New material transformer cooling fan and manufacturing method thereof

Abstract

The invention provides a new material transformer cooling fan and a manufacturing method thereof, and belongs to the technical field of fans, blades are manufactured through a one-time hot compression molding forming process, and the novel transformer cooling fan is formed in cooperation with supercritical airfoil profile (the bending factor is 1.15-0.7), efficient and low-noise front bay type blade profile design and a pressing block U-shaped bolt connection mode of the blades and a hub. The weight difference of the blades is controlled within 3 grams due to the non-metal material, the consistency of rotating torque is ensured, and vibration and noise are reduced (3-5 decibels lower than those of domestic like products); the aerodynamic performance is improved through the precise aerodynamic shape design, the air volume is large, the air pressure is high, the air cooler of 800 KW can be adapted, and a silencer is not needed; the PP long fiber reinforced plastic has the characteristics of corrosion resistance, ultraviolet resistance and aging resistance, and is suitable for various environments; and meanwhile, the forming efficiency of 3 minutes per piece is high, the production requirement on the environment is low, and the environment-friendly influence is small.

Description

Technical Field

[0001] This invention relates to the field of fan technology, specifically to a new material transformer cooling fan and its manufacturing method. Background Technology

[0002] With the development of China's power transmission and transformation industry, ultra-high voltage and high voltage transformers have become the core equipment of long-distance ultra-high voltage power transmission and transformation systems, and they are showing a layout trend of "close to cities and main roads". This has significantly increased the requirements for the noise, efficiency and stable operation of the supporting cooling fans (lower noise, higher efficiency and smoother rotation).

[0003] Traditional metal-bladed fans suffer from problems such as high noise, poor corrosion resistance, and inconsistent weight (leading to high vibration), failing to meet the new requirements. Currently, no other company in the industry has adopted a "non-metallic blade + unique airfoil design" approach to produce similar ultra-low noise transformer cooling fans. Therefore, a new material transformer cooling fan and its manufacturing method are proposed. Summary of the Invention

[0004] The present invention aims to solve the problems mentioned in the background art by providing a new material transformer cooling fan and its manufacturing method.

[0005] The specific technical solution is as follows:

[0006] A new material transformer cooling fan includes a hub and at least two blades; the blades are made of a non-metallic material, namely PP long fiber reinforced plastic; the cross section of the blade is a supercritical airfoil, and the bending factor of the supercritical airfoil is 1.15-0.7; the planar shape of the blade is a forward-curved blade; the blade is connected to the hub by a U-bolt connection.

[0007] In the aforementioned new material transformer cooling fan, the PP long fiber reinforced plastic contains UV-resistant additives and anti-aging additives, with the UV-resistant additives accounting for 0.5%-2% of the mass and the anti-aging additives accounting for 1%-3% of the mass.

[0008] The aforementioned new material transformer cooling fan, wherein the bending factor of the supercritical airfoil is 1.0-0.8.

[0009] In the aforementioned new material transformer cooling fan, the forward bend angle of the blade tip is 15°-30° and the forward bend angle of the blade root is 5°-10°.

[0010] In the aforementioned new material transformer cooling fan, the weight difference between the blades is ≤3 grams.

[0011] The aforementioned new material transformer cooling fan, wherein the hub is made of aluminum alloy and the pressure block U-bolt is made of stainless steel.

[0012] The aforementioned new material transformer cooling fan has blades with a surface roughness ≤0.8μm and a dimensional error ≤0.1mm.

[0013] This invention also provides a method for manufacturing a transformer cooling fan made of a new material, comprising the following steps:

[0014] Step 1: Prepare PP long fiber reinforced plastic raw material, wherein the raw material contains PP resin, long fibers, UV-resistant additives and anti-aging additives;

[0015] Step 2: Add the raw materials from Step 1 to the hot molding equipment, and use the molds corresponding to the supercritical airfoil (bending factor 1.15-0.7) and the forward-curved airfoil to hot mold the blades at a temperature of 180-220℃ and a pressure of 10-20MPa. The molding time is ≤3 minutes.

[0016] Step 3: Perform surface treatment on the formed blades to ensure that the surface roughness is ≤0.8μm;

[0017] Step 4: Connect the blades to the hub using U-bolts to complete the assembly of the cooling fan.

