Monitoring of the contact region in a plug device
11486941 · 2022-11-01
Assignee
Inventors
Cpc classification
G01R31/69
PHYSICS
G01R27/205
PHYSICS
International classification
G01R27/20
PHYSICS
Abstract
In a method for the determination of an electrical contact property in a contact region between a first contact element of a first plug device and a second complementary contact element of a second plug device, a property of a current path including the first contact element, the contact region, and from the second plug device only the second contact element is evaluated and an induction voltage is generated in the current path for a measurement in the current path to thereby enable to draw a conclusion about the electrical contact property.
Claims
1. A method for the determination of an electrical contact property in a contact region between a first contact element of a first plug device and a second complementary contact element of a second plug device, said method comprising: evaluating a property of a current path which includes the first contact element, the contact region, and from the second plug device only the second contact element; and generating an induction voltage in the current path for a measurement in the current path to thereby enable to draw a conclusion about the electrical contact property.
2. The method of claim 1, further comprising adding in the current path at least two sensors which are arranged in the first plug device and contact the second contact element when the first and second contact elements are plugged together.
3. The method of claim 1, further comprising synchronizing the evaluation of the property of the current path with a course of an operating current across the contact region.
4. The method of claim 1, further comprising: disposing in the current path a sensor which is arranged in the first plug device and contacts the second contact element when the first and second contact elements are plugged together, and forming in the current path a capacitance of more than about 10 pF to allow an alternating current flow in the current path.
5. The method of claim 1, further comprising measuring a voltage drop across the current path that occurs when an operating current flows across the contact region.
6. The method of claim 4, further comprising establishing a defined contact property between the sensor and the second contact element.
7. The method of claim 6, wherein the defined contact property between the sensor and the second contact element is established by applying a breakdown voltage.
8. The method of claim 1, wherein the current path forms a secondary coil on a magnetic core, and further comprising arranging a primary coil on the magnetic core.
9. The method of claim 1, wherein the second contact element is a plug pin and wherein the current path includes at least two contact fingers which both contact the plug pin.
10. A method for the determination of an electrical contact property in a contact region between a first contact element of a first plug device and a second complementary contact element of a second plug device, said method comprising: evaluating a property of a current path which includes the first contact element, the contact region, and from the second plug device only the second contact element; and adding in the current path at least two sensors which are arranged in the first plug device and contact the second contact element when the first and second contact elements are plugged together.
11. A method for the determination of an electrical contact property in a contact region between a first contact element of a first plug device and a second complementary contact element of a second plug device, said method comprising: evaluating a property of a current path which includes the first contact element, the contact region, and from the second plug device only the second contact element; and synchronizing the evaluation of the property of the current path with a course of an alternating operating current across the contact region by carrying out measurements in a range of zero crossings of the alternating operating current.
12. A method for the determination of an electrical contact property in a contact region between a first contact element of a first plug device and a second complementary contact element of a second plug device, said method comprising: evaluating a property of a current path which includes the first contact element, the contact region, and from the second plug device only the second contact element; disposing in the current path a sensor which is arranged in the first plug device and contacts the second contact element when the first and second contact elements are plugged together; and forming in the current path a capacitance of more than about 10 pF to allow an alternating current flow in the current path.
13. A plug device, comprising: a first plug device including a first contact element; a second plug device including a second contact element which complements the first contact element and contacts the first contact element, when the first and second contact elements are plugged together in a contact region; a current path including the first contact element, the contact region, and from the second plug device only the second contact element; and means for generating an induction voltage in the current path for a measurement in the current path to thereby enable to draw a conclusion about an electrical contact property in a contact region between the first contact element and the second contact element.
14. The plug device of claim 13, further comprising at least two sensors configured to contact the second contact element when the first and second contact elements are plugged together.
15. The plug device of claim 13, further comprising a sensor disposed in the current path and arranged in the first plug device, said sensor contacting the second contact element when the first and second contact elements are plugged together, wherein the means includes a magnetic core configured to surround the first contact element and/or the sensor and/or the contact region.
16. The plug device of claim 13, further comprising an evaluation circuitry configured to evaluate the electrical contact properties of the current path.
17. A plug device, comprising: a first plug device including a first contact element; a second plug device including a second contact element which complements the first contact element and contacts the first contact element, when the first and second contact elements are plugged together in a contact region; a current path including the first contact element, the contact region, and from the second plug device only the second contact element; and at least two sensors configured to contact the second contact element when the first and second contact elements are plugged together.
Description
BRIEF DESCRIPTION OF THE DRAWING
(1) In the following, exemplified embodiments of the invention will be explained in greater detail with reference to the figures. It is shown in:
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DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
(23) For the sake of clarity,
(24) Due to aging processes, corrosion, contamination, and the like, a relatively high contact resistance can occur in the contact regions, causing an unacceptably high amount of heat loss. Therefore, it is desirable to determine or monitor the electrical contact properties in the contact regions, especially the contact resistance in the contact region between a plug pin ST and the associated socket BU.
