High-voltage dry-type transformer with protection function

Abstract

The invention discloses a high-voltage dry-type transformer with a protection function, which comprises a transformer body which is sequentially provided with a plurality of layers of protection structures from outside to inside: an outer layer protection shell which adopts a detachable modular shell; the middle buffer layer is made of a honeycomb-shaped silicon-aluminum composite material, and the honeycomb structure is filled with high-damping rubber and fixed through an elastic support; the inner-layer insulating barrier is formed by composite vacuum casting of epoxy resin and nanometer aluminum oxide, and a bubble-free insulating layer is formed on the surface through a 3D printing process; the intelligent temperature control system comprises a micro heat pipe array embedded in the winding conductor, an intelligent shutter and an axial flow fan; the active protection system is internally provided with multiple types of sensors and is connected with the cloud platform; the memory alloy pressure release valve is arranged at the top of the shell. According to the high-voltage dry-type transformer, the environmental adaptability, the operation reliability and the full-life-cycle maintenance efficiency of the high-voltage dry-type transformer are comprehensively improved through deep integration of materials, structures, processes and intellectualization.

Description

Technical Field

[0001] The present invention relates to the technical field of dry-type transformers, and more specifically, to a high-voltage dry-type transformer with a protection function. Background Art

[0002] As a core device of the power system, the operating stability and protection ability of high-voltage dry-type transformers directly affect the safety of the power grid. Although traditional dry-type transformers have advantages such as maintenance-free and oil-free, they still face multiple challenges under complex working conditions:

[0003] 1. Insufficient environmental tolerance: Conventional protective enclosures mostly use integral metal or non-metal shells. When exposed to the outdoors for a long time, they are easily affected by ultraviolet rays, moisture, and chemical corrosion. The surface coating is prone to aging and peeling, resulting in a decline in protection performance. At the same time, the fixed structure requires the entire replacement when there is local damage, resulting in high maintenance costs.

[0004] 2. Weak anti-impact and shock-absorbing capabilities: Existing buffer layers mostly use single elastic materials or simple sandwich structures, and their ability to absorb mechanical shocks, vibrations, and electromagnetic stresses is limited. Especially under extreme working conditions (such as earthquakes and short-circuit electrodynamic forces), internal structure deformation is easily caused, accelerating insulation aging.

[0005] 3. Bottleneck in insulation reliability: The traditional epoxy resin casting process is prone to generate microbubbles or interface defects due to curing shrinkage, leading to potential local discharge hazards; when the surface roughness of the insulation layer is relatively high, the problem of uneven electric field distribution is aggravated, and flashover or breakdown accidents may occur during long-term operation.

[0006] 4. Shortcomings in temperature control efficiency and intelligence: Existing heat dissipation systems mostly rely on passive air cooling or single-fan forced convection, which are difficult to accurately match the temperature rise of the winding hot spots, easily causing local overheating; at the same time, the lack of a multi-parameter collaborative control mechanism makes it difficult to cope with load mutations or environmental temperature fluctuations.

[0007] 5. Passive and lagging safety protection: Most pressure relief devices use mechanical spring structures, with fixed response thresholds and difficult resetting, unable to achieve dynamic pressure regulation; fault monitoring relies on regular inspections or off-line diagnoses, making it difficult to timely warn of potential faults such as insulation degradation and local discharge. Summary of the Invention

[0008] The purpose of the present invention is to provide a high-voltage dry-type transformer with a protection function to solve the technical problems of low integration, single protection dimension, and poor adaptability of existing equipment.

[0009] The technical solution adopted by the present invention is as follows: A high-voltage dry-type transformer with a protection function includes a transformer body, which includes multiple protection structures arranged in sequence from outside to inside:

[0010] The outer protective shell adopts a detachable modular shell, and its outer surface is covered with a nano-composite coating containing titanium dioxide and graphene;

[0011] The middle buffer layer is made of a honeycomb silicon-aluminum composite material, the honeycomb structure is filled with high damping rubber and fixed by an elastic bracket;

[0012] The inner insulation barrier is made of epoxy resin and nano-alumina composite vacuum casting, and the surface is formed into a bubble-free insulation layer through 3D printing technology;

[0013] The transformer body is also provided with:

[0014] Intelligent temperature control system, including micro heat pipe array embedded in winding conductors, intelligent blinds and axial fans;

[0015] Active protection system, with multiple types of sensors built in and connected to the cloud platform;

[0016] Memory alloy pressure relief valve on the top of the shell.

[0017] The present invention reduces maintenance costs through comprehensive optimization of the multi-layer protective structure, and uses a detachable modular shell to reduce maintenance costs. The nano-composite coating (titanium dioxide + graphene) improves UV resistance, corrosion resistance and self-cleaning capabilities; the honeycomb silicon-aluminum composite material is combined with high-damping rubber to achieve multi-dimensional impact absorption (mechanical vibration, electromagnetic stress), and the elastic bracket avoids resonance damage; the vacuum casting + 3D printing process eliminates bubbles and interface defects in the insulation layer, and nano-alumina enhances insulation strength and resistance to local discharge; the intelligent temperature control system collaborates with micro heat pipes, fans and shutters to achieve dynamic heat dissipation; the active protection system achieves early warning of faults through multi-sensor fusion; the memory alloy pressure relief valve can be repeatedly triggered and automatically reset to improve the reliability of overvoltage protection.

[0018] Preferably, the intelligent temperature control system further includes:

[0019] The sunshade cover extends transversely to the top of the main body, and the two ends are fixed to the tops of two symmetrically arranged first clamp bodies;

[0020] The bottom of the first clamp body is connected to the top of the transformer body through a plurality of first damping blocks spaced apart along the length direction of the body;

[0021] An axially extending square heat dissipation channel is formed between the two first clamp bodies, an axial flow fan is arranged at one end of the channel, and an intelligent shutter is arranged at the other end.

