MODULAR MULTIPLE SINGLE-POLE ELECTROMAGNETIC SWITCHING SYSTEM AND METHOD

• US 20160134210A1
• Filed: 08/21/2015
• Published: 05/12/2016
• Est. Priority Date: 11/06/2014
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Inventors: Bock, Christopher H., Wieloch, Christopher J., Kinsella, James J., Dziekonski, Stefan T., Miller, James P.
• Granted Patent: US 9,806,642 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H01H 50/002 particular to three-phase electromagnetic relays synchronous switching H01H9/563
• CPC Class Codes: H01H 50/048 Plug-in mounting or sockets
• CPC Class Codes: H01H 50/323 for interlocking two or more relays
• CPC Class Codes: H01H 50/86 Means for introducing a predetermined time delay between the initiation of the switching operation and the opening or closing of the contacts circuit arrangements for introducing delay H01H47/18; short-circuited conducting sleeves, bands, or discs H01H50/46
• CPC Class Codes: H01H 9/48 Means for preventing discharge to non-current-carrying parts, e.g. using corona ring
• CPC Class Codes: H01H 9/56 for ensuring operation of the switch at a predetermined point in the ac cycle
• CPC Class Codes: H01H 9/563 for multipolar switches, e.g. different timing for different phases, selecting phase with first zero-crossing
• CPC Class Codes: H02P 1/32 by star/delta switching
• CPC Class Codes: H02P 1/40 in either direction of rotation
• CPC Class Codes: H02P 1/52 by progressive increase of frequency of supply to motor

Abstract

One embodiment describes a wye-delta starter, which includes a first single pole, single current carrying path switching device that selectively connects and disconnects a first winding of a motor in a wye configuration; a second single pole, single current carrying path switching device that selectively connects and disconnects the first winding in a delta configuration, in which the first switching device and the second switching device are coupled via a first interlock; a third single pole, single current carrying path switching device that selectively connects and disconnects a second winding and a third winding of the motor in the wye configuration; a fourth single pole, single current carrying path switching device that selectively connects and disconnects the second winding in the delta configuration, in which the third switching device and the fourth switching device are coupled via a second interlock; and a fifth single pole, single current carrying path switching device that selectively connects and disconnects the third winding in the delta configuration.

Claims

1. A wye-delta starter comprising:

a first single pole, single current carrying path switching device configured to selectively connect and disconnect a first winding of a motor in a wye configuration;

a second single pole, single current carrying path switching device configured to selectively connect and disconnect the first winding in a delta configuration, wherein the first switching device and the second switching device are coupled via a first interlock;

a third single pole, single current carrying path switching device configured to selectively connect and disconnect a second winding and a third winding of the motor in the wye configuration;

a fourth single pole, single current carrying path switching device configured to selectively connect and disconnect the second winding in the delta configuration, wherein the third switching device and the fourth switching device are coupled via a second interlock; and

a fifth single pole, single current carrying path switching device configured to selectively connect and disconnect the third winding in the delta configuration.

2. The wye-delta starter of claim 1, wherein the switching devices are substantially identical to one another.

3. The wye-delta starter of claim 1, comprising at least one bus coupled at least to load sides of at least two of the switching devices to pair the coupled devices for routing power to or from the paired devices.

4. The wye-delta starter of claim 1, wherein the switching devices are mounted to a common wiring and/or control base that provides control signals and/or power to or from the switching devices.

5. The wye-delta starter of claim 4, wherein the switching devices comprise plug-in terminals from plugging the devices into the base.

6. The wye-delta starter of claim 1, wherein:

the first single pole, single current carrying path switching device is configured to selectively connect the first winding based on a first predicted current zero-crossing and disconnect the first winding based on a first current zero-crossing;

the second single pole, single current carrying path switching device is configured to selectively connect first winding based on a second predicted current zero-crossing and disconnect the first winding based on a second current zero-crossing;

the third single pole, single current carrying path switching device is configured to selectively connect the second winding and the third winding of the motor based on a third predicted current zero-crossing and disconnect the second winding and the third winding of the motor based on a third current zero-crossing;

the fourth single pole, single current carrying path switching device is configured to selectively connect the second winding based on a fourth predicted current zero-crossing and disconnect the second winding based on a fourth current zero-crossing; and

the fifth single pole, single current carrying path switching device is configured selectively connect the third winding based on a fifth predicted current zero-crossing and disconnect the third winding based on a fifth current zero-crossing.