[0018] In the above-mentioned method for manufacturing a transformer cooling fan made of new materials, the long fiber mentioned in step 1 is glass fiber or carbon fiber, with a length of 5-15mm and a mass percentage of 20%-30% in the raw materials.

[0019] The manufacturing method of the above-mentioned new material transformer cooling fan includes the following steps: in step 2, the precision grade of the mold is IT5-IT6, and the surface roughness of the mold cavity is ≤0.02μm; in step 4, before connecting the blades and the hub, the blades are weight-screened to ensure that the weight difference between the blades is ≤3 grams; the surface treatment in step 3 includes dust removal, polishing and antistatic coating spraying, and the thickness of the antistatic coating is 5-10μm.

[0020] The present invention has the following beneficial effects:

[0021] 1. Ultra-low noise: Through airfoil optimization, improved material precision and balanced design, the noise level is 3-5 decibels lower than similar domestic products, meeting the stringent noise requirements near cities and main roads;

[0022] 2. High-efficiency heat dissipation: Large air volume, high air pressure, and high static pressure efficiency; it can be adapted to 800KW-class large-capacity air coolers without the need for additional silencers.

[0023] 3. Strong environmental adaptability: The non-metallic material (PP long fiber reinforced plastic) has corrosion resistance, UV resistance and aging resistance, making it suitable for various scenarios such as outdoor, nuclear power, and high humidity.

[0024] 4. Stable operation: The difference in blade weight is ≤3 grams, the torque is consistent, the rotational vibration is small, and the equipment life is extended;

[0025] 5. Highly efficient and environmentally friendly production: The molding speed of 3 minutes / piece improves production efficiency, the process has low environmental requirements, and the production process of non-metallic materials has little environmental impact;

[0026] 6. High precision and consistency: The mold forming and screening process ensures that the blade size error is ≤0.1mm and the surface roughness is ≤0.8μm, and the aerodynamic performance is close to the design theoretical value. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of a new material transformer cooling fan provided in an embodiment of the present invention;

[0028] Figure 2 The static pressure-flow characteristic curve of the new material transformer cooling fan provided in the embodiments of the present invention;

[0029] Figure 3 The dynamic pressure-flow characteristic curve of the transformer cooling fan provided in the embodiments of the present invention;

[0030] Figure 4 The full-pressure flow characteristic curve of the new material transformer cooling fan provided in the embodiments of the present invention;

[0031] Figure 5 The noise-flow characteristic curve of the cooling fan of the new material transformer provided in the embodiments of the present invention. Detailed Implementation

[0032] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0033] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual images. They should not be construed as limiting the scope of this patent. To better illustrate the embodiments of the present invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0034] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "inner," and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present patent. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0035] In the description of this invention, unless otherwise explicitly specified and limited, the term "connection" or similar designation indicating a connection between components should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0036] Example 1

[0037] The new material transformer cooling fan provided in this embodiment, such as Figures 1-5 As shown, it includes a hub and at least two blades; the blades are made of non-metallic material, which is PP long fiber reinforced plastic; the cross section of the blade is a supercritical airfoil, and the bending factor of the supercritical airfoil is 1.15-0.7; the planar shape of the blade is a forward-curved airfoil; the blade is connected to the hub by a U-bolt connection.

[0038] The above technical solution uses PP long fiber reinforced plastic blades with a supercritical airfoil cross-section (bending factor 1.15-0.7) and a forward-curved blade shape. The blades are connected to the hub via U-bolts. The combination of supercritical airfoil and forward-curved blade shape is more aerodynamic, reduces airflow disturbance, and significantly reduces noise by 3-5 decibels compared to similar domestic products. The non-metallic material allows for more precise airfoil design, resulting in large air volume and high air pressure, improving the cooling efficiency of the cooler (compatible with 800KW air coolers without the need for a silencer), and exhibiting excellent aerodynamic performance. PP long fiber reinforced plastic has corrosion resistance, UV resistance, and anti-aging properties, making it suitable for various environments (such as outdoor, nuclear power, and high humidity scenarios), with strong environmental adaptability. The U-bolt connection method ensures the stable fixation of the blades and hub, adapting to the stress requirements of high-speed fan rotation and providing high connection stability.