[0022] The sunshade cover reduces solar radiation heat input; the square heat dissipation channel combines with the axial flow fan and the intelligent blinds to form directional forced air cooling, improving the efficiency of air flow organization; the first shock-absorbing block isolates the vibration transmission between the clip body and the main body, reduces mechanical losses, and forms a three-dimensional heat dissipation structure.

[0023] Preferably, the micro heat pipe array includes:

[0024] The copper shell is composed of a flat evaporation section and a vertical condensation section formed by vacuum brazing. The two sections are connected by a corrugated connecting elbow;

[0025] The evaporation section is axially installed between the winding layers, and its flat contact surface forms a surface contact with the inner surface of the winding conductor;

[0026] The outer wall of the condensation section is provided with equally spaced annular heat dissipation fins. The top end extends into the square heat dissipation channel at the top of the transformer body, and the top end forms an inverted U-shaped flow channel through an elbow;

[0027] The encapsulated working fluid vaporizes in the evaporation section and then liquefies by heat dissipation in the condensation section, forming a self-circulating phase change heat transfer system.

[0028] The flat evaporation section is in surface contact with the inner surface of the winding conductor, increasing the heat conduction area; the self-circulating heat pipe does not require external power, reducing energy consumption; the inverted U-shaped flow channel uses gravity to accelerate the reflux of the condensate, avoiding uneven distribution of the working fluid; the annular fins enhance the convective heat dissipation of the condensation section, matching the longitudinal temperature gradient of the transformer to achieve an efficient phase change heat transfer design.

[0029] Preferably, the heat dissipation fins of the condensation section are arranged with a gradient pitch. The fin pitch in the area near the top end is reduced by 15%-20% compared with the bottom end area. The fin pitch at the top end of the condensation section is reduced by 15%-20%, enhancing the heat dissipation intensity in the high-temperature area; adapting to the heat transfer characteristics of the reduced steam density at the top end of the heat pipe to avoid the attenuation of the heat dissipation capacity with height.

[0030] Preferably, the intelligent louver includes:

[0031] The surface of the blade is coated with a polytetrafluoroethylene hydrophobic coating with a thickness of 50-100 μm; the polytetrafluoroethylene hydrophobic coating prevents the blade from accumulating dirt and condensing dew;

[0032] The opening and closing angle is controlled by a temperature gradient PID, and a humidity compensation sensor is embedded in the louver frame. The PID control combined with humidity compensation realizes the dynamic optimization of the opening and closing angle, balancing the heat dissipation demand and the moisture-proof requirement.

[0033] Preferably, an integrated shock absorption and heat dissipation structure is provided at the bottom of the transformer body:

[0034] Two symmetric second clamp bodies are connected to the bottom of the body through second shock absorption blocks, and the second shock absorption blocks are arranged axially at equal intervals;

[0035] A heat dissipation guide plate group perpendicular to the axis is transversely arranged between the second clamp bodies;

[0036] The bottom of the second clamp body is connected to two radially symmetric pads through third shock absorption blocks, and the deformation direction of the third shock absorption blocks is orthogonal to that of the second shock absorption blocks.

[0037] The second shock-absorbing blocks are arranged axially at equal intervals to suppress lateral vibration, and the third shock-absorbing blocks are orthogonally arranged to block longitudinal vibration transmission; the heat dissipation and flow guiding plate group guides the bottom airflow to form turbulence and enhances the convective heat dissipation efficiency.

[0038] Preferably, the heat dissipation and flow guiding plate group includes: straight-grooved guiding plates and corrugated guiding plates arranged alternately; the guiding plate surface is provided with V-shaped guiding grooves with a depth of 0.5-1 mm; the distance between adjacent guiding plates is 2-3 times the plate thickness. The alternating arrangement of the straight-grooved plates and the corrugated plates breaks the boundary layer and improves the heat transfer coefficient; the V-shaped guiding grooves increase the surface area and guide the airflow direction; the optimized distance avoids air flow short-circuit and ensures heat dissipation uniformity.

[0039] Preferably, the shape memory alloy pressure relief valve includes: a two-way shape memory spring made of Ni-Ti alloy; a porous ceramic filter layer is arranged in the pressure relief channel; the trigger pressure threshold is 1.5 times the rated internal pressure. The Ni-Ti two-way memory spring realizes automatic reset after pressure relief, avoiding fatigue failure of traditional springs; the porous ceramic filter layer blocks the backflow of external pollutants; the 1.5-fold pressure threshold takes into account both safety and economy.

[0040] Preferably, the active protection system includes: a first humidity sensor arranged on the surface of the insulation barrier; a second humidity sensor arranged in the air cavity area of the buffer layer; a three-axis vibration sensor arranged at the fixed point of the winding conductor; a high-frequency partial discharge sensor arranged at the lead-out terminal of the heat pipe; a distributed optical fiber temperature sensor integrated in the winding conductor. The first humidity sensor monitors the risk of condensation on the surface of the insulation barrier; the second humidity sensor warns of the failure of the buffer layer seal; the three-axis vibration sensor identifies mechanical looseness or structural deformation; the high-frequency partial discharge sensor captures early insulation deterioration signals; the distributed optical fiber temperature sensor realizes accurate positioning of the hot spots in the winding.

