiently long to still cause the initiation unit 5 to be initiated and is delayed by a time period TV such that the make contact 4 has closed again during normal switching operation. The time period TP is therefore in the region of a few milliseconds.
A series circuit comprising a diode 7 and an energy storage capacitor 2, and connected in parallel with the terminals, is illustrated in the left-hand part of the monitoring apparatus 1. The diode 7 is used for decoupling the voltage across the capacitor 2 from the switching voltage Us, so that the electronic circuit 8 can still be supplied with current in order to generate the drive pulses PL when there is no switching voltage Us.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2004 062 266.3 | Dec 2004 | DE | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/EP05/57076 | 12/22/2005 | WO | 6/21/2007 |