7. The wye-delta starter of claim 1, comprising:

a first mains switching device configured to selectively connect and disconnect a first phase of electric power to the wye-delta starter;

a second mains switching device configured to selectively connect and disconnect a second phase of electric power to the wye-delta starter; and

a third mains switching device configured to selectively connect and disconnect a third phase of electric power to the wye-delta starter.

8. The wye-delta starter of claim 1, wherein:

the first and second single pole, single current carrying path switching devices are substantially identical to one another; and

the third, fourth, and fifth single pole, single current carrying path switching device are substantially identical to one another.

9. A motor reverser comprising:

a first single pole, single current carrying path switching device configured to selectively connect and disconnect a first phase of electric power to a first terminal of a motor;

a second single pole, single current carrying path switching device configured to selectively connect and disconnect a second phase of electric power to the first terminal of the motor, wherein the first switching device and the second switching device are coupled via a first interlock;

a third single pole, single current carrying path switching device configured to selectively connect and disconnect the first phase of electric power to a second terminal of the motor;

a fourth single pole, single current carrying path switching device configured to selectively connect and disconnect the second phase of electric power to the second terminal of the motor, wherein the second third switching device and the fourth switching device are coupled via a second interlock; and

a fifth single pole, single current carrying path switching device configured selectively connect and disconnect a third phase of electric power to a third terminal of the motor.

10. The motor reverser of claim 9, wherein the motor actuates in a first direction when the first switching device, the fourth switching device, and the fifth switching device are closed, and actuates in a second direction when the second switching device, the third switching device, and the fifth switching device are closed.

11. The motor reverser of claim 10, wherein:

an input terminal of the first switching device and an input terminal of the third switching device are coupled via a first bus bar;

an input terminal of the second switching device and an input terminal of the fourth switching device are coupled via a second bus bar;

an output terminal of the first switching device and an output terminal of the second switching device are coupled via a third bus bar; and

an output terminal of the third switching device and an output terminal of the fourth switching device are coupled via a fourth bus bar.

12. The motor reverser of claim 9, wherein the switching devices are substantially identical to one another.

13. The motor reverser of claim 9, wherein the switching devices are mounted to a common wiring and/or control base that provides control signals and/or power to or from the switching devices.

14. The motor reverser of claim 9, wherein:

the first single pole, single current carrying path switching device is configured to selectively connect the first phase of electric power to the first terminal based on a first predicted current zero-crossings and disconnect the first phase of electric power to the first terminal based on a first current zero-crossings

the second single pole, single current carrying path switching device is configured to selectively connect the second phase of electric power to the first terminal based on a second predicted current zero-crossing and disconnect the second phase of electric power to the first terminal based on a second current zero-crossing;

the third single pole, single current carrying path switching device is configured to selectively connect the first phase of electric power to the second terminal based on a third predicted current zero-crossing and disconnect the first phase of electric power to the second terminal based on a third current zero-crossing;

the fourth single pole, single current carrying path switching device is configured to selectively connect the second phase of electric power to the second terminal based on a fourth predicted current zero-crossing and disconnect the second phase of electric power to the second terminal based on a fourth current zero-crossing; and

the fifth single pole, single current carrying path switching device is configured selectively connect the third phase of electric power to the third terminal based on a fifth predicted current zero-crossing and disconnect the third phase of electric power to the third terminal based on a fifth current zero-crossing.

15. A motor drive bypass comprising:

a first single pole, single current carrying path switching device configured to selectively connect and disconnect a first phase of electric power to a first input of a motor drive;

a second single pole, single current carrying path switching device configured to selectively connect and disconnect a second phase of electric power to a second input of the motor drive;

a third single pole, single current carrying path switching device configured to selectively connect and disconnect a third phase of electric power to a third input of the motor drive;

a fourth single pole, single current carrying path switching device configured to selectively connect and disconnect a first output of the motor drive to a first terminal of a motor;

a fifth single pole, single current carrying path switching device configured to selectively connect and disconnect a second output of the motor drive to a second terminal of the motor;

a sixth single pole, single current carrying path switching device configured selectively connect and disconnect a third output of the motor drive to a third terminal of the motor;

a seventh single pole, single current carrying path switching device configured to selectively connect and disconnect the first phase of electric power directly to the first terminal of the motor;

an eighth single pole, single current carrying path switching device configured to selectively connect and disconnect the second phase of electric power directly to the second terminal of the motor; and

a ninth single pole, single current carrying path switching device configured to selectively connect and disconnect the third phase of electric power directly to the third terminal of the motor.