[0041] Preferably, the sensor data is subjected to feature extraction through an edge computing module, and a machine learning algorithm optimized by a Transformer network is adopted to realize: mechanical fault warning based on vibration spectrum feature recognition; insulation deterioration diagnosis based on partial discharge pulse waveform recognition; temperature field reconstruction and hot spot prediction by multi-sensor data fusion. The edge computing module reduces the cloud transmission delay and realizes real-time response; the Transformer network optimization algorithm improves the feature extraction ability of time series data such as vibration spectrum and partial discharge waveform; multi-sensor data fusion constructs a three-dimensional temperature field model, predicts the development trend of hot spots, and supports preventive maintenance decision-making.

[0042] In summary, due to the adoption of the above technical solutions, the beneficial effects of the present invention are:

[0043] 1. The comprehensive protection performance is significantly enhanced. In terms of environmental and mechanical protection, the outer nano-composite coating (titanium dioxide + graphene) has self-cleaning, anti-ultraviolet and chemical corrosion resistance characteristics. There is no peeling after 480 hours of salt spray test, and the service life is more than twice that of the traditional coating. The modular shell supports local replacement, reducing the maintenance cost by 40%. The honeycomb silicon-aluminum composite material combined with high-damping rubber filling increases the vibration energy absorption efficiency by 60%, reduces the impact acceleration to 30% of the traditional solution, and the mechanical resonance amplitude ≤ 0.1 mm, meeting the strict vibration standard. In terms of insulation reliability, the vacuum casting + 3D printing process makes the bubble rate of the insulation layer < 0.01%, the partial discharge < 5 pC (national standard ≤ 10 pC), and the breakdown field strength is increased to 35 kV / mm, a 40% increase compared with the traditional process.

[0044] 2. Thermal management and energy consumption optimization, efficient heat dissipation design. The micro heat pipe array controls the temperature rise of the winding hot spots at ≤ 95 K (traditional ≥ 110 K), reducing the heat dissipation energy consumption by 40%. The gradient fins increase the heat dissipation intensity of the condensation section by 25%, matching the temperature distribution characteristics of the transformer. The intelligent temperature control system, with the PID algorithm linking the fan and the shutter, has a response time < 3 seconds, and the temperature rise fluctuation is ± 2 K (traditional ± 5 K). The polytetrafluoroethylene coating ensures long-term ventilation stability > 95%.

[0045] 3. Intelligent fault warning and maintenance, multi-dimensional perception: The positioning accuracy of the distributed optical fiber temperature sensor is ± 1 cm, and the sensitivity of the high-frequency partial discharge sensor reaches 1 pC (traditional 10 pC). The three-axis vibration sensor can identify deformations at the 0.01 mm level and give a 30-day early warning of mechanical looseness. Intelligent diagnosis: The Transformer algorithm has a classification accuracy of > 92% for partial discharge waveforms and a false alarm rate < 3%. The edge computing module has a fault diagnosis delay < 50 ms and supports real-time closed-loop control.

[0046] 4. Structural reliability and economy, safety and life optimization: The response time of the shape memory alloy pressure relief valve < 2 ms, which can be reused 5000 times (traditional 1000 times) and reset automatically. The porous ceramic filter layer blocks particles ≥ 10 μm with an efficiency > 99.5%. The shock absorption and heat dissipation collaborative design increases the bottom heat transfer coefficient by 20%, reduces the noise by 5 dB(A), and extends the expected service life to 15 years (traditional ≤ 10 years). Operation and maintenance efficiency: The modular shell replacement takes < 4 hours (traditional ≥ 24 hours), reducing the labor cost by 60%. The annual failure rate < 0.5 times (industry average ≥ 2 times).

[0047] 5. Total life cycle cost and environmental protection advantages, energy efficiency and emission reduction: The total loss is reduced by 8% - 10%, and a 2000 kVA transformer saves 5000 kWh of electricity annually. The nano-coating and solvent-free process reduce the VOC emissions by 90%, meeting the RoHS standard.

[0048] Core technical advantages and measured breakthroughs are achieved through the integration of materials (nano - coatings, shape - memory alloys), structures (honeycomb buffers, gradient fins), processes (3D printing), and intelligent technologies (edge computing + AI). A multi - level protection system is constructed to realize the collaborative control of thermal - vibration - electrical multi - physical fields, promoting the operation and maintenance mode to shift from "regular maintenance" to "predictive maintenance", with the full - life - cycle cost reduced by more than 30%. Measurements show that the partial discharge amount decreases by 75%, the hot - spot temperature rise decreases by 20.8%, the impact resistance doubles, and the annual failure rate decreases significantly, providing an innovative solution for the stable operation of power systems in complex environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] The present invention will be described by way of examples with reference to the accompanying drawings, where:

[0050] Figure 1 is the front - view structural schematic diagram of the present invention;

[0051] Figure 2 is the left - view structural schematic diagram of the present invention;

[0052] Figure 3 is the right - view structural schematic diagram of the present invention;

[0053] Figure 4 is the A - A cross - sectional structural schematic diagram of the present invention;

[0054] Figure 5 is the structural schematic diagram of the micro - heat - pipe array of the present invention;

[0055] The labels in the figures are: 1 - transformer body, 11 - micro - heat - pipe array, 111 - evaporation section, 112 - condensation section, 12 - outer protective shell, 13 - intermediate buffer layer, 14 - winding support, 15 - sensor, 16 - inner insulation barrier, 17 - winding conductor, 18 - shape - memory alloy pressure - relief valve, 2 - intelligent temperature control system, 21 - sun - shading top cover, 22 - axial - flow fan, 23 - first clamp body, 24 - first shock - absorbing block, 25 - intelligent louver, 3 - integrated shock - absorption and heat - dissipation structure, 31 - second shock - absorbing block, 32 - heat - dissipation flow - guiding plate group, 33 - second clamp body, 34 - third shock - absorbing block, 35 - backing plate. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0056] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. Usually, the components of the embodiments of the present invention described and shown in the accompanying drawings here can be arranged and designed in various different configurations.

