Extend mechanical and electrical operations as enabler for grid flexibility

One promising approach to solve the issues is the use of solid lubricants in the form of coatings on surfaces with relative sliding. This paper introduces the use of a novel graphene-based surface treatment for mechanical components in medium voltage (MV) circuit breakers (CB) as a promising manufacturing practice. This new type of treatment aims to extend scheduled maintenance intervals, while maintaining reliability and safety in this sector and enabling MV equipment at lower maintenance levels.

The experimental assessment of the mechanical actuator prototypes was carried out on MV AC and DC CBs with relevant parts coated with self-lubricating graphene-based surface treatments.

The graphene-based treatment not only improved the efficiency of the actuator but also has the potential to extend the intervals between scheduled maintenance, reducing downtime and operational costs. The coated components demonstrated significantly reduced friction and wear compared to their traditionally grease-lubricated counterparts.

In addition to the IEC 62271-100 standard for an M2 mechanical life (10,000 operations), a limit test was carried out to verify the true quality and robustness of the treatment implemented.

The results were highly satisfactory when the components and parts under test performed flawlessly, without any intermediate maintenance, and achieved an outstanding milestone of 29,000 operations, approximately three times the initial requirement.

After mechanical operations, the forces to push the opening and closing buttons are still within an acceptable range, demonstrating the stability and robustness of the low-friction treatment applied to the tested elements. Visual inspection and SEM image analysis of the wear surfaces showed the formation of a carbon-rich tribofilm at the interfaces, implying the effectiveness of the graphene-based dry-lubrication layer.

The ability or the surface treatment to enhance mechanical durability and reduce maintenance cycles can significantly improve the reliability and efficiency of electrical components, particularly in challenging environments. By leveraging graphene-based treatments, manufacturers can develop advanced solutions that meet the demands of modern electrical grids, ensuring long-lasting performance and sustainability.

The consistent performance of the treated surfaces, even after prolonged use, highlights the potential of this innovative technology to enhance the reliability and longevity of mechanical actuators. Reducing the need for frequent maintenance and re-lubrication, can lead to substantial cost savings and improved operational efficiency.

Graphene is an interesting solid lubricant that will open new routes for improved performance and durability of mechanical components in various industrial applications.