To measure the arc motion in interruption process of low voltage molded case circuit breakers (MCCBs) more precisely, a set of novel 2-D optical fiber system is developed. To improve the spatial resolution of optical fibers, lens with inhomogeneous dielectric is fixed on the top of each fiber. Furthermore, the full hardware control logic facilitates the real-time, synchronous and high-speed processing and breaks through the restricted bus operation frequency range and data stream capacity of microprocessor. The Publisher-Subscribe behavioral design pattern is applied to the software and the loosely coupled relationship between glyph and experimental data is once established, the graphic configuration can be implemented for simulation analysis, and the flexibility and applicability of the whole system are obviously improved. It demonstrates that the system provides a better research technique especially for new generation MCCB with gas driven arc.

Adjustability is an important function of the magnetic release for modern molded case circuit breakers. Based on virtual prototype technology, an automatic prediction method is proposed to design reasonable reactive spring parameters for this kind of magnetic release. 3-D finite element method is adopted to calculate the static characteristics of the magnetic release. Then the dynamic characteristics of the magnetic release can be simulated taking into account the variation of the spring parameters with multi-dynamics method. The calculation results have been verified by the relevant experiments. It demonstrates that the proposed method is feasible to perform the design task.

To predict the thermal behavior of switchgear quickly, the Thermal Network Finite Difference Analysis method (TNFDA) is adopted in thermal analysis of AC contactor in the paper. The thermal network model is built with nodes, thermal resistors and heat generators, and it is solved using finite difference method (FDM). The main circuit and the control system are connected by thermal resistors network, which solves the problem of multi-sources interaction in the application of TNFDA. The temperature of conducting wires is calculated according to the heat transfer process and the fundamental equations of thermal conduction. It provides a method to solve the problem of boundary conditions in applying the TNFDA. The comparison between the results of TNFDA and measurements shows the feasibility and practicability of the method.

Short-time withstand current is one of the crucial nominal parameters in air circuit breaker. A numerical method to evaluate the short-time withstand current is proposed. Cylindrical current carrying bridge is introduced to describe the contact spot between movable and fixed contacts. Taking into account the action of ferromagnetic splitter plates, the variation of the conductor properties with temperature and the variation of contact spot radius with the electro-dynamic repulsion force, a transient finite element calculation model is developed by coupling the electromagnetic field and thermal field. The loaded short circuit current is considered as the short-time withstand current once the highest temperature is near to the melting point of the contact material. It demonstrates that the method is useful to evaluate the performance of the air circuit breaker.

A method is proposed to investigate the dynamic characteristics of a magnet release in molded case circuit breaker. With the static field assumption, two grids of the magnetic torque and flux linkage are calculated with the variation of the current and air gap, firstly. Considering the influence of tripping torque, coupled with circuit equation and mechanism motion equation, the dynamic characteristics may be obtained with Runge-Kutta 4 method. Experiments have been done to verify the method, and the difference between the calculated results and the experimental results is below 10%. In addition, the influence of the reaction spring on the protection characteristics is analyzed using this method. It demonstrates that the setting current varies with the initial angle and the stiffness of the reaction spring, and the variation with the initial angle of the reaction spring is closely linear but the stiffness nonlinear.

Similarities and differences of the thermal analysis issues between the intelligent and general AC contactors are analyzed. Heat source model of the magnet system is established according to the unique control mode of the intelligent AC contactor. Linking with the features common of the two kinds of contactors, the extension of the thermal analysis method of the general AC contactor to the intelligent AC contactor is demonstrated. Consequently, a comprehensive thermal analysis model considering heat sources of both main circuit and magnet system is constructed for the intelligent AC contactor. With this model, the steady-state temperature rise of the intelligent AC contactor is calculated and compared with the measurements of an actual intelligent AC contactor.

For the optimization design of air circuit breaker (ACB), it is important and necessary to calculate the electro-dynamic repulsion force acting on the movable contact. A method based on 3-D FEM with the equations that describe the relationships among current, magnetic field and repulsion force, which takes the ferromagnet into account, is adopted to calculate the electro-dynamic repulsion force. The method enables one to analyze the factors that affect the electro-dynamic repulsion force, including the number of the movable conductor parallel branches as well as the location of the axis and the shape of the flexible connection. The discussion of the calculation results is also presented in this paper.

To one double-breaker model, experimental investigation on blow open force was carried out. It demonstrates that the ratio between the emerging blow open force and arc power FB/ui decreases with the arcing time, the contact gap has less effect on FB/ui, and the characteristics of the blow open force are similar when the peak value of the short circuit current is beyond 4 kA. Then, according to the experimental data and conclusions, considering the influence of blow open force, the interruption process of molded case circuit breakers (MCCBs) was investigated. It demonstrates the blow open force has significant influence on interruption process and the proposed method is effective to evaluate new design of MCCBs.

The precision of magnetic field calculation is crucial to predict the arc behavior using magnetohydrodynamic (MHD) model. A integrated calculation method is proposed to couple the calculation of magnetic field and fluid dynamics based on the commercial software ANSYS and FLUENT, which especially benefits to take into account the existence of the ferromagnetic parts. An example concerning air arc is presented using the method.