[0057] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0058] In one embodiment of the present invention, Figures 1-5 As shown, the present embodiment provides a high-voltage dry-type transformer with a protective function, including a transformer body 1, including a multi-layer protective structure arranged in sequence from the outside to the inside: an outer protective shell 12, which adopts a detachable modular shell, and its outer surface is covered with a nano-composite coating containing titanium dioxide and graphene; an intermediate buffer layer 13, which is composed of a honeycomb silicon-aluminum composite material, and the honeycomb structure is filled with high-damping rubber and fixed by an elastic bracket; an inner insulating barrier 16, which is vacuum casted by epoxy resin and nano-alumina composite, and a bubble-free insulating layer is formed on the surface by a 3D printing process; the transformer body 1 is also provided with: an intelligent temperature control system 2, including a micro heat pipe array 11 embedded in a winding conductor 17, an intelligent blind 25 and an axial flow fan 22; an active protection system, with built-in multi-type sensors 15 and connected to a cloud platform; a memory alloy pressure relief valve 18 on the top of the shell.

[0059] The present invention reduces maintenance costs through comprehensive optimization of the multi-layer protection structure, and the detachable modular shell reduces the maintenance cost. The nano-composite coating (titanium dioxide + graphene) improves the UV resistance, corrosion resistance and self-cleaning ability; the honeycomb silicon-aluminum composite material is combined with high-damping rubber to achieve multi-dimensional impact absorption (mechanical vibration, electromagnetic stress), and the elastic bracket avoids resonance damage; the vacuum casting + 3D printing process eliminates bubbles and interface defects in the insulation layer, and nano-aluminum oxide enhances the insulation strength and resistance to local discharge; the intelligent temperature control system 2 cooperates with micro heat pipes, fans and shutters to achieve dynamic heat dissipation; the active protection system achieves early warning of faults through the fusion of multiple sensors 15; the memory alloy pressure relief valve 18 can be repeatedly triggered and automatically reset to improve the reliability of overpressure protection.

[0060] The following is a detailed description from five aspects:

[0061] 1. Construction of multi-layer protection structure

[0062] 1.1 Outer protective shell 12

[0063] Modular shell production: 6063 aluminum alloy profiles are used and CNC processed into detachable hexagonal splicing modules. The size of a single module is 300mm×300mm, and waterproof sealing strips and snap-on interfaces are set on the edges.

[0064] Nano - coating spraying: Titanium dioxide (TiO2) nanoparticles (particle size 20 - 50 nm) and graphene sheets (2 - 5 layers in thickness) are dispersed in epoxy - modified fluorocarbon resin at a mass ratio of 3:1. An electrostatic spraying process is used to form a composite coating with a thickness of 80 μm on the outer shell surface, and it is cured at 150 °C for 2 hours.

[0065] 1.2 Intermediate buffer layer 13

[0066] Honeycomb structure forming: A silicon - aluminum composite material (Si content 12 wt%) is extruded into a hexagonal honeycomb core (side length of a single cell 5 mm, wall thickness 0.3 mm). After stacking, the overall size matches the shape of the transformer body 1.

[0067] High - damping rubber filling: Butyl rubber and carbon black (mass ratio 10:1) are mixed and injected into the inner cavity of the honeycomb core. Vacuum pressure is applied up to 0.5 MPa to ensure no voids, and the vulcanization temperature is maintained at 120 °C for 1 hour.

[0068] Elastic support installation: 304 stainless - steel spring sheets (elastic modulus 190 GPa) are arranged in a cross - shaped layout. A 2 - mm gap is reserved between the buffer layer and the outer shell and the insulation barrier, and the bolt pre - tightening force is controlled at 15 N·m.

[0069] 1.3 Inner insulation barrier 16

[0070] Vacuum casting process: Epoxy resin (type E - 51) and nano - aluminum oxide (particle size 50 nm, addition amount 8 wt%) are mixed. After being injected into the mold, it is evacuated to 10−3 Pa, pre - cured at 60 °C for 4 hours, and then heated to 120 °C for final curing for 6 hours.

[0071] 3D - printed insulation layer: Using the fused deposition modeling (FDM) process, a solvent - free epoxy layer with a thickness of 0.1 mm is printed layer by layer on the surface of the casting body. The printing temperature is 230 °C, and a pressure of 5 MPa is applied between layers to eliminate interface bubbles.

[0072] 2. Implementation of intelligent temperature control system

[0073] 2.1 Integration of micro - heat pipe arrays

[0074] Heat pipe structure: A copper flat evaporation section 111 (thickness 3 mm, width 30 mm) and a condensation section 112 (diameter 15 mm) are welded through a corrugated elbow, and deionized water working fluid (filling ratio 20%) is encapsulated inside.

[0075] Installation process: The evaporation section 111 is inserted into the inter - winding layer gap (spacing 10 mm), and the contact surface is coated with thermal conductive silicone grease (thermal conductivity 5 W / m·K). The condensation section 112 extends vertically upward to the heat dissipation channel, and the height difference between the top elbows is 50 mm.

[0076] Gradient fin processing: The fin spacing at the bottom of the condensation section 112 is 8 mm, the spacing at the top is 6.5 mm (a reduction of 18.75%), the fin height is 15 mm, and it is fixed by laser welding.

[0077] 2.2 Intelligent louver and fan linkage

[0078] Louver control: The blade surface is sprayed with a polytetrafluoroethylene coating (thickness 75 μm), and the opening and closing angle is driven by a stepper motor (0° - 90°). The PID controller adjusts in real time according to the winding temperature (threshold set at 85°C) and the humidity sensor 15 (restricts the opening degree ≤ 45° when RH > 80%).

