Modular multiple single-pole electromagnetic switching system and method

• US 9,806,642 B2
• Filed: 08/21/2015
• Issued: 10/31/2017
• Est. Priority Date: 11/06/2014
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Bock, Christopher H., Wieloch, Christopher J., Kinsella, James J., Dziekonski, Stefan T., Miller, James P.
• Primary Examiner(s): Ro, Bentsu
• Assistant Examiner(s): DINH, THAI T
• Application Number:
  US14/832,744
• Publication Number:
  US 20160134210A1
• Time in Patent Office: 802 Days
• Field of Search: 318739, 318744, 318754, 318771, 318772, 318778, 318779, 361600, 361601, 361624, 361627, 361629, 361631, 361633, 361662
• 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 modular electromechanical switching system comprising:

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

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

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

a wiring base, wherein;

the first single pole, single current carrying path switching device is pluggable into the wiring base to receive a first control signal from control circuitry that instructs the first single pole, single current carrying path switching device to switch between the conducting state and the non-conducting state;

the second single pole, single current carrying path switching device is pluggable into the wiring base to receive a second control signal from the control circuitry that instructs the second single pole, single current carrying path switching device to switch between the conducting state and the non-conducting state; and

the third single pole, single current carrying path switching device is pluggable into the wiring base to receive a third control signal from the control circuitry that instructs the third single pole, single current carrying path switching device to switch between the conducting state and the non-conducting state.

2. The modular electromechanical switching system of claim 1, wherein the wiring base comprises control circuitry configured to:

control switching of the first single pole, single current carrying path switching device by generating the first control signal;

control switching of the second single pole, single current carrying path switching device by generating the second control signal;

control switching of the third single pole, single current carrying path switching device by generating the third control signal;

or any combination thereof.

3. The modular electromechanical switching system of claim 1, wherein:

the wiring base comprises;

a first conductive trace configured to receive the first control signal from control circuitry; and

a first terminal electrically coupled to the first conductive trace; and

the first single pole, single current carrying path switching device comprises;

a housing;

an operator coil disposed in the housing; and

a second terminal electrically coupled to the operator coil and extending downwardly through the housing, wherein the second terminal is electrically coupled to the first terminal of the wiring base when the first single pole, single current carrying path switching device is plugged into the wiring base to facilitate supplying the first control signal to the operator coil.

4. The modular electromechanical switching system of claim 3, wherein:

the wiring base comprises;

a second conductive trace configured to be electrically coupled to a power source;

a first line-side terminal electrically coupled to the second conductive trace;

a third conductive trace configured to be electrically coupled to an electrical load; and

a first load-side terminal electrically coupled to the third conductive trace; and

the first single pole, single current carrying path switching device comprises;

a second line-side terminal, wherein the second line-side terminal is electrically coupled to the first line-side terminal of the wiring base when the first single pole, single current carrying path switching device is plugged into the wiring base;

a second load-side terminal, wherein the second line-side terminal is electrically coupled to the first load-side terminal of the wiring base when the first single pole, single current carrying path switching device is plugged into the wiring base; and

an armature, wherein the operator coil is configured to actuate the armature based at least in part on the first control signal to selectively connect and disconnect the second line-side terminal and the second load-side terminal.

5. The modular electromechanical switching system of claim 1, wherein:

the first single pole, single current carrying path switching device is substantially identical to the second single pole, single current carrying path switching device; and

the second single pole, single current carrying path switching device is substantially identical to the third single pole, single current carrying path switching device.

6. The modular electromechanical switching system of claim 1, comprising:

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

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

wherein the first single pole, single current carrying path switching device, the second single pole, single current carrying path switching device, the third single pole, single current carrying path switching device, the fourth, single pole, single current carrying path switching device, and the fifth single pole, single current carrying path switching device are configured to be electrically coupled to form a wye-delta starter.

7. The modular electromechanical switching system of claim 1, wherein the first single pole, single current carrying path switching device, the second single pole, single current carrying path switching device, and the third single pole, single current carrying path switching device are configured to be electrically coupled to form a motor reverser.

8. The modular electromechanical switching system of claim 1, wherein the first single pole, single current carrying path switching device, the second single pole, single current carrying path switching device, and the third single pole, single current carrying path switching device are configured to be electrically coupled to form a motor drive bypass.

9. The modular electromechanical switching system of claim 1, wherein first single pole, single current carrying path switching devices, the second single pole, single current carrying path switching device, and the third single pole, single current carrying path switching device are configured to be electrically coupled to form a direct-on-line switching device.

10. A modular electromechanical switching system comprising:

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

a wiring base, wherein each of the plurality of module switching devices is pluggable into the wiring base to receive corresponding control signals from control circuitry that instruct a corresponding one of the plurality of modular single pole, single current carrying path switching devices to switch between the conducting state and the non-conducting state.

11. The modular electromechanical switching system of claim 10, wherein each of the plurality of modular single pole, single current carrying path switching devices is configured to control supply of a single phase of three-phase electrical power from a power source to an electrical load.

12. The modular electromechanical switching system of claim 10, comprising an interlock disposed between and mechanically coupled to a first switching device and a second switching device of the plurality of modular single pole, single current carrying path switching devices, wherein the interlock is configured to:

mechanically block switching of the first switching device from the non-conducting state to the conducting state while the second switching device is in the conducting state; and

mechanically block switching of the second switching device from the non-conducting state to the conducting state while the first switching device is in the conducting state.

13. The modular electromechanical switching system of claim 10, wherein the wiring base comprises control circuitry configured to control switching of each of the plurality of modular single pole, single current carrying path switching devices by generating the corresponding control signals.