(25) The components necessary for such a determination should hereby be accommodated if possible only in one of the two plug devices SV1, SV2, so that monitoring is independent of the type and origin of the used complementary plug device. In most of the exemplary embodiments described hereinafter, the required components are accommodated in the coupling as the first plug device SV1, while any plug may in principle be used as second plug device SV2. However, the corresponding explanations also apply (with the corresponding adjustments) to reversed roles of coupling and plug.
(26)
(27) The afore-described structure corresponds to the situation with conventional plug devices and forms the starting point also in the following
(28) In the embodiment according to
(29) A second connection a is formed to the material of the socket BU. A current path is thus formed between the connections a, b, and includes the following components: the socket BU; the plug pin ST, which contacts the socket in the contact region of interest; the sensor F, which contacts the plug pin ST in a separate second contact region.
(30) A suitably designed evaluation circuitry (not shown) can be connected to the connections a, b in order to determine the properties of the current path and, in particular, those of the contact region of interest.
(31)
(32) The inset in the Figure (bottom right) shows an alternative embodiment in which the plug pin ST′ has a recess or groove extending in axial direction. A sensor F′, which can contact the socket BU from the inside, is arranged in this groove, insulated from the plug pin ST′.
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(37) The arrangement of
(38)
(39) The unknown contact resistance R.sub.F between the sensor and the plug pin does not interfere with such a voltage measurement when the contact resistance is sufficiently small compared to the internal resistance of the voltmeter. Because the voltage drop U.sub.B generated in the operating circuit at the contact resistance R.sub.0 generates across the connection a, the voltmeter, the connection b, and the contact resistance R.sub.F a measuring current which is small due to the high internal resistance in the voltmeter. In addition, a high internal resistance compared to the contact resistance R.sub.F ensures that essentially the entire voltage drops at the voltmeter.
(40)
(41) Initially, for a period of approx. 1 second, the switch S is closed (“phase 1”). A voltage U.sub.D of approx. 50 V has the effect that insulating oxides, foreign layers, etc. present on aged contacts are penetrated or fritted, so that afterwards via the contact and via a series resistor R.sub.v of approx. 500Ω a current of approx. 100 mA (=50 V/500Ω) flows. After breakdown/fritting, the voltage at the transition between sensor and plug pin is at a maximum in the order of magnitude of the melt voltage of the material of the contact surface. For nickel, for example, the melting temperature is 1453° C. and the associated melting voltage is 0.65 V. The contact resistance R.sub.F,frit sensor to plug pin, created by the fritting, is in the order of magnitude of 1 V/100 mA=10Ω.
(42) For checking purposes, a voltage measurement can be carried out when the switch S is closed. Otherwise, the purpose of phase 1 is only to establish between the sensor and the plug pin a contact resistance R.sub.F,frit, which is at least one order of magnitude lower than the high internal resistance with which the voltage measurement is carried out.
(43) At the beginning of the subsequent “phase 2”, the switch S is opened. A voltage measurement now yields the sought voltage drop U.sub.B between plug pin and socket during operation of the plug device.
(44) When the operating current I.sub.B is known from another point, an evaluation circuitry is able to calculate the contact resistance R.sub.0 from voltage drop U.sub.B and current I.sub.B. But even without knowledge of the operating current, the voltage drop represents a valuable information: In the case of a plug device, a voltage drop plug pin to socket of for example up to 25 mV is still regarded as a stable operation, but permanent operation can be called into question from approx. 50 mV onwards (this corresponds with a 125 A-plug device to a contact resistance plug pin to socket of 0.4 mΩ; other limit values for the voltage are possible).
(45) Since the crucial feature involves the measurement of the voltage drop in phase 2, phase 1 may be dispensed with entirely, when the sensor is appropriately designed.
(46) Phase 2 can be followed immediately by phase 1. However, a rest phase (“phase 3”) can also be taken between the two phases.
(47) An alternative course of a measurement in an arrangement with two sensors can look as follows (with reference to
(48) Phase 1: Momentary current across a and b to “prepare” the transition between first sensor F1 and plug pin ST.
(49) Phase 2: A current is briefly impressed across connections a (socket BU) and c (second sensor F2) and is in the order of magnitude of the later operating current (across socket BU and plug pin ST). The voltage drop between a and b (first sensor F1) is measured.
(50) Phase 3: If phase 2 has resulted in an “OK”, e.g. the operating voltage/the operating current is connected via a contactor. Otherwise a warning message is triggered.