[0079] Axial flow fan 22 selection: Select a brushless DC fan with a diameter of 200 mm (maximum air volume 1200 m 3 / h), installed on the inlet side of the heat dissipation channel, and the wind speed is controlled in stages through PWM signals.

[0080] 3. Shock-absorbing and heat-dissipating structure assembly

[0081] 3.1 Bottom shock-absorbing design

[0082] Layout of the second shock-absorbing block 31: Use nitrile rubber blocks (hardness 60 Shore A), arrange 6 groups equidistantly along the axial direction of the bottom of the body, with a spacing of 400 mm and a pre-compression amount of 10%.

[0083] Installation of the deflector plate group: The straight-grained deflector plate (thickness 2 mm) and the corrugated deflector plate (wave height 3 mm) are arranged alternately, with a spacing of 5 mm, the depth of the V-shaped deflector groove is 0.8 mm, and the angle with the air flow direction is 30°.

[0084] Orthogonal shock-absorbing configuration: The third shock-absorbing block 34 (silicone material, hardness 50 Shore A) is arranged at a 90° cross with the second shock-absorbing block 31, and the backing plate 35 is fixed to the foundation through M16 anchor bolts.

[0085] 4. Active protection system deployment

[0086] 4.1 Sensor network layout

[0087] Humidity monitoring: The first humidity sensor (capacitive, accuracy ±2% RH) is embedded in the groove on the surface of the insulating barrier (depth 2 mm), and the second humidity sensor is installed at the center of the air cavity of the buffer layer.

[0088] Vibration monitoring: The three-axis vibration sensor (frequency response range 5 - 2000 Hz) is fixed at the bolt of the winding support frame, and the sampling frequency is 10 kHz.

[0089] Partial discharge detection: The high-frequency sensor (bandwidth 100 MHz) is connected to the heat pipe terminal, and the signal is transmitted to the edge computing module through a coaxial cable.

[0090] Temperature monitoring: Distributed optical fiber (spatial resolution 1 m) is helically wound along the winding conductor 17, with a temperature measurement accuracy of ±0.5°C.

[0091] 4.2 Data processing and algorithm implementation

[0092] Edge computing module: An ARM Cortex-A72 processor is used to perform FFT transformation on the vibration signal (Hanning window function, 4096 points), and extract the characteristic frequencies (fundamental frequency ± 3 harmonics).

[0093] Transformer model training: Input the partial discharge pulse waveform (1024 points in length) and temperature field data, identify abnormal patterns through the multi-head attention mechanism, and output the fault probability value (a threshold > 0.7 triggers an early warning).

[0094] 5. Memory alloy pressure relief valve debugging

[0095] Spring heat treatment: Ni-Ti alloy wire (diameter 2 mm) undergoes shape memory training at 500°C, and the trigger pressure is set to 15 kPa (1.5 times the rated pressure of 10 kPa).

[0096] Sintering of the porous ceramic layer: Alumina porous ceramic (porosity 40%, average pore diameter 50 μm) is fixed in the pressure relief channel through a high-temperature binder, with a temperature tolerance of 600°C.

[0097] Verification of the effectiveness of the embodiment

[0098] Taking a 10 kV / 2000 kVA dry-type transformer as an example, after implementing this solution:

[0099] Protection performance: No coating peeling after 480 hours of salt spray test, and the impact resistance is increased to 30 g (IEC 60068-2-27 standard);

[0100] Temperature rise control: The hot spot temperature of the winding under rated load ≤ 95 K (national standard limit 120 K), and the heat dissipation energy consumption is reduced by 40%;

[0101] Fault early warning: Partial discharge < 5 pC (traditional solution > 20 pC), and the mechanical vibration amplitude is reduced by 60%.

[0102] Summary of implementation key points

[0103] This solution realizes the reliable operation and intelligent maintenance of high-voltage dry-type transformers in extreme environments through modular assembly processes (such as detachable enclosures), precision manufacturing technologies (vacuum casting + 3D printing), intelligent control strategies (PID + Transformer algorithm), and multi-physical field coupling designs (vibration damping / heat dissipation / insulation coordination).

[0104] In another embodiment of the present invention, the intelligent temperature control system 2 further includes: a sunshade top cover 21 extending horizontally at the top of the body, with both ends fixedly connected to the tops of two symmetrically arranged first clamping bodies 23; the bottom of the first clamping body 23 is connected to the top of the transformer body 1 through a plurality of first shock-absorbing blocks 24 arranged at intervals along the length direction of the body; a square heat dissipation channel extending axially is formed between the two first clamping bodies 23, with an axial flow fan 22 arranged at one end and an intelligent louver 25 arranged at the other end. The sunshade top cover 21 reduces the input of solar radiation heat; the square heat dissipation channel combines the axial flow fan 22 and the intelligent louver 25 to form directional forced air cooling, improving the air flow organization efficiency; the first shock-absorbing blocks 24 isolate the vibration transmission between the clamping body and the body, reducing mechanical loss and forming a three-dimensional heat dissipation structure.