16. The motor drive bypass of claim 15, wherein:

the seventh single pole, single current carrying path switching device is configured to selectively connect the first phase of electric power directly to the first terminal based on predicted current zero-crossings and disconnect the first phase of electric power directly to the first terminal based on current zero-crossings;

the eighth single pole, single current carrying path switching device is configured to selectively connect the second phase of electric power directly to the second terminal based on predicted current zero-crossings and disconnect the second phase of electric power directly to the second terminal based on current zero-crossings; and

the ninth single pole, single current carrying path switching device is configured to selectively connect the third phase of electric power directly to the third terminal based on predicted current zero-crossings and disconnect the third phase of electric power directly to the third terminal based on current zero-crossings.

17. The motor drive bypass of claim 15, wherein the switching devices are substantially identical to one another.

18. The motor drive bypass of claim 15, comprising at least one bus coupled at least to load sides of at least two of the switching devices to pair the coupled devices for routing power to or from the paired devices.

19. The motor drive bypass of claim 15, comprising

a first mechanical interlock coupled between the fourth switching device and the seventh switching device;

a second mechanical interlock coupled between the fifth switching device and the eighth switching device; and

a third mechanical interlock coupled between the sixth switching device and the ninth switching device.

20. A modular electromechanical switching system comprising:

a first single pole, single current carrying path switching device configured to selectively switch between conducting and non-conducting states;

a second single pole, single current carrying path switching device configured to selectively switch between conducting and non-conducting states;

a third single pole, single current carrying path switching device configured to selectively switch between conducting and non-conducting states;

a wiring and/or control base, each of the switching devices being pluggable into the base to receive at least control signals for controlling switching of the devices between their respective conducting and non-conducting states.

21. The system of claim 20, wherein the base comprises control circuitry configured to control switching of the devices.

22. The system of claim 20, wherein the base provides both control signals and power to the devices.

23. The system of claim 20, wherein the switching devices are substantially identical to one another.

24. The system of claim 20, comprising at least one bus coupled at least to load sides of at least two of the switching devices to pair the coupled devices for routing power to or from the paired devices.

25. The system of claim 20, comprising:

a fourth single pole, single current carrying path switching device configured to selectively switch between conducting and non-conducting states; and

a fifth single pole, single current carrying path switching device configured to selectively switch between conducting and non-conducting states;

wherein the switching devices and the base are configured to form a wye-delta starter.

26. The system of claim 20, wherein the switching devices and the base are configured to form a motor reverser.

27. The system of claim 20, wherein the switching devices and the base are configured to form a motor drive bypass.

28. The system of claim 20, wherein the switching devices and the base are configured to form a direct-on-line switching device.

29. A modular electromechanical switching system comprising:

a plurality of modular single pole, single current carrying path switching devices configured to selectively switch between conducting and non-conducting states; and

a wiring and/or control base, each of the switching devices being pluggable into the base to receive at least control signals for controlling switching of the devices between their respective conducting and non-conducting states.

30. The system of claim 29, wherein each of the switching devices is configured to conduct a single phase of three-phase electrical power.

31. The system of claim 29, comprising an interlock disposed between and mechanically coupled to a pair of the switching devices to prevent the simultaneous closing of the pair of switching devices.

32. The system of claim 29, wherein the base comprises control circuitry configured to control switching of the devices.

33. The system of claim 32, wherein the base provides both control signals and power to the devices.

34. The system of claim 29, wherein the switching devices are substantially identical to one another.

35. The system of claim 29, comprising at least one bus coupled at least to load sides of at least two of the switching devices to pair the coupled devices for routing power to or from the paired devices.

36. The system of claim 29, wherein the switching devices and the base are configured to form a wye-delta starter.

37. The system of claim 29, wherein the switching devices and the base are configured to form a motor reverser.

38. The system of claim 29, wherein the switching devices and the base are configured to form a motor drive bypass.

39. The system of claim 29, wherein the switching devices and the base are configured to for a direct-on-line switching device.

40. A modular electromechanical switching system comprising:

a plurality of modular single pole, single current carrying path switching devices configured to selectively switch between conducting and non-conducting states;

a wiring and/or control base, each of the switching devices being pluggable into the base to receive at least control signals for controlling switching of the devices between their respective conducting and non-conducting states; and

control circuitry configured to provide control signals to the switching devices to cause at least one of the single-phase switching devices to open or close the single current carrying path at a time coordinated with a current zero-crossing or a predicted current zero-crossing of a phase of three-phase power in accordance with a point-on-wave (POW) switching scheme.