[0039] Specifically, in this embodiment, UV-resistant additives and anti-aging additives are added to the PP long fiber reinforced plastic. The mass percentage of the UV-resistant additive is 0.5%-2%, and the mass percentage of the anti-aging additive is 1%-3%. By using the above technical solution, adding UV-resistant additives (0.5%-2% by mass) and anti-aging additives (1%-3% by mass) to the PP long fiber reinforced plastic enhances the material's inherent UV resistance and anti-aging properties, extending the blade's service life. This is particularly suitable for harsh environments such as outdoor and high-radiation environments (e.g., nuclear power plants), significantly improving resistance to environmental corrosion; preventing blade deformation and strength reduction due to UV radiation or aging, ensuring long-term efficient fan operation, and maintaining long-term performance stability.

[0040] Specifically, in this embodiment, the flexure factor of the supercritical airfoil is 1.0-0.8. When the flexure factor is in the range of 1.0-0.8, the thickness gradient of the blade section is more matched with the airflow characteristics, reducing airflow separation and turbulence, improving the balance between airflow and air pressure, and further optimizing aerodynamic efficiency; a more precise flexure factor design can reduce the frictional drag between the airflow and the blade surface, reduce aerodynamic noise, and further reduce noise.

[0041] Specifically, in this embodiment, the forward bend angle of the blade tip is 15°-30°, and the forward bend angle of the blade root is 5°-10°. The angle gradient design between the blade tip and the blade root allows the airflow to enter and exit the fan more smoothly along the axis, reducing turbulence generation and enhancing airflow guidance capability; it also efficiently guides the airflow through the transformer cooler, enhancing the heat dissipation effect on the transformer, adapting to large-capacity coolers (such as 800KW level), and improving heat dissipation efficiency.

[0042] Specifically, in this embodiment, the weight difference between the blades is ≤3 grams. High weight consistency of rotating components and balanced torque reduce vibration caused by weight deviations, lower additional noise, and improve operational stability. It also avoids additional wear and tear on components such as motors and bearings due to torque imbalance, thus extending the overall lifespan of the fan and the equipment.

[0043] Specifically, in this embodiment, the wheel hub is made of aluminum alloy, and the U-bolts for the clamping block are made of stainless steel. The aluminum alloy wheel hub reduces overall weight, while the stainless steel bolts improve the corrosion resistance of the connecting components, making it suitable for humid and dusty environments, achieving a balance between lightweight and strength. The good material compatibility avoids electrochemical corrosion from contact between different metals, ensuring long-term stability of the connection structure and strong assembly compatibility.

[0044] Specifically, in this embodiment, the surface roughness of the blades is ≤0.8μm, and the dimensional error is ≤0.1mm. Smooth, precisely sized blades are closer to the designed aerodynamic shape, reducing airflow friction resistance and improving fan efficiency, thus enhancing aerodynamic efficiency. The small dimensional error ensures the consistency of the assembly between the multiple blades and the hub, avoiding operational vibration caused by dimensional deviations, and ensuring high assembly precision.

[0045] Example 2

[0046] This embodiment provides a method for manufacturing a transformer cooling fan made of a new material, including the following steps:

[0047] Step 1: Prepare PP long fiber reinforced plastic raw material, which includes PP resin, long fibers, UV-resistant additives and anti-aging additives;

[0048] Step 2: Add the raw materials from Step 1 to the hot molding equipment, and use the molds corresponding to the supercritical airfoil (bending factor 1.15-0.7) and the forward-curved airfoil to hot mold the blades at a temperature of 180-220℃ and a pressure of 10-20MPa. The molding time is ≤3 minutes.

[0049] Step 3: Perform surface treatment on the formed blades to ensure that the surface roughness is ≤0.8μm;

[0050] Step 4: Connect the blades to the hub using U-bolts to complete the assembly of the cooling fan.