[0105] In another embodiment of the present invention, the micro heat pipe array 11 includes: a copper shell composed of a flat evaporation section 111 and a vertical condensation section 112 formed by vacuum brazing, and the two sections are connected through a corrugated connecting elbow; the evaporation section 111 is axially installed between the winding layers, and its flat contact surface forms a surface contact with the inner surface of the winding conductor 17; equally spaced annular heat dissipation fins are arranged on the outer wall of the condensation section 112, and the top end extends into the square heat dissipation channel at the top of the transformer body 1, and the top end forms an inverted U-shaped flow channel through the elbow; the encapsulated working fluid vaporizes in the evaporation section 111 and then dissipates heat and liquefies in the condensation section 112 to form a self-circulating phase change heat transfer system. The flat evaporation section 111 is in surface contact with the inner surface of the winding conductor 17, increasing the heat conduction area; the self-circulating heat pipe does not require external power, reducing energy consumption; the inverted U-shaped flow channel uses gravity to accelerate the reflux of the condensate, avoiding uneven distribution of the working fluid; the annular fins enhance the convective heat dissipation of the condensation section 112, matching the longitudinal temperature gradient of the transformer to achieve an efficient phase change heat transfer design.

[0106] In another embodiment of the present invention, the heat dissipation fins of the condensation section 112 are arranged with a gradient pitch, and the fin pitch in the area near the top end is reduced by 15%-20% compared with the bottom end area. The fin pitch at the top end of the condensation section 112 is reduced by 15%-20%, enhancing the heat dissipation intensity in the high-temperature area; adapting to the heat transfer characteristics of the reduced steam density at the top end of the heat pipe, avoiding the attenuation of the heat dissipation capacity with height.

[0107] In another embodiment of the present invention, the intelligent louver 25 includes: the blade surface is coated with a polytetrafluoroethylene hydrophobic coating with a thickness of 50-100 μm; the polytetrafluoroethylene hydrophobic coating prevents the blades from being soiled and condensed; the opening and closing angle is controlled by a temperature gradient PID, and a humidity compensation sensor is embedded in the louver frame. The PID control combined with humidity compensation realizes the dynamic optimization of the opening and closing angle, balancing the heat dissipation demand and the moisture-proof requirement.

[0108] In another embodiment of the present invention, an integrated shock-absorbing and heat-dissipating structure 3 is provided at the bottom of the transformer body 1: two symmetric second clamp bodies 33 are connected to the bottom of the body through second shock-absorbing blocks 31, and the second shock-absorbing blocks 31 are arranged at equal intervals axially; a heat-dissipating flow guide plate group 32 perpendicular to the axial direction is transversely arranged between the second clamp bodies 33; the bottoms of the second clamp bodies 33 are connected to two radially symmetric cushion plates 35 through third shock-absorbing blocks 34, and the deformation direction of the third shock-absorbing blocks 34 is orthogonal to that of the second shock-absorbing blocks 31. The equal axial spacing arrangement of the second shock-absorbing blocks 31 suppresses lateral vibration, and the orthogonal layout of the third shock-absorbing blocks 34 blocks the transmission of longitudinal vibration; the heat-dissipating flow guide plate group 32 guides the bottom air flow to form turbulence and enhances the convective heat dissipation efficiency.

[0109] In another embodiment of the present invention, the heat-dissipating flow guide plate group 32 includes: straight-grooved flow guide plates and corrugated flow guide plates arranged alternately; V-shaped flow guide grooves with a depth of 0.5-1 mm are provided on the surface of the flow guide plates; the distance between adjacent flow guide plates is 2-3 times the plate thickness. The alternating arrangement of the straight-grooved plates and the corrugated plates breaks the boundary layer and improves the heat transfer coefficient; the V-shaped flow guide grooves increase the surface area and guide the air flow direction; the optimized distance avoids air flow short-circuit and ensures heat dissipation uniformity.

[0110] In another embodiment of the present invention, the shape memory alloy pressure relief valve 18 includes: a two-way shape memory spring made of Ni-Ti alloy; a porous ceramic filter layer is arranged in the pressure relief channel; the trigger pressure threshold is 1.5 times the rated internal pressure. The Ni-Ti two-way memory spring realizes automatic reset after pressure relief and avoids fatigue failure of traditional springs; the porous ceramic filter layer blocks the reflux of external pollutants; the 1.5-fold pressure threshold takes into account both safety and economy.

[0111] In another embodiment of the present invention, the active protection system includes: a first humidity sensor arranged on the surface of the insulation barrier; a second humidity sensor arranged in the air cavity area of the buffer layer; a three-axis vibration sensor arranged at the fixed point of the winding conductor 17; a high-frequency partial discharge sensor arranged at the heat pipe lead-out terminal; a distributed optical fiber temperature sensor integrated in the winding conductor 17. The first humidity sensor monitors the risk of condensation on the surface of the insulation barrier; the second humidity sensor warns of the failure of the buffer layer seal; the three-axis vibration sensor identifies mechanical looseness or structural deformation; the high-frequency partial discharge sensor captures early insulation degradation signals; the distributed optical fiber temperature sensor realizes accurate positioning of the winding hot spot.

[0112] In another embodiment of the present invention, the sensor data is subjected to feature extraction by an edge computing module, and a machine learning algorithm optimized by a Transformer network is adopted to achieve: mechanical fault warning based on vibration spectrum feature recognition; insulation degradation diagnosis based on partial discharge pulse waveform recognition; temperature field reconstruction and hot spot prediction by multi-sensor data fusion. The edge computing module reduces the cloud transmission delay and realizes real-time response; the Transformer network optimization algorithm improves the feature extraction ability of time series data such as vibration spectrum and partial discharge waveform; multi-sensor data fusion constructs a three-dimensional temperature field model to predict the development trend of hot spots and supports preventive maintenance decision-making.

[0113] The working principle of the present invention is as follows: Through the collaborative action of a multi-layer protection structure, an intelligent temperature control system 2, an active protection system, and a shock absorption and pressure relief design, the transformer realizes efficient operation and active safety protection in a complex environment. Its core working principle is as follows:

[0114] 1. Collaborative protection mechanism of the multi-layer protection structure

[0115] Outer protective shell 12:

[0116] Modular design: Realize rapid replacement of local damage through a detachable outer shell, reducing maintenance downtime.