14. The modular electromechanical switching system of claim 13, wherein:

the wiring base comprises;

a plurality of conductive traces configured to receive the corresponding control signals from control circuitry; and

a plurality of terminals each electrically coupled to a corresponding one of the plurality of conductive traces; and

each of the plurality of modular single pole, single current carrying path switching devices comprises;

a housing;

an operator coil disposed in the housing; and

a control terminal electrically coupled to the operator coil and extending downwardly through the housing, wherein the control terminal is configured to be plugged into a corresponding one of the plurality of terminals of the wiring base to facilitate supplying the corresponding control signals to the operator coil.

15. The modular electromechanical switching system of claim 10, wherein each of the plurality of modular single pole, single current carrying path switching devices is substantially identical.

16. The modular electromechanical switching system of claim 10, comprising a bus electrically coupled to a first load side of a first switching device of the plurality of modular single pole, single current carrying path switching devices and a second load side of a second switching device of the plurality of modular single pole, single current carrying path switching devices to facilitate routing power to or from the first switching device and the second switching device.

17. The modular electromechanical switching system of claim 10, wherein the plurality of modular single pole, single current carrying path switching devices are configured to be electrically coupled to form a wye-delta starter.

18. The modular electromechanical switching system of claim 10, wherein the plurality of modular single pole, single current carrying path switching devices are configured to be electrically coupled to form a motor reverser.

19. The modular electromechanical switching system of claim 10, wherein the plurality of modular single pole, single current carrying path switching devices are configured to be electrically coupled to form a motor drive bypass.

20. The modular electromechanical switching system of claim 10, wherein the plurality of modular single pole, single current carrying path switching devices are configured to be electrically coupled to form a direct-on-line switching device.

21. A modular electromechanical switching system comprising:

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

a wiring base, wherein each of the plurality of modular single pole, single current carrying path switching devices is pluggable into the wiring base to receive corresponding control signals from control circuitry that instruct a corresponding one of the plurality of modular single pole, single current carrying path switching devices to switch between the conducting state and the non-conducting state; and

control circuitry configured to generate the corresponding control signals to instruct at least one of the plurality of modular single pole, single current carrying path switching devices to open or close 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.

22. The modular electromechanical switching system of claim 21, wherein, when implementing the POW switching scheme, the control circuitry:

instructs a first switching device of the plurality of modular single pole, single current carrying path switching devices to open or close at or immediately before a current zero-crossing or a predicted current zero-crossing; and

instructs a second switching device of the plurality of modular single pole, single current carrying path switching devices to open or close later in time.

23. The modular electromechanical switching system of claim 21, wherein each of the plurality of modular single pole, single current carrying path switching devices is configured to control supply of a single phase of three-phase electrical power from a power source to an electrical load.

24. The modular electromechanical switching system of claim 21, comprising an interlock disposed between and mechanically coupled to a first switching device and a second switching device of the plurality of modular single pole, single current carrying path switching devices, wherein the interlock is configured to:

mechanically block switching of the first switching device from the non-conducting state to the conducting state while the second switching device is in the conducting state; and

mechanically block switching of the second switching device from the non-conducting state to the conducting state while the first switching device is in the conducting state.

25. The modular electromechanical switching system of claim 21, wherein the control circuitry configured to control switching of each of the plurality of modular single pole, single current carrying path switching devices by generating the corresponding control signals.

26. The modular electromechanical switching system of claim 25, wherein:

the wiring base comprises;

a plurality of conductive traces configured to receive the corresponding control signals from control circuitry; and

a plurality of terminals each electrically coupled to a corresponding one of the plurality of conductive traces; and

each of the plurality of modular single pole, single current carrying path switching-devices comprises;

a housing;

an operator coil disposed in the housing; and

a control terminal electrically coupled to the operator coil and extending downwardly through the housing, wherein the control terminal is configured to be plugged into a corresponding one of the plurality of terminals of the wiring base to facilitate supplying the corresponding control signals to the operator coil.

27. The modular electromechanical switching system of claim 21, wherein each of the plurality of modular single pole, single current carrying path switching devices is substantially identical.

28. The modular electromechanical switching system of claim 21, comprising a bus electrically coupled to a first load side of a first switching device of the plurality of modular single pole, single current carrying path switching devices and a second load side of a second switching device of the plurality of modular single pole, single current carrying path switching devices to facilitate routing power to or from the first switching device and the second switching device.

29. The modular electromechanical switching system of claim 21, wherein the plurality of modular single pole, single current carrying path switching devices are configured to be electrically coupled to form a wye-delta starter.

30. The modular electromechanical switching system of claim 21, wherein the plurality of modular single pole, single current carrying path switching devices are configured to be electrically coupled to form a motor reverser.

31. The modular electromechanical switching system of claim 21, wherein the plurality of modular single pole, single current carrying path switching devices are configured to be electrically coupled to form a motor drive bypass.

32. A modular electromechanical switching system comprising:

a plurality of modular single pole, single current carrying path switching devices configured to selectively switch between a conducting state and a non-conducting state, wherein a first switching device and a second switching device of the plurality of modular single pole, single current carrying path switching devices are spaced apart from one another;

a wiring base, wherein each of the plurality of modular single pole, single current carrying path switching devices is pluggable into the wiring base to receive corresponding control signals from control circuitry that instruct a corresponding one of the plurality of modular single pole, single current carrying path switching devices to switch between the conducting state and the non-conducting states; and

control circuitry configured to generate the corresponding control signals to instruct at least one of the plurality of modular single pole, single current carrying path switching devices to open or close 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.