[0051] Using the above technical solution, blades are prepared by hot molding (temperature 180-220℃, pressure 10-20MPa, ≤3 minutes / blade). The raw materials include PP resin, long fibers, and UV-resistant / anti-aging additives. One blade can be produced within 3 minutes, which is far more efficient than traditional metal blade processing. It is suitable for mass production and significantly improves production efficiency. The hot molding process, combined with high-precision molds, ensures small blade shape errors and good surface gloss, directly meeting aerodynamic design requirements and achieving high molding accuracy. The production process has low requirements for the surrounding environment, reducing production site limitations and making it highly adaptable to different environments.

[0052] Specifically, in this embodiment, the long fibers in step 1 are glass fibers or carbon fibers, with a length of 5-15 mm, and account for 20%-30% of the mass of the raw materials. Long fiber reinforced plastic can improve the impact resistance and deformation resistance of the blades, meet the stress requirements of high-speed fan rotation, and balance the strength and toughness of the blades; compared with metal materials, it can reduce the weight of the blades while ensuring strength, reduce the motor load, improve operating efficiency, and has the advantage of lightweighting.

[0053] Specifically, in this embodiment, the precision level of the mold in step 2 is IT5-IT6, and the surface roughness of the mold cavity is ≤0.02μm; in step 4, before connecting the blades and the hub, the blades are weight-screened to ensure that the weight difference between the blades is ≤3 grams; the surface treatment in step 3 includes dust removal, polishing and antistatic coating spraying, and the thickness of the antistatic coating is 5-10μm.

[0054] Using the above technical solution, the mold precision level is IT5-IT6, and the cavity surface roughness is ≤0.02μm. The high-precision mold ensures that the airfoil, size, and surface smoothness of the blades perfectly match the design requirements, reducing aerodynamic performance loss caused by mold errors and maximizing blade forming accuracy. The stable mold precision results in small differences in blade shape and weight during mass production, laying the foundation for stable fan operation and high product consistency. The weight difference is controlled within 3 grams, ensuring consistent torque during blade rotation, reducing vibration and noise, and optimizing rotational balance. It avoids additional stress on the motor and bearings due to weight deviation, extending the fan's service life and reducing equipment wear. Dust removal and polishing reduce the interference of surface impurities on airflow, and the antistatic coating prevents dust adhesion, maintaining blade surface smoothness for a long time and ensuring stable aerodynamic performance. The antistatic coating improves the blade's suitability in dry and dusty environments, preventing dust accumulation from affecting heat dissipation efficiency and enabling it to adapt to various environments.

[0055] In summary, the new material transformer cooling fan provided in this embodiment has the following advantages:

[0056] 1. Ultra-low noise: Through airfoil optimization, improved material precision and balanced design, the noise level is 3-5 decibels lower than similar domestic products, meeting the stringent noise requirements near cities and main roads;

[0057] 2. High-efficiency heat dissipation: Large air volume, high air pressure, and high static pressure efficiency; it can be adapted to 800KW-class large-capacity air coolers without the need for additional silencers.

[0058] 3. Strong environmental adaptability: The non-metallic material (PP long fiber reinforced plastic) has corrosion resistance, UV resistance and aging resistance, making it suitable for various scenarios such as outdoor, nuclear power, and high humidity.

[0059] 4. Stable operation: The difference in blade weight is ≤3 grams, the torque is consistent, the rotational vibration is small, and the equipment life is extended;

[0060] 5. Highly efficient and environmentally friendly production: The molding speed of 3 minutes / piece improves production efficiency, the process has low environmental requirements, and the production process of non-metallic materials has little environmental impact;

[0061] 6. High precision and consistency: The mold forming and screening process ensures that the blade size error is ≤0.1mm and the surface roughness is ≤0.8μm, and the aerodynamic performance is close to the design theoretical value.

[0062] Working principle

[0063] This fan is an axial fan, and its core principle is to convert mechanical energy into fluid energy.

[0064] The motor drives the hub to rotate, which in turn rotates the blades;

[0065] The blades adopt supercritical airfoil (bending factor 1.15-0.7) and forward-curved airfoil, which conform to aerodynamic design, allowing fluid (air) to enter and exit axially;

[0066] High-precision molding of non-metallic material (PP long fiber reinforced plastic) ensures that the blade shape is close to the designed aerodynamic shape, reducing airflow disturbance and friction, and reducing noise while efficiently promoting airflow (achieving cooling);

[0067] The lightweight and balanced blade design reduces rotational resistance, improves energy conversion efficiency, and ultimately achieves efficient cooling of the transformer.

