Most power- or control-switching applications provide both manual and remote operator control
capabilities. For these remote switching functions, D.C. motors serve a vital role as remote motor
operators. Two remote control applications that employ DC motors are circuit switchers in
electrical transmission and distribution substations in the utilities industry and rail track switches
in the transportation industry.
Electrical Power Circuit Switchers
An electrical utilities substation is a high-voltage electric facility that’s used to switch, connect,
or disconnect generators, equipment and other circuits in or out of service throughout a power
grid. There are four types of electrical substations: Step-Up, Step-Down, Distribution and
Underground Distribution Transmission Substations. 1 In these applications, circuit switchers are
used to switch A.C. voltages up to 1100kV, and D.C. voltages up to 500kv. 2
Circuit switchers are electro-mechanical assemblies typically consisting of an interrupter sub-
assembly, disconnect switch, fault sensing & protection, and a motor operator. The motor
operator is used for remote switching or when the “disconnect switch’s function is integrated into
a comprehensive system monitor and performance scheme such as a supervisor control and data
acquisition system (SCADA).” 3
The motor operator is commonly a permanent magnet DC motor (brushed or brushless) that has
a high torque, torsional output. The motor is typically a NEMA-rated, 48 VDC or 125 VDC,
D.C. motor with features that can include permanently greased ball bearings, overload protection
and dynamic braking. The motor operator “can be powered either via a substation battery source
or via the input from an auxiliary AC source.” 4 For multiple switching operations, some motor
operators “have their own internal batteries that can be fed from an auxiliary A.C. source via an
A.C. to D.C. trickle charger for emergency operations in the event of loss of auxiliary AC power
supply.”
Railroad Track Switches
Railroad switching is integral to the safe and normal operations of railroad transportation. It
entails the manual or remote movement of switch rails, which are laterally moved from one
position to another in order to change a railway junction point or spur so railway traffic can
progress on its scheduled course.
The rail switching function can be accomplished manually or remotely. Manual, rail switching is
performed by an operator at the railroad switch who moves a lever, rail operator or a hand pump
to change the rail track’s position. Remote operation is performed via a track switch machine that
is computer controlled remotely. This computer controller can sense when a train is on a specific
length of rail track, provide warning signals, and initiate a rail switching operation by energizing
an electric motor that drives the track from one position to another. 5 The track switch, drive
motor is commonly a brushless, permanent magnet DC motor. “The controller has control
circuitry for energizing and de-energizing field coils of the [brushless D.C.] motor sequentially
as the armature rotates.” 6
Another type of rail switch machine is the electro-hydraulic rail switch. This type uses an
electro-hydraulic power pack to provide the force to move the switched rail. The hydraulic
power pack includes a manifold, control valves, pressure switch, pump and DC electric motor.
The moving force is provided by a hydraulic cylinder, including a position transducer that
provides feedback to control the movement of the cylinder or actuator. This rail switching type
can be powered from a D.C source, a battery bank or solar cells for rail switch operations even in
remote areas. In case of a loss of electrical power, a hand pump is available to manually switch
the rail. 7
1. Power Transformer, Inc. Substation Transformers. 2007.
2. Power Transformer, Inc. Substation Transformers. 2007.
3. John Douglas McDonald. Electric Power Substations Engineering. CRC Press, 2007.
4. John Douglas McDonald. Electric Power Substations Engineering. CRC Press, 2007.
5. Marshall Cavendish Corporation. How It Works: Science and Technology. Marshall Cavendish
Corporation, 2002. Page 1924.
6. Marshall Cavendish Corporation. How It Works: Science and Technology. Marshall Cavendish
Corporation, 2002. Page 1924.
7. Process Switch Company, LLC. The Process Rail Switch. Process Switch Company, LLC.