Gas flow in arc quenching chamber has an important effect on the interruption capability of low voltage circuit breakers. In this paper, based on a simplified model of arc chamber with a single break, which can be opened by the electro-dynamics repulsion force automatically, the effect of different vent configurations including middle vent and side vent on the interruption performance is investigated. First, the experiments are carried out to compare the different performance in the interruption process between middle vent type and side vent type. In addition, according to the experimental model, a 3-D magneto-hydrodynamic model was developed by adapting and modified the commercial computational fluid dynamics software FLUENT. The simulation results show the same trend in arc motion as explained in the experimental conclusions in theory.

This paper focuses on the latest research of switching arc both in vacuum and SF6 substitutes in our group. The crucial characteristics of vacuum arc are illustrated, including the motion and distribution of single cathode spot and multiple cathode spots, the influence of axial magnetic field on arc plasma characteristics, the influence of composite magnetic field on cathode jets, and the study of anode activities. Meanwhile, the arc characteristics in SF6 and its substitutes (Ar, CO2 and N2) at different pressures and gap distances are investigated by experiments and simulation.

In order to understand the recovery characteristics of AC contactors and improve their performance, experimental measurements were used to investigate the arcing gap recovery process including dielectric recovery strength and reignition, to a pair of splitter plate together and four kinds of arc chamber of AC contactors. A special circuit was designed to perform the work. It demonstrates that under lower current, the dielectric recovery strengths of all kinds of arc chambers in the paper have no significant difference. However, with the increase of current, the difference of dielectric recovery strengths of them is much clear. The reignition characteristics of a pair of splitter plate and arc chambers are similar. With different configurations of arc chambers and prospective currents, the forms of post current zero reignition are distinct.

In the optimum design of AC contactors, it is necessary to analyze the dynamic behavior. Moreover, movable contacts and core bounce have remarkable effect on the lifetime of contactors. A set of differential equations describes the coupling of the electric circuit, electromagnetic field and mechanical system taking account into bounce and the influence of friction. With virtual prototyping technology, the dynamic behavior, especially for contacts bounce, has been investigated according to different electrical circuit parameters. Two approaches are introduced to solve electromagnetic parameters. Based on 3D finite element static nonlinear analysis, the flux linkage and electromagnetic force can be evaluated with different air gap and exciting current for larger gap. In addition, concerning to the shading coil for smaller gap, magnetic circuit can facilitate the calculation. The validity of the proposed method is confirmed by experiments.

The gas-puffer effect has important effects on the interruption capability of a molded case circuit breaker (MCCB). In this paper, on the basis of a simplified model of an arc chamber with a single break, the effect of back-volume of an arc-quenching chamber on arc behavior in an MCCB is investigated. Firstly, using a 2-D optical-fiber arc-motion measurement system, experiments are performed to study the effect of back-volume on the arc-motion and gas pressure in an arc-quenching chamber. We demonstrate that the lower back-volume of the arc-quenching chamber is, the higher the pressure and the better the arc motion will be. Then, corresponding to the above experiments, the gas pressure inside the arc-quenching chamber is calculated using the integral conservation equation. The simulation results are consistent with the experimental results.

The paper is devoted to the experimental study of the arc plasma characteristics in SF6, N2 and CO2. To one flexible model of gas circuit breaker, short circuit experiments have been carried out considering the influence of contact gap (4–12 mm), gas pressure (1–5 atm), short circuit current (1–5 kA effective value) as well as gas species particularly. During the experiments, the arc image, arc current and arc voltage are recorded by the high speed camera, shunt and voltage transducer, respectively. It demonstrates that to the above mentioned three kinds of gases, the arc radius and arc voltage increase with the short circuit current and gas pressure normally; however, under the same experimental conditions, N2 arc holds the minimum arc radius and the maximum arc voltage, and the arc voltage of SF6 arc is the lowest.

A two-dimensional compressible magnetohydrodynamic (MHD) computational model has been developed to study the effect of gassing material on air arc behavior in low voltage circuit breaker. The properties of arc plasma and the electric, magnetic and radiative phenomena have been taken into account in the model. Based on the model, steady state solutions have been performed to study the effect of gassing material on the arc radius and electric field in the arc column. Then, the effect of gassing material on the transient process of arc motion also has been simulated. In addition, using the two-dimensional optical fiber measurement system, experiments have been done to measure the average velocity of arc motion with one model chamber and to verify the simulation model and prediction results. It demonstrates that the action of gassing material may yield the stronger electric field, less arc radius and higher arc motion velocity.

Two dimensional optical fiber measurement system is used to investigate experimentally the arc motion and reignition with four different configurations of quenching chamber in an AC contactor. It demonstrates that the splitter plate arrangement has significant effect on the arc motion in arc quenching chamber, and fixing arc runner in the first and last splitter plates benefits to arc motion, and increase the dielectric recovery strength. The results are very useful to design the quenching chamber in AC contactor with high performance.