[0068] How to use

[0069] 1. Application scenarios: Mainly used in the cooling system of transformer air coolers and plate heat sinks, suitable for large transformers (such as ultra-high voltage transformers, nuclear power engineering transformers, etc.);

[0070] 2. Installation method: The fan is assembled into the designated position of the transformer cooling system through the U-bolt connection structure between the blades and the hub;

[0071] 3. Operation mode: After the power is turned on, the fan drives the blades to rotate through the motor, generating axial airflow to cool the transformer's cooler or radiator and reduce the transformer's operating temperature.

[0072] 4. Scope of application: It can be used in conjunction with large-scale power transmission and transformation systems such as the "West-to-East Power Transmission" project, the "Five Vertical and Five Horizontal" power grid projects, and nuclear power projects. It can also be exported to Japan, the United States and other countries.

[0073] The above are merely preferred embodiments of the present invention and are not intended to limit the implementation methods and protection scope of the present invention. Those skilled in the art should recognize that any equivalent substitutions and obvious changes made based on the description and illustrations of the present invention should be included within the protection scope of the present invention.

Claims

1. A new material transformer cooling fan, characterized in that, It includes a hub and at least two blades; the blades are made of a non-metallic material, namely PP long fiber reinforced plastic; the cross section of the blade is a supercritical airfoil, and the bending factor of the supercritical airfoil is 1.15-0.7; the planar shape of the blade is a forward-curved airfoil; the blade is connected to the hub by a U-bolt connection.

2. The new material transformer cooling fan according to claim 1, characterized in that, The PP long fiber reinforced plastic contains UV-resistant additives and anti-aging additives, with the UV-resistant additives accounting for 0.5%-2% of the mass and the anti-aging additives accounting for 1%-3% of the mass.

3. The new material transformer cooling fan according to claim 1, characterized in that, The bending factor of the supercritical airfoil is 1.0-0.

8.

4. The new material transformer cooling fan according to claim 1, characterized in that, The forward bend angle of the leaf tip is 15°-30°, and the forward bend angle of the leaf root is 5°-10°.

5. The new material transformer cooling fan according to claim 1, characterized in that, The weight difference between the blades is ≤3 grams.

6. The new material transformer cooling fan according to claim 1, characterized in that, The wheel hub is made of aluminum alloy, and the U-bolt of the pressure block is made of stainless steel.

7. The new material transformer cooling fan according to claim 1, characterized in that, The surface roughness of the blade is ≤0.8μm, and the dimensional error is ≤0.1mm.

8. A method for manufacturing a transformer cooling fan of the novel material according to any one of claims 1-7, characterized in that, Includes the following steps: Step 1: Prepare PP long fiber reinforced plastic raw material, wherein the raw material contains PP resin, long fibers, UV-resistant additives and anti-aging additives; Step 2: Add the raw materials from Step 1 to the hot molding equipment, and use the molds corresponding to the supercritical airfoil (bending factor 1.15-0.7) and the forward-curved airfoil to hot mold the blades at a temperature of 180-220℃ and a pressure of 10-20MPa. The molding time is ≤3 minutes. Step 3: Perform surface treatment on the formed blades to ensure that the surface roughness is ≤0.8μm; Step 4: Connect the blades to the hub using U-bolts to complete the assembly of the cooling fan.

9. The method for manufacturing a transformer cooling fan of the new material according to claim 8, characterized in that, The long fibers mentioned in step 1 are glass fibers or carbon fibers, with a length of 5-15 mm, and account for 20%-30% of the mass of the raw materials.

10. The method for manufacturing a transformer cooling fan of the new material according to claim 8, characterized in that, The precision grade of the mold in step 2 is IT5-IT6, and the surface roughness of the mold cavity is ≤0.02μm; in step 4, before connecting the blades and the hub, the blades are weight-screened to ensure that the weight difference between the blades is ≤3 grams; the surface treatment in step 3 includes dust removal, polishing and antistatic coating spraying, and the thickness of the antistatic coating is 5-10μm.

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