[0117] Nanocomposite coating: Titanium dioxide (TiO2) photocatalytically decomposes surface pollutants, and graphene enhances the conductivity of the coating to avoid electrostatic accumulation; at the same time, it reflects ultraviolet rays and delays the aging of the outer shell.

[0118] Intermediate buffer layer 13:

[0119] Honeycomb silicon-aluminum structure: The hexagonal honeycomb core disperses mechanical impact energy through geometric configuration, and the silicon-aluminum material of the honeycomb wall provides rigid support.

[0120] High-damping rubber filling: The viscoelastic properties of the rubber absorb high-frequency vibration energy, and filling in the honeycomb cavity forms a multiple damping effect to suppress micro-vibrations caused by electromagnetic stress.

[0121] Inner insulation barrier 16:

[0122] Vacuum casting process: After epoxy resin is compounded with nano-aluminum oxide, bubbles are eliminated in a vacuum environment, and nano-particles fill the microscopic defects of the resin to block the partial discharge channel.

[0123] 3D printed insulation layer: Layer-by-layer printing forms a dense surface with a roughness <1μm, optimizing the electric field distribution and reducing the risk of surface creepage.

[0124] 2. Thermal management logic of the intelligent temperature control system

[0125] Micro heat pipe array 11:

[0126] Phase change heat transfer: When the winding conductor 17 generates heat, the working fluid in the water evaporation section 111 vaporizes and absorbs heat. The steam rises to the condensation section 112, liquefies after heat exchange with the forced air flow through the annular fins, and the liquid working fluid flows back under the action of gravity to form a self-circulating heat dissipation.

[0127] Gradient fin design: The fin spacing at the top is reduced to adapt to the characteristic that the steam density decreases with height, and the heat dissipation efficiency in the high-temperature area is enhanced.

[0128] The intelligent shutter 25 is linked with the fan:

[0129] Dynamic air cooling control: When the winding temperature > 85 °C, the PID controller increases the opening of the shutter and starts the axial flow fan 22 to form a directional air flow through the heat dissipation channel; when the humidity > 80%, the opening is restricted to avoid moisture intrusion.

[0130] Hydrophobic coating protection: The polytetrafluoroethylene coating prevents the blades from accumulating dust or condensing dew, ensuring long-term stable ventilation efficiency.

[0131] 3. Fault warning mechanism of the active protection system

[0132] Multi-sensor data fusion:

[0133] Insulation state monitoring: The high-frequency partial discharge sensor captures nanosecond-level pulse signals, and combines with humidity data to distinguish surface condensation and internal insulation deterioration.

[0134] Mechanical health diagnosis: The three-axis vibration sensor analyzes the vibration spectrum to identify winding looseness (characteristic frequency shift) or structural deformation (harmonic component mutation).

[0135] Temperature field reconstruction: The distributed optical fiber collects temperature every 1 meter, combines with the heat pipe temperature data, and constructs a three-dimensional thermal field model through interpolation algorithm to predict the hot spot position.

[0136] Edge intelligent analysis:

[0137] Transformer algorithm optimization: Use the multi-head attention mechanism to extract the time correlation features of the partial discharge waveform, and distinguish discharge modes such as corona discharge and surface discharge.

[0138] Multi-source data fusion: Input vibration, temperature, and humidity data into the neural network, and output the fault probability value (such as triggering a warning when the insulation deterioration probability > 70%).

[0139] 4. Dynamic response of shock absorption and pressure relief

[0140] Shock absorption system:

[0141] Orthogonal shock absorption layout: The second shock absorber block 31 arranged axially absorbs lateral vibration, and the third shock absorber block 34 arranged radially suppresses longitudinal vibration, forming multi-dimensional shock absorption and isolation.

[0142] Turbulence intensification of the deflector: The straight-grained and corrugated deflectors are arranged alternately to disrupt the laminar boundary layer of the air flow and increase the bottom heat dissipation efficiency by more than 20%.

[0143] Memory alloy pressure relief valve 18:

[0144] Two-way shape memory effect: When the internal pressure exceeds 15 kPa, the Ni-Ti spring undergoes a thermal phase change (austenite → martensite) to open the pressure relief; after the pressure recovers, it cools and undergoes a phase change, and the spring automatically resets and seals.

[0145] Porous ceramic filtration: When relieving pressure, the air flow passes through the ceramic layer for filtration to prevent external dust and moisture from infiltrating back.

[0146] 5. System-level collaborative working process

[0147] 1. Normal operation:

[0148] The heat pipe array conducts the winding heat to the heat dissipation channel through the phase change cycle, and the axial flow fan 22 starts according to the temperature gradient and cooperates with the shutter to adjust the air volume.

[0149] The sensor 15 network continuously collects data, and the edge computing module performs real-time health assessment.

[0150] 2. Abnormal conditions:

[0151] Overload heating: The temperature sensor detects that the hot spot temperature > 95 °C, triggering the fan to run at full speed and linking to the cloud for alarm.

[0152] Mechanical shock: The vibration sensor captures the abnormal frequency spectrum, and the system automatically starts the damping adjustment of the shock absorber block to suppress resonance amplification.

[0153] Insulation fault: The partial discharge sensor identifies the typical discharge signal with a pulse rise edge < 10 ns, triggering the self-check program of the insulation barrier.

[0154] 3. Extreme situations:

[0155] Internal short circuit explosion: The memory alloy pressure relief valve 18 responds to overpressure within 2 ms, releases high-pressure gas, and the porous ceramic layer blocks the arc splashes.

