Development of Double-Break Phase-Controlled Fast Circuit Breaker with Graphene Modified Copper-Based Contact Material for Capacitor Bank Switching
Ma Feiyue1,2, Wei Siyi1, Yao Xiaofei1, Liu Zhiyuan1, Niu Yuqian1
1. State Key Laboratory of Electrical Insulation and Power Equipment School of Electrical Engineering Xi’an Jiaotong University Xi’an 710049 China; 2. State Grid of Ningxia Electric Power Co. Ltd Electrical Power Research Institute Yinchuan 750002 China
Abstract：Switching capacitor banks are the most common method for reactive power compensation in power systems. During capacitor bank switching, traditional vacuum circuit breakers are prone to high-frequency inrush-current arcs due to pre-breakdown, which can cause severe erosion of the contact surfaces. After opening, micro-protrusions may form on the contact surface, reducing insulation strength and significantly increasing the probability of post-arc restrike. In 35 kV applications, the restrike probability is more than four times that of 10 kV scenarios, posing a serious threat to the safe and stable operation of the power system. In reactive power compensation capacitor bank switching, a vacuum circuit breaker is more suitable for frequent switching operations due to its simple structure, low maintenance cost, high safety, and long electrical life. Studying the physicochemical properties and electrical performance of contact materials provides valuable guidance for designing vacuum circuit breaker contacts. Doping contact materials with graphite is considered to improve erosion resistance, but its application in vacuum circuit breakers remains limited. In this study, three groups of contact materials were selected: CuCr40 alloy doped with 0wt%, 1wt%, and 3wt% graphene. To meet the operational requirements of capacitor bank switching, the erosion resistance, current-interruption characteristics, and insulation withstand properties of these contact materials were systematically investigated using high- and low-current-interruption tests, power-frequency withstand-voltage tests, and lightning-impulse tests. Following a comprehensive performance comparison, CuCr40 (GR-1wt%) was identified as the optimal contact material. Phase-controlled breaking technology can, in theory, effectively suppress inrush current and overvoltage by precisely controlling the circuit breaker to open and close at a specific phase point of the voltage or current. At the same time, the double-break structure can significantly reduce the circuit breaker’s prestrike voltage and dispersion. To achieve phase-controlled switching of capacitor banks, a design approach featuring a double-break, fast-vacuum circuit breaker with eddy-current repulsion was adopted. The drive system was designed, and its operational reliability was verified. The structural design and grading-capacitor selection for the arc-extinguishing chamber are carried out. The developed prototype successfully passed insulation withstand, temperature rise, dynamic and thermal stability, and phase selection closing type tests. Field tests were also conducted to collect current waveforms and verify the reliability of switching operations. This paper aims to address the impact of high-frequency inrush currents during capacitor bank closing on vacuum circuit breakers by combining advanced contact materials with phase-controlled switching technology. The performance of graphene-reinforced copper-based composite contact materials was investigated, and the most suitable material for capacitor bank switching was identified. Leveraging the short operating time and low-dispersion characteristics of the eddy-current-repulsion-type fast vacuum circuit breaker, precise phase- controlled switching of capacitor banks was achieved. The developed 40.5 kV double-break phase-controlled fast circuit breaker successfully passed a full set of type tests and has been deployed in a 220 kV substation for 35 kV capacitor bank applications.
马飞越, 卫思屹, 姚晓飞, 刘志远, 牛雨芊. 电容器组投切用石墨烯改性铜基触头材料双断口相控快速断路器研制[J]. 电工技术学报, 2026, 41(20): 7133-7146.
Ma Feiyue, Wei Siyi, Yao Xiaofei, Liu Zhiyuan, Niu Yuqian. Development of Double-Break Phase-Controlled Fast Circuit Breaker with Graphene Modified Copper-Based Contact Material for Capacitor Bank Switching. Transactions of China Electrotechnical Society, 2026, 41(20): 7133-7146.
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