PROPOSAL

Automatic Rack –In & Rack-Out System for VCB

1. Problem Statement
• VCBs are well protected with interlocking switches
for its switching device operation with busbar.

• Switching devices in VCBs have to be disabled or

enable for raking In-Out operation for maintenance
purpose.

• Malfunctioning of interlocking mechanism is very

unlikely but if it happens the results are life
threatening.

• There has been such failure in past and loss of life

in some incidents.
 2. The Solution

In view of the proximity of maintenance staff

required for manual raking In-out of VCB
carriage a motorized remotely controlled raking
system is being proposed to eliminate
personnel presence in vicinity of VCB during
this operation.
3. Design Criteria
 Should be able to operate on all
configuration of VCB in TNB Substations
 Light Weight and independent Portable
 No altercation to VCBs functioning and
operation
 Motorized unit with battery and charging
backup
 Complies with IEC/ANSI/IEEE standards
 Raking In-Out time 10sec – 15sec
 Ease of accessing crank nut avoiding
control devices on VCB front panel
3. Mechanical fixtures and fittings (schematic 1 & 2)

i) Triangular mounting frame – Aluminium alloy

 ii) Magnetic legs – Steel rod with magnet with pull
force 750 N or more.
 iii) Sliding and rotating arm – For alignment with crank
nut port
 iv) Geared 24 VDC motor with encoder – 20 to 30 rpm
and torque of ~250Ncm. Encoder provide distance
travel by VCB.
 v) Adapter shaft with crank socket - To access the
crank nut
 VCB front Panel

Triangular Frame

Magnetic legs

Anchor bolt

Sliding Arm Crank socket

Encoder Crank nut

DC Motor Gear Box

Schematic 1: Mechanical fixture and fittings

Schematic 2: One possibility of triangular mounting frame
3. Electrical System and fixtures (Schematic 3)

 Control of mechanical unit is achieved by wall

mounted control unit
 Programming Logic Controller (PLC) housed in control
unit controls the operation of motor
 PLC reads the motor encoder and computes the
distance moved by the VCB
 Interlocking functions of the systems will be provided
from the PLC ladder logic programming
 Battery backup and charger will be housed in control
unit
 The cables runs ~40m between mechanical and
control units
Schematic 3: Electrical Control Unit
Schematic 4: Operation
Flow diagram
4. System Specification, Testing and validation
 Details provided by TNB Distribution – Handout

5. Power Failure and Safety

 Control unit should be operational for four (4) hours from battery
 Thirty (30) rank In-Out operation from battery
 Mount or un-mount status of mechanical unit on VCB front panel

6. Material Cost
i) Triangular Frame + arm+ magnetic stand RM 4000
ii) Motor + encoder + gearbox RM 2000
iii) PLC + battery + accessories RM 2500
iv) Cabling + connectors + socket + adapters RM 1500
Total RM 10000
7. Development time
 Three (3) months from after receiving the advance money
CAD design of Mechanical mounting
CAD design of Mechanical mounting