(51) The method can thus be used to check the properties of the transition plug pin to sleeve before connecting the operating current.
(52) An advantage of the described methods is their functional independence on the mode of contact plug pin to socket (“X-contact” according to WO 2016/184673 A1, torsion spring, etc.). Furthermore, they can be carried out during ongoing operation and the operating current does not falsify any measured values.
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(55) According to the principle of a transformer, current fluctuations in the primary coil PSP generate a changing magnetic field which is bundled and forwarded by the core MK. As can be seen from the side view of
(56) The described structure involves ultimately two series-connected parallel connections of two contact fingers each according to the equivalent circuit diagram of
R.sub.13=R.sub.01R.sub.03/(R.sub.01+R.sub.03)
R.sub.24=R.sub.02R.sub.04/(R.sub.02+R.sub.04)
as
R.sub.tot,ind=R.sub.13+R.sub.24
(57) In contrast to the circuitry of
R.sub.tot,ind=R.sub.13R.sub.24/(R.sub.13+R.sub.24)
If all four contact resistances are the same, i.e.
R.sub.01=R.sub.02=R.sub.03=R.sub.04=R.sub.0,
then
R.sub.tot,ind=R.sub.0 and R.sub.tot,B=R.sub.0/4, i.e. R.sub.tot,B=R.sub.tot,ind/4 applies.
(58) If the four contact resistances assume unequal values (in practice statistically distributed), the measured value R.sub.tot,ind determined with the method described here can exceed the value of R.sub.tot,B, but is therefore “on the safe side”.
(59) In a modified approach, the evaluation circuitry AS could be configured on the primary winding PSP in such a way as to not only determine the complex input impedance Z and thus R.sub.tot,ind, but also to measure with I.sub.B13 the portion of the operating current flowing via the contact fingers KF1 and KF3 enclosed by the magnetic core MK in
I.sub.B=I.sub.B13+I.sub.B24
I.sub.B24R.sub.24=I.sub.B13R.sub.13
R.sub.tot,ind=R.sub.13+R.sub.24
R.sub.tot,B=R.sub.13R.sub.24/(R.sub.13+R.sub.24)
(60) The last two relations have already been used before. When this system of equations is solved for R.sub.tot,B, this leads to
R.sub.tot,B=R.sub.tot,indI.sub.B13I.sub.B24/(I.sub.B13+I.sub.B24).sup.2
(61) Using this formula, the evaluation circuitry AS can yield not only information about R.sub.tot,B, but R.sub.tot,B itself.
(62) To determine R.sub.tot,ind, the evaluation circuitry AS of
(63) In this regard,
(64) The simulation assumes that the magnetic core MK is designed in such a way that the magnetic flux density of 1 Tesla is attained when excited with 127 A. If the excitation is even stronger, saturation of the magnetic circuit can be expected. This saturation can occur, for example, when, during heavy start-up for several seconds, currents flow considerably above the nominal current, of which currents the two contact fingers that are enclosed by the core account for about half. The downstream electronics will therefore measure falsified Z values in the range of the operating current peak value, but will detect meaningful values in the vicinity of the operating current zero crossing. The evaluation circuitry AS can therefore optionally be designed in such a way that it carries out a measurement synchronized with the operating current (50 Hz), in particular only near the zero crossing of the operating current.
(65) The described method with the induction of a measuring current can, optionally, also be carried out using a sensor. For example, a sensor F according to
(66) The principle on which the above approaches are based is that per induction the contact points between socket and plug phi can be examined with the help of a magnetic core, when being able to form a dosed path (curve, line) guided through electrically conductive material and traversing the area spanned by the magnetic core, only with simultaneous participation of contact dements of the first and second plug devices.
(67) These conditions can also be achieved hi alternative constellations, as already illustrated (Note: For sake of clarity, the turns of a primary winding, which wrap around the magnetic core in a manner similar to that of a transformer, are not shown hi
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(69) Another approach is depicted in
(70) As can be seen from the perspective view of
(71) In the axial sectional view of
(72) The current path in which the desired induction voltage is generated runs from the plug pin ST via the first contact region KF1/ST, through the first contact finger KF1, via the bottom of the socket BU and/or the sleeve spring HF to the second contact finger KF2, from there via the second contact region KF2/ST back to the plug pin ST.
(73) An advantage of this embodiment is its applicability with sockets having free-standing contact fingers as well as (as shown) with sockets having distally connected contact fingers.
(74) In the examples presented so far, there was no further discussion as to whether the involved current paths were continuously conductive or (only) capacitively conductive. In any case, all examples work with a conductive conductivity, in which a permanent direct current can be conducted through the current path.
(75) However, it is also possible that an involved current path is only capacitively conductive at at least one point, i.e. a capacitance in series connection. Such a current path is unable to conduct permanent direct current, only alternating current. Apart from that, the described examples work unchanged.
