ULTRAVIOLET: Remote Overhead Switch Operation using the Safe-T-Rack Remote Racking System
The Customer Request: Remote Overhead Switch Operation
For almost 20 years, Remote Solutions LLC has developed and refined innovative, portable remote racking systems with the goal of making arc flash safety convenient and effective for facilities all over the world. Safe-T-Rack remote racking systems use a single motor drive unit to operate a variety of breakers and equipment, tailored to facility needs and designed specifically with portability and simplicity in mind.
Recently, Remote Solutions LLC was approached by an existing customer with a new request: a remote operating system that could be used to operate not just medium and high-voltage switchgear, but that could also be tailored for use to remotely operate overhead switches in switching yards across their organization.
The company aimed to protect their operators from the dangers inherent in manipulating these overhead switches by hand, which carries significant arc flash risk.
While the Remote Solutions team had not designed an overhead switch operator previously, the team met with the customer to learn all that they could about overhead switch designs, operation, and operating requirements. Without delay, the team initiated research and development to tailor the Safe-T-Rack system to this new, important use.
Remote Solutions Develops Unique and Effective Solution
Despite the new territory, the Remote Solutions team of engineers and designers were quickly able to design and build a prototype system. Since the existing Safe-T-Rack remote racking system often uses a tool adapter to engage with equipment and operate racking mechanisms, the team already possessed the groundwork to bridge the Motor Drive unit capabilities to operate a new design and system: HOGO Overhead Switches. These switches use a large rotating assembly to shift overhead equipment. This means that instead of turning a tool in a racking shaft, the system would now have to operate a much larger device, operating in a new rotational pattern.
The final solution? A custom smart drive bracket, designed to suspend from the overhead switch using the existing bolt pattern of the equipment paired with a custom tool-adapter that allows the Motor Drive Unit to attach to the overhead switch handle and turn the assembly using the drive motor.
As shown in the image above, this design suspends from the overhead switch securely, providing both the strength and structure to support the Motor Drive Unit and the clearance necessary for the handle to turn and operate the overhead switch.
Testing the Solutions On-Site
After rigorous testing in-house and combined design assessment in the Remote Solutions design warehouse in Tucson, this design was ready to test and deploy. A few weeks after the initial request, members of the Remote Solutions team traveled to the switching yard with the prototype of ULTRAVIOLET, to test the design in a real-world scenario.
On-site in the client testing yard, this design was suspended from and tested on de-energized equipment. The smart drive bracket suspended easily and intuitively, while the tool adapter and handle rotating cuff fit as expected, ready to operate the overhead switch. The customer watched while the Safe-T-Rack motor drive unit successfully began to operate the overhead switch.
This test was not a complete and immediate success. The system demonstrated some small issues, which the team quicky resolved. When the motor drive unit revealed lag and proved to be slightly under-powered, the team outfitted the Smart Drive Bracket with an additional gear box that increased torque and successfully withstands and supplies the required power to operate overhead switches.
After this on-site testing and some quick revisions to the design, this system is ready and able to remotely operate overhead switches without issue.
The final product: ULTRAVIOLET is currently ready to deploy and fully functional to operate overhead switches in facilities across the country.
Thanks to the innovative and dedicated efforts of the Remote Solutions engineering team, an already successful remote racking system was tailored for successful use in a new and important area of employee safety.
Know of a use case where Safe-T-Rack remote operation could be a benefit? Contact our team today!
Want to Learn More about ULTRAVIOLET Remote Overhead Operator?
Ready to learn more about ULTRAVIOLET? Visit the product page or contact our sales team to learn more about this remote racking system.
About Safe-T-Rack
Remote Solutions designs custom remote racking applications for all manner of breakers, contactors, and switchgear. As was the case with this facility, often there is a pre-existing design for a specific breaker or manufacturer; in these situations, the sales team can connect you with an application that suits your needs and timeline with a swift turnaround. Learn more about Safe-T-Rack Remote Racking applications at our website or contact our sales team to learn which application is right for you today.
For more information about Safe-T-Rack remote racking systems, contact our team today!
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