41. The system of claim 40, wherein the POW switching scheme causes at least one of the switching devices to open or close at or immediately before a current zero-crossing or a predicted current zero-crossing, and causes at least one other of the switching devices to open or close later in time.

42. The system of claim 40, wherein each of the switching devices is configured to conduct a single phase of three-phase electrical power.

43. The system of claim 40, comprising an interlock disposed between and mechanically coupled to a pair of the switching devices to prevent the simultaneous closing of the pair of switching devices.

44. The system of claim 40, wherein the base comprises control circuitry configured to control switching of the devices.

45. The system of claim 44, wherein the base provides both control signals and power to the devices.

46. The system of claim 40, wherein the switching devices are substantially identical to one another.

47. The system of claim 40, comprising at least one bus coupled at least to load sides of at least two of the switching devices to pair the coupled devices for routing power to or from the paired devices.

48. The system of claim 40, wherein the switching devices and the base are configured to form a wye-delta starter.

49. The system of claim 40, wherein the switching devices and the base are configured to form a motor reverser.

50. The system of claim 40, wherein the switching devices and the base are configured to form a motor drive bypass.

51. A modular electromechanical switching system comprising:

a plurality of modular single pole, single current carrying path switching devices configured to selectively switch between conducting and non-conducting states; and

a wiring and/or control base, each of the switching devices being pluggable into the base to receive at least control signals for controlling switching of the devices between their respective conducting and non-conducting states;

wherein pairs of the devices are spaced from one another;

control circuitry configured to provide control signals to the switching devices to cause at least one of the single-phase switching devices to open or close the single current carrying path at a time coordinated with a current zero-crossing or a predicted current zero-crossing of a phase of three-phase power in accordance with a point-on-wave (POW) switching scheme.

52. A wye-delta starter comprising:

a first single pole, single current carrying path switching device configured to selectively connect and disconnect a first winding of a motor in a wye configuration;

a second single pole, single current carrying path switching device configured to selectively connect and disconnect the first winding in a delta configuration, wherein the first switching device and the second switching device are coupled via a first interlock;

a third single pole, single current carrying path switching device configured to selectively connect and disconnect a second winding of the motor in the wye configuration;

a fourth single pole, single current carrying path switching device configured to selectively connect and disconnect the second winding in the delta configuration, wherein the third switching device and the fourth switching device are coupled via a second interlock;

a fifth single pole, single current carrying path switching device configured selectively connect and disconnect a third winding of the motor in the wye configuration; and

a sixth single pole, single current carrying path switching device configured to selectively connect and disconnect the third winding in the delta configuration, wherein the fifth switching device and the sixth switching device are coupled via a third interlock.

53. The wye-delta starter of claim 52, wherein the switching devices are substantially identical to one another.

54. The wye-delta starter of claim 52, wherein the switching devices are mounted to a common wiring and/or control base that provides control signals and/or power to or from the switching devices.

55. The wye-delta starter of claim 54, wherein the switching devices comprise plug-in terminals from plugging the devices into the base.

56. The wye-delta starter of claim 52, wherein:

the first single pole, single current carrying path switching device is configured to selectively connect the first winding based on predicted current zero-crossings and disconnect the first winding based on current zero-crossings;

the second single pole, single current carrying path switching device is configured to selectively connect the first winding based on predicted current zero-crossings and disconnect the first winding based on current zero-crossings;

the third single pole, single current carrying path switching device is configured to selectively connect the second winding based on predicted current zero-crossings and disconnect the second winding based on current zero-crossings;

the fourth single pole, single current carrying path switching device is configured to selectively connect the second winding based on predicted current zero-crossings and disconnect the second winding based on current zero-crossings;

the fifth single pole, single current carrying path switching device is configured selectively connect the third winding based on predicted current zero-crossings and disconnect the third winding based on current zero-crossings; and

the sixth single pole, single current carrying path switching device is configured selectively connect the third winding based on predicted current zero-crossings and disconnect the third winding based on current zero-crossings.

57. A switching device system comprising:

a first single pole, single current carrying path switching device configured to selectively connect and disconnect a first phase of electric power from a load;

a second single pole, single current carrying path switching device configured to selectively connect and disconnect a second phase of electric power form the load;

wherein the first and the second switching devices are configured to be spaced apart a first distance when the electric power is a first magnitude and to be spaced a second distance different from the first distance when the electric power is a second magnitude.

58. The switching device system of claim 57, wherein the first distance is greater than the second distance when the first magnitude is greater than the second magnitude.