(76) The use of a current path that is possibly only capacitively conductive is illustrated in
(77) The electrical equivalent circuit diagram of such an arrangement is shown superimposed in
(78) Optionally, in such an embodiment, only the conditions at the transition between sensor F and plug pin ST may initially be determined in a separate measurement, i.e. C.sub.F and R.sub.F, for example by a measurement without operating current and/or a measurement without inserted plug pin ST. The result of this determination can then enter into the implementation and/or evaluation of the subsequent actual measurement in order to improve its reliability.
(79) Another expansion of the invention is illustrated in
(80) The plugging state is preferably detected mechanically in order to be independent on the current feed. As indicated in
(81)
(82) In the modified arrangement, an alternating magnetic field is again induced in the magnetic core MK via the primary coil PSP by connecting an alternating voltage source U.sub.p to the primary coil PSP (this alternating voltage source is a part of the evaluation circuitry AS, not shown in detail in
(83) The (reactive) effects of a current flow induced by the magnetic alternating field of the core in the current path of interest are, however, no longer ascertained via the primary coil PSP in this arrangement. Instead, a further coil is arranged around the current path and is connected to the evaluation circuitry AS as measuring coil MS. A measurable electrical quantity (e.g. voltage) is induced in the measuring coil MS directly by the current flow in the current path that the measuring coil surrounds.
(84) As indicated in the Figure, the entire current path can run through the measuring coil MS, when the measuring coil MS encloses all of the contact fingers of a current direction (here KF2 and KF4 or KF1 and KF3) encloses. As an alternative, only part of the current path could be detected, for example when the measuring coil MS were to run only around a single contact finger.
(85) Finally, the most important aspects of the invention, which can be implemented individually or in combination, are listed again, with bracketed reference symbols referring to exemplary embodiments of the Figures:
(86) A) Method for the determination of the electrical contact properties (RÜ) in the contact region between a first contact element (BU) of a first plug device (SV1) and a second complementary contact element (ST) of a second plug device (SV2), with the properties of a current path being evaluated, which current path includes the first contact element (BU), the contact region, and from the second plug device (SV2) only the following: the second contact element (ST) and, optionally, further contact elements of the second plug device (SV2),
wherein
a) an induction voltage (Uind) is generated in the current path so that measurements can be made in the current path to allow conclusions about the contact properties of interest; and/or
b) the current path includes at least one sensor (F, F1, F2) which is arranged in the first plug device (SV1) and contacts the second contact element (ST) when plugged together; and/or
c) the current path includes at least two sensors (F, F1, F2) which are arranged in the first plug device (SV1) and contact the second contact element (ST) when plugged together; and/or
d) the current path includes at least one sensor (F, F1, F2) which is arranged in the first plug device (SV1) and contacts the second contact element (ST) when plugged together, and wherein a breakdown voltage (UD) is applied between the sensor (F, F1, F2) and the second contact element (ST); and/or
e) the evaluation is synchronized with the course of an operating current (IB) across the contact region; and/or
f) the current path includes at least one sensor (F, F1, F2) which is arranged in the first plug device (SV1) and contacts the second contact element (ST) when plugged together, and wherein a capacitance of more than approximately 10 pF is provided in the current path to allow an alternating current flow in the current path; and/or
g) the voltage drop (UB) is measured across the current path and occurs when an operating current (IB) flows across the contact region; and/or
h) the current path forms the secondary coil on a magnetic core (MK) on which a primary coil (PSP) is also arranged.
B) Plug device (SV1) with at least one first contact element (BU), which contacts in a contact region a complementary second contact element (ST) of a second plug device (SV2) when plugged together, with the plug device having a current path, which includes the first contact element (BU), the contact region, and from the second plug device (SV2) only the following: the complementary second contact element (ST) and, optionally, further contact elements of the second plug device (SV2),
wherein
a) the plug device includes means for generating an induction voltage (U.sub.ind) for a method according to point A); and/or
b) the plug device includes at least one sensor (F, F1, F2), which contacts a complementary second contact element (ST) of the second plug device (SV2) when plugged together; and/or
c) the plug device includes at least two sensors (F, F1, F2) which contact a complementary second contact element (ST) of the second plug device (SV2) when plugged together; and/or
d) the plug device includes at least one sensor (F, F1, F2), which contacts a complementary second contact element (ST) of the second plug device (SV2) when plugged together, and includes means for generating a breakdown voltage (UD); and/or
e) the plug device includes a magnetic core (MK), which surrounds the first contact element (BU) and/or a sensor (F) and/or the contact region; and/or
f) the plug device includes an evaluation circuitry (AS) for evaluating the properties of a current path according to a method according to point A).