[0156] Environmental mutation (such as heavy rain): The humidity sensor links to close the shutter and switches to the internal circulation heat dissipation mode to prevent moisture intrusion.

[0157] In summary, the material-structure-control of the present invention is a trinity: the nano-coating (material), honeycomb filling (structure), and PID algorithm (control) cooperate to enhance environmental adaptability. Optimization of the energy transfer path: heat is transferred through multiple levels of heat pipe phase change → forced air cooling → turbulent flow diversion, and vibration energy is dissipated layer by layer through honeycomb damping → elastic support → orthogonal shock absorption. Intelligent closed-loop protection: The closed-loop link of perception → analysis → decision → execution (such as partial discharge detection → edge computing diagnosis → relief valve action) realizes millisecond-level active protection. Through the triple protection system of physical protection layer (anti-corrosion / vibration damping / insulation), energy management (heat conduction / vibration dissipation), and intelligent decision-making (multi-sensor fusion + AI algorithm), the present invention solves the reliability bottleneck of traditional transformers in extreme environments and achieves a technological leap from "passive protection" to "active immunity".

Claims

1. A high-voltage dry-type transformer with a protection function, comprising a transformer body, characterized in that, It includes a multi-layer protection structure arranged from the outside to the inside: The outer protective shell adopts a detachable modular shell, and its outer surface is covered with a nano-composite coating containing titanium dioxide and graphene; The middle buffer layer is made of a honeycomb silicon-aluminum composite material, the honeycomb structure is filled with high damping rubber and fixed by an elastic bracket; The inner insulation barrier is made of epoxy resin and nano-alumina composite vacuum casting, and the surface is formed into a bubble-free insulation layer through 3D printing technology; The transformer body is also provided with: Intelligent temperature control system, including micro heat pipe array embedded in winding conductors, intelligent blinds and axial fans; Active protection system, with multiple types of sensors built in and connected to the cloud platform; Memory alloy pressure relief valve on the top of the shell.

2. The transformer according to claim 1, characterized in that, The intelligent temperature control system also includes: The sunshade cover extends transversely to the top of the main body, and the two ends are fixed to the tops of two symmetrically arranged first clamp bodies; The bottom of the first clamp body is connected to the top of the transformer body through a plurality of first damping blocks spaced apart along the length direction of the body; An axially extending square heat dissipation channel is formed between the two first clamp bodies, an axial flow fan is arranged at one end of the channel, and an intelligent shutter is arranged at the other end.

3. The transformer according to claim 2, wherein, The micro heat pipe array comprises: The copper shell consists of a flat evaporation section and a vertical condensation section formed by vacuum brazing, and the two sections are connected by a corrugated connecting elbow; The evaporation section is embedded between the winding layers along the axial direction, and its flat contact surface forms surface contact with the inner surface of the winding conductor; The outer wall of the condensation section is provided with annular heat dissipation fins with equal spacing, the top of which extends into the square heat dissipation channel at the top of the transformer body, and the top of which forms an inverted U-shaped flow channel through an elbow; The encapsulated water medium is vaporized in the evaporation section and then liquefied through the condensation section to dissipate heat, forming a self-circulating phase change heat transfer system.

4. The transformer according to claim 3, characterized in that, The heat dissipation fins of the condensation section are arranged with a gradient spacing, and the fin spacing near the top end area is reduced by 15%-20% compared with that in the bottom end area.

5. The transformer according to claim 2, characterized in that, The smart blinds include: The blade surface is coated with a polytetrafluoroethylene hydrophobic coating with a thickness of 50-100 μm; The opening and closing angles are controlled by temperature gradient PID, and a humidity compensation sensor is embedded in the shutter frame.

6. The transformer according to claim 1, characterized in that, The bottom of the transformer body is provided with an integrated shock-absorbing and heat-dissipating structure: Two symmetrical second clamping bodies are connected to the bottom of the main body through second shock absorbing blocks, and the second shock absorbing blocks are equidistantly arranged in the axial direction; A heat dissipation guide plate group perpendicular to the axial direction is arranged transversely between the second clamp bodies; The bottom of the second clamping body is connected to two radially symmetrical pads via a third shock-absorbing block, and the deformation direction of the third shock-absorbing block is orthogonal to that of the second shock-absorbing block.

7. The transformer according to claim 6, characterized in that, The heat dissipation guide plate group comprises: straight-grained guide plates and corrugated guide plates arranged alternately; the guide plate surface is provided with a V-shaped guide groove with a depth of 0.5-1mm; the distance between adjacent guide plates is 2-3 times the plate thickness.

8. The transformer according to claim 1, wherein The memory alloy pressure relief valve comprises: a two-way shape memory spring made of Ni-Ti alloy; a porous ceramic filter layer is arranged in the pressure relief channel; and a trigger pressure threshold is 1.5 times of the rated internal pressure.

9. The transformer according to claim 1, wherein The active protection system includes: a first humidity sensor disposed on the surface of the insulation barrier; a second humidity sensor disposed in the buffer layer gas cavity area; a triaxial vibration sensor disposed at the fixed points of the winding conductors; a high-frequency partial discharge sensor disposed at the heat pipe lead-out terminal; and a distributed optical fiber temperature sensor integrated in the winding conductors.

10. The transformer according to claim 9, characterized in that, The sensor data is subjected to feature extraction through an edge computing module, and a machine learning algorithm optimized by a Transformer network is used to achieve: mechanical fault early warning based on vibration spectrum feature recognition; insulation degradation diagnosis based on partial discharge pulse waveform recognition; temperature field reconstruction and hot spot prediction through multi-sensor data fusion.

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