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Optimization of a switch disconnector through multi-body simulation

Product: Switch Disconnector

Purpose of Analysis: Optimize the design to reduce arc generation

switch disconnector simulation

The most important aspect of a switch disconnector is the time taken to switch from the ON to the OFF configuration during an emergency maneuver. If it is too slow, an arc will be generated inside the switch that may damage the contacts and other nearby parts. Additionally, the overall design must deliver high robustness and sufficient durability.

Lovato Electric S.p.A., Italy, introduced RecurDyn into its product design cycle to optimize the dynamics of its electromechanical devices, including the switch disconnectors. In addition to achieving the above-mentioned design goals, the company was able to reduce the number of physical prototypes and experimental tests, achieving a significant saving in the cost of the development.

Process 

① Creation of a leaf-spring subsystem (flexible body, including the mounting pre-stress)

② Virtual installation of multiple leaf-springs in the switch disconnector device

③ Assignment of parameters to control initial positioning uncertainty (clearances, tolerances)

④ Creation of a command group model that consists of 3 cams

⑤ Simulation of the entire system in different configurations to identify the optimal design of the switch disconnector

Key Technologies for Switch Disconnector Analysis

• Full Flex technology to capture the large flexibility of leaf springs
• Geo-Contact technology to handle interactions between Full Flex bodies
• Subsystem modeling for maximum reusability of complex mechanisms
• Full Flex ability to create the deformed, pre-stressed initial states

Toolkits for Switch Disconnector Simulation

• RecurDyn/Professional
• RecurDyn/FFlex

Customer Challenges

• High speed dynamics including flexible bodies and contacts which requires solver power and solver stability
• Detailed shapes and coupling clearances that affect performances must be taken into account with high accuracy.
• Presence of largely deformable bodies, nonlinear materials, and extended contacts: highly nonlinear problem
• CAD-embedded multibody (already in use) was not enough for switch disconnector simulation.

Switch Disconnector Simulation Results

Solutions

• The virtualization of the system was relatively easy due to the advanced GUI and the subsystem modeling capabilities of RecurDyn.
• Assembly (with clearances) was completed by using multiple and extended 3D General Contacts.
• Detailed Full Flex bodies allowed for the correct representation of leaf springs.
• High-performance and reliable MFBD solver succeeded in this high-demanding application.

Outcomes

• The dynamics of the switch disconnector was accurately investigated.
• Many configurations were tested using simulation instead of building and testing multiple physical prototypes (time and cost saving).
• The optimal design was found and validated in a laboratory.

Other Applications Related to Switch Disconnector Simulation

• Simulation of a circuit breaker
  • The high-speed and precise motion of the circuit breaker
  • Simulation of the various types of circuit breakers
• High Speed Electrical Switching Mechanism at Siemens E&A