Study on the fast response characteristics and mechanical reliability of high-voltage circuit breaker solenoid valves

The response time of conventional hydraulic operating mechanism solenoid valves is slow, which affects the circuit breaker tripping time. We propose a design scheme for the electromagnetic repulsion tripping device, establishing a multiphysics coupling model that includes electrical circuits, electromagnetic fields, structural fields, and mechanical motion. Along with a fatigue life analysis module, a comprehensive analysis of the device's fast response characteristics and mechanical reliability was conducted. The results indicate that the initial design generates a peak repulsive force of up to 134.54 kN within 0.24 ms and achieves a design displacement of 15 mm within 1.56 ms. Although the initial design achieves a fast response, the maximum stress on the repulsion plate approaches its material's yield strength, failing to meet the mechanical life requirement of 10,000 cycles. By introducing a multi-objective optimization algorithm to improve the design of the repulsion mechanism, the peak electromagnetic repulsive force was reduced from 134.5 kN to 97.0 kN, enhancing the motion efficiency of the repulsion mechanism. The design displacement was achieved within 1.8 ms, and the maximum stress on the repulsion plate was significantly reduced, extending the fatigue life beyond 10,000 cycles. Test results of the prototype confirmed the accuracy of the simulation model and the effectiveness of the optimized design. The startup time of the operating mechanism is reduced to 2.6 ms, significantly shortening the activation time and demonstrating the potential of the proposed electromagnetic repulsion valve in improving the performance of high-voltage circuit breakers.